MOTO GUZZI CALIFORNIA EV 1997-2000 Workshop Manual
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MOTO GUZZI CALIFORNIA EV 1997-2000 Workshop Manual

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WORKSHOP MANUAL
WERKSTATTHANDBUCH
ONDERHOUDS-EN
REPARATIEHANDBOEK

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Summary of Contents for MOTO GUZZI CALIFORNIA EV 1997-2000

  • Page 1 WORKSHOP MANUAL WERKSTATTHANDBUCH ONDERHOUDS-EN REPARATIEHANDBOEK...
  • Page 2 Kriterien der Gesetzgebungen der einzelnen Länder zu erfüllen, ohne daß das Handbuch umgehend überarbeitet werden muß. De inhoud van dit handboek is niet bindend en de firma Moto Guzzi behoudt zich dan ook het recht voor, indien dit nodig mocht zijn, om door haar wenselijk geachte wijzigingen aan onderdelen, accessoires, hulpstukken e.d.
  • Page 3 NDEX ECTIONS BSCHNITTS NHOUD ECTIES...

  • Page 4: Table Of Contents

    SEC. A ENERAL NFORMATION HOW TO CONSULT THIS MANUAL ....2 ABBREVIATIONS AND SYMBOLS ....2 GENERAL SAFETY REGULATIONS ....4 RULES FOR MAINTENANCE PROCEDURES..4 WARRANTY ............6 SEC. B ODEL EATURES IDENTIFICATION DATA ........2 LUBRICANTS AND REFILLING ....... 4 TECHNICAL SPECIFICATIONS .......
  • Page 5 SEC. G ONTROLS CLUTCH AND FRONT BRAKE CONTROL ..2 GEARBOX CONTROL ........4 REAR BRAKE CONTROL ......... 8 ACCELERATOR /STARTER CONTROL ... 10 SEC. H HASSIS STEERING ............2 HANDLEBAR ............. 4 FOOT RESTS ............ 6 SIDE STAND ............. 8 CHASSIS DIMENSIONS .........
  • Page 6 SEC. N EARBOX MAIN FEATURES ..........2 REMOVAL AND INSTALLATION ...... 6 DISASSEMBLY ..........10 CHECK AND OVERHAUL ......24 GEARBOX UNIT REASSEMBLY ON THE BENCH ............30 SEC. O RANSMISSION OUSING AND HAFT REAR TRANSMISSION HOUSING ....2 TRANSMISSION SHAFT ........ 16 SEC.
  • Page 7 VIII...
  • Page 8 EV (1997 - 2000) ALIFORNIA EV 2001 ALIFORNIA...
  • Page 9 ALIFORNIA ACKAL ALIFORNIA TONE...
  • Page 10 ALIFORNIA PECIAL ALIFORNIA PECIAL PORT...
  • Page 11 ENERAL NFORMATION LLGEMEINE NFORMATIONEN LGEMENE INLICHTINGEN...

  • Page 12: How To Consult This Manual

    HOW TO CONSULT THIS MANUAL The purpose of this manual is to provide instructions for carrying out overhauls and repair work correctly. The following data aim at providing an overview of the main tests to be carried out when overhauling the various units.

  • Page 13: General Safety Regulations

    It is however very important that the technicians, carrying out any operation contained in this manual, even if the specific tools recommended by “Moto Guzzi” are used, always check that the methods and tools employed for carrying out any procedure do not endanger the safety of the operator or the vehicle.

  • Page 14: Warranty

    WARRANTY When replacing parts, request and make sure that only “Original Moto Guzzi Spare Parts” are used. The use of non original spare parts shall render any warranty claim void or null. ENERAL NFORMATION...
  • Page 15 ODEL EATURES ODELLEIGENSCHAFTEN ARAKTERISTIEKEN ODEL...

  • Page 16: Model

    IDENTIFICATION DATA Each vehicle is marked by an identification number stamped on the chassis lug and on the engine crankcase. The number marked on the chassis lug and reported in the registration document is the legal identification of the motorbike; this number is composed of digits and letters, as in the example illustrated below.

  • Page 17: Lubricants And Refilling

    LUBRICANTS AND REFILLING Parts to be refilled Liters Prescribed products Fuel tank Premium gasoline(97 No. - r.p.m.) 9 aprox (about 4 litres reserve) Premium unleaded gasoline (95 No - r.p.m.) Engine sump "Agip 4T SUPER RACING SAE 20W50" oil Gearbox housing "Agip Rotra MP SAE 80 W/90"...

  • Page 18: Technical Specifications

    TECHNICAL SPECIFICATIONS NGINE Two-cylinder with 4 stroke Cylinder arrangement ......... at “V” of 90° Bore ..............92 mm Stroke ............... 80 mm Total displacement ..........1064cc Compression ratio ..........9,5:1 Maximum torque ... Kgm 9,6(94 Nm) at 5000 r.p.m. Maximum capacity ..CV 73,5 (Kw 54) at 6400 r.p.m. IMING SYSTEM With rods and equalizers and 2 valves per cylinder.
  • Page 19 TART Electric start-up through a starter motor (12V - 1,2 Kw ) equipped with an electromagnetically controlled coupling. Ring gear fixed onto the motor. Button control (START) “ ” located on the RH side of the handlebar. RANSMISSIONS LUTCH Dry type clutch with two driven disks. Located on the engine flywheel.
  • Page 20 USPENSIONS RONT EV - ALIFORNIA . KD 131644 ALIFORNIA PECIAL SERIES UNTIL CHASSIS NO Telescopic hydraulic fork with MARZOCCHI “ø45 mm” inverted stems whose extension and compression can be adjusted separately. ALIFORNIA ACKAL ALIFORNIA TONE . KD 131645- ALIFORNIA PECIAL SERIES UNTIL CHASSIS NO ALIFORNIA PECIAL...
  • Page 21 EV 2001 ALIFORNIA Wheels with tubeless rims in the dimensions: RONT 18” x 2,50-MT-DOTE 17” x 4,00-MT-DOTE IRES EV (1997 -2000) - S ALIFORNIA PECIAL ACKAL RONT 110/90 - 18 - 61H/61V/61VB 140/80 - 17 - 69H/69V/69VB ALIFORNIA PECIAL PORT TONE RONT 110/90 - 18 - 61V...
  • Page 22 RAKES ALIFORNIA PECIAL ALIFORNIA PECIAL PORT ALIFORNIA Integral braking system with brake-power limiter and metering valve RONT Stainless steel semi-floating double disk BREMBO “gold series” with differentiated 4 piston calipers, fixed type. Lever control positioned on the RH side of the handlebar. Hydraulic transmission independent from rear brake;...
  • Page 23 Dimensions and weight Abmessungen und Gewicht Afmetingen en gewicht Wheelbase (loaded) Achsabstand (belastet) Wielbasis (geladen) Maximum length Max. Länge Maximale lengte Maximum width Max. Breite Maximale breedte Maximum height (without windscreen) Max. Höhe (ohne Windschutzscheibe) Maximale hoogte (zonder windscherm) Rider's seat height Höhe des Fahrersitzes Hoogte berijderzadel Ground clearance...
  • Page 24 CALIFORNIA SPECIAL - SPECIAL SPORT CALIFORNIA JACKAL - STONE ODELLEIGENSCHAFTEN ARAKTERISTIEKEN ODEL...

  • Page 25: Tightening Torques

    TIGHTENING TORQUES Tightening torque Description (Nm) Head to crankcase screws and stud bolts 40 ÷ 42 Spark plugs 25 ÷ 30 Fastening socket screw for oil fumes recovery pipe 38 ÷ 40 Fastening screws for rocker arms shafts 6 ÷ 8 Self-locking nut for con-rod caps fastening screws 46 ÷...

  • Page 26: Tools

    TOOLS - AUSRÜSTUNG - UITRUSTING ODELLEIGENSCHAFTEN ARAKTERISTIEKEN ODEL...
  • Page 27 POS. PART NO DESCRIPTION 01 92 91 00 Wrench to remove small cover from sump and filter 14 92 96 00 Support for gearbox 19 92 96 00 Degree wheel for cam and ignition timing 17 94 75 60 Indicator for cam and ignition timing control 12 91 36 00 Flange disassembling tool - flywheel side 12 91 18 01...

  • Page 29: Ontrol And 1 Preliminary Tests

    ONTROL AND SE OF THE ORBIKE ONTROLLE UND EBRAUCH DES OTORRADS ONTROLE EN EBRUIK VAN DE OTORFIETS...
  • Page 30 PRELIMINARY TESTS Before start-up check that: • there is sufficient fuel in the tank; • the oil in the crankcase sump is at the correct level; • the key “A” in the ignition switch is in the ON “ “ position;...
  • Page 31 ERSTE KONTROLLEN PRELIMINAIRE CONTROLES Vor dem Ingangsetzen kontrollieren, ob: Vóór het starten controleren of: • eine ausreichende Kraftstoffmenge im Tank vorhanden • er in de tank een voldoende hoeveelheid brandstof ist. aanwezig is; • das Öl in der Wanne des Kurbelgehäuses den richtigen •...

  • Page 32: Engine Ignition

    ENGINE IGNITION OOL ENGINE After having carried out the preliminary tests, pull the clutch lever fully and press the start button “A”. When the engine is running, before re-positioning the “CHOKE” control lever in running postion “2”, let the engine idle, with a low r.p.m., for a few seconds in the hot season and for some minutes in the cold season.

  • Page 33: Stopping The Engine

    STOPPING THE ENGINE Turn throttle off, use the brake control levers and only when the motorbike is almost still, pull the clutch lever fully. This manoeuvre must be carried out with great coordination in order to keep control of the motorbike. For a regular speed reduction, the gearbox must be used correctly and the engine brake must be employed with great care so as not to have the engine run at runaway...

  • Page 34: Adjustments And Regulations

    ADJUSTMENTS AND REGULATIONS TEERING SHOCK ABSORBER This is installed on the LH side of the vehicle, between the chassis and the steering column base. To increase or reduce damping effect, screw or unscrew nut “A”. This ring-nut helps to render steering more precise and more stable, thereby improving the motorbike driving comfort in all conditions.
  • Page 35 RONT FORK ADJUSTMENT EV – C ALIFORNIA ALIFORNIA PECIAL SERIES The motorbike is equipped with a hydraulic telescopic fork whose shock-absorber braking capacity, in terms of extension and compression, can be adjusted separately. Adjust hydraulic damping capacity by means of adjusters “A”...
  • Page 36 EAR SHOCK ABSORBERS ADJUSTMENT ALIFORNIA ALIFORNIA PECIAL SERIES The motorcycle is fitted with shock absorbers featuring hydraulic extension adjustment. Use the adjustment ring nut “A” in order to adjust the hydraulic extension of the shock absorber. According to the needs and the load on the motorcycle, various adjusting positions are available;...
  • Page 37 TEERING ADJUSTMENT For driving safety, the steering must be adjusted so as to let the handlebar move freely, but without play. To adjust the steering, carry out the following procedures: • Remove the small cover “A” and loosen the locking screw of the steering head;...

