MOTO GUZZI CALIFORNIA EV 1997-2000 Page 215 Workshop Manual Download

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NGINE

OMPONENT OVERHAUL

WARNING

During this procedure, inflammible vapours and

metal particles which may be expelled at high

speed are produced. It is therefore recommended

to work in an environment free of naked flames

or sparks. The operator must wear protective

goggles.

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Summary of Contents for CALIFORNIA EV 1997-2000

Page 1: ...WORKSHOP MANUAL WERKSTATTHANDBUCH ONDERHOUDS EN REPARATIEHANDBOEK...

Page 2: ...lich Moto Guzzi beh lt sich daher das Recht vor nderungen an Teilen Zubeh rteilen Ausr stungen usw anzubringen falls sich diese als notwendig erweisen solten um Verbesserungen auszuf hren technischen...

Page 3: ...I INDEX FOR THE SECTIONS ABSCHNITTSINDEX INHOUD VAN DE SECTIES...

Page 4: ...AT REST 16 9 CLEANING THE MOTORBIKE 18 SEC D SCHEDULED MAINTENANCE 1 SCHEDULED MAINTENANCE TABLE 2 2 MAINTENANCE PROCEDURES 4 SEC E TRIMMINGS 1 WING MIRRORS 2 2 FRONT AND REAR MUD GUARDS 4 3 SIDE PANE...

Page 5: ...1 16 9 THROTTLE BODY 2 18 10 BATTERY 1 22 11 STARTER SWITCH 2 22 12 RELAY 3 24 13 ECU I A W 15 M 4 26 14 AIR TEMPERATURE SENSOR 5 28 15 OIL SENSOR TEMPERATURE 6 28 16 R P M AND T D C SENSOR 7 30 17 CO...

Page 6: ...E BENCH 30 SEC O REAR TRANSMISSION HOUSING AND SHAFT 1 REAR TRANSMISSION HOUSING 2 2 TRANSMISSION SHAFT 16 SEC P ELECTRICAL SYSTEM 1 ELECTRICAL SYSTEM DESCRIPTION 2 2 BATTERY 20 2 BATTERY USA SGP CAN...

Page 7: ...VIII...

Page 8: ...CALIFORNIA EV 1997 2000 CALIFORNIA EV 2001...

Page 9: ...CALIFORNIA JACKAL CALIFORNIA STONE...

Page 10: ...CALIFORNIA SPECIAL SPORT CALIFORNIA SPECIAL...

Page 11: ...A B C D E F G H I L M N O P 1 GENERAL INFORMATION ALLGEMEINE INFORMATIONEN ALGEMENE INLICHTINGEN...

Page 12: ...divided into sections and then into chapters for a faster and more direct consultation the sections contain information and procedures regarding a particular motorbike system while the chapters analy...

Page 13: ...s must be carried out after 1500 Km as describedon the table in chapter 1 of section D carrying out these operations is essential as they allow the operator to check the initial wear which takes place...

Page 14: ...L M N O P 6 GENERAL INFORMATION 5 WARRANTY When replacing parts request and make sure that only Original Moto Guzzi Spare Parts are used The use of non original spare parts shall render any warranty c...

Page 15: ...A B C D E F G H I L M N O P 1 MODEL FEATURES MODELLEIGENSCHAFTEN KARAKTERISTIEKEN MODEL...

Page 16: ...al identification of the motorbike this number is composed of digits and letters as in the example illustrated below ZGUKDBKDXVM111111 1 Code WMI World Manufactures Identifier 2 Type of vehicle 3 Mode...

Page 17: ...emium unleaded gasoline 95 No r p m Engine sump 3 Agip 4T SUPER RACING SAE 20W50 oil Gearbox housing 0 5 7 0 Agip Rotra MP SAE 80 W 90 oil Final Drive bevel gear lubrication 0 5 2 0 of which 0 3 2 0 0...

Page 18: ...ber IW031injectors electric pump with pressure adjuster digital management for optimized injection times EXHAUST SYSTEM In stainless steel 2 two tubes connected to an expansion chamber and to two sile...

Page 19: ...gearings ratio 1 1 2353 z 17 21 GEARBOX 5 speed model with constant mesh gears with front clutch dogs Incorporated couplings Conrol with pedal lever positioned on the LH side of the vehicle GEAR RATIO...

Page 20: ...A JACKAL CALIFORNIA STONE Swinging arm with two adjustable hydraulic shock absorbers for spring pre load CALIFORNIA SPECIAL SPORT CALIFORNIA SPECIAL 1ST SERIES UNTIL CHASSIS NO KD 131950 Swinging arm...

Page 21: ...s FRONT 18 x 2 50 MT DOTE REAR 17 x 4 00 MT DOTE TIRES CALIFORNIA EV 1997 2000 SPECIAL JACKAL FRONT 110 90 18 61H 61V 61VB REAR 140 80 17 69H 69V 69VB CALIFORNIA SPECIAL SPORT STONE FRONT 110 90 18 61...

Page 22: ...iper Pedal lever control in the centre on the RH side of the vehicle disk 282 mm braking cylinder 30 32 mm pump 16 mm Rear brake is connected to front left brake through hydraulic transmission Each si...

Page 23: ...male lengte Maximum width Max Breite Maximale breedte Maximum height without windscreen Max H he ohne Windschutzscheibe Maximale hoogte zonder windscherm Rider s seat height H he des Fahrersitzes Hoog...

Page 24: ...A B C D E F G H I L M N O P 17 MODELLEIGENSCHAFTEN KARAKTERISTIEKEN MODEL CALIFORNIA SPECIAL SPECIAL SPORT CALIFORNIA JACKAL STONE B A C D E F G H I L M N O P...

Page 25: ...25 30 Gearbox oil level and drain plug 22 25 Safety nut for secondary shaft 70 80 Lock nut for bearing on bevel sprocket 180 200 Fastening screws for rear sprocket to drilled shaft 25 30 Fastening scr...

Page 26: ...O P 21 MODELLEIGENSCHAFTEN KARAKTERISTIEKEN MODEL 7 22 20 21 6 19 23 36 24 38 35 28 27 13 39 11 41 5 4 12 18 40 3 14 17 26 25 31 32 33 16 34 15 2 1 37 8 9 10 29 30 5 TOOLS AUSR STUNG UITRUSTING B A C...

Page 27: ...for secondary shaft outer roller bearing race on housing and outer bearing races on case 22 14 90 70 00 Ball bearing extractor for primary shaft on cover 23 12 90 69 00 Extractor for roller bearing ri...

Page 28: ......

Page 29: ...A B C D E F G H I L M N O P 1 CONTROL AND USE OF THE MORBIKE KONTROLLE UND GEBRAUCH DES MOTORRADS CONTROLE EN GEBRUIK VAN DE MOTORFIETS...

Page 30: ...the tank the oil in the crankcase sump is at the correct level the key A in the ignition switch is in the ON position the following warning lights are on red insufficient oil pressure B insufficient...

Page 31: ...nung C gr ne Kontrollleuchten Leerlaufanzeiger NEUTRAL D der Schalter E CHOKE bei kaltem Motor in der Startposition 1 ist der Schalter F in der Position Run ist 1 PRELIMINAIRE CONTROLES V r het starte...

