MOTO GUZZI California Titanium Instruction manual

WORKSHOP MANUAL
WERKSTATTHANDBUCH
ONDERHOUDS-EN
REPARATIEHANDBOEK

MOTO GUZZI S.p.A.
Via Parodi, 57 23286 Mandello del Lario
TECHNICAL PUBBLICATIONS / TECHNISCHE VERÖFFENTLICHUNGEN / TECHNISCHE UITGAVEN
Cod. 03 92 01 71
Impianto DECA Ravenna
05/03
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.

-2003-
CALIFORNIA EV
CALIFORNIA ALUMINIUM
CALIFORNIA EV TOURING

CALIFORNIA TITANIUM
CALIFORNIA STONE TOURING
CALIFORNIA STONE

I
-2003-
INDEX FOR THE SECTIONS
ABSCHNITTSINDEX
INHOUD VAN DESECTIES

II
VARIANTS CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
SEC. A GENERAL INFORMATION PAGE
1HOW TO CONSULT THIS MANUAL ................. 2
2ABBREVIATIONS AND SYMBOLS ................... 2
3GENERAL SAFETY REGULATIONS ................ 4
4RULES FOR MAINTENANCE PROCEDURES..4
5WARRANTY ...................................................... 6
SEC. B MODEL FEATURES
1IDENTIFICATION DATA .................................... 2
2LUBRICANTS AND REFILLING ....................... 4
3TECHNICAL SPECIFICATIONS ....................... 6
4TIGHTENING TORQUES................................ 18
5TOOLS ............................................................ 21
SEC. C CONTROL AND USE OF THE MORBIKE
1PRELIMINARY TESTS ...................................... 2
2ENGINE IGNITION ........................................... 4
3ENGINE WARMING-UP .................................... 4
4ENGINE RUNNING ........................................... 4
5STOPPING THE ENGINE ................................. 6
6PARKING .......................................................... 6
7ADJUSTMENTS AND REGULATIONS ............. 8
8PREPARATION FOR LONG PERIODS AT
REST............................................................... 16
9CLEANING THE MOTORBIKE........................ 18
SEC. D SCHEDULED MAINTENANCE
1SCHEDULED MAINTENANCE - TABLE ........... 2
2MAINTENANCE PROCEDURES ...................... 4
SEC. E TRIMMINGS
1WING MIRRORS .............................................. 2
2FRONT AND REAR MUD GUARDS ................. 4
3SIDE PANELS ................................................. 10
4FRONT SEAT .................................................. 12
5REAR SEAT .................................................... 14
6REAR CHASSIS COVER PROTECTIONS ..... 16
7FRONT CHASSIS COVER PROTECTIONS ... 18
SEC. F WHEEL PARTS
1FRONT WHEEL ................................................ 2
2REAR WHEEL................................................. 12
3WHEEL OVERHAUL ....................................... 20
4FRONT LEFT-HAND HYDRAULIC BRAKE
CALIFORNIA JACKAL - STONE ..................... 24
5FRONT RIGHT-HAND HYDRAULIC BRAKE
CALIFORNIA EV - SPECIAL - SPECIAL SPORT..... 26
6REAR AND FRONT LEFT-HAND HYDRAULIC
BRAKE CALIFORNIA EV - SPECIAL - SPECIAL
SPORT ............................................................ 32
7REAR HAND HYDRAULIC BRAKE CALIFORNIA
JACKAL - STONE ........................................... 34
8FRONT FORK ................................................. 44
9REAR SWING ARM ........................................ 72
10 REAR SHOCK-ABSORBER ........................... 76
11 STEERING SHOCK ABSORBER ................... 78
12 TIRES.............................................................. 78