  • Page 38: Preparation For Long Periods At Rest

    IGHT BEAM ADJUSTMENT The headlight must always be aimed at the correct height, for driving safety and in order not to cause troubles for on-coming vehicles. For vertical aiming it is necessary to: • Loosen screw “A” working from both sides of the headlight;...

  • Page 39: Cleaning The Motorbike

    CLEANING THE MOTORBIKE REPARATION FOR WASHING Before washing the vehicle, it is necessary to cover the following parts with nylon sheets: • Exhaust silencer terminal parts; • Clutch and brake levers; • Gas control; • LH light control device, • RH ignition device;...
  • Page 40 NSTRUCTIONS ON HOW TO CLEAN THE WINDSCREEN The windscreen can be cleaned with most soap, detergents and polishes used for other plastic surfaces and for glass. • Do not wash or clean the windscreen when air tem- perature is too high and when sunlight exposure is too strong.
  • Page 41 CHEDULED AINTENANCE ß EGELMÄ ARTUNG ERIODIEK ONDERHOUD...

  • Page 42: Scheduled Maintenance - Table

    SCHEDULED MAINTENANCE - TABLE MILIAGE COVERED 1000 mi. 6000 mi. 12000 mi. 18000 mi. 24000 mi. 30000 mi. (1500 Km) (10000 Km) (20000 Km) (30000 Km) (40000 Km) (50000 Km) PROCEDURES Engine oil Cartridge filter oil Mesh oil filter Air filter Fuel filter Spark plugs Valve play...

  • Page 43: Maintenance Procedures

    MAINTENANCE PROCEDURES The various maintenance procedures are described below. NGINE OIL REPLACEMENT A good engine oil has special qualities. Only use highly detergent engine oil whose container certifies that its quality corresponds to, or is higher than, SE,SF or SG operating requirements. ISCOSITY The other viscosity levels indicated in the table can be used if the average temperature of the motorbikeʼs area...
  • Page 44 “D” and oil pressure regulating valve “E”; • Unscrew filtering cartridge “C”, • Place a new original cartridge in the relevant seat and tighten it by hand to avoid excessive tightening. N.B. Only use original Moto Guzzi spare parts CHEDULED AINTENANCE...
  • Page 45 ASHING THE OIL MESH FILTER After the first 500/1500 km (300/1000 mi)(oil cartridge filter change) and thereafter each time the oil cartridge filter is replaced, it is a good rule to wash the mesh filter. To wash the mesh filter, follow the below procedures: •...
  • Page 46 Remove the filter cartridge “C” and clean it. Replace with a new cartridge if necessary N.B. Only use original Moto Guzzi spare parts. • Fit the cartridge into the filter housing, remembering to position it so that the flaps are turned upwards.
  • Page 47 UEL FILTER The filter is fitted under the fuel tank, between the pump and the throttle body unit. it is necessary to replace it every 20000 km (12000 mi), as described in the scheduled maintenance table, chapter 1 in this section. To replace the fuel filter it is necessary to proceed as follows: •...
  • Page 48 PARK PLUGS 0,7 mm The motorbike is equipped with NGK BPR 6 ES spark plugs with a distance of 0,7 mm between the electrodes. The spark plugs must be removed from time to time for cleaning and for checking the distance between the electrodes.
  • Page 49 APPET BACKLASH After the first 500÷1500 km (300÷1000 mi) and after evey 10000 km(6000 mi), or when the timing system becomes very noisy, check the backlash between the valves and the equalizers. Adjustment must be carried out when the engine is cold , with the piston at top dead center (T.D.C), in compression stage (valves closed).
  • Page 50 EARBOX LUBRICATION Every 5000 km (3000 mi)check that the oil almost reaches the hole in oil level plug “A”. Carry out the test with the vehicle in a perfectly vertical position and when the engine is hot; an incorrect position could cause a wrong the reading.
  • Page 51 INAL RIVE UBRICATION Every 5000 km (3000 mi) check that the oil touches the hole for the level plug “A”; if the oil is below this level, top up with oil of the type prescribed in the table in section B, chapter 2.
  • Page 52 TEERING BEARINGS The steering pin is supported on the chassis sleeve by two tapered roller bearings “B”. A nut “A” screwed onto the steering pin, determines the fitting backlash for the bearings. A test must be carried out every 20000 km (12000 mi). Disassembly: •...
  • Page 53 RONT FORK OIL REPLACEMENT The motorbike is equipped with a hydraulic telescopic fork with separate extension and compression adjustment for the shock-absorbersʼ braking: The RH rod works in extension while the LH one in compression. Although the two rods work in different ways, their internal components are similar.
  • Page 54 • Drain as much as possible of the oil contained in the rod in a special container; • Lock the rod again in the vice and while holding the tube in pre-load “C”, unscrew check nut “B”, but not fully, to release the inner spring; •...
  • Page 55 • Drain again the oil contained in the rod and master cylinder by repeatedly pushing on the rod “G” of the shock absorber to facilitate the oil drainage in the shock absorber assembly. WARNING By pumping on the rod “G” of the shock absorber, a high-pressure oil jet comes out of the rod end.
  • Page 56 ILLING • Refit the rod in reverse sequence with respect to the disassembly; remember not to screw down the cap; • Lock the rod in a vice; • Lift slightly the shock absorber with one hand and fill the fork with new oil in the prescribed quantity (see chapter 1 of this section);...
  • Page 57 HECKING THE BRAKING AND CLUTCH SYSTEM FLUID To obtain a high efficiency in the hydraulic system, follow the below rules : • Frequently check the fluid level in the front brake, clutch and rear brake tank; This level must never drop below the minimum level marked on the tanks, and must never exceed the maximum level.
  • Page 58 RAKE SYSTEM FLUID REPLACEMENT EV - S RONT RAKING YSTEM ALIFORNIA PECIAL PECIAL SPORT Draining: • Unscrew the cover together with diaphragm from the tank “A”; • Rotate the handlebar until the tank “A” is in a horizontal position; • Remove the rubber cover from the draining union “B”...
  • Page 59 EV - HAND FRONT AND REAR BRAKING SYSTEM ALIFORNIA PECIAL PECIAL PORT Draining: • Unscrew the cover together with diaphragm from the tank “A”; • Rotate the handlebar until the tank “A” is in a horizontal position; • Remove the rubber cover from the draining union “B” and fit a commercially available brake drainer onto the union;...
  • Page 60 MPIANTO RENANTE OSTERIORE ALIFORNIA ACKAL ALIFORNIA TONE Draining: • Remove the cover together with diaphragm from tank “A”; • Remove the rear caliper as described in chapter 5, section F; • Position the caliper so that the draining union “B” is directed upwards;...
  • Page 61 – HAND FRONT BRAKING SYSTEM ALIFORNIA ACKAL ALIFORNIA TONE Draining: • Unscrew the cover together with diaphragm from the tank “A”; • Rotate the handlebar until the tank “A” is in a horizontal position; • Remove the rubber cover from the draining union “B” and fit a commercially available brake drainer onto the union;...
  • Page 62 RAINING THE BRAKING SYSTEM FLUID EV – S IGHT HAND FRONT BRAKING SYSTEM ALIFORNIA PECIAL – S PECIAL PORT • Turn the handlebar until the tank is in a horizontal position; • Fill the tank if necessary • Remove the small rubber cover from the draining union “A”...
  • Page 63 – C EAR BRAKING SYSTEM ALIFORNIA ACKAL ALIFORNIA TONE • Fill the tank if necessary • Remove the caliper and hold it in horizontal position; • Remove the small rubber cover from the draining union “A” and fit a commercially available brake drainer onto the union;...
  • Page 64 HAND FRONT BRAKING SYSTEM – C ALIFORNIA ACKAL ALIFORNIA TONE • Rotate the handlebar until the reservoir “B” is in horizontal position; • Fill the tank if necessary • Remove the small rubber cover from the draining union “A” and fit a commercially available brake drainer onto the union;...
  • Page 65 HAND FRONT AND REAR BRAKING SYSTEM EV - S ALIFORNIA PECIAL PECIAL PORT • Fill the tank “A” if necessary; • Remove the small rubber cover from the draining union “B” and fit a commercially available brake drainer onto the union; •...
  • Page 66 RAKE PAD CHECK REPLACEMENT Every 3000 km (2000 mi) check for the thickness of the brake pads: • The minimum thickness of friction material is 1.5 mm. If the minimum thickness of the friction material is less than this value, it is necessary to replace the pads. After replacement, it is not necessary to drain the braking system.
  • Page 67 EAR BRAKE CALIPER Disassembly: • Unscrew screw “A”; • Remove brake caliper; • Remove the spring “B”; • Remove pin “C” to let the brake pads “D” free; • If the pads are worn beyond the prescribed limit, replace them. Reassembly: •...
  • Page 68 HEEL SPOKES TENSION ADJUSTMENT WARNING FOR WHEELS AND SPOKES (all models) Check wheel spokes integrity and tension after the first 1500 Km (1000 mi) and then after every 10000 Km (6000 mi). Driving with the wrong spokes tension or with one or more broken spokes may damage the wheel and cause risks to the vehicle safety and stability.
  • Page 69 EV (1997-2000) - C ALIFORNIA ALIFORNIA PECIAL SERIES Same as California EV 2001, bearing in mind that the locking pin (1) is not fitted on BBS wheels and that the nipples indicative tightening torque varies from 4Nm (minimum load) to 6Nm (maximum load). ) - C ALIFORNIA PECIAL...

  • Page 71: Trimmings

    RIMMINGS ERKLEIDUNG LEDING...

  • Page 72: Wing Mirrors

    WING MIRRORS Disassembly: • Use two wrenches, as illustrated in the figure, to unscrew the upper nut “A”, integral to the wing mirror, and to keep the lower one still “B”; • Unscrew the wing mirror to remove it. Reassembly: •...

  • Page 73: Front And Rear Mudguards

    FRONT AND REAR MUDGUARDS RONT MUDGUARD Removal: • Remove brake pipes from guides “A”; • Unscrew the 4 “B” screws fixing the anti-twist plate group and the mudguard to the fork; • Remove the mudguard Reassembly: Carry out the procedures in reverse order. RIMMINGS...
  • Page 74 EV(1997-2000) - EAR MUDGUARDS ALIFORNIA ALIFORNIA ACKAL ALIFORNIA TONE Removal: Remove front seat as described in chapter 4 section E; • • Disconnect electric wirings “A” between the main cable group and the tail-light wiring; • Unscrew clamping nuts “B” between mudguard and chassis;...
  • Page 75 EV(1997- EV(1997-2000) INTERES CHUTZBLECH ALIFORNIA CHTERSTE PATBORD ALIFORNIA 2000) - C ALIFORNIA ACKAL ALIFORNIA TONE ALIFORNIA ACKAL ALIFORNIA TONE Abnehmen: Demontage: Den Vordersitz, wie in Kap.4, Abschnitt E • • Demonteer het voorste zadel zoals beschreven in beschrieben, abnehmen. hoofdstuk 4 deel E; •...
  • Page 76 EV 2001 - EAR MUDGUARDS ALIF ORNIA ALIFORNIA PECIAL ALIFORNIA PECIAL PORT Removal: Remove front seat as described in chapter 4 section E; • • Disconnect electric wirings between the main cable group and the tail-light wiring; • Remove rear seat from mudguard; Remove side protections “A”...

