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MOTO GUZZI California EV V1100, Service Station Manual

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MOTO GUZZI California EV V1100 Service Station Manual Download Page 44

Vehicle preparation

To proceed with the removal of the engine/gear unit from the motorcycle, operate as follows:

•

Remove the front seat and lift the tool holder container.

•

Remove the battery after having disconnected the cables from the 2 poles (negative/posi-

tive).

•

Remove the fuel tank.

•

Remove the exhaust system.

•

Place an engine support under the oil sump.

•

Disconnect all the electrical connections between engine - gear and chassis: timing sensor,

oil pressure transmitter, alternator, oil temperature sensor, spark plug cables hoods, starter

motor, neutral switch on the gear, earth cable on the gear;

Removing the engine from the vehicle

•

Release the clutch control transmis-

sion from the lever on the gearbox cov-

er.

•

Unscrew the odometer control trans-

mission from the transmission on the

gearbox cover.

Engine from vehicle

California EV V1100

ENG VE - 44

Summary of Contents for California EV V1100

Page 1: ...SERVICE STATION MANUAL California EV V1100 ...

Page 2: ...nges to their own models at any time All rights regarding electronic data storage total or partial reproduction or adaptation of this manual by any means are reserved for all Countries Third party products or services referred to in this manual should be considered only informative and are not binding Moto Guzzi s p a shall not be liable for any functions or use of these products ...

Page 3: ...y 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 with this symbol indicate the correct use of the vehicle to prevent damaging the environment Vehicle intactness The incomplete or non observance of these regulations leads to the risk of serious damage...

Page 4: ......

Page 5: ...RISTICS CHAR SPECIAL TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS CLUTCH SYSTEM CLU SYS BODYWORK BODYW ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...CT WITH NAKED FLAMES SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off When handling these components wear insulating gloves or wait until the engine and the exhaust ...

Page 8: ... THE BATTERY RELEASES EXPLOSIVE GASES KEEP IT AWAY FROM 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 IT OR SPILL IT PARTICULARLY ON PLASTIC COMPONENTS ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT TERY TO BE ACTIVATED Maintenance rules...

Page 9: ...ore refitting them Smear a light layer of lithium based grease on the oil guard rims Reassemble oil guards and bearings with the brand or lot number facing outward visible side ELECTRIC CONNECTORS Electric connectors must be disconnected as described below failure to comply with this procedure causes irreparable damage to both the connector and the cable harness Press the relevant safety hooks if ...

Page 10: ... THIS CAUTION THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT THE END OF THE RUNNING IN PERIOD Follow these guidelines Do not twist the throttle grip abruptly and completely when the engine is working at a low revs either during or after run in During the first 100 Km 62 miles use the brakes gently avoiding sudden or prolonged braking That is to permit the adequate adjus...

Page 11: ...XX serial number 6 digits FRAME NUMBER The chassis number is stamped on the right side of the headstock ENGINE NUMBER The engine number is stamped on the left side close to the engine oil level check cap Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Length 2380 mm 93 7 in Width 815 mm 32 1 in Maximum height 1150 mm 45 3 in Saddle height 770 mm 30 3 in Minimum earth clearan...

Page 12: ... 5000 rpm 14V 25A Starter motor 12V 1 2 kW Frame and suspensions CHASSIS Specification Desc Quantity Chassis Modular double cradle high strength steel tubular chassis Front suspension MARZOCCHI hydraulic telescopic fork 45 mm 1 77 in with separate adjustment for rebound and compression damping Rear suspension Swingarm with 2 adjustable hydraulic shock absorbers in the hydraulic rebound damping Bra...

Page 13: ...t for secondary shaft 70 80 Nm Nut locking bearing on bevel pinion 180 200 Nm Screw fixing sprocket to drilled pin 25 30 Nm Screws fastening cradle to frame 70 80 Nm Nuts for screws fixing cradle to frame 70 80 Nm Blind nuts for swingarm support pins 70 80 Nm Nuts fixing gear case to the swingarm arm 25 30 Nm Upper caps for front fork 120 150 Nm Nut for front and rear wheel axle 140 150 Nm Steerin...

Page 14: ...ification Desc Quantity Selection class D 92 000 92 010 mm 3 62204 3 62243 in Selection class E 92 010 92 020 mm 3 62243 3 62282 in Selection class F 92 020 92 030 mm 3 62282 3 62322 in SELECTED DIAMETER PISTONS FROM ENGINE NO KD030429 Specification Desc Quantity Selection class D 91 953 91 963 mm 3 62019 3 62058 in Selection class E 91 963 91 973 mm 3 62058 3 62097 in Selection class F 91 973 91 ...

Page 15: ...ecification Desc Quantity Shaft support diameter 47 000 46 984 mm 1 85039 1 84976 inch Seat diameter on crankcase 47 025 47 050 mm 1 85137 1 85236 inch fitting clearance 0 025 0 066 mm 0 00098 0 00260 inch CAMSHAFT CAM SUPPORT DIAMETER AND THEIR SEATS ON THE CRANKCASE FLYWHEEL SIDE Specification Desc Quantity Shaft support diameter 32 000 31 984 mm 1 25984 1 25921 inch Seat diameter on crankcase 3...

Page 16: ...chart RECOMMENDED PRODUCTS TABLE Product Description Specifications eni i Ride PG 5W 40 Mandatory for hy draulic tappet Synthetic based lubricant for high per formance four stroke engines JASO MA MA2 API SL ACEA A3 eni i Ride Aprilia Racing 10W 60 Rec ommended for normal tappets Engine oil Use branded oils with performance equivalent to or exceeding API SG JA SO MA JASO MA2 specifications AGIP GEA...

Page 17: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 18: ...ed dial to control ignition timing 17 94 75 60 Arrow to control ignition timing 12 91 36 00 Tool to remove the flywheel side flange 12 91 18 01 Tool to lock the flywheel and the starting ring gear 10 90 72 00 Tool for valve removal and refitting Special tools California EV V1100 S TOOLS 18 ...

Page 19: ...the sealing ring on the flywheel side flange 12 91 20 00 Tool to fit the flywheel side flange togeth er with seal ring on the crankshaft 14 92 72 00 Tool for fitting seal ring on timing system cover 12 90 71 00 Tool to lock the secondary shaft 14 92 87 00 Pre selector start California EV V1100 Special tools S TOOLS 19 ...

Page 20: ... shaft bearing 17 94 92 60 Extractor for clutch shaft bearing on the box and for the secondary shaft on the cover 17 94 50 60 Extractor for outer track of the secondary shaft roller bearing on the box and outer track of the bearings on the case 14 90 70 00 Extractor for ball bearing for main shaft on the cover 12 90 69 00 Extractor for roller bearing ring from the gear case Special tools Californi...

Page 21: ...track of bearing related to the transmission box seal ring 17 94 54 60 Tool to drive the inner bearing ring on the main shaft and on the clutch shaft 14 92 86 00 Tool to drive the inner bearing ring on the secondary shaft 14 92 89 00 Punch to press the bearing for transmis sion shafts on the cover 14 92 91 00 Punch to press the sealing ring on the front fork sleeve and gear case inner sealing ring...

