MOTO GUZZI California EV V1100 Service Station Manual
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MOTO GUZZI California EV V1100 Service Station Manual

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SERVICE STATION MANUAL
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California EV V1100

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Summary of Contents for MOTO GUZZI California EV V1100

  • Page 1 SERVICE STATION MANUAL ????? California EV V1100...
  • Page 2 Countries. Third party products or services referred to in this manual should be considered only informative and are not binding. Moto Guzzi s.p.a. shall not be liable for any functions or use of these products.
  • Page 3 SERVICE STATION MANUAL California EV V1100 NOTE Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

  • Page 5: Index Of Topics

    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 CLU SYS LUTCH SYSTEM BODYW ODYWORK...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    California EV V1100 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 California EV V1100 Characteristics Brake and clutch fluid BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM- PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS.
  • Page 9 CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH- ERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.

  • 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 California EV V1100 Characteristics ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE FRAME NUMBER IMMEDIATELY VOIDS THE WARRANTY. This number consists of numbers and letters, as in the example shown below. ZGUKDBKDXMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code;...

  • Page 12: Electrical System

    California EV V1100 Characteristics Specification Desc./Quantity Gearbox 5 speed mechanical gearbox with gears always engaged to the front joint. Built-in flexible couplings. Foot gear shift lever on left hand side of engine Gear ratio 1st gear : 14/28 = 1:2.0000 2nd gear : 18/25 = 1:1.3889...

  • Page 13: Tightening Torques

    California EV V1100 Characteristics Specification Desc./Quantity Pump diameter: 13 mm (0.51 in) Rear brake Integral braking system with braking corrector and delay valve Ø 282-mm (11.1 in) stainless steel fixed disc, floating calliper with 2 pins. Foot gear shift lever placed on the right side of the vehicle.
  • Page 14 California EV V1100 Characteristics SELECTED DIAMETER CYLINDERS UP TO ENGINE NO.KD030428 Specification Desc./Quantity Selection class A 92.000 - 92.006 mm (3.62204 - 3.62227 in) Selection class B 92.006 - 92.012 mm (3.62227 - 3.62250 in) Selection class C 92.012 - 92.018 mm (3.62250 - 3.62275 in) SELECTED DIAMETER PISTONS UP TO ENGINE NO.KD030428...
  • Page 15 California EV V1100 Characteristics Piston rings Check the sealing piston rings and the oil scraper. On each piston there are: 1 top piston ring; 1 middle stepped piston ring; 1 oil scraper piston ring. The ends of the fitted piston rings are out of phase.
  • Page 16 California EV V1100 Characteristics Specification Desc./Quantity Tappet external diameter 22.046 - 22.028 mm (0.86795 - 0.86724 inch) Fitting clearances 0.004 - 0.043 mm (0.00016 - 0.00169 in.) TAPPET-SEAT COUPLING ON CRANKCASE DATA (GREATER ON Ø 0.10 ) (0.0039 Specification Desc./Quantity Seats diameter 22.121 - 22.100 mm...
  • Page 17 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 18 California EV V1100 Special tools SPECIAL TOOLS Stores code Description 65.92.84.00 Graduated dial hub 19.92.96.00 Graduated dial to control ignition timing 17.94.75.60 Arrow to control ignition timing 12.91.36.00 Tool to remove the flywheel-side flange 12.91.18.01 Tool to lock the flywheel and the starting ring gear 10.90.72.00...
  • Page 19 California EV V1100 Special tools Stores code Description 03.90.65.55 Tool for clutch fitting 12.90.59.00 Clutch shaft removal 14.92.71.00 Tool to fit the sealing ring on the flywheel- side flange 12.91.20.00 Tool to fit the flywheel-side flange togeth- er with seal ring on the crankshaft 14.92.72.00...
  • Page 20 California EV V1100 Special tools Stores code Description 14.90.54.00 Secondary shaft locking nut 14.91.31.00 Extractor for needle bearing for main shaft on the box and for clutch shaft on cover 14.92.85.00 Tool to slide off the inner track of the clutch shaft bearing 17.94.92.60...
  • Page 21 California EV V1100 Special tools Stores code Description 17.94.83.60 Extractor for inner track of the roller bear- ing on the drilled pin on the box 17.94.84.60 Tool to press the inner track of the roller bearing on the drilled pin on the gear case 17.94.88.60...
  • Page 22 California EV V1100 Special tools Stores code Description 14.92.88.00 Punch to press the roller bearing for the main shaft on the box and for clutch shaft on the cover 14.92.90.00 Punch to press the ball bearing for main shaft on the cover 14.92.94.00...
  • Page 23 California EV V1100 Special tools Stores code Description 19.92.71.00 Tool to fit the seal ring on the flywheel- side flange 14.92.96.00 Gearbox support GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body Special tools are necessary for correct removal and refitting and a good set-up. The use of special tools prevents possible damages that could be caused by inadequate tools and/or improvised techniques.
  • Page 24 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 25: Maintenance Chart

    California EV V1100 Maintenance Maintenance chart NOTE 1,000 (621 Action Engine oil - check 1,500 (932 Action Engine oil - Change Cartridge-type oil filter - Replace Mesh oil filter - Clean Spark plugs - Inspect, clean, adjust or replace if necessary...

  • Page 26: Spark Plug

    California EV V1100 Maintenance Action Mesh oil filter - Clean Air filter - Replace Spark plugs - Inspect, clean, adjust or replace if necessary Carburetion - Inspect, clean, adjust or replace if necessary Bolt, nut and screw tightening - Check and clean, adjust, grease or replace if necessary...

  • Page 27: Transmission Fluid

    California EV V1100 Maintenance • Even if the spark plug appears to be in good condition, it will be replaced after approximately 10000 Km (6213 MI), as shown in the regular maintenance table. CAUTION IN ORDER TO AVOID CAUSING MALFUNCTIONS AND INEFFICIENCY IN THE IGNITION SYSTEM,...