  • Page 77: Side Panels

    SIDE PANELS EV - C IDE PANELS ALIFORNIA ALIFORNIA ACKAL ALIFORNIA TONE Removal: • Remove the 2 screws “A” fastening the chassis • Remove the saddle cover “B”. Reassembly: Carry out the procedures in reverse order. IDE PANELS ALIFORNIA PECIAL ALIFORNIA PECIAL PORT...

  • Page 78: Front Seat

    FRONT SEAT To remove the saddle from the chassis it is necessary to: • Release the saddle using the wrench “A”; • Slightly lift the rear part of the saddle; • Detach the saddle “B” by moving it backwards To refit the saddle, lock it in the front part and lower it until it is fixed in its bay.

  • Page 79: Rear Seat

    REAR SEAT EV(1997-2000) - EAR S E AT ALIF ORN IA ALIFORNIA ACKAL ALIFORNIA TONE Removal: Remove front seat as described in chapter 4 of this • section; • Remove side protections “A” on C EV and “B ALIFORNIA “ on C ALIFORNIA TONE •...

  • Page 80: Rear Chassis Cover Protections

    REAR CHASSIS PROTECTIONS ALIFORNIA TONE Removal: • Unscrew the 2 nuts “A” fixing it to the chassis; • Remove protection “B”. Reassembly: Carry out the procedures in reverse order. ALIFORNIA Removal: • Unscrew the 3 screws “A” and the lower nut “B”; •...

  • Page 81: Front Chassis Cover Protections

    FRONT CHASSIS PROTECTIONS Removal: • Loosen the 2 screws “A”; • Remove protection “B”. Reassembly: Carry out the removal procedures in reverse order and pay attention to the exact routing of the electric wiring on the steering tube. RIMMINGS...

  • Page 83: Heel Parts

    HEEL PARTS ÄDERTEILE IELINSTALLATIES...

  • Page 84: Front Wheel

    FRONT WHEEL EV(1997-2000) - C ALIFORNIA ALIFORNIA ACKAL ALIFORNIA PECIAL The above-mentioned models can be fitted with 2 different types of wheel shaft fastening: 1) The threaded part of shaft “A” comes out of the left- hand leg and is then fixed with a nut “B”, the screws “C”...
  • Page 85 1 (W EMOVAL ITH THROUGH WHEEL SHAFT AND BACK • Place the vehicle on the centre stand (if available). • Place anyway a support under the motorbike to lift the front wheel from ground. • Unscrew screws “D” fixing the caliper (J ACKAL TONE or the calipers (EV - S...
  • Page 86 2 (W EMOVAL ITH SHAFT SCREWED ON THE LEG • Place a support under the motorbike to lift the front wheel from ground. • Remove calipers as described in removal (1). • Loosen the 2 fastening screws between the shaft and the fork legs.
  • Page 87 CALIFORNIA JACKAL (1 serie) CALIFORNIA SPECIAL (2 serie) CALIFORNIA SPECIAL SPORT HEEL PARTS...
  • Page 88 CALIFORNIA EV CALIFORNIA SPECIAL (1 serie) CALIFORNIA JACKAL (2 serie) CALIFORNIA STONE ÄDERTEILE IELINSTALLATIES...
  • Page 89 BRAKE DISKS SPACING FLANGES EMOVAL FOR ALIFORNIA ACKAL ALIFORNIA TONE • Remove wheel as described in chapter 1 of this section. • Remove brake disk as described in chapter 4 of this section. • Remove flange protection “A”. • Unscrew screws “B”. •...

  • Page 90: Rear Wheel

    REAR WHEEL CALIFORNIA EV CALIFORNIA SPECIAL (1 serie) EV (1997-2000) - EMOVAL FOR ALIFORNIA ALIFORNIA PECIAL ALIFORNIA ACKAL • Place a paddock stand under the swinging arm to keep the rear wheel lifted from ground. • Remove left-hand silencer as described in chapter 2 section L.
  • Page 91 HINTERRAD ACHTERWIEL CALIFORNIA JACKAL CALIFORNIA STONE CALIFORNIA SPECIAL (2 serie) CALIFORNIA SPECIAL SPORT EV(1997-2000) - ABNAHME C EV(1997-2000) - ERWIJDEREN ALIFORNIA AL I F O R N I A ALIFORNIA PECIAL ALIFORNIA ACKAL ALIFORNIA PECIAL ALIFORNIA ACKAL • Onder de achtervork een steun of standaard plaatsen •...
  • Page 92 EV 2001 - EMOVAL FOR ALIFORNIA ALIFORNIA TONE ALIFORNIA PECIAL PORT • Place a paddock stand under the swinging arm to keep the rear wheel lifted from ground. • Remove left-hand silencer as described in chapter 2 section L. • Unscrew brake caliper from the caliper “B”...
  • Page 93 REAR WHEEL HUB REMOVAL – RUBBER CUSH DRIVE DAMPER SIDE EMOVAL • Unscrew the screw “A”. • Remove the ring stop plate “B”. • Remove the split ring “C” with special pliers and a screwdriver. • Remove the rubber cush drive damper plate “D”. •...
  • Page 94 EAR BRAKE DISK SPACER FLANGE ALIFORNIA ACKAL ALIFORNIA TONE ALIFORNIA PECIAL SERIES ALIFORNIA PECIAL PORT EMOVAL • Remove the wheel as described in chapter 2 of this section. • Remove the brake disk as described in chapter 4 of this section. •...

  • Page 95: Wheel Overhaul

    WHEEL OVERHAUL EARINGS Before checking the dimensions, it is necessary to check for the wear condition of the wheel hub bearings; this test must be carried out manually with the bearing fitted in its seat. • Turn the inner ring in both directions: this must be capable of turning softly and silently, without interference.
  • Page 96 HEELS Having made sure that the bearings are in good condition, it is necessary to check the rim following the below procedures: • Check for any eventual irregularities, dents or cracks with a visual inspection: if these faults are present, replace the rim;...

  • Page 97: Front Left-Hand Hydraulic Brake

    FRONT LEFT-HAND HYDRAULIC BRAKE CALIFORNIA JACKAL - CALIFORNIA STONE RAKE CALIPERS Disassembly: • Drain the hydraulic system thoroughly, as described in chapter 2, section D; • Unscrew the hollow screw “A” and remove the tube as well as the two gaskets from the two calipers; •...

  • Page 98: Front Right-Hand Hydraulic Brake

    FRONT RIGHT-HAND HYDRAULIC BRAKE CALIFORNIA EV - CALIFORNIA SPECIAL - CALIFORNIA SPECIAL SPORT RAKE CALIPERS Disassembly: • Drain the hydraulic system thoroughly, as described in chapter 2, section D; • Unscrew the hollow screw “A” and remove the tube as well as the two gaskets from the two calipers; •...
  • Page 99 RAKE DISKS Disassembly: • Remove the brake calipers as described in this chapter; • Remove the wheel from the motorbike as described in chapter 1 of this section; • Unscrew the fastening screws “A” and remove the disk; Check: The disks must be perfectly clean, without rust, oil, grease or deposits and they must not have deep groovings.
  • Page 100 Reassembly: When reassembling, thoroughly clean the resting surfaces and lock the screws to the tightening torque prescribed in the table in chapter 4, section B. Apply Loctite 270 on the threading. HEEL PARTS...
  • Page 101 REAR FRONT LEFT-HAND HYDRAULIC BRAKE CALIFORNIA EV - CALIFORNIA SPECIAL - CALIFORNIA SPECIAL SPORT RAKE CALIPERS Disassembly: • Drain the hydraulic system thoroughly, as described in chapter 2, section D; • Unscrew the hollow screw “A” and remove the tube as well as the two gaskets from the two calipers;...

  • Page 102: Rear Hand Hydraulic Brake California

    REAR HYDRAULIC BRAKE CALIFORNIA JACKAL - CALIFORNIA STONE RAKE CALIPER Disassembly: • Drain the hydraulic system thoroughly, as described in chapter 2, section D; • Unscrew the hollow screw “A” and remove the tube as well as the two gaskets from the caliper; •...
  • Page 103 RAKE DISK Disassembly: • Remove the wheel from the motorbike as described in chapter 2 of this section; • Unscrew the screws ”A” fastening it to the wheel rim; • Remove the disk. Check; The brake disk must be perfectly clean, without rust, oil grease or deposits and it must not have deep groovings.
  • Page 104 ISK BRAKE TROUBLES Trouble cause Trouble removal The brake squeaks The brake caliper is not fully tightened Tighten fastening screws Positioning springs are faulty or missing Place new positioning springs Brake pads are worn beyond the limit Place new brake pads after checking disk condition Brake pads are dirty with oil or grease Replace brake pads...
  • Page 105 EV - RAKE POWER LIMITER ALIFORNIA ALIFORNIA PECIAL ALIFORNIA PECIAL PORT The brake-power limiter is a mechanic device connected to the rear swinging arm through a spring. According to its position (and therefore as a consequence of the load on the rear axle), the valve inside the limiter distributes the integral system brake oil pressure in variable proportion between front and rear caliper (if the load on the rear increases, the pressure on the rear caliper...

