MOTO GUZZI CALIFORNIA EV 1997-2000 Instruction manual

WORKSHOP MANUAL
WERKSTATTHANDBUCH
ONDERHOUDS-EN
REPARATIEHANDBOEK

MOTO GUZZI S.p.A.
Via Parodi, 57 22054 Mandello del Lario
TECHNICAL PUBBLICATIONS / TECHNISCHE VERÖFFENTLICHUNGEN / TECHNISCHE UITGAVEN
Cod. 03 92 01 01
Impianto DECA Ravenna
Printed in Italy /
Gedruckt in Italien / Printed in Italy da GraficheCola Lecco
500 K - 04/02
The contents of this Manual is not binding and Moto Guzzi reserves the right to make alterations, if and
when required, of components, accessories, tooling, etc. which are deemed expendient for the purpose
of improvement or, for any technical - commercial requirement, or in order to comply with law provision in
the different countries, without however undertaking to promptly up-date this Manual.
Der Inhalt dieses Handbuchs ist unverbindlich. Moto Guzzi behält sich daher das Recht vor, Änderungen
an Teilen, Zubehörteilen, Ausrüstungen usw. anzubringen, falls sich diese als notwendig erweisen solten.
um Verbesserungen auszuführen, technischen bzw. verkaufstechnischen Ansprüchen nachzukommen
order um die Kriterien der Gesetzgebungen der einzelnen Länder zu erfüllen, ohne daß das Handbuch
umgehend überarbeitet werden muß.
De inhoud van dit handboek is niet bindend en de firma Moto Guzzi behoudt zich dan ook het recht voor,
indien dit nodig mocht zijn, om door haar wenselijk geachte wijzigingen aan onderdelen, accessoires,
hulpstukken e.d. aan te brengen teneinde naar verbetering van de producten te streven of naar
aanleiding van welke noodzaak van technische of commerciële aard dan ook of met het oog op
aanpassing aan de wettelijke eisen van de verschillende landen zonder echter verplicht te zijn dit
handboek tijdig te updaten.

I
INDEX FOR THE SECTIONS
ABSCHNITTSINDEX
INHOUD VAN DESECTIES

II INDEX FOR THE SECTIONS
SEC. A GENERAL INFORMATION PAGE
1 HOW TO CONSULT THIS MANUAL ................. 2
2 ABBREVIATIONS AND SYMBOLS ................... 2
3 GENERAL SAFETY REGULATIONS ................ 4
4 RULES FOR MAINTENANCE PROCEDURES..4
5 WARRANTY ...................................................... 6
SEC. B MODEL FEATURES
1 IDENTIFICATION DATA .................................... 2
2 LUBRICANTS AND REFILLING ....................... 4
3 TECHNICAL SPECIFICATIONS ....................... 6
4 TIGHTENING TORQUES................................ 18
5 TOOLS ............................................................ 21
SEC. C CONTROL AND USE OF THE MORBIKE
1 PRELIMINARY TESTS ...................................... 2
2 ENGINE IGNITION ........................................... 4
3 ENGINE WARMING-UP .................................... 4
4 ENGINE RUNNING ........................................... 4
5 STOPPING THE ENGINE ................................. 6
6 PARKING .......................................................... 6
7 ADJUSTMENTS AND REGULATIONS ............. 8
8 PREPARATION FOR LONG PERIODS AT
REST............................................................... 16
9 CLEANING THE MOTORBIKE........................ 18
SEC. D SCHEDULED MAINTENANCE
1 SCHEDULED MAINTENANCE - TABLE ........... 2
2 MAINTENANCE PROCEDURES ...................... 4
SEC. E TRIMMINGS
1 WING MIRRORS .............................................. 2
2 FRONT AND REAR MUD GUARDS ................. 4
3 SIDE PANELS ................................................. 10
4 FRONT SEAT .................................................. 12
5 REAR SEAT .................................................... 14
6 REAR CHASSIS COVER PROTECTIONS ..... 16
7 FRONT CHASSIS COVER PROTECTIONS ... 18
SEC. F WHEEL PARTS
1 FRONT WHEEL ................................................ 2
2 REAR WHEEL................................................. 12
3 WHEEL OVERHAUL ....................................... 20
4 FRONT LEFT-HAND HYDRAULIC BRAKE
CALIFORNIA JACKAL - STONE ..................... 24
5 FRONT RIGHT-HAND HYDRAULIC BRAKE
CALIFORNIA EV - SPECIAL - SPECIAL SPORT..... 26
6 REAR AND FRONT LEFT-HAND HYDRAULIC
BRAKE CALIFORNIA EV - SPECIAL - SPECIAL
SPORT ............................................................ 32
7 REAR HAND HYDRAULIC BRAKE CALIFORNIA
JACKAL - STONE ........................................... 34
8 FRONT FORK ................................................. 44
9 REAR SWING ARM ........................................ 72
10 REAR SHOCK-ABSORBER ........................... 76
11 STEERING SHOCK ABSORBER ................... 78
12 TIRES.............................................................. 78

