2002 LeMans shifter Pawl Spring

[belfastguzzi]

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?

60974[/snapback]

I used a hand file, or 2 or 3 different grades of files. I didn't have a Dremel then, but a file is probably better and easier to control too. You could finish with a dremel. I don't think that removing a bit too much or not getting it exactly circular will matter too much. As far as I remember I deliberately offset mine a bit, probably because the repaired spring was shorter. It was a temporary repair as I ordered new parts under warranty. However it worked fine and I think that it would have kept on working. The spring might have given up some time, but certainly the adjusted pawl arm would go for ever.

[bigbikerrick]

I used a hand file, or 2 or 3 different grades of files. I didn't have a Dremel then, but a file is probably better and easier to control too. You could finish with a dremel. I don't think that removing a bit too much or not getting it exactly circular will matter too much. As far as I remember I deliberately offset mine a bit, probably because the repaired spring was shorter. It was a temporary repair as I ordered new parts under warranty. However it worked fine and I think that it would have kept on working. The spring might have given up some time, but certainly the adjusted pawl arm would go for ever.

60978[/snapback]

Thanks for the reply, I need to check mine, but im a little hesitant to take the side cover off and not put things back together properly. Is it pretty easy to do, or are there pitfalls with lining up the shifting mechanism properly? Rick

[belfastguzzi]

Thanks for the reply, I need to check mine, but im a little hesitant to take the side cover off and not put things back together properly. Is it pretty easy to do, or are there pitfalls with lining up the shifting mechanism properly? Rick

61001[/snapback]

 

If you're just looking but not disassembling, there aren't major pitfalls. Just take care. The most difficult part is getting the bottom left side allen bolt out. See the pictures, you may notice an allen key that I ground down so that it's easier to gat at that Allen head.

more inf here & pics & also a link to more pinks. Everything should be covered somewhere in the FAQ links. There are a number of bits of advice about lining up the internals.

 

Also see here.

 

Good luck.

[belfastguzzi]

Main pics here:

 

spring stuff 1

 

spring sprong 2

 

Makes me want to go out and whip the transmission cover off and start poking at things.

[bigbikerrick]

Main pics here:

 

spring stuff 1

 

spring sprong 2

 

Makes me want to go out and whip the transmission cover off and start poking at things.

61068[/snapback]

Thanks for the links, Bellfastguzzi,great pics, eh! I see you have an 02 scura, no spring problems yet? how many miles on it? I want to be proactive in this thing, I hate roadside repairs! makes no sense in waiting for that sucker to break,when a better spring is available for under $20. and the boss is easily filed down if needed. also I have a good supply of cold beer in my garage, and way too many rattlesnakes on the sides of the road here in Arizona!

[belfastguzzi]

no spring problems yet?

61072[/snapback]

 

Eh? Is there a problem with the spring?

[quazi-moto]

I'll try calling Bonnie for the spring, but does anyone have a P/N for the ratchet arm?

[edge]

Eh? Is there a problem with the spring? 

61075[/snapback]

 

Here we go again...

 

You guys spooked me and Bonnie will have one at my door tomorrow to ensure I get the good juju back

[windchill]

Well, I was going to start a new thread, but trhis one seems as appropriate!!

 

 

1950 miles: only 900 ish and less than 12 months since my gearbox was last repaired underwarranty (second time). A "comprehensive fix" according to Mr Guzzi.

 

Bull****!!!

 

It just went again, about 20 miles from home, leaving the bike with only second gear.

 

 

Aha, if you recall, the bike is still under warranty, and I got an extra extension too. I'll ring the recovery number I used on the last two occasions.

 

 

Mr Guzzi has changed it and not told me!! All the way home at 35!!

 

Ring the dealer only to find that he has given up his Guzzi franchise because of all the hassle he 's had. Nobidy told me did they.

 

Anyway, my dealer was actually very helpful, and found a new number - 00800 33 22 88 77. yes 00800. Make a note of it if you have an "aprilia" Guzzi still under warranty.

 

Monday will bring Trading Standards and my lawyer to Mr Guzzi's door this time. Probably some media involvement too: the timing couldn't be better: just before the NEC show, and with a new model.

 

There you go guys, now I feel (a bit) better!!!

 

Will let you know what unfolds.

[bigbikerrick]

Well, I was going to start a new thread, but trhis one seems as appropriate!!

1950 miles: only 900 ish and less than 12 months since my gearbox was last repaired underwarranty (second time). A "comprehensive fix" according to Mr Guzzi.

 

Bull****!!!

 

It just went again, about 20 miles from home, leaving the bike with only second gear.

Aha, if you recall, the bike is still under warranty, and I got an extra extension too. I'll ring the recovery number I used on the last two occasions.

Mr Guzzi has changed it and not told me!! All the way home at 35!!

 

Ring the dealer only to find that he has given up his Guzzi franchise because of all the hassle he 's had. Nobidy told me did they.

 

Anyway, my dealer was actually very helpful, and found a new number - 00800 33 22 88 77. yes 00800. Make a note of it if you have an "aprilia" Guzzi still under warranty.

 

Monday will bring Trading Standards and my lawyer to Mr Guzzi's door this time. Probably some media involvement too: the timing couldn't be better: just before the NEC show, and with a new model.

 

There you go guys, now I feel  (a bit) better!!!

 

Will let you know what unfolds.      

61143[/snapback]

Hey Windchill, all these problems your gearbox has given you, has it been the shift spring breaking every time, or have there been other issues with the gearbox? Maybe the solution would be to install one of the aftermarket springs that are made here in the US. They are supposed to be of better quality. also many have had success with rounding off the area where the spring touches. What is that number you posted,is it a phone number?

