MOTO GUZZI California Special Manuals

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MOTO GUZZI California Special Workshop Manual

MOTO GUZZI California Special Workshop Manual (512 pages)

1997-2000

Brand: MOTO GUZZI | Category: Motorcycle | Size: 50.95 MB

Table of Contents

English

4
- Table of Contents
  4
- California EV (1997 - 2000)
  11
- California EV 2001
  11
- California Jackal
  12
- California Stone
  12
- California Special
  13
- California Special Sport
  13
- Eneral Nformation
  14
- Abbreviations and Symbols
  15
- How to Consult this Manual
  15
- General Safety Regulations
  17
- Rules for Maintenance Procedures
  17
- Warranty
  19
- Identification Data
  22
- Lubricants and Refilling
  24
- Technical Specifications
  26
- Tightening Torques
  38
- Tools
  41
- Preliminary Tests
  46
- Engine Ignition
  48
- Engine Warming-Up
  48
- Engine Running
  48
- Stopping the Engine
  50
- Parking
  50
- Adjustments and Regulations
  52
- Sport
  52
- Clutch and Front Brake Control
  224
- Gearbox Control
  226
- Rear Brake Control
  230
- Steering
  237
- Handlebar
  239
- Foot Rests
  241
- Side Stand
  243
- Chassis Dimensions
  245
- Front Bumper
  247
- Chassis Dimensions
  249
- System Components
  255
- Tank "5
  257
- 10 Battery "1
  273
- 11 Starter Switch "2
  273
- 12 Relay "3
  275
- 14 Air Temperature Sensor "5
  279
- 15 Oil Sensor Temperature "6
  279
- 16 R.p.M. and T.D.C. Sensor "7
  281
- 17 Coils "8
  283
- 18 Throttle Position Potentiometer "9
  285
- 19 Operating Stages
  287
- 20 Diagnostics
  291
- Fuel Vapour Purification and Recirculation System (Usa, Sgp, Can)
  307
- System Features
  310
- Silencers
  310
- Exhaust Pipes
  312
- Expansion Chamber
  314
- General Rules for Engine Overhaul
  317
- Lubrication System
  323
- Heads and Timing System
  333
- Cylinders and Pistons
  357
- Clutch
  361
Dutch

14
- Lgemene Inlichtingen
  14
- Hoe Moet Deze Handleiding Geraadpleegd Worden
  16
- Afkortingen en Symbolen
  16
- Algemene Veiligheidsregels
  18
- Regels Voor de Onderhoudsoperaties
  18
- Garantie
  20
- Model Features
  21
- Arakteristieken
  21
- Gegevens Voor de Identificatie
  23
- Smeerproducten en Tanken
  25
- Technische Gegeven
  27
- Start-Up
  28
- Transmissions
  28
- Clutch
  28
- Primary Transmission
  28
- Suspensions
  30
- Front
  30
- Rear
  30
- Wheels
  30
- Brakes
  34
- Standard Values
  38
- Draaikoppe
  40
- Uitrusting
  41
- Control and Use of the Morbike
  45
- Ontrole en
  45
- Ebruik Van de
  45
- Otorfiets
  45
- Before Start-Up Check that
  46
- Preliminaire Controles
  47
- Cool Engine
  48
- Start Van de Motor
  49
- Verwarming Van de Motor
  49
- Motor in Werking
  49
- Stilstand Van de Motor
  51
- Parkeren
  51
- Steering Shock Absorber
  52
- Clutch Lever and Front Brake Lever Adjustment
  52
- Rear and Front Left Brake Pedal Adjustment
  52
- Registraties en Regelingen
  53
- Front Fork Adjustment
  54
- Rear Shock Absorbers Adjustment
  56
- Maximum Allowed Load
  56
- Steering Adjustment
  58
- Preparation for Long Periods at Rest
  60
- Light Beam Adjustment
  60
- Voorbereiding Voor Een Lange Inactiviteit
  61
- Cleaning the Motorbike
  62
- Preparation for Washing
  62
- While Washing
  62
- After Washing
  62
- Ontrolle und
  63
- Ebrauch des
  63
- Otorrads
  63
- Schoonmaak Van de Motorfiets
  63
- Instructions on How to Clean the Windscreen
  64
- Scheduled Maintenance
  66
- Leding
  123
- Spiegel
  125
- Spiegeltjes
  125
- Vorderes und Hinteres Schutzblech
  127
- Voorste en Achterste Spatbord
  127
- Kleine
  133
- Laterale Flanken
  133
- Vordersitz
  135
- Voorste Zadel
  135
- Hintersitz
  137
- Achterste Frameschotten
  139
- Frameschotten Vooraan
  141
- Äderteile
  142
- Ielinstallaties
  142
- Vorderrad
  144
- Voorwiel
  144
- Hinterrad
  154
- Achterwiel
  154
- Überholung der Räder
  162
- Revisie Wielen
  162
- California Jackal - Stone
  165
- Hydraulische Linker Voorrem
  166
- Hydraulische Rechter Voorrem
  168
- California Ev - Special - Special Sport
  173
- Special Sport
  173
- Hydraulische Achterrem California
  174
- Jackal - Stone
  175
- Vordere Gabel
  186
- Voorste Gaffel
  186
- Hintere Schwinge
  214
- Achterste Vork
  214
- Achterste Schokbreker
  218
- 11 Lenkungsstossdämpfer
  220
- 12 Reifen
  220
- 11 Schokbreker Van Sturing
  220
- 12 Banden
  220
German