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VARIANTEN CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
VARIATIES CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
ABS. A ALLGEMEINE INFORMATIONEN SEITE
1BENUTZUNG DIESES HANDBUCHS.............. 3
2ABKÜRZUNGEN UND SYMBOLE ................... 3
3ALLGEMEINE SICHERHEITSREGELN ........... 5
4REGELN FÜR DIE WARTUNGSARBEITEN .... 5
5 GARANTIE ........................................................ 7
ABS. B MODELLEIGENSCHAFTEN
1 IDENTIFIKATIONSDATEN................................ 3
2SCHMIERUNG UND FÜLLMENGEN ............... 5
3TECHNISCHE DATEN ...................................... 7
4 ANZUGSMOMENTE....................................... 19
5AUSRÜSTUNG ............................................... 21
ABS. C KONTROLLE UND GEBRAUCH DES MOTORRADS
1ERSTE KONTROLLEN ..................................... 3
2STARTEN DES MOTORS ................................ 5
3ANWÄRMEN DES MOTORS............................ 5
4MOTOR IN BETRIEB........................................ 5
5ABSTELLEN DES MOTORS ............................ 7
6PARKEN............................................................ 7
7 EINSTELLEN .................................................... 9
8VORBEREITUNG WEGEN LÄNGEREN
STILLSTANDS ................................................ 17
9REINIGUNG DES MOTORRADS ................... 19
ABS. D REGELMÄSSIGE WARTUNG
1TABELLE WARTUNGSPLAN ........................... 3
2WARTUNGSARBEITEN ................................... 5
ABS. E TRIMMINGS
1 SPIEGEL ........................................................... 3
2 VORDERES UND HINTERES SCHUTZBLECH... 5
3KLEINE SEITENTEILE ................................... 11
4VORDERSITZ ................................................. 13
5 HINTERSITZ ................................................... 15
6 HINTERSCHOTTEN DER RAHMENABDECKUNG .. 17
7 VORDERSCHOTTEN DER RAHMENABDECKUNG ....19
ABS. F RÄDERTEILE
1 VORDERRAD ................................................... 3
2 HINTERRAD ................................................... 13
3ÜBERHOLUNG DER RÄDER ........................ 21
4VORDERRADBREMSANLAGE LINKS
CALIFORNIA JACKAL - STONE..................... 25
5VORDERRADBREMSANLAGE RECHTS
CALIFORNIA EV - SPECIAL - SPECIAL SPORT .... 27
6VORDERBREMSANLAGE LINKS UND
HINTERRADBREMSANLAGE CALIFORNIA EV -
SPECIAL - SPECIAL SPORT ......................... 33
7HINTERRADBREMSE BREMSE JACKAL -
STONE ............................................................ 35
8VORDERE GABEL ......................................... 45
9HINTERE SCHWINGE ................................... 73
10 HINTERER STOSSDÄMPFER ....................... 77
11 LENKUNGSSTOSSDÄMPFER....................... 79
12 REIFEN ........................................................... 79
SEC. A ALGEMENE INLICHTINGEN PAG.
1HOE MOET DEZE HANDLEIDING
GERAADPLEEGD WORDEN ........................... 3
2AFKORTINGEN EN SYMBOLEN...................... 3
3ALGEMENE VEILIGHEIDSREGELS ................ 5
4REGELS VOOR DE ONDERHOUDS-
OPERATIES ...................................................... 5
5GARANTIE ........................................................ 7
SEC. B KARAKTERISTIEKEN MODEL
1GEGEVENS VOOR DE IDENTIFICATIE ........... 3
2SMEERPRODUCTEN EN TANKEN ................. 5
3TECHNISCHE GEGEVEN ................................ 7
4DRAAIKOPPE ................................................. 20
5UITRUSTING .................................................. 21
SEC. C CONTROLE EN GEBRUIK VAN DE MOTORFIETS
1PRELIMINAIRE CONTROLES.......................... 3
2START VAN DE MOTOR ................................... 5
3VERWARMING VAN DE MOTOR .................... 5
4MOTOR IN WERKING ...................................... 5
5STILSTAND VAN DE MOTOR ........................... 7
6PARKEREN ....................................................... 7
7REGISTRATIES EN REGELINGEN .................. 9
8VOORBEREIDING VOOR EEN LANGE
INACTIVITEIT ................................................. 17
9SCHOONMAAK VAN DE MOTORFIETS ........ 19
SEC. D PERIODIEK ONDERHOUD
1TABEL PERIODIEK ONDERHOUD .................. 3
2ONDERHOUDSOPERATIES ............................ 5
SEC. E KLEDING
1SPIEGELTJES .................................................. 3
2VOORSTE EN ACHTERSTE SPATBORD ........ 5
3LATERALE FLANKEN ..................................... 11
4VOORAAN ...................................................... 13
5VOORSTE ZADEL .......................................... 15
6ACHTERSTE FRAMESCHOTTEN ................. 17
7FRAMESCHOTTEN VOORAAN ..................... 19
SEC. F WIELINSTALLATIES
1VOORWIEL ....................................................... 3
2ACHTERWIEL ................................................. 13
3REVISIE WIELEN ........................................... 21
4HYDRAULISCHE LINKER VOORREM
CALIFORNIA JACKAL - STONE ..................... 25
5HYDRAULISCHE RECHTER VOORREM
CALIFORNIA EV - SPECIAL - SPECIAL SPORT ..... 27
6HYDRAULISCHE LINKER VOOR- EN
ACHTERREM CALIFORNIA EV - SPECIAL -
SPECIAL SPORT ............................................ 33
7HYDRAULISCHE ACHTERREM CALIFORNIA
JACKAL - STONE ........................................... 35
8VOORSTE GAFFEL ........................................ 44
9ACHTERSTE VORK ........................................ 73
10 ACHTERSTE SCHOKBREKER ...................... 77
11 SCHOKBREKER VAN STURING .................... 79
12 BANDEN ......................................................... 79