Page 32: ...en the engine is warm are the same as for a cool engine except that it is not necessary to place the CHOKE control lever in the start position WARNING The starter motor must not be activated for over...

Page 33: ...tly and the engine brake must be employed with great care so as not to have the engine run at runaway speed rates On wet and slippery roads take care when braking particularly when using the front bra...

Page 34: ...hread pin C loosen counter nut D and screw or unscrew fork E until the desired brake pedal position is reached reassemble pin C and its cotter pin B REAR AND FRONT LEFT BRAKE PEDAL ADJUSTMENT FOR CALI...

Page 35: ...n can be adjusted separately Adjust hydraulic damping capacity by means of adjusters A or B Left hand adjuster A controls hydraulic extension adjustment right hand adjuster B controls compression adju...

Page 36: ...acement of any component of the above mentioned systems must be carried out with original spare parts care of our dealers workshops REAR SHOCK ABSORBERS ADJUSTMENT CALIFORNIA JACKAL AND CALIFORNIA STO...

Page 37: ...et the handlebar move freely but without play To adjust the steering carry out the following procedures Remove the small cover A and loosen the locking screw of the steering head Remove the small cove...

Page 38: ...od of time eg in the winter season it is necessary to take the following precautions Throughly clean all the vehicle Empty the tank and the fuel system If left in the tank for a long time the fuel wou...

Page 39: ...U N B The ECU is placed under the left side body panel it is placed under the passenger s seat only on California EV 1st series WHILE WASHING Avoid spraying the instruments and the rear and front hub...

Page 40: ...brasive substances pumice garnet paper shave hooks etc Polishes can be used only after having removed dust and dirt with a good wash Small superficial scratches can be removed with soft polish Fresh p...

Page 41: ...A B C D E F G H I L M N O P 1 SCHEDULED MAINTENANCE REGELM IGE WARTUNG PERIODIEK ONDERHOUD...

Page 42: ...mi 6000 mi 12000 mi 18000 mi 24000 mi 30000 mi PROCEDURES 1500 Km 10000 Km 20000 Km 30000 Km 40000 Km 50000 Km Engine oil R R R R R R Cartridgefilteroil R R R R R R Meshoilfilter C C C C C C Airfilte...

Page 43: ...lace the oil Replacement should be carried out when the engine is warm to allow the oil to drain more quickly and thoroughly To bring the engine up to the standard temperature please see section C cha...

Page 44: ...an under the oil sump to collect the used oil Drain all the oil as described in the Engine oil replacement paragraph chapter 2 in this section Unscrew the screws 18 A and remove oil sump B from the cr...

Page 45: ...Drain all the oil as described in the Engine oil replacement paragraph in this chapter Unscrew the 18 screws A fastening the oil sump B to the crankcase Remove the oil sump B Unscrew screw D Remove th...

Page 46: ...tank as described in section I chapter 3 Remove the cartridge filter in the following way Unscrew the 2 upper screws A and lift the filter box cover B Remove the filter cartridge C and clean it Replac...

Page 47: ...lter it is necessary to proceed as follows Remove the saddle as described in section E chapter 4 Remove the tank as described in section I chapter 3 Detach the fuel inlet A and outlet B pipes from the...

Page 48: ...or some turns and then using the special key supplied with the motorbike tighten them to the torque prescribed in the table in chapter 4 section B N B Always replace and refit the spark plugs only whe...

Page 49: ...C in compression stage valves closed Work as follows Remove the head cover A by unscrewing the eight screws B Loosen the nuts C Loosen or unscrew the adjustment screw D until you obtain the following...

Page 50: ...oil This must be carried out when the engine is warm to allow the oil to drain more quickly and thoroughly To bring it to temperature followed the operations under listed Place a pan under the gearbox...

Page 51: ...the rear transmission box up to temperature drive for some kms and replace the oil following the below procedures Place a pan under the final drive to collect the used oil Remove the oil filler cap B...

Page 52: ...wear this test must be carried out manually with the bearing fitted in its seat Turn the inner ring in both directions this must be capable of turning softly and silently without interference Push th...

Page 53: ...e table chapter 2 section B N B During the oil draining and refilling procedures the rod and its internal parts must be locked in a vice take care not to damage them by excessive tightening always use...

Page 54: ...the oil contained in the rod in a special container Lock the rod again in the vice and while holding the tube in pre load C unscrew check nut B but not fully to release the inner spring Remove open w...

Page 55: ...acilitate the oil drainage in the shock absorber assembly WARNING By pumping on the rod G of the shock absorber a high pressure oil jet comes out of the rod end To avoid damages to objects and people...

Page 56: ...od in a vice Lift slightly the shock absorber with one hand and fill the fork with new oil in the prescribed quantity see chapter 1 of this section Slowly pump the shock absorber to fill it with oil C...

Page 57: ...of section D chapter 1 To allow the systems to work correctly it is necessary that the pipings are always full of fluid and without air bubbles if the control lever stroke is long and elastic this in...

Page 58: ...screw the draining union by a 1 4 turn and activate the control lever until all the fluid has been drained Filling Fill the tank with prescribed oil taken from a sealed container Activate the control...

Page 59: ...ivate the control lever until all the fluid has been drained Filling Fill the tank with prescribed oil taken from a sealed container Activate the control lever several times to fill the system and to...

Page 60: ...fluid container Unscrew the draining union and by a 1 4 turn and activate the control lever until all the fluid has been drained Filling Fill the tank with prescribed oil taken from a sealed container...

Page 61: ...Unscrew the draining union by a 1 4 turn and activate the control lever until all the fluid has been drained Filling Fill the tank with prescribed oil taken from a sealed container Activate the contr...

Page 62: ...of this tube must be immersed in a container with brake fluid Loosen the draining union A Fully pull the control lever on the handlebar then release it and wait some seconds before pumping again Repe...

Page 63: ...ust be immersed in a container with brake fluid Loosen the draining union A Fully pull the control lever on the handlebar then release it and wait some seconds before pumping again Repeat this procedu...

Page 64: ...ust be immersed in a container with brake fluid Loosen the draining union A Fully pull the control lever on the handlebar then release it and wait some seconds before pumping again Repeat this procedu...

Page 65: ...d in a container with brake fluid Loosen the draining union B Fully pull the control lever on the handlebar then release it and wait some seconds before pumping again Repeat this procedure until fluid...

Page 66: ...they must be replaced immediately if damaged N B After the pads have been replaced it is necessary to use the brakes with moderation for the first 100 Km 60 mi in order to allow them to bed in correc...

Page 67: ...Disassembly Unscrew screw A Remove brake caliper Remove the spring B Remove pin C to let the brake pads D free If the pads are worn beyond the prescribed limit replace them Reassembly Fit the 2 pads...

Page 68: ...ks the nipple rotation 2 WARNING Even if the wheel spokes tension 3 is correct a nipple might be unlocked Determine which wheel spokes 3 need tightening IMPORTANT following operations refer to the adj...

Page 69: ...er tube and the nipple covers Determine which wheel spokes 1 need tightening Adjust the concerned spoke tension 1 through the nipple 2 Screw the nipple in to tighten the spoke Unscrew the nipple to lo...

Page 70: ......

Page 71: ...A B C D E F G H I L M N O P 1 TRIMMINGS VERKLEIDUNG KLEDING...

