MOTO GUZZI California 1400 Instructions Manual Download Page 247

Page: 247 / 411

•

Remove the two dowel pins on the stud

bolts.

•

Remove the two gaskets between the

crankcase and the cylinder.

•

Cover the crankcase opening with a

clean cloth.

See also

Removing the

cylinder head

Disassembling the piston

NOTE

THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY
TO BOTH HEADS.

•

Remove the cylinder.

•

Cover the crankcase opening with a

clean cloth.

•

Release the snap ring.

•

Remove the pin.

•

Mark the piston crown on the exhaust

side so as to remember the refitting po-

sition.

•

Remove the piston.

Fitting the piston

NOTE

THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY
TO BOTH HEADS.

California 1400

Engine

ENG - 247

Summary of Contents for California 1400

Page 1: ...MMS California 1400 My12 B043157 California 1400...

Page 2: ...i original spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not b...

Page 3: ...out to prevent injuries to the repairer Personal safety Failure to completely observe these instructions will result in serious risk of personal injury Safeguarding the environment Sections marked wit...

Page 4: ...SPECIAL TOOLS S TOOLS MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS...

Page 5: ...INDEX OF TOPICS CHARACTERISTICS CHAR...

Page 6: ...NAKED FLAME SPARKS OR OTHER HEAT SOURCES WHICH MAY CAUSE IGNITION OR EXPLOSION DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the ex...

Page 7: ...OM FLAMES SPARKS CIGARETTES OR ANY OTHER HEAT SOURCES ENSURE ADE QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE DO NOT POUR OR...

Page 8: ...semble oil seals and bearings with the brand or batch number facing outward visible side ELECTRICAL CONNECTORS Electric connectors must be disconnected as described below failure to comply with this p...

Page 9: ...TO STRAIN ENGINE COMPONENTS DURING RUN IN HOWEVER MAKE SURE NOT TO OVERDO THIS CAUTION THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT THE END OF THE RUNNING IN PERIOD Follo...

Page 10: ...to the engine oil level check cap Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc Quantity Maximum length 2445 mm 96 26 in Maximum width at handlebar Touring 915 mm 36 02 in Maximum widt...

Page 11: ...6 Gearbox Mechanical 6 speeds with foot lever on the left hand side of the engine Gear ratios 1st gear 17 38 1 2 235 Gear ratios 2nd gear 20 34 1 1 7 Gear ratios 3rd gear 23 31 1 1 347 Gear ratios 4th...

Page 12: ...ght LED High beam warning light LED Neutral gear warning light LED General warning light LED Frame and suspensions FRAME Specification Desc Quantity Type Tubular made of steel closed double cradle wit...

Page 13: ...heel rim 3 50 x 18 Rear wheel rim 6 00 x 16 Tyres Dunlop D 251 Front 130 70 R18 63H Inflation pressure front 2 5 bar 250 kPa 36 3 PSI Inflation pressure with passenger front 2 5 bar 250 kPa 36 3 PSI R...

Page 14: ...screws M6x25 2 10 Nm 7 37 lb ft 8 Bracket plate self threading fixing screws M5x14 4 2 5 Nm 1 84 lb ft 9 Box fixing screws M5x12 2 6 Nm 4 42 lb ft 10 Horn fixing screws M6x16 stainless steel 2 10 Nm...

Page 15: ...cket fixing screws M5x12 4 6 Nm 4 42 lb ft 2 Bracket self threading fixing screws M5x14 4 2 5 Nm 1 84 lb ft 3 Fuse box bracket fixing screws M5x20 2 3 Nm 2 21 lb ft 4 ECU bracket self threading fixing...

Page 16: ...mp to supports M6x55 1 5 Nm 3 69 lb ft 2 Screw fixing headlamp to joint M6x30 1 10 Nm 7 37 lb ft 3 Fixing screws sup plate headlights sup steer ing M6x20 4 10 Nm 7 37 lb ft 4 Steering lower plate join...

Page 17: ...oil radiator to chassis M6x25 3 10 Nm 7 37 lb ft 2 Screws fixing electric fan to oil radiator 4 2x20 3 2 5 Nm 1 84 lb ft FORK pos Description Type Quantity Torque Notes 1 Lower suspension bars fixing...

Page 18: ...que Notes 1 Front mudguard fixing screws M5x12 4 4 Nm 2 95 lb ft FRONT WHEEL pos Description Type Quantity Torque Notes 1 Brake discs fixing screws M8x22 12 25 Nm 18 44 lb ft 2 Wheel axle 1 80 Nm 59 0...

Page 19: ...2 50 Nm 36 88 lb ft 4 Engine pin retainer nut M12 2 80 Nm 59 00 lb ft 5 Connecting rod fixing screw M10x80 1 50 Nm 36 88 lb ft 6 Connecting rod screw retainer nut M10 1 50 Nm 36 88 lb ft 7 Rear fixing...

Page 20: ...e Notes 1 ABS control unit lower cover fixing screws 2 6 Nm 4 42 lb ft 2 ABS control unit support plate fixing screws M6x25 3 10 Nm 7 37 lb ft 3 ABS control unit support plate fixing screws M6x16 3 10...

Page 21: ...sing fixing screws 8 6 Nm 4 42 lb ft 2 Fixing screw closing upper and lower saddle compartment M5x20 stainless steel 6 3 Nm 2 21 lb ft CENTRAL BODYWORK pos Description Type Quantity Torque Notes 1 Sid...

Page 22: ...0 2 25 Nm 18 44 lb ft 2 Retainer nut M8 2 25 Nm 18 44 lb ft 3 Gearbox connecting rod fixing screw M6x20 1 10 Nm 7 37 lb ft REAR BRAKE PUMP pos Description Type Quantity Torque Notes 1 Brake lever fixi...

Page 23: ...OOTREST UNIT pos Description Type Quantity Torque Notes 1 Footrest to frame fixing screw M8x20 6 25 Nm 18 43 lb ft 2 Passenger footrest to rubber ring fixing screws M5x20 4 6 Nm 4 42 lb ft 3 Passenger...

Page 24: ...Notes 1 Lock fixing screws M6x25 2 10 Nm 7 37 lb ft TANK COVER pos Description Type Quantity Torque Notes 1 Fairing fixing screws M5x10 6 6 Nm 4 42 lb ft 2 Dashboard fixing screw M5x16 2 5 Nm 3 68 lb...

Page 25: ...rew fastening cap flange to tank M5x16 5 6 Nm 4 42 lb ft EXHAUST pos Description Type Quantity Torque Notes 1 Exhaust cylinder retainer nut M8 4 25 Nm 18 44 lb ft 2 Side clamps 2 50 Nm 36 88 lb ft 3 H...

Page 26: ...plate to chassis M10x50 3 50 Nm 36 88 lb ft 2 Stand bolt 1 25 Nm 51 61 lb ft 3 Stand pin bolt M12x1 25 1 70 Nm 51 61 lb ft GUARDS KIT pos Description Type Quantity Torque Notes 1 Bumpers front fixing...

Page 27: ...he motorcycle 6 Fixing clip M5 1 Small parts of the motorcycle 7 Engine guard upper fixing screws M10 2 50 Nm 36 2 lb ft 8 Engine guard lower fixing nuts M12 2 50 Nm 36 2 lb ft 9 Engine guard lower fi...

Page 28: ...cription Type Quantity Torque Notes 1 Front fixing screws M8x20 2 25 Nm 18 44 lb ft 2 Upper fixing screw M8x16 1 25 Nm 18 44 lb ft 3 Side cover fixing screws M5x9 4 6 Nm 4 42 lb ft Characteristics Cal...

Page 29: ...wheel flange screws M8x20 6 25 Nm 18 44 lb ft 3 Wheel axle nut M25x1 5 1 100 Nm 73 76 lb ft SWINGARM pos Description Type Quantity Torque Notes 1 Swingarm pin 1 60 Nm 44 25 lb ft 2 Preloading bushing...

Page 30: ...T pos Description Type Quantity Torque Notes 1 Panniers supports fixing screws M8x20 10 24 Nm 17 4 lb ft 2 Panniers supports fixing screws M8x16 4 24 Nm 17 4 lb ft Engine Characteristics California 14...

Page 31: ...rew M14x1 5 1 35 Nm 25 81 lb ft 5 Oil jets fixing screw 3 By hand Loctite 243 6 Minimum oil pressure sensor M10 1 15 Nm 11 06 lb ft 7 Intake oil filter fixing screw M4x10 2 3 Nm 2 21 lb ft Loctite 243...

Page 32: ...oling oil intake filter fixing screw M4x10 2 By hand 2 Complete oil pressure control valve 1 20 Nm 14 75 lb ft Loctite 243 3 Mesh type oil filter fixing screw M6x14 1 6 Nm 4 42 lb ft 4 Oil filter 1 15...

Page 33: ...fixing screw M6x30 14 10 Nm 7 37 lb ft 9 Thermal switch interface connection 1 20 Nm 14 75 lb ft Loctite 542 10 Magnetic oil drainage cap 1 20 Nm 14 75 lb ft 11 Gear to engine fixing nut M8 5 20 Nm 14...

Page 34: ...42 Nm 30 98 lb ft Loctite 243 2 Clutch external flange fixing screw on flywheel M7x16 6 20 Nm 14 75 lb ft Loctite 243 3 Start up crown fixing screw on flywheel M6x12 6 10 Nm 7 37 lb ft 4 Clutch contr...

Page 35: ...n idle shaft fixing screw M6x16 1 8 10 Nm 5 90 7 37 lb ft Loctite 243 3 Idle shaft locking nut M18x1 5 1 150 Nm 110 63 lb ft 4 Crankshaft locking nut M25x1 5 2 200 Nm 147 51 lb ft CRANKSHAFT pos Descr...

Page 36: ...tion Type Quantity Torque Notes 1 Special aesthetic head cover fixing screw 8 8 Nm 5 90 lb ft Locked with cross sequence 2 Special head cover screw 8 8 Nm 5 90 lb ft Locked with cross sequence Charact...

Page 37: ...80 13 28 lb ft 2 Nut for tie rod M10x1 25 8 Pretorque 15 Nm 11 06 lb ft Final torque 42 Nm 30 98 lb ft 3 Cap M6x10 2 10 12 Nm 7 37 8 50 lb ft Loctite 542 4 Reference dowel on camshaft 1 Interference...

Page 38: ...00 lb ft Loctite 243 2 Generator upper fixing screw M8 1 22 Nm 16 23 lb ft 3 Generator lower fixing screw M10x60 1 30 Nm 22 13 lb ft GENERATOR COVER pos Description Type Quantity Torque Notes 1 Timing...

