Dr Gil

Good advice all around Rj and it's exactly what I did. The people at HMB Guzzi were wonderful about corresponding with me by email (and they speak ENGLISH!). As soon as I'd send a query off to them they responded within 1/2 hour. They take no PayPal or credit cards so I went down to my bank and did a bank transfer in Euros to them for a small fee. They had given me an account number to deposit into. After all is said and done I have both an '03 timing cover and a replacement seal on the way. Now I wait. No problem though...I still have several other chores to do on the bike while I'm waiting.

Jeeze, do I feel like a dope on that one I thought I had tried every possible combination of the three wires. I switched the black and red and bingo! Running lights AND a rear brake light...but alas, no front brake light. At least I'm on the right track now. It's freezing in my garage right now so I'm done for the day but tomorrow I'll persue it further. Thanks All!

It's coming Ouiji...I can "FEEL" it! I've been notified that ALL the parts (cover and seal) are on their way (how many times have I said this now...sigh?) ...but in the meantime please go visit my "tail light assembly" thread and sort out my electrics would ya? No time off for anyone until this bad-girl is back on the road!!!

While everything is "in the mail" pertaining to my timing cover I thought I'd deal with the electrics in the rear section. During the crash of my '02 Le Mans I slid tail first for quite a ways (200 feet). The tail section took the brunt of the slide. Prior to the crash the previous owner had wired two sets of LED lights into the brakes...I never cared for the looks of it but it worked fine. Fast forward to present time. Everything was pretty much a shambles in the tail section. I've replaced most everything. I have new turnsignals (Buell) and can get the license plate light and tail light to work...but still no brake light. There are only 3 wires to deal with (plus an extra off of what I assume is the brake wire (gray) for the second LED off of the "red/blue" wire) so how hard can it be? Electrics are not my thing (still trying to sort out what IS my thing). Two of the connections are side by each (see pic) on the back of the light. Running lights (yellow and black)? Why two? Why do I have a yellow wire and it doesn't show in the wiring diagram? The connection off to the side seems to be the brake light. If I connect a running light wire to it it goes into bright, "brake" mode. I have turnsignals working and can get the tail "running" light and license plate light working with the configuration in the photo...but no brake lights. Should I be looking for the problem to be elsewhere? Broken wire? It appears that the Le Mans has two brake micro switches. Am I correct in (again assuming...dangerous) that even if one switch was damaged in the crash (neither was impacted by the left-hand side slide) I would still get a brake light from the other one...so it is probably NOT a switch that's goofing me up? Geeze, I hate electrics.

Good news! HMB Guzzi (thanks for the tip Paul) had a 2003 timing cover in stock for the 39 Euros they advertised on their website It will be shiny black rather than my engine's lovely "mat" black but I can live with that (my engine is usually filthy anyway and there is no telling what color it is). The shipping to the U.S. is 27 Euro bringing the total to 66 Euro for the cover...a good deal. They are requesting I send a check by snail mail for payment and I'm a bit concerned about how slow that will be to get the check there and then the cover back by post during the holiday season. I'm checking on whether I can pay by an alternate method. I've also got the seal on order from Moto International (with whom I have a store credit...long story). Hopefully it will beat the cover getting here. So today I'm covering up all the open bits and will focus on other projects (new rubber, heated grips, speed bleeders and sorting out the rear light electrics) on the bike until the parts arrive.

Wha'? And deny my wife the use of that lovely "relish tray" (or bed pan)? Tis the "season of giving" ya know. Actually Ratchet this is pretty much my current "fall back" position. As much as I would hate to have to re-do this task, I could and the JB is strong stuff. It might be years before I had to revisit this nightmare and by that time I might actually have the parts I need to complete the job. At this juncture all seems to be depending on how available that seal is...it's always something isn't it?

Ahhh, the Italians... I've already put in a request from the Germans by translating their online order form via Babel Fish...that should amuse them to no end and have contacted an English "bike breaker" now residing in France that I've had good success with. jrt, I've purchased a few parts of Frank's bike but believe he is selling the engine as a unit. I'm going through my MGNOC newsletters as soon as I'm done here. Good tips all. Thanks guys.

How'd you know I was going to ask you Todd? Well, I was. I'm tempted by the JB Weld solution and encouraged by Ratchet's endorsement. But while it's a jim dandy product my experience is that it will eventually fail (certainly sooner than a pristine part would)...and I plan on keeping this bike forever. So my thinking at the juncture is to replace. But as you well know some parts just don't seem to be available. If this turns out to be the case with the timing cover (and it doesn't seem likely that any of the good members here, who have bailed me out so many times recently would have on hanging around) then I'll have to go with the patch and hope for the best. Meanwhile I'll try to come up with one I guess...will this never end?

