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MOTO GUZZI
Motorcycle
California Special
MOTO GUZZI California Special User Manual
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Table of Contents
English
4
Table of Contents
4
California EV (1997 - 2000)
11
California EV 2001
11
California Jackal
12
California Stone
12
California Special
13
California Special Sport
13
Eneral Nformation
14
Abbreviations and Symbols
15
How to Consult this Manual
15
General Safety Regulations
17
Rules for Maintenance Procedures
17
Warranty
19
Identification Data
22
Lubricants and Refilling
24
Technical Specifications
26
Tightening Torques
38
Tools
41
Preliminary Tests
46
Engine Ignition
48
Engine Warming-Up
48
Engine Running
48
Stopping the Engine
50
Parking
50
Adjustments and Regulations
52
Sport
52
Clutch and Front Brake Control
224
Gearbox Control
226
Rear Brake Control
230
Steering
237
Handlebar
239
Foot Rests
241
Side Stand
243
Chassis Dimensions
245
Front Bumper
247
Chassis Dimensions
249
System Components
255
Tank "5
257
10 Battery "1
273
11 Starter Switch "2
273
12 Relay "3
275
14 Air Temperature Sensor "5
279
15 Oil Sensor Temperature "6
279
16 R.p.M. and T.D.C. Sensor "7
281
17 Coils "8
283
18 Throttle Position Potentiometer "9
285
19 Operating Stages
287
20 Diagnostics
291
Fuel Vapour Purification and Recirculation System (Usa, Sgp, Can)
307
System Features
310
Silencers
310
Exhaust Pipes
312
Expansion Chamber
314
General Rules for Engine Overhaul
317
Lubrication System
323
Heads and Timing System
333
Cylinders and Pistons
357
Clutch
361
Dutch
14
Lgemene Inlichtingen
14
Hoe Moet Deze Handleiding Geraadpleegd Worden
16
Afkortingen en Symbolen
16
Algemene Veiligheidsregels
18
Regels Voor de Onderhoudsoperaties
18
Garantie
20
Model Features
21
Arakteristieken
21
Gegevens Voor de Identificatie
23
Smeerproducten en Tanken
25
Technische Gegeven
27
Start-Up
28
Transmissions
28
Clutch
28
Primary Transmission
28
Suspensions
30
Front
30
Rear
30
Wheels
30
Brakes
34
Standard Values
38
Draaikoppe
40
Uitrusting
41
Control and Use of the Morbike
45
Ontrole en
45
Ebruik Van de
45
Otorfiets
45
Before Start-Up Check that
46
Preliminaire Controles
47
Cool Engine
48
Start Van de Motor
49
Verwarming Van de Motor
49
Motor in Werking
49
Stilstand Van de Motor
51
Parkeren
51
Steering Shock Absorber
52
Clutch Lever and Front Brake Lever Adjustment
52
Rear and Front Left Brake Pedal Adjustment
52
Registraties en Regelingen
53
Front Fork Adjustment
54
Rear Shock Absorbers Adjustment
56
Maximum Allowed Load
56
Steering Adjustment
58
Preparation for Long Periods at Rest
60
Light Beam Adjustment
60
Voorbereiding Voor Een Lange Inactiviteit
61
Cleaning the Motorbike
62
Preparation for Washing
62
While Washing
62
After Washing
62
Ontrolle und
63
Ebrauch des
63
Otorrads
63
Schoonmaak Van de Motorfiets
63
Instructions on How to Clean the Windscreen
64
Scheduled Maintenance
66
Leding
123
Spiegel
125
Spiegeltjes
125
Vorderes und Hinteres Schutzblech
127
Voorste en Achterste Spatbord
127
Kleine
133
Laterale Flanken
133
Vordersitz
135
Voorste Zadel
135
Hintersitz
137
Achterste Frameschotten
139
Frameschotten Vooraan
141
Äderteile
142
Ielinstallaties
142
Vorderrad
144
Voorwiel
144
Hinterrad
154
Achterwiel
154
Überholung der Räder
162
Revisie Wielen
162
California Jackal - Stone
165
Hydraulische Linker Voorrem
166
Hydraulische Rechter Voorrem
168
California Ev - Special - Special Sport
173
Special Sport
173
Hydraulische Achterrem California
174
Jackal - Stone
175
Vordere Gabel
186
Voorste Gaffel
186
Hintere Schwinge
214
Achterste Vork
214
Achterste Schokbreker
218
11 Lenkungsstossdämpfer
220
12 Reifen
220
11 Schokbreker Van Sturing
220
12 Banden
220
German
66
Egelmässige Artung
66
Eriodiek Onderhoud
66
Tabel Periodiek Onderhoud
68
Maintenance Procedures
69
Engine Oil Replacement
69
Viscosity
69
Wartungsarbeiten
70
Onderhoudsoperaties
70
Oil Cartridge Filter Replacement
