MOTO GUZZI California III Instruction manual

WORKSHOP MANUAL
COD. 29 92 01 51
Additions to th e Workshop manual for th e m ode ls V1000 G5 e 1000 $P . COd . 1 7920 1 61

1lIe lHunrn lo,,1 I I'ItI dltKrlpti oll I.. thll book '" Irl l"dlutJ ... o nl, .nd ttl . mlnuf.C'luret' r ... rv• • 1tII"
the right 10 IlIIroduCi III, mocI ifk: nion II 1ft., H.m ... ClI •• .., lor utt.r plrtormlllCI or lor eonl t nu ,tJ VI
Of' eommlrelll r._ .... _!thou! prior Mllel .
SEIMM MO TO GUZZI - T EC HNICAL PU Bli CA TI ONS
COOE . 29 92 01 5\
300 K- 10181· Printed In Italy -D.E.Ca.· Ravenna

INDEX
OF m
1 Carburettors
6 Air cleaner replacement
1 Front fork
2 Fork arms lubrication
1 Front wheel
3 Rear wheel
5 Tyres .
11 R.H . front brake control pump
2 Alternator-Generator (Saprisa)
1 Electric system scheme legend
269

D MAIN SPECIFICATIONS
ENGINE
. - Cylinder configuration:
'- Bore:
-Stroke:
- Capacity:
. Compress ion ratio:
-Max. torque:
VALVE GEAR
CA RBURETTORS
LUBRICATION
GENERATOR ALTERNATOR
IGNITION
-Ignition timing
-Contact br eaker points gap :
-Spark
pl ugs:
-Spark plug gap:
-Ignition coils
STARTER
TRANSMISSION
CLUTCH
PRIMARY DRIVE
GEARBOX
"- Gear ratios
1sl
2nd
3rd
4th
5th
FINAL DRIVE
-Ratio:
-Overall,ratios (engine-wheel):
1 st gear
2nd gear
3rd
gear
4th gear
5th gear
270
4-stroke, twin cylinder
90° V-twin
88 mm
78 mm
948.8 cc
9.2:1
7.7 kgm at 5200 rpm
O.H.V. push rod operated r ocker arms
2 D
ell'Orto carburettors PHF 30 DO (right) and PHF 30 DS
(left)
Pressure feed by
gear pump
Wire mesh and cartrid ge filters on oil sump
Normal lubr ication pressure 3.8-4.2 kg/em (pressure valve on
oil sump)
Low oil pressure sensor (electrical) on oil crankcase
On front of crankshaft (14V-20A)
Battery-coil ignition, double contact breaker with automatic
advance.
Ignition advance (fixed) 2° ±10
Fu1l advance (static and automatic) 330 ± 10
0.37-0.43 mm
Marelli CW 7 LP; Bosch W 7 D; Bosch W 7 DC; Champion N
9 Y; L
odge HLNY.
0.6 mm
2
mount ed on frame.
El ectric starter motor (12 v-a .7KW) with electromagne tic rat-
chet control. Pinion fixed to flywheel. START push-button on
right handlebar,
Dry / tw in driven plates. Located on engine flywheel. Clutch le-
ve r on left handlebar.
By gears, 1:1.235 (Z= 17 /2 1)
5-speed, front engaging, constant mesh. Incorporated Cush
drive. Control pedal on Jeft side of machine,
1 : 2 (Z= 14 /2 6)
1 : 1.3 68 (Z = 16/25)
1: 1.047 (Z=21/22)
1 : 0. 669 (Z = 23/20)
1: 0. 750 ( Z=26 /21)
Cardan shaft with gears
1 : 4, 714 (Z = 7/33)
1 : 11,643
1: 6,080
1: 6,095
1: 5,059
1 : 4,366
1 : 5.333 (Z = 6/32)
1 :.13.1764
1: 9. 150 3
1 :
6.9019
1 : 5. 7269
1 : 4.9411