66
- Egelmässige Artung
  66
- Eriodiek Onderhoud
  66
- Tabel Periodiek Onderhoud
  68
- Maintenance Procedures
  69
- Engine Oil Replacement
  69
- Viscosity
  69
- Wartungsarbeiten
  70
- Onderhoudsoperaties
  70
- Oil Cartridge Filter Replacement
  71
- Washing the Oil Mesh Filter
  73
- Air Filter
  75
- Fuel Filter
  77
- Spark Plugs
  79
- Tappet Backlash
  81
- Gearbox Lubrication
  83
- Final Drive Lubrication
  85
- Steering Bearings
  87
- Front Fork Oil Replacement
  89
- Checking the Braking and Clutch System Fluid
  97
- Brake System Fluid Replacement
  99
- Draining the Braking System Fluid
  107
- Rear Braking System
  109
- Left-Hand Front Braking System
  111
- Left-Hand Front and Rear Braking System
  113
- Brake Pad Check/Replacement
  115
- Front Brake Caliper
  115
- Rear Brake Caliper
  117
- Wheel Spokes Tension Adjustment
  119
- Trimmings
  123
- Wing Mirrors
  124
- Front and Rear Mudguards
  126
- Side Panels
  132
- Front Seat
  134
- Rear Seat
  136
- Rear Chassis Protections
  138
- Front Chassis Protections
  140
- Wheel Parts
  142
- Front Wheel
  143
- Brake Disks Spacing Flanges
  151
- Rear Wheel
  153
- Rear Wheel Hub Removal – Rubber Cush Drive Damper Side
  157
- Rear Brake Disk Spacer Flange
  159
- Wheel Overhaul
  161
- Bearings
  161
- Wheel Spindle
  161
- Front Left-Hand Hydraulic Brake California Jackal - California Stone
  165
- Brake Calipers
  165
- Front Right-Hand Hydraulic Brake
  167
- Brake Disks
  169
- Rear and Front Left-Hand Hydraulic Brake
  173
- Rear Hydraulic Brake
  175
- Disk Brake Troubles
  179
- Brake-Power Limiter
  183
- Front Fork
  185
- Complete Fork Removal
  191
- Fork Leg Removal
  193
- General Rules for a Correct Overhaul
  193
- Troubles – Causes - Solutions
  195
- Disassembly/Overhaul
  197
- Overhaul of the Compression Shock Absorber
  201
- Overhaul of the "Rebound" Shock Absorber
  205
- Rear Swing Arm
  213
- Rear Shock Absorbers
  217
- Controls
  223
- Removal of Front Brake Lever with Master Cylinder
  224
- Removal of Front Clutch Lever
  224
- Disassembly of California Jackal - California Stone
  228
- Disassembly of California Special - California Special Sport
  228
- Accelerator / Starter Control
  232
- Accelerator Control
  232
- Maintenance of Accelerator Cables
  232
- Starter Circuit
  234
- Chassis
  236
- Disassembly of Front Footrests
  241
- Reassembly of Front Footrests
  241
- Disassembly of Rear Footrests Support
  241
- Fuel System
  252
- General Description of the Fuel System
  253
- Fuel Circuit
  255
- Electrical Fuel Pump “1”
  259
- Fuel Filter “2”
  261
- Electro-Injectors “3”
  261
- Pressure Adjuster “4”
  263
- Intake Air Circuit
  265
- Air Filter Box “1”
  267
- Throttle Body “2”
  269
- Electrical Circuit
  271
- Normal Mode
  287
- Start-Up Stage
  287
- Operation During the Acceleration Stage
  289
- Resetting the Ecu
  291
- Throttle Valve Potentiometer Circuit
