03 Stone Touring Revival

[chaoselephant23]

Howdy y'all!

Recently I inherited my uncles 03 Stone Touring!!! Thats the good part. Now for the bad news... it sat in storage for 8 years with a full tank of gas thanks to some pesky relatives:( All 8 years it was covered up by a DryRider. First 5 of those 8 years was in a fairly temperate garage. Last 3 of those 8 years was spent in a shed that was not good at keeping the weather or the critters out.

All summer long I have been procuring parts, tools and knowledge from all across the internet, service manuals, (this place:), etc... in the hopes of reviving a bike that I have wanted to ride the past 8 years. My plans are as follows:

* Oil change
  - new oil
  - new filter
  - replace or clean oil mesh filter
* Clean air filter box
* Replace air filter
* Replace fuel filter
* Clean inside of fuel tank
  - Going with SeaFoam
* Replace all fuel hoses
  - Visual inspection found cracked FI and Vapor Recovery hoses around connection points
  - FI with Gates 27340 Barricade MPI Fuel Line Hose
  - Vapor Recover with Goodyear 65126 and 65125
* Replace internal fuel pump hoses
  -  with Gates 27093 submersible hose
* Lubricate clutch cable
* Lubricate throttle cables
* Send fuel injectors out to RC Engineering for a cleaning
* Clean throttle body
* Balance throttle body
* Reset TPS (using excellent write up found on WildGuzzi.com)
* Replace spark plugs
* Adjust tappets
  - Will also be assuring that the hydraulic lifters are shimmed properly as per the service bulletins
* Tighten head nuts
* Gearbox oil change
  - Have the Moly Additive from Harpers
* Final drive oil change
* Front fork oil change
  - Going to do fork seals since I am in there
  - Also need to replace one of the dust boots
* Replace battery with Odyssey PC680
* Replace brake fluid
* Replace brake pads (if needed)
* Adjust wheel spoke tension (if needed)

Statement of work done! Now time for Q&A:

* Visual inspection found some small cracks in the front and rear tire. Do they need to be replaced?
  - Tires inflate to values in MOM without issue
  - Holding pressure without loss for past week

* Throttle moves very very slightly. Hoping that lubricating the cables frees them up. Where to next, should lubrication not be enough?

* Should I clean the fuel tank with the submersible pump in or out?

* Any tests I can run on the submersible pump to verify it still functions?
  - If operational, would you clean the pump? How would you clean the pump?

Anything missing? Anything optional? Anything listed you would recommend against?

Thanks in advance to all!

[Curtis Harper]

That's a long list. If you want to call, I will help you out. I don't type that much. 816.797.2753.

[sturgeon]

Stored for 8 years? I'd replace the tires without question.

[Steph]

You've got more patience than me!
I would have checked the oils, put a new Odessey battery-in and gone for a ride :)
Work-out the details later -life's too short.

Then you would have guess that your uncle parked it because it needed a new clutch and gone from there.
K.I.S.S. comes to mind  ;)

[Sasquatch Jim]

  03?  it may suffer from worn cam lobes if it didn't get the factory upgrades.
  That was the year engines were failing from over fast wear of cams and rocker problems.
  Don't ask how I know.

[balvenie]

            While/when/if the back tyre is off, remove the bevel box and lube the driveshaft splines. Replace box, lube splines in bevel box.

[fotoguzzi]

Welcome! can I just call you Chaos? that's a pretty big list.. with a lot of editing you could be riding by Sunday..
I'm w/Steph..
suck out all that old gas and put in some fresh non-oxy, check oil and tire pressure.. see if it runs..

[Rich A]

I'd put on some shoes on the bike if the old ones are cracked.

I'm with the other folks: get the throttle working smoothly, get rid of the old gas and put in some new, change the oil and fire it up. Do the other stuff, as needed, in the winter.

Rich A

[twhitaker]

Moly goes in final drive, not gearbox but it's okay if it's already in the tranny.

[twhitaker]

I agree with the responses above. If the bike was ridden much by the PO the internal fuel hose was, most likely, already replaced. The hose and pump should have survived the long immersion fine. I would not send the injectors out preemptively either. Since the tank was filled it should be in pretty good shape. Add a dose of Seafoam and see what happens.

[chaoselephant23]

Glad I consulted the Oracle's first. I've had the urge to cast off my patience as I can feel the bike sputtering into life already (no really its a recurring dream:)

Got down to business last night after work. Removed the tank. Removed the air box. Found it coated in leftover mice piss and stuffed full of pink fiberglass insulation. Checked the throttle action. When I engage the throttle, the left cable (standing from behind the bike) starts to move, but that's all that moves. With luck I'll get the chance to have more time observing this evening. Most definitely this weekend.

Stored for 8 years? I'd replace the tires without question.

Added to the winter list!

Then you would have guess that your uncle parked it because it needed a new clutch and gone from there.

