Author Topic: rainy day maintenance (G5 content)  (Read 2809 times)

Offline Chuck in Indiana

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rainy day maintenance (G5 content)
« on: July 31, 2018, 10:56:04 AM »
We're getting some much needed rain, so I thought I'd take a day and have a look at the new to me G5. I know there is a school of thought that says, "If it ain't broke, don't fix it." I don't subscribe to that one.  :smiley: Before taking it on some longer trips, I like to know what I have. The records from the anal  :thumb: previous owner say:
7-5-17    97867
Spark plugs
New exhaust gaskets
New o rings in heads
New head gaskets
adjust valves
oil and filter.
I changed the oil when I brought it home, and have ridden it 3 or 400 miles. It's time for head torque.
2018-07-31_11-37-12 by Charles Stottlemyer, on Flickr
Valves are at .004" If I had just set them back at .009" there would be a blown head gasket in our future.. :grin:
When I pulled the tank, I saw this:
2018-07-31_11-36-28 by Charles Stottlemyer, on Flickr
where the tank had started to eat into the throttle cable. I'll have to reroute that at the very least.
Probably ought to have a look here..
2018-07-31_11-35-58 by Charles Stottlemyer, on Flickr
I'm going to spend the rest of the day doing an "annual inspection" on the old G5. If anyone is interested, I'll document it.
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline Old Jock

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Re: rainy day maintenance (G5 content)
« Reply #1 on: July 31, 2018, 10:59:24 AM »
Ahh Chckee

It's not only me Eh?

The things you find when you dig  :grin:

Hope that's all you find

Online RinkRat II

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Re: rainy day maintenance (G5 content)
« Reply #2 on: July 31, 2018, 11:14:02 AM »

 We're all patiently waiting for your tutorial, however, if you get too distraught on your findings, don't fear one of us here will take it off your hands :evil:

       Paul B :boozing:
A Miller in the hand is worth two in the fridge.

Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #3 on: July 31, 2018, 11:19:32 AM »
We're all patiently waiting for your tutorial, however, if you get too distraught on your findings, don't fear one of us here will take it off your hands :evil:

       Paul B :boozing:

Sorry, Paul.. not much chance of that.  :smiley: I gave up the Monza to get it.
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #4 on: July 31, 2018, 11:23:09 AM »
Just came up for lunch, and checked out the most excellent info that LeRoy sent me  :thumb: to refresh my memory on the torque pattern, valve clearances, etc.
Back in a bit..
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline Zoom Zoom

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Re: rainy day maintenance (G5 content)
« Reply #5 on: July 31, 2018, 12:11:24 PM »
My rainy day project, although it has been ongoing for a few days, is prep on the 1.1 meter Stearman RC model. Getting the CG right, balancing a couple props, etc. (All the little stuff that makes you take more than the two hours that say it will take.) Don't want the maiden flight to be the last!

John Henry
A wide, unfettered road ahead,
and the flying motor singing.
Samuel C. Lancaster 1921

Online John A

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Re: rainy day maintenance (G5 content)
« Reply #6 on: July 31, 2018, 12:31:35 PM »
preventative maintenance at its best! :thumb:
John
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Offline Rick4003

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Re: rainy day maintenance (G5 content)
« Reply #7 on: July 31, 2018, 12:39:45 PM »
I would be very interested in reading about your annual inspection. Lasts ones was great info.
My buddy got a G5 not so long ago that surely could use a yearly inspection even if he has got it pretty reliable now.

