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Table Of Contents - MOTO GUZZI California EV Workshop Manual

1997-2000

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Manual (168 pages)

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Workshop manual (124 pages)

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Owner's manual (226 pages)

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Table Of Contents4

California Ev (1997 - 2000)11

California Ev 200111

California Jackal12

California Stone12

California Special13

California Special Sport13

Eneral Nformation14

Lgemene Inlichtingen14

Abbreviations And Symbols15

How To Consult This Manual15

Hoe Moet Deze Handleiding Geraadpleegd Worden16

Afkortingen En Symbolen16

General Safety Regulations17

Rules For Maintenance Procedures17

Algemene Veiligheidsregels18

Regels Voor De Onderhoudsoperaties18

Model Features21

Arakteristieken21

Identification Data22

Gegevens Voor De Identificatie23

Lubricants And Refilling24

Smeerproducten En Tanken25

Technical Specifications26

Technische Gegeven27

Transmissions28

Primary Transmission28

Tightening Torques38

Standard Values38

Control And Use Of The Morbike45

Ebruik Van De45

Preliminary Tests46

Before Start-Up Check That46

Preliminaire Controles47

Engine Ignition48

Engine Warming-Up48

Engine Running48

Start Van De Motor49

Verwarming Van De Motor49

Motor In Werking49

Stopping The Engine50

Stilstand Van De Motor51

Adjustments And Regulations52

Steering Shock Absorber52

Clutch Lever And Front Brake Lever Adjustment52

Rear And Front Left Brake Pedal Adjustment52

Registraties En Regelingen53

Front Fork Adjustment54

Rear Shock Absorbers Adjustment56

Maximum Allowed Load56

Steering Adjustment58

Preparation For Long Periods At Rest60

Light Beam Adjustment60

Voorbereiding Voor Een Lange Inactiviteit61

Cleaning The Motorbike62

Preparation For Washing62

While Washing62

After Washing62

Schoonmaak Van De Motorfiets63

Instructions On How To Clean The Windscreen64

Scheduled Maintenance66

Egelmässige Artung66

Eriodiek Onderhoud66

Tabel Periodiek Onderhoud68

Maintenance Procedures69

Engine Oil Replacement69

Wartungsarbeiten70

Onderhoudsoperaties70

Oil Cartridge Filter Replacement71

Washing The Oil Mesh Filter73

Tappet Backlash81

Gearbox Lubrication83

Final Drive Lubrication85

Steering Bearings87

Front Fork Oil Replacement89

Checking The Braking And Clutch System Fluid97

Brake System Fluid Replacement99

Draining The Braking System Fluid107

Rear Braking System109

Left-Hand Front Braking System111

Left-Hand Front And Rear Braking System113

Brake Pad Check/Replacement115

Front Brake Caliper115

Rear Brake Caliper117

Wheel Spokes Tension Adjustment119

Wing Mirrors124

Front And Rear Mudguards126

Vorderes Und Hinteres Schutzblech127

Voorste En Achterste Spatbord127

Laterale Flanken133

Voorste Zadel135

Rear Chassis Protections138

Achterste Frameschotten139

Front Chassis Protections140

Frameschotten Vooraan141

Ielinstallaties142

Brake Disks Spacing Flanges151

Rear Wheel Hub Removal – Rubber Cush Drive Damper Side157

Rear Brake Disk Spacer Flange159

Wheel Overhaul161

Wheel Spindle161

Überholung Der Räder162

Revisie Wielen162

Front Left-Hand Hydraulic Brake California Jackal - California Stone165

Brake Calipers165

California Jackal - Stone165

Hydraulische Linker Voorrem166

Front Right-Hand Hydraulic Brake167

Hydraulische Rechter Voorrem168

Rear And Front Left-Hand Hydraulic Brake173

California Ev - Special - Special Sport173

Special Sport173

Hydraulische Achterrem California174

Rear Hydraulic Brake175

Jackal - Stone175

Disk Brake Troubles179

Brake-Power Limiter183

Vordere Gabel186

Voorste Gaffel186

Complete Fork Removal191

Fork Leg Removal193

General Rules For A Correct Overhaul193

Troubles – Causes - Solutions195

Disassembly/Overhaul197

Overhaul Of The Compression Shock Absorber201

Overhaul Of The "Rebound" Shock Absorber205

Rear Swing Arm213

Hintere Schwinge214

Achterste Vork214

Rear Shock Absorbers217

Achterste Schokbreker218

11 Lenkungsstossdämpfer220

11 Schokbreker Van Sturing220

Clutch And Front Brake Control224

Removal Of Front Brake Lever With Master Cylinder224

Removal Of Front Clutch Lever224

Gearbox Control226

Disassembly Of California Jackal - California Stone228

Disassembly Of California Special - California Special Sport228

Rear Brake Control230

Accelerator / Starter Control232

Accelerator Control232

Maintenance Of Accelerator Cables232

Starter Circuit234

Disassembly Of Front Footrests241

Reassembly Of Front Footrests241

Disassembly Of Rear Footrests Support241

Chassis Dimensions245

Front Bumper247

General Description Of The Fuel System253

System Components255

Fuel Circuit255

Electrical Fuel Pump "1"259

Fuel Filter "2"261

Electro-Injectors "3"261

Pressure Adjuster "4"263

Intake Air Circuit265

Air Filter Box "1"267

Throttle Body "2"269

Electrical Circuit271

10 Battery "1273

11 Starter Switch "2273

14 Air Temperature Sensor "5279

15 Oil Sensor Temperature "6279

16 R.p.m. And T.d.c. Sensor "7281

18 Throttle Position Potentiometer "9285

Start-Up Stage287

19 Operating Stages287

Operation During The Acceleration Stage289