71
Washing the Oil Mesh Filter
73
Air Filter
75
Fuel Filter
77
Spark Plugs
79
Tappet Backlash
81
Gearbox Lubrication
83
Final Drive Lubrication
85
Steering Bearings
87
Front Fork Oil Replacement
89
Checking the Braking and Clutch System Fluid
97
Brake System Fluid Replacement
99
Draining the Braking System Fluid
107
Rear Braking System
109
Left-Hand Front Braking System
111
Left-Hand Front and Rear Braking System
113
Brake Pad Check/Replacement
115
Front Brake Caliper
115
Rear Brake Caliper
117
Wheel Spokes Tension Adjustment
119
Trimmings
123
Wing Mirrors
124
Front and Rear Mudguards
126
Side Panels
132
Front Seat
134
Rear Seat
136
Rear Chassis Protections
138
Front Chassis Protections
140
Wheel Parts
142
Front Wheel
143
Brake Disks Spacing Flanges
151
Rear Wheel
153
Rear Wheel Hub Removal – Rubber Cush Drive Damper Side
157
Rear Brake Disk Spacer Flange
159
Wheel Overhaul
161
Bearings
161
Wheel Spindle
161
Front Left-Hand Hydraulic Brake California Jackal - California Stone
165
Brake Calipers
165
Front Right-Hand Hydraulic Brake
167
Brake Disks
169
Rear and Front Left-Hand Hydraulic Brake
173
Rear Hydraulic Brake
175
Disk Brake Troubles
179
Brake-Power Limiter
183
Front Fork
185
Complete Fork Removal
191
Fork Leg Removal
193
General Rules for a Correct Overhaul
193
Troubles – Causes - Solutions
195
Disassembly/Overhaul
197
Overhaul of the Compression Shock Absorber
201
Overhaul of the "Rebound" Shock Absorber
205
Rear Swing Arm
213
Rear Shock Absorbers
217
Controls
223
Removal of Front Brake Lever with Master Cylinder
224
Removal of Front Clutch Lever
224
Disassembly of California Jackal - California Stone
228
Disassembly of California Special - California Special Sport
228
Accelerator / Starter Control
232
Accelerator Control
232
Maintenance of Accelerator Cables
232
Starter Circuit
234
Chassis
236
Disassembly of Front Footrests
241
Reassembly of Front Footrests
241
Disassembly of Rear Footrests Support
241
Fuel System
252
General Description of the Fuel System
253
Fuel Circuit
255
Electrical Fuel Pump “1”
259
Fuel Filter “2”
261
Electro-Injectors “3”
261
Pressure Adjuster “4”
263
Intake Air Circuit
265
Air Filter Box “1”
267
Throttle Body “2”
269
Electrical Circuit
271
Normal Mode
287
Start-Up Stage
287
Operation During the Acceleration Stage
289
Resetting the Ecu
291
Throttle Valve Potentiometer Circuit
293
Absolute Pressure Sensor Circuit
293
Oil Temperature Circuit Sensor
295
Air Temperature Sensor Circuit
295
Battery Voltage
295
Injector 1 and 2 Circuit
297
Circuit and Primary Winding of Coils
297
Fuel Pump Relay Circuit
299
Electronic Control Unit
299
Timing and Engine R.P.M. Sensor Circuit
299
Electronic Revolution Counter
301
Carburation
301
Carburation Procedure
303
Rules for Carburation, Regulation and Adjustment
305
CO% Check
305
Exhaust System
309
Installatie
309
Engine
316
Engine Unit Removal - Installation/Gearbox Removal from Chassis
317
Oil Sump
325
Oil Mesh Filter
325
Oil Cartridge Filter
325
Oil Pressure Transmitter
327
Engine Oil Pressure Regulator Valve
327
Oil Pump
329
Check for Oil Leakages from the Engine Crankcase
331
Head Disassembly
337
Check of Head Components
339
Heads
339
Valve Guides
339
Data Table for Valve and Guide Couplings
339
Valve Seats
341
Valve Spring Inspection
343
Outside Spring
343
Inside Spring
343
Spring Package Check
345
Rocker and Pin Check
347
Timing
349
Timing Data
349
Diameters for Camshaft Supports and Relative Seats on the Crankcase
353
Coupling Data for the Tappets and Relative Seats on the Crankcase
353
Check of the Timing System Setting
355
Reassembly of the Toothed Wheel and Measuring of the Air Gap
357
Check of Components
359
Grading Cylinder Diameter Since Engine N° Kd 030428
359
Grading Piston Diameter Since Engine N° Kd 030428
359
Grading Cylinder Diameter up to Engine N° Kd 030429
359
Coupling Data
361
Clutch Springs
367
Spring Pressure Plate