Page 72: ...renches as illustrated in the figure to unscrew the upper nut A integral to the wing mirror and to keep the lower one still B Unscrew the wing mirror to remove it Reassembly Screw down the wing mirror...

Page 73: ...EAR MUDGUARDS FRONT MUDGUARD Removal Remove brake pipes from guides A Unscrew the 4 B screws fixing the anti twist plate group and the mudguard to the fork Remove the mudguard Reassembly Carry out the...

Page 74: ...section E Disconnect electric wirings A between the main cable group and the tail light wiring Unscrew clamping nuts B between mudguard and chassis Remove protections C on CALIFORNIA STONE Remove pro...

Page 75: ...n Das Schutzblech mit montiertem R cklicht von hinten abnehmen und entfernen Wiedereinbau Den Ausbau in umgekehrter Reihenfolge ausf hren ACHTERSTE SPATBORD CALIFORNIA EV 1997 2000 CALIFORNIA JACKAL C...

Page 76: ...ion E Disconnect electric wirings between the main cable group and the tail light wiring Remove rear seat from mudguard Remove side protections A only on EV 2001 and F only on SPECIAl and SPECIAL SPOR...

Page 77: ...ng the chassis Remove the saddle cover B Reassembly Carry out the procedures in reverse order SIDE PANELS CALIFORNIA SPECIAL CALIFORNIA SPECIAL SPORT Removal Pull outwards to release the pressurized s...

Page 78: ...move the saddle from the chassis it is necessary to Release the saddle using the wrench A Slightly lift the rear part of the saddle Detach the saddle B by moving it backwards To refit the saddle lock...

Page 79: ...described in chapter 4 of this section Remove side protections A on CALIFORNIA EV and B on CALIFORNIA STONE Loosen screws C Remove the seat CALIFORNIA EV 2001 CALIFORNIA SPECIAL CALIFORNIA SPECIAL SP...

Page 80: ...l Unscrew the 3 screws A and the lower nut B Remove protection C and the 3 spacers D Reassembly Carry out the removal procedures in reverse order and remember to place again the 3 spacers D correctly...

Page 81: ...FRONT CHASSIS PROTECTIONS Removal Loosen the 2 screws A Remove protection B Reassembly Carry out the removal procedures in reverse order and pay attention to the exact routing of the electric wiring o...

Page 82: ......

Page 83: ...A B C D E F G H I L M N O P 1 WHEEL PARTS R DERTEILE WIELINSTALLATIES...

Page 84: ...assembly has been applied until chassis no CALIFORNIA EV 1997 2000 KD115426 CALIFORNIA JACKAL KD152328 CALIFORNIA SPECIAL KD131644 2 The shaft A is to be screwed on the threaded left hand leg the scr...

Page 85: ...leg Remove shaft A with its spacers and then remove the wheel Refer to chapter 3 of this section for wheel overhaul REASSEMBLY1 After carrying out all necessary wheel checks reassemble as follows Pla...

Page 86: ...After carrying out all necessary wheel checks reassemble as follows Place the complete wheel between the fork legs Lubricate the shank and the thread of the wheel shaft with the suggested grease Lubri...

Page 87: ...A B C D E F G H I L M N O P 8 WHEEL PARTS CALIFORNIA SPECIAL 2a serie CALIFORNIA SPECIAL SPORT B C C CALIFORNIA JACKAL 1a serie B C C A B A C D E F G H I L M N O P...

Page 88: ...A B C D E F G H I L M N O P 9 R DERTEILE WIELINSTALLATIES CALIFORNIA EV CALIFORNIA SPECIAL 1a serie CALIFORNIA JACKAL 2a serie CALIFORNIA STONE A B C C B A C D E F G H I L M N O P...

Page 89: ...ve flanges C N B See pages 8 9 of this section for reference REASSEMBLY Carry out the removal procedures in reverse order REMOVAL FOR CALIFORNIA SPECIAL 2ND SERIES CALIFORNIA SPECIAL SPORT Remove the...

Page 90: ...port plate B Unscrew brake caliper C from the caliper support plate B Unscrew nut D with washer E on shaft housing side Loosen locking screw of shaft F on the swinging arm Remove shaft G from housing...

Page 91: ...men werden k nnen Den Einbau des Rades in umgekehrter Reihenfolge ausf hren und ber cksichtigen dass die Zangentr gerplatte auf der Feststellvorrichtung A der linken Hinterradschwinge montiert werden...

Page 92: ...r from the caliper B support plate Unscrew nut D with washer E on the shaft housing side Remove shaft G from housing from hub and from swinging arm Remove calipersupport plate B and spacer H Tilt the...

Page 93: ...hese are damaged replace them See chapter 3 of this section for a complete wheel overhaul REASSEMBLY After carrying out all necessary wheel checks reassemble as follows Lubricate the shaft and the thr...

Page 94: ...ES CALIFORNIA SPECIAL SPORT REMOVAL Remove the wheel as described in chapter 2 of this section Remove the brake disk as described in chapter 4 of this section Unscrew the screws A see picture on page...

Page 95: ...o check if there is backlash Remove and replace the bearings which do not turn softly and silently or which feature a backlash IMPORTANT Excessive wear may be due to vehicle vibrations and instability...

Page 96: ...t the spindle into the wheel and position it on two fixed checking planes Insert a dial gauge supporting it in order to measure the wheel rim s side skidding and radial runout with respect to the spin...

Page 97: ...chapter 2 section D Unscrew the hollow screw A and remove the tube as well as the two gaskets from the two calipers Unscrew the two screws B fastening the supports and remove the two calipers Reassemb...

Page 98: ...horoughly as described in chapter 2 section D Unscrew the hollow screw A and remove the tube as well as the two gaskets from the two calipers Unscrew the two screws B fastening the supports and remove...

Page 99: ...l grease or deposits and they must not have deep groovings If the disks have one of these defects clean thoroughly If the defect cannot be removed they must be replaced Front disk thickness 4 1 mm Fro...

Page 100: ...L M N O P 30 WHEEL PARTS Reassembly When reassembling thoroughly clean the resting surfaces and lock the screws to the tightening torque prescribed in the table in chapter 4 section B Apply Loctite 27...

Page 101: ...he hydraulic system thoroughly as described in chapter 2 section D Unscrew the hollow screw A and remove the tube as well as the two gaskets from the two calipers Unscrew the two screws B fastening th...

Page 102: ...tem thoroughly as described in chapter 2 section D Unscrew the hollow screw A and remove the tube as well as the two gaskets from the caliper Unscrew the two screws B fastening the support and remove...

Page 103: ...and it must not have deep groovings If the disks have one of these defects clean thoroughly If the defect can not be removed they must be replaced Rear disk thickness 5 1mm Rear disk thickness at the...

Page 104: ...ng screws are too tight Lever shoulder nut is too tight non original screw Lever shim is bigger than the pump seat Brake fluid is dirty Tighten fastening screws Place new positioning springs Place new...

Page 105: ...sorbers are replaced with others having different technical features the system functioning is jeopardized Disassembly Drain the hydraulic system completely as described in chapter 2 section D Remove...

Page 106: ...RA 551 5 2 2 2 0 3 30 6 19 182 5 p s 224 38 84 56 59 78 37 5 A A 0 1 0 1 0 3 70 25 52 38 20 8 FRONT FORK N B Fork of the latest type with left hand leg featuring a threaded hole on which the wheel sha...