FRAME
SUSPENSION
-Front:
-Rear:
WHEELS
-Front:
-Rear:
TYRES
-Front:
-Rear:
BRAKES
-Front:
-Rea
r:
DIMENSIONS AND WEIGHT
- Wheelbase
-Overall length
-Overall width
-Height (with screen)
-
Weighl (dry)
PERFORMANCE
-Max. speed:
-Fuel consumption:
REFUELINGS
-Fuel tank
(reserve approx 6 It.)
-Oi l sump
-Gearbox
-Rear drive
(bevel set lub.)
-Front forks (per leg)
-Front and rear brake circuits
Modular duplex tubular cradle
.. MOTO·GUZZI patented- hydraulically damped telescqpic
forks. .
swinging arm with adjustable helical springs around adjustable
hydraulic damper.
Ught alloy castings
18 MT 2.50 H2
18 MT 3.00 H2
110/ 90 V18
120/90 V18
Type: TUBELESS or TUBE·TYPE
floating disc with fixed caliper, twin brake cylinder. Brake lever
on right handlebar. Independent hydraulic circuit for rear
brake.
C1> disc 300 mm ;
11> brake cylinder 38 mm;
11> master cylinder 13 mm.
floating disc with fixed caliper, twin brake
cy li nder . Brake pedal
on centre-right of motorbike;
C/) d is c 270 mm ;
(/) brake cylinder 38 mm;
0 .master cylinder
15 .875 mm ;
The rear brake is connected by a hydraulic circuit to the left
front brake; the left front brake has the same dimensions as
the right front'brake controlled by the brake lever.
1. 550 m
2. 330 m
0. 970 m
1.445 m
272 kg
with one rider approx.
190 kph
6.5 IV100 km
approx. 25
I. Super petrol (97 NO-RM/min.) .
3 L _Agip Sint 2000 SAE 10W/ 40 . oil
0.750 I. .Agip Rotr. MP SAE 80W/90. oil
0. 250 I. of wh ich: 0.230 1. _Agip Rotra MP SAE BOWI90 .. oil '
and 0. 020 L .. Agip Roeol ASO/R. or -type A Molykote ..
0. 150 L IC Agip ATF Dexron .. fluid
.. Agip Brake Fluid -SUPER HD ..
211

~ II . TABLE OF MAINTENANCE AND LUBRICATION OPERATIONS
ITEMS COVERED MILEAGEO> 1500 Km 3000 Km 6000 Km 9000 Km 12.000 Km 15.000 Km 18 .000 Km 21 .000 Km
•
Engine oil R R R R
Oil filter cartridge •
Wire ga uze 011 filler C
Air liltar C R
Ignition liming A A A A
Spark plugs A A A •
Rocker clearance A A A A
Carb uraU on A A • •
Nuts and bolls A
Fuel tank, fillers and pipes C
Gearbox 011
A A A •
Aaar dr ive box oil A • • •
Wheel and steering beat i ng
Fori( legs oil
Starter motor and generator
Brake system fluid A • • A
Brake pads A A • •
A • Inspections -Adjustment s· Possible replacements· Servicing f C _ Cleanings, A _ Replacements.
Operation required for mant .' nlng the vehkla accordIng to a ml ulon rqul.tlona (USA).
R R R
•
C
C •
A • A
A A •
A A A
A A A
A
C
A A •
A • •
A • •
• A •
Occ. al on .try, check the a'actrotyla laval In ba ttary . lubricate Joints and cabl •• j avery 500 Km (300 mil") check the angina 011 leval.
In any c .... ,anew this 011 a. ' •• st onee a y •• r.
R
A
A
A
A
A
A
A
•
A
A
•
24.000 KIn
27000 Km 30.000 Km
• • •
•
C
•
A A A
• • A
• • A
A • A
A
C
• R A
• • A
• • R
• • •

m ENGINE OVERHAULING AND
CHECKING
L--------------------------- ________________________ ~342
273

CYLINDERS
Cylind ers range (mm)
GRADE A GRADE 8 GRADE C
88 , 000 + 88,006 88,006 + 88,012 88.012 + 88,018
PISTONS
Platona range (mm)
GRADE A G
RACE B GRADE C
87,968 -;- 87.974 87,974
-;- 87,980 87,980
... 87,986
Pistons of an engine have to be balanced; only
a difference of 1.5 gr . in weight is admissible.
peso.
Values in mm.
4. 02 + 4. 04
~~//
"l: ~ ~
3.990 ..,. 3.911
1.52 + 1.54
~
When fitting a piston, ma ke sure that the .. SeA.
(exhaust) mark is fa cing towards the exhaust hole
of the cylinder.
o
..
.... + .,.'
1.490 : 1.411'
- ._ ' 1.
4'0 + 1.471
.... + .,SO
- ~
'\ / 0
.1....., + .1 ....
59.914 + 5' .910
o 22.000 +22.006
343L- ____________________________________________________ ~
Piston-pin and bushing mating data.
nserted end machl nec
Islon-pin d!a.
BlJStHng 10 plscon-p ln
bush Inner dis. mm mm
mating clearance mm
22. 015
21.994
0, 017 .;. 0,036
22. 030
21.998
274
CRANKSHAFT BALANCE CHECKING
To statica ll y balance the crankshaft it is neces·
sary to apply to the crankpin a load of
1,650 .;. 1,652 Kg .