Luckily the bike has the double plate clutch! During my initial research I came across the single plate nightmares. Scared me pretty bad. But thanks to you diligent forum members I was able to figure out how to identify the clutch type. Pic from the inspection hole. Note the clutch dust. Blew out the chamber with compressed air. Not much came out, but a nasty smell did. Fingers crossed.

  03?  it may suffer from worn cam lobes if it didn't get the factory upgrades.
  That was the year engines were failing from over fast wear of cams and rocker problems.
  Don't ask how I know.

About a month ago I contacted New Haven Powersports, New Haven, CT inquiring as to which recall services were not performed. Two came up: fork and valve/camshaft inspection. As far as I can tell from the Service Bulletin, properly shimmed hyrdraulic lifters avoid the issue. When I adjust the tappets (this winter:) I plan on verifying the clearances as per the service bulletins procedure. In addition, I plan on bringing the bike in for the inspections. Just need to find a trustworthy mechanic in CT or vicinity.

            While/when/if the back tyre is off, remove the bevel box and lube the driveshaft splines. Replace box, lube splines in bevel box.

Added to the winter list!

Moly goes in final drive, not gearbox but it's okay if it's already in the tranny.

Good to know on both fronts. Luckily I haven't changed the oil yet.

[chaoselephant23]

I have a feeling that I am almost there ;D

This weekend I got:
* Throttle working smoothly again
* Cleaned the air box
* Replaced the air filter
* Drained the old gas from the tank and filled with SeaFoam treated 93 Premium
* Checked all oil levels
* As per Harpers FAQ, sprayed penetrating oil into spark plug holes, let sit for 12 hours and slowly rotated crankshaft until it rotated freely
* Installed new battery

Turned key to Start position. Flipped engine stop switch to Start position. Hear the fuel pump engage. Checked that the headlights worked, turn signals and horn worked. Pressed the starter switch. POP!!! 15A fuse blew.

Pulled the starter relay and cleaned the contacts. Pressed the starter relay firmly back into place. Went through the ignition sequence. Blew the fuse again. This time however I heard the starter relay click.

Next I checked for loose connections from the battery to the solenoid. Everything is tight. Read the voltage on the battery. And the voltage at the solenoid. Same values: 12.84V.

Next I cleaned all the battery contacts and exposed fresh metal. Applied some dielectric grease to all contacts. Then connected em to the battery. Went through the ignition sequence. Blew the fuse again.

I then placed a screwdriver from the +12 solenoid terminal to the tiny start trigger terminal on the solenoid in hopes of un-sticking the solenoid. Got sparks to fly. Figuring I did not get this procedure right.

Next I focused in on the ignition switch. The soldered connections were a little dirty. Cleaned em up. Blew the fuse again.

Going to keep reading up on how to test electrical circuits. And scour the forums for any tips, tricks and testing procedures.

Tonights test are:
* more thorough inspection of solenoid connections
* voltage drop at the solenoid when the ignition switch is engaged

[fotoguzzi]

which fuse is blowing?

[chaoselephant23]

Fuse F2, Key Switch.

[krglorioso]

Chaos:  You said above that you are "going to adjust the tappets this winter".  Your bike is a "hydro" (I own two) and you don't adjust the tappets/valve clearances.  Really.  As in, "Never".   Leave them alone.  They're fine.

Ralph

[Chuck in Indiana]

Ok, now you know why he parked it. Sounds like the starter is frozen up from the magnets coming loose. You *can* turn the engine over by hand, right?

[geoff in almonte]

What Ralph said wrt to valves.  It's a hydro - you should never have to adjust them.

Having said that, if the cam recall has NOT been done.  DO IT!  You dont need little bits of your cam circulating thru your motor.

If you can provide the VIN, there is a lister who will research the vehicle's history wrt factory recalls.  Or remove the rocker boxes and post a pic of the valves/rockers - there will be visual evidence that the recall has been performed.

Cheers!

G

[Dilliw]

I blew that same fuse with a loose connection.  Keep checking them.

"Applied some dielectric grease to all contacts."  Uh oh raggy!

Check for hydro recall (see above) and check if it is a single or dual plate clutch (pics are on this forum).  Do these first!

[Gootsz]

STARTER

Chinese works fine mine 4 years old

http://www.ebay.com/itm/Moto-Guzzi-Starter-D6RA21-D6RA210-750-1100-1969-04-12V-18355-/201162016239?pt=Motorcycles_Parts_Accessories&hash=item2ed630c5ef&vxp=mtr#ht_2070wt_758


micky

[chaoselephant23]

Chaos:  You said above that you are "going to adjust the tappets this winter".  Your bike is a "hydro" (I own two) and you don't adjust the tappets/valve clearances.  Really.  As in, "Never".   Leave them alone.  They're fine.

Ralph

Excellent to know!

Ok, now you know why he parked it. Sounds like the starter is frozen up from the magnets coming loose. You *can* turn the engine over by hand, right?

Yes, I was. Sprayed penetrating oil into heads from spark plug holes. Let sit for 12 hours. Rotated the crankshaft slowly until it freely rotated.

I blew that same fuse with a loose connection.  Keep checking them.