367
Driven Disks
367
Toothed Crown for Ignition
367
Intermediate Plate
369
Control Transmission
369
Clutch Adjustment Screw on Lever
369
Lever Return Spring on Gearbox
369
Alternator and Flywheel
373
Flywheel
375
Crank Shaft and Connecting Rods
377
Connecting Rods
381
Check the Axis Parallelism
381
Connecting Rod Bearing Thickness
383
Crankpin Diameter
383
Coupling Data between the Piston Pin and Bushing
383
Crankshaft
385
Main Bearing Journal Diameter, Flywheel Side
385
Main Bearing Journal Diameter, Timing System Side
385
Weight Control for Crankshaft Balancing
387
Gearbox
391
Main Features
392
Gearboxes Fitted with New 5-Clutch Dog Gears
392
Removal and Installation
396
Disassembly
400
Removal of the Internal Clutch Body
402
Removal of the Gearbox Cover
402
Removal of Shaft Assembly and Splined Drum
404
Disassembly of the Secondary Shaft
406
Disassembly of the Primary Shaft
408
Disassembly of Clutch Shaft
410
Bearing Removal
412
Gear Box Housing and Cover
412
Check and Overhaul
414
Gearbox Housing and Cover
414
Roller Ball Bearings
414
Secondary Shaft
414
Secondary Shaft Gears
416
Engaging Gear Sleeve Control Forks
416
Engaging Gear Splined Drum
416
Drum Holder Rods and Gearbox Control Forks
416
Clutch Fixed Body on the Clutch Shaft
418
Sleeve on the Clutch Shaft
418
Transmission Gear on the Clutch Shaft
418
Gearbox Control Range Selector
418
Gearbox Unit Reassembly on the Bench
420
Bearing Assembly on the Gearbox Housing and on the Cover
420
Bearing Pressing Within Their Seats on the Gearbox Housing
420
Bearing Pressing Within Their Seats on the Gearbox Housing Cover
420
Range Selector Assembly on the Gearbox Cover
422
Primary Shaft Reassembly on the Housing
422
Primary Shaft Shimming
422
Secondary Shaft Reassembly on the Housing
424
Secondary Shaft Shimming
426
Control Forks and Splined Drum Assembly on the Gearbox Housing
426
Clutch Shaft Reassembly on the Housing
428
Cover Assembly on the Gearbox Housing
430
Final Drive Housing and Shaft
438
Final Drive Housing
439
Antriebsgehäuse Hinten
440
Flange on the Final Drive Housing
443
Adjustment Shims of the Final Drive Housing Flange
443
Drilled Shaft with Internal Teeth as a Connection to the Rear Wheel
443
Bevel Gear
445
Bearing Case
445
Adjustment Washers between Spacer and Bearing
445
Lock Nut for Bevel Gear Pinion on the Bearing Case
445
Case Components
447
Housing Case
447
Crown on the Drilled Shaft
449
Cover on the Transmission Housing
449
Contact Impression Check
451
Pinion – Crown Coupling
451
Final Drive Shaft
453
Sleeve for Transmission Shaft and Bevel Sprocket “A”
453
Double U-Joint “D”
453
Antriebswelle
454
Electrical System
455
Electrical System Description
456
Headlight
456
Taillight
456
Beschreibung der Elektroanlage
457
Battery
474
Instructions to Operate Dry Batteries
474
Maintenance Instructions for Batteries Charged with Acid
474
Batterie
475
Battery Charge Instructions
476
Battery (Usa - Sgp – Can Version)
478
Batterie (Version Usa - Sgp - Can)
479
Cyclic Use
480
Buffer Use
480
Starter Motor
482
Anlassermotor
483
Light and Acoustic Systems / Dashboard / Controls
484
Lichtanlage und Hupe / Instrumententafel / Schaltungen
485
Taillight Assembly
486
Front Direction Indicators
490
Light-Bulb Replacement
490
Rear Direction Indicators
492
Acoustic System
494
Dashboard Warning Lights
494
Revolution Counter - Odometer
500
Side Stand Switch
504
Schalter Seitenständer
505
Fuse Terminal Board
506
Sicherungsklemmenbrett
507
Alternator - Regulator
508
Check the Winding Isolation Towards Earth
508
Check the Winding Continuity
508
Check the Voltage Output
508
Alternator - Regler
509
Regulator
510
Regulator Checks
510
5
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MOTO GUZZI California Special Specifications
General
Brand
MOTO GUZZI
Model
California Special
Category
Motorcycle
Language
English
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