Page 22: ...aft on the cover 14 92 94 00 Punch to press the sealing ring on the gearbox for clutch shaft 14 92 95 00 Punch to press the sealing ring on the cover for secondary shaft 17 94 51 60 Punch to press the outer track of the bear ings on the box 14 92 93 00 Positioning tool for sliding sleeves control forks 14 92 73 00 Tool for camshaft gear sealing Special tools California EV V1100 S TOOLS 22 ...

Page 23: ...haft internal body Special tools are necessary for correct removal and refitting and a good set up The use of special tools prevents possible damages that could be caused by inadequate tools and or improvised techniques Here is a list of the special tools suitably designed for this vehicle If necessary ask for generic special tools California EV V1100 Special tools S TOOLS 23 ...

Page 24: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 25: ...lt nut and screw tightening Check and clean adjust grease or replace if necessary Fuel pipes Check and clean adjust grease or replace if necessary Gearbox oil Change Final transmission oil Change Brake system fluid Check clean adjust or replace if necessary Brake pad wear Check and clean adjust or replace if necessary AT 20 000 KM 12427 MI Action Engine oil Change Cartridge type oil filter Replace...

Page 26: ...ce if necessary Wheel bearings Check and clean adjust grease or replace if necessary Fork oil Change Starter motor and generator Check clean adjust or replace if necessary Brake fluid change Brake pad wear Check and clean adjust or replace if necessary AT 50 000 KM 31069 MI Action Engine oil Change Cartridge type oil filter Replace Mesh oil filter Clean Air filter Replace Spark plugs Inspect clean...

Page 27: ...uld ruin the cylinder head thread it is therefore recommended to tighten them with a few turns by hand and then with the supplied appropriate wrench tighten it to the prescribed torque ALWAYS PERFORM THE SPARK PLUG REMOVAL AND REFITTING OPERATIONS AT COLD ENGINE Transmission fluid Check Keep the vehicle upright with both wheels on the ground Unscrew and remove the cap dipstick 1 The level is corre...

Page 28: ...ug hole 1 CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN Screw and tighten the caps 1 2 Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL OIL IS BEST CH...

Page 29: ...N USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN Replacement Use an engine oil type with characteristics indicated in the table of recommended products The other viscosity levels indicated in this table can be used if the average temperature of the motor bike s area of use is within the indicated range NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY Pl...

Page 30: ... the drainage plug magnet Screw and tighten the drainage plug Pour new oil until it goes above the minimum level marked MIN Engine oil filter Drain the engine oil Unscrew and remove the eighteen screws Remove the oil sump CARTRIDGE TYPE ENGINE OIL FILTER Unscrew the filtering cartridge Install a new original cartridge in the appropriate seat tightening it by hand to avoid an excessive tightening M...

Page 31: ...M NOTE RIDE SOME km miles TO WARM UP ENGINE OIL Shut off the engine Keep the vehicle upright with both wheels on the ground Undo and remove the dipstick opening 1 located on the right side of the gear box The level is correct if the oil is close to the hole of the dipstick 1 If necessary Top up with oil until it reaches the dip stick opening 1 CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO TH...

Page 32: ...ew oil from the filling hole 2 until it reaches the dipstick opening 1 Tighten the filler plug 2 and the dip stick 1 CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER EL EMENT MAKE SURE IT IS PERFECTLY CLEAN See also Recommended products chart Fuel filter The filter is mounted under the fuel tank To re place the fuel filter proceed as follows Remove the...

Page 33: ...ted on the engine unit and the saddle and fuel tank must be removed in order to reach it Unscrew and remove the three upper screws and lift the filter box cover Remove the filtering element and clean it If required replace it with a new one of the same type NOTE DO NOT START THE ENGINE WITHOUT THE AIR FILTER TO CLEAN THE FILTERING ELEMENT USE A PRESSURE AIR JET FROM THE INSIDE TO THE OUTSIDE Calif...

Page 34: ...them THROTTLE GRIP CABLES MAINTENANCE Remove the right device B by un screwing the two fixing screws C Grease the end of the cables D and the pulley E Carefully close the throttle control again inserting the cables D in the pulley of the throttle control moving body E Lock the right device with the two fixing screws C CAUTION THE LATEST SERIES OF PRODUCED California EV 1997 2000 MOTORCYCLE HAS MOU...

Page 35: ...SSURE DROP ENGINE OVERHEAT VALVE BURN OUT ETC OPTION 02 HYDRAULIC TAPPET It is not necessary to perform the valve clearance as the hydraulic tappets automatically cancel the valve clearance during the engine operation al ways keeping the camshaft in contact with the bucket tappets CAUTION IF CLEARANCE IS LARGER THAN RECOMMENDED THE TAPPETS WILL BE NOISY OTHER WISE THE VALVES DO NOT CLOSE CORRECTLY...

Page 36: ...he same level with the plug Make sure that the fluid level in the reservoir is above the MIN reference mark MIN minimum level MAX maximum level If the fluid does not reach at least the MIN reference mark Check brake pads and disc for wear If the pads and or the disc do not need replacing top up the fluid Adjusting the levers If you want to change the position of the throttle pedal 1 proceed as fol...

Page 37: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 38: ...Electrical system installation General wiring diagram key Electrical system California EV V1100 ELE SYS 38 ...

Page 39: ...tion indicators warning horns 18 Alternator 12V 350 W 19 Voltage regulator 20 Blinker 21 Lights relay MINIRELAY SWITCH 22 Starter relay MINIRELAY BAFFLE 23 Starter motor 24 Battery 25 Rear stop switch 26 Rear light unit 6 way connector 27 Rear left turn indicator 10W 28 Rear right turn indicator 10W 29 Rear STOP light 21W with parking light 30 Rear parking light 5W with STOP light 31 Plug socket 1...

Page 40: ...7 Throttle valve potentiometer PF3C 58 Max pressure sensor inside the electronic unit ECU 59 2 way AMP connector key closed supply 60 1 way AMP connector rpm sensor in the injection side Checks and inspections Battery recharge circuit Checking the stator IF CONNECTIONS ARE INVERTED THE REGULATOR WILL BE IRREVERSIBLY DAMAGED CHECK THAT THE REGULATOR EARTH CONNECTIONS ARE EFFICIENT POSSIBLE CHECKS T...

Page 41: ... intensity at 1200 rpm 13 0 Amp 6 Direct current intensity at 1500 rpm 16 50 Amp 7 Direct current intensity at 2000 rpm 20 0 Amp 8 Direct current intensity at 3000 rpm 23 50 Amp 9 Direct current intensity at 4000 rpm 25 0 Amp 10 Direct current intensity at 6000 rpm 26 50 Amp 11 Direct current intensity at 10000 rpm 27 50 Amp Voltage regulator check The regulator has been calibrated in order to mai...

Page 42: ... rpm 8 No load current 600 A 9 Load current 230 A 10 Weight 2 8 kg 61 73 lb Fuses On the terminal block are mounted seven fuses Before changing a burnt fuse trace and repair the cause of the trouble 1 Battery recharge 30 A 2 Keys switch 15A 3 High beam light low beam light horn 15A 4 Tail lights turn indicator 5A 5 Plug socket 12V 15A 6 ECU 5 A 7 Pump coil injectors 10 A Electrical system Californ...

Page 43: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 44: ...ngine support under the oil sump Disconnect all the electrical connections between engine gear and chassis timing sensor oil pressure transmitter alternator oil temperature sensor spark plug cables hoods starter motor neutral switch on the gear earth cable on the gear Removing the engine from the vehicle Release the clutch control transmis sion from the lever on the gearbox cov er Unscrew the odom...

