Bringing a Guzzi back to life

Discussion in 'Some Assembly Required' started by cleatusj, Jan 8, 2016.

  1. cleatusj

    cleatusj Dirt floor engineer

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    September 13,2015 I inserted the front tire of my '93 Cali 3 Goose into a fence between pipe and rock pillar.

    [​IMG]

    The results was the installation of one screw in my neck and time on my hands with a lifting limit of 20 pounds, with a broken bike sitting outside my shop. This is what I saw when I got out of the hospital.

    [​IMG]

    [​IMG]

    Having time to think about how I could move it inside, while I was still waiting to go home, I came up with using a sled of c-purling under the front wheel and pulling it in with my overhead chain hoist. Once it was in I set about trying to find out caused the problem or was it me. Here is the wheel bearing with out balls that caused the front to shake when I down shifted for a right turn. I'm sure this pushed the pucks back into the front calipers, which lead to no brakes from either control as the the foot brake is integrated on Guzzi's.

    [​IMG]

    The forks after wheel removal.

    [​IMG]

    Another inmate forwarded a 640 adventure frontend to me and I started measuring what it would take to mate the two. The KTM bearings fit the Guzzi races, but the stem was about 1 1/2" to short. I pulled a piece of 1 1/4" bar stock out of my scrap pile and turned it down on an old '69 Craftsman 6" lathe I picked a few years ago. In the process I broke two gears, but was lucky enough to find them on Epay.

    Here is where it sits as of today.

    [​IMG]

    As I have been out of work for some time, from having the neck reworked with 4 screws and 2 rods, I'm moving a little slow on this resurrection. Tomorrow should see bars, controls and gauges.
    #1
    Bobmws, brstar, FR700 and 2 others like this.
  2. FR700

    FR700 Heckler ™©®℗

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    Ooh yeah.

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    .
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  3. cleatusj

    cleatusj Dirt floor engineer

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    I'm looking for another tank that's dented, to reshape, as the upper tree hits the tank before the lower contacts frame up rights.
    #3
  4. Foxed101

    Foxed101 Monkeywrench

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    I wish you a speedy recovery!
    You sure bounce back mentally quick:pynd

    What kind a tank are you planning to use?
    #4
  5. cleatusj

    cleatusj Dirt floor engineer

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    I'm open, but a stock one with dented front would be easy and match side covers. This is a resurrection not restoration.
    #5
  6. flemsmith

    flemsmith lurk

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    If I understand, your right front wheel bearing disintegrated and that led to no brakes? Were there no warning noises/vibrations before the wreck that something was not right? That's a scary thought, right or wrong, I always felt these older bike designs would let you know when something needed looking at....?!? Good luck on the healing process. roy
    #6
  7. nickguzzi

    nickguzzi Long timer

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    The Guzzi's linked brakes should not have been affected from what is visible in the photos's. The foot brake works the rear and left side front calliper - why should that fail? Even if the right calliper is taken out, that doesn't prevent the other two discs from functioning.

    Hauling a chair around is as good a way as any to fuck up wheel bearings. They need frequent monitoring as the front wheel is no longer working as designed but under considerable side loading at every turn.
    However you get your wheels back to rolling, keep your eyes on the front wheel bearings - they really do take a beating.
    Spoked wheels can also become victims to the excess side loads too.
    Perhaps doing something with the lock stops rather than allowing hard contact between forks and frame?

    Hope you heal ok and get mobile again soon.
    #7
    airheadDan and spress like this.
  8. cleatusj

    cleatusj Dirt floor engineer

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    Nick, with the front wheel/rotors wobbling the pucks in both front calipers get pushed back and it takes a few pumps to get full engagement back.

    For the lock stops there will be split tube with rubber added to the uprights and wheel bearings will be checked regularly.

    Flemsmith, I never felt any thing out of the ordinary until I down shifted.
    #8
  9. cleatusj

    cleatusj Dirt floor engineer

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    Did not get much done yesterday but forks, bars and some controls installed. Will need to fab a new gauge and headlight mount, plus find a 300mm disk from a 640 or 950 to have front brakes. Also need to plumb left front caliper to sidecar disk.
    #9
  10. cleatusj

    cleatusj Dirt floor engineer

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    Two steps forward now two steps back, because with straight forks on it I can see that the neck has some twist in it. I need to do some more measuring to see if it is the top or bottom of neck that has moved.
    #10
  11. nickguzzi

    nickguzzi Long timer

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    I have measured a few tonti frames and a couple had an offset at the headstock - no sign of any bent or twisted members or damaged welds. I came to the conclusion that the frames had been welded incorrectly. There certainly was a lot of spring when I cut the lower tubes off.
    Guzzi frames are heavy and strong. I realigned everything as per the manual and re welded it up. Worked really well.

    There have been stories that at certain periods of turmoil with financing, standards occasionally slipped - rumour? fact? Don't know. I have been told the frames are produced by a sub-contractor.

    It could also be having been hauling a chair around long term has taken its toll. This was pretty much a given on brit bikes in the 50's/60's.
    #11
  12. Boulder Ed

    Boulder Ed Bin Ridin

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    all I can add is hummm. I am sure there were never any excessive loads or riding conditions applied to that bike. Riding on two of the three wheels takes a load off right?
    #12
  13. cleatusj

    cleatusj Dirt floor engineer

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    The front is off set to the left and my chair is on the right. I find no cracks or point of bend either.
    #13
  14. cleatusj

    cleatusj Dirt floor engineer

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    Pulled the forks again and will cutting the neck. It will be moving up and have reduced rake. It will be back on the road.
    #14
    FR700 likes this.
  15. cleatusj

    cleatusj Dirt floor engineer

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    Not much to show, but I cut the neck and am mocking up where it will be located.

    [​IMG]
    #15
  16. redfishguide

    redfishguide Old Dirt Biker

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    Hey Cletus,

    Glad to hear your on the mend and back in the saddle! Well almost. Good for you.

    Just curious how are you going to do the measuring so you wind up with the right amount of trail reduction for the hack?

    Thanks,
    Jack
    #16
  17. cleatusj

    cleatusj Dirt floor engineer

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    Jack, this rig never had any trail reduction before, but the new forks are leading axle.
    #17
  18. redfishguide

    redfishguide Old Dirt Biker

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    So are you going for stock when you attach the neck or will you attempt a change? Not trying to bug you just curious as I ponder various options for my rig.

    Thanks,
    Jack
    #18
  19. cleatusj

    cleatusj Dirt floor engineer

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    I am reducing the rake so that the forks will be standing straighter. I will try to give the degrees of change when I get back out there.
    #19
  20. pinkius

    pinkius Been here awhile

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    :super
    #20