Well, the timing cover is off! Removing the bolts at the back of the sub-frame then loosening the front bolts allowed me to rotate the frame forward and it gave me just enough room to get the cover off! Thanks for the great tip Pete! So now my problem is twofold. The seal in the middle of the cover is rubber with a tiny spring inside a lip to keep it snug against the shaft. When removing I pulled the spring part way out. I've managed to put it back together and the rubber still seems smooth but I wonder if I should replace it. My second problem may make that point moot however. I've got a cracked timing cover You can barely see it on the outside of the cover but is quite obvious on the inside. Can this be simply repaired by JB Welding it and have lasting results (I really, really don't want to have to go down this road a second time) or should I just bite the expense of a new timing cover and resign myself to the inevitable long wait until it arrives? I await your counsel. Meanwhile here's a picture of the mighty Le Mans as the end of today's adventure. I can't believe what you guys have made me do to my (formerly) beautiful Italian girl!!!

So what does the tank look like with the pad removed? Can it be left off or are the pins ugly things that are part of the tank? If you have access to a digital camera could you snap a picture of it off for me Rick, I'm curious?

Whaa, frame sections come OFF??? Crap, if I'd of known that it would have saved me SO MUCH TIME! Oh foolish me...and yes, I do have the parts fische (sent to me by Todd at MPH Cycles...thank you again) but failed to make full use of it and to understand that the "frame" is actually in pieces! True, removing the tank is more work than I originally signed up for but at least it is something I've done before and it gives me some hope. With that obstinate section of frame out of the way EVERYTHING will become SO VERY MUCH easier! And yes, I think with it out of the way I think I will be able to get the cover off. Every day the pile of parts around the basic hulk grows. Tomorrow I will add more to it. Eventually I suspect I will be surrounded by nothing but various (sorted by where they were originally positioned on the bike and in size place) piles of parts...I sure hope this is not some kind of a sick joke you old timers play on the new guys to get him to totally disassemble their bikes...if so your better believe I'm a gonna come a lookin' for ya

The continuing drama... I think I'm screwed. The alternator is off and hanging and with much struggle (bolts behind frame members and not realizing that I had to remove the front two motormounts) I finally got the timing cover free! That's the good part. The bad part and I think what is going to beat me here is that I don't have enough free space at the top of the cover to move it far enough forward to clear the shaft to move it down get it out. I don't see anyway to do it unless I could remove the shaft (not likely) or to drop the engine, which I fear is WAY past my abilities...sigh. I'm attaching a couple of pictures to help with the explaination but I'm afraid it's a bit hard to discern what's going on from them. Everything is tight and in incredibly tight spaces! ...the icing on the cake is that I think I've messed up the seal in the cover that seals the shaft. CRAP!

Yeah, kind of sad to see Max's career in decline. But what with his connections and all I wouldn't be a bit surprised to seeing him take a shot at acting or some other tacky and embarrassing occupation. The "celebrity" thing is like drugs, you gotta have it once you've had a taste...not that I would know personally

Being such a new guy to Guzzi's I was oblivious to this piece of Moto Guzzi history. Lately it seems I have been so overwhelmed by the "nuts and bolts" of trying to resurrect my Le Mans and get it back on the road that I fear I've been neglecting the historic perspective that comes with owning a Moto Guzzi. Thank you for passing this info along...it is SO very cool!

It's an eagle alrighty...but Italian eagles are a differnt thing entirely than the ones here in the US. Meanwhile I finally got that nut off the shaft of the alternator. I had a friend come over and give me a hand (cost me a beer). For awhile I was afraid it was left handed but no, it turns out that it is indeed right handed. Putting the bike in a high gear and having the rear brake applied didn't work. The engine would still turn and even with quick pressure on the wrench I couldn't break it free. I finally resorted to putting a large screwdriver in the flywheel teeth (almost a last resort...I really, really don't want to have to deal with broken flywheel teeth) and the nut came right off...nolo problemo. Tomorrow I will respectfully attack the timing cover.

Update: Fluids have been drained, battery disconnected. Oil cooler is moved (somewhat) out of the way (still wondering if I need to disconnect it and go for the coil too). I have located all my bolts on the timing cover that need to be removed. There are a couple of them that may be "challenging" as the frame is in the way. I've taken off the alternator cover and tried to remove the center bold but with no luck. Even with the bike in gear I can't get enough force on it to break it free (rear wheel is elevated and just spins). I'm waiting on help to arrive to help me get the bike off the Guzzi jack (never figured out how to do that by myself) So we've postponed removing the gasket until tomorrow. Meanwhile it occurs to me why don't I try to cut a 1.5 inch hole in the alternator cover and put in a rubber plug to facilitate valve adjustments? While trying to break the center nut free I couldn't help but notice how nice this would be for finding top dead center. Here's a picture of my "field of battle."