Page 45: ...nkcase and on the cylinder head by loosening the rel ative sealing clamps Undo the screws fixing the battery holder plate to the gearbox and remove it Remove the rear swingarm Undo the two screws to release at the front end the two cradles from the chassis Undo the nut and slide the front pin fix ing the engine to the chassis off California EV V1100 Engine from vehicle ENG VE 45 ...

Page 46: ...rests Operating from both sides unscrew and remove the two screws and re move the two footrest supports At the same time release the cradles at the rear end from the chassis Engine from vehicle California EV V1100 ENG VE 46 ...

Page 47: ...INDEX OF TOPICS ENGINE ENG ...

Page 48: ...rbox Diagram key 1 Secondary shaft 2 Nut 3 Adjustment washer 4 Thrust washer 5 Gear 4a A S Z 20 6 Inner ring 4a 7 Roller cage 4a A S 8 Sleeve 3a 4a A S 9 Sleeve 10 Washer Engine California EV V1100 ENG 48 ...

Page 49: ...n 22 Adjustment washer 1 0 mm 0 039 in 22 Adjustment washer 1 2 mm 0 047 in 23 Rod 24 Pin 25 Rod 26 Fork 1a 2a 3a 4a 27 Fork 5a 28 O ring 29 Washer 30 Roller cage 31 O ring 32 Complete pre selector 33 Pre selector return spring 34 Ring nut 35 Washer 36 Clutch internal body 37 O ring 38 Clutch shaft 39 O ring 40 Oil spreading washer 41 Transmission gear bearing Z 17 42 Sleeve 43 Belleville springs ...

Page 50: ...m washer th 2 4 mm 0 094 in 49 Roller bearing 50 Gear 5a A P Z 28 51 Bushing retaining roller 52 Spring 53 Roller cage 54 Bushing for 5a A P 55 Sliding sleeve 5a Gearbox Removing the gearbox Remove the gear engine unit from the chassis Unscrew and remove the six screws Remove the gearbox Gearbox shafts Engine California EV V1100 ENG 50 ...

Page 51: ...il from the gear Specific tooling 05 90 25 30 Gearbox support Remove the caulking on the secondary shaft lock nut Unscrew the nut using the special spanner to lock the secondary shaft and to undo the nut Specific tooling 12 90 71 00 Tool to lock the secondary shaft 14 90 54 00 Secondary shaft locking nut Undo the odometer transmission and slide it off from the gear cover Remove the crown gear toge...

Page 52: ...panner code 14912603 Level the flap of the retaining ring safe ty washer Remove the body 6 Specific tooling 30 91 28 10 Clutch body locking GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body Undo the 11 screws paying attention to the breather pipe support to place it correctly during refitting Remove the cover Remove the speed pre selector com plete with the spring from ...

Page 53: ...x if necessary hit slightly on the shaft head with a leather mallet and remove the O Ring mounted above Bearings from gearbox removal Warm up the gearbox to a temperature of about 150 160 C 302 320 F Extract the roller bearing 9 for the main shaft with the extractor code 14913100 Extract the outer ring of the roller bear ing 10 for the secondary shaft with the extractor code 17945060 Undo the two ...

Page 54: ...g on the box and out er track of the bearings on the case 17 94 92 60 Extractor for clutch shaft bearing on the box and for the secondary shaft on the cover 14 90 70 00 Extractor for ball bearing for main shaft on the cover Removing the primary shaft Slide off the sleeve of 5a 6 With a special punch press the retain ing pawl down 1 and turn the bushing 2 so as to release it from the grooves Extrac...

Page 55: ...t in vice by interposing the ductile metal shoes Unscrew the seal nut 7 clockwise Remove the bearing the 4th gear 8 with the shimming washer 19 remove the roller cage 9 Extract the sliding sleeve 10 of the 4th and 3rd gear slide off the grooved fixed sleeve 11 and remove the 3rd gear 12 with bushing 13 roller cage 14 and intermediate washer 15 Then extract the 2nd gear 16 with the relative roller ...

Page 56: ... 92 85 00 Tool to slide off the inner track of the clutch shaft bearing 12 90 59 00 Clutch shaft removal Checking the primary shaft Primary shaft Check the teeth of the gears they must be free from grain and excessive consumption otherwise replace the shaft 5th gear on the primary shaft Check the teeth of the gear they must be free from grain and excessive consumption otherwise replace the gear Bu...

Page 57: ...ge on the gears 1a 2a 3a 4a on the secondary shaft Check that the surface where the roller cages are working is smooth and not scored or distorted oth erwise replace the bushings Roller cage on the gears 1a 2a 3a 4a on the secondary shaft Check that the rollers of the cage are in optimal condition otherwise replace the cages Checking the clutch shaft Clutch shaft Check that the grooves threads and...

Page 58: ...t the cover crankcase coupling surfaces are not scored or damaged the thread of the hub caps shall not be stripped Sealing rings The seal rings normally if removed from their seats they must be replaced this is to be sure of their perfect fit Ball and roller bearings The bearings must be in perfect condition The balls or rollers must be intact and smooth on their entire surface Assembling the gear...

Page 59: ...rate as follows The bearing for secondary shaft after spreading with Loctite is be pressed with a special punch code 14928900 The primary shaft bearing is pressed with a special punch code 14929000 The bearing for clutch shaft is pressed with a special punch code 14928800 PRESS THE BEARINGS IN THEIR SEATS ON THE GEARBOX AND COVER LET THEM SIT FOR 12 HOURS THIS IS USEFUL SO THE LOCTITE CAN DRY BEFO...

Page 60: ...ring on the gearbox cover for secondary shaft is performed with a special punch code 14929500 Specific tooling 14 92 95 00 Punch to press the sealing ring on the cover for secondary shaft span style FONT SIZE 12pt FONT FAMILY Arial mso fareast font family Times New Ro man mso ansi language IT mso fareast lan guage IT mso bidi language AR SA The O ring for pre selector shaft must be seated in the s...

Page 61: ...side shaft Insert the bushing for 2nd gear on the shaft observe that the head of the bushing should be facing the cover The cage complete with rolls for 2nd gear on the bushing The 2nd gear on the roller cage taking in mind that the front coupling notches should be directed toward the cover The thickness washer between the 3rd and 2nd gear The 3rd gear with roller cage taking in mind that the fron...

Page 62: ... side shaft Screw the nut on the 4th side secondary shaft with Loctite and then chamfer it Then fit the complete secondary shaft on the gearbox Fitting of control forks grooved drum on the gear box Before reassembling the grooved drum in the gearbox it is required to measure the distance be tween the two lateral stops A of the housing of the drum between box and cover This measurement must be perf...

Page 63: ...ox Specific tooling 14 92 93 00 Positioning tool for sliding sleeves control forks Refitting the clutch shaft on the box As a first step must be refitted on the clutch shaft the following parts operating as follows Insert the transmission gear bearing 3 on the shaft with coupling directed towards the cover Insert the coupling sleeve 4 on the shaft with the couplings directed to wards the transmiss...

Page 64: ...sliding up until it is close to the hole Insert the clip into the hole of the shaft and above the clip the retaining roller Keep the roller pressed with a specific tool formed by a plug and a tube or with the thumb of the left hand while with the right hand pushing the bushing complete to the bottom as described above for cage and gear Turn the bushing to the right or left until the roller engages...

