MOTO GUZZI B043157 Service Station Manual

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SERVICE STATION MANUAL

B043157

Moto Guzzi California 1400

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Page 1 SERVICE STATION MANUAL B043157 Moto Guzzi California 1400...
Page 2 The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding it, its regular maintenance and the use of original Moto Guzzi spare parts only are essential factors! For information on the nearest Official Dealer and/or Service Centre consult our website: www.motoguzzi.com...
Page 3 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
Moto Guzzi California 1400 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 Moto Guzzi California 1400 Characteristics THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING THE BRAKING SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKING SYSTEM. THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
Page 9 Moto Guzzi California 1400 Characteristics • Keep away from heat sources. REASSEMBLY OF COMPONENTS CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH- ERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Aprilia SPARE PARTS.
Page 10: Vehicle Identification
That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.
Page 11 Moto Guzzi California 1400 Characteristics This number consists of numbers and letters, as in the example shown below. ZGULVB0009MXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LV: model; B00: version variation; 0: free digit C: variable year of manufacture (C - for 2012) M: production plant (M= Mandello del Lario);...
Page 12 Moto Guzzi California 1400 Characteristics Engine ENGINE Specification Desc./Quantity Type traverse-mounted twin-cylinder four-stroke V 90° Cylinder number Cylinder arrangement V 90° Bore / stroke 104 x 81.2 mm (4.09 x 3.20 in) Engine capacity 1379.6 cm³ (84.19 cu.in) Compression ratio 10.5: 1...
Page 13 Moto Guzzi California 1400 Characteristics Specification Desc./Quantity Alternator (permanent magnet type) 12 V - 550 W Main fuses 40- 30- 10A Secondary fuses 15 (4) - 7.5 (2) A Front daylight running lights 8 low intensity LEDs (Halogen) low beam light...
Page 14 Moto Guzzi California 1400 Characteristics Brakes BRAKES Specification Desc./Quantity Front Ø 320-mm (12.6 in) stainless steel double floating disc, radial callipers with 4 opposed pistons. Rear Ø 282-mm (11.1 in) stainless steel disc, floating calliper with 2 different pins. Wheels and tyres...
Page 15 Moto Guzzi California 1400 Characteristics pos. Description Type Quantity Torque Notes Coil fixing screws M6x30 10 Nm (7.37 lb ft) Coil fixing screws M6x16 10 Nm (7.37 lb ft) Coil bracket fixing screws M6x30 10 Nm (7.37 lb ft) Coil bracket fixing screws M5x12 6 Nm (4.42 lb ft)
Page 16 Moto Guzzi California 1400 Characteristics EAR PART ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Relay bracket fixing screws M5x12 6 Nm (4.42 lb ft) Bracket self-threading fixing screws M5x14 2.5 Nm (1.84 lb ft) Fuse box bracket fixing screws M5x20 3 Nm (2.21 lb ft)
Page 17 Moto Guzzi California 1400 Characteristics Front side RONT HEADLAMP pos. Description Type Quantity Torque Notes Screw fixing headlamp to supports M6x55 5 Nm (3.69 lb ft) Screw fixing headlamp to joint M6x30 10 Nm (7.37 lb ft) Fixing screws sup. plate headlights sup. steer- M6x20 10 Nm (7.37 lb ft)
Page 18 Moto Guzzi California 1400 Characteristics IL RADIATOR pos. Description Type Quantity Torque Notes Screws fixing oil radiator to chassis M6x25 10 Nm (7.38 lb ft) Screws fixing electric fan to oil radiator 4.2x20 2.5 Nm (1.84 lb ft) RONT BRAKE CALLIPER pos.
Page 19 Moto Guzzi California 1400 Characteristics LUTCH CONTROL PUMP pos. Description Type Quantity Torque Notes Screws fixing clutch control pump to handle- 10 Nm (7.38 lb ft) pos. Description Type Quantity Torque Notes Lower suspension bars fixing screws M5x50 6 Nm (4.42 lb ft)
Page 20 Moto Guzzi California 1400 Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws M5x12 4 Nm (2.95 lb ft) ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes Screws fixing right switch to handlebar 1.5 Nm (1.11 lb ft) Screws fixing left switch to handlebar 1.5 Nm (1.11 lb ft)
Page 21 Moto Guzzi California 1400 Characteristics RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Brake pump to handlebar fixing screw 10 Nm (7.38 lb ft) RONT WHEEL pos. Description Type Quantity Torque Notes Brake discs fixing screws M8x22 25 Nm (18.44 lb ft) Wheel axle 80 Nm (59.00 lb ft)
Page 22 Moto Guzzi California 1400 Characteristics TEERING pos. Description Type Quantity Torque Notes Screws fixing forks to plate M8x35 25 Nm (18.44 lb ft) Lower ring nut 50 Nm (36.87 lb ft) Pretightening to 60 Nm (44.25 lb ft) Upper yoke fixing bushing 100 Nm (73.76 lb ft)
Page 23 Moto Guzzi California 1400 Characteristics RAME pos. Description Type Quantity Torque Notes Front support fixing screw M12x50 80 Nm (59.00 lb ft) Rear support fixing screw M12x50 50 Nm (36.88 lb ft) Engine pin 50 Nm (36.88 lb ft) Engine pin retainer nut 80 Nm (59.00 lb ft)
Page 24 Moto Guzzi California 1400 Characteristics EAR LEVER pos. Description Type Quantity Torque Notes Fastener screw M8x60 25 Nm (18.44 lb ft) Retainer nut 25 Nm (18.44 lb ft) Gearbox connecting rod fixing screw M6x20 10 Nm (7.38 lb ft) Joint adjustment nut...
Page 25 Moto Guzzi California 1400 Characteristics EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Brake lever fixing screw M8x75 25 Nm (18.44 lb ft) Brake lever screw retainer nut 25 Nm (18.44 lb ft) NDER ADDLE pos. Description Type Quantity...
Page 26 Moto Guzzi California 1400 Characteristics ENTRAL BODYWORK pos. Description Type Quantity Torque Notes Side fairing fixing screws M5x9 6 Nm (4.43 lb ft) OOTREST UNIT pos. Description Type Quantity Torque Notes Footrest to frame fixing screw M8x20 25 Nm (18.43 lb ft)
Page 27: Table Of Contents
Moto Guzzi California 1400 Characteristics pos. Description Type Quantity Torque Notes Passenger footrest to rubber ring fixing M5x20 6 Nm (4.42 lb ft) screws Passenger footrest support fixing screw M10x1.25 50 Nm (36.88 lb ft) ADDLE pos. Description Type Quantity...
Page 28 Moto Guzzi California 1400 Characteristics ANK COVER pos. Description Type Quantity Torque Notes Fairing fixing screws M5x10 6 Nm (4.42 lb ft) Dashboard fixing screw M5x16 5 Nm (3.68 lb ft) UEL TANK pos. Description Type Quantity Torque Notes Front fixing screw M8x16 25 Nm (18.44 lb ft)
Page 29 Moto Guzzi California 1400 Characteristics ISCHARGE pos. Description Type Quantity Torque Notes Exhaust - cylinder retainer nut 25 Nm (18.44 lb ft) Side clamps 50 Nm (36.88 lb ft) Heat shield fixing screws M6x10 8 Nm (5.90 lb ft) Central manifold clamp 20 Nm (14.75 lb ft)
Page 30 Moto Guzzi California 1400 Characteristics TAND pos. Description Type Quantity Torque Notes Screws fixing stand plate to chassis M10x50 50 Nm (36.88 lb ft) Stand bolt 25 Nm (51.61 lb ft) Stand pin bolt M12x1.25 70 Nm (51.61 lb ft) UARDS KIT pos.
Page 31 Moto Guzzi California 1400 Characteristics Back side EAR SHOCK ABSORBERS pos. Description Type Quantity Torque Notes Pins 40 Nm (29.50 lb ft) Shock absorber fixing screws M6x14 10 Nm (7.38 lb ft) CHAR - 31...
Page 32 Moto Guzzi California 1400 Characteristics EAR MUDGUARD pos. Description Type Quantity Torque Notes Front fixing screws M8x20 25 Nm (18.44 lb ft) Upper fixing screw M8x16 25 Nm (18.44 lb ft) Side cover fixing screws M5x9 6 Nm (4.42 lb ft) Side cover fixing screws - Nm (-.-- lb ft)
Page 33 Moto Guzzi California 1400 Characteristics pos. Description Type Quantity Torque Notes Swingarm pin 60 Nm (44.25 lb ft) Preloading bushing 10 Nm (7.38 lb ft) Clamp screws M6x25 10 Nm (7.38 lb ft) ANNIERS KIT pos. Description Type Quantity Torque...
Page 34 Moto Guzzi California 1400 Characteristics pos. Description Type Quantity Torque Notes Panniers supports fixing screws M8x16 24 Nm (17.4 lb ft) Engine UBRICATION YSTEM pos. Description Type Quantity Torque Notes Pump outlet oil pipe nipple M14x1.5 40 Nm (29.50 lb ft) Slot screw for oil pipe on the cylinder head M14x1.5...
Page 35 Moto Guzzi California 1400 Characteristics IL PUMP pos. Description Type Quantity Torque Notes Oil pump fixing screws M6x45 9 11 Nm (6.64 8.11 lb ft) Loctite 243 Low nut for oil pump M6x0.75 8 Nm (5.90 lb ft) Loctite 243 IL SUMP COMPONENTS pos.
Page 36 Moto Guzzi California 1400 Characteristics pos. Description Type Quantity Torque Notes Mesh type oil filter fixing screw M6x14 6 Nm (4.42 lb ft) Oil filter 15 Nm (11.06 lb ft) Engine oil RANKCASE AND pos. Description Type Quantity Torque Notes...
Page 37 Moto Guzzi California 1400 Characteristics EARBOX pos. Description Type Quantity Torque Notes Clutch housing to gearbox fixing screws M6x55 13 Nm (9.59 lb ft) Gearbox cap M18x1.5 28 Nm (20.65 lb ft) Breather stud bolt M10x1.5 8 Nm (5.90 lb ft)
Page 38 Moto Guzzi California 1400 Characteristics LUTCH pos. Description Type Quantity Torque Notes Flywheel on crankshaft fixing screw M8x25 42 Nm (30.98 lb ft) Loctite 243 Clutch external flange fixing screw on flywheel M7x16 20 Nm (14.75 lb ft) Loctite 243...
Page 39 Moto Guzzi California 1400 Characteristics RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws M10x1 Pre-torque 40 Nm (29.50 lb ft). Final torque 80 Nm (59.00 lb ft) CHAR - 39...
Page 40: Description
Moto Guzzi California 1400 Characteristics YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special aesthetic head cover fixing screw 8 Nm (5.90 lb ft) Locked with cross sequence Special head cover screw 8 Nm (5.90 lb ft) Locked with cross...
Page 41: Nm (36.88 Lb Ft)
Moto Guzzi California 1400 Characteristics OPTION 02 YLINDERS TIMING pos. Description Type Quantity Torque Notes Camshaft / rocker support fixing screws M8x30 16 - 18 Nm (11.80 - 13.28 lb ft) Nut for tie rod M10x1.25 Pretorque 15 Nm (11.06 lb ft) Final torque 42 Nm (30.98 lb ft)
Page 42: Nm (7.37 Lb Ft)
Moto Guzzi California 1400 Characteristics pos. Description Type Quantity Torque Notes M6x10 10 - 12 Nm (7.37 - 8.50 lb Loctite 542 Reference dowel on camshaft Interference insert Loctite 542 Long screw for chain compartment on head M6x120 10 Nm (7.37 lb ft)
Page 43: Type Quantity Torque
Moto Guzzi California 1400 Characteristics ENERATOR OVER pos. Description Type Quantity Torque Notes Timing system cover cap fixing screw M6x20 10 Nm (7.38 lb ft) Loctite 243 Timing system cover fixing screw M8x55 25 Nm (18.44 lb ft) Timing system cover fixing screw M6x30 10 ÷...
Page 44: Nm (17.4 Lb Ft)
Moto Guzzi California 1400 Characteristics IR FILTER pos. Description Type Quantity Torque Notes Air filter box fastening screw to frame 10 Nm (7.38 lb ft) Air filter box cover fastening screw SWP 5x20 3 Nm (2.21 lb ft) HROTTLE BODY pos.
Page 45 Moto Guzzi California 1400 Characteristics TARTER MOTOR pos. Description Type Quantity Torque Notes Starter motor fixing screws M8x75 25 Nm (18.44 lb ft) NGINE COVER pos. Description Type Quantity Torque Notes Engine cover fixing screws M6x16 10 Nm (7.37 lb ft)
Page 46 Moto Guzzi California 1400 Characteristics Overhaul data Assembly clearances Cylinder - piston assy. Measurement of the cylinder diameter must be done at three heights, turning the dial gauge 90°. Check that cylinders and pistons are of the same selection types (D, E, F).
Page 47 Moto Guzzi California 1400 Characteristics Specification Desc./Quantity Pin hole diameter on piston 22.020 - 22.015 mm (0.86693 - 0.86673 in) Clearance between pin and holes on piston 0.017 - 0.026 mm (0.00067 - 0.00102 in) Piston rings On each piston there are: •...
Page 48 Moto Guzzi California 1400 Characteristics 020676Y Dial gauge support for piston position checking • Reset the micrometer on the cylinder rim. • Move the tool so that the micrometer feeler reaches the top point of the piston crown. • Take note of the measurement and, according to the values found, consult the chart at the bottom of the page to decide the thickness of the gasket to be fitted between cylinder and head.
Page 49 Moto Guzzi California 1400 Characteristics Recommended products chart Piaggio & C. S.p.A. prescribes eni products for the scheduled maintenance of its vehicles ECOMMENDED PRODUCTS TABLE Product Description Specifications ENI i-RIDE PG RACING 10W-60 Engine oil SAE 10W - 60. As an alternative for rec-...
