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Cali III Cafe Project

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MisterB View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote MisterB Quote  Post ReplyReply Direct Link To This Post Posted: 27 Jun 2023 at 12:06
Tried again to start the engine again yesterday, but no luck. With no tank fitted, I attached a short hose to each carb and inject a bit of petrol into each carb, as well as squirting a little into each carb . But only got a cough from the engine. I did notice that one carb seemed to be overflowing. One item I didn't change in the carbs was the float valves, so ordered a pair of new ones and their seats and maybe that will help. If the valves are worn then they can stick open, causing the carb to overflow, or they can stick closed, keeping the carb dry. Recently had the same problem with the carbs on the old Kawasaki Zed I restored.
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MisterB View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote MisterB Quote  Post ReplyReply Direct Link To This Post Posted: 28 Jun 2023 at 16:04
Had to find a new home for the front indicators, as the LM1 fairing prevented them from bolting to the headlight brackets. I copied the Lemans, by making a bracket using an alloy tube, which is bolted below the headstock. Would look better if they were tucked in a little more, but then they would be hidden by the forks.


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MisterB View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote MisterB Quote  Post ReplyReply Direct Link To This Post Posted: 28 Jun 2023 at 21:47
meanwhile the original starter seemed to struggle to turn the engine over, despite hooking it up to a 30AH battery. So I fitted a new starter, surprisingly cheap. The original felt rough and difficult to spin when I checked it over once removed. Not sure if rebuild kits are avaliable, but will dismantle it either way.

 
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MisterB View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote MisterB Quote  Post ReplyReply Direct Link To This Post Posted: 05 Jul 2023 at 14:54
As I wait for parts to arrive for the carbs, I decided to weigh the bike, with no fuel, but all oils and other fluids in the bike. The result was an all up weight of 193.2kg or 426lbs.

In comparison an original Cali 3 weighs 250kg dry, while a LeMans 1 (a fairer comparison) weighs 198kg dry and 232kg wet, I assume the latter number must include a full tank of petrol. Normally you can add around 10kg for the additional weight of fluids excluding petrol. 
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MisterB View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote MisterB Quote  Post ReplyReply Direct Link To This Post Posted: 17 Jul 2023 at 10:40
After two weeks enforced break from the garage, I can work on the Guzzi again. Tried to bleed the front brake, only to find the Brembo master cylinder wasn't working. 

That master cylinder was given to me years ago, and had no idea what bike it came from. It was stamped '4' and '16', the latter being the piston size I assume. After a lot of time spend looking at Brembo master cylinders on Ebay, found it to be from a Yamaha R6 or R1. 

I was about to order a rebuild kit, but found the piston to be sized solid in the bore, which was badly corroded. Didn't think it could be saved, so bought a good used one, soon fitted and once bled felt ok with the original Brembo calipers.

I'm not used to working with modern stuff, so was surprised to find the master cylinder itself also had a bleed nipple.


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MisterB View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote MisterB Quote  Post ReplyReply Direct Link To This Post Posted: 20 Jul 2023 at 08:00
Two new float valves and seats arrived, fitted them to the carbs, and fitted the carbs to the bike.. surprisingly the engine fired up immediately. The first time in more than ten years since I've owned the bike. Bit of smoke from the exhaust at first, probably from the oil I poured down the bores years ago.


Testing, Testing
 
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johnno View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote johnno Quote  Post ReplyReply Direct Link To This Post Posted: 20 Jul 2023 at 15:42
Great news never doubted itThumbs Up
1100 sport corsa , Yam R1, guzzi 650tt rider
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MisterB View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote MisterB Quote  Post ReplyReply Direct Link To This Post Posted: 24 Jul 2023 at 18:49
Just a few small jobs to do, and the bike is complete, at least for now...


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