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
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indien dit nodig mocht zijn, om door haar wenselijk geachte wijzigingen aan onderdelen, accessoires,
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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

V
-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

VII
-2003-
VARIANTEN CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
VARIATIES CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
ABS. N GETRIEB SEITE
1ALLGEMEINE EIGENSCHAFTEN ................... 3
2AUS- UND EINBAU .......................................... 7
3 ZERLEGUNG .................................................. 11
4KONTROLLE UND ÜBERHOLUNG ............... 25
5ZUSAMMENBAU DER GETRIEBEGRUPPE AUF
DER WERKBANK ........................................... 31
ABS. O ANTRIEBSWELLE UND-GEHÄUSE HINTEN
1ANTRIEBSGEHÄUSE HINTEN ........................ 3
2ANTRIEBSWELLE .......................................... 17
ABS. P ELEKTROANLAGE
1BESCHREIBUNG DER ELEKTROANLAGE .... 3
2BATTERIE ....................................................... 21
2BATTERIE (VERSION USA - SGP - CAN) ..... 21
3ANLASSERMOTOR........................................ 29
4LICHTANLAGE UND HUPE / INSTRUMENTEN-
TAFEL / SCHALTUNGEN ............................... 31
5SCHALTER SEITENSTÄNDER ...................... 51
6SICHERUNGSKLEMMENBRETT .................. 53
7ALTERNATOR - REGLER .............................. 55
ABS. Q VARIANTS CALIFORNIA EV, CALIFORNIA
ALUMINIUM, CALIFORNIA TITANIUM, STONE
- 2003-
1 IDENTIFIKATIONSDATEN................................ 3
2SCHMIERUNG UND FÜLLMENGEN ............... 5
3TECHNICAL SPECIFICATIONS ....................... 6
4AUSRÜSTUNG ............................................... 18
5ERSTE KONTROLLEN................................... 21
6STARTEN DES MOTORS .............................. 23
7PARKEN ......................................................... 23
8WARTUNGSPROGRAMM.............................. 25
9ABNAHME DER COCKPITVERKLEIDUNG
(SERIENMÄSSIG AN DER CALIFORNIA EVTOURING,
OPTIONAL AN DER EV, ALUMINIUM, TITANIUM, STONE)27
10 ABNAHME DER COCKPITVERKLEIDUNG
(TITANIUM)......................................................... 27
11 ALLGEMEINE BESCHREIBUNG
DES VERSORGUNGSSYSTEMS .................. 29
12 LAMBDASONDE ............................................ 31
13 ZUSAMMENSETZUNG DER ANLAGE .......... 33
14 KRAFTSTOFF-KREISLAUF ........................... 33
15 KRAFTSTOFFTANK “3” .................................. 35
16 ELEKTRISCHE
KRAFTSTOFFPUMPENEINHEIT “1”.............. 37
17 KRAFTSTOFFFILTER .................................... 39
18 ANSAUGLUFTKREISLAUF ............................ 41
19 LUFTFILTERGEHÄUSE “1” ............................ 43
20 KLAPPENKÖRPER “2” ................................... 45
