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

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1
GENERAL INFORMATION
ALLGEMEINE INFORMATIONEN
ALGEMENE INLICHTINGEN

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2 G ENERAL I NFORMATION
1 HOW TO CONSULT THIS MANUAL
The purpose of this manual is to provide instructions for
carrying out overhauls and repair work correctly.
The following data aim at providing an overview of the
main tests to be carried out when overhauling the various
units.
For this reason, the manual contains illustrations,
drawings and diagrams necessary for carrying out
disassembly, testing and assembly procedures.
The manual can also be a guide for those who require a
deeper knowledge of the manufacturing details for the
parts to be examined: it is essential that technicians in
charge of repairs know these details for the work to be
carried out correctly.
The manual has been sub-divided into sections and then
into chapters for a faster and more direct consultation;
the sections contain information and procedures
regarding a particular motorbike system while the
chapters analyse the parts making up these systems in
more detail.
2 ABBREVIATIONS AND SYMBOLS
In order to make the manual immediately comprehensible,
the paragraphs are earmarked by graphic illustrations
identifying the subject to be dealt with.
This manual contains notes with important details:
Accident prevention regulations for the operator
and those working in the vicinity.
There is the possibility of causing damage to
the vehicle and/or its components.
Further information concerning the work in
progress
N.B.
“Right-hand” and “left-hand” refer to controls
seen from the driving position.
N.B.
All the technical drawings contained in this
manual use measurements expressed in mm.
The tightening torques are expressed in Newton
meter.

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4 G ENERAL I NFORMATION
3 GENERAL SAFETY REGULATIONS
This manual does not contain general safety rules
because they are considered part of standard manage-
ment within workshops; it contains however, warnings and
instructions of particular importance which, if not
respected, could injure the operator or the vehicle.
It is however very important that the technicians, carrying
out any operation contained in this manual, even if the
specific tools recommended by “Moto Guzzi” are used,
always check that the methods and tools employed for
carrying out any procedure do not endanger the safety of
the operator or the vehicle.
4 RULES FOR MAINTENANCE
PROCEDURES
To make sure that the vehicle is always in perfect working
condition, it is necessary to follow the instructions provided
in the scheduled maintenance program, described in
section D.
The first series of maintenance procedures must be
carried out after 1500 Km, as describedon the table in
chapter 1 of section D; carrying out these operations is
essential as they allow the operator to check the initial
wear, which takes place during the running-in period.
Furthermore, it is important to observe the following basic
rules during maintenance procedures:
• Seal rings, gaskets, split pins, O rings and all the parts
which ensure a seal must be replaced with new parts
during reassembly procedures.
• It is necessary to use tools specifically designed for
this motorbike, in order to avoid incorrect assemblies
or damages
• During the maintenance operations only use decimal
metric system material and tools as the nuts, bolts
and screws in this system cannot be interchanged with
the imperial system;
• When tightening nuts or bolts, it is a good practice to
always start with those with a larger diameter or those
positioned more internally; then proceed diagonally,
step by step, unless a specific sequence has been
prescribed.
• After reassembly operations make sure that all the
reinstalled components work correctly.
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6 G ENERAL I NFORMATION
5 WARRANTY
When replacing parts, request and make sure that only
“Original Moto Guzzi Spare Parts” are used.
The use of non original spare parts shall render any
warranty claim void or null.

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1
MODEL FEATURES
MODELLEIGENSCHAFTEN
KARAKTERISTIEKEN MODEL

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2 M ODEL F EATURES
1 IDENTIFICATION DATA
Each vehicle is marked by an identification number
stamped on the chassis lug and on the engine crankcase.
The number marked on the chassis lug and reported in
the registration document is the legal identification of the
motorbike;this number is composed of digits and letters,
as in the example illustrated below.
ZGUKDBKDXVM111111
1) Code WMI (World Manufacturesʼ Identifier)
2) Type of vehicle
3) Model
4) Version
5) Year of manufacturing, for example:Y = 2000
1 = 2001
6) Manufacturing plant (M = Mandello del Lario)
7) Chassis number (no.111111 refers to the first vehicle
built)
N.B. For California Jackal the number referred
to the 1st built vehicle is 150010
{
{
1 2 3 4 5 6 7 8
{
{
{ { {
{