  • Page 106: Front Fork

    FRONT FORK N.B. Fork of the latest type with left-hand leg featuring a threaded hole, on which the wheel shaft shall be screwed Gabel letzter Typ mit linkem, eine Gewindeöffnung aufweisenden Holm, auf welcher die Radachse angeschraubt wird. Vork van het laatste type met linkersteel met schroefdraadopening waarin de wielspil wordt geschroefd CALIFORNIA EV - CALIFORNIA SPECIAL 1 SERIE ±0,1...
  • Page 107 VORDERE GABEL VOORSTE GAFFEL N.B. Fork of the first type with left-hand leg featuring a through hole, as wheel shaft seat Gabel erster Typ mit linkem, eine Durchgangsöffnung aufweisenden Holm für das Gehäuse der Radachse. Vork van het eerste type met een doorsteekopening in de linkersteel waarin de wielspil wordt gestoken CALIFORNIA JACKAL - CALIFORNIA SPECIAL - CALIFORNIA SPECIAL 2 SERIE CALIFORNIA SPECIAL SPORT...
  • Page 108 CALIFORNIA EV CALIFORNIA SPECIAL 1 SERIE 58 59 56 1 ESCRIPTION ESCRIPCIÒN Screw Foot valve assembly Handlebar fastening jumper O-ring Screw Adapter Under jumper Dust scraper Stop ring Rubber pad Seal ring Fork head Retainer Ring nut Upper bushing Spacer tube Full right-hand leg Long screw Washer...
  • Page 109 CALIFORNIA JACKAL- CALIFORNIA STONE CALIFORNIA SPECIAL 2 SERIE- CALIFORNIA SPECIAL SPORT ESCRIPTION ESCRIPTION Screw Lower bushing Handlebar fastening jumper Rebound spring Screw Dust scraper Lower jumper Stop ring Retainer Seal ring Rubber pad Fork head Bushing Ring nut LH complete fork leg Spacer tube Complete left-hand leg RH complete fork leg...
  • Page 110 Motorbikes are fitted with a telescopic hydraulic fork with separate adjustment of extension and compression damping or with a non-adjustable fork: In case of adjustable fork, the left-hand fork leg works in extension while the right-hand one works in compression. Although the two rods work in different ways, their internal components are similar and therefore disassembly, overhauling and reassembly are carried out following the...
  • Page 111 Die Motorräder sind mit einer Teleskopgabel mit separater De motorvoertuigen zijn uitgerust met een hydraulische Einstellung der Federbeindämpfung in Bezug auf die telescopische voorvork met afzonderlijke reminstelling van Ausdehnung und Kompression oder mit einer nicht de schokbrekers in de in- en uit-beweging of met een niet einstellbaren Gabel ausgerüstet.
  • Page 112 ORK LEG REMOVAL • Place the motorbike on a firm mount, so that the front wheel is lifted from the ground • Remove the front brake calipers as described in chapter 4 section F, without disconnecting oil pipes; • Remove the front mudguard as described in chapter 2 section E;...
  • Page 113 TROUBLES – CAUSES - SOLUTIONS The following paragraph lists some of the fork troubles, their causes and suggests the possible solution. Always refer to this table before operating on the fork. ROUBLES AUSES OLUTIONS Oil leakage form the seal ring 1.
  • Page 114 ISASSEMBLY VERHAUL IMPORTANT The components of the forks are similar. accordingly, the below described procedures apply to both the forks. (adjustable / not adjustable). • Drain all the oil from the rod leg as described in chapter 2 section D. •...
  • Page 115 • Remove the stanchion “D” from the wheel-holder leg together with the seal ring “E”, the cap “F”, the upper bushing “G” on the leg and the lower bushing “H” on the stanchion. N.B. While removing stanchion “D” from the wheel-holder leg, the parts “E”, “F”...
  • Page 116 “COMPRESSION” VERHAUL OF THE SHOCK ABSORBER • Remove the shock absorber assembly “I” from the stanchion “D”. • Remove the bottom buffer “L”; this might remain fitted in the wheel-holder leg “A”, if so, remove it from the inside. • Push the foot valve “M”...
  • Page 117 • Push the foot valve “M” out of the case “N” with the shock absorber rod; • Check the foot valve “M” and its O-ring “O”; if damaged, replace them; • Remove the shock absorber rod together with the pumping unit from the case, after fully unscrewing the lock nut at its end.
  • Page 118 “REBOUND” VERHAUL OF THE SHOCK ABSORBER • The removal procedure is the same as for the COMPRESSION shock absorber, with the only difference that the components of the pumping unit fixed on the shock absorber rod are: - pos. 25, rebound spring; - pos.
  • Page 119 • Screw the foot screw in again with the gasket and tighten it to the torque of 50 Nm; • Place the cap “F” and the lubricated seal ring “E” on the stanchion “D”. Push the seal ring “E” inside the leg fully home by using a special tool “Z”.
  • Page 120 • Use the shock absorber rod to pump and keep the end hole closed. Make sure the oil has filled up the shock absorber cartridge; • Place the spring “F” and the pre-load tube “E”; • Place the open washer “D” between the pre-load tube and the lock nut;...
  • Page 121 • Place the plug “A” on the pumping unit, being careful not to damage the O-ring. Tighten the plug at the torque of 25 Nm. Fork leg reassembly • Place the fork leg on the motorbike and let the steering head pass through the bottom yoke;...

  • Page 122: Rear Swing Arm

    REAR SWING ARM Removal: • Position the motorbike on a stable support; • Remove the rear wheel as described in chapter 2 in this section; • Remove the rear transmission box as described in chapter 1, section O; • Disassemble the rear mud guard as described in chapter 2, section E;...
  • Page 123 Overhaul: Check that the swinging arm has no bent or unsoldered parts, that the bearing seats are in good condition and that the connection surface between the right-hand arms and the housing has no deep scoring. Check the wear of the bearings on the swinging arm pivot axis on the chassis and of the bearing on the right-hand section.

  • Page 124: Rear Shock-Absorber

    10 REAR SHOCK ABSORBERS Removal: To remove the rear shock absorbers from the chassis proceed as follows: ALIFORNIA • Remove the rear chassis-cover protections as described in chapter 6 section E; • Unscrew the screws “A” and remove the shock absorbers.

  • Page 125: Steering Shock Absorber

    11 STEERING SHOCK ABSORBER Its action helps to make the steering more precise and more stable, thereby improving the motorbike driving comfort in all conditions; it is fixed onto the front part of the motorbike, between the steering base and the chassis Disassembly: •...
  • Page 126 IMPORTANT When replacing tires, it is advisable to use a high quality type and make. Tire pressure must be measured when the tires are cold. Removal and Refitting The motorbike is equipped with light-alloy rims (California EV, Special 1 series) or with steel rims (California Special series, Special Sport, Jackal and Stone) For the above procedures, it is therefore advisable to use iron tools which do not have grooves and sharp edges...
  • Page 127 ONTROLS CHALTUNGEN EDIENINGEN...

  • Page 128: Controls

    CLUTCH AND FRONT BRAKE CONTROL Removal of front brake lever with master cylinder: • Drain the hydraulic system thoroughly, as described in chapter 2, section D; • Detach the connections “A” for the micro-switch “B” • Unscrew the hollow screw “C” fastening the tube to the pump;...

  • Page 129: Gearbox Control

    GEARBOX CONTROL ISASSEMBLY OF ALIFORNIA • Unscrew the 3 screws “A”; • Remove the frame section cover “B”; • Unscrew nut “C”; • Unscrew screw “D”; • Remove the gear shift lever “E”. N.B. To guarantee the proper reassembly, mark the position of lever “F”...
  • Page 130 ISASSEMBLY OF ALIFORNIA ACKAL ALIFORNIA TONE • Remove the left front footrest “A” as described in chapter 3 section H; • Remove the footrest mounting “C” after loosening screw “B”; • Unscrew cap nut “D”; • Remove the gear shift lever “E”. N.B.

  • Page 131: Rear Brake Control

    REAR BRAKE CONTROL ISASSEMBLY OF ALIFORNIA • Unscrew the 2 screws “A” and remove the frame section covers “B”; • Remove the split pin “C” and pull out pin “D”; • Unscrew the screw “E” and remove the brake lever “F”.

  • Page 132: Accelerator /Starter Control

    ACCELERATOR / STARTER CONTROL CCELERATOR CONTROL The accelerator control hand grip, in all steering positions, must feature a free travel, measured on the outer edge of the hand grip, of 1,5 ÷ 2 mm. If it needs adjustment: move the special adjusters “A” placed on the control itself.
  • Page 133 TARTER CIRCUIT EV 2001 - C ISASSEMBLY OF ALIFORNIA ALIFORNIA TONE ALIFORNIA PECIAL PORT • Remove the right lid of the throttle body cover; • With a wrench, hold the cable nut “A” still and with the other wrench unscrew the screw “B”; •...
  • Page 135 HASSIS AHMEN HASSIS...

  • Page 136: Steering

    STEERING Disassembly: • Place the motorbike on a firm mount, so that the front wheel is lifted from the ground; • Remove the front brake calipers as described in chapter 4 section F; • Remove the chromed plugs indicated with the arrows; •...

  • Page 137: Handlebar

    HANDLEBAR Disassembly: • Remove the mirrors as described in chapter 1 section • Remove the accelerator control and starter / stop device as described in charter 4 section G. • Remove the front brake master cylinder as described in chapter 1 section G. •...

  • Page 138: Foot Rests

    FOOT RESTS Disassembly of front footrests: ALIFORNIA • Unscrew the 2 screws “A” while holding the nuts “B” . • Remove the footrests. ALIFORNIA PECIAL ALIFORNIA ACKAL ALIFORNIA SPECIAL SPORT ALIFORNIA TONE • Remove the split pin “C”. • Pull out the pin “D” and the shims. Reassembly of front footrests: •...

  • Page 139: Side Stand

    SIDE STAND Stand removal: • Place the motorbike on the center stand or, in case it is not fitted, on a firm mount; • Remove the protection “A” (Stone) or the installed left- hand section frame cover, if any; • Remove the side stand sensor support plate with the assembled sensor;...

  • Page 140: Chassis Dimensions

    CHASSIS DIMENSIONS Overhauling: • Place the motorbike on a firm mount so that the rear wheel is completely lifted from the ground; • Release the 2 springs “A”; • With a wrench with fixed jaws hold the 2 screws “B” and simultaneously unscrew the nuts “C”;...

  • Page 141: Front Bumper

    FRONT BUMPER Overhauling: • Unscrew the 2 screws “A”; • Remove the support plate “B”; • Remove the chromed plugs “C” and unscrew the screws “D” beneath, while holding the nuts “E” ; • Remove the bumper. Reassembly: • Carry out the removal procedures in reverse order, being careful to properly reassemble the spacers “F”...

  • Page 142: Chassis Dimensions

    CHASSIS DIMENSIONS Overhauling: The chassis consists of two parts: the frame itself and two lower side arms forming the engine frame section. After a collision the chassis must be accurately checked according to the measures indicated in the technical drawing. If the chassisʼs measurements are not in line with those indicated it must be repaired, if possible, or replaced.
  • Page 143 RAHMENABMESSUNGEN AFMETINGEN CHASSIS RAHMENABMESSUNGEN AFMETINGEN CHASSIS Überholung: Revisie: Überholung: Revisie: Der Rahmen besteht aus zwei Teilen: Het frame bestaat uit twee delen: Der Rahmen besteht aus zwei Teilen: Het frame bestaat uit twee delen: Aus dem sogenannten Rahmen und aus zwei unteren het eigenlijke frame en twee armen op de zijkanten Aus dem sogenannten Rahmen und aus zwei unteren het eigenlijke frame en twee armen op de zijkanten...
  • Page 144 HASSIS...

  • Page 145: Uel System

    UEL SYSTEM RAFTSTOFFZUFUHRANLAGE OEDINGSINSTALLATIES...

  • Page 146: General Description Of The System

    GENERAL DESCRIPTION OF THE SYSTEM N.B. The model California EV, manufactured in the years 1997-2000 until chassis number KD115749, is fitted with the type ignition system / injection with ECU P08 (big); should it be necessary, refer to the specific workshop manual code 29920160.

