California EV V1100 SERVICE STATION MANUAL

SERVICE STATION MANUAL ?????

California EV V1100

While the basic features as described and illustrated in this manual remain unchanged, Moto Guzzi s.p.a. reserves the right to introduce changes 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. SERVICE STATION MANUAL California EV V1100

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry 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 to the vehicle and sometimes even the invalidity of the guarantee

INDEX OF TOPICS

CHARACTERISTICS 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 INDEX OF TOPICS

CHARACTERISTICS CHAR California EV V1100 Characteristics

Rules

Safety rules

Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system. CAUTION

EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH. Fuel CAUTION

THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VA- POURS, AVOIDING ANY CONTACT 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 system have cooled down.

Used engine oil and transmission oil CAUTION

IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE- HICLE. THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS. WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL. HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN

CHAR - 7 Characteristics California EV V1100

Brake and clutch fluid

BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM- PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE. KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID, IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS IN CONTACT WITH YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY. 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

GENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle follow the recommendations reported below carefully.

BEFORE REMOVING COMPONENTS

• Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle. Use the special tools designed for this bike, as required.

COMPONENTS REMOVAL

• Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific wrench. • Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and identify them with different distinctive symbols. • Each component needs to be clearly marked to enable identification during reassembly. • Clean and wash the dismantled components carefully using a low-flammability detergent. • Keep mated parts together since they have "adjusted" to each other due to normal wear.

CHAR - 8 California EV V1100 Characteristics

• Some components must be used together or replaced altogether. • Keep away from heat sources.

REASSEMBLY OF COMPONENTS CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH- ERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them. • When tightening nuts and screws, start from the ones with the largest section or from the internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap- plying the tightening torque. • Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins and screws with new ones if their tread is damaged. • When assembling the bearings, make sure to lubricate them well. • Check that each component is assembled correctly. • After a repair or routine maintenance procedure, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic density. • Clean all coupling surfaces, oil guard rims and gaskets before 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 any.

• Grip the two connectors and disconnect them by pulling them in opposite directions. • If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully with a jet of compressed air. • Ensure that the cables are correctly fastened to the internal connector terminals. • Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you will hear them "click" into place). CAUTION TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES. NOTE THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY ROUND. TIGHTENING TORQUES CAUTION DO NOT FORGET THAT THE TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL BOLTS AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.

CHAR - 9 Characteristics California EV V1100

CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL- WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COM- PLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.

Running-in

Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed during the run- in. This ensures that components operate under both "loaded" and "unloaded" conditions, allowing the engine components to cool. CAUTION THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH PLATES GET ADAPTED. IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN-IN, HOWEVER, MAKE SURE NOT TO OVERDO THIS. CAUTION THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT THE END OF THE RUNNING IN PERIOD. 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 adjustment of the pad friction material to the brake discs.

AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE. • Between 1000 km (625 miles) and 2000 km (1250 miles) travelled, ride more vigourously, vary speeds and twist throttle fully for some short periods for best coupling of the components; do not exceed 6000 rpm. • After 2000 km (1250 miles) a better engine performance may be expected, but without ex- ceeding the engine maximum rpm allowed (7600 rpm).

Vehicle identification

SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. NOTE

CHAR - 10 California EV V1100 Characteristics

ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE FRAME NUMBER IMMEDIATELY VOIDS THE WARRANTY. This number consists of numbers and letters, as in the example shown below. ZGUKDBKDXMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; KD: model; B: version variation; KD: Version; X: variable year of manufacture (Y - for 2000; 1 - for 2001) M: production plant (M= Mandello del Lario); XXXXXX: 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 clearance 165 mm (6.5 in) Wheelbase 1560 mm (61.4 in) Kerb weight 251 kg (553 lb)

Transmission

TRANSMISSION Specification Desc./Quantity Primary drive with coil gears, ratio: 17/21 = 1:1.2353

CHAR - 11 Characteristics California EV V1100

Specification Desc./Quantity Gearbox 5 speed mechanical gearbox with gears always engaged to the front joint. Built-in flexible couplings. Foot gear shift lever on left hand side of engine Gear ratio 1st gear : 14/28 = 1:2.0000 2nd gear : 18/25 = 1:1.3889 3rd gear : 21/22 = 1:1.0476 4th gear : 23/20 = 1:0.8696 5th gear : 28/21 = 1:0.7500 Final drive with U-joint Ratio 8/33 = 1:4.125