Page 107: ...5 2 2 2 L MAX 556 5 230 L MIN 416 5 L LIBERA 551 5 2 2 2 0 3 30 6 19 182 5 p s 224 38 120 39 95 37 5 70 20 N B Fork of the first type with left hand leg featuring a through hole as wheel shaft seat G...

Page 108: ...ube compression 46 LH rod compression 47 Cap 48 Calibration plate 12 mm 48 Calibration plate 15 mm 48 Calibration plate 17 mm 49 LH pin compression 50 LH piston compression 51 Nut 52 RH complete fork...

Page 109: ...ning jumper 3 Screw 4 Lower jumper 5 Retainer 6 Rubber pad 7 Fork head 8 Ring nut 9 Spacer tube 10 Nut 11 Fork base 12 Plug assembly 13 O ring 14 Rod 15 Ring 16 Buffer 17 Pre load tube 18 Spring 19 Ba...

Page 110: ...cked in a vice Take great care not to damage them by overtightening always use aluminium jaw coverings Complete fork removal Place the motorbike on a stable support so that the front wheel is raised f...

Page 111: ...es Anschlusses des Lenkungsd mpfers l sen Die Mutter E l sen und die Staubschutz Unterlegscheiben Gruppe F herausnehmen Die Gabel vom Rahmen entfernen De motorvoertuigen zijn uitgerust met een hydraul...

Page 112: ...ating it in one direction first then in the opposite direction GENERAL RULES FOR A CORRECT OVERHAUL Use new gasket during reassembly after a complete disassembly Always follow the 1 2 1 sequence when...

Page 113: ...om 1 The foot gasket is faulty 1 Replace the gasket 2 The foot screw is loose 2 Tighten the screw The fork is too soft in each oil 1 Oil lever is low 1 Top up the oil level adjustment condition 2 Spri...

Page 114: ...as described in chapter 2 section D Lock the wheel holder leg A in a vice and unscrew the foot screw with a wrench for 8 mm internal hexagons and remove the screw with its gasket Remove the dust scra...

Page 115: ...the wheel holder leg the parts E F and G may remain inside the leg If so they shall be removed afterwards paying attention not to damage the leg edge and the upper bushing G seat on the leg Check all...

Page 116: ...SORBER Remove the shock absorber assembly I from the stanchion D Remove the bottom buffer L this might remain fitted in the wheel holder leg A if so remove it from the inside Push the foot valve M ins...

Page 117: ...ut at its end Remove the clamping nut P of the calibration assembly and remove all the components Check and replace what necessary reassemble following the order in the picture retainer Q plate pack R...

Page 118: ...cleaned with special care Once all the overhaul procedures have been carried out reassemble the piston rod assembly in the shock absorber case Place the foot valve M with a new O ring at the base of t...

Page 119: ...ted seal ring E on the stanchion D Push the seal ring E inside the leg fully home by using a special tool Z Assemble the stop ring and the dust scraper Pour MARZOCCHI SAE 10 oil inside the stanchion m...

Page 120: ...re the oil has filled up the shock absorber cartridge Place the spring F and the pre load tube E Place the open washer D between the pre load tube and the lock nut Screw the lock nut on the shock abso...

Page 121: ...n the plug at the torque of 25 Nm Fork leg reassembly Place the fork leg on the motorbike and let the steering head pass through the bottom yoke Tighten the screws on the steering head on the bottom y...

Page 122: ...ox as described in chapter 1 section O Disassemble the rear mud guard as described in chapter 2 section E Loosen clamp A to release the protection cover Remove the rear right hand shock absorber Keepi...

Page 123: ...ivot axis on the chassis and of the bearing on the right hand section Use the proper extractor part no 18927250 to remove the U joint bearing Use the proper extractor part no 12904700 to remove the sw...

Page 124: ...crew the screws A and remove the shock absorbers CALIFORNIA JACKAL Unscrew the screws A and remove the shock absorbers CALIFORNIA STONE Remove the rear seat as described in chapter 5 section E Fully u...

Page 125: ...rder 12 TIRES The tires are one of the most important components to be checked As a matter of fact the following features depend on the tires stability vehicle driving comfort and in some cases also t...

Page 126: ...to use iron tools which do not have grooves and sharp edges on the parts which come into contact with the edge of the rim The contact surface must be wide well smoothed and with suitably rounded edges...

Page 127: ...A B C D E F G H I L M N O P 1 CONTROLS SCHALTUNGEN BEDIENINGEN...

Page 128: ...per E Remove the pump together with the tank and lever Reassembly Fit the pump onto the half handlebar by tightening the two fastening screws Reconnect the tube to the pump by tightening the hollow sc...

Page 129: ...crew D Remove the gear shift lever E N B To guarantee the proper reassembly mark the position of lever F on the gear selector shaft G with a felt tip pen before disassembly Reassembly Carry out the di...

Page 130: ...gear shift lever E N B To guarantee the proper reassembly mark the position of lever F on the gear selector shaft G with a felt tip pen before disassembly DISASSEMBLY OF CALIFORNIA SPECIAL CALIFORNIA...

Page 131: ...JACKAL CALIFORNIA STONE Remove the right front footrest and relevant mounting as indicated in chapter 3 section H Remove the cotter pin A and pull out pin B Remove the brake lever C from the frame sec...

Page 132: ...y E Close carefully the control while placing the cables D in the pulley of the gas control mobile body E Lock the right hand device with the two fastening screws C N B The latest series of motorbikes...

Page 133: ...oke lever and its components F together with the cable Reassembly Carry out the removal operations in reverse order being careful to properly place all the components of the choke lever assembly F as...

Page 134: ......

Page 135: ...A B C D E F G H I L M N O P 1 CHASSIS RAHMEN CHASSIS...

Page 136: ...e the chromed plugs indicated with the arrows Unscrew the nut A Unscrew the screw B Unscrew the two clamping screws C of the upper fork legs Remove the handlebar assembly and the fork head Unscrew the...

Page 137: ...in charter 4 section G Remove the front brake master cylinder as described in chapter 1 section G Remove the left hand controls assembly as described in chapter 4 section P Remove the clutch lever ass...

Page 138: ...rear footrests all models Unscrew the 2 screws E while holding the nuts F Remove the footrests Reassembly of rear footrests Carry out the removal procedures in reverse order DISASSEMBLY OF FRONT FOOT...

Page 139: ...ter stand or in case it is not fitted on a firm mount Remove the protection A Stone or the installed left hand section frame cover if any Remove the side stand sensor support plate with the assembled...

Page 140: ...hes of 5 5 mm DieFedermusssich bei einer Belastung von 30 5 kg um 5 2 mm verl ngern Ondereengewicht van 30 kg 5 wordt de veer 5 5 mm uitgerekt 5 CHASSIS DIMENSIONS Overhauling Place the motorbike on a...

Page 141: ...e the support plate B Remove the chromed plugs C and unscrew the screws D beneath while holding the nuts E Remove the bumper Reassembly Carry out the removal procedures in reverse order being careful...

Page 142: ...s the frame itself and two lower side arms forming the engine frame section After a collision the chassis must be accurately checked according to the measures indicated in the technical drawing If the...

