MOTO GUZZI California 1400 Instructions Manual

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MMS California 1400 My12

B043157

California 1400

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Page 1 MMS California 1400 My12 B043157 California 1400...
Page 2 The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding it, its regular maintenance and the use of original Moto Guzzi spare parts only are essential factors! For information on the nearest Official Dealer and/or Service Centre consult our website: www.motoguzzi.com...
Page 3 MMS California 1400 My12 California 1400 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.
Page 4 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 6: Safety Rules
California 1400 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.
Page 7 California 1400 Characteristics THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING THE BRAKING SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKING SYSTEM. THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
Page 8 California 1400 Characteristics • Keep away from heat sources. REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Aprilia SPARE PARTS. • Comply with lubricant and consumables use guidelines.
Page 9: Vehicle Identification
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.
Page 10 California 1400 Characteristics This number consists of numbers and letters, as in the example shown below. ZGULVB0009MXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LV: model; B00: version variation; 0: free digit C: variable year of manufacture (C - for 2012) M: production plant (M= Mandello del Lario);...
Page 11 California 1400 Characteristics Engine ENGINE Specification Desc./Quantity Type traverse-mounted twin-cylinder four-stroke V 90° No. of cylinders Cylinder arrangement V 90° Bore / stroke 104 x 81.2 mm (4.09 x 3.20 in) Engine capacity 1379.6 cm³ (84.19 cu.in) Compression ratio 10.5: 1...
Page 12 California 1400 Characteristics Specification Desc./Quantity Alternator (permanent magnet type) 12 V - 550 W Main fuses 40- 30- 10A Auxiliary fuses 15 (4) - 7.5 (2) A Front daylight running lights 8 low intensity LEDs (Halogen) low beam light 12V - 55W / H3...
Page 13 California 1400 Characteristics Brakes BRAKES Specification Desc./Quantity Front Ø 320-mm (12.6 in) stainless steel double floating disc, radial callipers with 4 opposed pistons. Rear Ø 282-mm (11.1 in) stainless steel disc, floating calliper with 2 different pins. Wheels and tyres...
Page 14 California 1400 Characteristics pos. Description Type Quantity Torque Notes Coil fixing screws M6x30 10 Nm (7.37 lb ft) Coil fixing screws M6x16 10 Nm (7.37 lb ft) Coil bracket fixing screws M6x30 10 Nm (7.37 lb ft) Coil bracket fixing screws M5x12 6 Nm (4.42 lb ft)
Page 15 California 1400 Characteristics EAR PART ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Relay bracket fixing screws M5x12 6 Nm (4.42 lb ft) Bracket self-threading fixing screws M5x14 2.5 Nm (1.84 lb ft) Fuse box bracket fixing screws M5x20 3 Nm (2.21 lb ft)
Page 16 California 1400 Characteristics Front side EADLAMP pos. Description Type Quantity Torque Notes Screw fixing headlamp to supports M6x55 5 Nm (3.69 lb ft) Screw fixing headlamp to joint M6x30 10 Nm (7.37 lb ft) Fixing screws sup. plate headlights sup. steer- M6x20 10 Nm (7.37 lb ft)
Page 17 California 1400 Characteristics IL RADIATOR pos. Description Type Quantity Torque Notes Screws fixing oil radiator to chassis M6x25 10 Nm (7.37 lb ft) Screws fixing electric fan to oil radiator 4,2x20 2.5 Nm (1.84 lb ft) pos. Description Type Quantity...
Page 18 California 1400 Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws M5x12 4 Nm (2.95 lb ft) RONT WHEEL pos. Description Type Quantity Torque Notes Brake discs fixing screws M8x22 25 Nm (18.44 lb ft) Wheel axle 80 Nm (59.00 lb ft)
Page 19 California 1400 Characteristics TEERING pos. Description Type Quantity Torque Notes Screws fixing forks to plate M8x35 25 Nm (18.44 lb ft) Lower ring nut 50 Nm (36.87 lb ft) Pretightening to 60 Nm (44.25 lb ft) Upper cover 100 Nm (73.76 lb ft)
Page 20 California 1400 Characteristics ABS B RAKING YSTEM pos. Description Type Quantity Torque Notes ABS control unit lower cover fixing screws 6 Nm (4.42 lb ft) ABS control unit support plate fixing screws M6x25 10 Nm (7.37 lb ft) ABS control unit support plate fixing screws M6x16 10 Nm (7.37 lb ft)
Page 21 California 1400 Characteristics NDER ADDLE pos. Description Type Quantity Torque Notes Lower saddle compartment closing fixing 6 Nm (4.42 lb ft) screws Fixing screw closing upper and lower saddle M5x20 3 Nm (2.21 lb ft) compartment stainless steel ENTRAL BODYWORK pos.
Page 22 California 1400 Characteristics EAR LEVER pos. Description Type Quantity Torque Notes Fastener screw M8x60 25 Nm (18.44 lb ft) Retainer nut 25 Nm (18.44 lb ft) Gearbox connecting rod fixing screw M6x20 10 Nm (7.37 lb ft) EAR BRAKE PUMP pos.
Page 23 California 1400 Characteristics pos. Description Type Quantity Torque Notes Brake lever screw retainer nut 25 Nm (18.43 lb ft) OOTREST UNIT pos. Description Type Quantity Torque Notes Footrest to frame fixing screw M8x20 25 Nm (18.43 lb ft) Passenger footrest to rubber ring fixing M5x20 6 Nm (4.42 lb ft)
Page 24 California 1400 Characteristics ADDLE pos. Description Type Quantity Torque Notes Lock fixing screws M6x25 10 Nm (7.37 lb ft) ANK COVER pos. Description Type Quantity Torque Notes Fairing fixing screws M5x10 6 Nm (4.42 lb ft) Dashboard fixing screw M5x16 5 Nm (3.68 lb ft)
Page 25 California 1400 Characteristics UEL TANK pos. Description Type Quantity Torque Notes Front fixing screw M8x16 25 Nm (18.44 lb ft) Rear fixing screw M6x25 10 Nm (7.37 lb ft) Fuel pump fixing screw M5x20 6 Nm (4.42 lb ft) Fuel level sensor fixing nuts 5 Nm (3.69 lb ft)
Page 26 California 1400 Characteristics TAND pos. Description Type Quantity Torque Notes Screws fixing stand plate to chassis M10x50 50 Nm (36.88 lb ft) Stand bolt 25 Nm (51.61 lb ft) Stand pin bolt M12x1.25 70 Nm (51.61 lb ft) UARDS KIT pos.
Page 27 California 1400 Characteristics pos. Description Type Quantity Torque Notes Bumpers central fixing screw M8x25 24 Nm (17.4 lb ft) Bumpers rear fixing screw M8x50 24 Nm (17.4 lb ft) Lower screw M8x20 24 Nm (17.4 lb ft) Small parts of the...