Page 65: ...e pre selector shaft the start tool code 14928700 Specific tooling 14 92 87 00 Pre selector start Adjust the gear shift with an eccentric screw after loosening the lock nut until the gear change is soft Try the gear changes from the 1st to 5th gear and up shifting from 5th to 1st and then in neutral If the shifting is difficult disassemble the cover again and shim properly between the box and the ...

Page 66: ...00 Specific tooling 14 90 54 00 Secondary shaft locking nut 12 90 71 00 Tool to lock the secondary shaft Tighten the nut with a gravel hit on the shank of the nut at the groove of the shaft so as to create the retaining nut Tighten the screws that secure the cov er to the box and remove the pre se lector shaft Insert the control lever on the pre se lector shaft locking it with a screw Fully tighte...

Page 67: ...djuster screw and lock nut with pin and cotter pins 18 The lever return spring in the slot on the cover 19 Fitting of the gearbox complete with shafts and gears on the engine For the refitting of the gearbox on the engine operate as follows Insert the gearbox on the stud bolts mounted on the engine making sure to perfectly insert the inner body of the clutch on both driven plates of the clutch alr...

Page 68: ...Removing the flywheel Remove the clutch Position the locking tool on the flywheel and loosen the six flywheel fixing screws operating diagonally and in stages Remove the locking tool Specific tooling 12 91 18 01 Tool to lock the flywheel and the starting ring gear Remove the flywheel See also Disassembling the clutch Checking Check that the flywheel surface that contacts the plate is not scratched...

Page 69: ...CREWS AS THEY ARE SUBJECT TO HIGH LOADS AND STRESS MUST BE REPLACED WITH NEW ONES AT THE FOLLOWING REFITTING Position the locking tool on the flywheel and tighten the six flywheel fixing screws operating diagonally and in stages Install the clutch Specific tooling 12 91 18 01 Tool to lock the flywheel and the starting ring gear See also Assembling the clutch Generator Removing the generator The al...

Page 70: ...ic tooling 12 91 18 01 Tool to lock the flywheel and the starting ring gear Unscrew the central nut 1 that se cures the rotor Remove the stator 2 by removing the three fixing screws 3 Remove the washer and take out the rotor IN ORDER TO AVOID DEMAGNETIZATION INSERT THE ROTOR AGAIN IN THE STATOR PREVIOUSLY REMOVED Installing the generator Starter motor Engine California EV V1100 ENG 70 ...

Page 71: ...tor Clutch side OPTION 01 Single plate clutch key 1 Clutch cover 2 Cup spring 3 Inner clutch plate 4 Clutch plate 5 Cotter pin 6 Rod 7 Bushing 8 Intermediate body 9 Thrust bearing 10 Outer body 11 O Ring 12 Clutch disengaging lever 13 Return spring lever 14 Set screw 15 Nut California EV V1100 Engine ENG 71 ...

Page 72: ...rew 16 Nut 17 Pin 18 Cotter pin 19 Crown gear Disassembling the clutch OPTION 01 The clutch is a dry type and is housed inside the engine flywheel It is composed of one driven disk one Belleville spring one inner disc one crown gear and flywheel Remove the engine unit Remove the alternator Bring the right piston to the TDC and mark the position of the flywheel 1 and the crown gear 2 with respect t...

Page 73: ...ch plate 8 the inner disc 9 the Belle ville spring 10 and the flywheel 11 OPTION 02 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 plate and 8 springs Remove the gearbox from the engine Use the locking tool and the clutch spring compression tool on the fly wheel Specific tooling 30 90 65 10 Tool for clu...

Page 74: ...he eight sealing screws from the crown gear on the en gine flywheel Remove the start up crown gear Extract from the inside of the engine flywheel the clutch plate The intermediate plate Engine California EV V1100 ENG 74 ...

Page 75: ...r disc are perfectly smooth and even otherwise replace it Inner disc Check that the support surfaces are perfectly smooth and even otherwise replace them OPTION 02 Driven plates Check that the supporting surfaces with the driven plates are perfectly smooth and even and that the external toothing that works inside the flywheel is not damaged otherwise replace the plate California EV V1100 Engine EN...

Page 76: ...late OPTION 02 Pressure plate Check that the plate does not show signs of wear on the opening where the control cap works and that the supporting surfaces with the driven plate are perfectly even Checking the springs OPTION 01 Cup spring Check that the spring is still flexible and is not deformed OPTION 02 Check that the springs are still flexible and are not deformed Springs compressed at 17 mm 0...

Page 77: ... to the specified torque six new screws 4 that secure the flywheel clutch unit to the crankshaft by apply ing threadlocker Loctite on the screws If removed position the locking tool Specific tooling 12 91 18 01 Tool to lock the flywheel and the starting ring gear With the special tool perform the cen tring of the clutch Tighten the screws 5 that secure the starter ring gear to the flywheel with th...

Page 78: ...reference on the flywheel Use the locking tool and the clutch spring compression tool on the fly wheel Specific tooling 30 90 65 10 Tool for clutch fitting 12 91 18 01 Tool to lock the flywheel and the starting ring gear Remove the locking tool Insert the clutch plate Specific tooling 12 91 18 01 Tool to lock the flywheel and the starting ring gear Engine California EV V1100 ENG 78 ...

Page 79: ... its refer ence with that on the flywheel Tighten the eight screws holding the crown gear to the flywheel to the prescribed torque Remove the special tool to compress the clutch springs Specific tooling 30 90 65 10 Tool for clutch fitting California EV V1100 Engine ENG 79 ...

Page 80: ...ILE THE LOWER ONES DO NOT HAVE ONE NOTE BETWEEN COVERS HEAD THERE IS A GASKET THAT MUST BE REPLACED AT EVERY REFITTING Removing the cylinder head The engine unit uses a timing system with rods and rockers with two valves per cylinder The opening and closing of the valves is controlled by a camshaft placed in the crankcase which re ceives the motion from the crankshaft via a duplex chain Engine Cal...

Page 81: ...DC in combus tion phase NOTE THIS OPERATION CAN BE CARRIED OUT EVEN WHEN THE GEAR IS ASSEMBLED TO THE ENGINE BLOCK AS THE POSITION OF THE NOTCH CAN BE VERIFIED BY THE APPROPRIATE HOLE Loosen the nut and disconnect the pipes that deliver oil to the head California EV V1100 Engine ENG 81 ...

Page 82: ...f the pipe that delivers oil to the head and collect the washer Undo and remove the four nuts Remove the rocker support Slightly detach the cylinder head and remove the four O rings Remove the head and collect the gasket Cylinder head Engine California EV V1100 ENG 82 ...

Page 83: ...es for the left cylinder Unscrew and remove the two screws Remove the rocker shafts Remove the rocker and the relative washers and bushings See also Removing the head cover Removing the valves Remove the head Place the special tool on the upper cap and at the centre of the head of the valve to be removed Specific tooling 10 90 72 00 Tool for valve removal and refitting California EV V1100 Engine E...

Page 84: ...king the rocker arms Check for wear and the size of the pins and rockers if the measures identified did not fall in the meas urements given in the drawings they must be replaced Valve check Make sure the springs are not deformed and have not lost the load Outer spring Released it has a length of 54 5 mm 2 15 in With closed valve it has a length of 36 mm 1 42 in and must provide a load of 29 5 kg 6...

