Unkept's V11 LeMans Repair, Maybe Restoration, Thread

[Mayor_of_BBQ]

Not sure if you have too many pics, or if they are too large.. but this thread is glacial in pace if it doesn't cause a full-on lock up!

Im on an older MacBook Pro using Firefox

[Unkept]

Nice work guys!

Something that you might want to do before you mount the rear shock reservoir is weld the nut onto the back side of the shock reservoir bracket.  If you that do then you only need to remove one cap screw (the 9 o'clock screw on the porkchop) to get the reservoir out of the way if you need access to the starter solenoid or need replace the shifter pawl spring, which is something else that you should consider if you haven't done that yet.

Wow, that is a good idea. Unfortunately I'm away from Chuck and his master skills and tools at the moment, and I'll probably be re-assembling the bike before too long. The next time I tear it down though (most likely there WILL be a next time. :) ) I'll certainly remember this suggestion. Thanks!

Not sure if you have too many pics, or if they are too large.. but this thread is glacial in pace if it doesn't cause a full-on lock up!

Im on an older MacBook Pro using Firefox

I'm going to have to spend some time and re-upload all of those pics compressed for web viewing. My apologies to you fine folks and your dinosaur computers.  ;)

At least you created a new page, so it should load this page just fine seeing as no photos are up yet. Page 3 is currently my "doomsday" page.  ;D

Joe the tensioner and plate you are trying to fit looks suspiciously like the old big block type to fit 70s/80s Guzzis but to be honest as I have never worked on a more modern V11 or some such, could not say if the tensioner and plate have changed?
That marine fuse box setup looks like an excellent idea. Probably especially for a more powerful modern, brushless alternator output.
Great thread and pics, thanks.

 :)

Rob

I really think you are right, and that they made some kind of change to that plate to accommodate the 1100 blocks are some point... but I don't know those tiny differences so we could both be wrong. *shrug*

The "old" V11 sport tensioner is likely going back in. I'll decide soon enough. A new chain though.

I really like the idea of that fuse box. I might replace the entire old one with another multi-fuse marine unit at some point.

Thank you for your kind words.

-Joe

[Chuck in Indiana]

Where my antique computer chokes is the pix you posted after coming here the last time. You kids and your lightning fast computers..always the latest thing.. probably even your phone takes pictures. Get off my lawn!  ;D

[Zoom Zoom]

Where my antique computer chokes is the pix you posted after coming here the last time. You kids and your lightning fast computers..always the latest thing.. probably even your phone takes pictures. Get off my lawn!  ;D

Camp out at Chucks house............. ;D :BEER: ~;

BYOB

John Henry

[Vasco DG]

Feel the rage! ;D

Where's my ear-trumpet? I can't hear the gramophone!

Pete

[Unkept]

You guys are cracking me up.  ;D

-Joe

[zedXmick]

Since you are going to work weekends anyway,you might as well upgrade to a no timing chain setup. ;)

Thanks for the very informative repair thread, I am anxiously awaiting the finished motorcycle.   :bow

[RayB]

U.K.:

This is quite the endeavor.
I haven't been keeping up with WG for a while.

When you asked about painters, etc last year I thought you were just going to clean some things up and have the tank painted!

Hope you didn't get caught up in the "While I'm in there" syndrome. And here I was last week fretting about spending $140 for another case of liquid gold AKA i-Ride 10W60.

Think you'll be finished in time to ride it to Elkader?

[Unkept]

Since you are going to work weekends anyway,you might as well upgrade to a no timing chain setup. ;)

Thanks for the very informative repair thread, I am anxiously awaiting the finished motorcycle.   :bow

Thanks! I can't wait to see it finished either...  ;)

Regarding timing gears vs. chain... I love the debate, and having read many of those threads myself I'm still leaning towards chain being the superior solution for a reliable Guzzi... there are always exceptions.

If I could find a set of custom made steel timing gears for an FI Guzzi I'd be ecstatic however.  ;-T

U.K.:

This is quite the endeavor.
I haven't been keeping up with WG for a while.

When you asked about painters, etc last year I thought you were just going to clean some things up and have the tank painted!