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VARIANTS CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
SEC. G CONTROLS PAGE
1CLUTCH AND FRONT BRAKE CONTROL ........ 2
2GEARBOX CONTROL ....................................... 4
3REAR BRAKE CONTROL ................................. 8
4ACCELERATOR /STARTER CONTROL ........... 10
SEC. H CHASSIS
1STEERING ........................................................ 2
2HANDLEBAR ..................................................... 4
3FOOT RESTS .................................................... 6
4SIDE STAND ..................................................... 8
5CHASSIS DIMENSIONS ................................. 10
6FRONT BUMPER ............................................ 12
7CHASSIS DIMENSIONS ................................. 14
SEC. I FUEL SYSTEM
1GENERAL DESCRIPTION OF THE SYSTEM .. 2
2SYSTEM COMPONENTS ................................. 4
3TANK “5” ............................................................ 6
4ELECTRICAL FUEL PUMP “1” ......................... 8
5FUEL FILTER “2” ............................................. 10
6ELECTRO-INJECTORS “3” ............................. 10
7PRESSURE ADJUSTER “4” ........................... 12
8AIR FILTER BOX “1”........................................ 16
9THROTTLE 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
1SYSTEM FEATURES ........................................ 2
2SILENCERS ...................................................... 2
3EXHAUST PIPES .............................................. 4
4EXPANSION CHAMBER ................................... 6
SEC. M ENGINE
1GENERAL RULES FOR ENGINE OVERHAUL . 2
2REMOVAL – REASSEMBLY OF ENGINE /
GEARBOX ASSEMBLY ..................................... 2
3LUBRICATION SYSTEM ................................... 8
4HEADS AND TIMING SYSTEM ...................... 18
5CYLINDERS AND PISTONS .......................... 44
6CLUTCH.......................................................... 48
7ALTERNATOR ................................................. 58
8CRANK SHAFT AND CONNECTING RODS ... 62