Capacities

CAPACITY Specification Desc./Quantity Fuel tank Approximately 19 litres (4 litres reserve) Motor oil sump 3000 cm³ (183 cu.in) Gearbox oil 0.75 litres Gear case (bevel gear lubrication) 0.25 litres Adjustable telescopic fork oil (per fork leg) 0.485 l (0.128 US gal)

Electrical system

ELECTRICAL SYSTEM Specification Desc./Quantity Spark plug NGK BPR6ES Electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in) Ignition coils 2 mounted on chassis Generator - Alternator Output power: 350 W at 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.

Brakes

BRAKES Specification Desc./Quantity Right front brake Ø 320-mm (12.6 in) stainless steel semi-floating disc, calliper with 4 different pins Hand lever control placed on the right side of the handlebar. Hydraulic transmission separate from the rear brake. Braking cylinder diameter: 30 - 34 mm (1.18 - 1.34 in) Pump diameter: 13 mm (0.51 in) Left front brake Ø 320-mm (12.6 in) stainless steel semi-floating disc, calliper with 4 different pins Foot gear shift lever placed on the right side of the vehicle. Hydraulic transmission connected to the rear brake. Braking cylinder diameter: 30 - 34 mm (1.18 - 1.34 in)

CHAR - 12 California EV V1100 Characteristics

Specification Desc./Quantity Pump diameter: 13 mm (0.51 in) Rear brake Integral braking system with braking corrector and delay valve Ø 282-mm (11.1 in) stainless steel fixed disc, floating calliper with 2 pins. Foot gear shift lever placed on the right side of the vehicle. Hydraulic transmission connected to the left front brake. Braking cylinder diameter: 30 - 32 mm (1.18 - 1.26 in) Pump diameter: 16 mm (0.63 in)

Tightening Torques

TIGHTENING TORQUES Name Torque in Nm Screws and stud bolts fixing head to crankcase 40 -42 Nm Spark plugs 25 - 30 Nm Hollow screw fixing the oil vapour recovery pipe 38 - 40 Nm Screw fixing the rocker pins 6 - 8 Nm Self-locking nuts for screws fixing the rod bearing caps 46 - 48 Nm Flywheel to crankshaft fixing screw 25 - 30 Nm Gear to camshaft fixing nut 140 - 150 Nm Intake pipe fixing screws 5 - 8 Nm Hollow screw fixing pipes that deliver oil to the heads 15 - 18 Nm Nut for front and rear engine tie rod to chassis 75 - 80 Nm Secondary shaft locking nut 55 - 60 Nm Oil introduction cap in the gearbox 25 - 30 Nm Oil level and drainage cap in the gearbox 22 - 25 Nm Safety nut 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 Steering lock bushing 170 - 180 Nm Screws and nuts diam. 4 mm (0.16 in) (standard value) 3 - 3.5 Nm Screws and nuts diam. 5x0.8 mm (0.20x0.03 in) (standard val- 6 - 7 Nm ue) Screws and nuts diam. 6x1.0 mm (0.24x0.039 in) (standard 8 - 12 Nm value) Screws and nuts diam. 8x1.25 mm (0.31x0.049 in) (standard 25 - 30 Nm value) Screws and nuts diam. 10x1.5 mm (0.39x0.059 in) (standard 45 - 50 Nm value)

Overhaul data

Assembly clearances

Cylinder - piston assy.

Measurement of the cylinder diameter must be done at three heights, turning the dial gauge 90°. Check that cylinders and pistons are of the same selection types (A,B,C - D,E,F). Check clearance between cylinders and pistons on the selected diameter; if it exceeds the value specified, it is necessary to replace cylinders and pistons. The pistons of an engine must be balanced; a weight difference of up to 1.5 (0.0033 lb) is admitted.

