Author Topic: 2009 Stelvio. Cracked Fork/Axle Pinch Bolt Damage. Help Please. (Read 31866 times)

sthomag · « **Reply #60 on:** September 11, 2015, 07:06:47 AM »

In your place I would start looking for a salvaged fork assembly from another ADV bike. You might even be able to find one that has the same or close the the same offset. If you do, you'd probably have to have a new stem machined, or the old one modified to fit. The stack height of the headstock and bearings are another consideration, but with most forks you have a considerable amount of leeway by moving the lower triple clamp up or down on the fork legs. A further consideration would be the master cylinder; you want to use the master cylinder from the donor bike, or make sure yours is the same diameter.

If the offset differences are too great, perhaps the old triple clamps can be a) bored out, or b) shimmed to accommodate the new legs. Or you might want to consider having new triple clamps made. There might be someone out there that does that all the time, and can do it for a reasonable price. I realize these are leading axle; are there any other long-travel street bikes out there with leading axle forks?

lucky · « **Reply #61 on:** September 11, 2015, 07:45:35 AM »

I don't know what determines these things, but my '09 Stelvio fork leg was replaced gratis earlier this year here in Toronto thanks to George at Corsa Meccanica.

Lannis · « **Reply #62 on:** September 11, 2015, 07:50:59 AM »

Quote from: lucky on September 11, 2015, 07:45:35 AM

I don't know what determines these things, but my '09 Stelvio fork leg was replaced gratis earlier this year here in Toronto thanks to George at Corsa Meccanica.

What might be driving it is a very smart and caring dealer who is doing what is necessary to assure that he has a customer who will come back to him for his next bike, all his parts, and any necessary repairs.

It would work on me, I'll say that ....

Lannis

Xlratr · « **Reply #63 on:** September 11, 2015, 09:37:49 AM »

Quote from: mphcycles on September 10, 2015, 08:51:30 PM

this probelm, while not common is not unheard of. I would never weld it. its cast pot metal. The one case I heard of was torqued by Larry with a digital snapon 1/4 drive wrench. The boy is meticulous about torquing fasteners. The bike we touched broke the clamp 1500 miles later in Canada.
I would source a later fork assembly if pointed emails to customer service didnt get you reults

The only time I ever get my torque wrench out is for stuff like cylinder heads. I can't imagine why anyone would want to use one on anything else. Especially on stuff like pinch bolts. I suppose, if you're a dealer in the land of litigation you're always on the safe side if you use a torque wrench. ;-)
John

WitchCityGuzzi · « **Reply #64 on:** September 11, 2015, 12:09:47 PM »

Right after I got my 09 Stelvio, the dealer cracked on side of the fork legs during a tire change. It was right before a trip and I was desperate to get a replacement. I found that Teo Lamers in the NL had them in stock, but right before I ordered it, the dealer got the replacement from Guzzi so all was good.

Interestingly, when they replaced the side that was broken, they also replaced the bolts. The bolts they replaced them with were small head allen bolts with no shoulder. The new side had more material around the bolt hole because it wasn't machined out for the shoulder of the original bolt.

The good news is, that that was 5 years ago now, and the original side has never been broken with the installation of the updated bolts.

Hope you find a solution. Have you tried contacting Marzocchi directly? Maybe they can help.

Not great pictures, but you can clearly see the difference in the bolt and the casting.

This is the original side...

This is the new side. Notice how there's more material around the bolts.

At the very least, if you repair them, I would use the smaller head allens.

Doug

Lannis · « **Reply #65 on:** September 11, 2015, 12:12:52 PM »

Quote from: Xlratr on September 11, 2015, 09:37:49 AM

The only time I ever get my torque wrench out is for stuff like cylinder heads. I can't imagine why anyone would want to use one on anything else. Especially on stuff like pinch bolts. I suppose, if you're a dealer in the land of litigation you're always on the safe side if you use a torque wrench. ;-)
John

Except that if you use a torque wrench on these unsupported dual clamp bolts, you will snap the clamp right in two ....

Lannis

WitchCityGuzzi · « **Reply #66 on:** September 11, 2015, 12:14:59 PM »

FWIW, I use a torque wrench on mine. I only make one pass on each though. Perhaps just lucky.