Page 85: ...35 700 mm 36 000 mm 1 405 1 417 in To reach this value fit washers code 14 03 73 00 with a 0 3 mm 0 012 in thickness After reaching the maximum opening the springs shall still have a length of mm 1 1 75 mm 0 039 0 069 in before the inner spring is packed Checking the valve guides Use a punch to extract the valve guides from the heads The valve guides should be replaced only if the clearance betwee...

Page 86: ...DATA CHART OUTLET Specification Desc Quantity Valve guide inside diameter mm in 8 000 8 022 0 3150 0 3158 Valve stem diameter mm in 7 965 7 980 0 3136 0 3142 Fitting clearance mm in 0 025 0 057 0 0010 0 0022 Checking the cylinder head Check that The planes of contact with the cover and with the cylinder are not scored or damaged so as to compromise a perfect seal Check that the clearance between t...

Page 87: ... and the shim ming washers Place the outer spring 4 Place the inner spring 3 Insert the upper cap 2 Place the two cotters 1 on the seats in the valves By compressing the spring with the special tool of the valve fit the valve cotters Specific tooling 10 90 72 00 Tool for valve removal and refitting Remove the special tool Timing California EV V1100 Engine ENG 87 ...

Page 88: ...iming system marks so as to restore correct timing at the next refit ting TDC of the left cylinder Unscrew the central nut that secures the gear to the camshaft Remove the cotter 1 Slide off the spacer 2 Unscrew the central nut 3 that se cures the timing system control gear on the crankshaft Engine California EV V1100 ENG 88 ...

Page 89: ... tensioner of the timing system by unscrewing the fixing screws See also Removing the generator Removing the rods Remove the rocker support Slide off the two rods Removing the tappets OPTION 01 Remove the engine unit Remove both heads From both sides slide off the tappets from their seats OPTION 02 California EV V1100 Engine ENG 89 ...

Page 90: ... residual oil DISCHARGE THE OIL IN A SUITABLE CONTAINER NOTE THE TAPPET IS DISCHARGED WHEN IT CAN BE COM PRESSED BY PRESSING WITH ONE FINGER See also Removing the engine from the vehicle Removing the cylinder head Removing the phonic wheel Remove the timing chain Slide off the tone wheel and collect the plug See also Chain removal Removing the camshaft Remove the timing chain Remove the tone wheel...

Page 91: ...lange Remove the camshaft See also Chain removal Removing the phonic wheel Removing the tappets Removing the rods Checking the tappets OPTION 01 TAPPET SEAT COUPLING ON CRANKCASE DATA PRODUCTION Specification Desc Quantity Seats diameter 22 021 22 000 mm 0 86697 0 86614 inch California EV V1100 Engine ENG 91 ...

Page 92: ...rnal diameter 22 096 22 078 mm 0 86992 0 86921 inch Fitting clearances 0 004 0 043 mm 0 00016 0 00169 in OPTION 02 For the correct operation of the hydraulic tappet it is important to use the engine oil given in the table of recommended products CAUTION IF OIL IS DEGRADED OR CONTAMINATED WITH FUEL IT CAN COMPROMISE THE OPERATION OF THE HYDRAULIC TAPPETS CAUTION WITH DISCHARGED TAPPET START THE ENG...

Page 93: ... SUPPORT DIAMETER AND THEIR SEATS ON THE CRANKCASE TIMING SYSTEM SIDE Specification Desc Quantity Shaft support diameter 47 000 46 984 mm 1 85039 1 84976 inch Seat diameter on crankcase 47 025 47 050 mm California EV V1100 Engine ENG 93 ...

Page 94: ...CTLY AND WITHOUT DAMAGING IT Follow the camshaft removal instructions but in reverse order Timing To check distribution timing follow these instruc tions Obtain a clearance between rockers and valves of 1 5 mm 0 059 in Place the hub for graduated dial and the relative graduated dial on the crankshaft slot inserting the spacer and fixing it to the shaft with the nut Specific tooling 65 92 84 00 Gra...

Page 95: ...upport and then the gauge itself on the right cylinder outer spark plug hole With a screw fix the arrow to the threaded hole to the right of the crankcase Turn the disc clockwise until the reference marked with letter D is aligned with the reference at the centre of the checking hole on the gearbox valves closed Repeat the operations described above for the left cylinder After the check and if eve...

Page 96: ...distance between the stop on the crankcase 1 and the surface of the tooth on the fly wheel 2 Measure the distance between the end 3 of the sensor and its stop plate 4 The difference between the two distan ces measured gives the real air gap If necessary intervene shimming the stop of the sensor Cylinder piston assembly Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REM...

Page 97: ...ng the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Fit the piston NOTE CHECK THE ORIENTATION OF THE PISTON ACCORDING TO THE REFERENCES AT THE TOP DO NOT ASSEMBLE PISTONS AND CYLINDERS OF DIFFERENT SELECTOR TYPES Insert the pin Insert the snap ring Installing the cylinder Fit the piston Remove the cloth used to prevent foreign bodies from getti...

Page 98: ...shaft Remove the connecting rods Undo and remove the six fixing screws and collect the washers Remove the alternator side crankshaft flange Undo and remove the eight fixing screws and collect the washers Using the suitable special tool remove the crankshaft flange Remove the sealing ring if necessary Specific tooling 12 91 36 00 Tool to remove the flywheel side flange Remove the crankshaft afterwa...

Page 99: ...rnals The undersized scale of the main journals is the following 0 2 0 4 0 6 mm 0 0079 0 0157 0 0236 in FITTING CLEARANCES Specification Desc Quantity Between the bearing and the main journal on the timing system side 0 028 0 060 mm 0 00110 0 00236 in Between the bearing and the main journal on the flywheel side 0 040 0 075 mm 0 00157 0 00295 in Between the bearing and the connecting rod pin 0 022...

Page 100: ...ollowing weight on the crank pin 1810 g 63 84 oz Checking the connecting rod CONNECTING RODS When examining the connecting rods check that Bushing conditions and bushings 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 marks are found Upon replacing the bear...

Page 101: ...in 43 264 43 258 mm 1 70330 1 70307 in PIN BUSHING COUPLING DATA Specification Desc Quantity fitted and machined bushing inside Ø mm inch 22 007 mm 0 86641 inch 22 020 mm 0 86692 inch pin Ø mm inch 21 994 mm 0 86590 inch 21 998 mm 0 86606 inch Clearance between pin and bushing mm inch 0 009 0 026 mm 0 000354 0 001024 inch TABLE OF CONNECTING ROD WEIGHTS Specification Desc Quantity Connecting rod t...

Page 102: ... 00252 inch maximum the clearance between the shim washers of the connecting rod and those of the crankshaft is 0 30 0 50 mm 0 0118 0 0197 in Lock the screws A on the caps with a torque wrench at the prescribed tor que Installing the crankshaft Carry out the disassembly operations in reverse order remembering the following Place the crankshaft support flanges taking into account the fitting order ...

Page 103: ...er 4 Oil pressure transmitter 5 Engine oil pressure regulator valve 6 Oil Pump NOTE ON THE MODELS MY2003 THE RECYCLING PIPE Y BETWEEN ENGINE AND FRAME IS PLACED BETWEEN THE COVER OF THE TIMING SYSTEM AND THE FRAME UP TO YEAR 2002 IT WAS LOCATED BETWEEN THE CRANKCASE REAR AREA AND THE FRAME Oil pump California EV V1100 Engine ENG 103 ...