Page 50 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 51 Moto Guzzi California 1400 Special tools ENGINE Stores code Description GU05902530 Gearbox support GU05911730 Front cover insertion cone GU05912530 Gearbox opening GU05927230 Timing system cover sealing ring punch GU12911801 Tool to lock the flywheel and the starting ring gear GU12912000...
Page 52 Moto Guzzi California 1400 Special tools Stores code Description GU12913600 Tool to remove the flywheel-side flange GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body GU14927100 Tool to fit the sealing ring on the flywheel- side flange...
Page 53 Moto Guzzi California 1400 Special tools Stores code Description 020672Y Clutch spring centre and pusher 020675Y Service shaft gear lock 020676Y Dial gauge support for piston position checking 020677Y Generator belt tensioner, lever for belt tensioning 020678Y Tool for clutch rod checking...
Page 54 Moto Guzzi California 1400 Special tools Stores code Description 020953Y Cam shaft lock for fixing 020954Y Centring cam shaft cup spring CHASSIS Stores code Description AP8140190 Tool for steering tightening 020376Y Adaptor handle 020359Y 42 x 47mm Adaptor 020360Y Adaptor 52x54 mm...
Page 55 Moto Guzzi California 1400 Special tools Stores code Description 001467Y001 Pliers to extract Ø 25-mm bearings 001467Y035 Bearing housing, external ø 47 mm FRONT FORK Stores code Description AP8140146 Weight AP8145758 Tool for oil seals fitting 020952Y Pumping member ring nut locking span-...
Page 56 Moto Guzzi California 1400 Special tools Stores code Description 020951Y Stanchion support DIAGNOSIS INSTRUMENT Stores code Description 020922Y P.A.D.S. S-TOOLS - 56...
Page 57 INDEX OF TOPICS MAIN AINTENANCE...
Page 58: Scheduled Maintenance Table
Moto Guzzi California 1400 Maintenance Scheduled maintenance table NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.
Page 59 Moto Guzzi California 1400 Maintenance km x 1,000 (mi x 1,000) (0.9) (6.2) (12.4) (18.6) (28.4) (31.1) (37.3) (43.5) (49.7) Bolts and nuts tightening Battery terminals tightening Suspension Filter box drainage tube Fuel lines (3) Brake lines (3) Brake pad wear (1)
Page 60 Moto Guzzi California 1400 Maintenance C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE (1) Check and clean and adjust or replace, if necessary, before every journey. (2) Replace every 2 years or 20000 Km (12427 mi). (3) Replace every 4 years.
Page 61: Transmission Fluid
Moto Guzzi California 1400 Maintenance km x 1,000 or (months) maximum 1.5 (1) 10 (10) 20 (20) 30 (30) 40 (40) 50 (50) 60 (60) 70 (70) 80 (80) Brake discs Air filter Engine oil filter Vehicle general operation Braking systems...
Page 62 Moto Guzzi California 1400 Maintenance • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the level plug (4). • The level is correct if the oil is close to the hole of the cap/dipstick (4).
Page 63: Engine Oil
Moto Guzzi California 1400 Maintenance • Pour new oil through the fill opening (4) until it reaches the cap/dipstick hole (4). CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL- EMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Page 64: Engine Oil Filter
Moto Guzzi California 1400 Maintenance • Place a container with + 4000 cm³ (244 cu.in) capacity under the drainage plug (2). • Unscrew and remove the drainage plug (2). • Empty and drain the oil filler plug / en- gine oil level dipstick (1).
Page 65 Moto Guzzi California 1400 Maintenance Inspection CHECK AND TOPPING-UP CAUTION GEARBOX OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM. NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM (10 miles).
Page 66: Air Filter
Moto Guzzi California 1400 Maintenance • Screw and tighten the drainage plug (2). • Pour in new oil until it reaches the cap/ dipstick opening (1). • Tighten the filler cap (1). CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID.
Page 67 Moto Guzzi California 1400 Maintenance • Remove the head cover protection by undoing and removing the four fixing screws. • Remove the two spark plug caps. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings.
Page 68 Moto Guzzi California 1400 Maintenance NOT CLOSE CORRECTLY, WHICH CAN LEAD TO PROB- LEMS SUCH AS: • PRESSURE DROP; • ENGINE OVERHEAT; • VALVE BURN OUT, ETC. Braking system Level check Brake fluid check • Rest the vehicle on its stand.
Page 69 Moto Guzzi California 1400 Maintenance Rear brake: • Unscrew and remove the cap (5). • Remove the under-cover (6). • Remove the diaphragm (7). • Top-up the tank with brake fluid to the correct level, which is between the two "MIN"...
Page 70 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 71 Moto Guzzi California 1400 Electrical system Components arrangement KEY: 1. Side stand sensor: 2. Fuel pump. 3. Instrument panel. ELE SYS - 71...
Page 72 Moto Guzzi California 1400 Electrical system 4. Engine temperature sensor. 5. Cooling fan. 6. Left injector. 7. Right injector. 8. Lambda probe 9. Lambda probe 10.Front speed sensor. 11.Rear speed sensor. 12.Headlamp. 13.Turn indicators and taillight. 14.Fall sensor. 15.Horn. 16.Battery.
Page 73 Moto Guzzi California 1400 Electrical system • 1 Complete antitheft kit The consumable parts like clamps or possible cable grommets are indicated in the images Motorcycle division The wiring timing is subdivided in three essential sections, as indicated in the figure.
Page 74 Moto Guzzi California 1400 Electrical system The operations for preassembly of the main cable harness on the frame are described in the tables below. TABLE A 1. Large clamps. TABLE B Pass the main cable harness as shown in figure.
Page 75 Moto Guzzi California 1400 Electrical system TABLE E Pass the main cable harness as shown in figure. TABLE F Pass the main cable harness as shown in figure. Front side TABLE A - THERMAL SWITCH SENSOR 1. Thermal switch. 2. Thermal switch connector 3.
Page 76 Moto Guzzi California 1400 Electrical system TABLE A2 - THERMAL SWITCH SENSOR • Clamp the thermal switch cable har- ness at the indicated points TABLE B - FAN 1. Fan 2. Fan connector 3. Fan cable harness • Clamp the cable harness at the indica-...
Page 77 Moto Guzzi California 1400 Electrical system TABLE E - RIGHT SIDE STEERING COLUMN AREA 1. Medium clamp. TABLE F - RIGHT SIDE STEERING COLUMN AREA 1. Medium clamp. TABLE G - RIGHT SIDE STEERING COLUMN AREA 1. Medium clamp. 2. Key connector.
Page 78 Moto Guzzi California 1400 Electrical system TABLE I - RIGHT SIDE STEERING COLUMN AREA 1. Medium clamp. 2. Right light switch. 3. Front stop switch. TABLE J - RIGHT SIDE STEERING COLUMN AREA 1. Medium clamp. 2. Turn indicators. 3. Headlamp.
Page 79 Moto Guzzi California 1400 Electrical system TABLE M - RIGHT SIDE STEERING COLUMN AREA 1. Front stop switch connector. 2. Right light switch connector. TABLE M1 - RIGHT SIDE STEERING COLUMN AREA • Clamp the light switch cable harness over the reference on the red belt for the version "Custom"...
Page 80 Moto Guzzi California 1400 Electrical system TABLE O - LEFT SIDE FORK AREA 1. Cable grommet. TABLE P - LEFT SIDE FORK AREA 1. Cable grommet. TABLE Q - LEFT SIDE FORK AREA 1. Small clamp. ELE SYS - 80...
Page 81 Moto Guzzi California 1400 Electrical system TABLE R - INSTRUMENT PANEL FASTENING 1. Medium clamp. TABLE S - INSTALLATION AIR TEMPERATURE SENSOR 1. Small clamp. 2. Medium clamp. TABLE T - FOG LIGHTS 1. Fog lights kit connection. ELE SYS - 81...
Page 82 Moto Guzzi California 1400 Electrical system TABLE U - FOG LIGHTS 1. Medium clamp (to hold the branch that goes toward the headlights). 2. Clip. 3. 12V 30A relay. 4. Relay mounting rubber block. TABLE V - FOG LIGHTS 1. Cable guide.
Page 83 Moto Guzzi California 1400 Electrical system TABLE C - FRAME AREA (FRAME LEFT EXTERNAL SIDE) 1. Satellite anti-theft connector (if fitted). • Clamp the connector for the satellite anti-theft to the main cable harness TABLE C1 - FRAME AREA (FRAME RIGHT EXTERNAL SIDE) 1.
Page 84 Moto Guzzi California 1400 Electrical system TABLE D1 - FRAME AREA (FRAME RIGHT INTERNAL SIDE) 1. Gear sensor connector. 2. Medium clamps. TABLE E - FRAME AREA (UNDER THE TANK) 1. Big clamp. TABLE F - FRAME AREA (UNDER THE TANK) 1.
Page 85 Moto Guzzi California 1400 Electrical system TABLE H - DIRECT CONNECTIONS TO THE ENGINE Engine temperature. 1. Medium clamp. TABLE I - BATTERY AREA 1. Bluedash plug pre-installation connector (if fitted) TABLE J - BATTERY AREA (RIGHT SIDE FAIRING, INTERNAL VIEW) 1.
Page 86 Moto Guzzi California 1400 Electrical system TABLE K - BATTERY AREA 1. Control unit connectors. TABLE M - CORRECT PASSING OF CORRU- GATED PIPES TABLE N - BATTERY AREA (RIGHT SIDE FAIRING, EXTERNAL VIEW) 1. Relay ELE SYS - 86...
Page 87 Moto Guzzi California 1400 Electrical system TABLE O - BATTERY AREA (LEFT SIDE FAIRING, INTERNAL VIEW) 1. Medium clamp. 2. ABS branch, must remain in its housing. TABLE P - STARTER MOTOR AREA 1. Left coil. 2. Medium clamp. 3. Rear stop connector.
Page 88 Moto Guzzi California 1400 Electrical system TABLE P2 - STARTER MOTOR AREA • The battery - engine ground cable must pass under the cable harness branch TABLE Q - STARTER MOTOR AREA Starter motor clamp 1. Medium clamps. TABLE R - STARTER MOTOR AREA 1.
Page 89 Moto Guzzi California 1400 Electrical system TABLE S - STARTER MOTOR AREA 1. Left injector connector. TABLE T - REAR STOP SWITCH 1. Medium clamps. 2. Rear stop switch. 3. Small clamp. TABLE U - REAR STOP SWITCH 1. Medium clamps.
Page 90 Moto Guzzi California 1400 Electrical system TABLE X - SIDE STAND 1. Clamp with support. 2. Medium clamp. TABLE W - REAR STOP SWITCH 1. Clamp with support. TABLE Y - RIGHT LAMBDA FASTENING 1. Medium clamp. 2. Right lambda.
Page 91 Moto Guzzi California 1400 Electrical system TABLE Z - HANDLEBAR AREA 1. Clutch switch. 2. Clip. 3. Cable guide. TABLE AA - HANDLEBAR AREA 1. Front stop switch. 2. Clip. 3. Cable guide. TABLE BB - LEFT SIDE H.V. CABLES Left injector connector.
Page 92 Moto Guzzi California 1400 Electrical system Back side TABLE A - TAILLIGHT LICENSE PLATE LIGHT 1. Retaining clip. TABLE B - TAILLIGHT LICENSE PLATE LIGHT 1. Medium clamp. TABLE C - TAILLIGHT LICENSE PLATE LIGHT 1. Hold the cable harness as shown in the fig- ure.
Page 93 Moto Guzzi California 1400 Electrical system TABLE D - REAR WHEEL SPEED SENSOR 1. Rear speed sensor. 2. Medium clamp. TABLE E - REAR WHEEL SPEED SENSOR 1. Cable grommet. 2. Medium clamp. 3. Rear speed sensor cable harness. ELE SYS - 93...
Page 94 Moto Guzzi California 1400 Electrical system General wiring diagram key: 1. Multiple connectors 2. Fog lamp switch (where provided) 3. Low beam light relay 4. High beam light relay ELE SYS - 94...
Page 95 Moto Guzzi California 1400 Electrical system 5. Light logic relay 6. Left light switch 7. Horn 8. Air temperature sensor 9. Bluedash pre-installation 10.Instrument panel 11.Heated handgrips (where provided) 12.Power supply for GPS 13.Right light switch 14.Front stop switch 15.Rear stop switch 16.Clutch switch...
Page 96 Moto Guzzi California 1400 Electrical system 43.Gear sensor 44.Lambda probe 2 (right) 45.Lambda probe 1 (left) 46.Right cylinder injector 47.Left cylinder injector 48.Coil 49.Map sensor 50.Motorised throttle 51.Handgrips position sensor 52.Engine speed sensor 53.7sm Control unit 54.Left fog light (if applicable) 55.Front left turn indicator...
Page 97 Moto Guzzi California 1400 Electrical system CONNECTOR CHECK PROCEDURE The procedure includes the following checks: 1. Observation and check of the connector correct position on the component or on the coupling con- nector, making sure that the locking catch is re- leased.
Page 98 Moto Guzzi California 1400 Electrical system CAUTION! IF THERE IS A GROUND CONNECTION COMING FROM THE CONTROL UNIT, MAKE SURE THAT DURING THE TEST THE CONTROL UNIT IS GROUND CONNECTED TO THE CIR- CUIT. VOLTAGE check Check goal: this control is to check if a cable is energised, i.e. if it receives power supply from the battery or the control unit.
Page 99 Moto Guzzi California 1400 Electrical system 3. Pulling the cables slightly from the back of the connector in order to check the correct position of terminals on the connector and of the cable on the terminal. CONTINUITY check Check goal: this control is to check that there are not any circuit interruptions nor excessive resistance, for instance caused by rust, on the two terminals being inspected.
Page 100 Moto Guzzi California 1400 Electrical system • The vehicle can be started if the immobilizer system is faulty. • The instrument panel need not be replaced should the ignition switch be changed. • New keys can be programmed The instrument panel has an immobilizer which prevents start-up in case the system does not identify a key which has been programmed before.
