Cali 3: in search of the lost gears.

Ogmios

Ogmios

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Finally!
I'm doing the job :bounce1
The Bike lost all but 1st and second gears. Well over a year ago - i'm only now doing the investigation / repair. :blush:

So, here's an incomplete report by a similarly minded mechanic. :pullface :marc
No Timmys rule apply. :D

They rust up rapidly if left unused. Mind you - so do we all.

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/j1u3QXquLbIWH-aoG7pGVcNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-edeeWZevHns/Ugvu6uBEctI/AAAAAAAACMo/KHyju_4EqxY/s640/DSCF0784.JPG" height="480" width="640" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

Worrying when you see moss growing out the saddle. :eek

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/l9DIV0xi3xzgqbX_MCcA_cNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-glTLtjnZwsE/UgvvBxYFltI/AAAAAAAACM0/dmvHXOpArcM/s640/DSCF0785.JPG" height="480" width="640" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/dtuSaRrLLeFTa6mIsp53vsNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-_5nEO-XreFE/UgvvDTzN_7I/AAAAAAAACM4/-JH2ojsF3t8/s400/DSCF0786.JPG" height="300" width="400" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

Delightful effect of cast iron discs. :blast

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/JHSD5iyAXOao4L5cfrgZ7MNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-CWgBX0FhPKs/Ugvvf98kRfI/AAAAAAAACNA/jragO3SDGW0/s400/DSCF0787.JPG" height="300" width="400" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

Marking the hole so i get the swingarm lined up properly on the rebuild.

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/2l8vnGAO__eSOfl3gpBLscNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-I8Rj7DzrG_g/UgvvsVWQw_I/AAAAAAAACNQ/76cCDo8ry4o/s400/DSCF0790.JPG" height="300" width="400" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

Pretty uneventful til i got to the point of pulling it off ... :augie
Now, how the hell do i extract this? :confused:

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/EIbKgr8IOVVsp0VwSMKhgcNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-bbCBdahbKuw/Ugvv6BLlADI/AAAAAAAACNc/vlViYjuEJPc/s640/DSCF0797.JPG" height="480" width="640" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

Whirry bits in here.

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/pcUOVPFLB3v_9OwpoWrazsNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-ZZqgCyUx9ok/UgvwSf5qBiI/AAAAAAAACOQ/kewJj-vyKRY/s640/DSCF0799.JPG" height="640" width="480" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

A Guzzi about to give birth.

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/gHElClzGQRI50qouuNtO9MNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-nD2tI-DYqLU/UgvwUvy63YI/AAAAAAAACNs/zvhxQCUvITw/s640/DSCF0801.JPG" height="480" width="640" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

Knackered, cut and bruised -but feeling smug ( and not a little suprised how well it's gone ... so far. ;) )

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/DS7iYugKsgKXCAVKpttzOMNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-ZiFJ8d52ER4/UgvwYY5_8MI/AAAAAAAACN0/aRI01RLGu2M/s400/DSCF0802.JPG" height="300" width="400" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

Tomorrow i'm going in! :eek:
Wish me luck. :D
 
If you need a hand Marc I am only up the road. :beerjug:

Not sure what use I would be though, I am good at drinking tea!
 