Page 143: ...en het chassis niet binnen de aangegeven maten valt het indien mogelijk herstellen zoniet vervangen A B C D E F G H I L M N O P 15 RAHMEN CHASSIS 7 RAHMENABMESSUNGEN berholung Der Rahmen besteht aus z...

Page 144: ...D E F G H I L M N O P 16 CHASSIS 549 2 165 620 1 2 4 8 5 2 1 3 9 340 3 8 5 2 2 8 3 0 3 2 5 3 2 0 220 8 6 5 3 125 98 251 1 2 0 5 62 7 8 65 30 276 245 500 292 324 5 15 7 5 188 205 1 5 0 0 5 0 5 0 0 1 0...

Page 145: ...A B C D E F G H I L M N O P 1 FUEL SYSTEM KRAFTSTOFFZUFUHRANLAGE VOEDINGSINSTALLATIES...

Page 146: ...a map inside the ECU The injector control per cylinder is a timed sequence type control this means that the two injectors are controlled according to the intake sequence while each cylinder supply ca...

Page 147: ...ic pump 1 sucks in fuel from the tank S and delivers it 2 to the electro injectors 3 by means of a filter The fuel pressure in the circuit is kept stable by the pressure adjustor 4 This controls the a...

Page 148: ...Elektroeinspritzventilen 3 Der Kraftstoffdruck im Kreislauf wird vom Druckregler 4 konstant gehalten der den Zugang des in denTank zur ckflie enden Kraftstoffs kontrolliert 2 SAMENSTELLING VAN DE INST...

Page 149: ...the front Remove the tube from the pressure adjuster D On the LH side detach The connection for the fuel level sensor E and the connection for the fuel solenoid valve F Loosen the clamp G and remove...

Page 150: ...not working It is also equipped with an pressure valve which short circuits the delivery with the intake when the pressure exceeds 5 bar thereby preventing the electrical motor from overheating N B Al...

Page 151: ...t by means of a helical spring whose load is determined by an adjustable thrust spring The winding is housed in the rear part of the body The injector snug is machined in the front part retaining seat...

Page 152: ...ressure and the intake manifold pressure must also be constant Disassembly Partly remove the fuel tank from the seat on the chassis as described in chapter 3 of this section Loosen the sealing clamp a...

Page 153: ...er is positioned downstream of the throttle valve The throttle position potentiometer is splined onto the throttle shaft The absolute pressure sensor integral to the ECU and the air temperature sensor...

Page 154: ...the above mentioned parts proceed as follows Loosen clamps A fastening the filter box to the throttle body move the manifolds B outwards Disconnect the bleeding pipe C positioned in the front part of...

Page 155: ...e adjusted correctly This will avoid any interference with the surrounding duct this screw must not be used to adjust the idling speed Disassembly Remove the air filter box as described in chapter 8 o...

Page 156: ...sensor 1 Battery 2 Starter switch 3 Relay 4 ECU I A W 15 M 5 Air temperature sensor 6 Oil temperature sensor 7 r p m and T D C sensor 8 Coils 9 Throttle position potentiometer 10 Injectors 1 Batterie...

Page 157: ...mfasst Batterie Z ndungsschalter zwei Relais elektronisches Steuerger t mit integriertem F hler f r den absoluten Druck Z ndungsaggregat Lufttemperaturf hler Potentiometer Drosselposition zwei Einspri...

Page 158: ...TARTER SWITCH 2 For information on its use see section C Disassembly After having removed the headlight and the dashboard as described in chapter 4 section P the starter switch A is visible Unscrew th...

Page 159: ...is actuated in the ECU using a protection against polarity inversion the two relays have specific purposes in the fuel system and can be distinguished in the following way pump relay coils electro inj...

Page 160: ...es the following input signals Absolute pressure Intake air temperature Oil temperature or engine temperature R p m and timing Battery voltage Throttle position Disassembly Remove the seat and the lef...

Page 161: ...or N B NTC means that the thermistor s resistance drops when the temperature rises Disassembly Detach the sensor wiring Unscrew the two screws fastening it to the filter box and remove the sensor 15 O...

Page 162: ...RF GBARE SCHEIBEN IN mm SPACERS AVAILABLE IN mm CODE KENNUMMER CODE 16 R P M AND T D C SENSOR 7 The sensor reads the signal from a toothed wheel fitted on the camshaft The information about the r p m...

Page 163: ...e type The coils receive the command from the ECU which processes the spark advance Disassembly 1 Disconnect cable A for the spark plugs 2 Detach connection B 3 Unscrew the two screws C and remove the...

Page 164: ...is used to correct the basic metering transistors metering and for possible corrections during the start up stage Disassembly Detach connection A on potentiometer C Unscrew and remove the two screws...

Page 165: ...tial deliveries The moment supply is started for each cylinder can be determined by means of a map which depends on the r p m START UP STAGE The moment in which the starter switch is activated the ECU...

Page 166: ...s are in perfect working condition Do not make electro weldings on the vehicle Do not use supplementary electrical devices for start up In order to avoid causing malfunctions and inefficiency in the i...

Page 167: ...ike to be used even if it is not in perfect working condition The following circuits can be diagnosed 1 Throttle valve potentiometer 2 Absolute pressure sensor inside the ECU 3 Oil temperature sensor...

Page 168: ...tentiometer through the Dashboard Monitor s front page In fact at the RH top of this page it is possible to view the opening angle for the throttle body Taking into account that max opening is 84 the...

Page 169: ...ont page In fact the engine temperature is displayed in the middle of the page When the engine is cool this can easily be compared with the external temperature AIR TEMPERATURE SENSOR CIRCUIT When on...

Page 170: ...if the test result is negative go back to one of the three above described cases CIRCUIT AND PRIMARY WINDING OF COILS 1 AND 2 When on the Dashboard Monitor page the item Coil 1 or 2 displays an error...

Page 171: ...hapter 3 in this section If the test result is negative go back to the previously illustrated cases ELECTRONIC CONTROL UNIT When on the Dashboard Monitor page an error is displayed in the following it...

Page 172: ...if the test result is negative the ECU does not send a correct signal It must be reset by clicking on the erase icon If after the resetting procedure the error is still displayed in the electronic re...

Page 173: ...3 2 3 6 Attach the connection rod between the two throttle bodies Check that the by pass screws are completely closed Bring the RH side body s adjustment screw flush Connect a vacuometer to the socke...

Page 174: ...le connected to the digital tester and positioning the completely closed throttle on the attached rod The correct value must be 150 mV 15mV CO CHECK Should the engine warming up procedure be carried o...

Page 175: ...SSA USA CALIFORNIA EV 1997 2000 CALIFORNIA JACKAL CALIFORNIA SPECIAL A 21 FUEL VAPOUR PURIFICATION AND RECIRCULATION SYSTEM USA SGP CAN N B The roll over shut off valve ref A must be fitted vertically...

Page 176: ...BENZIND MPFE USA SGP CAN N B Das Kippschutzventil Bez A muss vertikal 30 montiert sein mit wie in der Abbildung positioniertem Entl ftungsgaseingang 21 SYSTEEM VOOR ZUIVERING EN HERCIRCULATIE BENZINED...