Page 28 California 1400 Characteristics EAR MUDGUARD pos. Description Type Quantity Torque Notes Front fixing screws M8x20 25 Nm (18.44 lb ft) Upper fixing screw M8x16 25 Nm (18.44 lb ft) Side cover fixing screws M5x9 6 Nm (4.42 lb ft) CHAR - 28...
Page 29 California 1400 Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel pin 100 Nm (73.76 lb ft) Tone wheel flange screws M8x20 25 Nm (18.44 lb ft) Wheel axle nut M25x1.5 100 Nm (73.76 lb ft) WINGARM pos.
Page 30 California 1400 Characteristics ANNIERS KIT pos. Description Type Quantity Torque Notes Panniers supports fixing screws M8x20 24 Nm (17.4 lb ft) Panniers supports fixing screws M8x16 24 Nm (17.4 lb ft) Engine CHAR - 30...
Page 31 California 1400 Characteristics UBRICATION YSTEM pos. Description Type Quantity Torque Notes Pump outlet oil pipe nipple M14x1.5 40 Nm (29.50 lb ft) Slot screw for oil pipe on the cylinder head M14x1.5 20 Nm (14.75 lb ft) Nipple on the radiator and the oil pipe M16x1.5...
Page 32 California 1400 Characteristics IL SUMP COMPONENTS pos. Description Type Quantity Torque Notes Cooling oil intake filter fixing screw M4x10 By hand Complete oil pressure control valve 20 Nm (14.75 lb ft) Loctite 243 Mesh type oil filter fixing screw M6x14 6 Nm (4.42 lb ft)
Page 33 California 1400 Characteristics RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75 10 Nm (7.37 lb ft) Stud bolt M8x66 10 Nm (7.37 lb ft) Crankshaft rear support flange fixing screw M8x25 26 Nm (19.18 lb ft) Oil cap on the crankcase 25 Nm (18.44 lb ft)
Page 34 California 1400 Characteristics LUTCH pos. Description Type Quantity Torque Notes Flywheel on crankshaft fixing screw M8x25 42 Nm (30.98 lb ft) Loctite 243 Clutch external flange fixing screw on flywheel M7x16 20 Nm (14.75 lb ft) Loctite 243 Start-up crown fixing screw on flywheel M6x12 10 Nm (7.37 lb ft)
Page 35 California 1400 Characteristics IMING SYSTEM pos. Description Type Quantity Torque Notes Idle shaft flange fixing screws M6x14 7 - 8 Nm (5.16 - 5.90 lb ft) Loctite 542 only on through hole Bearing on idle shaft fixing screw M6x16 8 - 10 Nm (5.90 - 7.37 lb ft)
Page 36 California 1400 Characteristics YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special aesthetic head cover fixing screw 8 Nm (5.90 lb ft) Locked with cross sequence Special head cover screw 8 Nm (5.90 lb ft) Locked with cross sequence...
Page 37 California 1400 Characteristics ISTON CYLINDER pos. Description Type Quantity Torque Notes Tie rod on crankcase M10x1.25 5 Nm (3.69 lb ft) Right tensioner cover M30x1.5 40 Nm (29.50 lb ft) Left tensioner cover M20x1.5 30 Nm (22.13 lb ft) Left cylinder cover screw M6x10 10 - 12 Nm (7.37 - 8.50 lb...
Page 38 California 1400 Characteristics LTERNATOR pos. Description Type Quantity Torque Notes Generator control pulley locking nut 80 Nm (59.00 lb ft) Loctite 243 Generator upper fixing screw 22 Nm (16.23 lb ft) Generator lower fixing screw M10x60 30 Nm (22.13 lb ft)
Page 39 California 1400 Characteristics pos. Description Type Quantity Torque Notes Timing system cover fixing screw M8x55 25 Nm (18.44 lb ft) Timing system cover fixing screw M6x30 10 - 12 Nm (7.37 - 8.85 lb Generator cover fixing screw M6x16 10 - 12 Nm (7.37 - 8.85 lb IR FILTER pos.
Page 40 California 1400 Characteristics HROTTLE BODY pos. Description Type Quantity Torque Notes Guards fixing screws M5x15 6 Nm (4.42 lb ft) Brackets fixing screws M6x28 10 Nm (7.37 lb ft) Air temperature sensor fixing screw M6x16 10 Nm (7.37 lb ft)
Page 41 California 1400 Characteristics TARTER MOTOR pos. Description Type Quantity Torque Notes Starter motor fixing screws M8x75 25 Nm (18.44 lb ft) NGINE COVER pos. Description Type Quantity Torque Notes Engine cover fixing screws M6x16 10 Nm (7.37 lb ft) stainless...
Page 42 California 1400 Characteristics 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 (D, E, F).
Page 43 California 1400 Characteristics Specification Desc./Quantity Pin hole diameter on piston 22.020 - 22.015 mm (0.86693 - 0.86673 in) Clearance between pin and holes on piston 0.017 - 0.026 mm (0.00067 - 0.00102 in) Piston rings On each piston there are: •...
Page 44 California 1400 Characteristics 020676Y Dial gauge support for piston position checking • Reset the micrometer on the cylinder rim. • Move the tool so that the micrometer feeler reaches the top point of the piston crown. • Take note of the measurement and, according to the values found, consult the chart at the bottom of the page to decide the thickness of the gasket to be fitted between cylinder and head.
Page 45 California 1400 Characteristics Product Description Specifications CCMC G-4 A.P.I. SG specifications can be used. AGIP GEAR SAE 80 W 90 Transmission oil API GL-4 AGIP GEAR MG/S SAE 85 W 90 Gearbox oil API GL-5 FUCHS TITAN SAF 1091 Fork oil...
Page 46 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 47 California 1400 Special tools ENGINE Stores code Description GU05902530 Gearbox support GU05911730 Front cover insertion cone GU05912530 Gearbox opening GU05927230 Timing system cover sealing ring punch GU12911801 Tool to lock the flywheel and the starting ring gear GU12912000 Tool to fit the flywheel-side flange togeth-...
Page 48: Special Tools
California 1400 Special tools Stores code Description GU12913600 Tool to remove the flywheel-side flange GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body GU14927100 Tool to fit the sealing ring on the flywheel- side flange GU19927100...
Page 49 California 1400 Special tools Stores code Description 020672Y Clutch spring centre and pusher 020675Y Service shaft gear lock 020676Y Dial gauge support for piston position checking 020677Y Generator belt tensioner, lever for belt tensioning 020678Y Tool for clutch rod checking...