  • Page 28: Engine Oil

    California EV V1100 Maintenance • Place a container with suitable capacity under the drainage plug (3). • Unscrew and remove the drainage plug (3). • Unscrew and remove the filling plug (2). • Drain the oil into the container; allow several minutes for oil to drain out completely.
  • Page 29 California EV V1100 Maintenance • Check oil level by means of the oil dip- stick. • The oil level is correct when it close to the "MAX" mark. MAX = maximum level MIN = minimum level Add engine oil if required: •...

  • Page 30: Engine Oil Filter

    California EV V1100 Maintenance • Unscrew and remove the filler plug with dipstick. • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Check and, if necessary, replace the drainage plug sealing washers.

  • Page 31: Gearbox Oil

    California EV V1100 Maintenance MESH ENGINE OIL FILTER • Undo the screw. • Remove the mesh filter. • Wash the mesh filter in petrol. • Blow the filter with a jet of compressed air. • Refit the mesh filter in the oil sump, af- ter having blown the sump channels with compressed air.

  • Page 32: Fuel Filter

    California EV V1100 Maintenance • Place a container with suitable capaci- ty under the drainage plug (3). • Unscrew and remove the drainage plug (3). • Unscrew and remove the filler plug (2). • Drain the oil into the container; allow several minutes for oil to drain out com- pletely.

  • Page 33: Air Filter

    California EV V1100 Maintenance • Install a new fuel filter paying attention to the direction indicated by the arrow on it. • Refit all previously removed parts. DO NOT MOUNT THE FUEL FILTER IN THE OPPOSITE DI- RECTION. Air filter •...
  • Page 34 California EV V1100 Maintenance Throttle grip cables replacement ACCELERATOR CONTROL The throttle control handgrip, in all steering posi- tions, must have a free play of 1.5 - 2 mm (0.059 - 0.079 in). If required, adjust it; act on the specific adjuster screws (A) located in the control itself.

  • Page 35: Checking The Valve Clearance

    California EV V1100 Maintenance • Remove the cables (D) from the throt- tle body (G) • Loosen the two screws (C) and slide the throttle control together with the ca- bles off the handlebar. Checking the valve clearance CAUTION IF CLEARANCE IS LARGER THAN RECOMMENDED, THE TAPPETS WILL BE NOISY. OTHER- WISE, THE VALVES DO NOT CLOSE CORRECTLY, WHICH CAN LEAD TO PROBLEMS SUCH •...

  • Page 36: Braking System

    California EV V1100 Maintenance HYDRAULIC TAPPET: It is not necessary to perform the valve clearance as the hydraulic tappets automatically cancel the valve clearance during the engine operation, al- ways keeping the camshaft in contact with the bucket tappets. Braking system...

  • Page 37: Index Of Topics

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 38 California EV V1100 Electrical system Electrical system installation General wiring diagram key: ELE SYS - 38...
  • Page 39 California EV V1100 Electrical system 1 High beam light 60W (H4 Halogen with low beam light) 2 Daylight running light 5W 3 Low beam light 55W (H4 Halogen with high beam light) 4 Headlight 4-way Amp connector 5 Front right turn indicator 10W...
  • Page 40 California EV V1100 Electrical system 39 Right heated handgrip 40 2-way connector 41 Ignition switch 42 4-way AMP connector 43 IAW 15RC control unit 44 Air temperature sensor (NTC ATS05) 45 3-way AMP diagnosis connector 46 4-way AMP lambda probe connector...
  • Page 41 California EV V1100 Electrical system CHECK THE WINDING ISOLATION TOWARDS EARTH Connect one connecting point of the ohmmeter to one of the two yellow cables and the other connecting point to earth (laminar pack). The instrument should indicate a value above 10 MW.
  • Page 42 California EV V1100 Electrical system Start-up system check ENERAL SPECIFICATIONS Specification Desc./Quantity Voltage 12 V Power 1.2 kW No-load torque 11 Nm Load torque 4.5 Nm Pinion z=9 module 2.5 Rotation (pinion side) Anticlockwise Speed 1750 rpm No-load current 600 A...
  • Page 43 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...

  • Page 44: Vehicle Preparation

    California EV V1100 Engine from vehicle Vehicle preparation To proceed with the removal of the engine/gear unit from the motorcycle, operate as follows: • Remove the front seat and lift the tool holder container. • Remove the battery after having disconnected the cables from the 2 poles (negative/posi- tive).
  • Page 45 California EV V1100 Engine from vehicle • Loose the clamps fixing the throttle body to the intake pipe. • Disconnect the gear lever tie rods and rear brake lever. • Slide the oil breather pipes from the joints on the engine crankcase and on...
  • Page 46 California EV V1100 Engine from vehicle • Remove the rear footrests. • Operating from both sides, unscrew and remove the two screws and re- move the two footrest supports. • At the same time release the cradles at the rear end from the chassis.
  • Page 47 INDEX OF TOPICS NGINE...
  • Page 48 California EV V1100 Engine Gearbox Diagram key: 1 Secondary shaft 2 Nut 3 Adjustment washer 4 Thrust washer 5 Gear 4a A.S. (Z=20) 6 Inner ring 4a 7 Roller cage 4a A.S. 8 Sleeve 3a-4a A.S. 9 Sleeve 10 Washer...
  • Page 49 California EV V1100 Engine 11 Gear 3a A.S. (Z=22) 12 Bushing 1a-2a-3a A.S. 13 Gear 2a A.S. (Z=25) 14 Nut 15 Ball 16 Washer 17 Gear 5a A.S. (Z=21) 18 Gear 1a A.S. (Z=28) 19 Sliding sleeve 1a-2a A.S. 20 Grooved drum 21 Washer 22 Adjustment washer 0.6 mm (0.024 in)