  293
- Absolute Pressure Sensor Circuit
  293
- Oil Temperature Circuit Sensor
  295
- Air Temperature Sensor Circuit
  295
- Battery Voltage
  295
- Injector 1 and 2 Circuit
  297
- Circuit and Primary Winding of Coils
  297
- Fuel Pump Relay Circuit
  299
- Electronic Control Unit
  299
- Timing and Engine R.P.M. Sensor Circuit
  299
- Electronic Revolution Counter
  301
- Carburation
  301
- Carburation Procedure
  303
- Rules for Carburation, Regulation and Adjustment
  305
- CO% Check
  305
- Exhaust System
  309
- Installatie
  309
- Engine
  316
- Engine Unit Removal - Installation/Gearbox Removal from Chassis
  317
- Oil Sump
  325
- Oil Mesh Filter
  325
- Oil Cartridge Filter
  325
- Oil Pressure Transmitter
  327
- Engine Oil Pressure Regulator Valve
  327
- Oil Pump
  329
- Check for Oil Leakages from the Engine Crankcase
  331
- Head Disassembly
  337
- Check of Head Components
  339
- Heads
  339
- Valve Guides
  339
- Data Table for Valve and Guide Couplings
  339
- Valve Seats
  341
- Valve Spring Inspection
  343
- Outside Spring
  343
- Inside Spring
  343
- Spring Package Check
  345
- Rocker and Pin Check
  347
- Timing
  349
- Timing Data
  349
- Diameters for Camshaft Supports and Relative Seats on the Crankcase
  353
- Coupling Data for the Tappets and Relative Seats on the Crankcase
  353
- Check of the Timing System Setting
  355
- Reassembly of the Toothed Wheel and Measuring of the Air Gap
  357
- Check of Components
  359
- Grading Cylinder Diameter Since Engine N° Kd 030428
  359
- Grading Piston Diameter Since Engine N° Kd 030428
  359
- Grading Cylinder Diameter up to Engine N° Kd 030429
  359
- Coupling Data
  361
- Clutch Springs
  367
- Spring Pressure Plate
  367
- Driven Disks
  367
- Toothed Crown for Ignition
  367
- Intermediate Plate
  369
- Control Transmission
  369
- Clutch Adjustment Screw on Lever
  369
- Lever Return Spring on Gearbox
  369
- Alternator and Flywheel
  373
- Flywheel
  375
- Crank Shaft and Connecting Rods
  377
- Connecting Rods
  381
- Check the Axis Parallelism
  381
- Connecting Rod Bearing Thickness
  383
- Crankpin Diameter
  383
- Coupling Data between the Piston Pin and Bushing
  383
- Crankshaft
  385
- Main Bearing Journal Diameter, Flywheel Side
  385
- Main Bearing Journal Diameter, Timing System Side
  385
- Weight Control for Crankshaft Balancing
  387
- Gearbox
  391
- Main Features
  392
- Gearboxes Fitted with New 5-Clutch Dog Gears
  392
- Removal and Installation
  396
- Disassembly
  400
- Removal of the Internal Clutch Body
  402
- Removal of the Gearbox Cover
  402
- Removal of Shaft Assembly and Splined Drum
  404
- Disassembly of the Secondary Shaft
  406
- Disassembly of the Primary Shaft
  408
- Disassembly of Clutch Shaft
  410
- Bearing Removal
  412
- Gear Box Housing and Cover
  412
- Check and Overhaul
  414
- Gearbox Housing and Cover
  414