Page 101 Moto Guzzi California 1400 Electrical system Keys storage To modify the stored keys or to add other keys, it is necessary to use the diagnosis tool. After connecting the motorcycle with the diagnosis tool, turn on the instrument panel and enter the user code, if requested.
Page 102 Moto Guzzi California 1400 Electrical system After the identification of at least two keys, the user code is cleared to zero and the entering of the new code procedure starts immediately. Odometer coding It is possible to increase the mileage data at the instrument panel if necessary, for example after the instrument panel replacement.
Page 103 Moto Guzzi California 1400 Electrical system Diagnosis The instrument panel errors are detected through the diagnostics instrument. Therefore it must be connected to the vehicle. In the following the errors generated by the instrument panel are listed. OIL SENSOR Error code B0001 (OIL SENSOR ERROR) Oil sensor alarm disconnected: Alarms that are verified when the sensor is disconnected.
Page 104 Moto Guzzi California 1400 Electrical system Warning light (red) on plus key icon. Troubleshooting Check the good condition and the cable continuity of the CAN line: • between instrument panel PIN 19, ABS control unit PIN 5 and injection control unit PIN 80 •...
Page 105 Moto Guzzi California 1400 Electrical system Alarm that is verified when, because of different reasons, the starter button is blocked. Identification Handgrip cannot be activated. Troubleshooting Perform the check of the instrument panel and button connectors. Check the good condition and the wiring continuity: •...
Page 106 Moto Guzzi California 1400 Electrical system Perform the check of the instrument panel and button connectors. Check the good condition and the wiring continuity: • between instrument panel PIN 33 and Yellow/Pink button cable • between instrument panel PIN 15-16 and Blue/Black button cable...
Page 107 Moto Guzzi California 1400 Electrical system Store the new key. Error code B0004 (KEY CODE NOT READABLE) The key has no transponder or the transponder is damaged. Troubleshooting Replace the key and store it. Error code B0005 (AERIAL NOT WORKING, OPEN OR SHORT-CIRCUITED) An electric interruption or a ground short circuit or voltage to the circuit have been detected.
Page 108 Moto Guzzi California 1400 Electrical system • key released: the circuit is open • key pressed: the circuit is closed Pin out: 4: voltage + 5V 5: ground connection CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING...
Page 109: Control Unit
Moto Guzzi California 1400 Electrical system AUXILIARY FUSES DISTRIBUTION Specification Desc./Quantity 1) 15A fuse High beam/low beam, passing, stop light, fog light, daylight running lights, hazard button illumination, horn fuse 2) 7.5A fuse Instrument panel power, antitheft power fuse 3) 15A fuse ECU live positive fuse 4) 7.5A fuse...
Page 110 Moto Guzzi California 1400 Electrical system • Disconnect both control unit connec- tors • Undo and remove the three screws (1). • Remove the control unit. NOTE WHEN REFITTING THE CONNECTORS, THE SLIDES MUST MOVE FREELY TO THE END OF STROKE, WHICH HELPS WITH THE INSERTION OF THE CONNECTOR: YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE.
Page 111 Moto Guzzi California 1400 Electrical system • Software version number / 0000 • Type-approval Code / - • ISO Code / - • Marelli software code / - • Control unit series number (NIP) / 7SMPRA119 - Identifies the single control unit •...
Page 112 Moto Guzzi California 1400 Electrical system DIAGNOSTICS TOOL: STATUSES Engine status • Indefinite_Key ON_Running engine_Stopped_Power latch_Power latch 2_Power latch fin- ished Engine mode • Indefinite_Start-up_Stable_Idle_Acceleration_Deceleration_Enters Cut Off_Cut Off_Exits Cut Off Immobilizer signal • yes/no • Indicates whether the control unit has received the consent by the instrument panel regard- ing the immobilizer: coded key or user code entered manually.
Page 113 Moto Guzzi California 1400 Electrical system • The stop light logic relay is energised (No. 19 on the electrical circuit diagram, position to the right of the battery, in any case VERIFY identification of the relay with the colour of the...
Page 114 Moto Guzzi California 1400 Electrical system • Replace injection ECU Stop lights relay error P0610 • short circuit to positive/ short circuit to negative / open circuit Error cause • If shorted to positive: excessive voltage has been detected at PIN 31. If shorted to negative: no voltage has been detected.
Page 115 Moto Guzzi California 1400 Electrical system • Continue fault search for the other errors detected. CAUTION DELETING ALL THE SAVED DATA WHEN THE VEHICLE IS BEING MANUFACTURED (INCLUD- ING THE SELF-ADJUSTABLE PARAMETERS), THEN YOU MUST SELECT: HANDLE SELF- LEARNING AND VERIFY THAT THE TWO "THROTTLE VALVE AUTOMATIC SELF-LEARNING"...
Page 116 Moto Guzzi California 1400 Electrical system Battery Function Electrically supply the vehicle: the YTX20-BS bat- tery is already activated. Level in electrical circuit diagram: Battery recharge Location: • on the vehicle: under the saddle • connector: on the battery Electrical specifications:12 V / 18 Ah Pin out: 1.
Page 117: Speed Sensor
Moto Guzzi California 1400 Electrical system • If too high: too high a voltage has been detected at PIN 52. If too low: too low a voltage has been detected at PIN 52. The instrument panel does not indicate the presence of this error even in the ATT status.
Page 118 Moto Guzzi California 1400 Electrical system 5D90 electric malfunction: Electrical fault in sensor or cable harness. Troubleshooting: Check the sensor connector and the ABS control unit connector. If they are not OK, restore the connectors. If they are OK, check continuity of the white/brown cable between PIN 2 of the sensor on the cable harness side and PIN 14 of the ABS control unit connector.
Page 119 Moto Guzzi California 1400 Electrical system Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed.
Page 120 Moto Guzzi California 1400 Electrical system with the vehicle ground connection: if it is grounded, restore the cable harness. If OK, replace the control unit. If PIN 2 has approx. 12 V, check continuity of the yellow cable between PIN 1 of the sensor on the cable harness side and PIN 12 of the ABS control unit connector.
Page 121 Moto Guzzi California 1400 Electrical system OK, check that the tyre pressure is the correct one. If it is not OK, restore it; if it is OK, replace the speed sensor. Engine rpm sensor Function informs crankshaft position and speed to the Mar-...
Page 122 Moto Guzzi California 1400 Electrical system CARRY OUT THE TESTS FROM THE SENSOR CONNECTOR TO THE SENSOR. IF NOT OK, RE- STORE THE CABLE HARNESS/REPLACE THE SENSOR. IF OK, PERFORM THE TEST FROM PIN 20 AND 35 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR.
Page 123 Moto Guzzi California 1400 Electrical system THROTTLE GRIP POSITION SENSOR Function The throttle grip is the part to which the throttle control cables arrive; its task is to translate the rid- er's power request (Demand) into an electrical signal to be sent to the electronic control unit.
Page 124 Moto Guzzi California 1400 Electrical system • E: Track B ground (red/black cable) • F: Track B signal (purple cable) SLAVE connector (white) • A: Track C power (orange/white cable) • B: Track C ground (green/pink cable) • C: Track C signal (yellow/blue cable) •...
Page 125 Moto Guzzi California 1400 Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS Blue front connector throttle grip position sensor - track A P0150 •...
Page 126 Moto Guzzi California 1400 Electrical system throttle grip sensor connector or the control unit connector): if the cable is not ground insu- lated, restore the wiring. If it is ground insulated, and with the switch key set to ON, check that there is power supply for the potentiometer PIN D and that PIN F is connected to ground.
Page 127 Moto Guzzi California 1400 Electrical system cated by the diagnostics instrument: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. • if the circuit is open, shorted to negative: check the throttle grip sensor connector and the Marelli control unit connector.
Page 128 Moto Guzzi California 1400 Electrical system • inconsistent signal Error cause • The value of the front side sensor (tracks A-B) does not coincide with the value of the rear sensor (tracks C-D) Troubleshooting • Replace the throttle grip sensor...
Page 129 Moto Guzzi California 1400 Electrical system 2. Temperature signal 3. Power supply 5V 4. Signal DIAGNOSTICS INSTRUMENT: PARAMETERS Reference pressure Intake above sea level • Example value with key ON: 1009 mbar • Example value with engine on: 670 mbar •...
Page 130 Moto Guzzi California 1400 Electrical system • According to the engine operation data (rpm, throttle valve, etc.) an average value for the intake pressure is estimated: if the value read deviates by a given percentage, this error is activated. The most frequent causes can be: abnormal resistance in the sensor circuit (for example, rusted terminals) or sensor with poor performance.
Page 131 Moto Guzzi California 1400 Electrical system DIAGNOSTIC TOOL: ELECTRICAL ERRORS air temperature sensor P0110 • open circuit, shorted to positive / shorted to negative Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 37 of the ENGINE connector.
Page 132 Moto Guzzi California 1400 Electrical system Electrical specifications: NGINE TEMPERATURE SENSOR RESISTANCE Specification Desc./Quantity Resistance at -40 °C (-40 °F) 100.950 kOhm Resistance at -30 °C (-22 °F) 53.100 kOhm Resistance at -20 °C (-4 °F) 29.120 kOhm Resistance at -10 °C (14 °F) 16.600 kOhm...
Page 133 Moto Guzzi California 1400 Electrical system • If the circuit is open, shorted to positive: check sensor connector and Marelli control unit connector; if not OK, restore cable harness; if OK, check sensor continuity; if it is not OK, replace the sensor; if it is OK, check the continuity between the ENGINE connector PIN 12 and the sensor PIN 12: restore cable harness if there is not continuity;...
Page 134 Moto Guzzi California 1400 Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
Page 135 Moto Guzzi California 1400 Electrical system read by the control unit; a recovery value is dis- played instead Lambda sensor correction • Example value with key ON: 1.00 mV • Example value with engine on: 0.90 - 1.10mV In closed loop, the value must be close to 1.00 (values not within the 0.90 - 1.10 interval indicate...
Page 136 Moto Guzzi California 1400 Electrical system • shorted to positive Error cause • Excessive voltage (battery voltage) has been detected at PIN 10 and 22 of the ENGINE connector. Caution: the 'Oxygen sensor' parameter is not the real value that is read; a re- covery value is displayed instead.
Page 137 Moto Guzzi California 1400 Electrical system • Check circuit continuity from probe connector (PIN 1 and PIN 2) toward the probe: replace the oxygen sensor if there is no continuity; if there is continuity, check the sensor connector and the Marelli control unit connector: If not OK, restore. If OK, check continuity between the ENGINE connector PIN 22 and PIN 10 and restore the cable harness.
Page 138 Moto Guzzi California 1400 Electrical system (between the sensor connector PIN 3 and the ENGINE PIN 38) and restore the cable har- ness. WARNING The control unit does not detects the following malfunctions of the oxygen sensor circuit according to the signal: interrupted circuit, shorted to ground or sensor malfunction (for example non variable volt- age).
Page 139 Moto Guzzi California 1400 Electrical system • on the vehicle: intake manifold on the cylinder • connector: on injectors Electrical specifications: 14.8Ω ± 5% (at ambient temp) Pin out left cylinder: 1. Power (orange/green cable) 2. Ground (grey/red cable) Pin out right cylinder: 1.
Page 140 Moto Guzzi California 1400 Electrical system Error cause • If shorted to positive: excessive voltage has been detected at PIN 53. If shorted to negative: no voltage has been detected. If the circuit is open: an interruption has been detected Troubleshooting •...
Page 141: Fuel Pump
Moto Guzzi California 1400 Electrical system Fuel pump Function Fuel pump: keeps pressure of the injectors supply duct. Level in electrical circuit diagram: Injection load relay Location: • on the vehicle: under the tank. • connector: near the fuel pump (2 ways, black).
Page 142 Moto Guzzi California 1400 Electrical system • If the circuit is open, shorted to negative: check the relay electrical characteristics are correct by disconnecting it from the cable harness; if it is not OK, replace the relay, if it is OK, check relay connector, engine-vehicle cable harness connector and VEHICLE connector of the Marelli control unit: if not OK, restore;...
Page 143 Moto Guzzi California 1400 Electrical system CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSTICS INSTRUMENT: ACTIVATION Left Cylinder Central Coil The auxiliary relay (No. 35 in the wiring diagram, placed in the front relay box, left side; CHECK, how- ever, the identification of the relay with the colour of the cables) is energised for 5 seconds and the coil Pink cable is closed to ground for 2 ms per second.
Page 144 Moto Guzzi California 1400 Electrical system The auxiliary injection relay (No. 35 in the wiring diagram, placed in the front relay box, left side; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the coil Brown/Green cable is closed to ground for 2 ms per second.
Page 145 Moto Guzzi California 1400 Electrical system • If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with the diagnostics instrument and check voltage at connector PIN 27: if there is voltage, restore the cable harness; if voltage = 0, replace the coil.
Page 146: Throttle Body
Moto Guzzi California 1400 Electrical system OK, restore, if OK, check cable continuity between the two cable terminals: if there is not continuity, restore the cable harness; if there is cable continuity, with key set to ON, check the cable ground insulation (from coil connector or control unit connector), if not OK, restore...
Page 147 Moto Guzzi California 1400 Electrical system • Example value with engine at idle: engine hot 5.5°, engine cold 6,5° Throttle Potentiometer 1 (voltage) • Example value with key ON: 800 mV • Example value with engine on: engine hot 760 mV, engine cold 800 mV Throttle Potentiometer 2 (degrees) •...
Page 148 Moto Guzzi California 1400 Electrical system • If shorted to positive: excessive voltage has been detected at PIN 48. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 48. Troubleshooting • If shorted to positive: check the value indicated by the Throttle Potentiometer 1 parameter (voltage): disconnect the connector and read the value indicated by the diagnostics instru- ment: if the voltage does not vary, there is a short circuit in the cable;...