Lannis · « **Reply #67 on:** September 11, 2015, 12:47:21 PM »

Quote from: WitchCityGuzzi on September 11, 2015, 12:14:59 PM

FWIW, I use a torque wrench on mine. I only make one pass on each though. Perhaps just lucky.

I don't know. Better check the torque on that first one you did! JEEZ, it's barely more than finger tight! I KNOW I torqued it to 7 whatevers. All right, I got it now ... Now the OTHER one is just about finger tight!

Nothing else works like that except an unsupported dual-bolt clamp. Cylinder heads, flange covers, nothing else that we ever torque works like that. Is it any mystery why we find broken clamps ... ? Hardly any point in using a torque wrench if you're going to ignore the reading, which you have to do ....

Lannis

Lannis

catneck · « **Reply #68 on:** September 11, 2015, 01:02:09 PM »

Quote from: Lannis on September 11, 2015, 07:50:59 AM

What might be driving it is a very smart and caring dealer who is doing what is necessary to assure that he has a customer who will come back to him for his next bike, all his parts, and any necessary repairs.

It would work on me, I'll say that ....

Lannis

It would work on me too.
I am a serial bike buyer.
I want a V7.
But not if Piaggio customer service (per dealer, whose hands are tied, asked me to contact parent company directly) will not return email query.

ridingron · « **Reply #69 on:** September 11, 2015, 01:12:16 PM »

I had the same set up on another bike. I don't recall it being aluminum or steel but I would guess steel. The fork leg was a 1 piece unit including the clamp. I never used a torque wrench and never had a problem. Maybe it is because I use an "Allen" wrench not a socket and ratchet. The little Allen wrench kinda hurts your hand when you start pulling hard on it.

I guess that would be a different kind of torque wrench. Based on a pain index instead of a thought out system based on length and force.

oldbike54 · « **Reply #70 on:** September 11, 2015, 01:23:52 PM »

The handlebar clamps on old airheads were non symmetrical , the manual clearly states to tighten the skinny side first , and then the fatter side . The fatter side was designed to have a larger gap . I don't think any torque figures were published .

Dusty

catneck · « **Reply #71 on:** September 11, 2015, 03:50:54 PM »

Quote from: WitchCityGuzzi on September 11, 2015, 12:09:47 PM

Right after I got my 09 Stelvio, the dealer cracked on side of the fork legs during a tire change. It was right before a trip and I was desperate to get a replacement. I found that Teo Lamers in the NL had them in stock, but right before I ordered it, the dealer got the replacement from Guzzi so all was good.

Interestingly, when they replaced the side that was broken, they also replaced the bolts. The bolts they replaced them with were small head allen bolts with no shoulder. The new side had more material around the bolt hole because it wasn't machined out for the shoulder of the original bolt.

Hope you find a solution. Have you tried contacting Marzocchi directly? Maybe they can help?

This is the new side. Notice how there's more material around the bolts.RL]

At the very least, if you repair them, I would use the smaller head allens.

Doug

Thanks
I emailed Marzocchi. I will be using allen bolts too.

Mayor_of_BBQ · « **Reply #72 on:** September 11, 2015, 09:15:25 PM »

Quote from: catneck on September 11, 2015, 03:50:54 PM

Thanks
I emailed Marzocchi.

I don't think you will be getting a reply on that one

catneck · « **Reply #73 on:** September 16, 2015, 06:33:55 PM »

Quote from: Mayor_of_BBQ on September 11, 2015, 09:15:25 PM

I don't think you will be getting a reply on that one

Correct.
Crickets from Marzocchi.
Their website brags of their affiliation with Tenneco.
Is that still curent?
Not a peep from Piaggio either.
Guess I had to try.

WitchCityGuzzi · « **Reply #74 on:** September 16, 2015, 07:21:42 PM »

Did you try Teo Lamers in the Netherlands. They had them in stock when mine were broken?

Porterhouse · « **Reply #75 on:** September 17, 2015, 06:14:10 PM »

Didn't I just read somewhere that Marzocchi had gone tits?