Page 39: ...xing screw M6x30 9 10 12 Nm 7 37 8 85 lb ft 4 Generator cover fixing screw M6x16 6 10 12 Nm 7 37 8 85 lb ft AIR FILTER pos Description Type Quantity Torque Notes 1 Air filter box fastening screw to fr...

Page 40: ...lb ft 3 Air temperature sensor fixing screw M6x16 1 10 Nm 7 37 lb ft 4 Compensator volume fixing screw M6x16 2 10 Nm 7 37 lb ft 5 Throttle body manifold fixing screws M6x60 4 10 Nm 7 37 lb ft 6 Brack...

Page 41: ...tity Torque Notes 1 Starter motor fixing screws M8x75 2 25 Nm 18 44 lb ft ENGINE COVER pos Description Type Quantity Torque Notes 1 Engine cover fixing screws M6x16 stainless steel 6 10 Nm 7 37 lb ft...

Page 42: ...e balanced a weight difference of up to 1 5 g 0 0033 lb is allowed CYLINDER COUPLING CLEARANCE ABB REVI ATIO N CYLINDER PISTON FITTING CLEARANCE D 104 000 104 010 mm 4 0944 4 0948 in 103 935 103 945 m...

Page 43: ...0039 0 00709 in Gap between the end of the piston rings inserted in the cylinder Upper piston ring 0 20 0 32 mm 0 0079 0 0126 in Intermediate piston ring 0 35 0 50 mm 0 0138 0 0197 in Oil scraper pist...

Page 44: ...left cylinder gasket between cylinder and head also for the right cylinder CYLINDER GASKET THICKNESS HEAD Specification Desc Quantity Value X 0 34 0 52 mm 0 0134 0 0204 in gasket thickness 0 6 mm 0 02...

Page 45: ...90 Gearbox oil API GL 5 FUCHS TITAN SAF 1091 Fork oil AGIP GREASE SM2 Lithium grease with molybdenum for bearings and other points needing lubri cation NLGI 2 Neutral grease or petroleum jelly Batter...

Page 46: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS...

Page 47: ...ertion cone GU05912530 Gearbox opening GU05927230 Timing system cover sealing ring punch GU12911801 Tool to lock the flywheel and the starting ring gear GU12912000 Tool to fit the flywheel side flange...

Page 48: ...ing nut of the clutch shaft internal body GU14927100 Tool to fit the sealing ring on the flywheel side flange GU19927100 Tool to fit the seal ring on the flywheel side flange 020382Y Tool for removing...

Page 49: ...vice shaft gear lock 020676Y Dial gauge support for piston position checking 020677Y Generator belt tensioner lever for belt tensioning 020678Y Tool for clutch rod checking 020716Y Connecting rod lock...

Page 50: ...g clamp 020953Y Cam shaft lock for fixing 020954Y Centring cam shaft cup spring CHASSIS Stores code Description AP8140190 Tool for steering tightening 020376Y Adapter handle 020359Y 42 x 47 mm adaptor...

Page 51: ...to extract 25 mm diameter bear ings 001467Y035 Bell for 47 mm outside diameter bearings FRONT FORK Stores code Description AP8140146 Weight AP8145758 Tool for oil seals fitting 020952Y Pumping member...

Page 52: ...Stores code Description 020888Y Pliers for pre fill pipe 020951Y Stanchion support DIAGNOSIS INSTRUMENT Stores code Description 020922Y P A D S Special tools California 1400 S TOOLS 52...

Page 53: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 54: ...4854 mi or 48 months 8 Replace every 70000 km 43495 mi ROUTINE MAINTENANCE TABLE km x 1 000 1 5 10 20 30 40 50 60 70 80 Drive shaft 8 I R Exhaust pipe flange bolts I I I I I Spark plugs I R I R I R I...

Page 55: ...ect if the oil is close to the hole of the cap dipstick 4 If the oil is lower than specified top up until it reaches the cap dipstick hole 4 CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE...

Page 56: ...stick hole 4 CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN Screw and tighten the caps 3 4 Engine oil Check C...

Page 57: ...ontainer with 4000 cm 244 cu in capacity under the drainage plug 2 Unscrew and remove the drainage plug 2 Pull out the oil filler plug engine oil level dipstick 1 Drain the oil into the container allo...

Page 58: ...GINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM 10 miles Shut off the engine Keep...

Page 59: ...heck and replace if necessary the sealing washers of drainage plug 2 Remove any metal scrap attached to the drain age plug 2 magnet Screw and tighten the drainage plug 2 Pour in new oil until it reach...

Page 60: ...g the valve clearance If the timing system is very noisy check the clearance between the valves and the rocking levers NOTE ADJUST WITH COLD ENGINE WITH PISTON AT TOP DEAD CENTRE TDC IN COMPRESSION ST...

Page 61: ...OTHERWISE THE VALVES DO NOT CLOSE CORRECTLY WHICH CAN LEAD TO PROB LEMS SUCH AS PRESSURE DROP ENGINE OVERHEAT VALVE BURN OUT ETC Braking system Level check Brake fluid check Rest the vehicle on its st...

Page 62: ...REMOVED CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR LEAVE THE BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME NEEDED...

Page 63: ...CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORM ANCE OF THE BRAKING SYSTEM TAKE YOUR VEHICLE TO AN Official Moto Guzzi Dealer AS IT MAY BE NECES SARY TO PURGE THE AIR IN THE SYSTEM Califor...

Page 64: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Page 65: ...SELECTED AND IS DISPLAYED PRESS THE KEY TO OBTAIN FURTHER INFORMATION ABOUT THE ERROR THEN GO TO THE ELECTRICAL SYSTEM CHECKS AND CONTROLS CHAPTER AND READ THE INFORMATION CONCERNING THE DEFECTIVE COM...

Page 66: ...85 1 15 RANGE YES go to 15 NO note C 15 IN THE ENGINE PARAMETER READING SCREEN PAGE WITH ENGINE AT IDLE AND ENGINE TEMPERATURE AT 65 c IS THE THROTTLE CORRECTION PARAM ETER WITH ENGINE AT IDLE INCLUDE...

Page 67: ...FOLLOWING THE INSTRUCTION WITH KEY SET TO ON THE PARAMETERS STATUSES ETC ARE READ YES go to 4 NO go to DIAGNOSIS INSTRUMENT CONNECTION CHECK 4 WITH DIAGNOSIS INSTRUMENT DEVICES ACTIVATION SCREEN PAGE...

Page 68: ...SENSOR AND THE CABLE HAR NESS END 14 SET THE SENSOR TO THE CORRECT POSITION END 15 REFER TO THE CHAPTER ELECTRICAL SYSTEM CHECKS AND CONTROLS RUN STOP SWITCH INDICATION ON DIAGNOSIS INSTRUMENT ALWAYS...

Page 69: ...cable harness END See also Electrical system installation CHECK FUEL PUMP 1 WITH KEY SET TO ON DISCONNECT THE CONNECTOR AND CHECK THAT THERE IS BATTERY VOLTAGE ON PIN 1 YES go to 2 NO go to 4 2 CHECK...

Page 70: ...OR ON THE CABLE HARNESS SIDE YES go to 4 NO go to 7 4 CHECK CORRECT OPERATION OF THE RELAY THAT IS PROVIDING VOLTAGE ON THE CORRESPONDING PIN TO THE RED BROWN CABLE AND GROUND ON SPE CIFIC PIN TO THE...

Page 71: ...ntinuity restore cable harness END 5 WITH KEY SET TO OFF CHECK IF THERE IS VOLTAGE ON RED WHITE CABLE ON THE KEY SWITCH CONNECTOR YES go to 6 NO restore the cable harness END 6 WITH KEY SET TO ON AND...

Page 72: ...D PIN 58 OF THE CONTROL UNIT YES go to 4 NO restore the cable harness END 6 CHECK CONTINUITY OF PINK BLACK CABLE BETWEEN SWITCH CONNECTOR AND PIN 4 OF THE CONTROL UNIT YES go to 4 NO restore the cable...

Page 73: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 74: ...Components arrangement KEY 1 Side stand sensor 2 Fuel pump 3 Instrument panel Electrical system California 1400 ELE SYS 74...

Page 75: ...tem installation INTRODUCTION Scope and applicability This document aims at defining the cable harness routing in order to achieve the vehicle reliability targets Materials used and corresponding quan...

Page 76: ...roperly connected and correctly tightened to ensure proper engine and therefore proper vehicle operation Instrument panel connector Master and Slave Demand Connectors Pick Up connector and alternator...

Page 77: ...viously the correct connection of the other connectors is also important and essential for proper vehicle operation It is also important and essential that the instructions regarding the routing and f...

Page 78: ...E Pass the main cable harness as shown in figure TABLE F Pass the main cable harness as shown in figure Front side TABLE A FAN AND CONNECTED COMPONENTS 1 Thermal switch 2 Medium clamp Electrical syste...

Page 79: ...TABLE B FAN AND CONNECTED COMPO NENTS 1 Small clamp TABLE C FAN AND CONNECTED COMPONENTS 1 Medium clamp California 1400 Electrical system ELE SYS 79...

Page 80: ...E E RIGHT SIDE STEERING COLUMN AREA 1 Medium clamp TABLE F RIGHT SIDE STEERING COLUMN AREA 1 Medium clamp TABLE G RIGHT SIDE STEERING COLUMN AREA 1 Medium clamp 2 Key connector 3 Speed sensor 4 Immobi...

Page 81: ...I RIGHT SIDE STEERING COLUMN AREA 1 Medium clamp 2 Right light switch 3 Front stop switch TABLE J RIGHT SIDE STEERING COLUMN AREA 1 Medium clamp 2 Turn indicators 3 Headlamp TABLE K RIGHT SIDE STEERI...

Page 82: ...ectors 2 Left light switch connectors TABLE M RIGHT SIDE STEERING COLUMN AREA 1 Front stop switch connector 2 Right light switch connector TABLE N LEFT SIDE STEERING COLUMN AREA 1 Medium clamp 2 Left...

Page 83: ...TABLE O LEFT SIDE FORK AREA 1 Cable grommet TABLE P LEFT SIDE FORK AREA 1 Cable grommet TABLE Q LEFT SIDE FORK AREA 1 Small clamp California 1400 Electrical system ELE SYS 83...

Page 84: ...INSTRUMENT PANEL FASTENING 1 Medium clamp TABLE S INSTALLATION AIR TEMPERATURE SENSOR 1 Small clamp 2 Medium clamp TABLE T FOG LIGHTS 1 Fog lights kit connection Electrical system California 1400 ELE...