IV INDEX FOR THE SECTIONS
SEC. G CONTROLS PAGE
1 CLUTCH AND FRONT BRAKE CONTROL ........ 2
2 GEARBOX CONTROL ....................................... 4
3 REAR BRAKE CONTROL ................................. 8
4 ACCELERATOR /STARTER CONTROL ........... 10
SEC. H CHASSIS
1 STEERING ........................................................ 2
2 HANDLEBAR ..................................................... 4
3 FOOT RESTS .................................................... 6
4 SIDE STAND ..................................................... 8
5 CHASSIS DIMENSIONS ................................. 10
6 FRONT BUMPER ............................................ 12
7 CHASSIS DIMENSIONS ................................. 14
SEC. I FUEL SYSTEM
1 GENERAL DESCRIPTION OF THE SYSTEM .. 2
2 SYSTEM COMPONENTS ................................. 4
3 TANK “5” ............................................................ 6
4 ELECTRICAL FUEL PUMP “1” ......................... 8
5 FUEL FILTER “2” ............................................. 10
6 ELECTRO-INJECTORS “3” ............................. 10
7 PRESSURE ADJUSTER “4” ........................... 12
8 AIR FILTER BOX “1”........................................ 16
9 THROTTLE BODY “2” ..................................... 18
10 BATTERY “1” ................................................... 22
11 STARTER SWITCH “2” .................................... 22
12 RELAY “3” ....................................................... 24
13 ECU I.A.W. 15 M “4” ....................................... 26
14 AIR TEMPERATURE SENSOR “5” ................. 28
15 OIL SENSOR TEMPERATURE “6” ................. 28
16 R.P.M. AND T.D.C. SENSOR “7” ...................... 30
17 COILS “8” ........................................................ 32
18 THROTTLE POSITION POTENTIOMETER
“9”.................................................................... 34
19 OPERATING STAGES .................................... 36
20 DIAGNOSTICS ............................................... 40
21 FUEL VAPOUR PURIFICATION AND
RECIRCULATION SYSTEM
(USA, SGP, CAN) ............................................ 56
SEC. L EXHAUST SYSTEM
1 SYSTEM FEATURES ........................................ 2
2 SILENCERS ...................................................... 2
3 EXHAUST PIPES .............................................. 4
4 EXPANSION CHAMBER ................................... 6
SEC. M ENGINE
1 GENERAL RULES FOR ENGINE OVERHAUL. 2
2 REMOVAL – REASSEMBLY OF ENGINE /
GEARBOX ASSEMBLY ..................................... 2
3 LUBRICATION SYSTEM ................................... 8
4 HEADS AND TIMING SYSTEM ...................... 18
5 CYLINDERS AND PISTONS .......................... 44
6 CLUTCH.......................................................... 48
7 ALTERNATOR ................................................. 58
8 CRANK SHAFT AND CONNECTING RODS ... 62

VI INDEX FOR THE SECTIONS
SEC. N GEARBOX PAGE
1 MAIN FEATURES ............................................. 2
2 REMOVAL AND INSTALLATION ...................... 6
3 DISASSEMBLY ............................................... 10
4 CHECK AND OVERHAUL .............................. 24
5 GEARBOX UNIT REASSEMBLY ON THE
BENCH............................................................ 30
SEC. O REAR TRANSMISSION HOUSING AND SHAFT
1 REAR TRANSMISSION HOUSING .................. 2
2 TRANSMISSION SHAFT ................................ 16
SEC. P ELECTRICAL SYSTEM
1 ELECTRICAL SYSTEM DESCRIPTION ........... 2
2 BATTERY ........................................................ 20
2 BATTERY (USA - SGP – CAN VERSION) ...... 24
3 STARTER MOTOR .......................................... 28
4 LIGHT AND ACOUSTIC SYSTEMS /
DASHBOARD / CONTROLS ........................... 30
5 SIDE STAND SWITCH .................................... 50
6 FUSE TERMINAL BOARD .............................. 52
7 ALTERNATORAND VOLTAGE REGULATOR ....... 54

VIII

CALIFORNIA EV (1997 - 2000)
CALIFORNIA EV 2001

CALIFORNIA JACKAL
CALIFORNIA STONE

CALIFORNIA SPECIAL SPORT
CALIFORNIA SPECIAL