21 STROMKREIS ................................................ 47
22 BETRIEBSPHASEN ....................................... 49
23 DIAGNOSEINSTRUMENT AXONE 2000 ....... 53
24 NORM FÜR VERGASUNGSKONTROLLE, RE-
GULIERUNG UND REGULIERUNG MIT
DEM AXONE 2000.......................................... 65
SEC. N VERSNELLING PAG.
1ALGEMENE KARAKTERISTIEKEN ................. 3
2VERWIJDERING EN INSTALLATIE ................. 7
3ONTBINDING ................................................. 11
4CONTROLE EN REVISIE ............................... 25
5DE VERSNELLING OP DE WERKBANK
MONTEREN.................................................... 31
SEC. O ASEN KAST VAN ACHTERSTE
OVERBRENGING
1KAST VAN ACHTERSTE OVERBRENGING ... 3
2ÁRBOL DE TRANSMISIÓN ............................ 17
SEC. P ELEKTRISCHE INSTALLATIE
1BESCHRIJVING ELEKTRISCHE
INSTALLATIE .................................................... 3
2ACCU .............................................................. 21
2ACCU (UITVOERING USA - SGP - CAN)....... 25
3STARTMOTOR ................................................ 29
4LICHT- EN AKOESTISCHE INSTALLATIES/
DASHBOARD/ BEDIENINGEN ....................... 31
5SCHAKELAAR LATERAAL ONDERSTEL ...... 51
6KLEMBORD ZEKERINGHOUDER ................. 53
7DYNAMO - WORDEN..................................... 55
SEC. Q VARIANTS CALIFORNIA EV, CALIFORNIA
ALUMINIUM, CALIFORNIA TITANIUM, STONE
- 2003-
1GEGEVENS VOOR DE IDENTIFICATIE .......... 3
2SMEERPRODUCTEN EN TANKEN ................ 5
3TECHNISCHE GEGEVENS ............................. 7
4UITRUSTING .................................................. 19
5PRELIMINAIRE CONTROLES ....................... 21
6START VAN DE MOTOR ................................ 23
7PARKEREN..................................................... 23
8ONDERHOUDSSCHEMA............................... 25
9KUIPJE DEMONTEREN (STANDAARD OP
CALIFORNIA EVTOURING, OPTIONAL OP EV,
ALUMINIUM, TITANIUM, STONE).............................. 27
10 KUIPJE DEMONTEREN (TITANIUM)................. 27
11 ALGEMENE BESCHRIJVING VAN
HET BRANDSTOFSYSTEEM......................... 29
12 LAMBDA-SONDE ........................................... 31
13 SAMENSTELLING VAN DE INSTALLATIE ..... 33
14 CIRCUIT BRANDSTOF .................................. 33
15 TANK “3” ......................................................... 35
16 ELEKTRISCHE BRANDSTOFPOMP “1” ........ 37
17 BENZINEFILTER ............................................ 39
18 CIRCUIT AANGEZOGEN LUCHT .................. 41
19 KAST LUCHTFILTER “1” ................................ 43
20 SMOORKLEPLICHAAM “2” ............................ 45
21 ELECTRICAL CIRCUIT .................................. 46
22 FASEN VAN WERKING .................................. 49
23 DIAGNOSE-INSTRUMENT AXONE 2000 ...... 53
24 CONTROLESTANDAARD VOOR
VERBRANDING, REGELING EN
AFSTELLING MET AXONE 2000 .................. 65