  • Page 147: System Components

    SYSTEM COMPONENTS The system is composed of three circuits: A fuel circuit B intake air circuit C electrical circuit FUEL CIRCUIT The fuel is injected into each cylinderʼs intake duct, upstream of the intake valve. It includes: a tank, a pump, a filter, a pressure adjuster, electro-injectors.
  • Page 148 ZUSAMMENSETZUNG DER ANLAGE SAMENSTELLING VAN DE INSTALLATIE Die Anlage besteht aus drei Kreisläufen: De installatie bestaat uit drie circuits: A Kraftstoff-Kreislauf A circuit brandstof B Ansaugluft-Kreislauf B circuit aangezogen lucht C Elektrischer Stromkreis C lektrisch circuit RAFTSTOFF REISLAUF CIRCUIT BRANDSTOF Der Kraftstoff wird in den Einlasskanal jedes Zylinders De brandstof wordt geïnjecteerd in het aanzuigkanaal van oberhalb des Einlassventils eingespritzt.

  • Page 149: Tank "5

    TANK “5” WARNING The fuel contained in the tank is highly inflammable. Flames, cigarettes and other objects emitting heat, if present during tank removal procedures or in places where fuel is stored, are a great risk for the operator. Always work in well ventilated places. Disassembly: •...

  • Page 150: Electrical Fuel Pump "1

    ELECTRICAL FUEL PUMP “1” The motorbike is equipped with a volumetric roller type electrical pump whose motor is immersed in the fuel. The motor is composed of brushes with permanent magnet excitation. When the impeller rotates, driven by the motor, it generates volumes which move from the intake gate to the delivery gate.

  • Page 151: Fuel Filter "2

    FUEL FILTER “2” The filter is equipped with a paper filtering element, with a surface area of about 1200 cm2, and a filtering capacity of 10 µm: these features are essential, given the injectorsʼ high sensitivity to foreign bodies. The filter is fitted under the fuel pump between the pump and the throttle body units and has an arrow on its external casing which indicates the fuel flow direction.

  • Page 152: Pressure Adjuster "4

    PRESSURE ADJUSTER “4” The pressure adjuster is a device which is necessary for maintaining a constant pressure jump on the injectors. The pressure adjuster is a differential type with diaphragm, and is pre-set during assembly at 3±0,2 bar. Upon exceeding the pre-set pressure, the internal duct opens to allow the excess fuel to flow back into the tank.
  • Page 153 INTAKE AIR CIRCUIT The circuit is composed of: an air filter, an intake manifold and a throttle body. The socket for the pressure adjuster is positioned downstream of the throttle valve; The throttle position potentiometer is splined onto the throttle shaft; The absolute pressure sensor (integral to the ECU) and the air temperature sensor are positioned upstream of the throttle valve.

  • Page 154: Air Filter Box "1

    AIR FILTER BOX “1” Disassembly: • Remove the front seat as described in section E chapter 4; • Remove the fuel tank as described in section I, chapter 3 • Remove the side panels as described in section E, chapter 3 After having removed the above mentioned parts, proceed as follows: •...

  • Page 155: Throttle Body "2

    THROTTLE BODY “2” The quantity of intake air is determined by the opening of the throttle positioned on the initial part of the intake manifold on every cylinder. The air necessary for running at idling speed flows through a by-pass channel, equipped with an adjusting screw: turning this screw will vary the quantity of air which is introduced into the manifold and consequently also the idling speed.
  • Page 156 LECTRICAL CIRCUIT Through this circuit, the ECU detects the engine conditions and activates the fuel supply as well as the spark advance. It includes: a battery, a starter switch, two relays, an ECU with an integrated absolute pressure sensor, an ignition unit, an air temperature sensor, a throttle position potentiometer, two injectors, an oil temperature sensor, a rev.
  • Page 157 TROMKREIS LEKTRISCH CIRCUIT Über den Stromkreis führ t das Steuergerät die Dit is het circuit waardoor de elektronische centrale Messungen der Motorbedingungen aus und steuert die eenheid de opnames van de condities van de motor en Kraftstoffabgabe und die Zündvorverstellung. de activering van de verdeling van de brandstof en van Er umfasst: Batterie, Zündungsschalter, zwei Relais, de vervroeging van ontsteking uitvoert.

  • Page 158: Battery "1

    10 BATTERY “1” See chapter 2, section P. 11 STARTER SWITCH “2” For information on its use, see section C Disassembly: • After having removed the headlight and the dashboard as described in chapter 4, section P, the starter switch “A”...

  • Page 159: Relay "3

    12 RELAY “3” In the Weber injection-ignition system two standard car type relays are used. The connection to ground, for the relay excitation circuit, is actuated in the ECU using a protection against polarity inversion. the two relays have specific purposes in the fuel system and can be distinguished in the following way: •...
  • Page 160 13 ECU I.A.W. 15 M “4” The Weber injection-ignition system is a digital type electronic control unit with micro-processor; it controls the parameters relating to the engine fuel supply and ignition: • The quantity of fuel supplied to each cylinder in sequence (1-2) in a single delivery.

  • Page 161: Air Temperature Sensor "5

    14 AIR TEMPERATURE SENSOR “5” Caratteristica teorica Caracteristique theorique Característica teórica Temperatura ˚C Resistenza Kohm The sensor detects the air temperature. The obtained Temperature ˚C Resistance Kohm Temperatura ˚C Resistencia Kohm electrical signal reaches the ECU where it is used to activata an adjustment according to the air temperature.

  • Page 162: P.m. And T.d.c. Sensor "7

    16 R.P.M. AND T.D.C. SENSOR “7” The sensor reads the signal from a toothed wheel fitted on the camshaft. The information about the r.p.m and the camshaft position is obtained from the frequency of this signal. This allows the position of the various cylinders with respect to their explosion T.D.C.

  • Page 163: Coils "8

    17 COILS “8” The ignition used is an inductive discharge type. The coils receive the command from the ECU which processes the spark advance. Disassembly: 1 Disconnect cable “A” for the spark plugs; 2 Detach connection “B”; 3 Unscrew the two screws “C” and remove the coil; It may be necessary to remove some clamps “D”...

  • Page 164: Throttle Position Potentiometer "9

    18 THROTTLE POSITION POTENTIOMETER “9” The potentiometer is powered by the ECU, to which it sends a signal identifying the throttle position. This information is used to correct the basic metering, transistors metering, and for possible corrections during the start-up stage. Disassembly: •...

  • Page 165: Operating Stages

    19 OPERATING STAGES ORMAL MODE When the engine is thermally regulated, the I.A.W. 15 M ECU calculates the stage, the injection time and the spark advance exclusively by means of the interpolation on the relative stored maps, according to the r.p.m. and the throttle position.
  • Page 166 PERATION DURING THE ACCELERATION STAGE During acceleration, the system increases the quantity of fuel supplied in order to obtain optimal driving performances. This condition is recognised when the throttle angle variation reaches considerable values; the enrichment factor takes the oil and air temperature into account. WARNING In order to avoid damaging the electronic injection/ignition system, follow the below...

  • Page 167: Diagnostics

    20 DIAGNOSTICS • This system indicates any error on both the input and output signals. • As the errors are stored, they are indicated even if they are no longer present but occured during engine running (“yellow” errors); the ECU is not “reset” by removing the key OFF contact.
  • Page 168 HROTTLE VALVE POTENTIOMETER CIRCUIT When theThrottle Pos. error appears on the Dashboard Monitor page, this meas that the electrical circuit going from the potentiometer to the ECU is interrupted; this means that: • The wires are interrupted (check the circuit and the wire connections);...
  • Page 169 IL TEMPERATURE CIRCUIT SENSOR When the Engine Temp. item on the Dashboard Monitor page displays an error, this meas that the electrical circuit going from the potentiometer to the ECU is interrupted; this means that: • The sensor is damaged or the wires are cut out; it is therefore necessary to check the connections and the sensorʼs resistance;...
  • Page 170 NJECTOR CIRCUIT When on the Dashboard Monitor page the Throttle Pos. item displays an error, this meas that the electrical circuit going from injector 1 or 2 to the ECU is interrupted; this means that: • The internal circuit from the injector is interrupted: replace the injector as described in chapter 6 of this section;...
  • Page 171 UEL PUMP RELAY CIRCUIT When on the Dashboard Monitor page the item Fuel Pump Relay displays an error, this means that the power supply circuit for the injection to the ECU is interrupted; this means that: • The fuel pump relay is defective: replace the relay as described in chapter 12 in this section;...
  • Page 172 LECTRONIC REVOLUTION COUNTER If the electronic revolution counter does not work properly, it is useful to test it. To do this, open the Active Test page and, visually checking the revolution counter, click on the Tacho test icon If the test result is positive and during the test the revolution counter does not settle around 3800÷4000, then the instrument is faulty or the yellow-black wire carrying the pulse is cut out;...
  • Page 173 ARBURATION PROCEDURE Check of the starter control cut-out In the event that the throttle valve potentiometer has been replaced, removed or deregulated, before carrying out any carburation procedure it is necessary to adjust it once again, following the below instructions: •...
  • Page 174 ULES FOR CARBURATION REGULATION AND ADJUSTMENT Connect the PC to the diagnosis socket and the vacuometer • Detach the throttle body rod, 1/2 turn by-pass; • Using a throttle adjusting dowel, regulate the throttle potentiometer on the RH throttle body to a value of 3,6°±0,5;...

  • Page 175: Fuel Vapour Purification And Recirculation System (Usa, Sgp, Can)

    ±30°, with the gas breather inlet is positioned as illustrated in the figure. (V11 EV USA) - (V11 JACKAL USA) - (V11 BASSA USA) CALIFORNIA EV 1997-2000 - CALIFORNIA JACKAL - CALIFORNIA SPECIAL FROM FUEL TANK TO CANISTER UEL SYSTEM...
  • Page 176 21 REINIGUNGS- UND 21 SYSTEEM VOOR ZUIVERING EN RÜCKFÜHRSYSTEM DER HERCIRCULATIE BENZINEDAMPEN BENZINDÄMPFE (USA, SGP, CAN) (USA, SGP, CAN) N.B. OPMERKING Das Kippschutzventil Bez. “A” muss vertikal ±30° Het klepje tegen omkippen Ref. “A” moet montiert sein, mit wie in der Abbildung verticaal gemonteerd worden ±30°...
  • Page 177 XHAUST YSTEM USPUFFANLAGE FVOERINSTALLATIE...

  • Page 178: System Features

    SYSTEM FEATURES The exhaust system is composed of 3 parts: • Silencers; • Exhaust pipes; • Compensation chamber; These three parts are joined together with clamps. WARNING Carry out the disassembly procedures only when the engine is cool, as the exhaust system reaches very high temperatures when the engine is running.