m FUEL FEEDING
15.1 CARBURETORS (Iig. 344).
NO.2 Dell'Orto .PHF 30 DO. (R .H.) .PHF 30 OS .
(L.H.) type.
Carburator. controls
• thronle twist grip on the R.H. handlebar;
• .CHOKE., cold .tart control, on left han-
dlebar.
C.rburettor .ettlng
Diffuser ~ mm 30
Throttle valve
50 J3
Spray nozzle 264 AB
Main jet 125
Idle jet 50
Starting jet 75
Tapered needle K23 (3rd notch)
Float gr 10
Idling screw: open by 1 '/2 turns.
15.6 CHANGING THE AIR FILTER
(Iigg. 345-346).
Every 6000 km. check the filtering unit condition
and eventually clean
it with compressed ai r; ev -
ery 9000.km. replacement is prescribed.
To replace the air filter lift the sadd le, remove fue l
tank and side covers. Take out R/H"carburettor
and undo the screw fixi ng the airintake to the bi ke
frame; remove the two side screws and take out
from the RlH side the container -A,. complete with
air filter.
L- ________________ ~~ ____ ~345
~-- __________________________________________________ ~346
275

IEJ!I REAR SUSPENSIONS
Values mm .
I-- ¥ '-I ' I
I
341L- __________________________ L- ________________________ --J
~ free spring has the length of 235 mm.
Aspring under36.S Kg . load must have a 215 mm
lenght.
Aspri ng under 118 Kg .l oad must have a 170 mrn
lenghl.
Aspri ng under 19 7 Kg .l oad must have a 1 38 mm
lenghl.
216
A spri ng under 288.5 Kg. load must have a loa
mm lenght.
A fu lly loaded spring must have a 94 mm Length.
Note: I. 'prln".have notthe abovef •• tur ••
or prove warped, they mUlt be r.placed.

m FRONT SUSPENSION
21.1 FRONT FORK (fig. 351) .
• Stroke 140 mm.
• Sleeve inner diameter:
40 . 010 .;. 40.050 mm.
• For-k legs outer diameter:
39:975 + 39 ~95 0 mm .
UPPER SPRING
'"'''l-------7f
''-''
~~----------~.
,
:1:
'.
:'
'I: "
"
"
"
"
"
,
"
LOWER SPR ING
At!;" colli N _:IS
T ........... 21,15
t
""'~-------- --~
J
~
" ..
ChKk Il>llIIri'IO -'* hm'Ig ~
• !oed " ~ to I2Q ....... ....".,. lime.
••
L- ________ ~ ____________ ~ ____________________ __ ~348
.j
,,
~
~
t
HYORAULIC BRAKING TABLE
S TR OKE 60 mm
CYClES EXTENSION CO MPRE SSION
66/1'
loof(
mm 25 mm 1
Kl2.5K5
mm •
, 20
mm lS
K 7.5
Ta.1Ir!g temperatura 18°"'30°C
Load In Kg :!. 10%
~
;
",n" . '" ±O ,'
280
• /
L- ______ ________________________________________ ____ ~349
277

350L ___ ---===::::::=-- __ ----.J
21.2 FRONT FORK LEGS LUBRICATION
(fig. 350).
To replace the oil in the front fork legs, proceed
as follows: .
• the vehicle placed on the central ~tand , re-
move the handlebar fixing plale and the instru-
ment panel fixed to the same;
• loosen the side scew .e. locking the steer-
ing head to the fork leg;
• unscrew the upperplug .. e .; then undo drain
plug . A. ;
• slightly press down the front si de of the bike
to force out the plug .8. which issolid to theshock
absorber body;
• refit plug «A. and fill with the quantity of fluid
prescribed (ee 150 .Agip ATF Dexron. type)
through the space existing between the inner di-
ameter of the fork l eg and the ~hock absorber
body;
• after .having lifted the front side of the bike,
refit plug .8" and lock the side screw again.
Repeat the same operations for the otherfork leg.
35'L- ____ ________ ______________________ ______ ______________ ~
278

EEl SWINGING FORK
1,",-
~
11~
It-- (
1 2~ i/r-
1- --,
1---,
It-
469,9+4'O,lmm
<g., mm _
mm
25.00Q+ 25.052mm
/-,1
IF
';'1 E
"",'
E
~
..
~
EM ---
-r
E
\\
E
e
22
",.
8
0
136 mm
~
:1
8
~
'. •
m N
M +.
\ + 8
Ii!
N
'"
E
>ii,
E ~
e
~
6t~17*
•
~
i m
..
+ G
+
~
0
:;j
M
~
~
::l
~
~
~
+
0
"
N
~
-
~-
.135. 200 +134.9 00 mm 18. 150 + 18.050 mm P9.992: ¥/. %1 mm
. g' d
6O . 000+ ,¥ .100 mm , O.S m
352
219