Page 104: ...MILY Arial mso fare ast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi language AR SA Remove the oil pump See also Replacement Removing the generator Chain removal Inspection If any defects are found due to the pump control Height of the gears that should be within 15 973 16 000 mm 0 629 0 630 in Height of the seats on the pump casing should be within 16 032 16 0...

Page 105: ...COLLECT THE USED OIL AND DRAIN OUT ALL OIL Drain all the engine oil Undo and remove the eighteen screws fixing the oil sump to the engine crankcase Remove the engine oil sump NOTE BETWEEN THE OIL SUMP AND THE CRANKCASE IS A GASKET THAT MUST ALWAYS BE RE PLACED AFTER REMOVAL California EV V1100 Engine ENG 105 ...

Page 106: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 107: ...ks in fuel from the tank 3 and delivers it to the electro injectors 2 by means of a filter The fuel pressure in the circuit is kept stable by the pressure adjuster This controls the amount of fuel flowing back into the tank key 1 Electrical fuel pump unit immersed electric pump fuel filter pressure adjuster 2 Electro injectors 3 Tank Fuel pump California EV V1100 Power supply P SUPP 107 ...

Page 108: ... span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi lan guage AR SA WHEN REMOVING THE PUMP UNIT MAKE SURE NOT TO DAMAGE THE PIPES AND THE FUEL LEVEL SENSOR See also Fuel tank Checking span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso ...

Page 109: ...n is pressed on the sealing seat by a helical spring whose load is determined by an adjustable spring pressure In the rear part of the body is the winding in the front part is the nib of the injector sealing seat and pin guide The control pulses established by the electronic control unit create a magnetic field that attracts the stirring rod and determines the opening of the in jector This time is...

Page 110: ...so the pace of idle speed A second screw allows the correct adjustment of the throttle valve closure to avoid jamming with the surrounding duct said screw should not be used to adjust the idle Removal Remove the air box filter Disconnect from the throttle body The wiring harness of the potentiometer the wiring harness on the injectors the throttle grip transmission the starter for transmission con...

Page 111: ...idi language AR SA TO ACCESS THE SELF DIAGNOSIS FUNCTIONS IT IS NECESSARY THAT THE OBD MODULE IS FITTED ON THE BACK OF AXONE In the following screens select the mo torcycle brand MOTOGUZZI model engine type of system software of the injection system leading digits of the chassis type of electronic control unit fitted Turn the ignition key to ON AXONE will connect to the control unit Select the thr...

Page 112: ... balance of the de pression between the two cylinders In case of separation act on the adjuster screw 6 and level the depression Gradually open both bypasses so as to bring the idle speed to 1100 50 RPM readable on AXONE after select ing the rpm parameter while maintain ing balanced the depression The engine temperature should range between 70 C 158 F and 80 C 176 F Disconnect the vacuum gauge and...

Page 113: ... the verification of the potentiometer using a tester with the following procedure place the throttle valve fully closed on the duct throttle valve angle 0 put the ignition key to ON insert the tester pointer on the connector of the potentiometer between the poles Q and R and verify that the value of the measured voltage is 150mV 15mV if the potentiometer does not give the value indi cated above l...

Page 114: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 115: ...he shank and thread of the wheel axle with the recommended grease Grease the threads present in the left fork leg Place the spacers and tighten the wheel axle Tighten the two screws fixing the spindle to the fork leg to the specified torque Refit the clamp or brake callipers tightening the fixing screws to the specified torque Check that the discs slide freely within the clamps then repeatedly act...

Page 116: ...5 Cap assembly 16 Cap 17 Preloading pipe 18 Spring 19 Bare fork arm 20 Lower bushing 21 Ring 22 RH tube extension 23 Lock nut 24 RH rod extension 25 Counter spring 26 RH piston extension 27 RH piston ring extension 28 RH pin extension 29 Calibration blade 30 Nut 31 Foot valve assembly 32 OR ring 33 Adapter 34 Dust scraper 35 Snap ring 36 Seal ring 37 Cap Suspensions California EV V1100 SUSP 116 ...

Page 117: ...mpression 50 LH piston compression 51 Nut 52 RH complete fork arm 53 LH complete fork arm 54 O Ring screw 55 OR ring 56 Cap 57 Screw 58 Washer Adjustment The vehicle is equipped with a hydraul ic telescopic fork with separate adjust ment for rebound and compression damping The hydraulic rebound can be adjusted by acting on the adjustment knobs 1 and 2 The left adjustment knob 1 controls the adjust...

Page 118: ... a different way their internal components are similar and thus the removal overhaul and refitting are per formed following the same operations therefore the operations described below are valid for both stanchions STANCHION REMOVAL Place the vehicle on a stable support so that the front wheel does not touch the ground Remove the brake callipers without disconnecting the oil pipes Remove the front...

Page 119: ...ore the operations described below are valid for both stems CAUTION span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi language AR SA DURING OIL DRAINAGE AND REFILLING OPERATIONS THE STEM AND ITS INNER PARTS SHOULD BE LOCKED IN A VICE BE VERY CAREFUL NOT TO DAMAGE THEM BY EXERTING AN EXCESSIVE FORCE AL...

Page 120: ...an style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi lan guage AR SA Empty the stanchion again from the oil contained within it and for easy drainage of the oil inside the shock absorber assembly press the shock absorber rod to pump oil out span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast ...

Page 121: ...ure that there are no damaged ele ments If there are no damaged or worn elements refill the stem otherwise replace the damaged elements Disassembling the fork Drain all the oil from the stem Tighten the wheel holder sleeve in a vice Undo the bottom screw and remove it with the corresponding gasket Remove the dust scraper using a screwdriver as a lever CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RI...

Page 122: ... 4 on the tube NOTE WHEN REMOVING THE STEM FROM THE WHEEL HOLD ER SLEEVE SOME PARTS MAY REMAIN INSIDE THE SLEEVE IF THIS OCCURS THESE PARTS MUST BE RE MOVED AFTERWARDS BEING CAREFUL NOT TO DAM AGE THE SLEEVE RIM AND THE UPPER BUSHING SEAT Slide off the pumping member unit from the holding tube Remove the bottom buffer it could be remained mounted in the wheel holder fork leg in this case remove it...

Page 123: ... in side the shock absorber casing With a screwdriver remove the snap ring Push the foot valve with the shock ab sorber rod out of the casing Check the foot valve and its O ring re place if damaged California EV V1100 Suspensions SUSP 123 ...

Page 124: ...A WHILE REMOVING THE GASKET UNIT TAKE NOTE OF THE POSITION OF THE BLADES 8 span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi lan guage AR SA TIGHTENING THE SHOCK ABSORBER ROD IN VICE WITHOUT USING SPECIFIC SUPPORTS CAN CRUSH IT BEING INSIDE THE SLOT The disassembly procedure is identical to the one of...

Page 125: ...BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Spring Check the spring is in good conditions Check that the following components are in good conditions upper bushing lower bushing piston If there are signs of excessive wear or damage replace the affected component CAUTIO...

Page 126: ...leeve in a vice Pour oil into the stem Pump the stem making sure the oil has completely filled the pumping rod Introduce the spring and the preload tube Place the open washer locking the pre loading tube and the spring Suspensions California EV V1100 SUSP 126 ...