Page 50 California 1400 Special tools Stores code Description 020945Y Piston ring clamp 020953Y Cam shaft lock for fixing 020954Y Centring cam shaft cup spring CHASSIS Stores code Description AP8140190 Tool for steering tightening 020376Y Adapter handle 020359Y 42 x 47-mm adaptor...
Page 51 California 1400 Special tools Stores code Description 020360Y Adaptor 52x54 mm 001467Y001 Pliers to extract 25-mm diameter bear- ings 001467Y035 Bell for 47-mm outside diameter bearings FRONT FORK Stores code Description AP8140146 Weight AP8145758 Tool for oil seals fitting 020952Y...
Page 52 California 1400 Special tools Stores code Description 020888Y Pliers for pre-fill pipe 020951Y Stanchion support DIAGNOSIS INSTRUMENT Stores code Description 020922Y P.A.D.S. S-TOOLS - 52...
Page 53 INDEX OF TOPICS MAIN AINTENANCE...
Page 54: Maintenance Chart
California 1400 Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.
Page 55: Transmission Fluid
California 1400 Maintenance km x 1,000 Fuel lines (3) Brake lines (3) Brake pad wear (1) Labour time (minutes) Transmission fluid Check • Remove the rear wheel. • Undo and remove the three fixing screws (1) of the protection shield (2).
Page 56: Engine Oil
California 1400 Maintenance • Unscrew and remove the breather cap (3). • Drain the oil into the container; allow several minutes for oil to drain out completely. • Check and if necessary, replace the sealing washer of drainage plug (5).
Page 57 California 1400 Maintenance • Pull the filler plug / oil level dipstick (1) straight out. • Wipe the oil level dipstick (1) clean and reinsert it. • Pull it out again and check the oil level. • The oil level is correct when it is close to the "MAX"...
Page 58: Engine Oil Filter
California 1400 Maintenance Engine oil filter Replace the engine oil filter each time you change the engine oil. • Drain the engine oil completely. • Unscrew and remove the engine oil fil- ter from its seat. NOTE NEVER REUSE AN OLD FILTER.
Page 59: Air Filter
California 1400 Maintenance Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY. • Place a container with suitable capacity under the drainage plug (2). • Unscrew and remove the drainage plug (2). • Unscrew and remove the filler cap (1).
Page 60: Checking The Valve Clearance
California 1400 Maintenance • Lift the filter housing cover. • Remove the air filter. • Plug the intake duct with a clean cloth to prevent any foreign objects from entering the intake manifold. DO NOT START THE ENGINE WITHOUT THE AIR FILTER.
Page 61 California 1400 Maintenance • Loosen the nut (1). • Use a screwdriver to act on set screw (2) until the following clearances are obtained: Technical specifications Values valid with control clearance between rockers and valve Inlet valve: 0.15 mm (0.0059 in) Exhaust valve: 0.20 mm (0.0079 in)
Page 62 California 1400 Maintenance • Check brake pads and disc for wear. • If the pads and/or the disc do not need replacing, top-up the fluid. Top-up Front brake: • Using a Phillips screwdriver, unscrew the three screws (1) of the brake fluid tank (2).
Page 63 CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORM- ANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECES- SARY TO PURGE THE AIR IN THE SYSTEM. MAIN - 63...
Page 64 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 65 California 1400 Troubleshooting TROUBLESHOOTING PROCEDURE IF THE EFI WARNING LIGHT ON THE INSTRUMENT PANEL TURNS ON OR IF THERE IS ABNORMAL ENGINE PERFORMANCE CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 66 California 1400 Troubleshooting PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAULT AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 • 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEM- PERATURE"...
Page 67 California 1400 Troubleshooting THE DIAGNOSIS INSTRUMENT MUST OPERATE CORRECTLY AND PGDS MUST BE UPDATED AT LEAST TO VERSION 10.1.0 AND THE P.A.D.S. TO VERSION 8. CAUTION BEFORE ANY TROUBLESHOOTING, MAKE SURE THAT: 1) BATTERY VOLTAGE IS ABOVE 12V; 2) THE MAIN 30A FUSE IS NOT DAMAGED AND IS ADEQUATELY FITTED;...
Page 68 California 1400 Troubleshooting • 9. CHECK THROUGH THE DIAGNOSIS INSTRUMENT THE CORRECT OPERATION OF THE SIDE STAND, THE NEUTRAL SENSOR, THE CLUTCH SENSOR: OPERATE ANY DEVICE AND CHECK THE SUITABLE INDICATION ON THE DEVICE STATUS, ICON 0/1 SCREEN PAGE. If there is a fault, go to 10; if everything works correctly, go to 11 •...
Page 69 California 1400 Troubleshooting If there is continuity, go to 4; if there is not continuity, restore ground connection on the engine front part (ground point is on the engine, right side, on the clutch casing) or restore cable har- ness.
Page 70 California 1400 Troubleshooting • 2. CHECK THE CONTROL UNIT CONNECTOR AS WELL AS THE DIAGNOSIS BLACK CONNECTOR YES, go to 3; NO, restore faulty connector - END • 3. CHECK CORRECT OPERATION OF THE DIAGNOSIS INSTRUMENT CONNECTION CABLE AND THE CORRECT INSTALLATION OF THE PLIERS ON THE BATTERY - END AUXILIARY INJECTION RELAY 35 CHECK •...
Page 71 California 1400 Troubleshooting • 1. WITH KEY SET TO OFF, DISCONNECT THE RELAY CONNECTOR AND CHECK CONTINUITY OF BLUE CABLE WITH GROUND If there is continuity, go to 2; if there is not continuity, restore cable harness - END •...
Page 72 California 1400 Troubleshooting • 4. REPLACE THE CONTROL UNIT - END • 5. CHECK CONTINUITY OF PINK/BROWN CABLE BETWEEN SWITCH CONNECTOR AND PIN 58 OF THE CONTROL UNIT YES, go to 4; NO, restore the cable harness - END •...
Page 73 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 74 California 1400 Electrical system Components arrangement KEY: 1. Side stand sensor: 2. Fuel pump. 3. Instrument panel. ELE SYS - 74...
Page 75 California 1400 Electrical system 4. Engine temperature sensor. 5. Cooling fan. 6. Left injector. 7. Right injector. 8. Lambda probe 9. Lambda probe 10.Front speed sensor. 11.Rear speed sensor. 12.Headlamp. 13.Turn indicators and taillight. 14.Fall sensor. 15.Horn. 16.Battery. 17.Fuses. 18.Control unit.
Page 76 California 1400 Electrical system • 1 Complete antitheft kit • 7 Large clamps • 54 Medium clamps • 6 Small clamps • 5 Clamps with support • 2 Plastic rivets • 10 Retaining clips • 3 Cable grommets • 2 Cable guides...