CHAR - 13 Characteristics California EV V1100

SELECTED DIAMETER CYLINDERS UP TO ENGINE NO.KD030428 Specification Desc./Quantity Selection class A 92.000 - 92.006 mm (3.62204 - 3.62227 in) Selection class B 92.006 - 92.012 mm (3.62227 - 3.62250 in) Selection class C 92.012 - 92.018 mm (3.62250 - 3.62275 in)

SELECTED DIAMETER PISTONS UP TO ENGINE NO.KD030428 Specification Desc./Quantity Selection class A 91.966 - 91.972 mm (3.62069 - 3.62093 in) Selection class B 91.972 - 91.978 mm (3.62093 - 3.62117 in) Selection class C 91.978 - 91.984 mm (3.62117 - 3.62141 in)

SELECTED DIAMETER CYLINDERS FROM ENGINE NO.KD030429 Specification 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 - 91.983 mm (3.62097 - 3.62137 in)

PIN-PISTONS COUPLING DATA Specification Desc./Quantity Pin diameter 1 21.994 mm (0.8659 in) Piston holes 1 22.006 mm (0.8664 in) Pin diameter 2 21.998 mm (0.8661 in) Piston holes 2 22.011 mm (0.8666 in) Clearance between pin and holes on piston 0.008 - 0.017 mm (0.000315 - 0.000669 in)

CHAR - 14 California EV V1100 Characteristics

Piston rings

Check the sealing piston rings and the oil scraper. On each piston there are: 1 top piston ring; 1 middle stepped piston ring; 1 oil scraper piston ring. The ends of the fitted piston rings are out of phase. Fitting backlash detected between the ring thickness and seats on the piston: Sealing rings and oil scraper 0.030 - 0.065 mm (0.00118 - 0.00256 in) Gap between the end of the piston rings inserted in the cylinder: Upper sealing ring and stepped ring 0.40 - 0.65 mm (0.00158 - 0.00255 in) Oil scraper ring 0.30 - 0.60 mm (0.00118 - 0.00236 in). Turn the rings so that the coupling ends are 120 degrees from each other.

Crankcase - crankshaft - connecting rod

CAMSHAFT (CAM) 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 (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 32.025 - 32.050 mm (1.26082 - 1.26181 inch) fitting clearance 0.025 - 0.066 mm (0.00098 - 0.00260 inch)

TAPPET-SEAT COUPLING ON CRANKCASE DATA (PRODUCTION) Specification Desc./Quantity Seats diameter 22.021 - 22.000 mm (0.86697 - 0.86614 inch) Tappet external diameter 21.996 - 21.978 mm (0.86598 - 0.86527 inch) Fitting clearances 0.004 - 0.043 mm (0.00016 - 0.00169 in.)

TAPPET-SEAT COUPLING ON CRANKCASE DATA (GREATER ON Ø 0.05 MM) (0.00197 IN) Specification Desc./Quantity Seats diameter 22.071 - 22.050 mm (0.86893 - 0.86811 inch)

CHAR - 15 Characteristics California EV V1100

Specification Desc./Quantity Tappet external diameter 22.046 - 22.028 mm (0.86795 - 0.86724 inch) Fitting clearances 0.004 - 0.043 mm (0.00016 - 0.00169 in.)

TAPPET-SEAT COUPLING ON CRANKCASE DATA (GREATER ON Ø 0.10 MM) (0.0039 IN) Specification Desc./Quantity Seats diameter 22.121 - 22.100 mm (0.87090 - 0.87008 inch) Tappet external diameter 22.096 - 22.078 mm (0.86992 - 0.86921 inch) Fitting clearances 0.004 - 0.043 mm (0.00016 - 0.00169 in.)

See also Removing

Removing the oil sump

NOTE TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO 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.

ENG - 105 INDEX OF TOPICS

POWER SUPPLY P SUPP California EV V1100 Power supply

Circuit diagram

The fuel is injected in the intake duct of each cylinder, upstream of the intake valve. Including: tank, pump, filter, pressure adjuster, electro-injectors. The electric pump (1) sucks 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

P SUPP - 107 Power supply California EV V1100

Removing

The electrical fuel pump unit consists of following: - electrical pump (1); - fuel filter (2); - pressure adjuster (3); - collapse protection pre-filter (4); - fuel level control sensor (5). It is recommended to properly clean the system when disassembling and fitting the piping and the components.

• Set to the ignition switch to OFF. • Remove the front saddle. • Remove the tank. • Undo and remove the fixing screws of the fuel pump flange. • Slide off and remove the electrical fuel pump unit.