Page 127: ...en the upper cap to the prescribed torque Steering damper Removing The steering damper steering more precise and stable improving motorcycle handling in all con ditions The damper is fastened at the front of the motorcycle between the bottom yoke and the frame Removal Unscrew the chassis fixing screw Unscrew the fixing screw at the bottom yoke Remove the steering damper California EV V1100 Suspens...

Page 128: ...y with the bearing mounted in its place Turn the inner ring in both directions it must be able to rotate smoothly and quietly without jamming Then slide the inner ring out constantly changing position to check for clearance Remove and replace the bearings that do not rotate smoothly and quietly or show clearance EXCESSIVE WEAR CAN BE DUE TO VIBRATIONS AND INSTABILITY OF THE COMPONENT Assembling Ca...

Page 129: ...ultiple adjustment positions from position 1 very soft minimum hydraulic damping to position 11 very rigid maximum hy draulic damping The shock absorber is factory set to 4 TO OBTAIN A GOOD STABILITY IN YOUR MOTORCYCLE MAKE SURE THAT BOTH SHOCK ABSORBERS ARE AD JUSTED AT THE SAME POSITION Removing Remove the rear frame cover panels Remove the upper screws 1 of the shock absorbers Unscrew the lower...

Page 130: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 131: ...quipped with 2 different types of wheel axle fixing 1 The threaded part of the pin 1 comes out of the left fork leg and is fixed with a nut 2 the screws 3 ensure the seal NOTE THIS TYPE OF FITTING WAS IMPLEMENTED UP TO FRAME NUMBER KD115426 California EV V1100 Chassis CHAS 131 ...

Page 132: ...fork leg REMOVAL TYPE 1 Place the vehicle on the centre stand if present In any case place a support under the motorcycle which allows to lift the front wheel off the ground Remove the screws 3 securing the clamps to the fork legs Remove the clamp or the clamps from the brake discs With the specific wrench unscrew the retaining nut 2 of the wheel axle Loosen the 4 screws 3 fixing the pin to the fo...

Page 133: ...g position to check for clear ance Remove and replace the bearings that do not rotate smoothly and quietly or show clearance CAUTION EXCESSIVE WEAR CAN BE DUE TO VIBRATIONS AND IN STABILITY OF THE COMPONENT To remove the bearing use a hammer and a pin to press on the inner ring to obtain the extraction of the bearing Move continuously the pressure point so as to obtain an extraction as linear as p...

Page 134: ...ert the pin into the wheel and place it on two fixed matching parts Install a dial gauge supporting it in or der to detect the values of lateral devi ation and eccentricity of the wheel rim relative to the axis of the pin CAUTION The lateral deviation and actual eccentricity is half of the total reading of the measuring instrument Standard values Lateral deviation 0 5 mm 0 020 in Eccentricity 0 8 ...

Page 135: ...the swingarm Pull out the pin G of the box hub and swingarm Remove the calliper holding plate B Tilt the vehicle on the right side enough to be able to pull the wheel out of the swingarm and transmission box CALIFORNIA EV 2001 Place a stand under the swingarm so that the front wheel does not touch the ground Remove the left silencer Remove brake calliper from the calliper holding plate B Unscrew t...

Page 136: ...on box WHEEL HUB REMOVAL REMOVAL Undo the screw A Remove the ring retaining plate B Remove the circlip C with the help of a special clamp and screwdriver Remove the flexible coupling plate D When the plate is removed the flexible coupling rubbers will be visible E which must be replaced if damaged Spoke tension adjustment Chassis California EV V1100 CHAS 136 ...

Page 137: ...ening NOTE THE FOLLOWING OPERATIONS REFER TO ONLY ONE SPOKE Loosen the dowel 1 Operate on the nipple 2 to adjust the tension of the concerned spoke 3 Screw to tighten the spoke 3 Unscrew to loosen the spoke 3 Tightening torque indicative of the nipple 3 5 Nm 2 58 lbf ft CAUTION IF THE ADJUSTMENT OF THE NIPPLE 2 IS SUPPRESSED LOOSE AGAIN THE DOWEL 1 Without excessive force tighten the dowel 1 Tight...

Page 138: ... screw to tighten the spoke unscrew to loosen the spoke The tightening torque indicative of the nipples is Front wheel 4 5 Nm 3 32 lb ft Rear wheel right side nipples 4 Nm 2 95 lbf ft left side nipple 6 Nm 4 42 lbf ft Repeat the operations for all the spokes proceeding in successive or der After adjusting the wheel spoke ten sion proceed to verify the axial and radial clearance of the wheel rim WA...

Page 139: ...p to release the pro tection cap Remove the right rear shock absorber Keeping the pins 2 securing the frame locked unscrew and remove the two nuts 1 Make a note of the adjustment amount of the swingarm because it must be re stored when refitting Remove the two pins 2 Remove the swingarm See also Removing California EV V1100 Chassis CHAS 139 ...

Page 140: ...areast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi language AR SA To remove the bearing for the universal joint use a special extractor span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi language AR SA To remove the swingarm pin bearings use a special extractor NOT...

Page 141: ...ise replace them Cardan shaft 3 The splines on the cardan shaft must be intact free from grain or dents Check that the joint is not hardened or too loose otherwise replace it See also Removing Bevel gears Removing Remove the rear wheel Drain the oil from the transmission box Undo and remove the four nuts Remove the transmission box Detach the casing 1 from the box complete with the pinion 2 with g...

Page 142: ... tooling 12 90 69 00 Extractor for roller bearing ring from the gear case Unscrew the eight screws 4 and re move the crown pin unit 5 from the flange Remove the inner track of the roller bearing using the extractor Specific tooling 17 94 83 60 Extractor for inner track of the roll er bearing on the drilled pin on the box Chassis California EV V1100 CHAS 142 ...

Page 143: ...box and out er track of the bearings on the case Checking Transmission box Check that The box is free of cracks or leaks at any point otherwise seal or replace it The bearing housing is not scratched or damaged The coupling surfaces are not scored or damaged The seal ring is not damaged not disengaged or has lost elasticity The gaskets even if in very good condition must be replaced Flange on the ...

Page 144: ...ces are not scored or dented The bearing seats are not scored or damaged The gasket even if in very good condition should always be replaced Spacer within the bearings Check that the support surfaces are smooth and not damaged Adjustment washers between the spacer and bearing The adjustment washers are provided with two different thickness Check that the surfaces do not present wear or dents Bevel...

Page 145: ...aring and bevel pinion is identical If any replacement was made it requires a new shimming The lock ing of the nut should be done with a seal tool and screwdriver to the specified torque and with Loc tite NOTE IF THE PINION HAD A CORRECT SHIMMING IT MUST BE RUNNING FREE WITHOUT CLEARANCE Specific tooling 12 90 71 00 Tool to lock the secondary shaft Fitting the inner track of the roller bearing on ...

Page 146: ...ng that the eight screws should always be replaced be fore fitting properly degrease with trichlorethylene the threads formed in the drilled pin to ensure good adhesion of the block Loctite 601 previously applied to the threads of the screws Lock to the specified torque Cover on the transmission box When fitting the cover 4 on the box operate as follows place the gasket 2 on the box then the shim ...