Page 85: ...G LIGHTS 1 Cable guide 2 Rubber ring 3 Insert the light connections in the rubber rings and assemble them as shown in the figure Central part TABLE A FRAME AREA UNDER THE TANK 1 Throttle motor connect...

Page 86: ...2 Medium clamps TABLE D FRAME AREA UNDER THE TANK 1 Fog light connector optional 2 Slave Demand Connector 3 Master Demand Connector 4 Pick up connector 5 Big clamp 6 Medium clamp TABLE E FRAME AREA UN...

Page 87: ...2 Navigator pre installation TABLE G DIRECT CONNECTIONS TO THE ENGINE Alternator connections TABLE H DIRECT CONNECTIONS TO THE ENGINE Engine temperature 1 Medium clamp TABLE I BATTERY AREA 1 Fall sen...

Page 88: ...Medium clamp 2 Medium clamp 3 Fuses TABLE K BATTERY AREA LEFT SIDE FAIRING EXTERNAL VIEW 1 Medium clamp 2 Small clamp 3 Relay 4 Auxiliary fuse 5 Rear speed sensor TABLE K BATTERY AREA 1 Control unit...

Page 89: ...RU GATED PIPES TABLE N BATTERY AREA RIGHT SIDE FAIRING EXTERNAL VIEW 1 Relay TABLE O BATTERY AREA LEFT SIDE FAIRING INTERNAL VIEW 1 Medium clamp 2 ABS branch must remain in its housing California 1400...

Page 90: ...round cable the two crimp con nectors must be placed back to back as shown in the photo in order to favour the elec trical contact of the surfaces Check correct fixing of the engine ground screw with...

Page 91: ...S STARTER MOTOR AREA 1 Left injector connector TABLE T REAR STOP SWITCH 1 Medium clamps 2 Rear stop switch 3 Small clamp TABLE U REAR STOP SWITCH 1 Medium clamps California 1400 Electrical system ELE...

Page 92: ...LE X SIDE STAND 1 Clamp with support 2 Medium clamp TABLE W REAR STOP SWITCH 1 Clamp with support TABLE Y RIGHT LAMBDA FASTENING 1 Medium clamp 2 Right lambda Electrical system California 1400 ELE SYS...

Page 93: ...p 3 Cable guide TABLE AA HANDLEBAR AREA 1 Front stop switch 2 Clip 3 Cable guide TABLE BB LEFT SIDE H V CABLES Left injector connector TABLE CC RIGHT SIDE H V CABLES Right injector and coil connector...

Page 94: ...HT LICENSE PLATE LIGHT 1 Retaining clip TABLE B TAILLIGHT LICENSE PLATE LIGHT 1 Medium clamp TABLE C TAILLIGHT LICENSE PLATE LIGHT 1 Hold the cable harness as shown in the fig ure Electrical system Ca...

Page 95: ...E D REAR WHEEL SPEED SENSOR 1 Rear speed sensor 2 Medium clamp TABLE E REAR WHEEL SPEED SENSOR 1 Cable grommet 2 Medium clamp 3 Rear speed sensor cable harness California 1400 Electrical system ELE SY...

Page 96: ...General wiring diagram key 1 Multiple connectors 2 Fog lamp switch where provided 3 Low beam light relay 4 High beam light relay Electrical system California 1400 ELE SYS 96...

Page 97: ...1 Left fog lamp optional 22 License plate light bulb 23 Antitheft control unit optional equipment 24 Antitheft LED 25 ABS control unit 26 Front ABS sensor 27 Rear ABS sensor 28 Start up relay 29 Start...

Page 98: ...fog light if applicable 62 AUXILIARY FUSES 63 Fog lamp light relay where provided 64 Thermal switch 65 Fan Checks and inspections GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING THE CONNECTION DIAGRAM...

Page 99: ...position of terminals on the connector and of the cable on the terminal CONTINUITY check Check goal this control is to check that there are not any circuit interruptions nor excessive resistance for i...

Page 100: ...HE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING PROCEDURE ON THE VEHICLE C...

Page 101: ...r a circuit is in contact with the vehicle ground connection Tester set the tester on the continuity symbol and place one tester probe on the vehicle ground connection or on the battery terminal and t...

Page 102: ...key Error code B0004 KEY CODE NOT READABLE The key has no transponder or the transponder is damaged Troubleshooting Replace the key and store it Error code B0005 AERIAL NOT WORKING OPEN OR SHORT CIRCU...

Page 103: ...ustments page and set the unit of measurement to kph or mph Close the diagnostics session in progress and start a new one with the Continental dash board Go to the adjustments page and carry out a Veh...

Page 104: ...the circuit is open shorted to negative voltage equal to zero has been detected DIAGNOSTICS INSTRUMENT LOGIC ERRORS Starter switch P0169 signal not valid Error cause Fault in the switch lock of the e...

Page 105: ...fuses MAIN FUSES DISTRIBUTION Specification Desc Quantity A 40A fuse Battery recharge fuse B 30A fuse Primary injection key parking lights fuse auxiliary fuses 2 4 5 power D spare fuses Spare fuses C...

Page 106: ...REELY TO THE END OF STROKE WHICH HELPS WITH THE INSERTION OF THE CONNECTOR YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE CONTROL UNIT Diagnosis Function it controls the Ride by...

Page 107: ...mber NIP 7SMPRA119 Identifies the single control unit Person in charge for last programming Indicates the series number of the DIAGNOSTICS INSTRUMENT that has carried out the last control unit remappi...

Page 108: ...coded key or user code entered manually Potential errors will be shown on the Instrument Panel Errors screen page on the DIAGNOSIS section of the instrument panel Start up enabling yes no Indicates w...

Page 109: ...atch finished Odometer Mapping selection Indefinite Track Sport Road DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS EEPROM Error P0601 circuit not operational Error cause Replace injection ECU The instrumen...

Page 110: ...eplace the relay if OK check relay connector engine vehicle cable harness connector and ENGINE connector of the Marelli control unit if not OK restore if OK check continuity of cable harness Blue Pink...

Page 111: ...e updated mapping turn the key to ON and wait 3 seconds during this time the control unit carries out throttle position acquisition Connect to the diagnostics instrument and check that the status for...

Page 112: ...e of recovery this value is set by the control unit Battery voltage pre Recovery Example value with key ON 12 0 V Example value with engine on 14 2 V Value drawn from the signal read without taking in...

Page 113: ...harness if OK check correct operation of the electrical alternator restore if not OK Speed sensor VEHICLE FRONT SPEED SENSOR Function To generate a signal that the ABS control unit con verts into whe...

Page 114: ...t due to deformations or dirt pos sible alterations on the wheel bearing surface In very rare cases abnormal tone wheel vibrations Troubleshooting Check if the tone wheel is dirty deformed or wrongly...

Page 115: ...circuit diagram Level in wiring dia gram ABS control unit Location on the vehicle Swingarm right side on the brake calliper support plate Connector location if available Left side fairing external Pin...

Page 116: ...one wheel or tone wheel with wrong number of teeth Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer...

Page 117: ...lding with ground connection DIAGNOSTICS INSTRUMENT PARAMETERS Engine rpm rpm CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES...

Page 118: ...lectric circuit detected at PIN 20 35 of the ENGINE connector Troubleshooting Check the electric circuit is in good conditions and the flywheel teeth cleaning and correct positioning of the sensor in...

Page 119: ...e ters 4 control tracks by means of which the tor que demand is read and checked The 4 potentiometers are tinned and magnetically con trolled contactless they cannot be overhauled nor replaced Level i...

Page 120: ...e value times 2 of the front potentiometer track B White rear connector throttle grip position sensor track C Sample value with throttle released 3757 mV Voltage value of the rear potentiometer track...

Page 121: ...trol unit connector if the cable is not ground insu lated restore the wiring If it is ground insulated and with the key set to ON check that there is power supply for the potentiometer PIN A and that...

Page 122: ...or if the voltage drops to zero if the circuit is open shorted to negative with open circuit short it to negative check the throttle grip sensor connector and the Marelli control unit connector If not...

Page 123: ...acks A B Troubleshooting Check the parameters of the blue front connector Throttle Grip Position Sensor tracks A and B if one of the two values clearly deviates from 600 1400 mV it means that this po...

Page 124: ...HE THROTTLE GRIP SENSOR ARE ALIKE BUT THEY SHOULD NEVER BE INVERTED MARK OR CHECK THE CONNECTOR MARKING BEFORE RE MOVING THEM BLUE STAMP BLUE BAND THE CONNECTOR AND THE BLUE BAND SHOULD BE PLACED AT T...

Page 125: ...t vary it means that the cable is shorted between the control unit connector and the sensor connector restore the cable harness Replace the sensor if the value varies If the circuit is open shorted to...

Page 126: ...higher than the estimated one intake manifold condi tions Troubleshooting Check the conditions of the intake manifold and cleanliness of the hole for pressure reading Estimation error for cylinder int...

Page 127: ...means that the error cause is that the cable is shorted to positive and it is necessary to restore the cable harness between ENGINE PIN 37 and sensor PIN 2 check the sensor connector and the Marelli c...

Page 128: ...ce at 110 C 230 F 0 153 kOhm 17 Resistance at 120 C 257 F 0 102 kOhm Pin out PIN 1 0 5 V signal PIN 2 Ground connection CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU...

Page 129: ...to positive If shorted to negative check sensor correct resistance if resistance is null replace the sen sor if resistance is correct it means that the orange cable has ground connection restore the...

Page 130: ...on on the vehicle exhaust muffler under the rear head along the exhaust connector left side above the footrest Right lambda position on the vehicle exhaust muffler under the rear head along the exhaus...

Page 131: ...ECTRICAL SYSTEM CHAPTER DIAGNOSTICS INSTRUMENT STATUSES Oxygen sensor Start up_Lean_Rich_Fault due to rich value_Fault due to lean value If the probe connector is removed voltage almost equal to zero...

Page 132: ...ness Green Red cable If circuit is open shorted to negative check circuit continuity from probe connector PIN 3 and 4 toward the probe if it is not OK replace the probe if it is OK check the sensor co...

Page 133: ...ector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 38 of the ENGINE connector The instrument panel does not indicate the presence of this error even in the...

Page 134: ...ector PIN 1 and PIN 2 toward the probe replace the oxygen sensor if there is no continuity if there is continuity check the sensor connector and the Marelli control unit connector If not OK restore If...

Page 135: ...s ener gised for 5 seconds and the injector cable connected to control unit is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and inj...

Page 136: ...re the cable harness Right cylinder injector P0205 short circuit to positive short circuit to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 67 If...

Page 137: ...ow ever VERIFY the identification of the relay with the colour of the cables is energised for 30 seconds The continuity of the wiring is necessary for correct activation no error indications are displ...