Page 149 Moto Guzzi California 1400 Electrical system • Check the Throttle Potentiometer 1 parameter (voltage) to understand which signal the control unit receives. Check the throttle body connector as well as the control unit connector. Check that cable resistance between the throttle body connector (PIN 1) and the control unit (PIN48) is a few tenths of an Ohm.
Page 150 Moto Guzzi California 1400 Electrical system • failed test Error cause • Return time of the throttle, kept in position by the springs, not within the expected limits: the causes can be a deterioration of the performance of the springs or excessive throttle friction...
Page 151 Moto Guzzi California 1400 Electrical system Troubleshooting • Replace the throttle body DIAGNOSTICS INSTRUMENT: ADJUSTABLE PARAMETERS Throttle self-acquisition NOTE THROTTLE BODY ACTIVATION TAKES PLACE EVERY TIME THE KEY IS SET TO ON: CORRECT ACTIVATION IS INDICATED WHEN THE STOP LIGHTS TURN ON: IF DURING ACTIVATION, THE ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT TURN ON.
Page 152 Moto Guzzi California 1400 Electrical system Neutral sensor Function It tells the gear position to the control unit, from the 1st gear to the 6th gear, and if the gear is neutral or riding. Operation / Operating principle The sensor has 2 circuits: one to indicate the en-...
Page 153 Moto Guzzi California 1400 Electrical system • Yes/No Gear engaged: 0 - 1 - 2- 3 - 4 - 5 - 6 DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS Gear sensor P0461 • shorted to positive or open circuit / shorted to negative.
Page 154 Moto Guzzi California 1400 Electrical system Electrical specifications: • Clutch pulled: closed circuit (continui- • Clutch released: open circuit (infinite resistance). Pin out: 1. normally closed switch (white/purple cable) 2. ground (green/pink cable) 3. normally open switch (orange/blue cable) CAUTION...
Page 155 Moto Guzzi California 1400 Electrical system Side stand sensor Function it tells the side stand position to the control unit Operation / Operating principle If the gear is engaged and the side stand is unfol- ded, and therefore the circuit is open, the control...
Page 156: Bank Angle Sensor
Moto Guzzi California 1400 Electrical system Bank angle sensor Function It tells the vehicle position to the control unit Operation / Operating principle The sensor converts the vehicle position signal to electrical voltage. Level in electrical circuit diagram: Start-up enabling switches Location: •...
Page 157 Moto Guzzi California 1400 Electrical system • connector: under right side steering column. Electrical specifications: • STOP position: the circuit is open • RUN position: closed circuit (continui- Pin out: 1 ground (pink/black cable) 2 power 5 V (pink/brown cable)
Page 158 Moto Guzzi California 1400 Electrical system Engine pinout key: Right cylinder side spark plug coil command output PIN 1 Left cylinder side spark plug coil command output PIN 2 Sensors ground 2 PIN 4 Power ground PIN 5 Sensors ground 1 PIN 6...
Page 159 Moto Guzzi California 1400 Electrical system Output for throttle motor drive (-) PIN 29 Recovery logic relay command output (STOP light) PIN 31 Left Lambda heater command output PIN 32 Engine rpm sensor input (+) PIN 35 Air temperature sensor input PIN 37...
Page 160 Moto Guzzi California 1400 Electrical system Fall sensor input PIN 65 CAN L line (high speed) PIN 66 Right cylinder injector command output PIN 67 Starter relay command output PIN 69 Side stand input PIN 70 Gear sensor input PIN 72...
Page 161 Moto Guzzi California 1400 Electrical system Serial line K for diagnostics PIN 9 CAN L line (high speed) PIN 10 Battery positive PIN 11 Left rear turn indicator output PIN 12 Right rear turn indicator output PIN 13 Lights relay PIN 14...
Page 162 Moto Guzzi California 1400 Electrical system B aerial PIN 30 Key positive PIN 31 Left turn indicator command PIN 32 Normally open front stop switch input PIN 33 Hazard input PIN 34 Handgrip command PIN 35 Turn indicator reset command PIN 36...
Page 163 Moto Guzzi California 1400 Electrical system Rear speed sensor ground PIN 12 Front speed sensor ground PIN 13 Front speed sensor signal PIN 14 Vehicle identification (2) PIN 15 Serial K line for diagnostics PIN 16 Battery power PIN 18...
Page 164 Moto Guzzi California 1400 Electrical system Every network nod receives all the messages sent through the BUS (with reception confirmation or error messages) and each nod decides if the message is to be processed or rejected. Besides, every nod can request information from the other nodes (RTR = Remote Transmit Request).
Page 165 Moto Guzzi California 1400 Electrical system short circuited to positive testing from each of the 2 connectors (Marelli control unit, instru- ment panel connector) with 1 connector at a time disconnected and turning the key to the ON position: If not OK, restore; if OK, replace the Marelli control unit.
Page 166 Moto Guzzi California 1400 Electrical system • If there is no signal, no signal is received from the ABS control unit. In case of configuration error, some devices are present (e.g. ABS) that were not foreseen in the vehicle configura- tion stored in the control unit.
Page 167 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 168 Moto Guzzi California 1400 Engine from vehicle Vehicle preparation Before removing the engine block, proceed as follows: • From the back, secure the vehicle with belts attached to a hoist. • From the front, secure the vehicle with belts attached to the handlebar and fixed to the work bench.
Page 169 Moto Guzzi California 1400 Engine from vehicle • Disconnect the cable located behind the starter motor. • Disconnect the ground cable. • Disconnect the stand sensor connec- tor and rear stop switch. • Release it from the clamps. ENG VE - 169...
Page 170 Moto Guzzi California 1400 Engine from vehicle • Working from both sides, disconnect the engine oil breather tube. • Working from both sides, disconnect the injector connectors. • Working from both sides, unscrew the retaining screw of the injector and re- move it.
Page 171 Moto Guzzi California 1400 Engine from vehicle • Disconnect the alternator connectors. • Disconnect the oil pressure sensor connector. • Disconnect the engine temperature sensor connector. ENG VE - 171...
Page 172 Moto Guzzi California 1400 Engine from vehicle • Disconnect the speed sensor connec- tor. • Disconnect the ride by wire connec- tors. • Working from both sides, disconnect the connectors of the coils and cables of the plug caps. ENG VE - 172...
Page 173 Moto Guzzi California 1400 Engine from vehicle • Working from both sides, disconnect the lambda probe connectors. ENG VE - 173...
Page 174 Moto Guzzi California 1400 Engine from vehicle • Undo and remove the fixing screw of the oil radiator to the frame. • Disconnect the two connectors located behind the oil radiator. • Loosen the two fixing screws of the fil- ter box and the tube shown in the fig- ure.
Page 175 Moto Guzzi California 1400 Engine from vehicle • Remove the filter box. • Remove the connector of the throttle body. • Undo the four fixing screws and re- move the throttle body. • After disconnecting all the connectors, remove the various fixing clamps of the cables.
Page 176 Moto Guzzi California 1400 Engine from vehicle • Disconnect the horn connectors. • Support the engine with suitable equip- ment. • Working from both sides, remove the rear fixing screws of the cradle. • Working from both sides, remove the front fixing screws of the cradle.
Page 177 Moto Guzzi California 1400 Engine from vehicle • Undo the three fixing screws of the si- lent block support. • Remove the silent block. • Unscrew the front fixing screw that se- cures the engine to the silent block, ENG VE - 177...
Page 178 Moto Guzzi California 1400 Engine from vehicle • Move the engine from the frame so as to be able to access the clutch control cylinder. • Undo and remove the three fixing screws and move the clutch control cyl- inder.
Page 179 Moto Guzzi California 1400 Engine from vehicle • Insert the front pin that secures the en- gine to the silent block. • Fix the silent block support by tighten- ing the three fixing screws. • Working from both sides, insert the en- gine/connecting rod fixing pins.
Page 180 Moto Guzzi California 1400 Engine from vehicle • Working from both sides, position the front and rear fixing screws of the cra- dle. • Connect the horn connectors. ENG VE - 180...
Page 181 Moto Guzzi California 1400 Engine from vehicle • Position throttle body and secure it us- ing the four screws. • Connect the connector. • Install the air filter box. • Secure it with the two fixing screws and the two clamps.
Page 182 Moto Guzzi California 1400 Engine from vehicle • Connect the connectors located inside the oil radiator. • Install the oil radiator securing it with its lower joints and with the upper fixing screw. • Connect the connectors of the lambda probes.
Page 183 Moto Guzzi California 1400 Engine from vehicle • Connect the connectors of the coils and the cables of the plug caps. ENG VE - 183...
Page 184 Moto Guzzi California 1400 Engine from vehicle • Connect the connectors of the ride by wire and that of the engine speed sen- sor. • Connect the connectors of the engine temperature sensor and the oil pres- sure sensor. ENG VE - 184...
Page 185 Moto Guzzi California 1400 Engine from vehicle • Connect the alternator. • Operating from both sides, install the injectors, tightening the fixing screw. • Connect the connectors. ENG VE - 185...
Page 186 Moto Guzzi California 1400 Engine from vehicle • Working from both sides, connect the engine breather tube. • Connect the stand sensor connector and rear stop switch. • Connect the cable located behind the starter motor • Install the starter motor fixing it with the two fixing screws.
Page 187 Moto Guzzi California 1400 Engine from vehicle ENG VE - 187...
Page 188 INDEX OF TOPICS NGINE...
Page 189 Moto Guzzi California 1400 Engine Gearbox EARBOX pos. Description Type Quantity Torque Notes Clutch housing to gearbox fixing screws M6x55 13 Nm (9.59 lb ft) Gearbox cap M18x1.5 28 Nm (20.65 lb ft) Breather stud bolt M10x1.5 8 Nm (5.90 lb ft)
Page 190 Moto Guzzi California 1400 Engine EAR LEVER pos. Description Type Quantity Torque Notes Fastener screw M8x60 25 Nm (18.44 lb ft) Retainer nut 25 Nm (18.44 lb ft) Gearbox connecting rod fixing screw M6x20 10 Nm (7.38 lb ft) Joint adjustment nut...
Page 191 Moto Guzzi California 1400 Engine Diagram key: 1. Ball bearing 2. Circlip 3. Thickness 4. Pin ENG - 191...
Page 192 Moto Guzzi California 1400 Engine 5. Complete desmodromic 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10.Fifth wheel 11.Linking pin 12.Gear 13.Circlip 14.Thrust washer 15.Roller cage 16.Gear 17.Seal ring 18.Ball bearing 19.Gear 20.Circlip 21.Clutch shaft 22.Ball bearing 23.Oil plug 24.Washer...
Page 193 Moto Guzzi California 1400 Engine 43.Gear 44.Gear 45.Roller cage 46.Thrust washer 47.Circlip 48.Gear 49.Circlip 50.Gear 51.Primary shaft 52.Transmission gear 53.Fork (5th - 1st) 54.Fork shaft 55.Fork (3rd - 4th) 56.Fork (2nd - 4th) 57.Gear 58.Gear 59.Ball bearing 60.Transmission shaft 61.Gear 62.Spacer...
Page 194 Moto Guzzi California 1400 Engine • Unscrew and remove the three screws See also Removing the starter motor Replacement • Unscrew and remove the two lower screws • Unscrew and remove the screw • Remove the gearbox. ENG - 194...
Page 195 Moto Guzzi California 1400 Engine Installing the gearbox • Position the gearbox • Tighten the three upper nuts • Tighten the two lower nuts • Tighten the side nut ENG - 195...
Page 196 Moto Guzzi California 1400 Engine Gearbox shafts Disassembling the gearbox • Remove the gearbox. • Undo the two screws and remove the gear sensor. • From the outside, slide off the thrust cylinder and collect the O-Ring and the washer.
Page 197 Moto Guzzi California 1400 Engine • Slide off the rod with the two bushings. • Undo and remove the five external screws. • Place the gearbox on the specific gearbox support tool and on a vice. Specific tooling 05.90.25.30 Gearbox support •...
Page 198 Moto Guzzi California 1400 Engine • Remove the bearings from the gearbox if necessary. • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Use rubber bands to tie down the trans- mission shaft unit and extract it.
Page 199 Moto Guzzi California 1400 Engine • Once the transmission shaft unit is in on a bench, remove the rubber bands, being careful with the group. • Detach the shafts and label the forks before removal. • Remove the forks and collect the shaft.
Page 200 Moto Guzzi California 1400 Engine • Replace bearings if necessary and re- move the clutch shaft. See also Removing the gearbox Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side.
Page 201 Moto Guzzi California 1400 Engine • Remove the gear of the sixth gear and collect the shoulder washer. • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer.
Page 202 Moto Guzzi California 1400 Engine • Remove the gear of the fifth gear and collect the ball bearing cage. • Heat the shaft with a specific heater and remove the helical transmission gear. Removing the secondary shaft • Remove the transmission shaft.
Page 203 Moto Guzzi California 1400 Engine • Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the sixth gear. • Remove the circlip and collect the shoulder washer.
Page 204 Moto Guzzi California 1400 Engine • Remove the gear of the fourth gear and collect the ball bearing cage. • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip.
Page 205 Moto Guzzi California 1400 Engine • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage. • Remove the bearing if necessary. See also Disassembling the gearbox Checking the primary shaft...
Page 206 Moto Guzzi California 1400 Engine Checking the desmodromic drum Check gear drum for damage, scratches and wear and replace the desmodromic control rod if nec- essary. Check the desmodromic segment «3» for damage and wear and replace it if necessary.
Page 207 Moto Guzzi California 1400 Engine primary shaft Fitting the secondary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. See also Removing the...
Page 208 Moto Guzzi California 1400 Engine Disassembling the gearbox Generator LTERNATOR pos. Description Type Quantity Torque Notes Generator control pulley locking nut 100 Nm (73.76 lb ft) Loctite 243 Generator upper fixing screw 22 Nm (16.23 lb ft) Generator lower fixing screw M10x60 30 Nm (22.13 lb ft)
Page 209 Moto Guzzi California 1400 Engine ENERATOR OVER pos. Description Type Quantity Torque Notes Timing system cover cap fixing screw M6x20 10 Nm (7.38 lb ft) Loctite 243 Timing system cover fixing screw M8x55 25 Nm (18.44 lb ft) Timing system cover fixing screw M6x30 10 ÷...