  • Page 50: Removing The Gearbox

    California EV V1100 Engine 46 Thickness 47 Main shaft 48 Shim washer th. 2.0 mm (0.079 in) 48 Shim washer th. 2.1 mm (0.083 in) 48 Shim washer th. 2.2 mm (0.087 in) 48 Shim washer th. 2.4 mm (0.094 in) 49 Roller bearing 50 Gear 5a A.P.
  • Page 51 California EV V1100 Engine Disassembling the gearbox To disassemble the gear in its elements operate as follows: • Lock the gear support tool in vice and mount the complete gear on the sup- port. • To be able to easily perform the re- moval, it is recommended that the gear in neutral position.
  • Page 52 California EV V1100 Engine • Remove the clutch outer body (1), the thrust bearing (2), the inner body (3) and the clutch control rod (4) from the seat on the cover. • From the clutch side, undo the ring nut...
  • Page 53 California EV V1100 Engine • Unscrew and remove the neutral indi- cator (7). • Undo and remove the cap (8) (used to hold the speed retaining pawl on the grooved drum). • Remove the spring. NOTE THE PAWL REMAINS IN THE HOLE OF THE BOX AND WILL BE RECOVERED AFTER HAVING COMPLETELY RE- MOVED THE GEARBOX UNIT.
  • Page 54 California EV V1100 Engine • Extract the ball bearing (14) for the main shaft with the extractor code 14907000. • Extract the roller bearing (15) for the clutch shaft with the extractor code 14913100. • Undo the screws (16) and remove the safety plate (17).
  • Page 55 California EV V1100 Engine Removing the secondary shaft • Slide off the 5th gear (1), recovering the shim (4). • Slide off the 1st gear (2) with the relative roller cage (3), remove the rubber seal ring, slide off the bushing (5) and remove the sliding sleeve (6) of the 1st and 2nd gear.
  • Page 56 California EV V1100 Engine Disassembling the clutch shaft • With the extractor code 14928500, slide off the inner track of the roller bearing and the thickness nut (1). • Then place the complete shaft on a press and with a special extractor code 12905900 com- press the spring so far to be able to slide off the two flexible coupling cap sealing semi- sectors (2) and slide off: - The cap (3);...

  • Page 57: Checking The Secondary Shaft

    California EV V1100 Engine Check that it is smooth and not scored or distorted, otherwise replace it. Push spring for bushing roller for 5th gear Check that it is still flexible and is not deformed. The spring compressed to 8 mm (0.31 in) must provide a load of Kg 1.40 (3.1 lb) + or - 5%.

  • Page 58: Checking The Gearbox

    California EV V1100 Engine Flexible coupling caps on the clutch shaft It does not require any verification, only check that the inner grooves are smooth. Flexible coupling springs on the clutch shaft Check that they are not deformed or have lost elasticity, otherwise replace them.
  • Page 59 California EV V1100 Engine - Bearing for secondary shaft on the housing. - Bearing for secondary shaft on the cover. Pressing of bearings in their seats on the gearbox To press the bearings on the gearbox operate as follows: •...
  • Page 60 California EV V1100 Engine Fitting of the seal rings on the gearbox for clutch shaft and on the cover for secondary shaft and pre-selector shaft The fitting of the seal ring for clutch shaft on the gearbox is performed with a special punch code 14929400.
  • Page 61 California EV V1100 Engine Refitting the primary shaft on the box The primary shaft before being refitted on the box, must be shimmed so that between the bearing box and the bearing on the cover there is a measurement equal to 167.1 - 167.2 mm (6.578 - 6.583 in). To obtain such a measure it is necessary to act on the shim washers, these washers are supplied in sizes of 2.0 - 2.1 - 2.2 - 2.4 mm (0.0787 - 0.0827 - 0.0866 - 0.0945 in).
  • Page 62 California EV V1100 Engine 14.92.86.00 Tool to drive the inner bearing ring on the secondary shaft On the cover side shaft • The 1st and 2nd coupling sleeve on the shaft. • The bushing for 1st gear with head directed towards the 2nd gear.
  • Page 63 California EV V1100 Engine Insert the grooved drum together with shims in the box and fit: The 1st- 2nd - 3rd - 4th gear shift forks on the slid- ing sleeve on the secondary shaft. Looking through the hole of the speed retaining pawl, it must appear one of the six niches for speed retaining on the drum in axis with the said hole.
  • Page 64 California EV V1100 Engine • Insert the inner track of the roller bear- ing with special tool code 17945460 to press it on the shaft. Specific tooling 12.90.59.00 Clutch shaft removal 17.94.54.60 Tool to drive the inner bearing ring on the main shaft and on the clutch shaft Then fit on the box side shaft: The seal ring into the specific groove on the shaft.
  • Page 65 California EV V1100 Engine • Place the gasket on the box.. • Temporarily secure the cover with four screws. • Insert the transmission shaft on the cover and screw it tight. • Insert the sealing ring (OR) (7), the thickness washer (8), the crown of the odometer transmission and the retain- ing ball on the secondary shaft.
  • Page 66 California EV V1100 Engine of difficulty of the shifting from 2nd to 4th gear. The shimming washers are supplied in the follow- ing sizes: 0.6 - 0.8 - 1 - 1.2 mm (0.0236 - 0.0315 - 0.0394 - 0.0472 in).
  • Page 67 California EV V1100 Engine The inner body (10) of the clutch on the shaft. The safety washer (11). The ring nut (12) locking the inner body on the clutch shaft. To lock the ring nut to use tool code 30912810 and hook spanner code 14912603.

  • Page 68: Gear Selector

    California EV V1100 Engine transmission is housed shall be 75 mm (2.95 in). Gear selector Checking the gear selector Check that the control rocker on the pegs of the grooved drum is not hardened, and that the two nibs are not ginned, otherwise replace it.