- Roller Ball Bearings
  414
- Secondary Shaft
  414
- Secondary Shaft Gears
  416
- Engaging Gear Sleeve Control Forks
  416
- Engaging Gear Splined Drum
  416
- Drum Holder Rods and Gearbox Control Forks
  416
- Clutch Fixed Body on the Clutch Shaft
  418
- Sleeve on the Clutch Shaft
  418
- Transmission Gear on the Clutch Shaft
  418
- Gearbox Control Range Selector
  418
- Gearbox Unit Reassembly on the Bench
  420
- Bearing Assembly on the Gearbox Housing and on the Cover
  420
- Bearing Pressing Within Their Seats on the Gearbox Housing
  420
- Bearing Pressing Within Their Seats on the Gearbox Housing Cover
  420
- Range Selector Assembly on the Gearbox Cover
  422
- Primary Shaft Reassembly on the Housing
  422
- Primary Shaft Shimming
  422
- Secondary Shaft Reassembly on the Housing
  424
- Secondary Shaft Shimming
  426
- Control Forks and Splined Drum Assembly on the Gearbox Housing
  426
- Clutch Shaft Reassembly on the Housing
  428
- Cover Assembly on the Gearbox Housing
  430
- Final Drive Housing and Shaft
  438
- Final Drive Housing
  439
- Antriebsgehäuse Hinten
  440
- Flange on the Final Drive Housing
  443
- Adjustment Shims of the Final Drive Housing Flange
  443
- Drilled Shaft with Internal Teeth as a Connection to the Rear Wheel
  443
- Bevel Gear
  445
- Bearing Case
  445
- Adjustment Washers between Spacer and Bearing
  445
- Lock Nut for Bevel Gear Pinion on the Bearing Case
  445
- Case Components
  447
- Housing Case
  447
- Crown on the Drilled Shaft
  449
- Cover on the Transmission Housing
  449
- Contact Impression Check
  451
- Pinion – Crown Coupling
  451
- Final Drive Shaft
  453
- Sleeve for Transmission Shaft and Bevel Sprocket “A”
  453
- Double U-Joint “D”
  453
- Antriebswelle
  454
- Electrical System
  455
- Electrical System Description
  456
- Headlight
  456
- Taillight
  456
- Beschreibung der Elektroanlage
  457
- Battery
  474
- Instructions to Operate Dry Batteries
  474
- Maintenance Instructions for Batteries Charged with Acid
  474
- Batterie
  475
- Battery Charge Instructions
  476
- Battery (Usa - Sgp – Can Version)
  478
- Batterie (Version Usa - Sgp - Can)
  479
- Cyclic Use
  480
- Buffer Use
  480
- Starter Motor
  482
- Anlassermotor
  483
- Light and Acoustic Systems / Dashboard / Controls
  484
- Lichtanlage und Hupe / Instrumententafel / Schaltungen
  485
- Taillight Assembly
  486
- Front Direction Indicators
  490
- Light-Bulb Replacement
  490
- Rear Direction Indicators
  492
- Acoustic System
  494
- Dashboard Warning Lights
  494
- Revolution Counter - Odometer
  500
- Side Stand Switch
  504
- Schalter Seitenständer
  505
- Fuse Terminal Board
  506
- Sicherungsklemmenbrett
  507
- Alternator - Regulator
  508
- Check the Winding Isolation Towards Earth
  508
- Check the Winding Continuity
  508
- Check the Voltage Output
  508
- Alternator - Regler
  509
- Regulator
  510
- Regulator Checks
  510

