2002 LeMans shifter Pawl Spring

[Jim Malm]

The pawl spring just broke on the trip home from the dealer after my 6K service. From reading past posts on this topic it looks like my problem occurred right on schedule. The tranny stuck in 2nd gear so I was able to limp back to the dealer. They discovered the broken spring and ordered the part which has an ETA of October 5th (maybe). I talked to Micha at MotoI to see if they had the part and he said they were also back ordered on the part. There was a reference to a spring supplier in past posts - Bonnie in OK at 405-524-7223 who is shipping me a replacement spring today for about $16 including shipping. My question is: Has Guzzi done anything special to address this problem on the bikes experiencing this problem? We are running out of riding season here and I would like to have my machine back before it snows, but don't want to do the repair now if a better fix is on the way. Any current updates on this problem would be appreciated. Thanks.

 

Jim

[dbdicker]

Jim,

 

The proper fix is to replace the pawl arm as well as the spring. Don't bother just putting in a new spring, even the 'heavier' one that was custom made that you've already ordered. It will inevitably break in the same place.

 

When looking up the part for a new pawl arm, DO NOT use the part no. for the 02 Lemans or V11. Instead, look up the part number for an 04 Ballabio, which will insure the correct boss size. If you need it, I'll look it up for you. It's a $90 part, but worth it for your own confidence, the springs have been known to break at most inopportune times, although some guys claim they can do a replacement on the road with a set of hex keys and a stout pair of pliers.......Good luck to that!

 

I replaced the pawl arm using the 'updated' part number here on the list and did not measure the boss before replacing the arm. I'm now sure that the updated arm in my transmission has the same WRONG boss size as the original I removed. I've since gotten the correct arm, and am waiting for a reason to open up the trans to replace it correctly. Either the next spring will break, or i'll be doing a fuller service that will make it worthwhile. You'll get it right the first time

 

Dan

[Guzzirider]

I ordered a new ratchet arm from my local dealer for Helen's V11 and when it eventually arrived it was definitely the updated version with a smaller boss.

 

Seems like the factory have sorted this now but be careful of accidently getting old stock from a part specialist which happened to me on my first attempt at ordering.

 

Guy

[belfastguzzi]

We are running out of riding season here and I would like to have my machine back before it snows, but don't want to do the repair now if a better fix is on the way. 

60872[/snapback]

 

It's up you really. If the spring broke at the end, rather than the middle, you can repair the spring and happily use it while you await new parts – so the bike needn't be off the road at all. Otherwise it's whatever amount of time it takes to get the correct parts in.

 

If you can do the repair now, there's no point in not doing it while you wait for 'better fix' parts, as in your question. Fix it, ride it and then when you get the 'better parts' swap them in some afternoon.

 

By now everything is well documented and photographed. It seems like you maybe didn't see all the info. Have you checked the info in the F.A.Q. Forum?

[Ouiji Veck]

The pawl spring just broke on the trip home from the dealer after my 6K service.  From reading past posts on this topic it looks like my problem occurred right on schedule.  The tranny stuck in 2nd gear so I was able to limp back to the dealer.  They discovered the broken spring and ordered the part which has an ETA of October 5th (maybe).  I talked to Micha at MotoI to see if they had the part and he said they were also back ordered on the part.  There was a reference to a spring supplier in past posts - Bonnie in OK at 405-524-7223 who is shipping me a replacement spring today for about $16 including shipping.  My question is:  Has Guzzi done anything special to address this problem on the bikes experiencing this problem?  We are running out of riding season here and I would like to have my machine back before it snows, but don't want to do the repair now if a better fix is on the way.  Any current updates on this problem would be appreciated.  Thanks.

 

Jim

60872[/snapback]

 

It's not a big job...you'll be on the road this w/e ...git'er done..

 

"We always do it nice 'cause we always do it twice."

[bigbikerrick]

Jim,

 

The proper fix is to replace the pawl arm as well as the spring.  Don't bother just putting in a new spring, even the 'heavier' one that was custom made that you've already ordered.  It will inevitably break in the same place. 