  • Page 69: Installing The Flywheel

    California EV V1100 Engine • Check that the contact faces on the crankshaft are not distorted; if they are, replace the flywheel. Installing the flywheel • Position the flywheel. NOTE RESPECT THE FLYWHEEL POSITIONING REFERENCES. CAUTION <span style="FONT-SIZE: 12pt; FONT-FAMILY: "Times New Roman";...

  • Page 70: Installing The Generator

    California EV V1100 Engine With engine unit removed • Unscrew the four screws and remove the alternator cover. • Slide off the rubber and the plastic flange. • Apply the specific locking tool on the engine flywheel. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear •...

  • Page 71: Removing The Starter Motor

    California EV V1100 Engine Removing the starter motor • Undo and remove the two screws and collect the washers. • Slide off the starter motor. Clutch side OPTION 01 Single plate clutch key: 1. Clutch cover 2. Cup spring 3. Inner clutch plate 4.

  • Page 72: Disassembling The Clutch

    California EV V1100 Engine 16.Pin 17.Crown gear OPTION 02 Dual plate clutch key: 1. Clutch cover 2. Clutch spring 3. Cap 4. Complete clutch discs 5. Inner clutch plate 6. Cap 7. Rod 8. Bushes 9. Intermediate body 10.Thrust bearing 11.Outer body...
  • Page 73 California EV V1100 Engine • Apply the locking tool on the engine flywheel. • Loosen the six screws (4) fixing clutch and flywheel. • Undo the six screws (5) and remove the flywheel-clutch unit (6). Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear •...
  • Page 74 California EV V1100 Engine • Undo and remove the eight sealing screws from the crown gear on the en- gine flywheel. • Remove the start-up crown gear. Extract from the inside of the engine flywheel: • the clutch plate. •...

  • Page 75: Checking The Clutch Plates

    California EV V1100 Engine • The second clutch plate. • The pressure plate disc cover. • The pressure plate disc with springs. Checking the clutch plates OPTION 01 Driven plate Check that the surfaces touching the crown gear and the inner disc are perfectly smooth and even, otherwise replace it.

  • Page 76: Checking The Clutch Housing

    California EV V1100 Engine Crown gear for start-up Check that the supporting surface with the driven plate is perfectly smooth and even. Also check that the toothing where the starter motor pinion works is not chipped or scratched; otherwise, replace it.
  • Page 77 California EV V1100 Engine • Reassemble the flywheel- clutch unit on the bench respecting the alignment of the marks (1) and (2). • Tighten without locking the six fixing screws (3). • Position the flywheel-clutch unit in the seat on the engine, in accordance with...
  • Page 78 California EV V1100 Engine Insert the components in the clutch housing in the following order: • The pressure plate with springs. • Make sure that the reference marked on the pressure plate tooth is aligned with the reference on the flywheel.
  • Page 79 California EV V1100 Engine • The intermediate plate. • The clutch plate. • Place the crown gear aligning its refer- ence with that on the flywheel. • Tighten the eight screws holding the crown gear to the flywheel to the prescribed torque •...

  • Page 80: Removing The Head Cover

    California EV V1100 Engine • Insert the pressure plate disc cover. • Install the gearbox unit. Head and timing Removing the head cover • Undo and remove the screws securing the head cover. • Remove the head cover. NOTE THE UPPER FIXING SCREWS HAVE A WASHER WHILE THE LOWER ONES DO NOT HAVE ONE.
  • Page 81 California EV V1100 Engine • Remove the spark plug. • Turn the crankshaft bringing the left cylinder piston to the TDC in combus- tion phase. NOTE THIS OPERATION CAN BE CARRIED OUT EVEN WHEN THE GEAR IS ASSEMBLED TO THE ENGINE BLOCK, AS THE POSITION OF THE NOTCH CAN BE VERIFIED BY THE APPROPRIATE HOLE.

  • Page 82: Cylinder Head

    California EV V1100 Engine • Unscrew and remove the threaded cap. • Unscrew and remove the joint of the pipe that delivers oil to the head and collect the washer. • Undo and remove the four nuts. • Remove the rocker support.

  • Page 83: Removing The Valves

    California EV V1100 Engine Removing the rocker arms NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Remove the head cover. • Rotate the crankshaft to TDC position in com- bustion phase (closed valves) for the left cylinder.

  • Page 84: Checking The Rocker Arms

    California EV V1100 Engine • Tighten the tool screw until fitted, and then hit the tool head (where the upper retainer works) with a mallet so that the two cotters (1) get detached from the upper retainer (2). • Once the two cotters (1) are detached, screw these cotters until they can be slid off the valve seats;...

  • Page 85: Checking The Valve Guides

    California EV V1100 Engine • With open valve, it has a length of 22 mm (0.87 in) and must provide a load of 27.4 kg (60.4 lb) ± 3%. • Packed, it has a length of 19.75 - 20.25 mm (0.777 - 0.797 in).

  • Page 86: Checking The Cylinder Head

    California EV V1100 Engine • Lubricate the valve guide. • Fit the circlips. • Press a punch with the valve guides. • Use a reamer to bore the holes the valve stems slide through so that the inside diameter is at the prescribed val- ue.

  • Page 87: Installing The Valves

    California EV V1100 Engine Installing the valves NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Place the valve (6) inside the head. • Place the lower cap (5) and the shim- ming washers.

  • Page 88: Chain Removal

    California EV V1100 Engine Chain removal • Remove the engine unit. • Remove the alternator. • Undo the fourteen screws. • Remove the timing system cover. • Note the timing system marks so as to restore correct timing at the next refit- ting (TDC of the left cylinder).
  • Page 89 California EV V1100 Engine • After unscrewing the nut (4) that se- cures the oil pump control gear, re- move the three gears together with the chain. Remove the chain tensioner of the timing system by unscrewing the fixing screws.