Hope you didn't get caught up in the "While I'm in there" syndrome. And here I was last week fretting about spending $140 for another case of liquid gold AKA i-Ride 10W60.

Think you'll be finished in time to ride it to Elkader?

It's become quite a project eh? The irony of course is I haven't even touched the paint job! It's fallen off my radar.  ;D I did get a touch up pen to try though... more on that at a later point.

Elkader... it's the one Guzzi meet I'm absolutely trying to make. Have the time off at work and everything, so fingers crossed I'll be there... hopefully my wife and I will both be there on each of our own Guzzis!

-Joe

[Chuck in Indiana]

Whew , thought it was just my stone age device that was causing the issue , on the back it says " inspected by Ugh.
Joe , you are making me feel old , so much energy  :bow Ahh youth , when did thee dessert me ? Now just hurry the heck up and get this thing done  :D
Dusty

Yeah.. he's only working 7 days a week. He's slackin if he doesn't get it done shortly..  ;D

[Unkept]

Hey Guys,

Just a thread bump mostly. I just batch downloaded the photos, compressed them 80%, and re-uploaded them. Please let me know if page 3 loads better for you now!

I also have setup my camera in the garage with time lapse, so soon I'll be putting the bike back together and taking time lapse photos of it. I hope it'll make a cool video.  ???

Still waiting on just a few parts from MI.

-Joe

[fotoguzzi]

Nothing wrong with the stock tensioner..good to get a new chain tho. and I don't think the timing gears will work the cam sensor.

hope to see ya at Elkader, I'll be late Friday or maybe not till Saturday, can't get off Fri.

[Chuck in Indiana]

Please let me know if page 3 loads better for you now!

Chrome crashed again. Twice. It *is* better, though.

[Unkept]

Chrome crashed again. Twice. It *is* better, though.

Thanks Chuck.

OK! I find that the forum re sizes photos to 800x600, or 600x800 anyways... so I used the new nifty program I found to compress each image at 80% and to resize each photo to the forum resolution.

This should improve speeds and decrease those kind of issues... let me know! I've already replaced the album once again with the even smaller photos.

-Joe

P.S. The program rocks, it's truly free, and it's called Caesium

[Chuck in Indiana]

Alrighty, now.. Chrome walked right through them.  ;D First time I've seen all the pix. Now. Get to work on that lemon.. ;D It's no hill for a climber.  ;-T

[CalVin2007]

  Much better Pg 3, Joe.  ;-T  Thanks. There's gotta be a couple hrs a week when you're not working....so put that thing together and ride! ;) ;)

   Terry

[Unkept]

Ok guys, got some sh*t done today.  :D

Ah, I remember where I left off now...  :-\


Time to give the pup a new chain.


Set up a camera for time lapse. I've never tried this before.



Another set of eyes to watch me as I work.


Looks right to me. Don't worry, the timing marks only moved after I put them on... I had tightened the stuff down and turned over the engine before I took the pic.


MAKE SURE to put the tiny key into the oil pump before you slide the assembly on. It's easy to lose...

I placed the gasket on carefully, applying light coats of oil to each side, and mounted it up!


Hopefully the area doesn't get oily again...


Take some pictures Joe... I was kinda rushing it today so my photos weren't great. I used the point and shoot instead of the DSLR.


Make sure to tighten the screws and check that the gasket isn't being snagged and is sitting correctly... then tighten stuff up. :) I then put the electrical stuff back in.


This is another part of the process which uses a small key on the crankshaft, place the key on and line up the alternator.



There is a little rubber grommet for the wiring, don't forget that...


Wooo

I can do one more thing tonight.


This is the easy part.


The back part of the hose is very annoying.


Looks ok to me.


A little better!


Goodnight...

-Joe

[balvenie]

           Sleep well Joe, you've earned it ;-T

[Chuck in Indiana]

Attaboy..  ;D

[Unkept]

Thanks for the encouragement guys. Another 10 hour Saturday shift tomorrow, *sigh*, so I'm not sure how much I'll get done again until Sunday. Gonna have to miss the Guzzi lunch.  :'(

So I did some "small things". I should have my pivot cover, battery tray, and throttle cable early next week though... once I have those things I'll be comfortable with putting the front end of the bike back together!  ;D

Pile o' stuff to do.