Page 77 California 1400 Electrical system • Check fixing of the grounds on the engine body (left side • Check correct running of the Battery-Starter Relay cable • Check fixing of the positive cable on the starter motor and positioning of the hood The connectors in the list are circled in the different pictures.
Page 78 California 1400 Electrical system TABLE D 1. Large clamps. TABLE E Pass the main cable harness as shown in figure. TABLE F Pass the main cable harness as shown in figure. Front side TABLE A - FAN AND CONNECTED COMPONENTS 1.
Page 79 California 1400 Electrical system TABLE B - FAN AND CONNECTED COMPO- NENTS 1. Small clamp. TABLE C - FAN AND CONNECTED COMPONENTS 1. Medium clamp ELE SYS - 79...
Page 80 California 1400 Electrical system TABLE D - FAN AND CONNECTED COMPO- NENTS 1. Medium clamp TABLE E - RIGHT SIDE STEERING COLUMN AREA 1. Medium clamp TABLE F - RIGHT SIDE STEERING COLUMN AREA 1. Medium clamp TABLE G - RIGHT SIDE STEERING COLUMN AREA 1.
Page 81 California 1400 Electrical system TABLE H - RIGHT SIDE STEERING COLUMN AREA 1. Medium clamp 2. Clutch switch. 3. Left light switch. TABLE I - RIGHT SIDE STEERING COLUMN AREA 1. Medium clamp 2. Right light switch. 3. Front stop switch.
Page 82 California 1400 Electrical system TABLE L - RIGHT SIDE STEERING COLUMN AREA 1. Clutch switch connectors. 2. Left light switch connectors. TABLE M - RIGHT SIDE STEERING COLUMN AREA 1. Front stop switch connector. 2. Right light switch connector. TABLE N - LEFT SIDE STEERING COLUMN AREA 1.
Page 83 California 1400 Electrical system TABLE O - LEFT SIDE FORK AREA 1. Cable grommet. TABLE P - LEFT SIDE FORK AREA 1. Cable grommet. TABLE Q - LEFT SIDE FORK AREA 1. Small clamp. ELE SYS - 83...
Page 84 California 1400 Electrical system TABLE R - INSTRUMENT PANEL FASTENING 1. Medium clamp TABLE S - INSTALLATION AIR TEMPERATURE SENSOR 1. Small clamp. 2. Medium clamp TABLE T - FOG LIGHTS 1. Fog lights kit connection. ELE SYS - 84...
Page 85 California 1400 Electrical system TABLE U - FOG LIGHTS 1. Medium clamp (to hold the branch that goes toward the headlights). 2. Clip. 3. 12V 30A relay. 4. Relay mounting rubber block. TABLE V - FOG LIGHTS 1. Cable guide.
Page 86 California 1400 Electrical system TABLE C - FRAME AREA (FRAME RIGHT INTERNAL SIDE) 1. Gear sensor connector. 2. Medium clamps. TABLE D - FRAME AREA (UNDER THE TANK) 1. Fog light connector (optional). 2. Slave Demand Connector. 3. Master Demand Connector.
Page 87 California 1400 Electrical system TABLE F - FRAME AREA (UNDER THE TANK) 1. Medium clamp 2. Navigator pre-installation. TABLE G - DIRECT CONNECTIONS TO THE ENGINE • Alternator connections. TABLE H - DIRECT CONNECTIONS TO THE ENGINE Engine temperature. 1. Medium clamp TABLE I - BATTERY AREA 1.
Page 88 California 1400 Electrical system TABLE J - BATTERY AREA (RIGHT SIDE FAIRING, INTERNAL VIEW) 1. Medium clamp 2. Medium clamp 3. Fuses. TABLE K - BATTERY AREA (LEFT SIDE FAIRING, EXTERNAL VIEW) 1. Medium clamp 2. Small clamp. 3. Relay.
Page 89 California 1400 Electrical system TABLE M - CORRECT PASSING OF CORRU- GATED PIPES TABLE N - BATTERY AREA (RIGHT SIDE FAIRING, EXTERNAL VIEW) 1. Relay TABLE O - BATTERY AREA (LEFT SIDE FAIRING, INTERNAL VIEW) 1. Medium clamp 2. ABS branch, must remain in its housing.
Page 90 California 1400 Electrical system TABLE P - STARTER MOTOR AREA 1. Left coil. 2. Medium clamp 3. Rear stop connector. 4. Side stand connector. 5. Engine ground. 6. Clamp with support. 7. Lambda Probe Connector. In the engine ground cable, the two crimp con- nectors must be placed "back to back"...
Page 91 California 1400 Electrical system TABLE S - STARTER MOTOR AREA 1. Left injector connector. TABLE T - REAR STOP SWITCH 1. Medium clamps. 2. Rear stop switch. 3. Small clamp. TABLE U - REAR STOP SWITCH 1. Medium clamps. ELE SYS - 91...
Page 92 California 1400 Electrical system TABLE X - SIDE STAND 1. Clamp with support. 2. Medium clamp TABLE W - REAR STOP SWITCH 1. Clamp with support. TABLE Y - RIGHT LAMBDA FASTENING 1. Medium clamp 2. Right lambda. ELE SYS - 92...
Page 93 California 1400 Electrical system TABLE Z - HANDLEBAR AREA 1. Clutch switch. 2. Clip. 3. Cable guide. TABLE AA - HANDLEBAR AREA 1. Front stop switch. 2. Clip. 3. Cable guide. TABLE BB - LEFT SIDE H.V. CABLES Left injector connector.
Page 94 California 1400 Electrical system Back side TABLE A - TAILLIGHT LICENSE PLATE LIGHT 1. Retaining clip. TABLE B - TAILLIGHT LICENSE PLATE LIGHT 1. Medium clamp TABLE C - TAILLIGHT LICENSE PLATE LIGHT 1. Hold the cable harness as shown in the fig- ure.
Page 95 California 1400 Electrical system TABLE D - REAR WHEEL SPEED SENSOR 1. Rear speed sensor. 2. Medium clamp TABLE E - REAR WHEEL SPEED SENSOR 1. Cable grommet. 2. Medium clamp 3. Rear speed sensor cable harness. ELE SYS - 95...
Page 96 California 1400 Electrical system General wiring diagram key: 1. Multiple connectors 2. Fog lamp switch (where provided) 3. Low beam light relay 4. High beam light relay ELE SYS - 96...
Page 97 California 1400 Electrical system 5. Light logic relay 6. Left light switch 7. Horn 8. Air temperature sensor 9. - 10.Instrument panel 11.Heated handgrips (where provided) 12.Power supply for GPS 13.Right light switch 14.Front stop switch 15.Rear stop switch 16.Clutch switch 17.Ignition switch...