  • Page 90: Removing The Camshaft

    California EV V1100 Engine • With a specific tool (1) commercially available extract the hydraulic tappet • Using a piece of thin metal wire (3), press on the inner ball of the tappet (2) using the upper hole; • Direct the tappet downwards and pump until discharging the residual oil;...
  • Page 91 California EV V1100 Engine • Remove the tappets. • Remove the rods. • Unscrew and remove the three screws and collect the washers. • Remove the flange. • Remove the camshaft. See also Chain removal Removing the phonic wheel Removing the tappets...
  • Page 92 California EV V1100 Engine Specification Desc./Quantity Tappet external diameter 21.996 - 21.978 mm (0.86598 - 0.86527 inch) Fitting clearances 0.004 - 0.043 mm (0.00016 - 0.00169 in.) TAPPET-SEAT COUPLING ON CRANKCASE DATA (GREATER ON Ø 0.05 ) (0.00197 Specification Desc./Quantity Seats diameter 22.071 - 22.050 mm...

  • Page 93: Checking The Camshaft

    California EV V1100 Engine Checking the camshaft CAMSHAFT (CAM) SUPPORT DIAMETER AND THEIR SEATS ON THE CRANKCASE (TIMING SYSTEM SIDE) Specification Desc./Quantity Shaft support diameter 47.000 - 46.984 mm (1.85039 - 1.84976 inch) Seat diameter on crankcase 47.025 - 47.050 mm...

  • Page 94: Installing The Camshaft

    California EV V1100 Engine Specification Desc./Quantity (1.85137 - 1.85236 inch ) fitting clearance 0.025 - 0.066 mm (0.00098 - 0.00260 inch) CAMSHAFT (CAM) SUPPORT DIAMETER AND THEIR SEATS ON THE CRANKCASE (FLYWHEEL SIDE) Specification Desc./Quantity Shaft support diameter 32.000 - 31.984 mm (1.25984 - 1.25921 inch)
  • Page 95 California EV V1100 Engine • Rotate the crankshaft until the left cylinder piston is actually at the top dead centre (with valves closed). • Reset the dial gauge and make sure the references (on the timing system gears and the...

  • Page 96: Removing The Cylinder

    California EV V1100 Engine Measuring air gap • Place the tone wheel with the mill toothing part from the opposite side to the one of the timing sensor. • Check with a feeler gauge inserted be- tween the ends of the timing sensor and the surface of the teeth of the tone wheel, that the air gap is between 0.7...

  • Page 97: Disassembling The Piston

    California EV V1100 Engine Disassembling the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS. • Remove the cylinder. • Cover the crankcase opening with a clean cloth. • Release the snap ring.

  • Page 98: Crankcase - Crankshaft

    California EV V1100 Engine • Lubricate the piston and the cylinder. • Place the cylinder. CAUTION DURING THIS OPERATION, PAY ATTENTION NOT TO DAMAGE THE PISTON. • Place the gasket on the cylinder base. • Install the head. See also...
  • Page 99 California EV V1100 Engine Disassembling the connecting rod • Remove the heads. • Remove the cylinders and the pistons. • Remove the clutch. • Remove the flywheel. • Remove the timing system. • Remove the oil sump. • Loosen the coupling screws 'A' from inside the crankcase and remove the connecting rods 'B'.
  • Page 100 California EV V1100 Engine MAIN JOURNAL DIAMETER ON THE TIMING SYSTEM SIDE (A) Specification Desc./Quantity Main journal regular production 37.975 mm (1.49507 inch) 37.959 mm (1.49444 inch) CRANKPIN DIAMETER (B) Specification Desc./Quantity Regular production 44.008 - 44.020 mm - (1.73259 - 1.73307 in) Undersized diameter: 0.254 mm (0.01000 in)
  • Page 101 California EV V1100 Engine CONNECTING ROD BEARING THICKNESS Specification Desc./Quantity Connecting rod bearing regular (production) 1.535 - 1.544 mm (0.06043 - 0.06079 in) Bearing for pin diameter of undersized rod bearing: 0.254 mm 1.662 - 1.671 mm (0.06543 - 0.06578 in) (0.01000 in)

  • Page 102: Installing The Crankshaft

    California EV V1100 Engine Assembling the connecting rod • Place the connecting rods (B) on the crankshaft. • Proceed with the refitting, remember- ing that: - The screws (A) fixing the connecting rods to the crankshaft must be replaced with new ones at the following refitting as they are subject to high loads and stress;...

  • Page 103: Oil Pump

    California EV V1100 Engine Conceptual diagrams The lubrication system is composed of the following parts: 1 oil sump 2 Mesh oil filter 3 Cartridge-type oil filter 4 Oil pressure transmitter 5 Engine oil pressure regulator valve 6 Oil Pump NOTE ON THE MODELS MY2003 THE RECYCLING PIPE "Y"...
  • Page 104 California EV V1100 Engine Removing The oil pump used is of the gear type and takes the motion from the crankshaft via a chain. • Drain all the engine oil. • Remove the alternator. • Remove the engine pinion, the timing system gear and the oil pump gear to- gether with the timing chain.
  • Page 105 California EV V1100 Engine See also Removing Removing the oil sump NOTE TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL. • Drain all the engine oil. •...

  • Page 106: Index Of Topics

    INDEX OF TOPICS P SUPP OWER SUPPLY...

  • Page 107: Circuit Diagram

    California EV V1100 Power supply Circuit diagram The fuel is injected in the intake duct of each cylinder, upstream of the intake valve. Including: tank, pump, filter, pressure adjuster, electro-injectors. The electric pump (1) sucks in fuel from the tank (3) and delivers it to the electro-injectors (2) by means of a filter.
  • Page 108 California EV V1100 Power supply Removing The electrical fuel pump unit consists of following: - electrical pump (1); - fuel filter (2); - pressure adjuster (3); - collapse protection pre-filter (4); - fuel level control sensor (5). It is recommended to properly clean the system when disassembling and fitting the piping and the components.