VIII
25 EXHAUST SYSTEM ....................................... 74
25.1 SYSTEM SPECIFICATIONS ....................................... 74
25.2 EXPANSION CHAMBER AND LAMBDA SENSOR .............. 76
25.3 CHECKING LAMBDA SENSOR CORRECT OPERATION ..... 76
26 LUBRICATION SYSTEM ................................ 78
27 CYLINDER HEADS ........................................ 80
27.1 HYDRAULIC TAPPETS ............................................ 86
27.2 CHECK OF THE TIMING SYSTEM
SETTING............................................................. 88
28 CLUTCH ......................................................... 90
28.1 CHECKING COMPONENTS ....................................... 94
29 ELECTRICAL SYSTEM DESCRIPTION......... 96
30 HEATED TWISTGRIPS (CALIFORNIA TOURING)102
31 FUSE BOX .................................................... 104
31.1 CHANGING FUSES .............................................. 104
32 12V POWER OUTLET .................................. 106
33 SHINDENGEN REGULATOR ....................... 108

IX
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25 AUSPUFFANLAGE ......................................... 75
25.1 ANLAGENEIGENSCHAFTEN ...................................... 75
25.2 AUSDEHUNGSKAMMER UND LAMBDASONDE ............... 77
25.3 FUNKTIONSKONTROLLE DER LAMBDASONDE .............. 77
26 SCHMIERUNGSSYSTEM .............................. 79
27 ZYLINDERKÖPFE .......................................... 81
27.1 HYDRAULISCHE STÖSSEL ...................................... 87
27.2 KONTROLLE DER PHASENEINSTELLUNG
DER STEUERUNG ................................................. 89
28 KUPPLUNG .................................................... 91
28.1 KONTROLLE DER KOMPONENTEN ............................ 95
29 BESCHREIBUNG DER ELEKTROANLAGE .. 97
30 BEHEIZTE LENKERGRIFFE
(CALIFORNIA TOURING)....................................... 103
31 SICHERUNGSLEISTE.................................. 105
31.1 WECHSEL DER SICHERUNGEN .............................. 105
32 STROMANSCHLUSS 12V ............................ 107
33 SPANNUNGSREGLER SHINDENGEN ........ 109
25 UITLAATSYSTEEM ........................................ 75
25.1 KENMERKEN VAN HET SYSTEEM .............................. 75
25.2 EXPANSIEKAMER EN LAMBDA-SONDE ....................... 77
25.3 DELAMBDA-SONDE TESTEN ................................... 77
26 SMEERSYSTEEM .......................................... 79
27 CILINDERKOPPEN ........................................ 81
27.1 HYDRAULISCHE KLEPSTOTERS ................................ 87
27.2 DEIN FASE STELLING VAN DE DISTRIBUTIE
CONTROLEREN..................................................... 89
28 KOPPELING ................................................... 91
28.1 ELK COMPONENT CONTROLEREN ............................. 95
29 BESCHRIJVING ELEKTRISCHE
INSTALLATIE .................................................. 30
30 VERWARMDE HENDELS
(CALIFORNIA TOURING)....................................... 103
31 KLEMMENBORD VOOR ZEKERINGEN ...... 105
31.1 DEZEKERINGEN VERVANGEN ................................ 105
32 STROOMCONTACT 12V .............................. 107
33 SHINDENGEN SPANNINGREGELAAR ....... 109

X

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VARIANTS
VARIANTEN
VARIATIES
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-2003-
-2003-

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VARIANTS CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
1IDENTIFICATION 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.
1) Code WMI (World Manufactures’ Identifier)
2) Type of vehicle
3) Variant C
4) Version
5) Free digit
6) Year of manufacturing, for example: 2 = 2002
3 = 2003
7) Manufacturing plant (M = Mandello del Lario)
8) Chassis number
ZGUKDC1202M111111
57 812346

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VARIANTEN CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
VARIATIES CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
1 IDENTIFIKATIONSDATEN
Jedes Fahrzeug besitzt eine Identifikationsnummer, die
auf dem Rahmen-Steuerrohr und auf dem
Kurbelgehäuse eingeprägt ist.
Die auf dem Rahmen-Steuerrohr eingeprägte Nummer
ist im Fahrzeugschein angegeben und dient der
gesetzlich vorgeschriebenen Identifizierung des
Motorrads. Diese Nummer besteht aus Ziffern und
Buchstaben, so wie im unten angeführten Beispiel
1) WMI (World Manufactures Identifier) Kennnummer
2) Fahrzeugtyp
3) Variante C
4) Version
5) Freie Ziffer
6) Variables Fabrikationsjahr, z.B.: 2 = 2002
3 = 2003
7) Werk (M = Mandello del Lario)
8) Rahmennummer
ZGUKDC1202M111111
57 812346
1) Code WMI (World Manufactures Identifier)
2) Type van voertuig
3) Variatie C
4) Uitvoering
5) Vrij cijfer
6) Bouwjaar variabele, voorbeeld: 2 = 2002
3 = 2003
7) Productie-etablissement (M = Mandello del Lario)
8) Nummer van chassis
1GEGEVENS VOOR DE IDENTIFICATIE
Elk voertuig wordt onderscheiden door een
identificatienummer gedrukt op de pijp van het chassis
en op het motorblok.
Het nummer gedrukt op de pijp van het chassis wordt
aangegeven in de motopapieren en dient voor de wet
voor de identificatie van de motorfiets zelf; dit nummer
bestaat uit cijfers en letters zoals in het onderstaand
voorbeeld.
ZGUKDC1202M111111
57 812346

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VARIANTS CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
2LUBRICANTS AND REFILLING
Part Litres Reccommended product
Fuel tank (reserve approx 4 lt.) approx. 19 Unleaded petrol (95 NO-RM/min.)
Oil sump 3 Oil “Agip 4T RACING SAE 5W/40”
Gear box 0,750 Oil “Agip Rotra MP SAE 80 W/90”
Rear drive of which 0,250
(bevel set lub.) of which
0,230 “Agip Rotra MP SAE 80 W/90”
0,020 “Agip Rocol ASO/R”
or “Molykote tipo A”
Front forks adjustable (for leg) 0,485 Shock - Absorbers oil (SAE 10)
Front forks not adjustable (for leg) 0,565 Shock - Absorbers oil (SAE 10)
Front and rear brake circuits — “Agip Brake Fluid - DOT4”