Page 138: ...nsor on the vehicle 1 LEFT CYLINDER SIDE COIL left side on the frame ABOVE THE STARTER MOTOR 2 RIGHT CYLINDER SIDE COIL right side above the rear brake reservoir 3 LEFT CYLINDER CENTRAL COIL left side...

Page 139: ...ation The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation Right Cylinder Central Coil The auxiliary relay No 35 in the wir...

Page 140: ...open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 28 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detecte...

Page 141: ...tage at connector PIN 2 if there is voltage restore the cable harness if voltage 0 replace the coil If the circuit is open shorted to negative check electric characteristics of the coil if not OK repl...

Page 142: ...ectrical diagnosis is possible for the throttle body but for the circuits connected to it only Level in electrical circuit diagram Throttle and handgrip sensor control Demand Location on the vehicle u...

Page 143: ...ECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTICS INSTRUMENT STATUSES Throttle automatic self acquisition ice interrupted carried out limp...

Page 144: ...ircuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 50 If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 50 Trouble...

Page 145: ...te throttle body throttle position potentiometer P0124 inconsistent signal Error cause Potentiometer 1 and potentiometer 2 do not show a logical value the sum of the two voltages should be constant Th...

Page 146: ...ect throttle rotation cannot be detected given low ambient and engine temperatures some ice may have formed in the duct at each key ON The instrument panel does not indicate the presence of this error...

Page 147: ...sition then verify that the Automatic throttle self acquisition status indicates carried out If indication is not Carried out delete possible errors on the vehicle and then with key set to ON check th...

Page 148: ...am Start up enabling switches Location on the vehicle rear part above the gearbox connector near the sensor Electrical specifications PIN 64 gear indication closed circuit continuity gear engaged open...

Page 149: ...if the cable is in voltage if it is in voltage restore the cable harness if it is not in voltage replace the sensor there is an interruption or shorted to positive of the Pink Black cable in the secti...

Page 150: ...diagnostics instrument always Released check the sensor connector and the control unit connector special attention to PIN56 if not OK restore cable harness if OK disconnect both terminals from the sen...

Page 151: ...ENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTICS INSTRUMENT STATUSES Side stand sensor up down ind...

Page 152: ...ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER RUN STOP switch Func...

Page 153: ...f OK verify the presence of voltage on the Pink Brown cable with the key ON if absent restore cabling if present verify insulation from ground of the Pink Brown cable If there is continuity with groun...

Page 154: ...input PIN 13 Serial line K for diagnostics PIN 14 PIN 16 Ground connection Sensors ground 1 PIN 17 Engine rpm sensor input PIN 20 Left Lambda sensor input PIN 22 Track C handgrip input PIN 23 Intake...

Page 155: ...Lambda heater command output PIN 44 Throttle potentiometer 1 signal input PIN 48 Throttle potentiometer 2 signal input PIN 50 Reference voltage output 5V tracks A C throttle and pressure sensor MAP P...

Page 156: ...Normally open clutch switch input PIN 76 Engine stop input PIN 78 Vehicle speed input PIN 79 CAN H line high speed PIN 80 Dashboard Grey bodied instrument panel pinout key Battery positive PIN 1 Front...

Page 157: ...PIN 16 Right handgrip PIN 17 Fuel sensor PIN 18 CAN H line high speed PIN 19 A aerial PIN 20 Black bodied instrument panel pinout key Battery positive PIN 21 Right turn indicator command PIN 22 DRL i...

Page 158: ...7 Normally open rear stop switch input PIN 38 Normally closed rear stop switch input PIN 39 ABS warning light PIN 40 ABS Modulator ABS control unit pin out key PIN 1 Ground connection Vehicle identifi...

Page 159: ...ugh two cables and the signal reading is differential voltage difference between the two signals on both cables If the two signals are disturbed by an external factor their difference remains unaltere...

Page 160: ...F THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS CAN line Mute Node U1601 Mute Node Error cause The injection ECU cannot send CAN signals it re...

Page 161: ...the CAN line Troubleshooting Carry out the Vehicle connector check on pins 66 and 80 if NOT OK restore if OK carry out the check procedure on pins 10 and 19 and the instrument panel connector if NOT...

Page 162: ...the control unit setting is actually consistent with the motorcycle setting Example if the bike has an ABS control unit the correct state that should be found in the diagnostics instrument device stat...

Page 163: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 164: ...exhaust system the swingarm with cardan shaft fuel tank and the rear shock absorber and the two footrest brackets Removing the engine from the vehicle Acting on the left side of the vehicle remove th...

Page 165: ...ect the cable located behind the starter motor Disconnect the ground cable Disconnect the stand sensor connec tor and rear stop switch Release it from the clamps California 1400 Engine from vehicle EN...

Page 166: ...sconnect the engine oil breather tube Working from both sides disconnect the injector connectors Working from both sides unscrew the retaining screw of the injector and re move it Engine from vehicle...

Page 167: ...Disconnect the alternator connectors Disconnect the oil pressure sensor connector Disconnect the engine temperature sensor connector California 1400 Engine from vehicle ENG VE 167...

Page 168: ...ct the speed sensor connec tor Disconnect the ride by wire connec tors Working from both sides disconnect the connectors of the coils and cables of the plug caps Engine from vehicle California 1400 EN...

Page 169: ...Working from both sides disconnect the lambda probe connectors California 1400 Engine from vehicle ENG VE 169...

Page 170: ...tors located behind the oil radiator Loosen the two fixing screws of the fil ter box and the tube shown in the fig ure Undo the two fixing screws of the side bracket and the upper screws of the duct R...

Page 171: ...e the connector of the throttle body Undo the four fixing screws and re move the throttle body After disconnecting all the connectors remove the various fixing clamps of the cables California 1400 Eng...

Page 172: ...ment Working from both sides remove the rear fixing screws of the cradle Working from both sides remove the front fixing screws of the cradle Working from both sides undo the screws fixing the engine...

Page 173: ...do the three fixing screws of the si lent block support Remove the silent block Unscrew the front fixing screw that se cures the engine to the silent block California 1400 Engine from vehicle ENG VE 1...

Page 174: ...the engine from the frame Installing the engine to the vehicle Place the vehicle chassis over the engine with the gear From the back secure the chassis with belts attached to a hoist From the front se...

Page 175: ...secures the en gine to the silent block Fix the silent block support by tighten ing the three fixing screws Working from both sides insert the en gine connecting rod fixing pins California 1400 Engin...

Page 176: ...Working from both sides position the front and rear fixing screws of the cra dle Connect the horn connectors Engine from vehicle California 1400 ENG VE 176...

Page 177: ...secure it us ing the four screws Connect the connector Install the air filter box Secure it with the two fixing screws and the two clamps Connect the tube as shown in the fig ure California 1400 Engi...

Page 178: ...tors located inside the oil radiator Install the oil radiator securing it with its lower joints and with the upper fixing screw Connect the connectors of the lambda probes Engine from vehicle Californ...

Page 179: ...Connect the connectors of the coils and the cables of the plug caps California 1400 Engine from vehicle ENG VE 179...

Page 180: ...ct the connectors of the ride by wire and that of the engine speed sen sor Connect the connectors of the engine temperature sensor and the oil pres sure sensor Engine from vehicle California 1400 ENG...

Page 181: ...Connect the alternator Operating from both sides install the injectors tightening the fixing screw Connect the connectors California 1400 Engine from vehicle ENG VE 181...

Page 182: ...ect the stand sensor connector and rear stop switch Connect the cable located behind the starter motor Install the starter motor fixing it with the two fixing screws Connect the ground cable and the p...

Page 183: ...California 1400 Engine from vehicle ENG VE 183...

Page 184: ...INDEX OF TOPICS ENGINE ENG...

Page 185: ...9 lb ft 2 Gearbox cap M18x1 5 1 28 Nm 20 65 lb ft 3 Breather stud bolt M10x1 5 1 8 Nm 5 90 lb ft Loctite 243 4 Gear sensor fixing screw M5x16 2 4 9 6 Nm 3 61 4 42 lb ft Loctite 243 5 Magnetic gearbox...

Page 186: ...Description Type Quantity Torque Notes 1 Fastener screw M8x60 2 25 Nm 18 44 lb ft 2 Retainer nut M8 2 25 Nm 18 44 lb ft 3 Gearbox connecting rod fixing screw M6x20 1 10 Nm 7 37 lb ft Engine Californi...

Page 187: ...Diagram key 1 Ball bearing 2 Circlip 3 Thickness 4 Pin California 1400 Engine ENG 187...

Page 188: ...earing 19 Gear 20 Circlip 21 Clutch shaft 22 Ball bearing 23 Oil plug 24 Washer 25 Gearbox 26 Aluminium washer 27 Breather cap 28 Neutral sensor 29 Gasket 30 Seal ring 31 Bushing 32 Gasket 33 Oil drai...

Page 189: ...k 5th 1st 54 Fork shaft 55 Fork 3rd 4th 56 Fork 2nd 4th 57 Gear 58 Gear 59 Ball bearing 60 Transmission shaft 61 Gear 62 Spacer Gearbox Removing the gearbox Remove the starter motor in engine removal...

Page 190: ...nscrew and remove the three screws See also Removing the starter motor Replacement Unscrew and remove the two lower screws Unscrew and remove the screw Remove the gearbox Engine California 1400 ENG 19...

Page 191: ...Installing the gearbox Position the gearbox Tighten the three upper nuts Tighten the two lower nuts Tighten the side nut California 1400 Engine ENG 191...

Page 192: ...gearbox Remove the gearbox Undo the two screws and remove the gear sensor From the outside slide off the thrust cylinder and collect the O Ring and the washer Remove the thrust bearing and the washer...

Page 193: ...rews Place the gearbox on the specific gearbox support tool and on a vice Specific tooling 05 90 25 30 Gearbox support Undo and remove the nine internal screws Open the gearbox using the specific tool...

Page 194: ...ngs from the gearbox if necessary Release the spring Pressing the selector slide off the whole transmission lever Use rubber bands to tie down the trans mission shaft unit and extract it Engine Califo...

Page 195: ...nsmission shaft unit is in on a bench remove the rubber bands being careful with the group Detach the shafts and label the forks before removal Remove the forks and collect the shaft California 1400 E...

Page 196: ...e clutch shaft See also Removing the gearbox Removing the primary shaft Remove the main shaft Operate on the main shaft from the second gear side Remove the gear of the second gear and collect the bal...

Page 197: ...the gear of the sixth gear and collect the shoulder washer Remove the circlip Remove the gear of the third and fourth gears Remove the circlip and collect the shoulder washer California 1400 Engine E...