Page 98 California 1400 Electrical system 43.Gear sensor 44.Lambda probe 2 (right) 45.Lambda probe 1 (left) 46.Right cylinder injector 47.Left cylinder injector 48.Coil 49.Map sensor 50.Motorised throttle 51.Handgrips position sensor 52.Engine speed sensor 53.Control unit 7sm 54.Left fog light (if applicable) 55.Front left turn indicator 56.Complete headlamp...
Page 99 California 1400 Electrical system CONNECTOR CHECK PROCEDURE The procedure includes the following checks: 1. Observation and check of the connector correct position on the component or on the coupling con- nector, making sure that the locking catch is re- leased.
Page 100 California 1400 Electrical system CAUTION! IF THERE IS A GROUND CONNECTION COMING FROM THE CONTROL UNIT, MAKE SURE THAT DURING THE TEST THE CONTROL UNIT IS GROUND CONNECTED TO THE CIR- CUIT. VOLTAGE check Check goal: this control is to check if a cable is energised, i.e. if it receives power supply from the battery or the control unit.
Page 101 California 1400 Electrical system IN CASE OF TEMPORAL MALFUNCTIONING, CARRY OUT ALL DUE CHECKS LOOKING FOR FAULT BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED. 3. Pulling the cables slightly from the back of the connector in order to check the correct position of terminals on the connector and of the cable on the terminal.
Page 102: System Components
California 1400 Electrical system System components Function detects the transponder code in the key and sends it to the instrument panel Level in electrical circuit diagram: Immobilizer Location: • on the vehicle: in the instrument panel • connector: grey two-way, under the...
Page 103 California 1400 Electrical system There is a fault in the instrument panel. Troubleshooting Replace the instrument panel. Error code B0007 (ONLY ONE KEY STORED) The number of stored keys is less than two Identification Warning light (red) fix plus icon "URGENT" "SERVICE"...
Page 104 California 1400 Electrical system Location: • on the vehicle: right light switch. • connector: under right side steering column. Electrical specifications: • key released: the circuit is open • key pressed: the circuit is closed Pin out: 4: voltage + 5V...
Page 105 California 1400 Electrical system Specification Desc./Quantity 7) 20A fuse ABS power fuse 8) Spare fuses Spare fuses MAIN FUSES - DISTRIBUTION Specification Desc./Quantity A) 40A fuse Battery recharge fuse B) 30A fuse Primary injection, key, parking lights fuse (auxiliary fuses 2, 4,...
Page 106: Control Unit
California 1400 Electrical system Control unit Removal • Remove the saddle. • Undo and remove the four fixing screws of the battery cover. • Remove the battery cover • Disconnect both control unit connec- tors • Undo and remove the three screws (1).
Page 107 California 1400 Electrical system • connector: on the ECU 52 PIN ENGINE connector (figure 1), 28 PIN VEHICLE connector (figure 2) Pin out:See the CONNECTORS section DIAGNOSTICS INSTRUMENT: PARAMETERS ISO Screen page (screen/example value with key set to ON) •...
Page 108 California 1400 Electrical system DIAGNOSTICS INSTRUMENT: STATUSES Engine status • Indefinite_Key ON_Running engine_Stopped_Power latch_Power latch 2_Power latch fin- ished Engine mode • Indefinite_Start-up_Stable_Idle_Acceleration_Deceleration_Enters Cut Off_Cut Off_Exits Cut Off Immobilizer signal • yes/no • Indicates whether the control unit has received the consent by the instrument panel regard- ing the immobilizer: coded key or user code entered manually.
Page 109 California 1400 Electrical system • The stop light logic relay is energised (No. 19 on the electrical circuit diagram, position to the right of the battery, in any case VERIFY identification of the relay with the colour of the cables)
Page 110 California 1400 Electrical system • Replace injection ECU Stop lights relay error P0610 • short circuit to positive/ short circuit to negative / open circuit Error cause • If shorted to positive: excessive voltage has been detected at PIN 31. If shorted to negative: no voltage has been detected.
Page 111 California 1400 Electrical system • Continue fault search for the other errors detected. CAUTION DELETING ALL THE SAVED DATA WHEN THE VEHICLE IS BEING MANUFACTURED (INCLUD- ING THE SELF-ADJUSTABLE PARAMETERS), THEN YOU MUST SELECT: HANDLE SELF- LEARNING AND VERIFY THAT THE TWO "THROTTLE AUTOMATIC SELF-LEARNING" STATUS IS "CARRIED OUT".
Page 112 California 1400 Electrical system Battery Function Electrically supply the vehicle: the YTX20-BS bat- tery is already activated. Level in electrical circuit diagram: Battery recharge Location: • on the vehicle: under the saddle • connector: on the battery Electrical specifications:12 V / 18 Ah Pin out: 1.
Page 113: Speed Sensor
California 1400 Electrical system • If too high: too high a voltage has been detected at PIN 52. If too low: too low a voltage has been detected at PIN 52. The instrument panel does not indicate the presence of this error even in the ATT status.
Page 114 California 1400 Electrical system 5D90 electric malfunction: Electrical fault in sensor or cable harness. Troubleshooting: Check the sensor connector and the ABS control unit connector. If they are not OK, restore the connectors. If they are OK, check continuity of the white/brown cable between PIN 2 of the sensor on the cable harness side and PIN 14 of the ABS control unit connector.
Page 115 California 1400 Electrical system Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed.
Page 116 California 1400 Electrical system with the vehicle ground connection: if it is grounded, restore the cable harness. If OK, replace the control unit. If PIN 2 has approx. 12 V, check continuity of the yellow cable between PIN 1 of the sensor on the cable harness side and PIN 12 of the ABS control unit connector.
Page 117 California 1400 Electrical system OK, check that the tyre pressure is the correct one. If it is not OK, restore it; if it is OK, replace the speed sensor. Engine rpm sensor Function informs crankshaft position and speed to the Mar-...
Page 118 California 1400 Electrical system CARRY OUT THE TESTS FROM THE SENSOR CONNECTOR TO THE SENSOR. IF NOT OK, RE- STORE THE CABLE HARNESS/REPLACE THE SENSOR. IF OK, PERFORM THE TEST FROM PIN 20 AND 35 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR.
Page 119 California 1400 Electrical system THROTTLE GRIP POSITION SENSOR Function The throttle grip is the part to which the throttle control cables arrive; its task is to translate the rid- er's power request (Demand) into an electrical signal to be sent to the electronic control unit.
Page 120 California 1400 Electrical system • E: Track B ground (red/black cable) • F: Track B signal (purple cable) SLAVE connector (white) • A: Track C power (orange/white cable) • B: Track C ground (green/pink cable) • C: Track C signal (yellow/blue cable) •...
Page 121 California 1400 Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS Blue front connector throttle grip position sensor - track A P0150 •...