  • Page 179: Exhaust Pipes

    EXHAUST PIPES Disassembly: • Unscrew the 2 nuts “A” with the ring-nut fastening washer “B” on the heads; • Remove the ring-nut “B” • Remove the 2 half-bushings and the gasket positioned between the manifold and the exhaust pipe. • Loosen the clamp “C”...

  • Page 180: Expansion Chamber

    EXPANSION CHAMBER Disassembly: • Remove the silencers from the motorbike as described in chapter 2 in this section; • Loosen the 2 clamps “A” on the exhaust pipes; • Remove the expansion chamber “B” by pulling it out of the exhaust pipes. Reassembly: Carry out the procedures in reverse order.

  • Page 181: Engine

    NGINE OTOR OTOR...

  • Page 182: General Rules For Engine Overhaul

    GENERAL RULES ENGINE OVERHAUL During fitting, take the Engine / gearbox assembly weight and center of gravity into account; support it accordingly. Take care of any dangerous points which may cause squeezing or cuts. Engine and system maintenance involve a specific and acquired know-how as well as the use of special tools.
  • Page 183 • Release clutch control transmission from lever “D” on the gearbox cover; • Unscrew odometer control transmission “E” from the drive on the gearbox cover; • Loosen the clamps “F” between the throttle body and the intake pipes; • Remove the tie rods of the gear lever and rear brake lever controls as described in chapter 2 and 3 section G;...
  • Page 184 • Remove front bumper, if fitted, as described in chapter 6 section H; if the bumper has not been fitted, unscrew the 2 screws “I” to free from the front the 2 frame sections from the chassis; • Unscrew nut “L” and remove front nut “M” fixing the engine to the chassis;...

  • Page 185: Lubrication System

    LUBRICATION SYSTEM The lubrication system consists of the following components: 1 Oil sump 2 Oil mesh filter 3 Oil cartridge filter 4 Oil pressure transmitter 5 Engine oil pressure regulator valve 6 Oil pump NGINE...
  • Page 186 “1” IL SUMP The oil sump is positioned under the engine and is fastened onto it by means of 18 screws. To remove the oil sump: • Position a suitable pan under the sump for collecting the used oil; • Drain all the oil as described in paragraph “Engine oil replacement”, chapter 2 section D;...
  • Page 187 “4” IL PRESSURE TRANSMITTER This is fitted on the engine crankcase, and it is connected to the dashboard lamp by means of electric wires; it indicates when the pressure inside the lubrication system is insufficient. When the lamp on the dashboard comes on (during running), it indicates that the pressure is below the preset limits;...
  • Page 188 “7” IL PUMP The oil pump used is a gear type pump and is driven directly by the crankshaft through a belt. Removal: • Drain all the engine oil as described in chapter 2 section D; • Remove the entire engine following the instructions reported in chapter 2 of this section;...
  • Page 189 HECK FOR OIL LEAKAGES FROM THE ENGINE CRANKCASE FLYWHEEL FLANGE SIDE In the event of oil leakages from the rear side of the engine crankcase (flywheel area), it is necessary to check that: • The seal ring on the flange, flywheel side, is not worn; •...

  • Page 190: Heads And Timing System

    HEADS AND TIMING SYSTEM The engine unit uses a timing system with rods and rockers, with 2 valves per cylinder. The valve opening and closing is controlled by a camshaft located in the crankshaft, which is driven by means of a duplex belt.
  • Page 191 Removal: • Remove the engine unit from the motorbike as described in chapter 2 of this section. • Unscrew the fastening screws “A” on the head cover “B” and remove the latter. REASSEMBLY NOTES The upper fastening screws are equipped with a washer, while the lower ones are not.
  • Page 192 Ausbau: Demontage: • Das Motoraggregat aus dem Motorrad ausbauen, wie • De aandrijfgroep wegnemen van de moto zoals in Kap. 2 dieses Abschnitts beschrieben. beschreven wordt in hoofdstuk 2 van deze sectie. • Dichtungsschrauben “A” • De schroeven “A” van dichting op het deksel kop “B” Zylinderkopfdeckel “B”...
  • Page 193 EAD DISASSEMBLY N.B. The procedures described below refer to the disassembly of only one head, but they are valid for both. To disassemble the heads and their components work as follows: • Position tool “A” (code 10 90 72 00) on the upper plate and in the middle of the valve head that you want to remove;...
  • Page 194 HECK OF HEAD COMPONENTS EADS Check that: • The contact surfaces for the cover and cylinder are not grooved or damaged so as to jeopardize a perfect packing; • The tolarance between the holes for the valve guides and the valve stems are within the prescribed limits; •...
  • Page 195 Valve seats The valve seats must be trued using a miller. The tilt angle for the seat is 45° ± 5'. After milling, to obtain a good coupling and a perfect packing between the ring nuts and the valve heads, it is necessary to proceed with grinding.
  • Page 196 ALVE SPRING INSPECTION Check that the springs are not deformed and are still loaded. UTSIDE SPRING When free, it has a length of 54,5 mm; • • When the valve is closed, it has a length of mm 36 and must provide a load of Kg. 29,5 ± 3%; When the valve is open, it has a length of mm 27 •...
  • Page 197 PRING PACKAGE CHECK When the valve seats on the heads are trued, after having fitted the valves on the heads, it is necessary to check that the above said springs are compressed between mm 35,700 ÷ 36,000; to reach this value, fit washers “A” (code 14 03 73 00) with a 0.3 mm thickness.
  • Page 198 OCKER AND PIN CHECK RH EXHAUST ROCKER AND LH +0.032 ø15E8 +0.059 INTAKE ROCKER Check the wear condition and the dimensions of the pins KIPPHEBEL AUSLASS and of the rockers; if the read measures are not within RECHTS UND EINLASS the range indicated on the drawings, it is necessary to LINKS replace them.
  • Page 199 IMING EXHAUST VALVE CLOSES AFTER T.D.C. INTAKE VALVE OPENS BEFORE T.D.C. AUSLASSENDE NACH DEM OT EINLASSBEGINN VOR DEM OT P.M.S. EINDE UITLAAT NA B.D.P. BEGIN AANZUIGING VOOR B.D.P. Timing data: NTAKE • Opens 20° before the T.D.C. • Closes 50° after the B.D.C . XHAUST P.M.I.
  • Page 200 TEUERUNG ISTRIBUTIE Gegevens van de distributie: Steuerdaten: ANZUIGING INLASS • Opent 20° voor de P.M.S. • Sluit 50° na de P.M.I. • Öffnet 20° vor dem OT • Schließt 50° nach dem UT FVOER • Opent 44° voor de P.M.I. USLASS •...
  • Page 201 • Remove the toothed wheel “O”; • Disassemble the timing chain tensioner “P” by unscrewing the relative fastening screws; • Unscrew the 3 screws “Q” fastening the flange “R” retaining the camshaft “S” and extract the latter after having removed the tappets from their seats “T”; Having removed all timing components, it is necessary to check them, and if they are not in perfect condition they must be replaced.
  • Page 202 DIAMETERS FOR THE CAMSHAFT SUPPORTS AND RELATIVE SEATS ON THE CRANKCASE Ø SHAFT SUPPORT Ø SEATS ON THE CRANK- ASSEMBLY BACKLASH CASE mm Timing side 47,000÷46,984 47,025÷47,050 0,025÷0,066 Flywheel side 32,025÷32,050 32,000÷31,984 COUPLING DATA FOR THE TAPPETS AND RELATIVE SEATS ON THE CRANKCASE SEATS Ø...
  • Page 203 HECK OF THE TIMING SYSTEM SETTING To check the engine timing setting, work as follows: • Set valve clearance to 1,5 mm between rockers; • Unscrew the engine pinionʼs fastening nut; • Fit the hub, Code 65 92 84 00 “2”, onto the engine shaft slot, having fitted the index plate, Code 19 92 96 00 “3”, and fastening it to the engine shaft by means of a screw;...

  • Page 204: Cylinders And Pistons

    EASSEMBLY OF THE TOOTHED WHEEL AND MEASURING OF THE AIR GAP • Position the toothed wheel “A” with the milled toothing “B” on the opposite side to the timing sensor one “C”; • Insert a feeler gauge between the timing sensor terminal and the toothed wheelʼs toothed surface, to make sure the air gap is between 0.7 and 0.9 mm.
  • Page 205 N.B. The procedures described below refer to the disassembly of only one head, but they are valid for both. Disassembly: • Remove the engine unit, as described in chapter 2 in this section; • Remove the head, as described in chapter 4 in this section;...

  • Page 206: Clutch

    During overhaul, descale the crown, the pistons and the seats for the flexible rings; check the backlash between the cylinders and pistons on the selection diameter; if this exceeds the prescribed value, the cylinders and the pistons must be replaced. The engine pistons must be balanced;...
  • Page 207 The clutch is a dry type and is housed inside the engine flywheel. It is composed of two driven disks, one intermediate disk, one spring pressure washer and 8 springs. Disassembly: NGINE...
  • Page 208 Remove the engine unit from the motorbike as described in chapter 2 in this section; • Remove the alternator as described in chapter 7 in this section; • Apply the locking tool “A” (cod. 12 91 18 01) to the engine flywheel and tool “B”...
  • Page 209 Clutch springs “1” Check that the springs have not lost their elasticity and are not deformed: • Springs compressed to 20 mm must give a load of 21 ÷ 21.5 Kg ; • Springs compressed to 17 mm must give a load of 28.7 ÷...
  • Page 210 Also check: Intermediate plate “4” Check that the surfaces touching the driven plates (with friction material) are perfectly smooth and even and that the external teeth inside the flywheel is not damaged, otherwise replace the plate. Control transmission Check that the transmission cable has no damaged wires, otherwise replace the transmission.
  • Page 211 Carry out the removal procedures in reverse order, remembering that: • When refitting the clutch assembly, make sure that reference “I” marked on one of the spring pressure plateʼs teeth is aligned with reference “L”, marked on the flywheel; • For centering the clutch disks use the special tool (code 30 90 65 10);...

  • Page 212: Alternator

    ALTERNATOR AND FLYWHEEL LTERNATOR The alternator is composed of two elements: The stator, which is fastened on the timing cover, and the rotor, which is fitted on the crankshaft. The output power supplied by the alternator is equal to 350 W at 5000 r.p.m. (14V - 25A) Disassembly: With the engine unit removed •...
  • Page 213 LYWHEEL The flywheel is fitted on the crankshaft on the opposite side to the alternator; the clutch is housed inside it. Disassembly: • Remove the engine unit from the motorbike following the instructions described in chapter 2 in this section. •...