[belfastguzzi]

Ring the dealer only to find that he has given up his Guzzi franchise because of all the hassle he 's had.

61143[/snapback]

Who? OYB by any chance?

[windchill]

Dealer is Colwyn Bay Motorcycles. They just had enough!!

 

Number is the one needed to access MG Assistance/Recovery if your bike is an "aprillia" and under warranty. It was changed some time ago, but nobody , as far as I can tell, advised the owners.

 

Not sure if its UK only, but it connects in Italy.

[Baldini]

...Monday will bring Trading Standards and my lawyer to Mr Guzzi's door this time. Probably some media involvement too: the timing couldn't be better: just before the NEC show, and with a new model....There you go guys, now I feel  (a bit) better!!!

 

Windchill,

 

It appears you have had the pawl arm spring break. This is a very common failure on 02 bikes. The problem is that some pawl arms had an oversize boss that caused the spring to bind. Many owners here have had same, & fixed it or had it fixed (it is a quick & simple job for any competent mechanic).

 

I remember when you first had the spring break. Having had the same problem myself & fixed it, I offered advice re the fix & sources of immediately available parts. You preferred not to take me up on this, instead waiting some considerable while for your (multi-franchise) dealer to obtain parts & fix. I do not know why this dealer did not obtain parts, as they were certainly available, nor do I understand why he was apparently unable to address the source of the problem. At that time, it was common knowledge here that oversize pawl arm bosses were causing the breakages.

 

Moto Guzzis will run many thousands of miles reliably. They will maintain a consistent level of performance over many, many years (they require at least 10k miles before they are even run in). This is in contrast to many other motorcycles. In return, Guzzis require more hands on involvement from the owner, &/or a good, specialist dealer/workshop, esp in the first few k miles, to acheive optimum running. Some call this character, & to those, the payback is a feeling of kinship with the motorcycle & also to those who made it.

 

Some find that this level of involvement is not suited to them. If that is the case, I would suggest that, generally they are better suited to owning other makes of motorcycle.

 

I have cursed Guzzi for their lack of commitment to customer care, their unwillingness to own up to faults & deal properly with problems. But on the other hand, I find the self reliance, & mutual support from other owners that this lack of interest from the factory encourages, to be something I really value. Well, until the flywheel explodes anyhow....

 

Each to his own.

 

KB

[bigbikerrick]

Windchill,

 

It appears you have had the pawl arm spring break. This is a very common failure on 02 bikes. The problem is that some pawl arms had an oversize boss that caused the spring to bind. Many owners here have had same, & fixed it or had it fixed (it is a quick & simple job for any competent mechanic).

 

I remember when you first had the spring break. Having had the same problem myself & fixed it, I offered advice re the fix & sources of immediately available parts. You preferred not to take me up on this, instead waiting some considerable while for your (multi-franchise) dealer to obtain parts & fix. I do not know why this dealer did not obtain parts, as they were certainly available, nor do I understand why he was apparently unable to address the source of the problem. At that time, it was common knowledge here that oversize pawl arm bosses were causing the breakages.

 

Moto Guzzis will run many thousands of miles reliably. They will maintain a consistent level of performance over many, many years (they require at least 10k miles before they are even run in). This is in contrast to many other motorcycles. In return, Guzzis require more hands on involvement from the owner, &/or a good, specialist dealer/workshop, esp in the first few k miles, to acheive optimum running. Some call this character, & to those, the payback is a feeling of kinship with the motorcycle & also to those who made it.

 

Some find that this level of involvement is not suited to them. If that is the case, I would suggest that, generally they are better suited to owning other makes of motorcycle.

 

I have cursed Guzzi for their lack of commitment to customer care, their unwillingness to own up to faults & deal properly with problems. But on the other hand, I find the self reliance, & mutual support from other owners that this lack of interest from the factory encourages, to be something I really value. Well, until the flywheel explodes anyhow....

 

Each to his own.

 

KB

61214[/snapback]

Excellent post KB, very well said. To be quite honest, though, I love my guzzi, and its a fact that there is no feeling like riding a Guzzi, my 21 year old son who has been riding motorcycles since he was 7 ,and currently rides a new fuel injected CBR 600, takes my V 11 out for a ride and comes back saying" this bike is really fun, I cant explain it ,but it really makes you feel good all over to ride it" Were it not for this forum,and the excellent people here, I would not own a Guzzi ,though.

[windchill]

Gentlemen, you miss the point.

 

Its not that I declined to take up the offer of immediately available parts, or that I am averse to tinkering. That's what my 1994 Daytona is for. However, having paid a reasonable sum for what is , after all, a consumer item: a toy (as opposed to any sort of necessity), with a warranty, from a franchised dealer, I expected them to sort it if/when it broke down. I don't want a bland, characterless Jap bike. I do, however, expect something which will at least give reasonable reliability. We are, after all talking tractor technology here: nothing complex, with no major stress levels, or massive performance. I can live with misting clocks, flaking paint and so on, but not being stranded for want of a tuppeny h'appeny spring.

 

The Daytona has done 36000 miles, and cost me about £2500, so I expect to have to fix it from time to time. A bike bought brand new for something like £7000, breaking down for the third time in less than 2000 miles has got to be unacceptable to anybody. As has a manufacturer unable and or unwilling to sort the problem.

 

I like "character" that's why I bough the Guz, but not at any price.