  • Page 109: Removing The Injector

    California EV V1100 Power supply Fuel filter • Remove the front saddle. • Disconnect the battery. • Remove the electrical fuel pump. • Remove the clamps and the fuel filter. See also Removing Injection Removing the injector With the injector is activated the control of the quantity of fuel introduced into the engine.

  • Page 110: Removing The Throttle Body

    California EV V1100 Power supply coming out from the nozzle (atomization), forming a cone of about 30°. Resistance value: 12 ohm. If you want to perform an electrical test in the in- jector, apply a maximum voltage of 6V, for very limited periods.
  • Page 111 California EV V1100 Power supply • Connect a vacuum gauge to the sockets on the intake manifolds. • Connect the diagnostic tool AXONE, using the specific cable to the diagnostic socket, and to the battery of the motorcycle (not an external battery).
  • Page 112 California EV V1100 Power supply • Connect the dipstick (1) of the left side throttle body. • Start the engine and bring the temper- ature to 50°C (122 ° F) (readable on AXONE) after selecting the engine temperature parameter. •...
  • Page 113 California EV V1100 Power supply IT CAN HAPPEN THAT AXONE BLOCKS DURING OPERA- TION. IN THIS CASE, PUT THE IGNITION KEY TO 'OFF', TURN OFF AXONE, PRESS 'ON / OFF', DISCONNECT THE UPPER CONNECTOR AND WAIT A FEW SECONDS BEFORE CON- NECTING THE CONTROL UNIT AGAIN.
  • Page 114 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 115: Removing The Front Wheel

    California EV V1100 Suspensions Front Removing the front wheel • Place a support under the motorcycle, which allows to lift the front wheel off the ground. • Remove the brake callipers. • Loosen the two screws fixing the pin to the fork legs.
  • Page 116 California EV V1100 Suspensions key: 1 Screw 2 Handlebar fixing U-bolt 3 Screw 4 Under U-bolt 5 Cap 6 Rubber ring 7 Fork head 8 Ring nut 9 Spacing pipe 10 Nut 11 Fork base 12 Screw 13 RH adjustment knob (ext.)
  • Page 117 California EV V1100 Suspensions 38 Upper bushing 39 Complete right fork leg 40 Long screw 41 Washer 42 Screw 43 Complete left fork leg 44 LH adjustment knob (compression) 45 LH pipe (compression) 46 LH rod (compression) 47 Cap 48 Calibration blade diam 12 mm (0.47 in) 48 Calibration blade diam 15 mm (0.59 in)

  • Page 118: Removing The Fork Legs

    California EV V1100 Suspensions • Both adjustment knobs have 15 adjust- ment positions (notches); • Turning clockwise (+) increases the re- bound, vice versa, anticlockwise (-) it decreases. NOTE DO NOT FORCE THE ADJUSTER SCREW IN THE END OF STROKE POSITION...

  • Page 119: Draining Oil

    California EV V1100 Suspensions Draining oil <span style="FONT-SIZE: 12pt; FONT-FAMILY: "Times New Roman"; mso-fareast-font-family: 'Times New Roman'; mso-ansi-language: IT; mso-fareast-language: IT; mso-bidi-language: AR-SA"> The vehicle is equipped with a hydraulic telescopic fork with separate adjustment for rebound and compression damping: The left stem works in extension while the right one in compression.
  • Page 120 California EV V1100 Suspensions • Empty the most possible the stanchion from the oil in its inside in a specific container. • Tighten the stanchion in vice and keep the tube in preload, not completely un- screw the lock nut to release the inner spring.

  • Page 121: Disassembling The Fork

    California EV V1100 Suspensions guage: AR-SA">BY PUMPING THE SHOCK ABSORBER WITH THE ROD, FROM THE END OF THE ROD, A JET OF COMPRESSED OIL ESCAPES, SO TO PREVENT DAMAGE TO PERSONS OR OBJECTS DIRECT THE END OF THE ROD TOWARDS A SPECIFIC CONTAINER.
  • Page 122 California EV V1100 Suspensions • Remove the locking ring inside the sleeve using a thin screwdriver. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM. • Remove the stem from the wheel hold- er sleeve together with the seal ring (1),...
  • Page 123 California EV V1100 Suspensions • Push the foot valve with the finger in- side the shock absorber casing. • With a screwdriver, remove the snap ring. • Push the foot valve with the shock ab- sorber rod out of the casing.
  • Page 124 California EV V1100 Suspensions • Remove the shock absorber rod with the pumping member unit from the cas- ing after having completely unscrewed the lock nut at its end. • Unscrew the nut (6) securing the cali- bration unit and remove all compo- nents.

  • Page 125: Checking The Components

    California EV V1100 Suspensions Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value.

  • Page 126: Filling Oil

    California EV V1100 Suspensions • O-Ring on the cap. Filling oil • Tighten the wheel holder sleeve in a vice. • Pour oil into the stem. • Pump the stem, making sure the oil has completely filled the pumping rod.

  • Page 127: Steering Damper

    California EV V1100 Suspensions • Screw the lock nut on the pumping member rod. So as to compress the spring. • Fix the fork upper cap up to the pump- ing member stem. • Place the upper cap on the bearing tube, taking care not to damage the O- ring.

  • Page 128: Steering Bearing

    California EV V1100 Suspensions Steering bearing • The steering pin is supported on the headstock of the frame with two ta- pered roller bearings (2). • To determine the assembly clearance of the bearings a nut (1) is screwed on the steering pin.