WHEN REMOVING THE PUMP UNIT MAKE SURE NOT TO DAMAGE THE PIPES AND THE FUEL LEVEL SENSOR.. See also

Fuel tank

Checking

If the collapse protection pre-filter shows traces of sediment, clean it with a jet of compressed air, directing it so that impurities do not enter in its inside.

See also Removing

P SUPP - 108 California EV V1100 Power supply

Fuel filter

• Remove the front saddle. • Disconnect the battery. • Remove the electrical fuel pump. • Remove the clamps and the fuel filter.

See also Removing

Injection

Removing the injector

With the injector is activated the control of the quantity of fuel introduced into the engine. It is a "all or nothing" device in the sense that it can only remain two stable states: open or closed. The injector consists of a body and a pin integral with the magnetic stirring rod. The pin 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 injector. This time is determined by the control unit depend- ing on the conditions of use of the engine, the fuel metering is realized in this way. Finally, from the hydraulic point of view, compression of the fuel of 3 +/- 0.2 bar, the jet shatters

P SUPP - 109 Power supply California EV V1100

coming out from the nozzle (atomization), forming a cone of about 30°. Resistance value: 12 ohm. If you want to perform an electrical test in the injector, apply a maximum voltage of 6V, for very limited periods. Removal:

• Remove the throttle body. • Undo the two retainer screws and remove the electro-injector unit.

Removing the throttle body

The amount of intake air is determined by the opening of the throttle valve located at the beginning of the intake manifold of each cylinder. The air required for the operation at idle speed passes through a by-pass channel, equipped with a adjuster screw: turning this screw, the amount of air varies, which is introduced in the manifold and consequently also 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 control; - The fuel intake and return pipes;

• Loosen the clamps securing the engine and remove the throttle body from the engine.

CLOG THE DUCTS OF THE INTAKE MANIFOLD TO PREVENT FOREIGN BODIES TO ENTER THE COM- BUSTION CHAMBER.

Co rate adjustment

• Remove the saddle. • Remove the left fairing.

P SUPP - 110 California EV V1100 Power supply

• Connect a vacuum gauge to the sockets on the intake manifolds. • Connect the diagnostic tool AXONE, using the specific cable to the diagnostic socket, and to the battery of the motorcycle (not an external battery). • Always connect first the positive terminal and then the negative one. • Turn on the AXONE device by pressing the button 'ON / OFF' • With the side arrows go to the menu "self diagnosis". CAUTION 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 motorcycle 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 throttle valve potentiometer parameter. • Remove the dipstick (1) of the left side throttle body by loosening the lock ring (2). • On the left throttle body, using the throttle adjustment dowel (3), adjust the throttle potentiometer to 3.6° (+/- 0.1°) readable on AXONE.

USE A WRENCH TO ACT ON THE ADJUST- MENT DOWEL (3).

P SUPP - 111 Power supply California EV V1100

• Connect the dipstick (1) of the left side throttle body. • Start the engine and bring the temperature to 50°C (122 ° F) (readable on AXONE) after selecting the engine temperature parameter. • Fully close the by-pass (4) on both sides • Disconnect the dipstick (1) of the left side throttle body;

• Level the depression in the right cylinder with the throttle adjustment dowel (5). • Connect the dipstick (1) of the left side throttle body.

• Check out of the idle (2000/3000 RPM approximately) the balance of the depression 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 selecting 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 check the idle speed. • Turn off and disconnect AXONE. CAUTION

P SUPP - 112 California EV V1100 Power supply

IT CAN HAPPEN THAT AXONE BLOCKS DURING OPERA- TION. IN THIS CASE, PUT THE IGNITION KEY TO 'OFF', TURN OFF AXONE, PRESS 'ON / OFF', DISCONNECT THE UPPER CONNECTOR AND WAIT A FEW SECONDS BEFORE CON- NECTING THE CONTROL UNIT AGAIN. If after this procedure the minimum shall not be included within the indicated range, proceed with 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 indicated above, loosen the two screws fixing the potentiometer and replace it correctly.

P SUPP - 113 INDEX OF TOPICS

SUSPENSIONS SUSP California EV V1100 Suspensions

Front

Removing the front wheel

• Place a support under the motorcycle, which allows to lift the front wheel off the ground. • Remove the brake callipers. • Loosen the two screws fixing the pin to the fork legs. • Remove the pin, the spacers and remove the wheel.