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VARIANTEN CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
VARIATIES CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
2 SCHMIERUNG UND FÜLLMENGEN
Versorgungsteile Liter Benzin-und Öltypen
Kraftstoffbehälter (Reserve ca. 4 L.) 19 ca. Benzin Bleifrei (95 NO-RM/min.)
Ölwanne 3 Öl “Agip 4T RACING SAE 5W/40”
Getriebegehäuse 0,750 Öl “Agip Rotra MP SAE 80 W/90”
Antriebsgehäuse 0,250
(Schmierung des Kegelpaares) davon
0,230 Öl “Agip Rotra MP SAE 80 W/90”
0,020 Öl “Agip Rocol ASO/R”
oder “Molykote tipo A”
Teleskopgabel justierbar (Je Holm) 0,485 Öl für Stoßdampfer (SAE 10)
Teleskopgabel nicht justierbar (Je Holm) 0,565 Öl für Stoßdampfer (SAE 10)
Bremsanlager, vorne und hinten — Öl “Agip Brake Fluid - DOT4”
2SMEERPRODUCTEN EN TANKEN
TERUG TE LEVEREN GEDEELTEN LITERS TE GEBRUIKEN PRODUCTEN
Tank brandstof 19 ong. Benzine zonder lood (95 No - RM/min.)
(reserve ongeveer 4 liters)
Motorkap 3 Olie “Agip 4T RACING SAE 5W40”
Versnellingsbak 0,750 Olie “Agip Rotra MP SAE 80 W/90”
Overbrengingskast 0,250
(smering conisch koppel) waarrvan
0,230 Olie “Agip Rotra MP SAE 80 W/90”
0,020 Olie “Agip Rocol ASO/R”
of “Molikote typ A”
Instelbare telescopische vork (per poot) 0,485 Olie voor schokbrekers (SAE10)
Niet instelbare telescopische vork (per poot) 0,565 Olie voor schokbrekers (SAE10)
Voorste en achterste remleiding - Vloeistof “Agip Brake Fluid - DOT 4”

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VARIANTS CALIFORNIA EV - CALIFORNIA ALUMINIUM -
CALIFORNIA TITANIUM - STONE -2003-
3TECHNICAL SPECIFICATIONS
ENGINE
4-stroke, twin cylinder
Cylinder configuration ................................. 90° V-twin
Bore:................................................................. 92 mm
Stroke: .............................................................. 80 mm
Capacity: ......................................................... 1064 cc
Compression ratio: .............................................. 9.8:1
TIMING SYSTEM
With rods and rockers taking automatically up clearance
by means of hydraulic valve tappets and 2 valves per
cylinder. A camshaft positioned inside engine block is
driven by a duplex chain with automatic chain tensioner.
FEED SYSTEM
Indirect electronic injection, timed sequential MAGNETI
MARELLI, 2 throttle valves Ø 40 mm with Weber IW031
injectors, electric pump with pressure regulator, digital
control of optimised injection times.
EXHAUST SYSTEM
In stainless steel - 2 tubes equipped with balancing bar,
connected to an expansion chamber and two silencers
catalytic converter. Lambda probe for exhaust gas control
is fitted in the expansion chamber.
USA versions are not equipped with catalytic
exhaust system.
LUBRICATION
Pressure fed by gear pump
Wire mesh and cartridge filters on oil sump
Normal lubrication pressure 3.8÷4.2 kg/cm2(pressure
valve on oil sump).
Low oil pressure sensor (electrical) on crankcase.
GENERATOR / ALTERNATOR
On front of crankshaft.
Output power: 350W at 5000 rev./min. (14V - 25A).
IGNITION
“MAGNETI MARELLI” Inductive discharge digital
electronics.
Spark plugs: ....................................... NGK BPR 6 ES.
Spark plug gap: ................................................ 0.7 mm
2 ignition coils..................................mounted on frame
STARTER
Electric starter motor 12V-1,2 Kw with electromagnetic
ratchet control. Ring gear on the flywheel. START « »
push-button on right handlebar.