Page 198: ...l bearing cage Heat the shaft with a specific heater and remove the helical transmission gear Removing the secondary shaft Remove the transmission shaft Operate on the shaft from the grooved side Remo...

Page 199: ...ar of the second gear and collect the ball bearing cage and the shoulder washer Remove the circlip Remove the gear of the sixth gear Remove the circlip and collect the shoulder washer California 1400...

Page 200: ...fourth gear and collect the ball bearing cage Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer Remove the circlip Remove the gear of the fifth gear Engine C...

Page 201: ...ting teeth for cracks damage and wear and replace those damaged if necessary Check the transmission gears movement and if it is not regular replace the damaged part Checking the secondary shaft Measur...

Page 202: ...ID FOR ALL GEARBOX FORKS Check the transmission fork cam roller 1 and the transmission fork tooth 2 for damage deformation and wear Replace the transmission fork if nec essary Check the transmission f...

Page 203: ...engine block Fit the tool in the gearbox to determine the clutch control rod length Measure rod protrusion using a depth gauge see picture According to the value found select the correct rod based on...

Page 204: ...cription Type Quantity Torque Notes 1 Generator control pulley locking nut M16 1 80 Nm 59 00 lb ft Loctite 243 2 Generator upper fixing screw M8 1 22 Nm 16 23 lb ft 3 Generator lower fixing screw M10x...

Page 205: ...9 10 12 Nm 7 37 8 85 lb ft 4 Generator cover fixing screw M6x16 6 10 12 Nm 7 37 8 85 lb ft key 1 Alternator 2 Spacer 3 Screw 4 Screw 5 Nut 6 Belt 7 Generator control pulley 8 Nut 9 Washer 10 Magneto...

Page 206: ...pipe Loosen the oil radiator to be able to remove the cradle Remove the left coil Remove the right side light switch connectors box Proceed with the following operations Remove the fixing screws of th...

Page 207: ...with silent block from the lower part paying atten tion not to damage the alternator cover Remove the three upper screws of the alternator cover Remove the central screws of the al ternator cover Cali...

Page 208: ...lower part paying atten tion not to damage it Loosen the screw Loosen the nut and undo the set screw so that the alternator slides Position the wrench on the specific belt tensioning tool and then app...

Page 209: ...t tensioning Tighten the belt to a torque of 50 Nm 36 88 lb ft Tighten the adjuster and tighten the locknut Removing the generator Remove the screw Loosen the nut and undo the set screw so that the al...

Page 210: ...h pulley Installing the generator Insert the alternator as shown in the figure After correctly inserting the belt on the pulleys tighten the screw with the rela tive nut Position the screw and pre tig...

Page 211: ...ng tool Lock the set screw in position by screwing the lock nut Specific tooling 020677Y Generator belt tensioner lever for belt tensioning Tighten the alternator fixing screws Insert the alternator c...

Page 212: ...rews Insert the lower screws Tighten all the screws of the cover Starter motor STARTER MOTOR pos Description Type Quantity Torque Notes 1 Starter motor fixing screws M8x75 2 25 Nm 18 44 lb ft Engine C...

Page 213: ...Removing the starter motor Undo and remove the two screws and collect the washers Slide off the starter motor Clutch side Disassembling the clutch California 1400 Engine ENG 213...

Page 214: ...243 3 Start up crown fixing screw on flywheel M6x12 6 10 Nm 7 37 lb ft 4 Clutch control cylinder fixing screw 3 10 Nm 7 37 lb ft Loctite 243 key 1 Complete clutch 2 Clutch 3 Clutch bell 4 TCEI screw...

Page 215: ...ntrol cylinder 19 TE flanged screw Remove the complete gearbox Undo and remove the six screws 1 Remove the start up crown gear Remove the clutch bell and the friction disc by undoing the six screws 2...

Page 216: ...the clutch pressure plate Unscrew and remove the six screws Remove the clutch plate CAUTION DURING REMOVAL FITTING OF THE SCREWS DO NOT USE WASHERS IF PREVIOUSLY INSTALLED See also Removing the gearbo...

Page 217: ...2 mm 0 386 0 441 in Clutch control rod length 183 mm 7 205 in Protrusion 9 9 7 mm 0 354 0 382 in Clutch control rod length 184 5 mm 7 264 in Protrusion 8 25 8 95 mm 0 325 0 352 in Clutch control rod...

Page 218: ...n the two centring tool screws Specific tooling 020672Y Clutch spring centre and pusher Once the centring tool is fitted lock the plate with the snap ring Undo and remove the two screws fixing the too...

Page 219: ...c in the cap by matching the centring with the slot in the cap Fit the clutch bell Place the starter sprocket Tighten the six screws to the prescri bed torque operating diagonally and in stages Califo...

Page 220: ...Description Type Quantity Torque Notes 1 Special aesthetic head cover fixing screw 8 8 Nm 5 90 lb ft Locked with cross sequence 2 Special head cover screw 8 8 Nm 5 90 lb ft Locked with cross sequence...

Page 221: ...Loctite 542 5 Long screw for chain compartment on head M6x120 4 10 Nm 7 37 lb ft 6 Screws for sprocket timing on camshaft M8x1 2 30 Nm 22 13 lb ft Loctite 243 7 Screws for blow by cap on head M5x16 4...

Page 222: ...10x1 25 6H 23 Flanged screw M6x120 24 Flat washer 12x6 1x2 25 Timing system gear 26 Breather plate 27 Flanged screw 28 Seal ring 2 62x46 52 29 Timing chain 30 Chain guide slider 31 Chain tensioner pad...

Page 223: ...INVERT TWO SPARK PLUG CAPS Unscrew and remove the four head cover fixing screws and collect the sealing O rings Remove the head cover together with the gaskets Remove the two spark plugs California 14...

Page 224: ...pay ing attention not to damage the seal ring Undo the external fixing screws of the head CAUTION PAY ATTENTION WHEN MOUNTING TO THE SCREW IN DICATED ON THE RIGHT CYLINDER BECAUSE IT IS THE ONLY ONE...

Page 225: ...With the help of a screwdriver act on the chain tensioner slider so as to dis charge the thrust of the tensioner and simultaneously insert a pin in said hole so as to block the return Remove the crown...

Page 226: ...securing the cam tower and the head unit Remove the complete head of the cam tower timing system Undo the fixing screws of the rocker bridge Remove the rocker bridge Remove the rockers Engine Californ...

Page 227: ...the screws as shown in the figure to extract the cam tower Remove the timing system cam tower complete with the camshaft See also Removing the head cover Cylinder head key California 1400 Engine ENG...

Page 228: ...verhead camshaft Using the special tool hold the cam shaft Specific tooling 020953Y Cam shaft lock for fixing Unscrew and remove the camshaft fix ing screw Undo and remove the four fixing screws of th...

Page 229: ...ts seat Remove the hydraulic tappets with roll ers from their seats See also Removing the rocker arms Removing the rocker arms Undo the fixing screws of the rocker bridge Remove the rocker bridge Cali...

Page 230: ...e Tighten the tool screw until fitted and then hit the tool head where the upper cap works with a mallet so that the two cotters 1 get detached from the upper cap 2 Once the two cotters 1 are detached...

Page 231: ...0 in VALVE GUIDE COUPLING VALVES INLET Specification Desc Quantity Valve guide inside diameter 5 0 5 012 mm 0 19685 0 19732 in Valve stem diameter 4 972 4 987 mm 0 19574 0 19633 in Fitting clearance 0...

Page 232: ...ER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Place the valve guide oil seal 4 in the head Place the lower cap 5 Place the valve 6 inside the head Place the spring 3 Fit the upper cap 2 Place t...

Page 233: ...it the camshaft Place the half spheres 1 into the ap propriate seats 2 of the rocker Place the two rocking levers in the cam tower seats Position the U bolt on the rockers Position the ground plate an...

Page 234: ...re that the roller 1 in the appro priate milling 2 of the cam tower coincides Position the cam shaft paying attention to the direction Position the U bolt on the camshaft matching up the reference pin...

Page 235: ...020953Y Cam shaft lock for fixing Tighten the camshaft fixing screw Between the two washers there is a cup spring which recovers the axial clearance of the shaft The spring must necessarily be centred...

Page 236: ...0 Nm 5 90 7 37 lb ft Loctite 243 3 Idle shaft locking nut M18x1 5 1 150 Nm 110 63 lb ft 4 Crankshaft locking nut M25x1 5 2 200 Nm 147 51 lb ft Removing the phonic wheel First remove the generator and...

Page 237: ...he special tool remove the tim ing system gear Specific tooling 12 91 36 00 Tool to remove the flywheel side flange Remove the tone wheel Recover the cotter and the shim wash er California 1400 Engine...

Page 238: ...Service shaft removal Remove the tone wheel Remove both cylinders Undo and remove the two screws Remove the service shaft closing cap Mark the timing chains so as not to in vert the direction of rotat...

Page 239: ...shaft Insert the service shaft in its crankcase seat by sliding it through the two chains Fit each chain to the corresponding service shaft gear Fit the roller cage and a new O ring on the service sha...

Page 240: ...t and the service shaft on the crankcase Fit the fixed chain sliders and tighten the fixing screws Tighten the chain caps with O rings The operations related to the movable chain sliders are described...

Page 241: ...he tone wheel with the chamfered side facing the crankcase on the serv ice shaft Lock crankshaft rotation Unscrew and remove the nut fixing the crankshaft gear Remove the oil pump control gear Specifi...

Page 242: ...e washer and tighten the timing system gear fixing nut of the service shaft Place a new gasket between the crank case and the oil pump Fit the oil pump Tighten the three oil pump fixing screws Place t...

Page 243: ...control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to the specified torque Tighten the screw with the washer t...

Page 244: ...heel If the distance measured is 0 55 0 7 mm 0 0216 0 0275 in the 1 mm 0 0394 in adjustment plate must be replaced with a 1 2 mm 0 0472 in thick plate 0 71 0 9 mm 0 0279 0 0354 in the measurement is c...

Page 245: ...Torque Notes 1 Tie rod on crankcase M10x1 25 8 5 Nm 3 69 lb ft 2 Right tensioner cover M30x1 5 1 40 Nm 29 50 lb ft 3 Left tensioner cover M20x1 5 1 30 Nm 22 13 lb ft 4 Left cylinder cover screw M6x10...

Page 246: ...linder 14 Washer 15 Chain tensioner cap 16 Washer 17 Left chain tensioner 18 Right chain tensioner Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY T...

Page 247: ...RATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS Remove the cylinder Cover the crankcase opening with a clean cloth Release the snap ring Remove the pin Mark the piston...