Page 210 Moto Guzzi California 1400 Engine • Saddle removal; • Battery removal; • Removal of steering column fairings; • Removal of tank cap cover; • Tank removal; • Removal of side fairings; • Removal of silencers; • Removal of starter motor cover;...
Page 211 Moto Guzzi California 1400 Engine • Remove the front bracket with silent block from the lower part paying atten- tion not to damage the alternator cover. • Remove the three upper screws of the alternator cover. • Remove the central screws of the al- ternator cover.
Page 212 Moto Guzzi California 1400 Engine • Remove the lower screws of the alter- nator cover. • Remove the alternator cover by pulling it off from the lower part, paying atten- tion not to damage it. • Loosen the screw. •...
Page 213: Removing The Generator
Moto Guzzi California 1400 Engine 020677Y Generator belt tensioner, lever for belt tensioning • Tighten the belt to a torque of 50 Nm (36.88 lb ft). • Tighten the adjuster and tighten the locknut. Removing the generator • Remove the screw.
Page 214: Installing The Generator
Moto Guzzi California 1400 Engine • Remove the belt and the alternator with pulley. Installing the generator • Insert the alternator as shown in the figure • After correctly inserting the belt, on the pulleys tighten the screw with the rela- tive nut •...
Page 215 Moto Guzzi California 1400 Engine • Using the belt tensioning tool, tension the belt to the prescribed torque and tighten the set screw. • Remove the belt tensioning tool. • Lock the set screw in position by screwing the lock nut.
Page 216: Starter Motor
Moto Guzzi California 1400 Engine • Insert the central screws • Insert the lower screws • Tighten all the screws of the cover Starter motor TARTER MOTOR pos. Description Type Quantity Torque Notes Starter motor fixing screws M8x75 25 Nm (18.44 lb ft)
Page 217 Moto Guzzi California 1400 Engine Removing the starter motor • Undo and remove the two screws and collect the washers. • Slide off the starter motor. Clutch side Disassembling the clutch ENG - 217...
Page 218 Moto Guzzi California 1400 Engine LUTCH pos. Description Type Quantity Torque Notes Flywheel on crankshaft fixing screw M8x25 42 Nm (30.98 lb ft) Loctite 243 Clutch external flange fixing screw on flywheel M7x16 20 Nm (14.75 lb ft) Loctite 243...
Page 219 Moto Guzzi California 1400 Engine 17.Thrust cylinder 18.Clutch control cylinder 19.TE flanged screw • Remove the complete gearbox. • Undo and remove the six screws (1). • Remove the start-up crown gear. • Remove the clutch bell and the friction disc by undoing the six screws (2).
Page 220 Moto Guzzi California 1400 Engine • Remove the retainer ring. • Remove the clutch pressure cap. • Unscrew and remove the six screws. • Remove the clutch plate. CAUTION DURING REMOVAL/FITTING OF THE SCREWS DO NOT USE WASHERS IF PREVIOUSLY INSTALLED.
Page 221 Moto Guzzi California 1400 Engine Checking the clutch actuator If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod. Measure as follows: • Fit the new clutch on the crankshaft.
Page 222 Moto Guzzi California 1400 Engine • Place the clutch pressure plate. • Fit the tool to centre and compress the plate. • Fully tighten the two centring tool screws. Specific tooling 020672Y Clutch spring centre and pusher • Once the centring tool is fitted, lock the plate with the snap ring.
Page 223 Moto Guzzi California 1400 Engine • Insert the friction disc in the cap by matching the centring with the slot in the cap. • Fit the clutch bell. • Place the starter sprocket. • Tighten the six screws to the prescri- bed torque operating diagonally and in stages.
Page 224 Moto Guzzi California 1400 Engine Heads YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special aesthetic head cover fixing screw 8 Nm (5.90 lb ft) Locked with cross sequence Special head cover screw 8 Nm (5.90 lb ft) Locked with cross...
Page 225 Moto Guzzi California 1400 Engine OPTION 02 YLINDERS TIMING pos. Description Type Quantity Torque Notes Camshaft / rocker support fixing screws M8x30 16 - 18 Nm (11.80 - 13.28 lb ft) Nut for tie rod M10x1.25 Pretorque 15 Nm (11.06 lb ft) Final torque 42 Nm (30.98 lb ft)
Page 226 Moto Guzzi California 1400 Engine pos. Description Type Quantity Torque Notes M6x10 10 - 12 Nm (7.37 - 8.50 lb Loctite 542 Reference dowel on camshaft Interference insert Loctite 542 Long screw for chain compartment on head M6x120 10 Nm (7.37 lb ft)
Page 227 Moto Guzzi California 1400 Engine 13.5.3x10x0.5 spring washer 14.Complete breather cover 15.Screw 16.Plate 17.TE flanged screw M6x25 18.Cup spring 19.Shim washer 20.Shim washer 21.Roller 22.Nut M10x1.25 6H 23.Flanged screw M6x120 24.Flat washer 12x6.1x2 25.Timing system gear 26.Breather plate 27.Flanged screw 28.Seal ring 2.62x46.52...
Page 228: Removing The Cylinder Head
Moto Guzzi California 1400 Engine • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings. • Remove the head cover together with the gaskets. • Remove the two spark plugs. Removing the cylinder head OPTION 01...
Page 229 Moto Guzzi California 1400 Engine • Undo and remove the two fixing screws of the pliers of the blow-by. • Remove the pliers of the blow-by pay- ing attention not to damage the seal ring. • Undo the external fixing screws of the head.
Page 230 Moto Guzzi California 1400 Engine • Discharge the left chain tensioner from the oil pressure undoing the screw shown. • With the help of a screwdriver act on the chain tensioner slider so as to dis- charge the thrust of the tensioner and simultaneously insert a pin in said hole so as to block the return.
Page 231 Moto Guzzi California 1400 Engine • Undo the nuts securing the cam tower and the head unit. • Remove the complete head of the cam tower timing system. • Undo the fixing screws of the rocker bridge • Remove the rocker bridge.
Page 232 Moto Guzzi California 1400 Engine • Use the screws as shown in the figure to extract the cam tower. • Remove the timing system cam tower complete with the camshaft. See also Removing the head cover OPTION 02 • Unscrew and remove the two fixing screws in the points in the figure.
Page 233 Moto Guzzi California 1400 Engine • Undo the external fixing screws of the head. CAUTION PAY ATTENTION WHEN MOUNTING TO THE SCREW IN- DICATED ON THE RIGHT CYLINDER BECAUSE IT IS THE ONLY ONE WITH DUAL SPACERS. • Undo and remove the centrifugal sep- arator fixing screw.
Page 234 Moto Guzzi California 1400 Engine • Discharge the left chain tensioner from the oil pressure undoing the screw shown. • With the help of a screwdriver act on the chain tensioner slider so as to dis- charge the thrust of the tensioner and simultaneously insert a pin in said hole so as to block the return.
Page 235 Moto Guzzi California 1400 Engine • Undo the nuts securing the cam tower and the head unit. • Remove the complete head of the cam tower timing system. • Undo the fixing screws of the rocker bridge • Remove the rocker bridge.
Page 236: Cylinder Head
Moto Guzzi California 1400 Engine • Use the screws as shown in the figure to extract the cam tower. • Remove the timing system cam tower complete with the camshaft. See also Removing the head cover Cylinder head key: ENG - 236...
Page 237 Moto Guzzi California 1400 Engine 1. Rockers. 2. Hydraulic tappets with rollers. 3. Camshaft. Removing the overhead camshaft • Using the special tool hold the cam- shaft. Specific tooling 020953Y Cam shaft lock for fixing • Unscrew and remove the camshaft fix- ing screw.
Page 238 Moto Guzzi California 1400 Engine • Remove the camshaft from its seat. • Remove the hydraulic tappets with roll- ers from their seats. See also Removing the rocker arms Removing the rocker arms • Undo the fixing screws of the rocker bridge •...
Page 239: Removing The Valves
Moto Guzzi California 1400 Engine • Remove the rockers. See also Removing the cylinder head Removing the valves • Remove the head. • Place the special tool on the upper cap and at the centre of the head of the valve to be removed.
Page 240: Checking The Cylinder Head
Moto Guzzi California 1400 Engine Checking the valve guides Use a punch to extract the valve guides from the heads. The valve guides should be replaced only if the clearance between them and the stem cannot be elim- inated by simply replacing the valves.
Page 241: Installing The Valves
Moto Guzzi California 1400 Engine OUTLET VALVE SEAT DETAIL DRAWING - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45° milling cutter and then grind. - Replace the head in case of excessive wear or damage.
Page 242 Moto Guzzi California 1400 Engine Installing the rocker arms • Insert the roller hydraulic tappets. • Fit the camshaft • Place the half spheres (1) into the ap- propriate seats (2) of the rocker. • Place the two rocking levers in the cam tower seats.
Page 243 Moto Guzzi California 1400 Engine Installing the overhead camshaft Installing the overhead camshaft • Insert the roller hydraulic tappets mak- ing sure that the roller (1) in the appro- priate milling (2) of the cam tower coincides. • Position the cam shaft paying attention to the direction.
Page 244 Moto Guzzi California 1400 Engine • Remove the bushing so as to be able to fix the tool. • Be careful when removing it not to damage it. Specific tooling 020953Y Cam shaft lock for fixing • Tighten the camshaft fixing screw.
Page 245 Moto Guzzi California 1400 Engine Timing IMING SYSTEM pos. Description Type Quantity Torque Notes Idle shaft flange fixing screws M6x14 7 - 8 Nm (5.16 - 5.90 lb ft) Loctite 542 only on through hole Bearing on idle shaft fixing screw M6x16 8 - 10 Nm (5.90 - 7.37 lb ft)
Page 246 Moto Guzzi California 1400 Engine • Using the special tool, remove the tim- ing system gear. Specific tooling 12.91.36.00 Tool to remove the flywheel-side flange • Remove the tone wheel. • Recover the cotter and the shim wash- ENG - 246...
Page 247 Moto Guzzi California 1400 Engine • Undo and remove the timing sensor fixing screw. • Remove the timing sensor and its O- Ring See also Removing the generator Service shaft removal • Remove the tone wheel. • Remove both cylinders.
Page 248 Moto Guzzi California 1400 Engine Removing the phonic wheel Installing the service shaft • Place the service shaft bearing (if pre- viously removed) on the crankcase. • Fix it to the seat with the lock washer and screw. • Fit the timing chains according to the references marked at the removal phase.
Page 249 Moto Guzzi California 1400 Engine • Undo and remove the two M6 flanged screws. • Tighten the cap with the two original TBEI screws. Installing sliders • Fit the crankshaft and the service shaft on the crankcase. • Fit the fixed chain sliders and tighten the fixing screws.
Page 250 Moto Guzzi California 1400 Engine Cam timing • Fit the crankshaft and the service shaft on the crankcase. • Fit the cylinders. • Turn the crankshaft until the left cylin- der piston reaches the top dead centre (TDC). • Fit the cotter and the shim washer on the service shaft.
Page 251 Moto Guzzi California 1400 Engine • After shimming the timing sensor prop- erly, proceed to fit it. • Fit the washer and tighten the timing system gear fixing nut of the service shaft. • Place a new gasket between the crank- case and the oil pump.
Page 252 Moto Guzzi California 1400 Engine • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the...
Page 253 Moto Guzzi California 1400 Engine Measuring air gap • Undo the screw and remove the engine speed sensor. • Space the sensor with a 1 mm (0.0394 in) thick adjustment plate. • Measure the distance between the engine speed sensor and the tone wheel. If the distance measured is: - 0.55 - 0.7 mm (0.0216 - 0.0275 in), the 1 mm (0.0394 in) adjustment plate must be replaced with a...
Page 254 Moto Guzzi California 1400 Engine Cylinder-piston assembly ISTON CYLINDER pos. Description Type Quantity Torque Notes Tie rod on crankcase M10x1.25 5 Nm (3.69 lb ft) Right tensioner cover M30x1.5 40 Nm (29.50 lb ft) Left tensioner cover M20x1.5 30 Nm (22.13 lb ft)
Page 255 Moto Guzzi California 1400 Engine key: 1. Right cylinder 2. Piston 3. Screw 4. Top piston ring 5. Middle piston ring 6. Oil scraper piston ring 7. Pin 8. Retainer ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket 13.Left cylinder...
Page 256 Moto Guzzi California 1400 Engine • Remove the two dowel pins on the stud bolts. • Remove the two gaskets between the crankcase and the cylinder. • Cover the crankcase opening with a clean cloth. See also Removing the cylinder head...
Page 257 Moto Guzzi California 1400 Engine • The reference on the piston ring must be facing the piston crown. • Fit the piston rings on the piston: - the oil scraper in the lower slot; - the thicker smooth ring in the intermediate slot; - the less thick smooth ring in the upper slot.
Page 258 Moto Guzzi California 1400 Engine Installing the cylinder RIGHT CYLINDER • Fit the piston. • Remove the cloth used to prevent for- eign bodies from getting into the crank- case. • Turn the rings so that the coupling ends are 120 degrees from each other.
Page 259 Moto Guzzi California 1400 Engine • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner and the chain tensioner cap temporarily and keep the chain taut on the service shaft. LEFT CYLINDER • Fit the piston.
Page 260: Installing The Cylinder Head
Moto Guzzi California 1400 Engine DURING THIS OPERATION, PAY ATTENTION NOT TO DAMAGE THE PISTON. Specific tooling 020674Y Piston ring clamp 020716Y Connecting rod locking • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft.
Page 261 Moto Guzzi California 1400 Engine • Fit a new O-ring in the spark plug hole. • Fit the complete cam cap. • Fix the cam cap with the four nuts on the stud bolts. • Fix the head with the two screws.