Installing the front wheel

• Insert the complete wheel between the fork legs. • Lubricate the 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 actuate the brake lever to bring the clamps pistons back in the normal position.

Front fork

Diagram

SUSP - 115 Suspensions California EV V1100

key: 1 Screw 2 Handlebar fixing U-bolt 3 Screw 4 Under U-bolt 5 Cap 6 Rubber ring 7 Fork head 8 Ring nut 9 Spacing pipe 10 Nut 11 Fork base 12 Screw 13 RH adjustment knob (ext.) 14 Screw with O-Ring 15 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

SUSP - 116 California EV V1100 Suspensions

38 Upper bushing 39 Complete right fork leg 40 Long screw 41 Washer 42 Screw 43 Complete left fork leg 44 LH adjustment knob (compression) 45 LH pipe (compression) 46 LH rod (compression) 47 Cap 48 Calibration blade diam 12 mm (0.47 in) 48 Calibration blade diam 15 mm (0.59 in) 48 Calibration blade diam 17 mm (0.67 in) 49 LH pin (compression) 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 hydraulic telescopic fork with separate adjustment 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 adjustment of the hydraulic rebound damping. • The right knob (2) is the one in compression.

SUSP - 117 Suspensions California EV V1100

• Both adjustment knobs have 15 adjustment positions (notches); • Turning clockwise (+) increases the rebound, vice versa, anticlockwise (-) it decreases. NOTE DO NOT FORCE THE ADJUSTER SCREW IN THE END OF STROKE POSITION

Removing the fork legs

The vehicles are equipped with a hydraulic telescopic fork with separate adjustment for rebound and compression damping: In the case of adjustable fork, the left stanchion works in extension while the right one in compression. Although the two stanchions work in a different way, their internal components are similar and thus the removal, overhaul and refitting are performed 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 mudguard. • Remove the front wheel. • Remove the chrome caps on the screws (1) and (2). • Undo the upper sealing screw (1). • Undo the two lower sealing screws (2). • Slide off the stem downwards by turning it slightly first in one direction then to the opposite direction.

SUSP - 118 California EV V1100 Suspensions

Draining oil

The vehicle is equipped with a hydraulic telescopic fork with separate adjustment for rebound and compression damping: The left stem works in extension while the right one in compression. Although the two stanchions work in a different way, their internal components are similar and thus the discharge and refilling of the oil are performed following the same operations; therefore, the operations described below are valid for both stems. CAUTION 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; ALWAYS USE ALUMINIUM JAW CAPS. Outlet:

• Remove the stanchion. • Tighten the removed stanchion in a vice fitted with aluminium jaw caps in order to avoid damaging them. • Use an Allen key to unscrew the upper closing cap. Be careful not to damage the O-Ring during extraction. Press the bearing tube inside the wheel holder. • Holding the upper cap with the key used previously, lock the lock nut, using an Allen key. Completely unscrew and remove the upper cap from the shock absorber rod end.

SUSP - 119 Suspensions California EV V1100

• Empty the most possible the stanchion from the oil in its inside in a specific container. • Tighten the stanchion in vice and keep the tube in preload, not completely unscrew the lock nut to release the inner spring.

• Remove the open washer to release the preloading tube and the spring.

• Remove the preload tube and the spring.

• 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.

SUSP - 120 California EV V1100 Suspensions

guage: AR-SA">BY PUMPING THE SHOCK ABSORBER WITH THE ROD, FROM THE END OF THE ROD, A JET OF COMPRESSED OIL ESCAPES, SO TO PREVENT DAMAGE TO PERSONS OR OBJECTS DIRECT THE END OF THE ROD TOWARDS A SPECIFIC CONTAINER. • Carefully check each part of the stanchion and make sure that there are no damaged elements. • 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 RIM AND THE DUST SCRAPER.

SUSP - 121 Suspensions California EV V1100

• Remove the locking ring inside the sleeve using a thin screwdriver. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM.

• Remove the stem from the wheel holder sleeve together with the seal ring (1), the cap (2), the upper bushing on the fork leg (3), the lower bushing (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 from its inside.