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Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #8 on: July 31, 2018, 01:33:12 PM »
Ok, here we go. To get to the top cylinder head bolt, you have to remove the "blanking plug." Inspect the o ring underneath it. A bad one will cause a mystery oil leak. Torque in a cross pattern according to "the book" at 30 ft. lbs. As expected, the left head bolts were quite loose.
2018-07-31_01-58-58 by Charles Stottlemyer, on Flickr
Have a look at the rocker arm pins. This is the worst one.. about .001" wear.
2018-07-31_01-59-28 by Charles Stottlemyer, on Flickr
Proves the robustness (is that a word?)  :smiley: of the Guzzi powerplant.
I have ejector pins from my days as a mold maker, and one makes quick work of reinstalling the rocker pin. It's undersized, so just insert it, roll it around the bore to align the spring and washer.. slide the rocker pin home. Easy Peasey.
2018-07-31_02-00-32 by Charles Stottlemyer, on Flickr
BTW, it's good practice to rotate the rocker arm pin 180 degrees at each valve adjustment to even out wear.
Once the valves are adjusted to .009" and .009, it's the perfect time to do a leak down test. Here is my home made (naturally)  :wink: leak down tester. You have to be *exactly* at TDC, or the air pressure will just push the piston down.
2018-07-31_02-01-06 by Charles Stottlemyer, on Flickr
Yeah, baby! 80/76. That means 80 psi in through a regulated orifice, and read the leakage on the second gauge. 10% leakage is a good used cylinder. This one is considerably better than that.  :thumb: Listening for the air leakage will tell you where the engine is worn. Out the carbs, intake valves, out the exhaust is exhaust valve, out the breather, rings. This cylinder has a little (not very much) ring wear.
The other cylinder reads 80/75. Rings, also.  :thumb: again. These small valve Guzzi engines will run a *long* time, if properly maintained.
How long did all this take? Considerably less than telling you about it. :grin: That Dusty fellow called, and wants pictures from Oshkosh.
While I'm here, we might as well see what is under this black thing..
2018-07-31_02-01-39 by Charles Stottlemyer, on Flickr
Still waiting are some wires and connectors that obviously haven't seen the light of day in some time.
2018-07-31_02-02-13 by Charles Stottlemyer, on Flickr
2018-07-31_02-02-49 by Charles Stottlemyer, on Flickr
This is the stuff that will have you standing by the side of the road. At night. In the rain.  :grin: Let's go through it.
To be continued..

Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline guzzisteve

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Re: rainy day maintenance (G5 content)
« Reply #9 on: July 31, 2018, 01:36:15 PM »
Chuck,  Do a video and play it on the big sheet at WI Rally, then sell copies. Autographed copies of course!!
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Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #10 on: July 31, 2018, 02:05:41 PM »
Chuck,  Do a video and play it on the big sheet at WI Rally, then sell copies. Autographed copies of course!!

 :grin: Riiiiight..
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline normzone

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Re: rainy day maintenance (G5 content)
« Reply #11 on: July 31, 2018, 02:14:44 PM »
I'll buy one, preordered to help defray the production expense, if you'll include an explanation about what rain is.
Could be the timing chain or the kickstand spring - the suggestion is bunkum

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Re: rainy day maintenance (G5 content)
« Reply #12 on: July 31, 2018, 03:41:25 PM »
Of course it's raining Chuck. We are bloody rain gods. After we left yesterday it pissed down all the way to Terre Haute and followed us out again this morning. We seem to have finally shaken it off in Quincy but I reckon it'll find us again before we get to Kansas City! :grin:

Pete

Online LeRoy

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Re: rainy day maintenance (G5 content)
« Reply #13 on: July 31, 2018, 04:13:03 PM »
I'd be interested in seeing how the whole airbox and crankcase breather apparatus is working on your G5. I just learned (the hard way) the joys of an over-pressurized crankcase on my new-to-me 1000 SP. Shoulda' looked that whole system over more closely on my pre-flight check before I took the first long-ish ride. It all seemed so good on short around-town trips. But it was all so oily on the return from an afternoon ride. It gave a new perspective to the concept of a total-loss lubrication system.
LeRoy (Bob Sharp)
Rochester, MI  U.S.A.
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Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #14 on: July 31, 2018, 04:41:19 PM »
I'd be interested in seeing how the whole airbox and crankcase breather apparatus is working on your G5. I just learned (the hard way) the joys of an over-pressurized crankcase on my new-to-me 1000 SP. Shoulda' looked that whole system over more closely on my pre-flight check before I took the first long-ish ride. It all seemed so good on short around-town trips. But it was all so oily on the return from an afternoon ride. It gave a new perspective to the concept of a total-loss lubrication system.