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-2003-
VARIANTEN CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
VARIATIES CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
ABS. G SCHALTUNGEN SEITE
1SCHALTUNG HYRDRAULIKKUPPLUNG
UND VORDERRADBREMSE ........................... 3
2 GETRIEBESCHALTUNG .................................. 5
3SCHALTUNG DER HINTERRADBREMSE ...... 9
4GAS- / STARTERSCHALTUNG ...................... 11
ABS. H RAHMEN
1 LENKUNG ......................................................... 3
2 LENKER............................................................ 5
3 USSRASTEN .................................................... 7
4 SEITENSTÄNDER ............................................ 9
5RAHMENABMESSUNGEN ............................ 11
6VORDERER STOSSFÄNGER........................ 13
7 RAHMENABMESSUNGEN ............................ 15
ABS. I FUEL SYSTEM
1ALLGEMEINE BESCHREIBUNG DER
ANLAGE ........................................................... 3
2ZUSAMMENSETZUNG DER ANLAGE ............ 5
3KRAFTSTOFFTANK “5” .................................... 7
4ELEKTRISCHE KRAFTSTOFFPUMPE “1” ...... 9
5KRAFTSTOFFFILTER “2” ............................... 11
6ELEKTROEINSPRITZVENTILE “3” ................ 11
7DRUCKREGLER “4” ....................................... 13
8LUFTFILTERGEHÄUSE “1” ............................ 17
9KLAPPENKÖRPER “2” ................................... 19
10 BATTERIE “1” ................................................. 23
11 ZÜNDUNGSSCHALTER “2” ........................... 23
12 RELAIS “3” ...................................................... 25
13 ELEKTRONISCHES STEUERGERÄT
I.A.W. 15 M “4” ............................................... 27
14 LUFTTEMPERATURFÜHLER “5” ................... 29
15 ÖLTEMPERATURFÜHLER “6” ....................... 29
16 MOTORDREHZAHLSENSOR UND OT “7” .... 31
17 SPULEN “8” .................................................... 33
18 POTENTIOMETER DROSSELPOSITION “9” 35
19 BETRIEBSPHASEN ....................................... 37
20 DIAGNOSE ..................................................... 41
21 REINIGUNGS- UND RÜCKFÜHRSYSTEM
DER BENZINDÄMPFE (USA, SGP, CAN) ...... 57
ABS. L AUSPUFFANLAGE
1MERKMALE DER ANLAGE .............................. 3
2 SCHALLDÄMPFER .......................................... 3
3 AUSPUFFROHRE ............................................ 5
4 EXPANSIONSKAMMER ................................... 7
ABS. M MOTOR
1 ALLGEMEINE RICHTLINIEN FÜR DIE
ÜBERHOLUNG DES MOTORS....................... 3
2ABNAHME - INSTALLATION GRUPPE MOTOR /
GETRIEBE VOM RAHMEN .............................. 3
3 SCHMIERUNGSSYSTEM ................................ 9
4ZYLINDERKÖPFE UND STEUERUNG .......... 19
5ZYLINDER UND KOLBEN .............................. 45
6KUPPLUNG .................................................... 49
7LICHYMASCHINE UND SCHWUNGRAD ...... 59
8KURBELWELLE UND PLEUELSTANGEN ..... 63
SEC. G BEDIENINGEN PAG.
1HYDRAULISCHE BEDIENING KOPPELING EN
VOORSTE REM ................................................ 3
2BEDIENING VERSNELLING............................. 5
3BEDIENING ACHTERSTE REM ....................... 9
4BEDIENING GASPEDAAL/STARTER ............. 11
SEC. H CHASSIS
1STUUR .............................................................. 3
2STUUR .............................................................. 5
VOETPLANK ..................................................... 7
4LATERAAL ONDERSTEL ................................. 9
5AFMETINGEN CHASSIS ................................ 11
6VOORBUMPER .............................................. 13
7AFMETINGEN CHASSIS ................................ 15
SEC. I VOEDINGSINSTALLATIES
1ALGEMENE BESCHRIJVING INSTALLATIE .... 3
2SAMENSTELLING VAN DE INSTALLATIE ........ 5
3TANK “5” ............................................................ 7
4ELEKTRISCHE POMP BRANDSTOF”1" .......... 9
5FILTER BRANDSTOF “2” ................................ 11
6ELEKTROINJECTOREN “3”............................ 11
7DRUKREGELAAR “4” ..................................... 13
8KAST LUCHTFILTER “1”................................. 17
9SMOORKLEPLICHAAM “2” ............................ 19
10 ACCU “1” ......................................................... 23
11 AAN-/UIT-SCHAKELAAR VAN
ONTSTEKING”2" ............................................ 23
12 RELAIS “3” ...................................................... 25
13 ELEKTRONISCHE CENTRALE EENHEID
I.A.W. 15 M “4”................................................ 27
14 SENSOR TEMPERATUUR LUCHT “5” ........... 29
15 SENSOR TEMPERATUUR OLIE “6” ............... 29
16 SENSOR AANTAL MOTORTOEREN EN
P.M.S. “7” .......................................................... 31
17 BOBINES “8” ................................................... 33
18 POTENTIOMETER STAND SMOORKLEP “9”35
19 FASEN VAN WERKING................................... 37
20 DIAGNOSE ..................................................... 41
21 SYSTEEM VOOR ZUIVERING EN HERCIRCULATIE
BENZINEDAMPEN (USA, SGP, CAN) .............. 57
SEC. L AFVOERINSTALLATIE
1KARAKTERISTIEKEN INSTALLATIE ................ 3
2GELUIDDEMPERS ........................................... 3
3AFVOERBUIZEN .............................................. 5
4EXPANSIEKAMER ............................................ 7
SEC. M MOTOR
1ALGEMENE NORMEN VOOR DE REVISIE
VAN DE MOTOR ............................................... 3
2 VERWIJDERING - INSTALLATIE AANDRIJF GROEP
/ DE VERSNELLING UIT HET FRAMEHALEN .... 3
3SMEERSYSTEEM ............................................ 9
4KOPPEN EN DISTRIBUTIE ............................ 19
5CILINDERS EN ZUIGERS .............................. 45
6KOPPELING.................................................... 49
7STROOMWISSELGENERATOR EN
VLIEGWIEL ..................................................... 59
8MOTORAS EN DRIJFSTANGEN .................... 63