Page 177: ...A B C D E F G H I L M N O P 1 EXHAUST SYSTEM AUSPUFFANLAGE AFVOERINSTALLATIE...

Page 178: ...embly Unscrew the nut A while holding the screw B Slide out the screw fastening the silencer to the passenger foot rest support bracket taking care not to lose the grommets the shim and the washers Sl...

Page 179: ...n the exhaust pipes and the expansion chamber Remove the exhaust pipe D WARNING Plug the exhaust ducts on the head to avoid foreign bodies getting into the combustion chamber Reassembly Fit the exhaus...

Page 180: ...MBER Disassembly Remove the silencers from the motorbike as described in chapter 2 in this section Loosen the 2 clamps A on the exhaust pipes Remove the expansion chamber B by pulling it out of the ex...

Page 181: ...A B C D E F G H I L M N O P 1 ENGINE MOTOR MOTOR...

Page 182: ...bers wheel cylinder connecting rod right hand side and left hand side pistons in order to facilitate reassembly and avoid possible mistakes 2 ENGINE UNIT REMOVAL INSTALLATION GEARBOX REMOVAL FROM CHAS...

Page 183: ...body and the intake pipes Remove the tie rods of the gear lever and rear brake lever controls as described in chapter 2 and 3 section G Remove the oil drain pipes from the unions on the engine crankca...

Page 184: ...4 screws N 2 for each frame section in order to remove the 2 footrest supports O and at the same time release the frame sections from the chassis from the rear end Lift the rear end and remove the ch...

Page 185: ...3 1 5 3 LUBRICATION SYSTEM The lubrication system consists of the following components 1 Oil sump 2 Oil mesh filter 3 Oil cartridge filter 4 Oil pressure transmitter 5 Engine oil pressure regulator va...

Page 186: ...pter 2 section D Unscrew the 18 screws A fastening the oil sump to the engine crankcase Remove the oil sump 1 Between the oil sump and the crankcase there is a gasket which must always be replaced aft...

Page 187: ...n compressed air through the union for the above mentioned tool making sure that the tester arrow moves when the pressure looking at the pressure gauge reaches a value of Kg cmq 0 15 0 35 ENGINE OIL P...

Page 188: ...ve the timing system cover as described in chapter 4 of this section Remove the engine pinion the timing system gearing and the oil pump gearing together with the timing belt following the procedures...

Page 189: ...To carry out this check rest the engine on a bench with the flywheel side facing upwards after having removed the flywheel from the crankshaft Fill the upper part of the crankcase with water Blow low...

Page 190: ...system with rods and rockers with 2 valves per cylinder The valve opening and closing is controlled by a camshaft located in the crankshaft which is driven by means of a duplex belt HEADS N B The pro...

Page 191: ...sed of the LH cylinder N B This procedure can be carried out even when the gearbox is assembled with the engine block as the notch position can be checked through the speciale hole E Unscrew the 2 scr...

Page 192: ...P entfernen und den Zylinderkopf Q herausnehmen Die Dichtung R abnehmen die sich zwischen Kopf und Zylinder befindet Demontage De aandrijfgroep wegnemen van de moto zoals beschreven wordt in hoofdstuk...

Page 193: ...tool screw until it is tightened then hammer the tool head where it works on the upper plate using a mallet so that the two half cones B get detached from the upper plate C Once the two half cones ar...

Page 194: ...the stem cannot be eliminated by replacing the valves only To fit the valve guides on the head proceed as described below Warm up the head in a furnace at ca 60 C Lubricate the valve guides Fit the f...

Page 195: ...g a miller The tilt angle for the seat is 45 5 After milling to obtain a good coupling and a perfect packing between the ring nuts and the valve heads it is necessary to proceed with grinding DETAIL S...

Page 196: ...36 and must provide a load of Kg 29 5 3 When the valve is open it has a length of mm 27 and must provide a load of Kg 45 5 3 When packed it has a length of mm 22 75 23 25 INSIDE SPRING When free it h...

Page 197: ...es on the heads it is necessary to check that the above said springs are compressed between mm 35 700 36 000 to reach this value fit washers A code 14 03 73 00 with a 0 3 mm thickness After reaching t...

Page 198: ...ker support underframe with new O rings upon every reassembly Replace the gasket between the head and cylinders with a new one every reassembly Tighten the nuts and central stud bolt fastening the hea...

Page 199: ...10 mm Exhaust 0 15 mm Disassembly Remove the engine unit from the motorbike as described in chapter 2 in this section Remove the alternator following the instructions described in chapter 7 in this s...

Page 200: ...r lpumpensteuerung gel st wurde die Dreierzahnr der zusammen mit der Kette N herausnehmen DISTRIBUTIE Gegevens van de distributie AANZUIGING Opent 20 voor de P M S Sluit 50 na de P M I AFVOER Opent 44...

Page 201: ...the flange R retaining the camshaft S and extract the latter after having removed the tappets from their seats T Having removed all timing components it is necessary to check them and if they are not...

Page 202: ...025 0 066 DIAMETERS FOR THE CAMSHAFT SUPPORTS AND RELATIVE SEATS ON THE CRANKCASE 32 000 31 984 SEATS mm OUTER TAPPET mm ASSEMBLY BACKLASH mm Production oversize mm 0 05 22 021 22 000 21 996 21 978 22...

Page 203: ...h the inspection hole on the gearbox housing to make sure that the line with the letter S is perfectly aligned with the mark made on the centre of the hole At this point align the tip of the arrow wit...

Page 204: ...air gap is between 0 7 and 0 9 mm To determine the air gap when the engine is fitted proceed as follows Using a gauge measure the distance between the striking point on the crankcase D and the tooth s...

Page 205: ...r the piston pin C Remove the piston pin C using the special tool commercially available Remove the piston D CHECK OF COMPONENTS Cylinder wear control The cylinders diameter must be measured at three...

Page 206: ...end parts of the compression rings must be fitted out of step with each other Assembly backlashes measured between the ring shims and their seats on the piston Seal and oil scraper rings 0 030 0 065...

Page 207: ...1 5 3 4 3 15 12 13 14 10 11 9 8 7 6 The clutch is a dry type and is housed inside the engine flywheel It is composed of two driven disks one intermediate disk one spring pressure washer and 8 springs...

Page 208: ...ction Apply the locking tool A cod 12 91 18 01 to the engine flywheel and tool B cod 30 90 65 10 for clutch spring compression Unscrew the 8 retaining screws C for the toothed crown D fitted on the en...

Page 209: ...t the toothing inside the fly wheel is in perfect condition Driven disks 3 Check that the coupling surfaces with the driven disks are completely smooth and flat and that the external toothing which wo...

Page 210: ...elasticity otherwise replace it Outer body 10 Check where the adjustment screw head works if the mark is very deep replace it Thrust bearing 9 Make sure that the bearing is in good condition otherwise...

Page 211: ...e of the spring pressure plate s teeth is aligned with reference L marked on the flywheel For centering the clutch disks use the special tool code 30 90 65 10 Observe the markings M when fitting the i...

Page 212: ...emove the grommet and the plastic flange Apply the special locking tool D code 12 91 18 01 onto the engine flywheel C Unscrew the central nut E restraining the rotor F Remove the stator G by unscrewin...