Page 122 California 1400 Electrical system throttle grip sensor connector or the control unit connector): if the cable is not ground insu- lated, restore the wiring. If it is ground insulated, and with the switch key set to ON, check that there is power supply for the potentiometer PIN D and that PIN F is connected to ground.
Page 123 California 1400 Electrical system cated by the diagnostics instrument: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. • if the circuit is open, shorted to negative: check the throttle grip sensor connector and the Marelli control unit connector.
Page 124 California 1400 Electrical system • inconsistent signal Error cause • The value of the front side sensor (tracks A-B) does not coincide with the value of the rear sensor (tracks C-D) Troubleshooting • Replace the throttle grip sensor DIAGNOSTICS INSTRUMENT: ADJUSTABLE PARAMETERS...
Page 125 California 1400 Electrical system 2. Temperature signal 3. Power supply 5V 4. Signal DIAGNOSTICS INSTRUMENT: PARAMETERS Reference pressure Intake above sea level • Example value with key ON: 1009 mbar • Example value with engine on: 670 mbar • NOTE: pressure estimated by the control unit according to the throttle position...
Page 126 California 1400 Electrical system • According to the engine operation data (rpm, throttle, etc.) an average value for the intake pressure is estimated: if the value read deviates by a given percentage, this error is activa- ted. The most frequent causes can be: abnormal resistance in the sensor circuit (for example, rusted terminals) or sensor with poor performance.
Page 127 California 1400 Electrical system DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS air temperature sensor P0110 • open circuit, shorted to positive / shorted to negative Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 37 of the ENGINE connector.
Page 128 California 1400 Electrical system Electrical specifications: NGINE TEMPERATURE SENSOR RESISTANCE Specification Desc./Quantity Resistance at -40 °C (-40 °F) 100.950 kOhm Resistance at -30 °C (-22 °F) 53.100 kOhm Resistance at -20 °C (-4 °F) 29.120 kOhm Resistance at -10 °C (14 °F) 16.600 kOhm...
Page 129 California 1400 Electrical system • If the circuit is open, shorted to positive: check sensor connector and Marelli control unit connector; if not OK, restore cable harness; if OK, check sensor continuity; if it is not OK, replace the sensor; if it is OK, check the continuity between the ENGINE connector PIN 12 and the sensor PIN 12: restore cable harness if there is not continuity;...
Page 130 California 1400 Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
Page 131 California 1400 Electrical system read by the control unit; a recovery value is dis- played instead Lambda sensor correction • Example value with key ON: 1.00 mV • Example value with engine on: 0.90 - 1.10mV In closed loop, the value must be close to 1.00 (values not within the 0.90 - 1.10 interval indicate...
Page 132 California 1400 Electrical system • shorted to positive Error cause • Excessive voltage (battery voltage) has been detected at PIN 10 and 22 of the ENGINE connector. Caution: the 'Oxygen sensor' parameter is not the real value that is read; a re- covery value is displayed instead.
Page 133 California 1400 Electrical system • Check circuit continuity from probe connector (PIN 1 and PIN 2) toward the probe: replace the oxygen sensor if there is no continuity; if there is continuity, check the sensor connector and the Marelli control unit connector: If not OK, restore. If OK, check continuity between the ENGINE connector PIN 22 and PIN 10 and restore the cable harness.
Page 134 California 1400 Electrical system (between the sensor connector PIN 3 and the ENGINE PIN 38) and restore the cable har- ness. WARNING The control unit does not detects the following malfunctions of the oxygen sensor circuit according to the signal: interrupted circuit, shorted to ground or sensor malfunction (for example non variable volt- age).
Page 135 California 1400 Electrical system • on the vehicle: intake manifold on the cylinder • connector: on injectors Electrical specifications: 14.8Ω ± 5% (at ambient temp) Pin out left cylinder: 1. Power (orange/green cable) 2. Ground (grey/red cable) Pin out right cylinder: 1.
Page 136 California 1400 Electrical system Error cause • If shorted to positive: excessive voltage has been detected at PIN 53. If shorted to negative: no voltage has been detected. If the circuit is open: an interruption has been detected Troubleshooting •...
Page 137: Fuel Pump
California 1400 Electrical system Fuel pump Function Fuel pump: keeps pressure of the injectors supply duct. Level in electrical circuit diagram: Injection load relay Location: • on the vehicle: under the tank. • connector: near the fuel pump (2 ways, black).
Page 138 California 1400 Electrical system • If the circuit is open, shorted to negative: check the relay electrical characteristics are correct by disconnecting it from the cable harness; if it is not OK, replace the relay, if it is OK, check relay connector, engine-vehicle cable harness connector and VEHICLE connector of the Marelli control unit: if not OK, restore;...
Page 139 California 1400 Electrical system CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSTICS INSTRUMENT: ACTIVATION Left Cylinder Central Coil The auxiliary relay (No. 35 in the wiring diagram, placed in the front relay box, left side; CHECK, how- ever, the identification of the relay with the colour of the cables) is energised for 5 seconds and the coil Pink cable is closed to ground for 2 ms per second.
Page 140 California 1400 Electrical system The auxiliary injection relay (No. 35 in the wiring diagram, placed in the front relay box, left side; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the coil Brown/Green cable is closed to ground for 2 ms per second.
Page 141 California 1400 Electrical system • If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with the diagnostics instrument and check voltage at connector PIN 27: if there is voltage, restore the cable harness; if voltage = 0, replace the coil.
Page 142: Throttle Body
California 1400 Electrical system OK, restore, if OK, check cable continuity between the two cable terminals: if there is not continuity, restore the cable harness; if there is cable continuity, with key set to ON, check the cable ground insulation (from coil connector or control unit connector), if not OK, restore...
Page 143 California 1400 Electrical system • Example value with engine at idle: engine hot 5.5°, engine cold 6,5° Throttle Potentiometer 1 (voltage) • Example value with key ON: 800 mV • Example value with engine on: engine hot 760 mV, engine cold 800 mV Throttle Potentiometer 2 (degrees) •...
Page 144 California 1400 Electrical system • If shorted to positive: excessive voltage has been detected at PIN 48. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 48. Troubleshooting • If shorted to positive: check the value indicated by the Throttle Potentiometer 1 parameter (voltage): disconnect the connector and read the value indicated by the diagnostics instru- ment: if the voltage does not vary, there is a short circuit in the cable;...
Page 145 California 1400 Electrical system • Check the Throttle Potentiometer 1 parameter (voltage) to understand which signal the control unit receives. Check the throttle body connector as well as the control unit connector. Check that cable resistance between the throttle body connector (PIN 1) and the control unit (PIN48) is a few tenths of an Ohm.