Page 248: ...at 120 one from the other Fit one of the two pin snap rings on the piston Lock crankshaft rotation Specific tooling 12 91 18 01 Tool to lock the flywheel and the starting ring gear Fit the piston NOTE...

Page 249: ...on the stud bolts Lu bricate the piston and the cylinder Lock connecting rod motion with the fork tool Using the suitable piston ring clamp tool place the cylinder and fit the chain in the timing sys...

Page 250: ...he cylinder Place the two dowel pins on the stud bolts Undo the screw which will be used to time the upper gear Check that the oil in the left cylinder chain tensioner has been drained off by compress...

Page 251: ...he service shaft Installing the cylinder head Fit the valves in the head if previously removed Take the left cylinder piston to TDC and lock crankshaft rotation Determine the thickness of the gasket t...

Page 252: ...four nuts on the stud bolts Fix the head with the two screws Tighten nuts and screws to the prescri bed torque operating diagonally and in stages Loosen the valve set screws Using a thin screwdriver r...

Page 253: ...ioner hole with screw and washer Rotate the crankshaft by 90 so that the right cylinder piston reaches the TDC lock crankshaft rotation Also determine the thickness of the gasket for the right cylinde...

Page 254: ...in ten sioner Undo and remove the screws used to place the gear on the camshaft Place the bulkhead and align the holes with the timing system gear Fix the bulkhead on the timing system gear using a sc...

Page 255: ...ead cover Replace the four rubber rings Tighten the four screws to the prescri bed torque Position the two plug caps of the spark plug Position the head cover and tighten the four screws to the prescr...

Page 256: ...he connecting rods Undo and remove the eight fixing screws and collect the washers Hold the crankshaft during flange re moval Using the suitable special tool remove the crankshaft flange Remove the se...

Page 257: ...Disassembling the clutch Removing the phonic wheel Disassembling the connecting rod CRANKSHAFT pos Description Type Quantity Torque Notes 1 Connecting rod screws M10x1 4 Pre torque 40 Nm 29 50 lb ft F...

Page 258: ...shaft main journal timing system side 37 975 37 959 mm 1 49507 1 49444 in Inside diameter of crankshaft bushing timing system side 38 016 38 0 mm 1 49669 1 49606 in Clearance between bushing and main...

Page 259: ...hings pins clearance Shaft parallelism Connecting rod bearings These are thin shell bearings anti friction alloy that does not allow for any adaptation replace them immediately if seizing or wear mark...

Page 260: ...DATA Specification Desc Quantity Fitted and machined bushing inside 22 003 22 020 mm 0 86626 0 86692 in Pin diameter 21 998 21 994 mm 0 86606 0 86590 in Clearance between pin and bushing 0 005 0 026 m...

Page 261: ...ing the connecting rods to the crankshaft must be replaced with new ones at the following refitting as they are subject to high loads and stress The fitting clearance between bearing and connecting ro...

Page 262: ...tooling 19 92 71 00 Tool to fit the seal ring on the flywheel side flange Prepare loctite 510 between the crankcase and the crankshaft flange on the flywheel side Fit the crankshaft on the crankcase...

Page 263: ...w the eight flange screws on the flywheel side proceeding diagonally Remove the sealing ring centring tool from the crankshaft Specific tooling 12 91 20 00 Tool to fit the flywheel side flange togethe...

Page 264: ...Nm 29 50 lb ft 2 Slot screw for oil pipe on the cylinder head M14x1 5 2 20 Nm 14 75 lb ft 3 Nipple on the radiator and the oil pipe M16x1 5 2 20 Nm 14 75 lb ft Apply Vaseline oil 4 Oil delivery pipe...

Page 265: ...1 lb ft Loctite 243 2 Low nut for oil pump M6x0 75 1 8 Nm 5 90 lb ft Loctite 243 OIL SUMP COMPONENTS pos Description Type Quantity Torque Notes 1 Cooling oil intake filter fixing screw M4x10 2 By hand...

Page 266: ...e fixing screw M8x25 8 26 Nm 19 18 lb ft 4 Oil cap on the crankcase 2 25 Nm 18 44 lb ft 5 Oil filter support flange fixing screw M6x45 4 10 Nm 7 37 lb ft 6 Thermal switch M6x1 5 1 20 Nm 14 75 lb ft 7...

Page 267: ...the oil is sent to the radiator 1 through the hoses 3 Oil passes through the radiator 1 dispersing part of the heat and reaches the heads through the hoses 2 Oil goes down to the sump again and joins...

Page 268: ...ng 8 Rotor control shaft 9 Oil pump cover 10 Oil pump control gear 11 Lubrication oil intake filter 12 Cooling oil intake filter General characteristics Lubrication circuit diagram key 1 Oil sump 2 Lu...

Page 269: ...e on the oil pump control gear and another on the driven gear so as to place them correctly again upon refitting Unscrew and remove the nut on the crankshaft Remove the oil pump control gear Screw the...

Page 270: ...he timing system cover Unscrew and remove the nipple Collect the gasket Unscrew and remove the three screws Remove the oil pump Remove the gasket between the crankcase and the oil pump See also Removi...

Page 271: ...ew gasket between the crank case and the oil pump Fit the oil pump Tighten the three oil pump fixing screws Place the driving pin on the oil pump shaft Place the gear on the oil pump shaft California...

Page 272: ...pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to the specified torque Fit the nipple with the gaske...

Page 273: ...ter 6 Oil filter 7 Cartridge type oil filter 8 Joint 9 Special gasket 10 Exhaust cap 11 Oil sump gasket NOTE TO REMOVE THE OIL SUMP PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAI...

Page 274: ...level plug and collect the O Ring Undo and remove the fourteen screws fixing the oil sump to the engine crank case Unscrew and remove the four screws Remove the pump inlet filter Remove the flange Eng...

Page 275: ...Unscrew and remove the filter fixing screw Remove the filter Remove the overpressure valve Refitting the oil sump Position the gasket of the overpressure valve California 1400 Engine ENG 275...

Page 276: ...Apply threadlock on the overpressure valve Tighten it to the prescribed torque Make sure that the OR is in good con dition otherwise replace it Position the joint Engine California 1400 ENG 276...

Page 277: ...sure the OR is in good condition Replace the OR if necessary Place a new gasket between the crank case and the flange Insert the flange the intake filter Secure the flange and the filter with the fou...

Page 278: ...r oil vapours to be recycled The law requires that these gas and oil vapours cannot be released into the atmosphere for environmental reasons Therefore there are sys tems for the recirculation of thes...

Page 279: ...the joint 4 5 while the liquid portion returns to the oil sump by means of the joint 3 IN ORDER TO PREVENT THE BLOW BY PIPE FROM BEING CRUSHED BETWEEN THE ALTERNATOR AND THE COR RUGATED PIPE TAKE PAR...

Page 280: ...INDEX OF TOPICS POWER SUPPLY P SUPP...

Page 281: ...Circuit diagram key 1 Fuel tank 2 Throttle body 3 Fuel filter 4 Fuel delivery pipe 5 Fuel pump unit Injection California 1400 Power supply P SUPP 281...

Page 282: ...el 3 Ignition switch 4 Battery 5 Fuel pump 6 Throttle valve position sensor 7 Air pressure sensor and intake air 8 Injectors 9 Engine temperature sensor 10 Crankshaft position sensor 11 Gear sensor 12...

Page 283: ...the parameters ready by the vari ous sensors are shown engine rpm engine tem perature and their units of measurement ENGINE PARAMETER READING SCREEN PAGE Navigator characteristic P A D S characteristi...

Page 284: ...rack A mV Blue connector throttle grip posi tion sensor track B Blue connector throttle grip posi tion sensor track B mV White connector throttle grip posi tion sensor track C White connector throttle...

Page 285: ...d errors Deleting stored errors Freezes and saves the param eter and states values Freezes and saves the param eter and states values Rpm indicator Rpm indicator Errors ambient parameters reading Erro...

Page 286: ...alise Throttle self learning with diagnostics instru ment Throttle self learning with diagnostics instru ment Carried out Not carried out Carried out Not carried out Start up enabling Start up enablin...

Page 287: ...t to positive or open circuit short circuit to ground Short circuit to positive or open circuit short circuit to ground P0 11 6 Engine tempera ture sensor Engine tempera ture sensor Signal not valid S...

Page 288: ...A B Inconsistent signal Inconsistent signal P0 15 5 Throttle Grip Po sition Redundan cy tracks C D Throttle Grip Po sition Redundan cy tracks C D Inconsistent signal Inconsistent signal P0 15 6 Thrott...

Page 289: ...n circuit P0 46 1 Analogue gear sensor Analogue gear sensor Short circuit to positive or open circuit short circuit to ground Short circuit to positive or open circuit short circuit to ground P0 50 2...

Page 290: ...ror No signal Configuration error U1 71 2 ABS Control Unit Frame Counter ABS Control Unit Frame Counter Intermittent signal or communication er ror Intermittent signal or communication er ror SETTINGS...

Page 291: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 292: ...discs fixing screws M8x22 12 25 Nm 18 44 lb ft 2 Wheel axle 1 80 Nm 59 00 lb ft Removing the front wheel Working from both sides undo and re move the two fixing screws from the front brake callipers a...

Page 293: ...the front wheel FRONT WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION ESPECIALLY THOSE LISTED AS FOL LOWS ROTATION CHECK Manually r...

Page 294: ...wear ALWAYS REPLACE BOTH GASKETS ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE WHEEL AXLE Use a dial gauge to check the wheel axle eccentricity Replace the wheel axle if the eccentricity ex...

Page 295: ...FRONT WHEEL REMOVAL Remove the spacer Undo and remove the six fixing screws 1 of the tone wheel and the front disc Remove the tone wheel and the front disc California 1400 Suspensions SUSP 295...

Page 296: ...remove the spacer Remove the dust gaiter Undo and remove the six fixing screws 2 of the front disc and remove it Remove the Seeger ring Using the special tool remove the bear ing and the spacer Suspen...

Page 297: ...After removing the bearing 3 and the spacer 4 operate from the opposite side and remove the bearing 5 California 1400 Suspensions SUSP 297...

Page 298: ...two fixing screws of the clutch pump bracelet Remove the pump Undo and remove the three fixing screws of the left switch Remove the switch Undo and remove the two fixing screws of the front brake pump...

Page 299: ...o and remove the two fixing screws of the right switch Remove the switch Removing Undo and remove the four fixing screws of the handlebar bracelet Remove the handlebar California 1400 Suspensions SUSP...

Page 300: ...Front fork FORK pos Description Type Quantity Torque Notes 1 Lower suspension bars fixing screws M5x50 4 6 Nm 4 42 lb ft Suspensions California 1400 SUSP 300...