LeRoy, my SP's Distinguished Previous Owner made up a Mickey Mouse arrangement with a cobbled up copper thing (tm) run up to the front of the bike on a rubber hose with a roughly 2 inch diameter air filter on it. Get the picture? It made a *very* fine oil mist that totally covered everything aft of it. Dust would settle in it and then the whole process would be started over on the next ride.  :evil: :grin:
After scraping about 1/4" off everything, I binned that and used a LeMans breather hooked up in the conventional way. My new old G5 apparently uses the same thing. I'll get a picture tomorrow..
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #15 on: July 31, 2018, 05:04:42 PM »
I only have records for the last 15000 miles or so, and no mention has been made of the points.
Had a look, and gapped them .014" Both were around .018-.020.
2018-07-31_05-42-31 by Charles Stottlemyer, on Flickr
Started putting the valve covers back on, and the screws apparently are stainless. You need to use anti seize with stainless/aluminum. A little dab will do ya, as the old saying goes.  :smiley:
2018-07-31_05-42-48 by Charles Stottlemyer, on Flickr
I'd be remiss if I didn't tell you how I was turning the engine over. Just put an allen wrench in the bolt that holds the alternator on. Turn the engine clockwise, viewed from the front.
2018-07-31_05-43-22 by Charles Stottlemyer, on Flickr
While we're there..
2018-07-31_05-43-39 by Charles Stottlemyer, on Flickr
is the best stuff for electrical gizmos I've ever used. I've lost track of the things I've "fixed" with it. For instance, we were leaving for the Oshkosh fly in, and I plugged in the camper lights. Nothing. Nada. "Crap." Unplugged, replugged, wiggled it around.. nothing. Went to the Guzzi Garage (tm) got my can of DeOxit, sprayed the connector, plugged it in, and had lights. Just like new.
At any rate, take off the connectors off the alternator and give em a spray/wiggle.
2018-07-31_05-44-04 by Charles Stottlemyer, on Flickr
The three yellow wires are about 45 volts AC, and go to the diode board. More on that later. Have a look at the brushes, springs, too. An electrical failure is the most common breakdown on these old Tontis.
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Online John A

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Re: rainy day maintenance (G5 content)
« Reply #16 on: July 31, 2018, 05:21:08 PM »
There is a service bulliten to clock the stator 90 degrees from what that one is. Supposed to help keeping brush bounce to a minimum.
John
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Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #17 on: July 31, 2018, 05:24:46 PM »
Starting from the front.. here are the coils. You know the drill.  :grin:
2018-07-31_05-44-23 by Charles Stottlemyer, on Flickr
Power to/from the key switch. they are not waterproof. The tendency is to just let them be. As the old ad says, "Just do it." :smiley:
2018-07-31_05-44-38 by Charles Stottlemyer, on Flickr
Now, we are getting into the nitty gritty. The last guy that has seen these was Luigi.
2018-07-31_05-44-56 by Charles Stottlemyer, on Flickr
This is the connector to the voltage regulator. It is *very* difficult to get to on the G5 for whatever reason.
2018-07-31_05-45-12 by Charles Stottlemyer, on Flickr
The temptation is to think, "Oh, no problem, I'll just remove it from the bracket, DeOxit the connections, and reinstall.
*Avoid that temptation.*  :smiley: Luigi assembled all that stuff before he put the engine in.  :evil: It's been an hour and a half, and I still don't have it back together. Just do whatever you have to do to get the plug out, squirt it, and put it back in. Trust me.
"Tweeeet." Quitting whistle. Beer o'clock. *maybe* more tomorrow.
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #18 on: July 31, 2018, 05:31:38 PM »
There is a service bulliten to clock the stator 90 degrees from what that one is. Supposed to help keeping brush bounce to a minimum.

Thanks for that, John. I remember that, now that you have jogged my (failing) memory.  :embarrassed:
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline twodogs

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Re: rainy day maintenance (G5 content)
« Reply #19 on: July 31, 2018, 07:11:38 PM »
This is good stuff Chuck, please document everything you do and send it to me for my winter project because I don't have a clue what I'm doing on mine, your pics are going to show me the way on my g5, looking toward winter for the first time in a long time  :boozing:
Bruce
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Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #20 on: July 31, 2018, 08:01:59 PM »
This is good stuff Chuck, please document everything you do and send it to me for my winter project because I don't have a clue what I'm doing on mine, your pics are going to show me the way on my g5, looking toward winter for the first time in a long time  :boozing:
Bruce
Glad to see it will be of some value.  :smiley: I'll continue as I get time. Thought I'd get mostly through it today, but ran into a snag with the voltage regulator. Pay attention to that..  :evil:
Normally, a guy can spend a day and be pretty sure he won't have a breakdown in BF Utah.   :boozing: :wink: At night. In the rain..
What are you going to do for the rest of the Winter?  :grin:
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Online Guzzistajohn

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Re: rainy day maintenance (G5 content)
« Reply #21 on: July 31, 2018, 08:24:24 PM »
Good stuff Chuck! Thanks for sharing your "skills" If we had a like button I'd be tearing that sucker up right now  :wink:
« Last Edit: July 31, 2018, 09:05:00 PM by Guzzistajohn »
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Offline twodogs

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Re: rainy day maintenance (G5 content)
« Reply #22 on: August 01, 2018, 06:08:00 AM »
Between the beer and honey do list and so on, you know how it goes  :boozing: seriously though the pics and specs you listed are priceless to me, I look at a wrench and my knuckles start bleeding. LOL
Bruce
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2008 Buell XB12XT

Offline brider

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Re: rainy day maintenance (G5 content)
« Reply #23 on: August 01, 2018, 06:38:36 AM »
[img width=600 height=800]This is the stuff that will have you standing by the side of the road. At night. In the rain.  :grin: Let's go through it.
To be continued..