Page 213: ...18 01 on the flywheel C as illustrated in the figure Unscrew the 6 screws B fastening the flywheel to the crankshaft Remove the flywheel C N B Screws B must be replaced with new ones upon the followin...

Page 214: ...ibed in chapter 6 in this section Remove the alternator and the flywheel following the descriptions in chapter 7 in this section Remove the timing system as described in chapter 4 in this section Remo...

Page 215: ...During this procedure inflammible vapours and metal particles which may be expelled at high speed are produced It is therefore recommended to work in an environment free of naked flames or sparks The...

Page 216: ...allellisme van de assen nauwkeurig verzorgen CONNECTING RODS Carry out the following controls when overhauling the connecting rods The bushing conditions and the backlash between them and the piston p...

Page 217: ...der Pleuelstangen parallel und schlagfrei sind Die Abweichung des Parallelismus und der Koplanarit t der beiden Achsen des Pleuelkopfes und fu es im Abstand von 200 mm gemessen darf h chstens 0 10 mm...

Page 218: ...onnecting rod bearing thickness Table of connecting rod weights from engine n KD 28720 CALIFORNIA JACKAL CALIFORNIA SPECIAL n KD 280067 CALIFORNIA EV 1st SERIES from the 1st number of CALIFORNIA EV 20...

Page 219: ...and the main bearing journal flywheel side 0 022 0 064 mm between the bearing and the connecting rod pin IMPORTANT When reconditioning the crankshaft pins it is necessary to make sure that the union s...

Page 220: ...of 4 grams is permissible To balance the engine shaft from a static point of view it is necessary to apply the following weight to the crank pin 1st series until engines n KD 28719 gr 1790 CALIFORNIA...

Page 221: ...n is 0 022 minimum 0 064 maximum The backlash between the shimmings for the connecting rods and those for the crankshaft is 0 30 0 50 mm Tighten the screws on the caps using a torque wrench to the tor...

Page 222: ......

Page 223: ...A B C D E F G H I L M N O P 1 GEARBOX GETRIEB VERSNELLING...

Page 224: ...Z 14 28 2nd gear 1 1 3889 Z 18 25 3rd gear 1 1 0476 Z 21 22 4th gear 1 0 8696 Z 23 20 5th gear 1 0 7500 Z 28 21 N B For the CALIFORNIA EV 1a SERIES CALIFORNIA SPECIAL CALIFORNIA JACKAL models startin...

Page 225: ...2 2 1 48 Washer thickness 2 4 1 49 Needle bearing 1 50 Gear 5th P S z 28 1 51 Bushing retaining roller 1 52 Spring 1 53 Roller bearing cage 1 54 Bushing for 5th P S 1 55 Sliding sleeve 5th 1 POS DESC...

Page 226: ...attery cables from the 2 poles ne gative positive and remove the battery Remove the fuel tank as described in chapter 3 section I Remove the exhaust system as described in section L Remove the ground...

Page 227: ...x and remove it Remove the rear foot rests as described in chapter 3 section H Remove the rear swinging arm as described in chapter 9 section F Remove the drain pipes F from guide G Detach the gearbox...

Page 228: ...ommended that the gear is in neutral Drain the oil from the gearbox by following the instructions described in chapter 2 section D Remove the caulking on the securing nut B in the secondary shaft Unsc...

Page 229: ...en Das Vorgelege des Kilometerz hlers C l sen und aus dem Getriebedeckel herausnehmen Den Zahnkranz D mit der Kugel E und der Ausgleichsscheibe F entfernen 3 ONTBINDING Alle componenten van de versnel...

Page 230: ...e internal body lock ring nut N by means of the proper tool O code 30912810 and the gib head wrench code 14912603 after straightening out the ring nut retainer safety washer rib P then remove the M bo...

Page 231: ...gleichen Stelle positioniert werden muss Den Gangvorw hler U mit der Feder V entfernen Haal het uitwendige gedeelte van de koppeling G uit de kast het taatslager H het inwendige gedeelte I en de stang...

Page 232: ...neutral indicator Z Unscrew and remove the plug X it is used to retain the W gear pawl on the splined drum Remove the spring Y N B The pawl W remains in the housing hole and will be collected after di...

Page 233: ...ve F of the 1st and 2nd speed Lock the shaft in a vice interposing jaws in ductile metal Unscrew the retaining nut G in a clockwise direction Remove the bearing the 4th speed gear H with washers U and...

Page 234: ...eve of the 5th speed F With a proper punch push down the retainer pawl A and rotate the bushing B in order to disengage it from grooves Remove the bushing B and the pawl A the spring C the roller bear...

Page 235: ...ve the roller bearing inner race and the nut C Then place the complete shaft on a press and by means of extractor B code 12905900 press the spring enough to remove the two half sections D retaining th...

Page 236: ...ller bearing B with extractor code 17945060 see chapter 5 section B Unscrew the screws C and remove the locking plate D Remove the clutch shaft bearing E with the extractor code 17949260 see chapter 5...

Page 237: ...not be damaged nor extremely worn out otherwise replace the gear Bushing for 5th speed gear Check that the roller working surface is smooth and not scored nor dented Check also the bushing internal sl...

Page 238: ...orking surfaces are smooth and not so worn out to loose their temper characteristics and that the retaining keys working in the drum splines are not worn out otherwise replace the forks Engaging gear...

Page 239: ...hecks required except checking that the internal splines are smooth Cush drive damper pad springs on the clutch shaft Check that they are neither deformed nor rigid otherwise replace them Sleeve on th...

Page 240: ...proceed as follows After being covered with Loctite the clutch shaft bearing shall be pressed with the relevant punch code 14928900 see chapter 5 section B After being covered with Loctite the second...

Page 241: ...gearbox housing cover shall be carried out with the relevant punch code 14929500 see chapter 5 section B The range selector shaft O ring C shall be placed in the relevant seat on the gearbox cover Ra...

Page 242: ...ear on the shaft with head facing the mobile sleeve The fixed sleeve making sure that the lowered internal part is assembled facing the 3rd speed gear The inner bearing race 4th speed gear side with t...

Page 243: ...ary to measure the distance between the two side stops A of the drum housing and between housing and cover This measurement shall be carried out with a depth gauge in the housing and in the cover and...

Page 244: ...he lubricating ring between the shaft and the bearing on the housing Lastly insert the complete clutch shaft on the bearing and on the seal ring on the housing 5th speed gear and relevant engaging sle...

Page 245: ...tle freely in the control notches indicated by the arrows Place the gasket A on the housing Temporarily secure the cover with four screws Insert the transmission shaft B on the cover by screwing it ca...

Page 246: ...nd the drum in case of difficulties between 1st and 3rd gear and between the drum and the cover between 2nd and 4th gear Shims are supplied in the following sizes 0 6 0 8 1 1 2 mm Once shimmed reassem...

Page 247: ...assemble The O ring A between the bearing and the clutch internal body The clutch internal body B on the shaft The safety washer C The internal body locking ring nut D on the clutch shaft To lock the...

Page 248: ...gears on the engine To reassemble the gearbox housing on the engine proceed as follows Insert the gearbox housing on the stud bolts assembled on the engine carefully placing the clutch internal body o...

Page 249: ...A B C D E F G H I L M N O P 1 FINAL DRIVE HOUSING AND SHAFT ANTRIEBSWELLE UND GEH USE HINTEN AS EN KAST VAN ACHTERSTE OVERBRENGING...

