Breva 1100 Transmission replacement AKA the Guzzi from hell

[BrevaIsTheName]

Good afternoon, all! I am new to Moto Guzzis and the board in general, and have come seeking your advice. Please excuse this wall of a post, and I humbly ask that you hear my story:

    About two months ago, I bought a Moto Guzzi Breva 1100. We shared 1,000 wonderful miles together before the shift return spring inside the transmission failed, falling into the gears and locking/grenading the gearbox. (Yes, catastrophically, at almost 50mph). This being my first guzzi (but not at all my first bike), I took the bike to the first guzzi mechanic willing to help me sort the bike out-- the previous owner was "gracious" enough to supply me the transmission from a 2V Norge for free to swap in.





$2,000 and a few days later, my Brevonna was back on her feet again, if not a little weary. The new box seemed to shift okay, but made a distinct warbling noise from the input shaft side of the box-- ONLY when accelerating or maintaining speed. Slowly, I kept riding to determine whether this was just another case of the infamous "standard guzzi noises". All seemed to be going well...  then yesterday, something loudly CLUNKED near the input shaft side of the box. Now my gears just sound 'wobbly', like they are not meshing well or being carried adequately at all. I suspect the point of failure to be a bad input bearing and will be changing the trans oil soon-- but ultimately I don't know how many miles are on this box and want a proper Breva box back in to have this whole bike "done correctly". There were also issues with my mechanic: missing bolts, kickstand not being fastened down upon delivery, etc...





In short,  a series of bad decisions were made in haste due to my anxiety about working on this bike myself when my previous experience has been exclusively working on chain-driven Japanese machines. I would like to have this job done right.

I have purchased a new, tested transmission from SunCoastCycleSports, and am armed with a motorcycle lift, torque-wrench, all the metric sockets and tools needed (so I believe), a label maker, spare parts catalog and factory service manual.

My background is in engineering. I am not a complete idiot, but far from experienced. I can do basic maintenance like adjusting the valve lash and checking/replacing all three fluids in the bike, but that's about as far as said experience lies.





My question, dear guzzisti, is whether this is a job I can take on-- and if so, what I need to know about it. It looks like (despite their strange design) crabbing the frame by the motor mount brackets is still viable on CARC frames, so I shouldn't have to completely drop the engine... but what should I worry about? How can I accomplish this? Is the service manual missing any critical information? I will take any advice or chastisement you folks would care to throw my way.

Grazie Mille,
- BrevaIsTheName

[guzzisteve]

Can't crab a CARC bike, frame wraps around & under the trans. Motor & trans comes out together. That is the quickest way. Been doing them 16yrs. No easy way.

[BrevaIsTheName]

yikes... good to know, thanks for the reply. Any tricks a novice should know before attempting? I won't lie, that sounds pretty daunting as I've never had to pull a motor completely before.

[guzzisteve]

Swing arm, pipes off & TB's loose from head. Take off breather LH front on cover, enough room to go forward, tilt & roll back of trans over the lump sideplates are bolted to. Then lift frame in back & slide motor & trans out to one side. Unplug & disconnect everything

Get the service manual, it's all covered.

[BrevaIsTheName]

Awesome! I have the service manual. Just checking, no "special" tools or major gaskets needed? I don't see any gasket between the gearbox and the motor, is that correct? Sorry for the barrage of questions, but I really appreciate your responses. 

Here is my incredibly basic shadetree setup right now:

[guzzisteve]

I have a copy of the Tune up Guide for Shade Tree Mechanic, it was put out by MCNOC for tuning up a Guzzi.
You will be OK

[BrevaIsTheName]

just found that.. this is awesome!! Thank you GuzziSteve! I'm stoked. This is my first big project and only makes me want to keep the bike for life if all works out :)

[guzzisteve]

I still have 2 of the new ones I bought in 80's. Going to work, have a 03 Stone to install clutch & fix oil leaks and put back together. Enjoy.

[Huzo]

For heaven’s sake don’t do it outdoors.
At least get a garden shed or something, give yourself a fighting chance at success.

[Pescatore]

You're a brave soul for doing this outside. Not impossible, but definitely an additional obstacle for a first timer.

 I'm guessing the Breva is a Norge w/o fairing.   If so, you might want to do other tasks, like air filter, inner spark plugs, generator belt... check oil pressure sensor for leaks, clean the engine.
All reasons for doing this indoors.
Please post your progress.

[BrevaIsTheName]

I wish I had space anywhere indoors. Sadly this is the only option for me at the moment short of dragging the bugger into my kitchen and going at it there... at least snacks wouldn't be a problem!

I have two jacks coming to support the transmission under the lift as the frame comes off. New fluids as well, and to top this adventure off, it's looking like I'll be grabbing a 750 Breva this weekend for an irresistible deal. ($1,000 and in need of "only" a new dash.. but we will see).

Either way, I promise to keep you all entertained throughout this. If anyone familiar with CARC guzzis has any input or tips facilitating easy remove and reinstallation, please chime in!

[moto]

Only a kitchen? Here's inspiration for you!

https://m.youtube.com/watch?v=b91iJMd1Nio

[n3303j]

When I moved to the new place there was no garage for the first year.
This $400 12'X15" tent with polytarp laid as a floor was the temporary solution.
Great garage built and tent now houses the lawn tractorand related devices.

[Moparnut72]

I once replaced a broken valve torsion bar in my buddy's 450 Honda in my kitchen. I was of course single and lived in a small mill house with no garage let alone much of a yard. We left on a 3 week ride through the north west with no further issues. Couldn't say the same for my BMW though.
kk

[guzzisteve]

When I moved to the new place there was no garage for the first year.
This $400 12'X15" tent with polytarp laid as a floor was the temporary solution.
Great garage built and tent now houses the lawn tractorand related devices.

This &  4 x 8 sheet of plywood to put bike on. No loosing parts in the grass.

[DoubleGuzzi]

Good ideas from n3303j & guzzisteve 

[BrevaIsTheName]

Great ideas! I think I will survive without the tent THIS time, but will put it on the list of things to buy before the fun purchases (exhaust, beetle map... various goodies). Thank you all for the ideas. I think I'll throw down plywood and a large tarp to watch the screws! Hopefully everything should be here by this weekend so stand-by before the updates really start coming :D Will post pic of the "operating room" shortly

[Huzo]

Where is your bike stored when you’re not tiding it ?

[kballowe]

HEY ! 

What's all this business about working on motorbikes in the kitchen ?