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4 M ODEL F EATURES
2 LUBRICANTS AND REFILLING
For California Special 1ST series (adjustable fork) until chassis no. KD 131644
For California Special 2ND Series(non-adjustable fork) from chassis no. KD 131645
*
Parts to be refilled Liters Prescribed products
Fuel tank
(about 4 litres reserve) 9 aprox1 Premium gasoline(97 No. - r.p.m.)
Premium unleaded gasoline (95 No - r.p.m.)
Engine sump 3 "Agip 4T SUPER RACING SAE 20W50" oil
Gearbox housing 057,0 "Agip Rotra MP SAE 80 W/90" oil
Final Drive
(bevel gear lubrication)
052,0
of which
032,0
020,0 ("Molikote type A")
"Agip Rotra MP SAE 80 W/90" oil
"Agip Rocol ASO/R" oil
Telescopic fork(per strut) 584,0
Shock-absorber oil (SAE10)( California Special 1ST series,EV )
Shock-absorber oil (SAE10)(California Jackal, Stone,
For California Special 1ND series, Special sport)
Front and rear braking system - "Agip Brake Fluid - DOT 4"
*
565,0
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6 M ODEL F EATURES
3 TECHNICAL SPECIFICATIONS
ENGINE
Two-cylinder with 4 stroke
Cylinder arrangement .................................at “V” of 90°
Bore................................................................... 92 mm
Stroke ............................................................... 80 mm
Total displacement ............................................. 1064cc
Compression ratio ................................................ 9,5:1
Maximum torque ...........Kgm 9,6(94 Nm) at 5000 r.p.m.
Maximum capacity ....... CV 73,5 (Kw 54) at 6400 r.p.m.
TIMING SYSTEM
With rods and equalizers and 2 valves per cylinder. A
camshaft in the crankcase is driven by a duplex chain
with automatic chain tightener.
FUEL SUPPLY SYSTEM
MAGNETI MARELLI IAW 15M indirect electronic injection,
sequential and timed type, “Alfa-N” system, no.2 ø40
mm throttle bodies with Weber IW031injectors, electric
pump with pressure adjuster, digital management for
optimized injection times.
EXHAUST SYSTEM
In stainless steel - 2 two tubes connected to an expansion
chamber and to two silencers.
LUBRICATION
Pressure system with gear pump. Mesh and cartridge
filters fitted in the crankcase sump.
Standard lubrication pressure is 3.8-4.2 Kg/sq cm
(controlled by a special valve fitted in the crankcase
sump).
Electrical transmittor for indicating insufficient pressure
in the crankcase.
ALTERNATOR GENERATOR
Installed on the front part of the crankshaft.
Output capacity: 350 W at 5000 r.p.m/min. (14 V - 25 A)
IGNITION
“MAGNETI MARELLI” digital electronic ignition with
inductive output
spark plugs ............................................NGK BPR 6ES
Distance between the spark plugs electrodes... mm 0,7
no. 2 ignition coils ......................... fitted on the chassis

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8 M ODEL F EATURES
START-UP
Electric start-up through a starter motor (12V - 1,2 Kw )
equipped with an electromagnetically controlled coupling.
Ring gear fixed onto the motor.
Button control (START) “ ” located on the RH side of the
handlebar.
TRANSMISSIONS
CLUTCH
Dry type clutch with two driven disks. Located on the
engine flywheel.
Hydraulic control through the handlebar lever (LH side).
PRIMARY TRANSMISSION
With helical gearings, ratio 1:1,2353 (z=17/21)
GEARBOX
5-speed model with constant mesh gears with front clutch
dogs.
Incorporated couplings.
Conrol with pedal lever positioned on the LH side of the
vehicle.
GEAR RATIO
1st gear = 1: 2,0000 (14/28)
2nd gear = 1: 1,3889 (18/25)
3rd gear = 1: 1,0476 (21/22)
4th gear = 1: 0,8696 (23/20)
5th gear = 1: 0,7500 (28/21)
SECONDARY TRANSMISSION
Shaft with universal joint and gearings.
Ratio 1: 4,125 (z=8/33)
Total ratio (engine-wheel):
1nd gear = 1: 10,1912
2rd gear = 1: 7,0772
3th gear = 1: 5,3382
4th gear = 1: 4,4309
5th gear = 1: 3,8217
CHASSIS
Tubular type with double dismountable section made of
high yield stress steel
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10 M ODEL F EATURES
SUSPENSIONS
FRONT
CALIFORNIA EV -
CALIFORNIA SPECIAL 1ST SERIES UNTIL CHASSIS NO. KD 131644
Telescopic hydraulic fork with MARZOCCHI “ø45 mm”
inverted stems whose extension and compression can
be adjusted separately.
CALIFORNIA JACKAL - CALIFORNIA STONE -
CALIFORNIA SPECIAL 2ND SERIES UNTIL CHASSIS NO. KD 131645-
CALIFORNIA SPECIAL SPORT
MARZOCCHI “ø45 mm” non-adjustable telescopic
hydraulic fork.
REAR
CALIFORNIA EV -
CALIFORNIA SPECIAL 1ST SERIES UNTIL CHASSIS NO. KD 131949
Swinging arm with two adjustable hydraulic shock
absorbers for extension hydraulic braking.
CALIFORNIA JACKAL - CALIFORNIA STONE
Swinging arm with two adjustable hydraulic shock
absorbers for spring pre-load.
CALIFORNIA SPECIAL SPORT -
CALIFORNIA SPECIAL 1ST SERIES UNTIL CHASSIS NO. KD 131950
Swinging arm with two non-adjustable hydraulic shock
absorbers.
WHEELS
CALIFORNIA EV (1997-2000) -
CALIFORNIA SPECIAL 1ST SERIES UNTIL CHASSIS NO. KD 131644
Wheels with spokes and with “BBS” patented tubeless
rims in the dimensions:
FRONT
18” x 2,50-B-40 H2 -T DOT or
18” x 2,50-B-40 H2 -TC e DOT
REAR
17” x 3,50-B-40 H2 -T DOT or
17” x 3,50-B-40 H2 -TR e DOT
CALIFORNIA JACKAL – CALIFORNIA STONE - CALIFORNIA SPECIAL
2ND SERIES UNTIL CHASSIS NO. KD 131645 –
CALIFORNIA SPECIAL SPORT
Wheels with steel rims in the dimensions:
FRONT
18” x 2,50-B-40 H2 -T DOT or
18” x 2,50-B-40 H2 -TC e DOT
REAR
17” x 3,50-B-40 H2 -T DOT or
17” x 3,50-B-40 H2 -TR e DOT