Page 301: ...0 Nm 73 76 lb ft Removing the fork legs Rest the vehicle on its centre stand Secure the rear part of the vehicle through belts in order to lift the front wheel Remove the mudguard Remove the front whe...

Page 302: ...ng 020951Y Stanchion support Unscrew the upper cap of the stan chion Using the special tool to hold the locked preloading pipe Undo and remove the upper cap of the stanchion Specific tooling 020888Y P...

Page 303: ...c wrench on the ring nut of the piston Unscrew the fork bottom and remove it with the corresponding washer Specific tooling 020952Y Pumping member ring nut locking spanner Remove the piston and its co...

Page 304: ...in 1 If the scorings are deep replace the stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTE...

Page 305: ...hing piston If there are signs of excessive wear or damage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SUR FACE Replace the following co...

Page 306: ...ork oil or grease for seals Install the lower and upper bushing on the stanchion the dust scraper the seal ring and the washer Position the stanchion in the sleeve and with the prescribed tool put the...

Page 307: ...e dust gaiter with the specific tool Specific tooling AP8140146 Weight Insert the pumping member in the sleeve Install the lock key of the piston Specific tooling 020952Y Pumping member ring nut locki...

Page 308: ...mpressed Pour part of the fork oil into the sleeve Wait some minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times Measure the air gap between the oil level and the...

Page 309: ...sert all components in the piston Fit the spring Fit the washer and the preload tube Using pliers support the piston while maintaining the stanchion resting on the sleeve Using the special tool lock t...

Page 310: ...orks in a vertical position Tighten the cap to the prescribed tor que Specific tooling 020951Y Stanchion support Installing the fork legs Insert the stanchion in position Insert the wheel axle so that...

Page 311: ...few trips in order to perfectly align the sleeve Removing First remove the handlebar the front wheel Working from both sides undo the screws fixing the upper plates to the forks Unscrew and remove the...

Page 312: ...Remove the upper plate Remove the OR from the forks and the upper cover Undo and remove the screws fixing the lower plate to the fork Suspensions California 1400 SUSP 312...

Page 313: ...ecial tool loosen the upper ring nut 1 and the lower ring nut 2 Retrieve the rubber spacer 3 placed between the two ring nuts Be careful to properly hold the lower plate Remove the two dust gaiter rin...

Page 314: ...bearing 5 6 Remove the lower plate Working from both sides undo and re move the two fixing screws of the fork lower cover Remove the fork by unscrewing the fix ing screws to the lower plate See also R...

Page 315: ...lb ft Pretightening to 60 Nm 44 25 lb ft 3 Upper cover 1 100 Nm 73 76 lb ft Adjusting play First remove the upper steering plate Remove the safety washer unscrew and remove the counter lock ring 1 the...

Page 316: ...ely from right to left and then check correct tightening torque of such ring nut Fit the upper ring nut tightening it manually plus about 90 degrees so that the grooves are lined up Position the safet...

Page 317: ...g the up per bearing hit it from bottom upwards using the appropriate tool to extract the lower one Assembling Using the special tool install the two bearings first the lower then the upper one Lubric...

Page 318: ...screw the abovementioned ring nut and retighten it Fit the dust gaiter 5 from the back B Insert the rubber washer 7 and tighten the counter lock ring 8 manually until making contact with the washer 7...

Page 319: ...lb ft 2 Tone wheel flange screws M8x20 6 25 Nm 18 44 lb ft 3 Wheel axle nut M25x1 5 1 100 Nm 73 76 lb ft Removing the rear wheel Support the vehicle rear part using a suitable stand Unscrew the fasten...

Page 320: ...AS FOL LOWS REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless...

Page 321: ...WHEEL AXLE Use a dial gauge to check the wheel axle eccentricity 1 Replace the wheel axle if the eccentricity exceeds the limit value 1 Characteristic Maximum eccentricity 0 20 mm 0 0079 in REAR WHEE...

Page 322: ...ll within the control parameters Replace both bearings of the final drive unit FLEXIBLE COUPLING Check that the flexible couplings 3 are not dam aged or excessively worn To check Position the complete...

Page 323: ...1 Remove the flange paying attention to the spacer Remove the flexible coupling disc Operating from the opposite side undo and remove the six fixing screws 2 of the tone wheel Remove the tone wheel C...

Page 324: ...Remove the dust gaiter and the seeger ring locking the bearings Undo and remove the six fixing screws of the rear disc Remove the rear disc Suspensions California 1400 SUSP 324...

Page 325: ...ng the special tool remove the bearings After removing the bearing 3 and the spacer 4 operating from the opposite side and using the special tool remove the bearing 5 California 1400 Suspensions SUSP...

Page 326: ...cessary to add a coupling spacer between the wheel and the car dan joint There are two types of flange which differ from one another by the presence or not of a step If there is a type A flange no cou...

Page 327: ...xing screws M6x14 4 10 Nm 7 37 lb ft Removing The following procedure refers to one single shock absorber but is valid for both Adequately support the vehicle Unscrew and remove the upper fixing screw...

Page 328: ...ting As for the Touring version unscrew and remove the two fixing screws of the shock absorber Unscrew and remove the nut fixing the expansion tank of the shock absorber located on the right side of t...

Page 329: ...INDEX OF TOPICS CHASSIS CHAS...

Page 330: ...25 lb ft 2 Preloading bushing 1 10 Nm 7 37 lb ft 3 Clamp screws M6x25 2 10 Nm 7 37 lb ft Removing First remove the rear wheel Working from both sides undo the screw 1 of the rear shock absorber Undo...

Page 331: ...Remove the clamp that fixes the dust gaiter 3 to the swingarm Unscrew and remove the pin making sure that the swingarm does not fall Cardan shaft California 1400 Chassis CHAS 331...

Page 332: ...wdriver remove the uni versal joint Remove the cardan shaft Checking Carefully check The splines on the cardan shaft 1 must be intact free from grain or dents Check that the joints 2 are not hardened...

Page 333: ...acceptable wear the cardan shaft must be replaced Stand STAND pos Description Type Quantity Torque Notes 1 Screws fixing stand plate to chassis M10x50 3 50 Nm 36 88 lb ft 2 Stand bolt 1 25 Nm 51 61 lb...

Page 334: ...ty Torque Notes 1 Front fixing screw M8x16 2 25 Nm 18 44 lb ft 2 Rear fixing screw M6x25 1 10 Nm 7 37 lb ft 3 Fuel pump fixing screw M5x20 6 6 Nm 4 42 lb ft 4 Fuel level sensor fixing nuts M5 4 5 Nm 3...

Page 335: ...to both exhausts Loosen and remove the three fixing screws of the heat shield Remove the heat shield Loosen the side clamp Loosen the lower clamp Undo and remove the two fixing screws of the support...

Page 336: ...Undo and remove the two nuts on the exhaust stud bolts of the head Remove the exhaust manifold Chassis California 1400 CHAS 336...

Page 337: ...RADIATOR pos Description Type Quantity Torque Notes 1 Screws fixing oil radiator to chassis M6x25 3 10 Nm 7 37 lb ft 2 Screws fixing electric fan to oil radiator 4 2x20 3 2 5 Nm 1 84 lb ft California...

Page 338: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 339: ...ft 2 ABS control unit support plate fixing screws M6x25 3 10 Nm 7 37 lb ft 3 ABS control unit support plate fixing screws M6x16 3 10 Nm 7 37 lb ft Interventions rules CAUTION THE FRONT BRAKE DISC SHA...

Page 340: ...9 Starter motor 10 Fuses ABS control unit pin out key PIN 1 Ground connection Vehicle identification 1 PIN 2 Vehicle speed output PIN 3 Key input PIN 4 CAN H line high speed PIN 5 CAN L line low speed...

Page 341: ...tification 2 PIN 15 Serial K line for diagnostics PIN 16 Battery power PIN 18 Foreword key 1 Rear brake calliper 2 Modulator 3 Front bleed valve 4 Front brake reservoir 5 Front brake callipers 6 Rear...

Page 342: ...Operating diagram ABS functional diagram key 1 Front system circuit 2 Front brake pump 3 Front brake lever 4 Rear system circuit Braking system California 1400 BRAK SYS 342...

Page 343: ...d of the wheels in order to assess potential wheel slippage When in standby the system does not intervene at all when the rider brakes the braking system is the same as the one without ABS Stages in A...

Page 344: ...gnals this out and adjusts the pressure in the braking circuit accordingly NOTE WHEN THE ABS SYSTEM STARTS WORKING A VIBRATION IS FELT ON THE BRAKE LEVER THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PRE...

Page 345: ...s exceeding the 5 km h 3 1 mph Each time the key is ON if at least one current or stored error of the ABS system is not detected the ABS warning light flashes When the 5 km h 3 1 mph are exceeded if e...

Page 346: ...ERVICE 8 PERFORM THESE CHECKS A Cable continuity between PIN 8 of the ABS control unit connector and PIN40 of the in strument panel B Check connectors refer to the operations described in the chapter...

Page 347: ...injection control unit vehicle code reader PARAMETERS screen page This screen page shows the parameters meas ured by the several sensors engine revs engine temperature etc or values set by the control...

Page 348: ...oltage Speed Ambient parameter error reading 2 Number of error detections number of times the error has been detected by the control unit Ambient parameter error reading 3 for example if it indicates...

Page 349: ...ation after pressure reduction Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Front speed sensor 5D95 excessive measured speed Faulty sensor to...

Page 350: ...essive voltage measured at PIN 18 of the ABS control unit Vehicle code 5E59 Inconsistency detected between memory coding INFO ECU Vehicle code and what is measured at cable harness identification PIN...

Page 351: ...he line Vehicle code Modulator Remove the plastic cover of the ABS system Cut the clamp that fastens the wiring With a felt tip pen mark a reference on the pipes and on the ABS control unit to avoid i...

Page 352: ...lly inserted the distance between the connector and the ABS control unit must be 7 5 mm 0 29 in If the initial position of the connector and the driving lever is not that shown in fig 1 the connector...

Page 353: ...E TOLERANCE RANGE IS MEAS URED REPLACE THE SENSOR 1 AND OR THE TONE WHEEL 2 AND REPEAT THE CHECKS MAKE SURE THAT THE VALUES ARE WITHIN THE TOLERANCE LIM ITS TONE WHEELS 2 CLEANING It is important to c...

Page 354: ...ction FRONT CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM The following operations must be car ried out with the brake discs fitted on t...

Page 355: ...in with respect to the wheel centre line Front brake pads Removal Undo and remove the two screws Slide off the brake calliper from the disc Turn the pins and remove both split pins Remove both pins Ca...