  • Page 129: Shock Absorbers

    California EV V1100 Suspensions Rear Shock absorbers Adjusting The motorcycle is equipped with shock absorbers with hydraulic rebound damping adjustment. Turn the adjustment control on the ring nut (1) to adjust the shock absorber hydraulic rebound damping. Depending on the need and the load on the mo- torcycle, there are multiple adjustment positions;...

  • Page 130: Index Of Topics

    INDEX OF TOPICS CHAS HASSIS...

  • Page 131: Front Wheel

    California EV V1100 Chassis Wheels Front wheel Removal CALIFORNIA EV (1997-2000) The motorcycles can be equipped with 2 different types of wheel axle fixing: 1) The threaded part of the pin (1) comes out of the left fork leg and is fixed with a nut (2), the screws (3) ensure the seal.
  • Page 132 California EV V1100 Chassis 2) The pin (1) is screwed into the left fork leg that is threaded, the screws (3) ensure the seal. NOTE THIS TYPE OF FITTING WAS IMPLEMENTED UP TO FRAME NUMBER "KD115427" CALIFORNIA EV (2001) The above mentioned motorcycles are equipped from the first motorcycle produced with a pin that is screwed directly into the fork leg.
  • Page 133 California EV V1100 Chassis REMOVAL TYPE 2 • Place a support under the motorcycle, which allows to lift the front wheel off the ground • Remove the clamps as described for removal (1) • Loosen the 2 screws fixing the pin to the fork legs •...

  • Page 134: Rear Wheel

    California EV V1100 Chassis WHEEL AXLE Check the amount of distortion of the wheel axle: Turn the pin on a surface plate and check with a feeler gauge the maximum value of the distortion • Service limit 100 mm (3.94 in): 0.2 mm (0.0079 in)
  • Page 135 California EV V1100 Chassis • Place a stand under the swingarm so that the front wheel does not touch the ground • Remove the left silencer • Unscrew the screw-pin (A) for retaining the calliper holding plate (B) • Remove brake calliper (C) from the cal- liper holding plate (B) •...
  • Page 136 California EV V1100 Chassis • Remove the calliper holding plate (B) and the spacer (H) • Tilt the vehicle on the right side enough to be able to pull the wheel out of the swingarm and transmission box. WHEEL HUB REMOVAL REMOVAL •...
  • Page 137 California EV V1100 Chassis DRIVING WITH THE WRONG SPOKES TENSION G OR WITH ONE OR MORE BROKEN SPOKES MAY DAMAGE THE WHEEL AND CAUSE RISKS TO THE VEHICLE SAFETY AND STABILITY. ALWAYS COMPLY WITH THE INSTRUCTIONS ON THE MAXIMUM ALLOWED LOAD California EV 2001: •...

  • Page 138: Swinging Arm

    California EV V1100 Chassis As for California EV 2001 taking into account that the dowel (1) is not mounted on the BBS wheels and that the tightening torque indicative of the nipples is from 4 Nm (2.95 lbf ft) (minimum load) to 6 Nm (4.42 lbf ft) (maximum load).
  • Page 139 California EV V1100 Chassis Removing • Place the motorcycle on a solid base. • Remove the rear wheel. • Remove the rear transmission box. • Remove the rear mudguard. • Loosen the clamp to release the pro- tection cap. •...

  • Page 140: Cardan Shaft

    California EV V1100 Chassis Checking <span style="FONT-SIZE: 12pt; FONT-FAMILY: "Times New Roman"; mso-fareast-font-family: 'Times New Roman'; mso-ansi-language: IT; mso- fareast-language: IT; mso-bidi-language: AR- SA"> Check that the swingarm does not show bending or unsoldered parts, that the seats of the bearings...
  • Page 141 California EV V1100 Chassis Removing Checking Sleeve for transmission shaft and bevel pinion (1). The inner splines must be intact; free from grain or dents, otherwise replace it. Transmission shaft Seeger rings (2) Check that the rings are not cracked or have lost elasticity, otherwise replace them.
  • Page 142 California EV V1100 Chassis • Undo the eight seal screws and re- move the flange complete with crown unit. • With an extractor remove the outer track of the roller cage from the box. Specific tooling 12.90.69.00 Extractor for roller bearing ring from the gear case •...
  • Page 143 California EV V1100 Chassis • Using the special tool to lock the pinion shaft, loosen the seal nut. Specific tooling 12.90.71.00 Tool to lock the secondary shaft • Detach the pinion (7), the shimming washer (8), the outer tapered roller...
  • Page 144 California EV V1100 Chassis The shims are provided in six different sizes, namely: mm 0.8 - 0.9 - 1 - 1.1 - 1.2 - 1.3 (in 0.0315 - 0.0354 - 0.039 - 0.043 - 0.047 - 0.051). Check that the coupling surfaces are not scored or damaged.
  • Page 145 California EV V1100 Chassis Installing Outer track of tapered bearings on the casing To fit the outer tracks of the tapered bearings on the casing use a special punch. Specific tooling 17.94.51.60 Punch to press the outer track of the bearings on the box...
  • Page 146 California EV V1100 Chassis Fitting of the outer track of the roller bearing on the box To press the outer track of the roller bearing on the box. Specific tooling 17.94.88.60 Punch for outer track of bearing re- lated to the transmission box seal ring...
  • Page 147 California EV V1100 Chassis then tighten the screws (6) to the bot- tom. Crown - pinion coupling To check the coupling of the pinion and the crown spread the teeth of the pinion from the drive side, with red lead based grease. Using an arm extrac- tor and a spacer (7) keep the hub-crown unit slight- ly forced into the cover;...
  • Page 148 California EV V1100 Chassis • If the contact is like this, the pinion is too far away from the rotation axis of the crown: approach the pinion by in- creasing the spacer thickness between bearing and pinion. • If the contact is like this, the crown is...
  • Page 149 California EV V1100 Chassis NOTE TO BE SURE OF THE CORRECT REFITTING, MARK THE POSITION ON THE GEAR SELECTOR SHAFT (G) OF THE LEVER (F) WITH A MARKER BEFORE ANY REMOVAL CHAS - 149...