Page 146 California 1400 Electrical system • failed test Error cause • Return time of the throttle, kept in position by the springs, not within the expected limits: the causes can be a deterioration of the performance of the springs or excessive throttle friction...
Page 147 California 1400 Electrical system Troubleshooting • Replace the throttle body DIAGNOSTICS INSTRUMENT: ADJUSTABLE PARAMETERS Throttle self-acquisition NOTE THROTTLE BODY ACTIVATION TAKES PLACE EVERY TIME THE KEY IS SET TO ON: CORRECT ACTIVATION IS INDICATED WHEN THE STOP LIGHTS TURN ON: IF DURING ACTIVATION, THE ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT TURN ON.
Page 148 California 1400 Electrical system Neutral sensor Function It tells the gear position to the control unit, from the 1st gear to the 6th gear, and if the gear is neutral or riding. Operation / Operating principle The sensor has 2 circuits: one to indicate the en-...
Page 149 California 1400 Electrical system • Yes/No Gear engaged: 0 - 1 - 2- 3 - 4 - 5 - 6 DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS Gear sensor P0461 • shorted to positive or open circuit / shorted to negative. Error cause •...
Page 150 California 1400 Electrical system Electrical specifications: • Clutch pulled: closed circuit (continui- • Clutch released: open circuit (infinite resistance). Pin out: 1. normally closed switch (white/purple cable) 2. ground (green/pink cable) 3. normally open switch (orange/blue cable) CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING,...
Page 151 California 1400 Electrical system Side stand sensor Function it tells the side stand position to the control unit Operation / Operating principle If the gear is engaged and the side stand is unfol- ded, and therefore the circuit is open, the control...
Page 152: Bank Angle Sensor
California 1400 Electrical system Bank angle sensor Function It tells the vehicle position to the control unit Operation / Operating principle The sensor converts the vehicle position signal to electrical voltage. Level in electrical circuit diagram: Start-up enabling switches Location: •...
Page 153 California 1400 Electrical system • connector: under right side steering column. Electrical specifications: • STOP position: the circuit is open • RUN position: closed circuit (continui- Pin out: 1 ground (pink/black cable) 2 power 5 V (pink/brown cable) CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING,...
Page 154 California 1400 Electrical system Engine pinout key: Right cylinder side spark plug coil command output PIN 1 Left cylinder side spark plug coil command output PIN 2 Sensors ground 2 PIN 4 Power ground PIN 5 Sensors ground 1 PIN 6...
Page 155 California 1400 Electrical system Output for throttle motor drive (-) PIN 29 Recovery logic relay command output (STOP light) PIN 31 Left Lambda heater command output PIN 32 Engine rpm sensor input (+) PIN 35 Air temperature sensor input PIN 37...
Page 156 California 1400 Electrical system Fall sensor input PIN 65 CAN L line (high speed) PIN 66 Right cylinder injector command output PIN 67 Starter relay command output PIN 69 Side stand input PIN 70 Gear sensor input PIN 72 Injection auxiliary relay command output PIN 73 Normally open clutch switch input PIN 76 "Engine stop"...
Page 157 California 1400 Electrical system Serial line K for diagnostics PIN 9 CAN L line (high speed) PIN 10 Battery positive PIN 11 Left rear turn indicator output PIN 12 Right rear turn indicator output PIN 13 Lights relay PIN 14...
Page 158 California 1400 Electrical system B aerial PIN 30 Key positive PIN 31 Left turn indicator command PIN 32 Normally open front stop switch input PIN 33 Hazard input PIN 34 Handgrip command PIN 35 Turn indicator reset command PIN 36...
Page 159 California 1400 Electrical system Rear speed sensor ground PIN 12 Front speed sensor ground PIN 13 Front speed sensor signal PIN 14 Vehicle identification (2) PIN 15 Serial K line for diagnostics PIN 16 Battery power PIN 18 Can line Function It allows communication between the Marelli injection ECU and the instrument panel.
Page 160 California 1400 Electrical system Every network nod receives all the messages sent through the BUS (with reception confirmation or error messages) and each nod decides if the message is to be processed or rejected. Besides, every nod can request information from the other nodes (RTR = Remote Transmit Request).
Page 161 California 1400 Electrical system short circuited to positive testing from each of the 2 connectors (Marelli control unit, instru- ment panel connector) with 1 connector at a time disconnected and turning the key to the ON position: If not OK, restore; if OK, replace the Marelli control unit.
Page 162 California 1400 Electrical system • If there is no signal, no signal is received from the ABS control unit. In case of configuration error, some devices are present (e.g. ABS) that were not foreseen in the vehicle configura- tion stored in the control unit.
Page 163 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 164 California 1400 Engine from vehicle Vehicle preparation Before removing the engine block, proceed as follows: • From the back, secure the vehicle with belts attached to a hoist. • From the front, secure the vehicle with belts attached to the handlebar and fixed to the work bench.
Page 165 California 1400 Engine from vehicle • Disconnect the cable located behind the starter motor. • Disconnect the ground cable. • Disconnect the stand sensor connec- tor and rear stop switch. • Release it from the clamps. ENG VE - 165...
Page 166 California 1400 Engine from vehicle • Working from both sides, disconnect the engine oil breather tube. • Working from both sides, disconnect the injector connectors. • Working from both sides, unscrew the retaining screw of the injector and re- move it.
Page 167 California 1400 Engine from vehicle • Disconnect the alternator connectors. • Disconnect the oil pressure sensor connector. • Disconnect the engine temperature sensor connector. ENG VE - 167...
Page 168 California 1400 Engine from vehicle • Disconnect the speed sensor connec- tor. • Disconnect the ride by wire connec- tors. • Working from both sides, disconnect the connectors of the coils and cables of the plug caps. ENG VE - 168...
Page 169 California 1400 Engine from vehicle • Working from both sides, disconnect the lambda probe connectors. ENG VE - 169...
Page 170 California 1400 Engine from vehicle • Undo and remove the fixing screw of the oil radiator to the frame. • Disconnect the two connectors located behind the oil radiator. • Loosen the two fixing screws of the fil- ter box and the tube shown in the fig- ure.
Page 171 California 1400 Engine from vehicle • Remove the filter box. • Remove the connector of the throttle body. • Undo the four fixing screws and re- move the throttle body. • After disconnecting all the connectors, remove the various fixing clamps of the cables.
Page 172 California 1400 Engine from vehicle • Disconnect the horn connectors. • Support the engine with suitable equip- ment. • Working from both sides, remove the rear fixing screws of the cradle. • Working from both sides, remove the front fixing screws of the cradle.
Page 173 California 1400 Engine from vehicle • Undo the three fixing screws of the si- lent block support. • Remove the silent block. • Unscrew the front fixing screw that se- cures the engine to the silent block, ENG VE - 173...