Page 147: ...he extractor disas semble the cover and check the contact area on the teeth of the pinion Contact impression check If the contact is regular the mark on the pinion teeth will be like on the picture the pinion is seen from the crankshaft side If the contact is like in the picture the crown is too near the pinion rotation axis detach the crown by increasing spacer thickness between box and cover If ...

Page 148: ... from the pinion rotation axis ap proach the crown by reducing the spacer thickness between box and cover With a proper coupling the clearance between the pinion teeth and the teeth of the crown should be between 0 10 0 15 mm 0 0039 0 0059 in Pedaline Rimozione GEAR SHIFT REMOVAL Undo the 3 screws A Remove the cradle cover B Unscrew the nut C Undo the screw D Remove the gearbox lever E Chassis Cal...

Page 149: ...NOTE TO BE SURE OF THE CORRECT REFITTING MARK THE POSITION ON THE GEAR SELECTOR SHAFT G OF THE LEVER F WITH A MARKER BEFORE ANY REMOVAL California EV V1100 Chassis CHAS 149 ...

Page 150: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 151: ...letely drain off the hydraulic sys tem Unscrew the hollow screw and remove the tube and the two gaskets from the calliper Undo the two screws fixing the sup ports and remove the calliper California EV V1100 Braking system BRAK SYS 151 ...

Page 152: ... screw and remove the tube and the two gaskets from the calliper Undo the two screws fixing the sup ports and remove the calliper CAUTION REMOVING THE LEFT FRONT BRAKE CALLIPER IS DE SCRIBED TOGETHER WITH THE REMOVAL OF THE REAR BRAKE CALLIPER Braking system California EV V1100 BRAK SYS 152 ...

Page 153: ...scs must be perfectly clean without rust oil grease or scales and shall not show deep scratches If the disks have one of these anomalies perform a thorough cleaning if the defect still remains the discs must be replaced Front disc thickness 4 1 mm 0 16 in Front disc thickness at the wear limit 3 9 mm 0 15 in If the discs are not within the above shown measurements they must be replaced The front d...

Page 154: ...OT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS Rear brake pads Removal Undo and remove the two screws Remove the brake calliper from the disc Turn the pin and pull out the cotter pin Remove the cotter pin Braking system California EV V1100 BRAK SYS 154 ...

Page 155: ...SEATS RESULTING IN BRAKE FLUID LEAKS Insert two new pads placing them so that the holes are aligned with the calliper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED IN SIDE THE CALLIPER Insert the pin Position the cotter pin Check the brake fluid level in the reservoir California EV V1100 Braking system BRAK SYS 155 ...

Page 156: ...h the cal liper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Insert the pin Position the cotter pin Check the brake fluid level in the res ervoir Bleeding the braking system Braking system California EV V1100 BRAK SYS 156 ...

Page 157: ...ve Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con tainer to collect the fluid Remove the front brake fluid reservoir cap Quickly press and release the front brake lever several times and then keep it fully pressed Loosen the bleed valve 1 4 of a turn so that the brake fluid flows into the con tainer This will release the te...

Page 158: ...E HY DRAULIC SYSTEM FILL THE RESERVOIR WITH THE NEC ESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid Remove the rear brake fluid reser...

Page 159: ... brake fluid level is obtained Refit and lock the rear brake oil reservoir cap Refit the rubber protection cover Front brake pump Removal Completely drain off the hydraulic sys tem Disconnect the connectors A of the microswitch B Undo the hollow screw C securing the tube to the pump Remove the tube and the gaskets from the pump Remove the rear view mirror Unscrew the two screws D securing the pump...

Page 160: ...al system integral in varying proportions between the front and rear calliper increasing the load on the rear increases the pressure on the rear calliper and vice versa This ensures a more secure braking limiting the possibility of locking of the wheels NOTE span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT ms...

Page 161: ...ast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi language AR SA Fill the braking system with recommended fluid span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi language AR SA Perform some pumping operations with the lever so that the pads are setting up span style...

Page 162: ... in The adjustment is made by adjusting the part code 03 66 73 00 NOTE span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi lan guage AR SA WHEN THE SYSTEM IS ADJUSTED THE MOTORCYCLE MUST BE PUT ON THE CENTRAL STAND OR WITHOUT ANY CHARGE ON THE REAR WHEEL Braking system California EV V1100 BRAK SYS 162 ...

Page 163: ...INDEX OF TOPICS CLUTCH SYSTEM CLU SYS ...

Page 164: ...D securing the clutch lever support to the handlebar with the U bolt E Remove the rear view mirror Move the protection cap A and dis connect the STARTER B transmis sion and clutch C from the corre sponding levers Clutch system California EV V1100 CLU SYS 164 ...

Page 165: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 166: ...t the rear part of the saddle Slide off the saddle 2 by moving it for wards CALIFORNIA EV 1997 2000 PASSENGER SADDLE Removal Remove the front saddle Remove the lateral panels 1 Loosen the screws 2 Remove the saddle CALIFORNIA EV 2001 Bodywork California EV V1100 BODYW 166 ...

Page 167: ...cle Air box span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi language AR SA The circuit is composed of air filter in take manifold throttle body The throttle position potentiometer is splined onto the throttle shaft span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times N...

Page 168: ...ction ducts to the outside Disconnect the breather pipe located in the front part of the filter box Unscrew the frame fixing screw 1 Unscrew the two screws 2 and re move the U bolt Remove the air filter box See also Seat Fuel tank Rear mudguard CALIFORNIA EV 1997 2000 Removal Remove the front saddle Disconnect the electrical connections 1 between the main cable assembly and rear light wiring harne...

Page 169: ...e nuts 2 fixing the mud guard to the frame Remove the panels 3 and the pack holder 4 Remove the rear saddle 5 Remove the mudguard with light fitted sliding it off afterwards California EV V1100 Bodywork BODYW 169 ...

Page 170: ...remove the fixing screw Remove the washer Lift the rear part of the tank and push it to the side by sliding it backwards Disconnect the breather pipe 1 Disconnect the quick coupling 2 of the fuel pipe CAUTION span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi lan guage AR SA PLACE A CLOTH UNDER THE QUI...

Page 171: ...ipe 4 of the petrol vapour recirculation system Remove the tank by placing it on a clean surface with the pump unit facing upwards Front mudguard Removal Remove the brake pipe from the guides 1 Unscrew the 4 screws 2 securing the anti torsion plate unit and mudguard to the fork Remove the mudguard California EV V1100 Bodywork BODYW 171 ...

Page 172: ... 88 90 91 104 Clutch 56 57 68 69 71 72 75 76 164 Crankcase 15 98 Crankshaft 15 98 99 102 Cylinder 13 80 82 84 86 90 96 99 164 E Electrical system 12 38 Engine oil 28 F Fork 115 118 121 Forks 58 Front wheel 115 131 Fuel 32 107 109 168 170 Fuel pump 107 Fuses 42 G Gearbox oil 31 H Head cover 80 83 I Identification 10 M Maintenance 8 25 Mirrors 167 Mudguard 168 171 ...

Page 173: ... 56 R Rear wheel 134 Recommended products 16 32 S Secondary shaft 55 57 Shock absorbers 129 Spark plug 26 Start up 42 Starter motor 70 71 Steering damper 127 T Tank 108 168 170 Throttle body 110 Transmission 11 27 V Voltage regulator 41 W Wiring diagram 38 ...

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