Page 262 Moto Guzzi California 1400 Engine • Screw two screws in the threaded holes of the timing system upper gear. • Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain. • Place the gear in the chain.
Page 263 Moto Guzzi California 1400 Engine • Screw two screws in the threaded holes of the timing system upper gear. • Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain. • Place the gear in the chain.
Page 264 Moto Guzzi California 1400 Engine • Fit the valves in the head, if previously removed. • Take the left cylinder piston to TDC and lock crankshaft rotation. • Determine the thickness of the gasket to be fitted between the head and the cylinder as described in the section: Shimming system.
Page 265 Moto Guzzi California 1400 Engine • Fix the head with the two screws. • Tighten nuts and screws to the prescri- bed torque operating diagonally and in stages. • Loosen the valve set screws. • Using a thin screwdriver relief oil pres- sure from the left cylinder chain ten- sioner.
Page 266 Moto Guzzi California 1400 Engine • Fit the gasket with the correct thick- ness between the head and the cylin- der. • Fit the right cylinder head. • Unscrew and remove the right chain tensioner cap. • Screw two screws in the threaded holes of the timing system upper gear.
Page 267 Moto Guzzi California 1400 Engine • Also place the centrifugal separator of the other head. • Place the cap. • Tighten the two screws to the prescri- bed torque. • Also place the cap of the other head. • Adjust valve clearance.
Page 268 Moto Guzzi California 1400 Engine • Position the two plug caps of the spark plug. • Position the head cover and tighten the four screws to the prescribed torque. Crankcase - crankshaft Removing the crankshaft • Remove the clutch. •...
Page 269 Moto Guzzi California 1400 Engine • Hold the crankshaft during flange re- moval. • Using the suitable special tool, remove the crankshaft flange. • Remove the sealing ring from the flange, if necessary. Specific tooling 12.91.36.00 Tool to remove the flywheel-side flange •...
Page 270 Moto Guzzi California 1400 Engine Disassembling the connecting rod RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws M10x1 Pre-torque 40 Nm (29.50 lb ft). Final torque 80 Nm (59.00 lb ft) • Remove both heads. • Remove the cylinders and the pistons.
Page 271 Moto Guzzi California 1400 Engine Inspecting the crankshaft components Check the surfaces of the main journals; if they are scored or oval-shaped, reface them (observing the undersize charts), and replace the main bushing/ Reference (1) indicates the position where the col- oured reference is applied to select diameter (B).
Page 272 Moto Guzzi California 1400 Engine Upon replacing the bearings it may be necessary to ream the crankshaft pin. Before reaming the crankpin, measure the pin diameter (B) comparing it with the maximum wear al- lowed, as indicated in the figure; this defines what kind of undersizing the bearing should have and to which diameter the pin (B) should be reamed.
Page 273 Moto Guzzi California 1400 Engine The connecting rods have a marked area for weight selection. The weight indicated in the chart includes screws, dowels and the bushing. CONNECTING ROD WEIGHT SELECTION Specification Desc./Quantity Connecting rod - brown 0.588 - 0.598 kg (0.02074 - 0.02109 oz) Connecting rod - green 0.598 - 0.608 kg (0.02109 - 0.02145 oz)
Page 274 Moto Guzzi California 1400 Engine • Lock the screws (A) on the caps (B) with a torque wrench at the prescribed torque. PAY ATTENTION TO CRANKSHAFT ROTATION WHEN ONLY THE CONNECTING RODS ARE FITTED BECAUSE IT COULD HIT THE TWO LUBRICATION JETS INSIDE THE CRANKCASE.
Page 275 Moto Guzzi California 1400 Engine • Place the flywheel-side flange on the crankshaft and check if the dowel pin with the O-ring is correctly placed. • Apply Teflon tape on the two lower fix- ing screws at the back in order to pre- vent oil leaks.
Page 276 Moto Guzzi California 1400 Engine Refitting the crankcase halves In case the lubrication jets are removed, replace them with two new of the same type. Check that the O-ring is fitted on the jets. Do not interchange them upon refitting because they have a different length.
Page 277 Moto Guzzi California 1400 Engine IL PUMP pos. Description Type Quantity Torque Notes Oil pump fixing screws M6x45 9 11 Nm (6.64 8.11 lb ft) Loctite 243 Low nut for oil pump M6x0.75 8 Nm (5.90 lb ft) Loctite 243 IL SUMP COMPONENTS pos.
Page 278 Moto Guzzi California 1400 Engine pos. Description Type Quantity Torque Notes Mesh type oil filter fixing screw M6x14 6 Nm (4.42 lb ft) Oil filter 15 Nm (11.06 lb ft) Engine oil RANKCASE AND pos. Description Type Quantity Torque Notes...
Page 279 Moto Guzzi California 1400 Engine Conceptual diagrams The oil pump is operated by the gear (10) which receives the motion directly from the crankshaft. The gear (10) is mounted on the shaft (8), on which two rotors are fitted: one for engine cooling (7) and another for lubrication (6).
Page 280 Moto Guzzi California 1400 Engine 2. Oil delivery pipe to heads 3. Oil delivery pipe to radiator 4. Oil pump body 5. Oil pump gasket 6. Rotor for lubrication 7. Rotor for cooling 8. Rotor control shaft 9. Oil pump cover 10.Oil pump control gear...
Page 281: Oil Pump
Moto Guzzi California 1400 Engine 8. Flywheel-side 9. Piston cooling jets 10.Auxiliary shaft 11.Chain tensioner 12.Camshaft 13.Hydraulic tappet with roller 14.Rocker axes Oil pump Removing • Bring the left cylinder piston to the TDC in combustion phase. • Mark a reference on the oil pump control gear and another on the driven gear so as to place them correctly again upon refitting.
Page 282 Moto Guzzi California 1400 Engine • Drain the engine oil. • Remove the generator and the timing system cover. • Unscrew and remove the nipple. • Collect the gasket. • Unscrew and remove the three screws. • Remove the oil pump.
Page 283 Moto Guzzi California 1400 Engine Installing • Place a new gasket between the crank- case and the oil pump. • Fit the oil pump. • Tighten the three oil pump fixing screws. • Place the driving pin on the oil pump shaft.
Page 284 Moto Guzzi California 1400 Engine • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear.
Page 285 Moto Guzzi California 1400 Engine Removing the oil sump key: 1. Flange 2. Pressure adjuster valve 3. Flange inlet pipe 4. Pump inlet pipe 5. Pump inlet filter 6. Oil filter 7. Cartridge-type oil filter 8. Joint 9. Special gasket 10.Exhaust cap...
Page 286 Moto Guzzi California 1400 Engine • Unscrew and remove the oil level plug and collect the O-Ring. • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Unscrew and remove the four screws.
Page 287 Moto Guzzi California 1400 Engine • Unscrew and remove the filter fixing screw. • Remove the filter. • Remove the overpressure valve. Refitting the oil sump • Position the gasket of the overpressure valve. ENG - 287...
Page 288 Moto Guzzi California 1400 Engine • Apply threadlock on the overpressure valve. • Tighten it to the prescribed torque. • Make sure that the OR is in good con- dition, otherwise replace it. • Position the joint. ENG - 288...
Page 289 Moto Guzzi California 1400 Engine • Insert the joint in the oil sump, making sure the OR is in good condition. • Replace the OR if necessary. • Place a new gasket between the crank- case and the flange. •...
Page 290 Moto Guzzi California 1400 Engine • Fit the filter and tighten it to the speci- fied torque. • Place the oil sump. • Tighten the fourteen screws to the pre- scribed torque. • Add engine oil up to the correct level.
Page 291 Moto Guzzi California 1400 Engine The oil vapours coming from the joints (1) and (2), are filtered and enter into the filter box through the joint (4)(5), while the liquid portion returns to the oil sump by means of the joint (3).
Page 292 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 293 Moto Guzzi California 1400 Power supply Circuit diagram key: 1. Fuel tank 2. Throttle body 3. Fuel filter 4. Fuel delivery pipe 5. Fuel pump unit Injection P SUPP - 293...
Page 294 Moto Guzzi California 1400 Power supply Diagram key: 1. Control unit position 2. Instrument panel 3. Ignition switch 4. Battery 5. Fuel pump 6. Throttle valve position sensor 7. Air pressure sensor and intake air 8. Injectors 9. Engine temperature sensor 10.Crankshaft position sensor...
Page 295 Moto Guzzi California 1400 Power supply 13.Lambda probe ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date NOTE THE FIGURE ONLY SHOWS THE ICON THAT APPEARS IN THE NAVIGATOR.
Page 296 Moto Guzzi California 1400 Power supply Navigator characteristic P.A.D.S. characteristic Unit of measurement Throttle grip opening percentage Throttle grip opening percentage Throttle valve position potentiom- Throttle valve position potentiom- ° eter 1 eter 1 Throttle position correction Throttle position correction °...
Page 297 Moto Guzzi California 1400 Power supply DEVICES ACTIVATION Navigator characteristic P.A.D.S. characteristic Description / Value Right cylinder central coil Right cylinder central coil Left cylinder central coil Left cylinder central coil Right cylinder side coil Right cylinder side coil Left cylinder side coil...
Page 298 Moto Guzzi California 1400 Power supply DEVICE STATUS Navigator P.A.D.S. Navigator Description / Value P.A.D.S Description / Value characteristic characteristic Left cylinder title control Left cylinder title control Open loop/Closed loop/Rich in half Open loop/Closed loop/Rich in half closed loop/Lean in half closed loop...
Page 299 Moto Guzzi California 1400 Power supply ERRORS screen page This screen page displays any errors detected in the vehicle (ATT) or stored in the control unit (MEM) and you can check that the cancellation of error (STO) has taken place.
Page 300 Moto Guzzi California 1400 Power supply Navigator P.A.D.S. Navigator Description / Value P.A.D.S Description / Value characteristic characteristic Left cylinder Left cylinder Short circuit to positive Short circuit to positive lambda probe lambda probe Heating left cylin- Heating left cylin-...
Page 301 Moto Guzzi California 1400 Power supply Navigator P.A.D.S. Navigator Description / Value P.A.D.S Description / Value characteristic characteristic Cylinder manifold Cylinder manifold Pressure too high/pressure too low Pressure too high/pressure too low intake pressure intake pressure error error Manifold pres-...
Page 302 Moto Guzzi California 1400 Power supply Navigator P.A.D.S. Navigator Description / Value P.A.D.S Description / Value characteristic characteristic NQS - No Dash- NQS - No Dash- Signal absent Signal absent board Node board Node NQS - Dash- NQS - Dash-...
Page 303 INDEX OF TOPICS SUSP USPENSIONS...
Page 304 Moto Guzzi California 1400 Suspensions Handlebar ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes Screws fixing right switch to handlebar 1.5 Nm (1.11 lb ft) Screws fixing left switch to handlebar 1.5 Nm (1.11 lb ft) Screws fixing anti-vibration to handlebar M6x18 10 Nm (7.38 lb ft)
Page 305 Moto Guzzi California 1400 Suspensions • Undo and remove the three fixing screws of the left switch. • Remove the switch. • Undo and remove the two fixing screws of the front brake pump bracelet. • Remove the pump. •...
Page 306 Moto Guzzi California 1400 Suspensions HANDLEBAR REMOVAL • Undo and remove the four fixing screws of the handlebar bracelet. • Remove the handlebar. Installing • To fix the handlebar on the steering yoke, use a torque wrench with a bush- ing of 13, socket 3/8, with a maximum external diameter ≤...
Page 307 Moto Guzzi California 1400 Suspensions • Tighten the two M10 fixing screws of the steering wheel with a torque of 50 Nm (36.88 lbf ft) applying Loctite 243 Front fork pos. Description Type Quantity Torque Notes Lower suspension bars fixing screws M5x50 6 Nm (4.42 lb ft)
Page 308: Removing The Fork Legs
Moto Guzzi California 1400 Suspensions TEERING pos. Description Type Quantity Torque Notes Screws fixing forks to plate M8x35 25 Nm (18.44 lb ft) Lower ring nut 50 Nm (36.87 lb ft) Pretightening to 60 Nm (44.25 lb ft) Upper yoke fixing bushing 100 Nm (73.76 lb ft)
Page 309 Moto Guzzi California 1400 Suspensions Draining oil • Lock the stanchion in a vice with the specific tool. Specific tooling 020951Y Stanchion support • Unscrew the upper cap of the stan- chion. • Using the special tool to hold the locked preloading pipe.
Page 310 Moto Guzzi California 1400 Suspensions • Remove the spring. • Pour the oil inside a container of ade- quate capacity. Disassembling the fork • Discharge all the oil from the sleeve. • Tighten the wheel holder sleeve in a vice.
Page 311 Moto Guzzi California 1400 Suspensions • Remove the retainer ring. • Take out the sleeve from the stem us- ing the stem as a hammer puller. • Remove all components of the stanchion. Checking the components Stem Check the sliding surface for scorings and/or scratches.
Page 312 Moto Guzzi California 1400 Suspensions Check that the following components are in good conditions: • upper bushing; • lower bushing; • piston. If there are signs of excessive wear or damage, replace the affected component. CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SUR- FACE.
Page 313 Moto Guzzi California 1400 Suspensions • O-Ring on the cap. Reassembling the fork • Lock the sleeve in the vice. • Lubricate the stanchion sliding edges with fork oil or grease for seals. • Install the lower and upper bushing on the stanchion, the dust scraper, the seal ring and the washer.
Page 314 Moto Guzzi California 1400 Suspensions • Insert the retainer ring in its position. • Fit the dust gaiter with the specific tool. Specific tooling AP8140146 Weight • Insert the pumping member in the sleeve. • Install the lock key of the piston.
Page 315 Moto Guzzi California 1400 Suspensions • Tighten the piston fixing screws in the fork end to the prescribed torque. Filling oil • Place the sleeve upright in a vice fitted with protection shoes. • Compress the sleeve in the stem.