SUSP - 122 California EV V1100 Suspensions

• Push the foot valve with the finger inside the shock absorber casing.

• With a screwdriver, remove the snap ring.

• Push the foot valve with the shock absorber rod out of the casing.

• Check the foot valve and its O-ring, replace if damaged.

SUSP - 123 Suspensions California EV V1100

• Remove the shock absorber rod with the pumping member unit from the casing after having completely unscrewed the lock nut at its end. • Unscrew the nut (6) securing the calibration unit and remove all components. Carry out the necessary checks and/or replacement, proceed with the refitting in the following order:

- cap (7); - blades pack (8); - pin (9); - piston (10); - Retainer nut (6).

WHILE REMOVING THE GASKET UNIT, TAKE NOTE OF THE POSITION OF THE BLADES (8)

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 the "COMPRESSION" shock absorber with the only difference in the components of the pumping member unit fixed on the shock absorber rod, which are: - pos. 11, counter spring; - pos. 12, piston; - pos. 13, ring for piston; - pos. 14 RH pin - pos. 15, calibration blades; - pos. 16, retainer nut.

See also Removing

CHAS - 139 Chassis California EV V1100

Checking

Check that the swingarm does not show bending or unsoldered parts, that the seats of the bearings are in good condition and that the junction surface of the right arm to the box does not have deep scratches. Check the wear of the bearings on the swingarm pivot axis on the frame and the bearing on the right arm. To remove the bearing for the universal joint use a special extractor. To remove the swingarm pin bearings use a special extractor. NOTE ONCE A BEARING IS REMOVED FROM ITS SEAT IT CAN NOT BE USED AGAIN.

Cardan shaft

Removing

• Remove the swingarm. • Remove the cardan shaft.

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 gasket (OR) (3).

CHAS - 141 Chassis California EV V1100

• Undo the eight seal screws and remove the flange complete with crown unit.

• With an extractor remove the outer track of the roller cage from the box.

Specific tooling

12.90.69.00 Extractor for roller bearing ring from the gear case

• Unscrew the eight screws (4) and remove 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 roller bearing on the drilled pin on the box

CHAS - 142 California EV V1100 Chassis

• Using the special tool to lock the pinion shaft, loosen the seal nut.

Specific tooling

12.90.71.00 Tool to lock the secondary shaft

• Detach the pinion (7), the shimming washer (8), the outer tapered roller cage (9), the adjustment washers (10), the pinion side roller cage (11) and the spacer (12) from the casing (6). • Remove the outer track of the tapered roller bearing cages (9) and (11) from the casing (7) using the appropriate extractor.

Specific tooling

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

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 transmission box Check that:

• There are no cracks at any point; • The coupling surface is not scratched or damaged; • The bearing housing and the seal ring are not scratched or damaged; • The seal ring is not damaged, not disengaged or has lost elasticity.

Transmission box flange adjusting shims

CHAS - 143 Chassis California EV V1100

The shims are provided in six different sizes, namely: mm 0.8 - 0.9 - 1 - 1.1 - 1.2 - 1.3 (in 0.0315 - 0.0354 - 0.039 - 0.043 - 0.047 - 0.051). Check that the coupling surfaces are not scored or damaged.

Bevel gear The bevel gear consists of a pinion and a "Gleason" crown gear, the teeth shall not show evidence of shelling or excessive wear. The pinion stem shall be free of dents and the splines at the end should be smooth and free of dents.

Cage seal ring The surfaces shall not be damaged, dented or worn, otherwise replace them.

Spacer for rear wheel axle Check the support surfaces, they shall not be damaged.

Bearings casing Check that:

• The coupling surfaces 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 gear pinion lock nut on the bearings holder casing Since during the fitting the shank is pushed into a groove of the pinion stem, it is always recommended to replace the nut during refitting.

Sleeve for transmission shaft and bevel pinion The inner splines must be intact; free from grain or dents, otherwise replace it.

Pinion - crown selection The pinion and the crown should show the same number

CHAS - 144 California EV V1100 Chassis

Installing

Outer track of tapered bearings on the casing To fit the outer tracks of the tapered bearings on the casing use a special punch.

