Sounds like a real horror story. You’re right to take a step back and do the full assessment. None of the gear parts are going to be cheap.
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If you are thinking yours is beyond repair, there is a complete 5 speed gearbox for a Tonti bike on ebay, for sale by a guy that is a regular on the Tonti Guzzi facebook group, Ion Drakos. He’s asking £370. Alternatively speak to Nigel at NBS or Gitsibits aor Baldrick or Pete Morecombe (Reboot Guzzi) to see what they have in stock or can recommend.
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Thanks Don, I’ll give them a try if it’s past repair state.
Dont forget Nik Wallis
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Success! Well that was a lot less hassle than I thought it would be - not cheap but fixed and running again. Nick Wallis had a used output shaft, a pair of selector forks and a complete speedo drive which he sold me for a very reasonable price as well as giving me plenty of useful information for the rebuild. The only out of the ordinary tools that I needed where the castle socket for the clutch boss, which I had, a deep 27mm socket and impact wrench for the output shaft, which I borrowed, and a bent coat hanger. Took a while as I went very slowly, taking videos and snap shots and making copious notes but the end result is a huge improvement in gear changes. The shimming was pretty straightforward and well overdue - the selector drum needed a whopping 0.6mm added.
I found that on a previous rebuild, the double row output bearing had a load of loctite around it, blocking the two channels that run to the outer side of the races. Maybe that was why it collapsed - lack of oil? I used a small amount of Loctite green on the new bearing and kept it well away from the channels.
The reason that the speedo drive bit the dust was, I think, that the two hardened shims were missing so it flapped about and chewed the spline.
Useful contacts:
Nik Wallis 07980 639289 - new and used parts + advice
Gutsibits https://www.gutsibits.co.uk/pr/Home/index.php - consumables, shims etc
Simply Bearings Simply Bearings Ltd - Ball Bearings, Oil Seals, O-rings, V-Belts, SKF - bearings and oil seals
The two articles mentioned above by Don Spada proved invaluable, thanks Don and thanks Mr P for the offer of a drive but Nik had one.
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That gives me hope! I want to rebuild mine as it’s got quite noisy. I want to do a big trip next year so the bike needs to be as fit as I can reasonably make it. I have done a couple of other gearboxes before but it’s still a bit scary!
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