Page 316 Moto Guzzi California 1400 Suspensions 612 cm³ (37.35 cu.in) (for each stem) Oil level (from sleeve rim, without the spring and with pumping member fully down) 110 mm (4.33 in). • Insert all components in the piston. • Fit the spring.
Page 317: Installing The Fork Legs
Moto Guzzi California 1400 Suspensions • Screw the upper cap on the pumping member pin. • Position the stanchion in a vice by means of the special tool, keeping the forks in a vertical position. • Tighten the cap to the prescribed tor- que.
Page 318 Moto Guzzi California 1400 Suspensions • Mount the front wheel. • Before tightening torque the clamp screw, turn the fork a few trips in order to perfectly align the sleeve. Removing • First remove the handlebar, the front wheel. •...
Page 319 Moto Guzzi California 1400 Suspensions • Remove the upper plate. • Remove the OR from the forks and the upper cover. • Undo and remove the screws fixing the lower plate to the fork. SUSP - 319...
Page 320 Moto Guzzi California 1400 Suspensions • Retrieve the safety plate. • Using the special tool loosen the upper ring nut (1) and the lower ring nut (2). • Retrieve the rubber spacer (3) placed between the two ring nuts. •...
Page 321 Moto Guzzi California 1400 Suspensions • Remove the spacer located in the low- er plate. • Remove the axial ball bearing (5)(6). • Remove the lower plate. • Working from both sides, undo and re- move the two fixing screws of the fork lower cover.
Page 322 Moto Guzzi California 1400 Suspensions Steering bearing TEERING pos. Description Type Quantity Torque Notes Screws fixing forks to plate M8x35 25 Nm (18.44 lb ft) Lower ring nut 50 Nm (36.87 lb ft) Pretightening to 60 Nm (44.25 lb ft) Upper yoke fixing bushing 100 Nm (73.76 lb ft)
Page 323 Moto Guzzi California 1400 Suspensions • Adjust the preloading of the steering bearings by tightening the lower ring nut to the prescribed torque. • Turn the steering 3-4 times completely from right to left and then check correct tightening torque of such ring nut.
Page 324 Moto Guzzi California 1400 Suspensions Disassembling • Using the special tool remove the up- per bearing. • Subsequently, after removing the up- per bearing hit it from bottom upwards, using the appropriate tool, to extract the lower one. Assembling •...
Page 325: Shock Absorbers
Moto Guzzi California 1400 Suspensions • Assemble the components from (1) to (5). • Insert the upper oil seal and make sure the straight section of the column (A) is secured. • Tighten the ring nut (6) to the specified torque before the dust gaiter (5), then unscrew the abovementioned ring nut and retighten it.
Page 326 Moto Guzzi California 1400 Suspensions EAR SHOCK ABSORBERS pos. Description Type Quantity Torque Notes Pins 40 Nm (29.50 lb ft) Shock absorber fixing screws M6x14 10 Nm (7.38 lb ft) Removing (Touring SE - Touring) • The following procedure refers to one single shock absorber, but is valid for both.
Page 327 Moto Guzzi California 1400 Suspensions • Unscrew and remove the lower fixing screw. • Remove the rear shock absorber. (Custom) • The following procedure is visible from one side of the motorcycle, but is valid for both rear shock absorbers.
Page 328 Moto Guzzi California 1400 Suspensions SUSP - 328...
Page 329 INDEX OF TOPICS CHAS HASSIS...
Page 330: Front Wheel
Moto Guzzi California 1400 Chassis Front wheel RONT WHEEL pos. Description Type Quantity Torque Notes Brake discs fixing screws M8x22 25 Nm (18.44 lb ft) Wheel axle 80 Nm (59.00 lb ft) Removal • Working from both sides, undo and re-...
Page 331 Moto Guzzi California 1400 Chassis • Hold the motorcycle front section. • Loosen the screw on the wheel axle clamp. • Undo and remove the wheel axle. • During the pin extraction operation, support the wheel and then remove it.
Page 332 Moto Guzzi California 1400 Chassis • Undo and remove the six fixing screws (1) of the tone wheel and the front disc. • Remove the tone wheel and the front disc. • Working on the opposite side remove the spacer.
Page 333 Moto Guzzi California 1400 Chassis • Remove the Seeger ring. • Using the special tool remove the bear- ing and the spacer. CHAS - 333...
Page 334 Moto Guzzi California 1400 Chassis • After removing the bearing (3) and the spacer (4), operate from the opposite side and remove the bearing (5). Checking FRONT WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel.
Page 335 Moto Guzzi California 1400 Chassis • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: • Replace both wheel bearings.
Page 336: Rear Wheel
Moto Guzzi California 1400 Chassis Rear wheel EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle 100 Nm (73.76 lb ft) Tone wheel flange screws M8x20 25 Nm (18.44 lb ft) Wheel axle nut M25x1.5 100 Nm (73.76 lb ft) Rimozione •...
Page 337 Moto Guzzi California 1400 Chassis • Remove the pin and remove the rear wheel. REMOVAL OF REAR WHEEL • Remove the lock of the flexible cou- pling disc. CHAS - 337...
Page 338 Moto Guzzi California 1400 Chassis • Unscrew and remove the five screws (1). • Remove the flange paying attention to the spacer. • Remove the flexible coupling disc. • Operating from the opposite side undo and remove the six fixing screws (2) of the tone wheel.
Page 339 Moto Guzzi California 1400 Chassis • Remove the dust gaiter and the seeger ring locking the bearings. • Undo and remove the six fixing screws of the rear disc. • Remove the rear disc. CHAS - 339...
Page 340 Moto Guzzi California 1400 Chassis • using the special tool, remove the bearings. • After removing the bearing (3) and the spacer (4), operating from the opposite side and using the special tool, remove the bearing (5). Checking CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS.
Page 341 Moto Guzzi California 1400 Chassis Carry out the check with the bearings fitted on the wheel. ROTATION CHECK • Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless. If one or both bearings do not fall within the control parameters: •...
Page 342 Moto Guzzi California 1400 Chassis REAR WHEEL RIM • Using a dial gauge, check that the ra- dial (A) and the axial eccentricity (B) of the rim (2) do not exceed the limit val- An excessive eccentricity is usually caused by worn or damaged bearings.
Page 343 Moto Guzzi California 1400 Chassis pling rubber rings and the coupling holder. If there is excessive clearance: • Replace all the flexible couplings (3). ALWAYS REPLACE ALL THE FLEXIBLE COUPLINGS WITH OTHERS OF THE SAME TYPE. Swinging arm pos. Description...
Page 344 Moto Guzzi California 1400 Chassis Removing • First remove the rear wheel. • Working from both sides, undo the screw (1) of the rear shock absorber. • Undo and remove the four fixing screws (2) of the bevel gear set.
Page 345 Moto Guzzi California 1400 Chassis Cardan shaft Removing • First remove the swingarm. • Remove the rubber protection. • Using a screwdriver, remove the uni- versal joint. • Remove the cardan shaft. CHAS - 345...
Page 346 Moto Guzzi California 1400 Chassis Checking Carefully check: The splines on the cardan shaft (1) must be intact, free from grain or dents. Check that the joints (2) are not hardened or ex- cessively loose, otherwise replace it. In the figure are shown two worn toothing profiles: •...
Page 347: Side Stand
Moto Guzzi California 1400 Chassis TAND pos. Description Type Quantity Torque Notes Screws fixing stand plate to chassis M10x50 50 Nm (36.88 lb ft) Stand bolt 25 Nm (51.61 lb ft) Stand pin bolt M12x1.25 70 Nm (51.61 lb ft) Side stand •...
Page 348 Moto Guzzi California 1400 Chassis ISCHARGE pos. Description Type Quantity Torque Notes Exhaust - cylinder retainer nut 25 Nm (18.44 lb ft) Side clamps 50 Nm (36.88 lb ft) Heat shield fixing screws M6x10 8 Nm (5.90 lb ft) Central manifold clamp 20 Nm (14.75 lb ft)
Page 349 Moto Guzzi California 1400 Chassis • Undo and remove the two fixing screws of the support bracket. • Remove the exhaust end. • Undo and remove the two nuts on the exhaust stud bolts of the head. • Remove the exhaust manifold.
Page 350 Moto Guzzi California 1400 Chassis Engine oil cooler IL RADIATOR pos. Description Type Quantity Torque Notes Screws fixing oil radiator to chassis M6x25 10 Nm (7.38 lb ft) Screws fixing electric fan to oil radiator 4.2x20 2.5 Nm (1.84 lb ft) Removing •...
Page 351 Moto Guzzi California 1400 Chassis • Lift and remove the oil radiator (2) from the support as in the figure. • Disconnect the connector (3) of the electric fan. • Unscrew the two oil pipes (4) and re- move the radiator (2).
Page 352 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 353 Moto Guzzi California 1400 Braking system ABS B RAKING YSTEM pos. Description Type Quantity Torque Notes ABS control unit lower cover fixing screws 6 Nm (4.42 lb ft) ABS control unit support plate fixing screws M6x25 10 Nm (7.38 lb ft)
Page 354 Moto Guzzi California 1400 Braking system key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Start-up relay 6. ECU 7. Instrument panel 8. K line (diagnosis) 9. Starter motor 10.Fuses ABS control unit pin out key:...
Page 355 Moto Guzzi California 1400 Braking system Front speed sensor ground PIN 13 Front speed sensor signal PIN 14 Vehicle identification (2) PIN 15 Serial K line for diagnostics PIN 16 Battery power PIN 18 Foreword key: 1. Rear brake calliper 2.
Page 356 Moto Guzzi California 1400 Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit BRAK SYS - 356...
Page 357 Moto Guzzi California 1400 Braking system 5. Rear brake pump 6. Rear brake pedal control 7. ABS control unit 8. Rear brake calliper 9. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open) 11.Humidifier 12.Rear brake circuit intake solenoid valve (normally open) 13.Rear brake exhaust circuit solenoid valve (normally closed)
Page 358 Moto Guzzi California 1400 Braking system D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider.
Page 359 Moto Guzzi California 1400 Braking system Riding with an active ABS system • At engine starter, the ABS warning light (5) on the instrument panel (4) flashes until the vehicle exceeds 5 km/h (3.1 mph). If the ABS warning light remains on when the...
Page 360 Moto Guzzi California 1400 Braking system - error code 5D93 requires some minutes before it is diagnosed during the given time: the ABS warning light ABS keeps flashing. ABS FAULTS - GUIDE TO THE DIAGNOSIS 1. ABS WARNING LIGHT ON 2.
Page 361 Moto Guzzi California 1400 Braking system P.A.D.S./Navigator characteristic Value/example Unit of Notes measure ment Software version Vehicle code The vehicle code stored in the control unit is read. Vehicle identification according to A different type of vehicle is associated with each...
Page 362 Moto Guzzi California 1400 Braking system ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. ACTIVATION P.A.D.S./Navigator characteristic Value/example Unit of Notes measure...
Page 363 Moto Guzzi California 1400 Braking system ERRORS screen page This screen page displays any errors detected in the vehicle (ATT) or stored in the control unit (MEM) and you can check that the cancellation of error (STO) has taken place.
Page 364 Moto Guzzi California 1400 Braking system P.A.D.S./Navigator characteristic Value/example Unit of Notes measure ment Rear speed sensor: excessive meas- Faulty sensor or tone wheel with wrong number of ured speed 5DA5 teeth or wrong tyre size Control unit: missing valve calibra-...
Page 365 Moto Guzzi California 1400 Braking system ADJUSTMENTS P.A.D.S./Navigator characteristic Value/example Unit of Notes measure ment Coding (1) Used for re-coding the control unit or coding a new one. Coding (2) The identification of the vehicle is carried out based on the injection control unit reading.
Page 366 Moto Guzzi California 1400 Braking system • Disconnect the ABS control unit con- nector. • Remove the ABS control unit. INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR • Check the initial position of the lever that couples the connector. •...
Page 367 Moto Guzzi California 1400 Braking system IT IS ADVISABLE TO CREATE A TEMPLATE TO CHECK THE CORRECT CONNECTOR IN- SERTION. • Fit the protection casing. Component maintenance The vehicle is fitted with a two-channel ABS sys- tem, i.e. it works on both the front and the rear wheel.
Page 368 Moto Guzzi California 1400 Braking system Disc Inspection REAR CAUTION THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI- FICATIONS OF THE SYSTEM. • The following operations are to be car- ried out with brake disc fitted on the wheel.
Page 369: Front Brake Pads
Moto Guzzi California 1400 Braking system Disc oscillation tolerance: 0.15 mm (0.0059 in), with respect to the wheel centre line. Front brake pads Removal • Undo and remove the two screws. • Slide off the brake calliper from the disc.
Page 370 Moto Guzzi California 1400 Braking system • Remove the vibration-damping plate. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
Page 371 Moto Guzzi California 1400 Braking system Rear brake pads Removal • Remove the lock and remove the pin. BRAK SYS - 371...
Page 372 Moto Guzzi California 1400 Braking system • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS. Installing •...
Page 373 Moto Guzzi California 1400 Braking system Bleeding the braking system VEHICLE PREPARATION • It is important to check that there is always enough brake fluid in the reservoir. • Using a bleed device facilitates these operations while, in the meantime, the "Brake fluid replacement"...
Page 374 Moto Guzzi California 1400 Braking system REPLACE THE ABS CONTROL UNIT VEHICLE PREPARATION • Connect the bleed bottle to the bleed screws of the front and rear callipers and open it. • Fully press down the lever and the brake pedal and fix them into position with the respective locking devices.
Page 375 Moto Guzzi California 1400 Braking system • Check the stroke and the sensitivity of both the lever and the brake pedal. • If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in the braking system and if everything is ok, continue bleeding operations using Navigator as described.
Page 376 Moto Guzzi California 1400 Braking system BLEEDING SYSTEM WITH DIAGNOSTICS INSTRUMENT This type of bleeding has to be carried out if after all the checks the brake lever and the pedal are still spongy. The operations described here are valid for both systems even though the description refers to the front system.