m WHEELS
23.1 FRONT WHEEL (fig. 353) .
To remove the front wheel from the vehicle, pro-
ceed as follows:
• set thevehicle up on the central stand, place
a support under the engine block to keep the front
wheel up from the ground;
• undo screws .. A- securing the calipers to the
fork legs and remove calipers together with their
pipes from same;
• undo spindle wheel securing nut .. C. on the
l.H . side; .
• undo screws .. E. securing the fork tubes to
wheel spindle;
• withdraw spindle . F. paying attention to the
mounting position of spacers ,,0 .. and remove the
wheel;
• the reassembly operation is a reversal of the
dismantling one. Pay attention to the correct po-
sition of spacers; then operate different times the
brakecontrols to re-set ca liper pistons in their nor-
mal position.
35 4L- ______________________________________________________ ~
280

23.3 REAR WHEEL (fig. 355).
To remove the rear wheel from theswing arm and
the dr ive box, proceed as follows:
• set up the bike on the central stand;
• remove the L. H. silencer;
• undo nut .. A. with washer .8. on the spindle,
rear drive box side;
• loosen spindle locking screw .. 0. on fork arm;
• withdraw spindle .C. from the drive box, the
hub and the swing arm;
• withdraw the plate group with fitted the . E.
caliper; from the stop spindle on the fork, fixing
the same group to the.frame;
• lean the vehicle to the ri ght just enough to al-
low the wheel to be withdrawn from the rear fork
arm and the rear drive box.
To reassemble the wheel, reverse the dismant li ng
sequencepaying attenti on to insert theplate com -
plete with caliperon the stop of the swing fork left
arm ,
L- ______________________ ~355
L- ______________ __ __________________________ __ ____ ~~ __ ~356
23.5 TYRES
Recommended pressures are:
• fro nt wheel: with pilot only and with pillion too:
2.2 BAR ;
• rear wheel: with pilot only: 2,4 BAR; with pil·
lion too: 2,8 BAR .
Above flgur ••• r. for normal rkllng . (crulslng
.peed). When uslnSi the motorcycle at con·
stant high speed or on highway., It It: rKom·
mended to Incr .... the pressure by 0.1 BAR.
281

23.11 RIGHT FRONT BRAKE CONTROL MASTER CYLINDER
357L- __ ________________________________________ ____ ______ ~
358 L- ____ -------------------- --~
282
For the floating overhaul, in order to make reas-
sembly of mastercylindereasier, insert a pin -A.
2 mm dia. to lock the floating as shown in the
drawing (fig. 358). Before filling the tank with fluid,
remove the pin.

m ELECTRICAL APPARATUS
24.2 ALTERNATOR·GENERATOR (SAPRISA)
Cor'IiciIy 1:5
L- __ ________ ______ ________ ____ __________ ______________ ~ 359
A
"3
."
19
17
15
13
11
..
7
..
3
1
Charge c urr ent intensity diagram
,/
/
/
I
1 " 3
..
..
B
Battery =12V
Room tempe rature = 20°C
7 x1000 R.P .M
L- __________ ________________ ______________ __________ ____ ~360
283

m ELECTRI.C·SYSTEM SCHEME
25.1 Key to wiring diagram.
1 Bulb, mainfdipped beam 60 1 55 W
2 Bulb, fronf sidelights 4 W
3 Bulb, rfh direction indicator warning light.
4 Bulb, speedometer light
5 Bulb, rev. counter light
6 Bulb, I/h direction indicator warning light.
7 Connector, 4·way Molex
8 Bulb, fuel level warning light
9 Bulb, oil pres:sure warning light
10 Bulb, generator warning light
11 "Bulb, neutral warning light
12 Bulb, sidelight warning light
13 Bulb, main beam warning light
14 Flasher switch
15 R/H front direction indicator
16 Front brake stop switch
17 Starter switch
18 UH front direction indicator
19 Two-note horn
20 Control switch: start/stop engine, lights
21 Neutral switch
22 Oil pressure switch
23 Blinker unit (12 V - 46 W)
24 Control switch: lights-hom-directi on indi-'
cators
25 Spark plugs
26 H.T. coil
27 Contact breaker
28 Rear brake stop switch
29 Fuse terminal board
30 Low fuel level warning sensor
31 Voltage regulator
32 Altern,ator 14 V - 20 A
33 Side stand microswitch
34 Battery 12 V - 24 · Ah
35 Starter solenoid
36 Starter motor
37 RlH rear direction indicator
38 Bulb, number plate and stop light
39 UH rear direction indicator
40 Two-note horn switch
41 Solenoid for side stand.
42 Connector, 6-way AMP
43 Connector, 6-way Molex
284