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MOTO GUZZI California Special Workshop Manual

MOTO GUZZI California Special Workshop Manual (288 pages)

Brand: MOTO GUZZI | Category: Motorcycle | Size: 55.32 MB

Table of Contents

Table of Contents
4
Sec. a General Information Page

12
- Abbreviations and Symbols
  12
- How to Consult this Manual
  12
- General Safety Regulations
  13
- Rules for Maintenance Procedures
  13
- Warranty
  14
Model

16
- Identification Data
  16
- Lubricants and Refilling
  17
- Technical Specifications
  18
- Tightening Torques
  25
- Tools
  26
- Ontrol and 1 Preliminary Tests
  29
Sec. C Control and Use of the Morbike

32
- Engine Ignition
  32
- Engine Warming-Up
  32
- Engine Running
  32
- Stopping the Engine
  33
- Parking
  33
- Adjustments and Regulations
  34
- Preparation for Long Periods at Rest
  38
- Cleaning the Motorbike
  39
Sec. D Scheduled Maintenance

42
- Scheduled Maintenance - Table
  42
- Maintenance Procedures
  43
Trimmings

71
- Wing Mirrors
  72
- Front and Rear Mudguards
  73
- Side Panels
  77
- Front Seat
  78
- Rear Seat
  79
- Rear Chassis Cover Protections
  80
- Front Chassis Cover Protections
  81
Heel Parts

83
- Front Wheel
  84
- Rear Wheel
  90
- Wheel Overhaul
  95
- Front Left-Hand Hydraulic Brake
  97
  - California Jackal - Stone
    97
- Front Right-Hand Hydraulic Brake
  98
  - Sport
    98
- Rear Hand Hydraulic Brake California
  102
  - Jackal - Stone
    102
- Front Fork
  106
- Rear Swing Arm
  122
- Rear Shock-Absorber
  124
- Steering Shock Absorber
  125
- Tires
  125
Controls

128
- Clutch and Front Brake Control
  128
- Gearbox Control
  129
- Rear Brake Control
  131
- Accelerator /Starter Control
  132
Sec. H Chassis

136
- Steering
  136
- Handlebar
  137
- Foot Rests
  138
- Side Stand
  139
- Chassis Dimensions
  140
- Front Bumper
  141
- Chassis Dimensions
  142
Uel System

145
- General Description of the System
  146
- System Components
  147
- Tank "5
  149
- Electrical Fuel Pump "1
  150
- Fuel Filter "2
  151
- Electro-Injectors "3
  151
- Pressure Adjuster "4
  152
- Air Filter Box "1
  154
- Throttle Body "2
  155
- Battery "1
  158
- Starter Switch "2
  158
- Relay "3
  159
- Air Temperature Sensor "5
  161
- Oil Sensor Temperature "6
  161
- P.M. and T.D.C. Sensor "7
  162
- Coils "8
  163
- Throttle Position Potentiometer "9
  164
- Operating Stages
  165
- Diagnostics
  167
- Fuel Vapour Purification and Recirculation System (Usa, Sgp, Can)
  175
Sec. L Exhaust System

178
- System Features
  178
- Silencers
  178
- Exhaust Pipes
  179
- Expansion Chamber
  180
Engine

181
- General Rules for Engine Overhaul
  182
- Gearbox Assembly
  182
- Lubrication System
  185
- Heads and Timing System
  190
- Cylinders and Pistons
  204
- Clutch
  206
- Alternator
  212
- Crankshaft and Connecting Rods
  214
Gearbox

224
- Main Features
  224
- Removal and Installation
  226
- Disassembly
  228
- Check and Overhaul
  237
- Gearbox Unit Reassembly on the Bench
  240
Sec. O Rear Transmissionhousing Andshaft

250
- Rear Transmission Housing
  250
- Transmission Shaft
  257
Sec. P Electrical System

260
- Electrical System Description
  260
- Battery
  269
- Battery (Usa - Sgp - Can Version)
  271
- Starter Motor
  273
- Light and Acoustic Systems / Dashboard / Controls
  274
- Side Stand Switch
  284
- Fuse Terminal Board
  285

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