Enough! You bunch of chicken abusers!
I am getting counselling from ghiribizzo. :comfort
With enough use of rubber mallet, T.L.C. and B.F.I - this 'box will soon be forensically investigated. ;)
Excuse me for now - i'm off to the shed.
Damien -if you hear wailing and gnashing of teeth from your house - that'll be the signal to drop over and take up a sympathetic pose.

~~~
The Guzzi Worrier.
 
if you're lucky :eek, the nut on the output shaft will be loose and you'll be able to get it off without the special tools. i'm amazed how often they are just held on by the lock washer :eek:

doing it up again is another matter however. then there's the castellated nut inside the clutch hub...
 
Cookie Will you Behave ! :blast

As we say here "the Poor man is demented enough as it is!!!"

cookie said:
if you're lucky :eek, the nut on the output shaft will be loose and you'll be able to get it off without the special tools. i'm amazed how often they are just held on by the lock washer :eek:

doing it up again is another matter however. then there's the castellated nut inside the clutch hub...
Click to expand...
 
But if you're REALLY lucky you'll have a set of these... :augie


 
Sadly my local friendly mechanic is either on holiday or knew i was coming - and legged it. :rolleyes:
So, getting that big nut offa the rear of the 'box didn't happen today.
That's slowed me down to put it mildly - and time is limited. :( (o.k - and i'm impatient too).
Mind you, the state of the nut - i'm tempted to dremel it off and get a new one as i will have to get some bits for this in any case. But i'll listen to reason too... (reluctantly :D)
Here's some pics (and i'm suprised no one commented on the shovel in the last bunch of pics. :p)

just to prove i did get the effer out.

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/yDzmvDBBcoW0xuvNHUvNk8NrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-PfPAqBN2f-s/Ug0MN-u8EhI/AAAAAAAACOg/mLkyPkVSLkA/s400/DSCF0806.JPG" height="300" width="400" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table> innit simple?! <table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/-Bkw_y_7lgZvc4zwOp0s4cNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-UpFwejBs_T0/Ug0MdcGczxI/AAAAAAAACOo/fr5vm9ua4AI/s400/DSCF0807.JPG" height="300" width="400" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

First of the Is it supposed to look like that? :eek pictures.
(not improved now by my gentle efforts to 'unlock' the ... tab i suppose you'd call it - really! i WAS gentle! :p )

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/MQRWKUWpMQCSdYgtFx9hZsNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-nQx6UTwQLG8/Ug0MthwwphI/AAAAAAAACOw/q3VciKxiGJA/s640/DSCF0810.JPG" height="480" width="640" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

This is not muck in the speedo drive - it's pinholes in there! :eek:

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/Z7yFn-nfcR9RsLdt_PALecNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-XgQduUqhduo/Ug0NYp1Xr5I/AAAAAAAACPQ/kuqt5b7YbyU/s640/DSCF0820.JPG" height="480" width="640" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

Should it be this oily?

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/Ew5bzPJTvs7EwuJcRfCSscNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-iUj_m9bpgGg/Ug0RVQwW2-I/AAAAAAAACP4/p38LZgbt2ak/s400/DSCF0824.JPG" height="300" width="400" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

And this looks like it was 'tabbed' / secured with a blunt nail. :mad:

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/B_qsIUhthJgW53af0uyspsNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-1rABIcppHP0/Ug0RlqpfQrI/AAAAAAAACQA/Bf2uFSaJbZo/s640/DSCF0828.JPG" height="480" width="640" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

The good bits.
Guzzi reliable clutch pushrod assembly - in 65k miles, never given trouble - unlike BM ones i've had. Last pic - the 'bullet' that finds neutral?

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/6hVf2J9HuPnZgK_TMpwGLMNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-12-ImIG0ro8/Ug0NCDNymXI/AAAAAAAACO4/hHMnjpMeRgg/s400/DSCF0813.JPG" height="300" width="400" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table> <table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/bKeMBU7FbsO_LdNH_spE8cNrOPp0J9VjAYACV_X6MiA?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-FpmsXMwYFRg/Ug0NlL5Ia_I/AAAAAAAACPY/3gMFG0Iu1FY/s400/DSCF0821.JPG" height="300" width="400" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/110392685136049648662/GuzziBoxRebuild2013?authuser=0&feat=embedwebsite">Guzzi 'Box Rebuild 2013</a></td></tr></table>

So.
dremel out that 'tab washery yoke and get a new one? (least i could get on with the job then) or... ?
P.S;
is it just me - i'm light headed from ( i suspect) A./ the degreaser and B./ the euphoria of finally getting this job seen to! :D
 
a new output shaft nut is not expensive, and i'd buy one anyway looking at that, but i doubt you'd get a dremel in there without doing damage to something else :nenau

a deep socket and an impact gun will spin it off, but you still need to torque it back up somehow.

when you do get it off, look out for the little ball bearing that locks the speedo drive to the shaft ;)

you did get the hardened steel washer out from under the cable drive thing? sometimes it's not there, as a previous mechanic has lost it :rolleyes:
 
Ogmios said:
Sadly my local friendly mechanic is either on holiday or knew i was coming - and legged it. :rolleyes:
Click to expand...

He is in Sligo for a week, I was speaking to him last week when I got some new tyres.
 
Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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