 

When looking up the part for a new pawl arm, DO NOT use the part no. for the 02 Lemans or V11.  Instead, look up the part number for an 04 Ballabio, which will insure the correct boss size.  If you need it, I'll look it up for you.  It's a $90 part, but worth it for your own confidence, the springs have been known to break at most inopportune times, although some guys claim they can do a replacement on the road with a set of hex keys and a stout pair of pliers.......Good luck to that!

 

I replaced the pawl arm using the 'updated' part number here on the list and did not measure the boss before replacing the arm.  I'm now sure that the updated arm in my transmission has the same WRONG boss size as the original I removed.  I've since gotten the correct arm, and am waiting for a reason to open up the trans to replace it correctly.  Either the next spring will break, or i'll be doing a fuller service that will make it worthwhile.  You'll get it right the first time 

Do all the V 11,s older than 04 have the 16mm incorrect boss or do some older ones have the correct 15 mm diameter boss? I have an 02 naked and am wondering if I should replace it before it breaks....or at least open it up and measure it ...

Dan

60873[/snapback]

[quazi-moto]

I've got 7500 miles on my '02 with original spring. Should I be getting concerned?

[belfastguzzi]

I've got 7500 miles on my '02 with original spring. Should I be getting concerned?

60910[/snapback]

Yeah, might as well be concerned.

 

I just think that it's better to check and be sure. Take the cover off and measure. If it's got the problem parts change them, rather than wait 'til it breaks at an inconvenient time/place. Mine and some others went at around 2,000 miles, but there are ones that have hung on 'til 6 or 7,000: so you never know, 'til you look see.

 

If you can't get parts easily then you'll have to wait, so again, better check and then be prepared/order parts. If you need to order parts, you could then put the box back together while it's still working and keep riding until parts arrive. Better still, file the boss down to the right size. That's as good as getting a new one if you do it carefully, but I'd still fit a new spring as the old one will be stressed.

[quazi-moto]

What are the P/N's for the updated components?

[twhitaker]

My spring broke in '02 and was replaced at 7500 miles. I now have 24,000 miles on it and the bike is still good to go. Don't know or care if I have the correct pawl arm. I carry a spare spring as a talisman to ward off the evil spring gods. Seems to work too.

[Ouiji Veck]

My spring broke in '02 and was replaced at 7500 miles. I now have 24,000 miles on it and the bike is still good to go. Don't know or care if I have the correct pawl arm. I carry a spare spring as a talisman to ward off the evil spring gods. Seems to work too.

60937[/snapback]

 

I've got 13000 mi on mine.

OK so far ...I'm figuring they musta got some of 'em right or there

would have been a total recall.

I looked @ it and the coil seemed loose on the pawl but I got

a spare one in the bag as a talisman as well. I always have

vise grips and allen wrenches.

Hey! Duct tape got the astronauts back from the moon!

[rocketman]

Is this an issue with the newer 2004 Lemans? I would hope that guzzi made the necessary changes since 2002.

 

Rocketman

[txrider]

Is this an issue with the newer 2004 Lemans?  I would hope that guzzi made the necessary changes since 2002.

 

Rocketman

60960[/snapback]

 

I posed this question to Todd Haven at MPH. He said there had been a redesign and as of early summer MPH had not repaired any 2004's.

[rocketman]

I posed this question to Todd Haven at MPH.  He said there had been a redesign and as of early summer MPH had not repaired any 2004's.

60966[/snapback]

 

Boy am I glad to here that. One less thing to worry about. Thanks txrider.

 

Rocketman

[bigbikerrick]

Yeah, might as well be concerned.

 

I just think that it's better to check and be sure. Take the cover off and measure. If it's got the problem parts change them, rather than wait 'til it breaks at an inconvenient time/place. Mine and some others went at around 2,000 miles, but there are ones that have hung on 'til 6 or 7,000: so you never know, 'til you look see.

 

If you can't get parts easily then you'll have to wait, so again, better check and then be prepared/order parts. If you need to order parts, you could then put the box back together while it's still working and keep riding until parts arrive. Better still, file the boss down to the right size. That's as good as getting a new one if you do it carefully, but I'd still fit a new spring as the old one will be stressed.

60917[/snapback]

Whats the best way to file that boss down, a Dremel? is there a danger of messing it up if you remove a little too much material?