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VARIANTS CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
SEC. N GEARBOX PAGE
1MAIN FEATURES ............................................. 2
2REMOVAL AND INSTALLATION ...................... 6
3DISASSEMBLY ............................................... 10
4CHECK AND OVERHAUL .............................. 24
5GEARBOX UNIT REASSEMBLY ON THE
BENCH............................................................ 30
SEC. O REAR TRANSMISSION HOUSING AND SHAFT
1REAR TRANSMISSION HOUSING .................. 2
2TRANSMISSION SHAFT ................................ 16
SEC. P ELECTRICAL SYSTEM
1ELECTRICAL SYSTEM DESCRIPTION ........... 2
2BATTERY ........................................................ 20
2BATTERY (USA - SGP – CAN VERSION) ...... 24
3STARTER MOTOR .......................................... 28
4LIGHT AND ACOUSTIC SYSTEMS /
DASHBOARD / CONTROLS ........................... 30
5SIDE STAND SWITCH .................................... 50
6FUSE TERMINAL BOARD .............................. 52
7ALTERNATOR AND VOLTAGE REGULATOR .... 54
SEC. Q VARIANTS CALIFORNIA EV, CALIFORNIA
ALUMINIUM, CALIFORNIA TITANIUM, STONE
- 2003-
1IDENTIFICATION DATA .................................... 2
2LUBRICANTS AND REFILLING ....................... 4
3TECHNICAL SPECIFICATIONS ....................... 6
4TOOLS ............................................................ 17
5PRELIMINARY TESTS ................................... 20
6ENGINE IGNITION ......................................... 22
7PARKING ........................................................ 22
8SERVICE SCHEDULE .................................... 24
9REMOVING THE FRONT FAIRING
(STANDARD ON CALIFORNIA EVTOURING, OPTIONAL
ON EV, ALUMINIUM, TITANIUM, STONE).................... 26
10 REMOVING THE FRONT FAIRING
(TITANIUM)......................................................... 26
11 FUEL FEED SYSTEM DESCRIPTION ........... 28
12 LAMBDA SENSOR ......................................... 30
13 SYSTEM COMPONENTS .............................. 32
14 FUEL CIRCUIT ............................................... 32
15 TANK “3” ......................................................... 34
16 FUEL ELECTRIC PUMP “1” UNIT .................. 36
17 FUEL FILTER .................................................. 38
18 INTAKE AIR CIRCUIT ..................................... 40
19 AIR FILTER BOX “1” ....................................... 42
20 THROTTLE BODY “2”..................................... 44
21 ELECTRICAL CIRCUIT .................................. 46
22 OPERATING STAGES .................................... 48
23 THE AXONE 2000 DIAGNOSIS TESTER ...... 52
24 CARBURATION CONTROL, ADJUSTMENT
AND SETTING PROCEDURE WITH AXONE
2000 ................................................................ 64