Easy job #1. My rear axle has always been missing it's own plug.


Tad-ah!



Easy job #2. Replacing the fork pinch bolts. The hard part is that Guzzi discontinued the item, and even Moto International couldn't find the info to get the right bolt. A trip to Lowes and I found them though....


For Guzzista reference. At least on the 2002 V11 LeMans, the fork pinch bolts GU01530595 are replaceable with a socket cap screw. M6-1.00 x 25.


I can't remember if I broke this or not... regardless, it was hanging on for dear life and it bothered me.


Replaced easily enough.


Next up, replacing the old fuel filter. This is a pretty easy job, but be sure to catch the fuel which will spit out of your FI lines.


The new, smaller, cheaper, Japanesier, fuel filter I received from MI.


Be sure to check the markings on the fuel filter, "out" should be on the "downward" side toward the rider, not upwards towards the dash.


Next up, these cracked old buggers.



They weren't crumbling or anything, but knowing my luck one would crack and create an air leak sooner than later.

You'll have to take off two little bolts to move the throttle bodies back enough to remove and install the intake sleeves.


Viola... is that how it's spelled?


Changing my old rubbers for new.  ;D


They are a bitch to install, but wrigglin' and pushin' will get the job done. Those clamps may come loose, don't worry about it. Just unscrew them almost all the way, and while wearing gloves... pull them back together.



Checked them out, and woohoo the bolts MI sent me do fit for the front subframe. The old Guzzi bolts were the easy to break hex head versions.


I also decided to replace some of the sealing washers used on the oil return lines.




Speaking of which, if you've noticed I'm ditching my airbox in favor of long runner pods. So I need to route any oil vapor to atmosphere since I don't have an airbox for it to go to anymore.

Need a longer line.


Rockin' out! and installing oil vapor lines...


Peace, and also... I decided to route the line to where the tank overflow goes.


I decided to get curious about the clutch hose replacement.



I routed the hoses side by side to show the difference when installed.


At the back, this is where you swap the hoses. 11 wrench.



Now removing the hose from the lever assembly was very hard... but if it were mounted to the bike it would've been easier I reckon. Loosen that puppy before you pull the bars!


Another days work.


-Joe

[oldbike54]

Joe , your'e making me tired just watching  :D Geez , so good to see young folks carrying on the tradition of
"I want to see how this thing works" , you make us proud  ;-T

Dusty

[balvenie]

             Never mind the spelling. We're here for the bike story ;-T

[Zoom Zoom]

As you're making progress toward reassembly, if you have not though about it, you should consider putting anti-sieze on many of the bolts so you can get them back out in the future. (You probably have but I felt it worth mentioning.)

Glad to see things are coming back together Joe. ;-T

John Henry

[Chuck in Indiana]

Well, the pile on the floor is getting smaller.. that's a good sign.  ;D

[zedXmick]

Way to go Joe....you might have to change your screen name to "keptup"  ;D

One tip....you might want to buy a quality kneeling  pad for your knees.....trust me when you get to be +50 years of age your knees will thank you. ;)

[Unkept]

Joe , your'e making me tired just watching  :D Geez , so good to see young folks carrying on the tradition of
"I want to see how this thing works" , you make us proud  ;-T

Dusty

I want to see how everything works... "Question everything" is my motto.

            Never mind the spelling. We're here for the bike story ;-T

 :)

As you're making progress toward reassembly, if you have not though about it, you should consider putting anti-seize on many of the bolts so you can get them back out in the future. (You probably have but I felt it worth mentioning.)

Glad to see things are coming back together Joe. ;-T

John Henry

Hey John, thanks for the tip. I was being a bit neglectful... and due to your reminder I decided to remedy that.  ;-T It's anti-seize or thread locker on anything I touch.  :BEER:

Well, the pile on the floor is getting smaller.. that's a good sign.  ;D

Yep yep!  :)

Way to go Joe....you might have to change your screen name to "keptup"  ;D

One tip....you might want to buy a quality kneeling  pad for your knees.....trust me when you get to be +50 years of age your knees will thank you. ;)

That's a fantastic idea. I'm a bit out of funding at the moment, but once this project is "done" I plan on doing a bit of a site survey and seeing how I can improve my work flow in the garage. I'm thinking an adjustable stool, and a workbench is my best bet. Kneeling pad should be a good addition.  ;-T

Well firstly, yesterday I decided to try and clean the exhaust a bit more.