After I get the extranious stuff out of the way it looks like the timing cover will be a pretty straightforward "remove bolts, take off cover, remove gasket, replace gasket, replace cover, tighten bolts" sort of thing. Doesn't look like a big deal at all. After reading the shop manual what does cause me more concern is the alternator removal. It calls for a "special locking tool" to hold the stator while the central nut is loosened. Also of some concern is its warning about "avoiding demagnitization" by replacing the rotor back into the stator while working on the bike. How big a problem do you suppose this is? Demagnitizing the alternator would be a BAD thing. Last question (I'm trying to have everything clear in my mind and all my tools and parts ready for the operation) is about coating the gasket. It seems as though most of the responses in this thread assumed it would be made of fiber (as did I). I'm surprised to find that it is actually metal. Will this make a difference in the gasket compound I should use (I'm thinking of going the silicone route complete with thread)? I'm off to drain the bike's precious bodily fluids...

ok, so here goes. I think I've got "all" the parts in place and I can procrastinate no longer...I have the beloved Le Mans on an "official MG jack" (rear end lifted by the lower bolts on the pork chops) and stabilized by a motorcycle jack underneath the pan and have the new gasket in hand (whoa! I really wasn't expecting a "metallic" gasket...but I guess that's what the doctor ordered). I have the oil cooler released and tied up. I am simultaneously trying to sort out some rear end lighting problems (the bike mostly slid tail first during the crash and took the most damage...now trying to make sense of the electrics and the "puzzle pieces" of the Le Mans rear end body parts...sigh). And now to business. Tomorrow I'm draining the fluids, disconnecting the battery and thinking that Tuesday I'm going to dive right in, pull off everything that's left and try to replace that timing cover gasket. After a close inspection I find that the front wheel may be in the way...sigh (maybe this is the time to get that front tire replaced?). Perhaps I can work around it. It is hard not to try to deal with "everything" at once...I keep telling myself "baby steps" and it will all eventually get done...but it is hard. My fear is that while concentrating on one task I will "forget" about other stuff...it is all so confusing. Everyone please stand by for "emergency" requests and questions...I'm flying by the seat of my pants here and am depending on your support. Please hang in there and wish me luck..."...we're in for a bumpy ride" (Mae West). -(dr.) gilberto

I just found out today that Triumph isn't taking part in this year's show What's with that? I am planning on hitting the show when it comes to San Jose in a couple of weeks and was really looking forward to finally being able to set on the Sprint and Speed 3 (they were at last year's show but roped off). I've heard good things about the Guzzi booths on other forums too...nice to be getting a bit of positive attention

Yuck indeed...but I must say that the final scene with the two guys skewered on the forklift blades, one with a running chainsaw, really shouldn't be missed. I felt it was a sort of Keystone Cops do "Texas Chainsaw Massacre" homage. I give it a "thumbs up."

Very, VERY cool ...and yup, required multiple viewings

It looks like removing (or at least loosening and moving out of the way to gain access) the oil cooler, removing the alternator and then removing the timing cover. It sounds easier that it looks like it may be. Much of this work has to be done in teenie-tiny spaces surrounded by frame/engine mount bits. Beyond this I don't really know. There may be more bits that must be removed... Ratchethack I thank you (and everyone who has contributed to this thread) for your thoughtful and encouraging reply(s). Your rely is causing me to reasses my plan...and that's probably a good thing There is a part of me who simply "wants it done" and is tired of dealing with the difficulties and simple bad luck that just keeps-on-a-comin (it's been a long year...I now have TWO dead bikes in my ramshackle garage) and to just pay someone to make it right. But there is another part of me that knew owning my first Guzzi was going to be a "hands on" sort of motorcycle life (although I never expected THIS much THIS soon!) and know that doing the work (if possible) myself will be a great learning experience and remove some more of the "mystery" about this bike. I'm in it for the long run...I expect to own this bike the rest of my life. I guess I better go out and take a look at what this job really looks like.

You have hit on a problem I've had since I recently came into "Guzzi-ness." One of the reasons I ended up knowing that there really is no motorcycle but Moto Guzzi was a fellow Sport Touring.Net? member letting me ride his V11 Sport. I, of course would love to pass on this feeling of what it is to ride a Guzzi. I think it is VERY important for someone interested in the bike for whatever reasons to actually ride one...as we all know, they are "different." Which brings me to my personal dilemma...I am SO uncomfortable letting anyone ride my bike. Guzzi's ARE different and letting a person unfamiliar with their idiosyncrasies ride MY BABY is VERY, VERY hard. I am in total sympathy with your problem and my own advice and what I pass on to you is to take it on a person by person basis and hope for the best.

Well the silicone didn't seem to work After cleaning the offending bolt thoroughly and applying silicone sealant to the underside of the head and along the "weeping" seam and then letting it cure for 24 hours and then firing up the bike and then witnessing the EXACT SAME leakage from the bolt but with perhaps a bit less flow on along the seam, I'm sick of it all. I'm ready to order the new timing cover (39 euros is soooo sweet a deal), timing gasket cover and perhaps front crank seal and just hauling the whole mess south and letting the dealership deal with replacing everything. Ok, so now that I've gotten that off my chest...perhaps/maybe I applied the sealant too timidly. I resisted going heavy because a) I didn't want to make a big messy thingie on the side of my engine (even though I "stealthed it" by spraying graphite power on it and I'm not all that sure that this would be any kind of a permanent fix that would not just be failing in the near future and leaving with me having to deal with it all over again ad infiniutum. Just to be on the safe side however, before I go and order a bunch of parts (which will probably turn out to not be available for the next 6 months anyhoo), rent the trailer to make the 500 mile haul and commit to this plan I think I'll pause, take a deep breath and wait to see what you guys think.

I have nothing but respect for this gentleman...