  • Page 214: Crankshaft And Connecting Rods

    CRANKSHAFT AND CONNECTING RODS Disassembly: • Remove the engine unit from the motorbike, following the instructions described in chapter 2 in this section; • Remove the heads, as described in chapter 4 in this section; • Remove the cylinders and pistons following the instructions described in chapter 5 in this section;...
  • Page 215 OMPONENT OVERHAUL WARNING During this procedure, inflammible vapours and metal particles which may be expelled at high speed are produced. It is therefore recommended to work in an environment free of naked flames or sparks. The operator must wear protective goggles.
  • Page 216 ONNECTING RODS Carry out the following controls when overhauling the connecting rods: • The bushing conditions and the backlash between them and the piston pins; • Axis parallelism; • Connecting rod bearings. The bearings are slim-shell type, with anti-friction alloy which means they cannot be adjusted;...
  • Page 217 LEUELSTANGEN RIJFSTANGEN Bei der Überholung der Pleuelstangen die folgenden Bij de revisie van de drijfstangen de volgende controles Kontrollen ausführen: uitvoeren: • Zustand der Buchsen und Spiel zwischen den • Condities van de moffen en speling tussen deze en Buchsen und den Bolzen. de pinnen;...
  • Page 218 Connecting rod bearing thickness Bearings for Ø mm undersized Standard Bearing connecting rod pin (Production) mm 0,254 0,508 0,762 from 1,535 1,662 1,789 1,916 to 1,544 1,671 0,798 1,925 Crankpin diameter Standard Undersized Undersized Undersized Ø mm 0,508 mm 0,254 mm 0,762 44,008÷44,020 43,754÷43,766 43,500÷43,512 43,264÷43,258...
  • Page 219 Main bearing journal diameter, flywheel side RANKSHAFT UNDERSIZED BY mm PRODUCTION Examine the surfaces for the main bearing journals; if STANDARD mm they show signs of grooving or ovality, it is necessary to 52.970 53.770 53.570 53.370 recondition the pins (observing the undersize tables), 53.751 53.551 53.351...
  • Page 220 EIGHT CONTROL FOR CRANKSHAFT BALANCING The weight of the connecting rods together with screws must be balanced. A difference of 4 grams is permissible. To balance the engine shaft from a static point of view, it is necessary to apply the following weight to the crank pin: •...
  • Page 221 EASSEMBLY ONNECTING RODS Carry out the removal procedures in reverse order, remembering that: • Given the high load and stresses to which the fastening screws for the crankshaft connecting rods are subjected, they must be replaced with new screws. • The assembly backlash between the bearing and the connecting rod pin is 0,022 minimum, 0,064 maximum;...
  • Page 223 EARBOX ETRIEB ERSNELLING...

  • Page 224: Gearbox

    MAIN FEATURES 5-speed gear model with constant mesh gears with front clutch dogs. Built-in rubber cush drive damper pads. Pedal control placed on the LH side of the vehicle. Gearbox speeds: gear = 1:2 (Z = 14/28) gear = 1:1.3889(Z = 18/25) gear = 1:1.0476 (Z = 21/22) gear = 1:0.8696 (Z = 23/20) gear = 1:0.7500 (Z = 28/21)
  • Page 225 ESCRIPTION ESCRIPTION Secondary shaft Washer Roller bearing cage Adjustment washer 2÷4 O-ring Abutments washer Complete range selector Gear 4th S.S. (z=20) Range selector return spring Internal ring 4 gear Ring nut Roller bearing cage 4 S.S. Washer Sleeve 3 S.S. Clutch internal body Sleeve O-ring...

  • Page 226: Removal And Installation

    REMOVAL AND INSTALLATION Removal: To remove the gearbox from the motorcycle proceed as follows: • Remove the seat (see chapter 4 section E) and the toolbox “A”. • Disconnect the battery cables from the 2 poles (ne- gative/positive) and remove the battery. •...
  • Page 227 • Remove the tie rod of the gear lever control, as described in chapters 2 and 3 of section ”G”. • Unscrew the screws “G” fixing the battery plate “H” to the gearbox and remove it. • Remove the rear foot rests as described in chapter 3 section “H”.

  • Page 228: Disassembly

    DISASSEMBLY To disassemble the gearbox in all its components proceed as follows: • Lock with a vice the gearbox support tool “A” code 14929600 and assemble the complete gearbox on its support. • To simplify the removal operations, it is recommended that the gear is in neutral.
  • Page 229 ZERLEGUNG ONTBINDING Für die Zerlegung des Getriebes in seine Einzelteile, wie Alle componenten van de versnellingsbak demonteren: folgt, vorgehen: • Het gereedschap om de versnellingsbak te • Die Getriebehaltevorrichtung “A” Kennnr. 14929600 ondersteunen vastklemmen (“A” codenummer blockieren und auf dem Halter das komplette Getriebe 14929600) en op het versnellingsbakblok monteren: einbauen.
  • Page 230 • Remove the external clutch body “G” from its seat on the cover, remove the thrust bearing “H”, the internal body “I” and the clutch control rod “L”. Removal of the internal clutch body “M” • On the clutch side, unscrew the internal body lock ring nut “N”...
  • Page 231 • Den Kupplungsaußenkörper �G“, das Drucklager �H“, • Haal het uitwendige gedeelte van de koppeling “G” uit den Innenkörper �I“ und den Kupplungssteuerstab �L“ de kast, het taatslager “H”, het inwendige gedeelte “I” aus dem Sitz auf dem Deckel entfernen. en de stang “L”...
  • Page 232 Removal of shaft assembly and splined drum • Unscrew and remove the neutral indicator “Z”. • Unscrew and remove the plug “X” (it is used to retain the “W” gear pawl on the splined drum). • Remove the spring “Y”. N.B.
  • Page 233 Disassembly of the secondary shaft • Remove the 5 -speed gear “A” • Remove the 1 -speed gear “B” with the relevant roller bearing cage “C”, remove the rubber seal ring, the bushing “E” and the sliding sleeve “F” of the 1 and 2 speed.
  • Page 234 Disassembly of the primary shaft • Remove the sleeve of the 5 speed “F”. • With a proper punch push down the retainer pawl “A” and rotate the bushing “B” in order to disengage it from grooves. • Remove the bushing “B” and the pawl “A”, the spring “C”, the roller bearing cage “D”...
  • Page 235 Disassembly of clutch shaft • Using extractor “A” code 14928500, remove the roller bearing inner race and the nut “C”. • Then place the complete shaft on a press and by means of extractor “B” code 12905900, press the spring enough to remove the two half-sections “D” retaining the cush driver damper pads cup and then remove: cup “E”;...
  • Page 236 Bearing removal From the gearbox: • To remove bearings, warm up the gearbox at a tem- perature of approximately 150° ÷ 160° C. • Remove the primary shaft needle bearing “A” with the extractor code 14913100, see chapter 5 section B. •...

  • Page 237: Check And Overhaul

    CHECK AND OVERHAUL Gearbox housing and cover The gearbox housing and cover shall not show any cracks. The surfaces jointing base and cover shall not be scored nor damaged; the knob threading shall not be stripped. Seal rings If the seal rings are removed from their seats, they shall be replaced in order to seal properly.
  • Page 238 Secondary shaft gears They shall not be extremely worn out on the toothing and on the front engaging notches. The surfaces touching the teeth shall be smooth, not dented nor damaged, otherwise replace the gears. Roller bearing locking nut on the secondary shaft Check that the thread is in good condition, not dented nor damaged, otherwise replace the nut.
  • Page 239 Seal ring between clutch fixed body and bearing on the clutch shaft Check that they are neither crushed nor rigid, otherwise replace them. Clutch fixed body on the clutch shaft The teeth shall not be worn out nor broken, the touching surfaces of teeth shall be smooth, otherwise replace the body.

  • Page 240: Gearbox Unit Reassembly On The Bench

    GEARBOX UNIT REASSEMBLY ON THE BENCH After all the checks, tests and replacements reassemble the gearbox as follows: Bearing assembly on the gearbox housing and on the cover N.B. Warm up the gearbox housing and cover at a temperature of roughly 150° ÷ 160°C before assembly Firstly, carefully clean the bearing seats and rings with solvent (trichloroethylene).
  • Page 241 Locking plate assembly on the clutch shaft bearing on the housing and on the secondary shaft cover. Make sure that they perfectly stick to the bearing external ring nut. Before screwing the retaining screws, the locking plates on the housing and cover, cover the threaded part with “Loctite”.
  • Page 242 Secondary shaft reassembly on the housing Follow the procedure below to reassemble gears and sleeves on the very shaft. On the shaft, housing side, insert the following: • The bushing for the 2 -speed gear on the shaft; make sure that the head of the bushing faces the cover. •...
  • Page 243 Secondary shaft shimming • Assemble the abutments washer on the 4 -speed side, then the adjustment washers until the established distance of 144.7 ÷ 145.2 mm is reached between the adjustment washers and the 5 -speed gear. (To measure remove the O-ring between the 1 -speed gear) (see page 16 of this section) •...
  • Page 244 Clutch shaft reassembly on the housing Proceed as follows to reassemble the following parts on the clutch shaft: • Insert the transmission gear “A” on the shaft with clutch dog towards the cover. • Insert the clutch dog sleeve “B” on the shaft with the clutch dogs towards the transmission gear.
  • Page 245 Cover assembly on the gearbox housing N.B. While reassembling the cover complete with range selector, make sure that the gearbox control splined drum is in neutral. If not so, the retaining keys of the range selector would interfere with the drum crown instead of settle freely in the control notches indicated by the arrows.
  • Page 246 • Adjust the gearbox control by means of the eccentric screw “A” after unscrewing the lock nut “B” until the gear engages smoothly. • Try to engage the gears from 1 to 5 and shift down from 5 to 1 and then in neutral.
  • Page 247 Reassembly of the clutch internal body on the shaft and of the clutch control unit on the shaft housing side Reassemble: • The O-ring “A” between the bearing and the clutch internal body. • The clutch internal body “B” on the shaft. •...
  • Page 248 Reassembly of the clutch control unit in the clutch shaft and on the gearbox housing cover Reassemble: • The internal body “B” on the shaft. • The thrust bearing “C” on the internal body end. • The external body “D” provided with the cover seal ring “E”.
  • Page 249 INAL RIVE OUSING AND HAFT NTRIEBSWELLE UND GEHÄUSE HINTEN S EN KAST VAN ACHTERSTE OVERBRENGING...