Chuck: What's your position on using dielectric grease? I read a bunch of recent and very interesting threads here on this forum about it's use, and your attention to the elec connections makes me think they would be a good candidate for it's use.

My Cal 2 is about at the same stage as your G5 right now, and I think I'm going to apply it after a quick spritz with contact cleaner.
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Offline chuck peterson

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Re: rainy day maintenance (G5 content)
« Reply #24 on: August 01, 2018, 06:40:09 AM »
Nice details, thanks. Would you go with the adjustable vr?
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Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #25 on: August 01, 2018, 06:48:16 AM »
Nice details, thanks. Would you go with the adjustable vr?

Only if I was running in town all the time. I put one on the AeroLario. I'd been watching the voltmeter, and it had been trending lower. You could see the voltage regulator doing it's regulating.  :smiley: Thought a preemptive strike might be in order, so looked at Cheesehead and Gordon's website. Even though it cost $2 more <snapping suspenders> I ordered the adjustable one, just in case. It comes set at 14.3 volts, and is perfect. Dang! Wasted $2.. :grin:
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline nobleswood

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Re: rainy day maintenance (G5 content)
« Reply #26 on: August 01, 2018, 11:12:42 AM »
 :popcorn:

There's a few Rallies coming up, Ohio & Kentucky, are you thinking of riding the G5 to them ?
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Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #27 on: August 01, 2018, 12:17:14 PM »
I'd be interested in seeing how the whole airbox and crankcase breather apparatus is working on your G5. I just learned (the hard way) the joys of an over-pressurized crankcase on my new-to-me 1000 SP. Shoulda' looked that whole system over more closely on my pre-flight check before I took the first long-ish ride. It all seemed so good on short around-town trips. But it was all so oily on the return from an afternoon ride. It gave a new perspective to the concept of a total-loss lubrication system.

Ok, Bob.. I haven't been slackin.. the guys from Centroid were here this morning finishing the retrofit of the latest stuff to my ancient (naturally) CNC mill.
Here's the breather box the G5 is using.
2018-08-01_12-58-40 by Charles Stottlemyer, on Flickr
You can see the two lines from the heads here. It is apparently working fine. If you need more pix, just say so.
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #28 on: August 01, 2018, 12:24:00 PM »
This is good stuff Chuck, please document everything you do and send it to me for my winter project because I don't have a clue what I'm doing on mine, your pics are going to show me the way on my g5, looking toward winter for the first time in a long time  :boozing:
Bruce

Bruce, one of the things I'm not going to address is rebuilding the ignition switch. This one, unfortunately, has a new switch, so I'm not going to mess with it at this time. I have to have two keys because of the unnecessary new switch.  :evil:
The switches are easy to take apart, clean off the old hardened grease, wire brush the contacts, apply fresh Vaseline.. not dielectric grease.. :evil: and reassemble.  :smiley: You *need* to do this to your "survivor."
I did a tutorial on the switch, among other things,  on the Monza annual inspection thread.
http://wildguzzi.com/forum/index.php?topic=89034.0
« Last Edit: August 01, 2018, 12:34:12 PM by Chuck in Indiana »
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

Offline Chuck in Indiana

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Re: rainy day maintenance (G5 content)
« Reply #29 on: August 01, 2018, 12:27:43 PM »
Chuck: What's your position on using dielectric grease? I read a bunch of recent and very interesting threads here on this forum about it's use, and your attention to the elec connections makes me think they would be a good candidate for it's use.

My Cal 2 is about at the same stage as your G5 right now, and I think I'm going to apply it after a quick spritz with contact cleaner.

Wayne, who knows a brazillion per cent more about this stuff than me, is adamant about not using dielectric grease on your Guzzi, except for the spark plug boots. I could tell you the story of my barn find Strada that someone thought it was a good idea to pack every connector with dielectric grease. I'll just say, not a good idea.
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
I think senility is going to be a fairly smooth transition for me..

 

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