Page 377 Moto Guzzi California 1400 Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con- tainer to collect the fluid.
Page 378 Moto Guzzi California 1400 Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid.
Page 379 INDEX OF TOPICS BODYW ODYWORK...
Page 380 Moto Guzzi California 1400 Bodywork EAR MUDGUARD pos. Description Type Quantity Torque Notes Front fixing screws M8x20 25 Nm (18.44 lb ft) Upper fixing screw M8x16 25 Nm (18.44 lb ft) Side cover fixing screws M5x9 6 Nm (4.42 lb ft) Side cover fixing screws - Nm (-.-- lb ft)
Page 381 Moto Guzzi California 1400 Bodywork NDER ADDLE pos. Description Type Quantity Torque Notes Lower saddle compartment closing fixing 6 Nm (4.42 lb ft) screws Fixing screw closing upper and lower saddle M5x20 3 Nm (2.21 lb ft) compartment stainless steel ENTRAL BODYWORK pos.
Page 382 Moto Guzzi California 1400 Bodywork ANK COVER pos. Description Type Quantity Torque Notes Fairing fixing screws M5x10 6 Nm (4.42 lb ft) Dashboard fixing screw M5x16 5 Nm (3.68 lb ft) UEL TANK pos. Description Type Quantity Torque Notes Front fixing screw M8x16 25 Nm (18.44 lb ft)
Page 383 Moto Guzzi California 1400 Bodywork pos. Description Type Quantity Torque Notes Fuel pump fixing screw M5x20 6 Nm (4.42 lb ft) Fuel level sensor fixing nuts 5 Nm (3.69 lb ft) Screw fastening cap flange to tank M5x16 6 Nm (4.42 lb ft) RONT HEADLAMP pos.
Page 384 Moto Guzzi California 1400 Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws M5x12 4 Nm (2.95 lb ft) Engine guard (IF APPLICABLE) NGINE GUARD KIT pos. Description Type Quantity Torque Notes Engine guard upper fixing screws 50 Nm (36.2 lb ft)
Page 385 Moto Guzzi California 1400 Bodywork • The following procedure is described for one single engine guard, but is valid for both. • Unscrew and remove the screw indi- cated in the figure. • Position engine guard and secure it with the screw provided in the kit.
Page 386 Moto Guzzi California 1400 Bodywork • Rotate the engine guard to the left and secure it with the screw from the kit. • Finally replace the lower screw of the engine guard with the one supplied in the kit. •...
Page 387 Moto Guzzi California 1400 Bodywork IDE BUMPERS KIT pos. Description Type Quantity Torque Notes Bumpers front fixing screw M8x70 24 Nm (17.4 lb ft) Bumpers central fixing screw M8x25 24 Nm (17.4 lb ft) Bumpers rear fixing screw M8x50 24 Nm (17.4 lb ft)
Page 388 Moto Guzzi California 1400 Bodywork pos. Description Type Quantity Torque Notes Luggage rack upper fixing screws M8x25 25 Nm (18.4 lb ft) Luggage rack side fixing screws M8x20 25 Nm (18.4 lb ft) • First remove the rear handle. Working on both sides of the bike: •...
Page 389 Moto Guzzi California 1400 Bodywork INSTALLATION OF LUGGAGE RACK ON BIKE WITH PANNIERS • First remove the cases and the rear handle. Working on both sides of the bike: • Screw the spacer (1) into the bike frame. • Remove the screw (2).
Page 390: Instrument Panel
Moto Guzzi California 1400 Bodywork Instrument panel • Undo and remove the two front fixing screws of the instrument panel; during operation, take care to support it ade- quately. • Undo and remove the three fixing screws (1). • Remove the rear cover.
Page 391 Moto Guzzi California 1400 Bodywork • Disconnect the front headlamp con- nectors. • Unscrew and remove the fixing screw behind the headlight assembly. • Undo and remove the two side fixing screws. • Be careful to adequately support the headlight assembly before removing the screws.
Page 392 Moto Guzzi California 1400 Bodywork Additional lights • Undo and remove the three lower fixing screws (1) taking care to properly sup- port the additional headlamps. • Remove the two connectors (2) from the bulkhead, pulling slightly. • Disconnect the additional light connec- tors.
Page 393 Moto Guzzi California 1400 Bodywork Footrest • The following procedure is described for one single footrest, but is valid for both. • Disconnect the stop light connector. • Undo and remove the three fixing screws (1). NOTE BEFORE PROCEEDING WITH THE LEFT FOOTREST RE- MOVAL, DISCONNECT THE GEAR TIE ROD.
Page 394 Moto Guzzi California 1400 Bodywork • Remove the fixing clamp of the stop light switch (3). • Undo and remove the two fixing screws (2). • Remove the switch. • Unscrew and remove the fixing screw of the brake lever.
Page 395 Moto Guzzi California 1400 Bodywork GEAR LEVER REMOVAL • To remove the gear lever, unscrew the screw shown in the figure. PASSENGER FOOTREST • Unscrew and remove the four screws (1). • Unscrew and remove the rear screw. • Remove the passenger footrest.
Page 396 Moto Guzzi California 1400 Bodywork Side body panels • Operating from both sides, unscrew and remove the fixing screw. • Remove the side fairing. SADDLE RELEASE CONTROL REMOVAL • Remove the fork spring. • Disconnect the saddle release cable. •...
Page 397 Moto Guzzi California 1400 Bodywork • Remove the ignition switch assembly. License plate holder • Disconnect the light connector located under the rear mudguard. • Undo and remove the two fixing screws of the license plate support. • Remove the license plate support.
Page 398 Moto Guzzi California 1400 Bodywork Rear mudguard • First remove the rear handle. • Disconnect the connector of the li- cense plate light. • Unscrew and remove the lower fixing screw. See also Rear grab rail • Working from both sides, release the two side locks.
Page 399 Moto Guzzi California 1400 Bodywork • Undo and remove the turn indicator fix- ing screws. • Remove the wiring by its fasteners. • Remove the turn indicator. BODYW - 399...
Page 400: Fuel Tank
Moto Guzzi California 1400 Bodywork Fuel tank During the removal and refitting of the tank be very careful, in fact two types can be found: 1. Model "1" 2. Model "2" (Tank fitted on the USA version) In this case the difference is the number of breath- er pipes that are on the fuel pump side.
Page 401 Moto Guzzi California 1400 Bodywork • Undo and remove the two fixing screws of the tank cap cover. • Remove the cover. • Disconnect the two connectors of the fuel level sensor. BODYW - 401...
Page 402 Moto Guzzi California 1400 Bodywork • Working from both sides, undo and re- move the two side screws. • Unscrew and remove the rear screw. • Slightly lift the tank so as to be able to reach the connector. •...
Page 403 Moto Guzzi California 1400 Bodywork • Disconnect the two breather pipes (1) located under the tank. • Remove the tank. Rear wheelhouse • First remove the control unit, license plate support and side panniers sup- port. • Working from both sides, undo and re- move the two side fixing screws.
Page 404 Moto Guzzi California 1400 Bodywork • Unscrew and remove the two rear screws. See also License plate holder Pannier mounting • Working from both sides, undo and re- move the two screws on the side of the rear shock absorber.
Page 405 Moto Guzzi California 1400 Bodywork Front mudguard • Working from both sides, undo and re- move the two fixing screws (1). • Remove the front mudguard. Side panniers (IF APPLICABLE) BODYW - 405...
Page 406 Moto Guzzi California 1400 Bodywork • Open the top box using the key. • Undo and remove the four fixing screws (1), being careful to support the top box. • Remove the side top box. • Undo and remove the two bottom screws (2) and the side screw (3).
Page 407 Moto Guzzi California 1400 Bodywork • Insert the four clips (4). • Insert the eight rubber block clips (5). • Proceed with assembly of the side pan- niers, reversing the dismantling proce- dure and tightening the screws to the prescribed torque.
Page 408 Moto Guzzi California 1400 Bodywork • Fill in the recently made holes with the rubber rings insert (2), from the inside of the case. • Fix the reflector (3) on the support (4) with the nuts (5). • Fix all together on the cases with the two screws (6).
Page 409 Moto Guzzi California 1400 Bodywork Pannier mounting The following steps are described for only one side of the frame but apply to both. • Undo and remove the screw fixing the passenger footrest to the pannier hold- er frame. •...
Page 410 Moto Guzzi California 1400 Bodywork pos. Description Type Quantity Torque Notes Top box attachment plate fastening screws M6x20 10 Nm (7.37 lb ft) • First install the luggage rack. • Secure the attachment plate (1) to the luggage rack (2) using the four screws (3) complete with pads (4), bushes (5), washers (6) and self-locking nuts (7).
Page 411 Moto Guzzi California 1400 Bodywork • Secure the cover (8) to the plate (1) using the four screws (9). Rear grab rail (Touring) • First remove the saddle. • Undo and remove the three fixing screws (1) of the rear handle.
Page 412 Moto Guzzi California 1400 Bodywork • Remove the saddle. • Undo and remove the three fixing screws (1). • Remove the rear handgrip (2). • Collect the two washers (3). • Loosen and remove the three screws (4). • Remove the cover (5).
Page 413 Moto Guzzi California 1400 Bodywork Windscreen INDSHIELD KIT Position Description Quantity Windshield frame fixing screws kit (TBEI M6x20 stainless) Windshield frame-upper steering yoke fixing screws kit (TCEI M6x25 stainless) Frame-lower mounting bracket fixing screws (TSEI M6x40 stainless) Lower mounting bracket-lower steering yoke fixing screws (TBEI M6x20)
Page 414 Moto Guzzi California 1400 Bodywork the cable grommet in the right bracket (11). • Using the upper bayonet mount, con- nect the frame, complete with wind- shield, to the fasteners (2) which have just been assembled. • Secure the lower mounting bracket (5) to the lower steering yoke using the two screws (4).
Page 415 Moto Guzzi California 1400 Bodywork • Disconnect the two battery cables starting from the negative and then move to the positive. • Remove the battery. BODYW - 415...
Page 416 INDEX OF TOPICS PRE DE DELIVERY...
Page 417 Moto Guzzi California 1400 Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. CAUTION USE THE DIAGNOSTIC TOOL TO CHECK FOR ANY ERRORS AND CHECK THAT ALL PARAM- ETERS ARE CORRECT. ENSURE THAT THE VEHICLE CALIBRATION HAS BEEN UPDATED TO LATEST VERSION AVAILABLE, AFTER UPDATING THE DIAGNOSTIC TOOL.
Page 418: Road Test
Moto Guzzi California 1400 Pre-delivery - Helmet compartment electrical opening switch (if present) - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 419 Moto Guzzi California 1400 Pre-delivery - Instrument panel operation - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive:...
Page 420 Moto Guzzi California 1400 Pre-delivery Specific operations for the vehicle ANTI-THEFT DEVICE • Remove the left fairing. • Cut the indicated clamp and free the LED connector. • Take half of the adhesive backed foam in the anti-theft device kit and stick it to the bottom of the anti-theft control unit.
Page 421 Moto Guzzi California 1400 Pre-delivery • Install the left side fairing on the bike. (ACCESSORY) EATED HANDGRIPS KIT pos. Description Type Quantity Torque Notes Counterweighted fastening screws M6x30 10 Nm (7.37 lb ft) • Remove both side fairings first. LEFT HEATED HANDGRIP INSTALLATION •...
Page 422 Moto Guzzi California 1400 Pre-delivery • Collect the fixing screws (5) from the heatable handgrip (4). • Position the heatable handgrip all the way, taking care to align the holes on the grip with those on the handlebar, and screw in the fixing screws (5).
Page 423 Moto Guzzi California 1400 Pre-delivery • Insert and secure to the handlebar us- ing the screw (10), the spacer (8) and the counterweight (9). RIGHT HEATED HANDGRIP INSTALLATION • Remove the brake master cylinder first. • Remove the counterweight (2), undo- ing the screw (1).
Page 424 Moto Guzzi California 1400 Pre-delivery • Insert the heatable handgrip (5) in the handlebar and connect the gas cables which were removed from the block earlier. • Close the accelerator control block, taking care to insert the peg in the dedi- cated hole on the handlebar.
Page 425 Moto Guzzi California 1400 Pre-delivery • Insert and secure to the handlebar us- ing the screw (8), the spacer (10) and the counterweight (9). HANDLEBAR • Unscrew and remove the four fixing screws (1) of the handlebar top U-bolts (2).
Page 426 Moto Guzzi California 1400 Pre-delivery REAR-VIEW MIRRORS • Fit the washer (1) and nut (2). • Screw in the nut (2). • Fit and screw in the counter-nut (3) without tightening completely. • Fit the mirror inside the counter-nut (3) as in the figure.
Page 427 Moto Guzzi California 1400 Pre-delivery • Connect the rear light assembly con- nector as indicated in the figure. (Touring SE) BACKREST CUSHION • Place the handgrip (1) in correspond- ence with the fixing holes of the back- rest cushion. •...
Page 428 ABS: 162, 354 Air filter: 66 Alternator: Battery: 116, 414 Brake: 369, 371 Brake calliper: Brake pads: 369, 371 Brake pump: CAN line: 163 Cardan shaft: 345 Clutch: 153, 217, 221, 269 Coil: 142 Connectors: 157 Crankcase: 268, 276 Crankshaft: 249, 252, 268, 271, 274 Cylinder: 46, 228, 236, 239, 240, 255, 256, 258, 260, 270 Desmodromic drum: 206 Display:...
Page 429 Headlight: 390 Heated handgrips: Identification: 10 Instrument panel: 390 Intake pressure sensor: 128 License plate holder: 397, 404 Luggage rack: Maintenance: 8, 58, 367 Maintenance Table: Mudguard: 398, 405 Oil filter: 64 Oil pressure sensor: 151 Oil sump: 285, 287 Primary shaft: 200, 205–207 Radiator: Rear wheel: 62, 336...

MOTO GUZZI B043157 Service Station Manual

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Section 2

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Type Quantity Torque

Type Quantity Torque

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