"Applied some dielectric grease to all contacts."  Uh oh raggy!

Check for hydro recall (see above) and check if it is a single or dual plate clutch (pics are on this forum).  Do these first!

Guzzi dealer, New Haven Powersports in New Haven, CT was kind enough to run my VIN. Here are the recall inspections that were NOT performed:
* CAM
* Front Fork

Luckily the bike has the double plate clutch. Proof is in the pudding: https://drive.google.com/file/d/0B6D0kHUZb3RtY3NkYVl6alQyQnM/edit?usp=sharing

STARTER

Chinese works fine mine 4 years old

http://www.ebay.com/itm/Moto-Guzzi-Starter-D6RA21-D6RA210-750-1100-1969-04-12V-18355-/201162016239?pt=Motorcycles_Parts_Accessories&hash=item2ed630c5ef&vxp=mtr#ht_2070wt_758


micky

Thanks for the tip! Hopefully I won't have to, but good to know they can be had for less than a hundo.



Didn't get the chance to run my growing lists of tests (no thanks to Kiwi_Roy's input in various other postings:) last night:( Busy preparing for a camping trip this weekend! Chances are I won't be able to run my tests until my day off on Monday. Post up with more findings as I get them.

Been having the feeling that the +12 lead out to the starter needs to be cleaned, greased up and reconnected. Fingers are crossed!

[rodekyll]

Consider the engine to be junk until the cam recall is done.

[Chuck in Indiana]

Been having the feeling that the +12 lead out to the starter needs to be cleaned, greased up and reconnected. Fingers are crossed!

You've already said you jumpered the starter and it didn't crank. I'm still saying the starter is toast. No cam recall done? <sigh> I know of one 40K mile bike that hasn't had it done, but it's the ONLY one. The triple tree crack is easy enough to inspect.

[Dilliw]

Luckily the bike has the double plate clutch. Proof is in the pudding: https://drive.google.com/file/d/0B6D0kHUZb3RtY3NkYVl6alQyQnM/edit?usp=sharing

Great to see!

Bunch of bikes went over 30k waiting on the hydro kits to hit stock back in '05-'06 (mine did 36k), but it's the first issue you need to address. You don't want a bunch of metal in that motor.  There have been a couple of posts on here in the past few months that have been able to get that covered by MG so start working that now.

[rodekyll]

And don't forget to have the oil pump examined during the cam procedure.  That's where the metal bits go.

[chaoselephant23]

You've already said you jumpered the starter and it didn't crank. I'm still saying the starter is toast. No cam recall done? <sigh> I know of one 40K mile bike that hasn't had it done, but it's the ONLY one. The triple tree crack is easy enough to inspect.

I am somewhat suspect of the jumpered starter tests results. Are sparks supposed to fly when the jumper, in my case a screwdriver, is connected?

And don't forget to have the oil pump examined during the cam procedure.  That's where the metal bits go.

Added to my reminders. Thanks!

[cookiemech]

Great to see!

Bunch of bikes went over 30k waiting on the hydro kits to hit stock back in '05-'06 (mine did 36k), but it's the first issue you need to address. You don't want a bunch of metal in that motor.  There have been a couple of posts on here in the past few months that have been able to get that covered by MG so start working that now.

I surely hope that MG is still covering that one. Right now I'm awaiting MG approval to cover this job on my 03 Aluminium (VERY low miles) that was supposedly done back in about 2005 by a local dealer, for the previous owner. Was never done. Europa Macchina is trying their best for me.

[Chuck in Indiana]

I am somewhat suspect of the jumpered starter tests results. Are sparks supposed to fly when the jumper, in my case a screwdriver, is connected?


Added to my reminders. Thanks!

Yep. Electrons gotta go somewhere.. ;D

[Cal3Me]

remove the starter and bench test it.....see if it kicks out the gear or not?  ???


Tim

[krglorioso]

You've already said you jumpered the starter and it didn't crank. I'm still saying the starter is toast. No cam recall done? <sigh> I know of one 40K mile bike that hasn't had it done, but it's the ONLY one. The triple tree crack is easy enough to inspect.

Yes, very easy to inspect.  Also, I believe the at-risk lower triple clamps had "35-02" stamped on them.  Mostly the 2002 and early 2003 models had these, from what I recall.

Stay away from the cheap Chinese starters.  They run about $100 on E-bay.  For under $200, you can get a genuine Valeo.  They last a lot longer and won't get you stranded.  Remember, you cannot bump start an EFI Guzzi.

Ralph

[chaoselephant23]

Had a chance to bench test the starter today. First test didn't get the gear spinning. So I disassembled the starter. Cleaned up the gears and other moving parts. Started playing with the action of each mechanism. Got the solenoid to click. Then the stater shaft started to spin freely. Reassembled. Performed another bench test... Gear started spinning!!!!!

I put the starter back in the bike. Performed the starting procedure. Fuse F2 did not blow. Bike didn't start :-[

Going to replace the spark plugs. Figure they may have fouled. If that's not it I'll be trawling ye olde internet for more data.