Resetting The Ecu291

20 Diagnostics291

Throttle Valve Potentiometer Circuit293

Absolute Pressure Sensor Circuit293

Oil Temperature Circuit Sensor295

Air Temperature Sensor Circuit295

Battery Voltage295

Injector 1 And 2 Circuit297

Circuit And Primary Winding Of Coils297

Fuel Pump Relay Circuit299

Electronic Control Unit299

Timing And Engine R.p.m. Sensor Circuit299

Electronic Revolution Counter301

Carburation Procedure303

Rules For Carburation, Regulation And Adjustment305

Fuel Vapour Purification And Recirculation System (Usa, Sgp, Can)307

Exhaust System309

System Features310

Exhaust Pipes312

Expansion Chamber314

General Rules For Engine Overhaul317

Engine Unit Removal - Installation/Gearbox Removal From Chassis317

Lubrication System323

Oil Mesh Filter325

Oil Cartridge Filter325

Oil Pressure Transmitter327

Engine Oil Pressure Regulator Valve327

Check For Oil Leakages From The Engine Crankcase331

Heads And Timing System333

Head Disassembly337

Check Of Head Components339

Valve Guides339

Data Table For Valve And Guide Couplings339

Valve Spring Inspection343

Outside Spring343

Inside Spring343

Spring Package Check345

Rocker And Pin Check347

Diameters For Camshaft Supports And Relative Seats On The Crankcase353

Coupling Data For The Tappets And Relative Seats On The Crankcase353

Check Of The Timing System Setting355

Cylinders And Pistons357

Reassembly Of The Toothed Wheel And Measuring Of The Air Gap357

Check Of Components359

Grading Cylinder Diameter Since Engine N° Kd 030428359

Grading Piston Diameter Since Engine N° Kd 030428359

Grading Cylinder Diameter Up To Engine N° Kd 030429359

Coupling Data361

Clutch Springs367

Spring Pressure Plate367

Driven Disks367

Toothed Crown For Ignition367

Intermediate Plate369

Control Transmission369

Clutch Adjustment Screw On Lever369

Lever Return Spring On Gearbox369

Alternator And Flywheel373

Crank Shaft And Connecting Rods377

Connecting Rods381

Check The Axis Parallelism381

Connecting Rod Bearing Thickness383

Crankpin Diameter383

Coupling Data Between The Piston Pin And Bushing383

Main Bearing Journal Diameter, Flywheel Side385

Main Bearing Journal Diameter, Timing System Side385

Weight Control For Crankshaft Balancing387

Main Features392

Gearboxes Fitted With New 5-Clutch Dog Gears392

Removal And Installation396

Removal Of The Internal Clutch Body402

Removal Of The Gearbox Cover402

Removal Of Shaft Assembly And Splined Drum404

Disassembly Of The Secondary Shaft406

Disassembly Of The Primary Shaft408

Disassembly Of Clutch Shaft410

Bearing Removal412

Gear Box Housing And Cover412

Check And Overhaul414

Gearbox Housing And Cover414

Roller Ball Bearings414

Secondary Shaft414

Secondary Shaft Gears416

Engaging Gear Sleeve Control Forks416

Engaging Gear Splined Drum416

Drum Holder Rods And Gearbox Control Forks416

Clutch Fixed Body On The Clutch Shaft418

Sleeve On The Clutch Shaft418

Transmission Gear On The Clutch Shaft418

Gearbox Control Range Selector418

Gearbox Unit Reassembly On The Bench420

Bearing Assembly On The Gearbox Housing And On The Cover420

Bearing Pressing Within Their Seats On The Gearbox Housing420

Bearing Pressing Within Their Seats On The Gearbox Housing Cover420

Range Selector Assembly On The Gearbox Cover422

Primary Shaft Reassembly On The Housing422

Primary Shaft Shimming422

Secondary Shaft Reassembly On The Housing424

Secondary Shaft Shimming426

Control Forks And Splined Drum Assembly On The Gearbox Housing426

Clutch Shaft Reassembly On The Housing428

Cover Assembly On The Gearbox Housing430

Final Drive Housing And Shaft438

Final Drive Housing439

Antriebsgehäuse Hinten440

Flange On The Final Drive Housing443

Adjustment Shims Of The Final Drive Housing Flange443

Drilled Shaft With Internal Teeth As A Connection To The Rear Wheel443

Bearing Case445

Adjustment Washers Between Spacer And Bearing445

Lock Nut For Bevel Gear Pinion On The Bearing Case445

Case Components447

Housing Case447

Crown On The Drilled Shaft449

Cover On The Transmission Housing449

Contact Impression Check451

Pinion – Crown Coupling451

Final Drive Shaft453

Sleeve for Transmission Shaft and Bevel Sprocket "A"453

Double U-Joint "D"453

Antriebswelle454

Electrical System455

Electrical System Description456

Beschreibung Der Elektroanlage457

Instructions To Operate Dry Batteries474

Maintenance Instructions For Batteries Charged With Acid474

Battery Charge Instructions476

Battery (Usa - Sgp – Can Version)478

Batterie (Version Usa - Sgp - Can)479

Starter Motor482

Anlassermotor483

Light And Acoustic Systems / Dashboard / Controls484

Lichtanlage Und Hupe / Instrumententafel / Schaltungen485

Taillight Assembly486

Front Direction Indicators490

Light-Bulb Replacement490

Rear Direction Indicators492

Acoustic System494

Dashboard Warning Lights494

Revolution Counter - Odometer500

Side Stand Switch504

Schalter Seitenständer505

Fuse Terminal Board506

Sicherungsklemmenbrett507

Alternator - Regulator508

Check The Winding Isolation Towards Earth508

Check The Winding Continuity508

Check The Voltage Output508

Alternator - Regler509

Regulator Checks510

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