Specific tooling

17.94.51.60 Punch to press the outer track of the bearings on the box

Casing in its entirety For the above fitting, operate in reverse order as for the disassembly, checking that no piece was changed, that the number of shim rings between the spacer and bearing and between the bearing and bevel pinion is identical. If any replacement was made, it requires a new shimming. The locking 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 the drilled pin To press the inner track of the roller bearing on the drilled pin.

Specific tooling

17.94.84.60 Tool to press the inner track of the roller bearing on the drilled pin on the gear case

CHAS - 145 Chassis California EV V1100

Fitting of the outer track of the roller bearing on the box To press the outer track of the roller bearing on the box.

Specific tooling

17.94.88.60 Punch for outer track of bearing re- lated to the transmission box seal ring

Box casing During fitting of the casing on the transmission box, it should be noted that the lubrication holes of the box and on the casing indicated by the arrow are in line; remember to put between casing and box the seal ring (OR) (1).

Crown on the drilled pin Refit the crown on the drilled pin remembering that the eight screws should always be replaced; before 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 ring (3) and finally the other gasket (2) by observing that the holes are in line with those of the box. The cover is fitted on the box, checking that the word "Down" is facing toward the ground; also observe that the arrow "X" printed on the cover (4) is in line with the arrow "Y" stamped on the box (5),

CHAS - 146 California EV V1100 Chassis

then tighten the screws (6) to the bottom.

Crown - pinion coupling To check the coupling of the pinion and the crown spread the teeth of the pinion from the drive side, with red lead based grease. Using an arm extractor and a spacer (7) keep the hub-crown unit slightly forced into the cover; turn the pinion (8) by hand in the direction of travel, keeping the crown dam- ped with the tool. Remove the 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 the contact is like this, the pinion is too near the rotation axis of the crown: detach the pinion by reducing spacer thickness between bearing and pinion.

CHAS - 147 Chassis California EV V1100

• If the contact is like this, the pinion is too far away from the rotation axis of the crown: approach the pinion by increasing the spacer thickness between bearing and pinion.

• If the contact is like this, the crown is too far from the pinion rotation axis: approach 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)

CHAS - 148 California EV V1100 Chassis

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

CHAS - 149 INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS California EV V1100 Braking system

Rear brake calliper

Removal

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Front brake calliper

Removal

• Completely drain off the hydraulic system. • Unscrew the hollow screw and remove the tube and the two gaskets from the calliper. • Undo the two screws fixing the supports and remove the calliper. CAUTION REMOVING THE LEFT FRONT BRAKE CALLIPER IS DE- SCRIBED TOGETHER WITH THE REMOVAL OF THE REAR BRAKE CALLIPER.

BRAK SYS - 152 California EV V1100 Braking system

Rear brake disc

Disc Inspection

The brake disc must be perfectly clean, without rust, oil, grease or scales and shall not show deep scratches. If the disk has one of these anomalies, perform a thorough cleaning, if the defect still remains, the disc must be replaced. Rear disc thickness: 5.1 mm (0.2 in). Rear disc thickness at the wear limit: 4.9 mm (0.19 in). If the disc is not within the above shown measurements it must be replaced.

Front brake disc

Disc Inspection

The brake discs 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 discs are composed of a part integral with the wheel rim and a floating brake clamp. If the disc must be replaced, it is necessary to replace both components.

Front brake pads

Removal

• Turn the pins and remove both cotter pins.

BRAK SYS - 153 Braking system California EV V1100

• Remove both pins.

• Remove the vibration-damping plate.

• Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT 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.

BRAK SYS - 154 California EV V1100 Braking system

• Remove the pin.

• Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR 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.

BRAK SYS - 155 Braking system California EV V1100

Installing

• 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 INSIDE THE CALLIPER.

• Insert the pin. • Position the cotter pin. • Check the brake fluid level in the reservoir.

Bleeding the braking system

BRAK SYS - 156 California EV V1100 Braking system

Front

CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO ITS REGULAR USE CON- DITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED. NOTE THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED.WHILE PURGING THE HYDRAUL- IC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESER- VOIR. • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a container 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 container. This will release the tension on the brake lever and will make it reach the end of stroke. • Close the bleed valve before the lever reaches its end of stroke. • Repeat the operation until the fluid draining into the container is air-bubble free. NOTE WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. • Screw the bleeding valve and remove the pipe. • Top-up the reservoir until the correct brake fluid level is obtained.