  • Page 250: Rear Transmission Housing

    FINAL DRIVE HOUSING Disassembly: • Remove the rear wheel as described in chapter 2, section F; • Drain the oil from the final drive housing as described in chapter 2 section D. • Unscrew and remove the 4 nuts “A”. •...
  • Page 251 • Remove the crown – pin assembly “G” from the flange “F”. • Unscrew the 8 screws “H” and remove the crown. • Remove the roller bearing inner race “I” with the extractor “L” code 17948360. • Use the proper locking tool “M” of the pinion shaft, code 12907100, to unscrew the back nut “N”.
  • Page 252 • Remove the pinion “P”, the washer “Q”, the outer roller cone bearing cage “R”, the adjustment washers “S”, the roller bearing cage “T” - pinion side, and the spacer “U” from the case “O”. • Use extractor “V”, code 17945060, to remove the outer race of the roller cone bearing cages “T”...
  • Page 253 Bevel gear The bevel gear consists of a pinion and a “Gleason” crown wheel. The crown toothing shall not be ungeared or excessively worn. The pinion shank shall not be dented and the end fits shall be smooth and not dented. Cage sealing ring The surfaces shall not be damaged, dented or worn, otherwise replace them.
  • Page 254 Reassembly Before reassembly, check each component accurately, as described in the chapter “Check and overhaul” of this section. Outer races of the cone bearings on the case Use proper punch “A”, code 17945160, to assemble the cone bearings outer races on the case. Case components To reassemble, carry out the removal procedures in reverse order, checking that the number of shim rings...
  • Page 255 Crown on the drilled shaft Reassemble the crown on the drilled shaft and remember to always replace the 8 screws “Z”. Clean the drilled shafts threads accurately with trichloroethylene to guarantee a good adherence of the sealant “Loctite 601” that was previously applied on the screw thread.
  • Page 256 Pinion – crown coupling To check the pinion and crown coupling, grease the pinion toothing, drive side, with red lead grease. Using an armed extractor “A” and a suitable shim “B” keep the hub-crown unit slightly forced towards the cover; turn the pinion “C”...

  • Page 257: Transmission Shaft

    FINAL DRIVE SHAFT Disassembly: • Remove rear swinging arm as described in chapter 9 section F. CHECK AND OVERHAUL Sleeve for transmission shaft and bevel sprocket “A” Internal fits shall be intact, not damaged or dented, otherwise replace the sleeve. Snap rings on transmission shaft “B”...
  • Page 258 ANTRIEBSWELLE ÁRBOL DE TRANSMISIÓN Ausbau: Demontage: • Die Hinterradschwinge, wie in Kap. 9, Abschnitt F, • De achtervork verwijderen zoals beschreven in beschrieben, entfernen. hoofdstuk 9 deel F. KONTROLLE UND ÜBERHOLUNG CONTROLE EN REVISIE Muffe für Antriebswelle und konisches Ritzel “A” Verbindingpijp voor transmissieas en conisch tandwiel “A”...
  • Page 259 LECTRICAL YSTEM LEKTROANLAGE LEKTRISCHE INSTALLATIE...

  • Page 260: Electrical System Description

    ELECTRICAL SYSTEM DESCRIPTION The electrical system is composed of: • Battery • Electro-magnetic control starter motor; • Generator - Alternator, fitted on the front part of the crankshaft; • Indicator device for low fuel; • Headlight control switch; • Starter coils; •...
  • Page 262 KEYS FOR ELECTRICAL SYSTEM DIAGRAM CALIFORNIA EV 2001 - STONE - SPECIAL SPORT 1 High beam 60 W (H4 halogen with high beam) 2 Dipped light 4 W 3 Low beam 55 W (H4 halogen with high beam) 4 4-way Amp connector, headlight 5 RH front direction indicator 10 W 6 Connector Cannon 2 way RH direction indicator 7 LH front direction indicator 10 W...
  • Page 264 KEYS FOR ELECTRICAL SYSTEM DIAGRAM CALIFORNIA EV (1997 - 2000) 1 High beam and low beam light bulb 60/55W 2 Front parking light bulb 3W 3 RH direction indicator warning light bulb 4 Speedometer light bulb 5 Revolution counter light bulb 6 LH direction indicator warning light bulb 7 Microprocessor control unit 8 Fuel level warning light bulb...
  • Page 266 KEYS FOR ELECTRICAL SYSTEM DIAGRAM CALIFORNIA SPECIAL 1 High beam 60 W (H4 halogen with high beam) 2 Dipped light 4 W 3 Low beam 55 W (H4 halogen with high beam) 4 4-way Amp connector, headlight 5 RH front direction indicator 10 W 6 Connector Cannon 2 way RH direction indicator 7 LH front direction indicator 10 W 8 Connector Cannon 2 way LH direction indicator...
  • Page 268 KEYS FOR ELECTRICAL SYSTEM DIAGRAM CALIFORNIA JACKAL 1 High beam 60 W (H4 halogen with high beam) 2 Dipped light 5 W 3 Low beam 55 W (H4 halogen with high beam) 4 4-way Amp connector, headlight 5 RH front direction indicator 10 W 6 Connector Cannon 2 way RH direction indicator 7 LH front direction indicator 10 W 8 Connector Cannon 2 way LH direction indicator...

  • Page 269: Battery

    BATTERY The batteryʼs voltage is 12 V with a capacity of 30 Ah; it is charged by the generator. NSTRUCTIONS TO OPERATE DRY BATTERIES • Remove the plugs. • Fill every battery element with sulphuric acid, density 1.28 (1.23 for tropical countries) up to 15 mm above the separation plates.
  • Page 270 ATTERY CHARGE INSTRUCTIONS • Remove the plugs. • Recharge the battery only with direct current. • Connect the battery charger positive cable (+) to the battery positive pole (+) and the battery charger ne- gative cable (-) to the battery negative pole (-). •...

  • Page 271: Battery (Usa - Sgp - Can Version)

    BATTERY (USA - SGP – CAN VERSION) The batteryʼs voltage is 12 V with a capacity of 16 Ah; it is charged by the generator. The battery used on the motorbike is a sealed type lead acid battery (without maintenance) which does not require any checks.
  • Page 272 YCLIC USE From 14.7V to 15.0V per battery, at 25°C. No current limit requested. UFFER USE From 13.50V to 13.80V per battery, at 25°C. No current limit requested. Removal: • Remove the saddle as described in chapter 4 section • Release the locking belt “C”...

  • Page 273: Starter Motor

    STARTER MOTOR General features: Voltage 12 V Power 1,2 Kw Torque with no load 11 Nm Torque with load 4,5 Nm Pinion z=9 mod. 2,5 Pinion side rotation Anti-clockwise Speed 1750 r.p.m. Current with no load 600 A Current with load 230 A Weight 2,8 Kg...

  • Page 274: Light And Acoustic Systems / Dashboard / Controls

    LIGHT AND ACOUSTIC SYSTEMS / DASHBOARD / CONTROLS EADLIGHT Removal: • Unscrew the two screws “A” and remove them together with the two washers; • Remove the headlight and the inner shims; • Detach connector “B”; Refitting: Refit following the removal procedures in reverse order. Replacing the light bulbs: •...
  • Page 275 EV 1997-2000 - AILLIGHT ASSEMBLY ALIFORNIA ACKAL TONE Removal: • Unscrew the 3 screws “A” and remove the licence plate holder. • Unscrew the screw “B” by retaining the nut “C”. • Remove the lock rings “D”. • Remove the taillight assembly. N.B.
  • Page 276 EV 2001 - S AILLIGHT ASSEMBLY ALIFORNIA PECIAL PECIAL PORT Removal: • Unscrew the 3 screws “A” placed within the rear mudguard. • Remove the taillight assembly. N.B. For a complete removal it is necessary to disconnect all the electric wiring inside the taillight and the direction indicators after disassembling the relevant rear reflectors and parabola.
  • Page 277 RONT DIRECTION INDICATORS Removal: • Remove the headlight, as described in this chapter; • Disconnect the wiring “A” for the indicator to be removed; • Unscrew the screw “B”; • Remove the indicator, taking care not to damage the cable. N.B.
  • Page 278 EAR DIRECTION INDICATORS Removal C - EV 2001: ALIFORNIA PECIAL PECIAL PORT • Remove the taillight assembly as described in this section. • Unscrew the screw “A” and remove the rear reflector. • Disconnect the electric wiring on the parabola. •...
  • Page 279 COUSTIC SYSTEM The acoustic system is composed of two horns; 1 high tone (H) and one low tone (L). The one on the RH side is the low tone. Removal: • Remove the horn cover “A”. • Detach the two connectors “B”; •...
  • Page 280 ASHBOARD WARNING LIGHTS ALIFORNIA ACKAL TONE Removal: • Disassemble the headlight. • Disassemble the lower warning light support “C” after unscrewing the 3 screws “A”. • Unscrew the screws “B”. • Extract the bulb holder and replace the bulb. EV - ASHBOARD WARNING LIGHTS ALIFORNIA PECIAL...
  • Page 281 ONTROLS SIDE Removal: • Remove the accelerator control as described in chapter 4 section G; • Remove the saddle as described in chapter 4 section • Remove the tank as illustrated in chapter 3 sect. I; • Detach the RH control cable from the main connector “A”;...
  • Page 282 EVOLUTION COUNTER ODOMETER ALIFORNIA PECIAL PORT Revolution counter removal: • Remove the headlight , as described in this chapter; • Detach the resetting pin “A”; • Unscrew the 4 nuts “B”; • Remove the dashboard lower cover “C”; • Unscrew the stud bolts “D”; •...
  • Page 283 EVOLUTION COUNTER ODOMETER ALIFORNIA ALIFORNIA PECIAL Revolution counter removal: • Unscrew the screws “A”. • Remove the revolution counter “B”. • Extract the bulb holder and replace the bulb. Odometer removal: • Disassemble the headlight. • Unscrew the screws “C”. •...

  • Page 284: Side Stand Switch

    SIDE STAND SWITCH The motorbike is equipped with an arm which serves a side support for parking. When the stand is in parking position (completely down), the micro-switch “A” activates a solenoid starter, which interrupts the power supply to the starter motor. In these conditions the engine cannot be started.

  • Page 285: Fuse Terminal Board

    FUSE TERMINAL BOARD 2001 - S ALIFORNIA TONE PECIAL PORT 6 fuses are fitted on the terminal board. Before replacing a fuse or the fuses, it is necessary to eliminate the failure which caused melting. The 6 fuses are listed below: FUSE “1”: Battery charger ........30 A FUSE “2”: Key-operated switch ........15 A FUSE “3”: High beam, low beam, warning horn ..15 A...
  • Page 286 ALTERNATOR - REGULATOR WARNING If connections are inverted the regulator will be irreversibly damaged. Check that the regulator earth connections are efficient. Possible checks to be carried out on the alternator or regulator if the battery fails to re-charge or the power supply is no longer regulated.
  • Page 287 ALTERNATOR - REGLER DYNAMO - WORDEN ACHTUNG OPGELET Eine eventuelle Umkehrung der Anschlüsse Als de aansluitingen eventueel verwisseld beschädigt den Regler. worden kan de spanningsregelaar hierdoor onherstelbaar beschadigd worden. Sicherstellen, daß der Erdungsanschluß des Reglers einwandfrei funktioniert. Verzeker u ervan dat de massa-aansluiting van de spanningsregelaar absoluut deugdelijk is.
  • Page 288 EGULATOR The regulator has been calibrated in order to maintain the battery voltage at a value between 14÷14.6 Volts. The pilot light (illuminated when the engine is not running, but the key is in ON position) will switch off when the generator begins to charge, (approx.

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