Kiwi_Roy · « **Reply #76 on:** September 17, 2015, 07:03:33 PM »

Sorry but I think I would have come up with a fix by now

Ducking, running.

catneck · « **Reply #77 on:** September 18, 2015, 03:56:05 PM »

Not my only bike, I keep waiting on a workaround revelation, or a used setup.

catneck · « **Reply #78 on:** September 23, 2015, 05:52:05 PM »

Just bucked up for new. Looking forward to getting the Guzzi off the lift and on the tarmac.

brlawson · « **Reply #79 on:** September 23, 2015, 06:23:31 PM »

http://www.tlm.nl/en/parts/used-parts/gedemonteerd-stelvio-8v/

As posted earlier, Teo Lamers is a good source for Guzzi part. Very competent dealership.

The have an 09 recently broken down. Send them an email. As I have a 2010 model I do keep diligent about not breaking my own. I would try to get both fork in there entirety.

catneck · « **Reply #80 on:** September 23, 2015, 08:58:53 PM »

Sent an inquiry their way last week.
Cost prohibitive.
My local(ish) dealer is getting the business.
He has been a great help.

tris · « **Reply #81 on:** September 24, 2015, 01:47:14 AM »

Ignoring the question as to whether its good practice to weld this up or not, I think the welding alone would cause a problem.

I would expect any welding to "pull" to some extent and the bored hole where the axle fits would be come oval/distorted and the clamp bolts wouldn't cause the casting pull down evenly around the axle

catneck · « **Reply #82 on:** October 09, 2015, 11:04:38 AM »

New parts in house.

Bike will go together tomorrow. Looking forward to getting the Stelvio back on the road.

catneck · « **Reply #83 on:** October 10, 2015, 12:24:27 PM »

Ok. Thats done. Any hot tips on fork oil weight/level?

Lannis · « **Reply #84 on:** October 10, 2015, 06:27:43 PM »

Quote from: catneck on October 10, 2015, 12:24:27 PM

Ok. Thats done. Any hot tips on fork oil weight/level?

I have some experience with 2009 Stelvio forks, including knowing how to tighten the axle clamps after realizing that people were breaking them!

When I lowered the rear suspension 1" with a much heavier spring, I also put a heavier spring in the front end (105 pounds/inch rather than the stock 95). I took apart the forks, fabricated longer pre-load tubes out of Schedule 60 PVC, replaced the seals and dust covers, and reassembled with the tubes slid 1" higher into the clamps to match the rear.

But I never did anything that made me think that I should monkey with the weight or amount of oil in the fork. What problem would I be trying to solve? Sometimes folks just want to be different, but I don't think this is the place for it ....

Good luck and glad things went well (if expensively) for you!

Lannis

catneck · « **Reply #85 on:** October 10, 2015, 11:30:43 PM »

Looking to reduce brake dive. I am a somewhat agressive rider. Used to telelever front ends.
Not needing to lower, in fact just raised the bike up from the (shorter than me) P.O.
His method had raised the fork tubes and backed off the rear shock preload.

Peter from Sch'dy · « **Reply #86 on:** October 11, 2015, 12:27:25 AM »

Why not just add oil until it feels good? No personal experience with these particular forks..

Best,
Peter

catneck · « **Reply #87 on:** October 16, 2015, 07:49:13 PM »

All better! Back on the road with new lowers, allen bolts, and 10w oil at 110 mm.

oldbike54 · « **Reply #88 on:** October 16, 2015, 07:55:51 PM »

Thanks for the update , too many times folks post up some problem , and then simply disappear . We love hearing how things get solved

Dusty

Lannis · « **Reply #89 on:** October 16, 2015, 08:07:53 PM »

Quote from: cheese1 on October 11, 2015, 12:27:25 AM

Why not just add oil until it feels good? No personal experience with these particular forks..

Best,
Peter

Gotta take the fork to pieces to add oil. Not an easy experiment .....

Lannis

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Author Topic: 2009 Stelvio. Cracked Fork/Axle Pinch Bolt Damage. Help Please. (Read 31866 times)

ridingron

oldbike54

oldbike54