BRAK SYS - 157 Braking system California EV V1100

• Refit and block the front brake oil reservoir cap. • Refit the rubber protection cover.

Integrated

Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. The presence of air is signalled by the "spongi- ness" of the brake control and poor braking effi- ciency. CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGU- LAR USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURGING THE 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 reservoir cap. • Press the rear brake pedal to the bottom, then release it and wait some seconds before performing the following pumping. • Loosen the bleed valve 1/4 of a turn so that the brake fluid flows into the container. This will release the tension on the rear brake pedal and will make it reach the end of stroke. • Close the bleed valve before the rear brake pedal reaches its end of stroke.

BRAK SYS - 158 California EV V1100 Braking system

• Repeat the operation until the fluid draining into the container is air-bubble free. NOTE WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. • Screw the bleeding valve and remove the pipe. • Top-up the reservoir until the correct 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 system • 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 to the handlebar with the U- bolt (E) • Remove the pump complete with the tank and lever

Rear brake pump

BRAK SYS - 159 Braking system California EV V1100

Rimozione

REAR BRAKE LEVER REMOVAL

• Undo the 2 screws (A) and remove the cradle cover (B)

• Remove the cotter pin (C) and slide off the pin (D) • Undo the screw (E) and remove the brake lever (F)

Rear brake pump - combined

Removal

It is a mechanical device connected to the rear swingarm by a spring; based on its position (thus as a result of the weighing load on the rear axle load), the valve in the distribution mechanism distributes the brake oil pressure of the integral 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 THE SYSTEM OPERATES IN ACCORDANCE WITH THE CALIBRATION OF THE REAR SHOCK AB- SORBERS, REPLACING THEM WITH OTHERS OF DIFFERENT TECHNICAL CHARACTERISTICS COMPROMISES THE SYSTEM OPERATION.

BRAK SYS - 160 California EV V1100 Braking system

Removal:

• Completely drain off the hydraulic system. • Remove the brake pipe (1). • Release the spring (2). • Undo the screw (3). • Remove the braking corrector (4).

Refitting:

• Perform the removal operations in reverse order. • Fill the braking system with recommended fluid. • Perform some pumping operations with the lever so that the pads are setting up. • Adjust the system as follows:

BRAK SYS - 161 Braking system California EV V1100

SYSTEM ADJUSTMENT After the fitting of the spring code 03.66.88.01 to the braking corrector code 03.66.82.00 and on the swingarm, make sure the distance between the two couplings is 67 +/- 0.5 (2.64 +/- 0.02 in). The adjustment is made by adjusting the part code 03.66.73.00. NOTE WHEN THE SYSTEM IS ADJUSTED, THE MOTORCYCLE MUST BE PUT ON THE CENTRAL STAND OR WITHOUT ANY CHARGE ON THE REAR WHEEL.

BRAK SYS - 162 INDEX OF TOPICS

CLUTCH SYSTEM CLU SYS Clutch system California EV V1100

Removing the clutch master cylinder

• Unscrew the 2 screws (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 disconnect the STARTER (B) transmission and clutch (C) from the corresponding levers

CLU SYS - 164 INDEX OF TOPICS

BODYWORK BODYW Bodywork California EV V1100

Seat

RIDER SADDLE Removal:

• Unlock the saddle with the key (1)

• Slightly lift 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)

BODYW - 166 California EV V1100 Bodywork

Removal:

• Unscrew the 4 nuts that secure it to the inside of the rear mudguard

Driving mirrors

Removal:

• Unscrew the upper nut (1), integral with the mirror, while holding the lower one (2) using the two keys as in the figure; • Remove mirror by unscrewing it.

Side body panels

Removal:

• Unscrew the 2 screws (1) fixing it to the frame • Remove the fairing (2) from the motorcycle

Air box

The circuit is composed of: air filter, intake manifold, throttle body. The throttle position potentiometer is splined onto the throttle shaft. The absolute pressure sensor (integral to

BODYW - 167 Bodywork California EV V1100

the ECU) and the air temperature sensor are positioned upstream of the throttle valve.

• Remove the front saddle. • Remove the fuel tank. • Remove the side fairings. • Loosen the clamps that secure the filter box to the throttle body and move the connection 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 remove the U-bolt. • Remove the air filter box.