Using this wire brush I was able to get spots cleaner, but it's still stubborn with 12 years of caked on bug guts and pitting stainless.



Today I got some goodies from MI and from some jolly folks in the UK...

The pivot/swingarm cap/cover I've been missing since I bought the bike!



New rubbery tray for the battery.


Rare in the USA as hen's teeth Champion spark plug caps. The stock caps on a V11 Sport. I only needed one, but the shipping was the main cost so I bought three.  ;D These are only available from England it seems.


And the longer throttle cable.


Replacing the cap is easy peasy.


Just unscrew, and screw on your new cap.


I even transferred the little labeled collar.


A tale of two pivot covers.


A mockup of the swingarm with covers and inner fender installed.


Battery tray comparison.


Ah, so much better.


To remove the old throttle cable, I had to loosen the fuel pump. It snagged the cable, preventing it from moving.


I was excited about the cable...f&$(


The cable I got was for a Ballabio, my fault, but I didn't know the Ballabio and later model handlebar V11 Sports have a different throttle setup.

There is this bend and different thread adapter, because the new one uses a throttle cable and a throttle return cable for added safety. Bummer, won't work!

So I did some research and found the only stock cable which would work and is longer is the V10/Centauro cable. Luckily, MG Cycle shows one in stock! SO I made the order and hopefully our friends at MG Cycle will get me one this week.  8)

Let's attack the o-ring for the timing sensor.


Honestly, the original looks OK to me... but let's replace it anyway.


I've been using this stuff on the hot areas, thanks again Zoom Zoom/John.


Woo, stay clean timing sensor and oil pressure sensor!


As an aside, I flushed out the old grease in the driveshaft and it's u-joints. I like Lucas red synthetic... but lets not turn this into a grease thread.  ;) ;D


Mocked up the front subframe, now with functional solenoid mounts. The old ones had fallen apart, but Chuck re-glued mine.  ;-T Thanks again for all of your help Chuck.


I'm holding off on installing the front bits until my throttle cable arrives.

Time to bust out the red stuff, only using this on one area.


Say hello, to the rotor bolts from hell. Red loctited in there, I'll remember a torch next time.  ;D


I had planned on doing more, I did spray down the bike with a more concentrated dose of Simple Green. I then tried to mess with the steering damper, and proceeded to stab myself in the leg with a small pick.  :o Ouch.

So I put some antibiotics on my pinholed leg, and made this post.  :BEER: I called it a night.

That's all for now folks, hope you are entertained.

-Joe

[zedXmick]

Great work...it's coming along nicely.  Here is the knee pads I use. Very good quality pad.

The model 5050 ErgoKneel
Specifications:
Reduce knee trauma and low back stress
Made of heavy, resilient, 1 inch closed-cell foam rubber
Prevents compression setting
Non absorbent
Impervious to petroleum
Self extinguishing and non-conductive
Easy to clean
Size large, 14 in. x 21 in.
Part Number:
5050

[Vasco DG]

I fin fit really satisfying to see a kid knuckling down and working it through. I have customers who cry like babies if their bike blows an indicator globe.

While the bevelbox is off I'd suggest pulling the pinion carrier and crownwheel plate. The pinion nose bearing is a bit weedy on V11's. Look at the CW&P at the same time. I have a second hand set I'll donate as an 'Encouragement Award' if you need a set. Chuck can learn ya how to set 'em up.  ;D

Pete

[Rob Morton]

 :+1

IMHO a kneeling pad is a much idea than knee pads which can actually damage your knees by not centering your weight on the patellas, when in a kneeling position.
How do I know this, building work.

Unkept it must be great to get all those bits replaced you've been needing to for ages.

 :bow

Rob

[Zoom Zoom]

Along with the kneeling pad, Sears has a decent and inexpensive shop stool. 30 bucks gets you a stool with wheels that lets you work low and still be able to sit, and roll around.

Boy, once you get things back together, you're not going to know how to act. ;D



John Henry