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Dude, that is rad. I have seen a similar mod for the VWs.
I'd love that setup on the Guzzi. Traffic is my left arm's worst enemy on that bike. Its a heavy ass clutch pull.
Appliance Epoxy works great.
I have a local outfit that does blast + powder on a frame for under $200, which at this point is worth it to me. I hate painting frames, lol.
Not sure if this was mentioned already but since you are working with CV carbs, check the rubber diaphragms for cracks or splits. I always hold them up against a bright light and gently stretch the material outwards and look for light passing through.
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There should be a section in your manual to test the stator output. Your charging issue will either be the stator output or the Regulator/Rectifier. Definitely get that resolved first.
As for vacuum leaks, spray any kind of solvent around the boots, any areas of the carburetors with a rubber...
Is it turning over slowly? If so the starter may be gummed up causing hard starting.
Ideally if your carbs are set up properly you shouldn't have to turn it over with the starter more than one or two revolutions for the bike to start up.
I would start by comparing the CCA/Ah of your batteries...
Yep, it looks like the swarf was simply from the clutch plate bits that probably ran through some of the gears. Looks like it definitely could have been worse.
Do it, Tim!
I think so. I didn't find anything else broken or damaged other than that clutch plate and the broken shim, but the shim was still in place when I took the gear off.
Top end looked great too so the filter did its job.
Finished the engine tear down and found a few surprises. A broken shim on one of the gears, exploded clutch plate and tons of metal shavings in the oil filter.
Bearings, crank and transmission all look good.
My main lighting fuse kept blowing. The handlebar switches are not the greatest design, and I suspected that was the culprit. Sure enough the horn button was grounding out on the pivot post for the headlight on/off/park switch, which has power.
I superglued some heat shrink wrap to the metal...
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