  • Page 150: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 151: Rear Brake Calliper

    California EV V1100 Braking system Rear brake calliper Removal • Completely drain off the hydraulic sys- tem. • Unscrew the hollow screw and remove the tube and the two gaskets from the calliper. • Undo the two screws fixing the sup- ports and remove the calliper.

  • Page 152: Front Brake Calliper

    California EV V1100 Braking system Front brake calliper Removal • Completely drain off the hydraulic sys- tem. • Unscrew the hollow screw and remove the tube and the two gaskets from the calliper. • Undo the two screws fixing the sup- ports and remove the calliper.

  • Page 153: Front Brake Pads

    California EV V1100 Braking system Rear brake disc Disc Inspection The brake disc must be perfectly clean, without rust, oil, grease or scales and shall not show deep scratches. If the disk has one of these anomalies, perform a thorough cleaning, if the defect still remains, the disc must be replaced.

  • Page 154: Rear Brake Pads

    California EV V1100 Braking system • Remove both pins. • 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 155 California EV V1100 Braking system • Remove the pin. • 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 156 California EV V1100 Braking system Installing • Insert two new pads, placing them so that the holes are aligned with the cal- liper holes. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. •...
  • Page 157 California EV V1100 Braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency.
  • Page 158 California EV V1100 Braking system • Refit and block the front brake oil reservoir cap. • Refit the rubber protection cover. Integrated Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper.

  • Page 159: Front Brake Pump

    California EV V1100 Braking system • Repeat the operation until the fluid draining into the container is air-bubble free. NOTE WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
  • Page 160 California EV V1100 Braking system Rimozione REAR BRAKE LEVER REMOVAL • Undo the 2 screws (A) and remove the cradle cover (B) • Remove the cotter pin (C) and slide off the pin (D) • Undo the screw (E) and remove the...
  • Page 161 California EV V1100 Braking system Removal: • Completely drain off the hydraulic sys- tem. • Remove the brake pipe (1). • Release the spring (2). • Undo the screw (3). • Remove the braking corrector (4). Refitting: • <span style="FONT-SIZE: 12pt; FONT-FAMILY: "Times New Roman"; mso-fareast-font- family: 'Times New Roman';...
  • Page 162 California EV V1100 Braking system SYSTEM ADJUSTMENT After the fitting of the spring code 03.66.88.01 to the braking corrector code 03.66.82.00 and on the swingarm, make sure the distance between the two couplings is 67 +/- 0.5 (2.64 +/- 0.02 in).
  • Page 163 INDEX OF TOPICS CLU SYS LUTCH SYSTEM...
  • Page 164 California EV V1100 Clutch system Removing the clutch master cylinder • Unscrew the 2 screws (D) securing the clutch lever support to the handlebar with the U-bolt (E) • Remove the rear view mirror • Move the protection cap (A) and dis-...
  • Page 165 INDEX OF TOPICS BODYW ODYWORK...
  • Page 166 California EV V1100 Bodywork Seat RIDER SADDLE Removal: • Unlock the saddle with the key (1) • Slightly lift the rear part of the saddle • Slide off the saddle (2) by moving it for- wards. CALIFORNIA EV (1997-2000) PASSENGER SADDLE Removal: •...

  • Page 167: Side Body Panels

    California EV V1100 Bodywork Removal: • Unscrew the 4 nuts that secure it to the inside of the rear mudguard Driving mirrors Removal: • Unscrew the upper nut (1), integral with the mirror, while holding the lower one (2) using the two keys as in the figure;...

  • Page 168: Rear Mudguard

    California EV V1100 Bodywork the ECU) and the air temperature sensor are posi- tioned upstream of the throttle valve. • Remove the front saddle. • Remove the fuel tank. • Remove the side fairings. • Loosen the clamps that secure the filter box to the throttle body and move the connection ducts to the outside.
  • Page 169 California EV V1100 Bodywork • Unscrew the nuts (2) fixing the mud- guard to the frame • Remove the panels (3) and the pack holder (4) • Remove the rear saddle (5) • Remove the mudguard with light fitted, sliding it off afterwards...

  • Page 170: Fuel Tank

    California EV V1100 Bodywork Removal: • Remove the front saddle • Disconnect the electrical connections between the main cable assembly and rear light wiring harness • Remove the rear saddle from the mud- guard • Remove the lateral panels (1) •...

  • Page 171: Front Mudguard

    California EV V1100 Bodywork • Disconnect the electrical connections (3) of the electric pump supply and of the fuel level sensor. • For USA versions also disconnect the pipe (4) of the petrol vapour recirculation system. • Remove the tank by placing it on a clean surface with the pump unit facing upwards.
  • Page 172 Air filter: 33 Alternator: Battery: 40 Brake: 151–154, 159, 160 Brake calliper: 151, 152 Brake disc: 153 Brake pads: 153, 154 Brake pump: 159, 160 Cardan shaft: 140 Chain: 88, 90, 91, 104 Clutch: 56, 57, 68, 69, 71, 72, 75, 76, 164 Crankcase: 15, 98 Crankshaft: 15, 98, 99, 102 Cylinder: 13, 80, 82, 84, 86, 90, 96–99, 164...
  • Page 173 Oil filter: 30 Oil sump: 105 Pistons: Primary shaft: 54, 56 Rear wheel: 134 Recommended products: 16, 32 Secondary shaft: 55, 57 Shock absorbers: 129 Spark plug: 26 Start-up: 42 Starter motor: 70, 71 Steering damper: 127 Tank: 108, 168, 170 Throttle body: 110 Transmission: 11, 27 Voltage regulator: 41...

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