Page 356: ...t two new pads placing them so that the holes are aligned with the cal liper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Position the anti vi...

Page 357: ...Rear brake pads Removal Remove the lock and remove the pin California 1400 Braking system BRAK SYS 357...

Page 358: ...sert two new pads placing them so that the holes are aligned with the cal liper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Insert the pin Po...

Page 359: ...ne Connect the brake pipe to the new brake pump Fill the reservoir with new brake fluid CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEEDING AS DESCRIBED AT THE END OF THE CHAPTER Always fill the reser...

Page 360: ...from the ABS control unit to the brakes and also seal these unions with protective caps Install the new ABS control unit previ ously filled up So that the brake fluid remains in the ABS control unit f...

Page 361: ...ice so as to avoid fluid flowing out from the open system Close the bleed screws of the front cal liper and remove the bleed bottle Replace the damaged calliper with a new one Unlock the brake lever R...

Page 362: ...HE REGULAR BRAKING SYSTEM BLEEDING AS DESCRIBED AT THE END OF THE CHAPTER See also Front Rear Front Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by...

Page 363: ...nt brake oil reservoir cap Refit the rubber protection cover Rear Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and minimising the...

Page 364: ...ate the brake lever and then open the bleed valve on the calliper 1 4 of a turn to let the air out Close the bleed again before reaching the lever end of the stroke and repeat the operation until ther...

Page 365: ...INDEX OF TOPICS BODYWORK BODYW...

Page 366: ...Description Type Quantity Torque Notes 1 Front fixing screws M8x20 2 25 Nm 18 44 lb ft 2 Upper fixing screw M8x16 1 25 Nm 18 44 lb ft 3 Side cover fixing screws M5x9 4 6 Nm 4 42 lb ft Bodywork Califor...

Page 367: ...losing fixing screws 8 6 Nm 4 42 lb ft 2 Fixing screw closing upper and lower saddle compartment M5x20 stainless steel 6 3 Nm 2 21 lb ft CENTRAL BODYWORK pos Description Type Quantity Torque Notes 1 S...

Page 368: ...ixing screws M5x10 6 6 Nm 4 42 lb ft 2 Dashboard fixing screw M5x16 2 5 Nm 3 68 lb ft FUEL TANK pos Description Type Quantity Torque Notes 1 Front fixing screw M8x16 2 25 Nm 18 44 lb ft 2 Rear fixing...

Page 369: ...nk M5x16 5 6 Nm 4 42 lb ft HEADLAMP pos Description Type Quantity Torque Notes 1 Screw fixing headlamp to supports M6x55 1 5 Nm 3 69 lb ft 2 Screw fixing headlamp to joint M6x30 1 10 Nm 7 37 lb ft 3 F...

Page 370: ...escription Type Quantity Torque Notes 1 Engine guard upper fixing screws M10 2 50 Nm 36 2 lb ft 2 Engine guard lower retainer nut M12 2 50 Nm 36 2 lb ft 3 Engine guard lower fixing screw M12 2 50 Nm 3...

Page 371: ...ove the screw indi cated in the figure Position engine guard and secure it with the screw provided in the kit Do not tighten the screw Rotate the engine guard until you have free access to the second...

Page 372: ...the left and secure it with the screw from the kit Finally replace the lower screw of the engine guard with the one supplied in the kit Tighten all screws to torque Side fairings IF APPLICABLE Bodywor...

Page 373: ...of the motorcycle 5 License plate fixing screw M8x20 1 4 Nm 2 9 lb ft Small parts of the motorcycle 6 Fixing clip M5 1 Small parts of the motorcycle Position the chassis guard and secure it with the...

Page 374: ...into the bike frame Position the bracket 2 and secure it with the two screws 3 and the relative washers Apply the rubber block 4 on the lower hole of the bracket Position and secure the luggage rack...

Page 375: ...h the two screws 3 and 4 and the relative washers Apply the rubber block 5 on the lower hole of the bracket Position and secure the luggage rack 6 with the three screws 7 and the relative corrugated w...

Page 376: ...trument panel during operation take care to support it ade quately Undo and remove the three fixing screws 1 Remove the rear cover Disconnect the connector Remove the instrument panel Headlight assy C...

Page 377: ...two side fixing screws Be careful to adequately support the headlight assembly before removing the screws HEADLAMP SUPPORTS The following procedure is described for one sin gle support but is valid fo...

Page 378: ...ng screws 1 taking care to properly sup port the additional headlamps Remove the two connectors 2 from the bulkhead pulling slightly Disconnect the additional light connec tors Remove the additional h...

Page 379: ...the three fixing screws 1 NOTE BEFORE PROCEEDING WITH THE LEFT FOOTREST RE MOVAL DISCONNECT THE GEAR TIE ROD ON THIS FOOTREST THE MICRO IS NOT PRESENT AS IN THE RIGHT FOOTREST Remove the footrest Rem...

Page 380: ...fixing clamp of the stop light switch 3 Undo and remove the two fixing screws 2 Remove the switch Unscrew and remove the fixing screw of the brake lever Remove the brake lever Bodywork California 140...

Page 381: ...To remove the gear lever unscrew the screw shown in the figure PASSENGER FOOTREST Unscrew and remove the four screws 1 Unscrew and remove the rear screw Remove the passenger footrest California 1400...

Page 382: ...om both sides unscrew and remove the fixing screw Remove the side fairing SADDLE RELEASE CONTROL REMOVAL Remove the fork spring Disconnect the saddle release cable Remove the cable support plate Bodyw...

Page 383: ...assembly License plate holder Disconnect the light connector located under the rear mudguard Undo and remove the two fixing screws of the license plate support Remove the license plate support Califor...

Page 384: ...or of the li cense plate light Unscrew and remove the lower fixing screw See also Rear grab rail Working from both sides release the two side locks Disconnect the two connectors of the rear turn indic...

Page 385: ...Undo and remove the turn indicator fix ing screws Remove the wiring by its fasteners Remove the turn indicator California 1400 Bodywork BODYW 385...

Page 386: ...n this case the difference is the number of breath er pipes that are on the fuel pump side In model 1 are two pipes while in model 2 there is one The other difference is the breather pipes routing In...

Page 387: ...ve the two fixing screws of the tank cap cover Remove the cover Disconnect the two connectors of the fuel level sensor Working from both sides undo and re move the two side screws California 1400 Body...

Page 388: ...to reach the connector Disconnect the connector of the fuel pump Disconnect the fuel pipe CAUTION PAY ATTENTION TO THE LEAKAGE OF FUEL EVEN IF IN A MINIMUM QUANTITY Disconnect the two breather pipes 1...

Page 389: ...nit license plate support and side panniers sup port Working from both sides undo and re move the two side fixing screws Unscrew and remove the two rear screws See also License plate holder Pannier mo...

Page 390: ...e the two screws on the side of the rear shock absorber Undo and remove the fixing screws in the lower protection part of the ABS control unit Remove the rear wheel housing by pulling it off from the...

Page 391: ...undo and re move the two fixing screws 1 Remove the front mudguard Side panniers IF APPLICABLE Open the top box using the key Undo and remove the four fixing screws 1 being careful to support the top...

Page 392: ...the right support Insert the four clips 4 Insert the eight rubber block clips 5 Proceed with assembly of the side pan niers reversing the dismantling proce dure and tightening the screws to the presc...

Page 393: ...l the cases with a drill bit of 9 5 mm 0 37 in at the indicated points 1 Fill in the recently made holes with the rubber rings insert 2 from the inside of the case Fix the reflector 3 on the support 4...

Page 394: ...the license plate holder 5 Pannier mounting The following steps are described for only one side of the frame but apply to both Undo and remove the screw fixing the passenger footrest to the pannier ho...

Page 395: ...x20 4 10 Nm 7 37 lb ft First install the luggage rack Secure the attachment plate 1 to the luggage rack 2 using the four screws 3 complete with pads 4 bushes 5 washers 6 and self locking nuts 7 Centre...

Page 396: ...the cover 8 to the plate 1 using the four screws 9 Rear grab rail First remove the saddle Undo and remove the three fixing screws 1 of the rear handle Remove the rear handle Bodywork California 1400 B...

Page 397: ...ng bracket 1 6 Frame 1 7 Windshield 1 8 Left finishing 1 9 Right finishing 1 10 Central finishing 1 11 Cable grommet 1 12 Rubber blocks 2 Installation Assemble the windshield 7 to the frame 6 and to t...

Page 398: ...cure the lower mounting bracket 5 to the lower steering yoke using the two screws 4 Slightly widen the cable grommet 11 and pass the accelerator cables through as illustrated Slightly lubricate the ru...

Page 399: ...Disconnect the two battery cables starting from the negative and then move to the positive Remove the battery California 1400 Bodywork BODYW 399...

Page 400: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 401: ...xing screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front an...

Page 402: ...CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OI...

Page 403: ...ent Functional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal no...

Page 404: ...theft control unit Position the clamps in the specific seats prepared on the mounting plas tic Pass the right clamp through the two slots on the anti theft device control unit Pull the clamps securin...

Page 405: ...orque Notes 1 Counterweighted fastening screws M6x30 2 10 Nm 7 37 lb ft HEATED HANDGRIPS Remove both side fairings first LEFT HEATED HANDGRIP INSTALLATION Remove the counterweight 2 undo ing the screw...

Page 406: ...th those on the handlebar and screw in the fixing screws 5 Replace the two cable grommets with the ones in the kit 6 Also take care to insert the cabling of the heatable handgrip in the rubber cable g...

Page 407: ...ight 9 RIGHT HEATED HANDGRIP INSTALLATION Remove the brake master cylinder first Remove the counterweight 2 undo ing the screw 1 Open the accelerator block removing the two screws 4 Disconnect both th...

Page 408: ...peg in the dedi cated hole on the handlebar Tighten the two screws 4 Refit the brake master cylinder Replace the two cable grommets with the ones in the kit 6 Also take care to insert the cabling of...

Page 409: ...Insert and secure to the handlebar us ing the screw 8 the spacer 10 and the counterweight 9 California 1400 Pre delivery PRE DE 409...

Page 410: ...243 255 256 258 262 Cylinder 42 224 227 230 231 246 247 249 251 258 D Desmodromic drum 202 Display E ECU 154 283 346 Electrical system 11 69 74 75 401 Engine oil 56 337 Engine temperature sensor 127 E...

Page 411: ...147 Oil sump 273 275 P Primary shaft 196 201 203 R Radiator Rear wheel 55 319 320 326 Recommended products 44 Run Stop switch 152 S Saddle Secondary shaft 198 201 203 Shock absorbers 326 Side fairing...

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MOTO GUZZI California 1400, Instructions Manual

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