Page 250: ...as described in chapter 2 section D Unscrew and remove the 4 nuts A Remove the final drive housing Remove case B with pinion C and O ring D from the housing Unscrew the 8 fastening screws E and remove...

Page 251: ...emove the crown pin assembly G from the flange F Unscrew the 8 screws H and remove the crown Remove the roller bearing inner race I with the extractor L code 17948360 Use the proper locking tool M of...

Page 252: ...d or damaged The sealing ring is intact not damaged and has not lost elasticity Gaskets shall be replaced even if in good conditions Flange on the Final Drive housing Check that It has no cracks The m...

Page 253: ...scored or damaged The gasket shall always be replaced even if in good conditions Spacer between the bearings Check that the supporting surfaces are smooth and not damaged Adjustment washers between s...

Page 254: ...een replaced a new shimming is required Nut N locking shall be carried out with the locking tool M code 12907100 and with a wrench with torque 18 20 Nm and Loctite If the pinion is shimmed correctly i...

Page 255: ...601 that was previously applied on the screw thread Tighten to a torque of 40 42 Nm Cover on the transmission housing Assemble the cover F on the housing as follows Place gasket A on the housing then...

Page 256: ...is like illustration 2 the crown is too near the pinion s rotating axis loosen the crown by increasing the thickness of the shim P previous page between the box and the cover If the contact is like i...

Page 257: ...ternal fits shall be intact not damaged or dented otherwise replace the sleeve Snap rings on transmission shaft B Check that the rings are not cracked and have not lost elasticity otherwise replace th...

Page 258: ...sehrt sein und d rfen keine Besch digungen oder Verbeulungen ausweisen berpr fen dass das Gelenk nicht verh rtet oder berm ig gelockert ist Andernfalls austauschen Wiedereinbau Den Ausbau in umgekehrt...

Page 259: ...A B C D E F G H I L M N O P 1 ELECTRICAL SYSTEM ELEKTROANLAGE ELEKTRISCHE INSTALLATIE...

Page 260: ...coils and electro injectors Starter control relay Headlight Tailight Direction indicators Switch for connected devices activation Control devices for indicator lights horn and flash light Intermittanc...

Page 261: ......

Page 262: ...switch 39 RH device Start Run Start light 40 10 way Pakard connector Pos RH 41 Front Stop light switch 42 Key Starter switch 43 4 way Amp connector 44 ECU IAW 15M 45 Air temperature sensor 46 3 way d...

Page 263: ......

Page 264: ...14 Electric cock 15 RH front direction indicator 16 Front brake stop switch 17 Ignition switch 18 LH front direction indicator 19 Dual tone horns 20 Engine starter and stop device 21 Neutral switch 2...

Page 265: ......

Page 266: ...ch 39 RH device Start Run Start light 40 10 way Pakard connector Pos RH 41 Front Stop light switch 42 Key Starter switch 43 4 way Amp connector 44 ECU IAW 15M 45 Air temperature sensor 46 3 way diagno...

Page 267: ......

Page 268: ...light 40 10 way Pakard connector Pos RH 41 Front Stop light switch 42 Key Starter switch 43 4 way Amp connector 44 ECU IAW 15M 45 Air temperature sensor 46 3 way diagnosis connector 47 LED diode ligh...

Page 269: ...ators Keep the terminals clean and tightened and greased with Vaseline Keep the battery upper part dry by preventing the acid from getting spilled this reduces isolation and corrodes frames and housin...

Page 270: ...an carefully IMPORTANT A bent or twisted drainer may increase the battery pressure and damage it WARNING The battery contains sulphuric acid electrolyte Avoid any contact with skin and eyes since it m...

Page 271: ...ends on the flatness of the accumulator on the method re charging time and temperature It is important that the battery is capable of supplying all or nearly all of its capacity before receiving the r...

Page 272: ...Disconnect the negative terminal A then the positi ve B by unscrewing the nuts Remove the battery from the motorbike N B Always disconnect the negative terminal first A then the positive one B N B The...

Page 273: ...cover A if any Disconnect the cable B from the starter motor Unscrew the two screws C with washer fastening the starter motor to the engine crankcase Remove the complete starter motor from the motorbi...

Page 274: ...ht and the inner shims Detach connector B Refitting Refit following the removal procedures in reverse order Replacing the light bulbs Unscrew the screw C located at the bottom of the optic unit Remove...

Page 275: ...ssary to disconnect all the electric wiring inside the taillight and the direction indicators after disassembling the relevant rear reflectors and parabola Refitting Refit following the removal proced...

Page 276: ...l the electric wiring inside the taillight and the direction indicators after disassembling the relevant rear reflectors and parabola Refitting Refit following the removal procedures in reverse order...

Page 277: ...wiring inside the indicator after disassembling the rear reflector and the parabola Refitting Refit following the removal procedures in reverse order Light bulb replacement Unscrew the screw C fasten...

Page 278: ...emoval CALIFORNIA EV 1997 2000 JACKAL STONE Unscrew the screw C and remove the rear reflector Disconnect the electric wiring on the parabola Unscrew the screw D and remove the indicator Refitting Refi...

Page 279: ...ether with the washers Remove the horn Refitting Refit following the removal procedures in reverse order N B On the JACKAL and STONE models the sound system consists of one single standard horn the se...

Page 280: ...Disassemble the lower warning light support C after unscrewing the 3 screws A Unscrew the screws B Extract the bulb holder and replace the bulb DASHBOARD WARNING LIGHTSCALIFORNIA EV SPECIAL Removal D...

Page 281: ...emoval procedure in reverse order CONTROLS RH SIDE Removal Remove the accelerator control as described in chapter 4 section G Remove the saddle as described in chapter 4 section E Remove the tank as i...

Page 282: ...the revolution counter Detach the revolution counter by pulling it upwards and remove it Refitting Follow the removal procedure in reverse order Odometer removal Remove the headlight as described in...

Page 283: ...er removal Disassemble the headlight Unscrew the screws C Remove the resetting pin D Remove the odometer E Extract the bulb holder and replace the bulb Refitting Follow the removal procedure in revers...

Page 284: ...he micro switch A activates a solenoid starter which interrupts the power supply to the starter motor In these conditions the engine cannot be started Removal Remove the frame section cover Disconnect...

Page 285: ...placement Remove front seat as described in chapter 4 section E Remove the RH side cover Replace the damaged fuses CALIFORNIA EV 1997 2000 JACKAL SPECIAL 6 fuses are fitted on the terminal board 15A B...

Page 286: ...regulated ALTERNATOR With the engine switched off disconnect the two yellow generator cables from the rest of the system and then carry out the following tests with a ohmmeter CHECK THE WINDING ISOLAT...

Page 287: ...zwei gelben Kabel anschlie en Motor anlassen und berpr fen ob die Ausgangs spannungen den Werten entsprechen die in der nach folgenden Tabelle aufgef hrt sind Toeren p min 1000 3000 6000 A C volt 15...

Page 288: ...off when the generator begins to charge approx 700 r p m REGULATOR CHECKS Normal work shop tools are generally insufficient for regulator checking however listed below are certain operations that can...

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MOTO GUZZI CALIFORNIA EV 1997-2000, Workshop Manual

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