Page 174 California 1400 Engine from vehicle • Move the engine from the frame so as to be able to access the clutch control cylinder. • Undo and remove the three fixing screws and move the clutch control cyl- inder. • Lock the cylinder using a clamp in or- der to avoid the leakage of oil.
Page 175 California 1400 Engine from vehicle • Insert the front pin that secures the en- gine to the silent block. • Fix the silent block support by tighten- ing the three fixing screws. • Working from both sides, insert the en- gine/connecting rod fixing pins.
Page 176 California 1400 Engine from vehicle • Working from both sides, position the front and rear fixing screws of the cra- dle. • Connect the horn connectors. ENG VE - 176...
Page 177 California 1400 Engine from vehicle • Position throttle body and secure it us- ing the four screws. • Connect the connector. • Install the air filter box. • Secure it with the two fixing screws and the two clamps. •...
Page 178 California 1400 Engine from vehicle • Connect the connectors located inside the oil radiator. • Install the oil radiator securing it with its lower joints and with the upper fixing screw. • Connect the connectors of the lambda probes. ENG VE - 178...
Page 179 California 1400 Engine from vehicle • Connect the connectors of the coils and the cables of the plug caps. ENG VE - 179...
Page 180 California 1400 Engine from vehicle • Connect the connectors of the ride by wire and that of the engine speed sen- sor. • Connect the connectors of the engine temperature sensor and the oil pres- sure sensor. ENG VE - 180...
Page 181 California 1400 Engine from vehicle • Connect the alternator. • Operating from both sides, install the injectors, tightening the fixing screw. • Connect the connectors. ENG VE - 181...
Page 182 California 1400 Engine from vehicle • Working from both sides, connect the engine breather tube. • Connect the stand sensor connector and rear stop switch. • Connect the cable located behind the starter motor • Install the starter motor fixing it with the two fixing screws.
Page 183 California 1400 Engine from vehicle ENG VE - 183...
Page 184 INDEX OF TOPICS NGINE...
Page 185 California 1400 Engine Gearbox EARBOX pos. Description Type Quantity Torque Notes Clutch housing to gearbox fixing screws M6x55 13 Nm (9.59 lb ft) Gearbox cap M18x1.5 28 Nm (20.65 lb ft) Breather stud bolt M10x1.5 8 Nm (5.90 lb ft)
Page 186 California 1400 Engine EAR LEVER pos. Description Type Quantity Torque Notes Fastener screw M8x60 25 Nm (18.44 lb ft) Retainer nut 25 Nm (18.44 lb ft) Gearbox connecting rod fixing screw M6x20 10 Nm (7.37 lb ft) ENG - 186...
Page 187 California 1400 Engine Diagram key: 1. Ball bearing 2. Circlip 3. Thickness 4. Pin ENG - 187...
Page 188 California 1400 Engine 5. Complete desmodromic 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10.Fifth wheel 11.Linking pin 12.Gear 13.Circlip 14.Thrust washer 15.Roller cage 16.Gear 17.Seal ring 18.Ball bearing 19.Gear 20.Circlip 21.Clutch shaft 22.Ball bearing 23.Oil plug 24.Washer 25.Gearbox 26.Aluminium washer...
Page 189 California 1400 Engine 43.Gear 44.Gear 45.Roller cage 46.Thrust washer 47.Circlip 48.Gear 49.Circlip 50.Gear 51.Primary shaft 52.Transmission gear 53.Fork (5th - 1st) 54.Fork shaft 55.Fork (3rd - 4th) 56.Fork (2nd - 4th) 57.Gear 58.Gear 59.Ball bearing 60.Transmission shaft 61.Gear 62.Spacer Gearbox Removing the gearbox •...
Page 190 California 1400 Engine • Unscrew and remove the three screws See also Removing the starter motor Replacement • Unscrew and remove the two lower screws • Unscrew and remove the screw • Remove the gearbox. ENG - 190...
Page 191 California 1400 Engine Installing the gearbox • Position the gearbox • Tighten the three upper nuts • Tighten the two lower nuts • Tighten the side nut ENG - 191...
Page 192 California 1400 Engine Gearbox shafts Disassembling the gearbox • Remove the gearbox. • Undo the two screws and remove the gear sensor. • From the outside, slide off the thrust cylinder and collect the O-Ring and the washer. • Remove the thrust bearing and the washer.
Page 193 California 1400 Engine • Slide off the rod with the two bushings. • Undo and remove the five external screws. • Place the gearbox on the specific gearbox support tool and on a vice. Specific tooling 05.90.25.30 Gearbox support •...
Page 194 California 1400 Engine • Remove the bearings from the gearbox if necessary. • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Use rubber bands to tie down the trans- mission shaft unit and extract it.
Page 195 California 1400 Engine • Once the transmission shaft unit is in on a bench, remove the rubber bands, being careful with the group. • Detach the shafts and label the forks before removal. • Remove the forks and collect the shaft.
Page 196 California 1400 Engine • Replace bearings if necessary and re- move the clutch shaft. See also Removing the gearbox Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side. •...
Page 197 California 1400 Engine • Remove the gear of the sixth gear and collect the shoulder washer. • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer. ENG - 197...
Page 198 California 1400 Engine • Remove the gear of the fifth gear and collect the ball bearing cage. • Heat the shaft with a specific heater and remove the helical transmission gear. Removing the secondary shaft • Remove the transmission shaft.
Page 199 California 1400 Engine • Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the sixth gear. • Remove the circlip and collect the shoulder washer.
Page 200 California 1400 Engine • Remove the gear of the fourth gear and collect the ball bearing cage. • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. •...
Page 201 California 1400 Engine • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage. • Remove the bearing if necessary. See also Disassembling the gearbox Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace it if not complying with specifications.
Page 202 California 1400 Engine Checking the desmodromic drum Check gear drum for damage, scratches and wear and replace the desmodromic control rod if nec- essary. Check the desmodromic segment «3» for damage and wear and replace it if necessary. Check the desmodromic bearing «4» for damage and cracks and replace it if necessary.
Page 203 California 1400 Engine primary shaft Fitting the secondary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. See also Removing the secondary shaft...
Page 204 California 1400 Engine Disassembling the gearbox Generator LTERNATOR pos. Description Type Quantity Torque Notes Generator control pulley locking nut 80 Nm (59.00 lb ft) Loctite 243 Generator upper fixing screw 22 Nm (16.23 lb ft) Generator lower fixing screw M10x60 30 Nm (22.13 lb ft)
Page 205 California 1400 Engine ENERATOR OVER pos. Description Type Quantity Torque Notes Timing system cover cap fixing screw M6x20 10 Nm (7.37 lb ft) Loctite 243 Timing system cover fixing screw M8x55 25 Nm (18.44 lb ft) Timing system cover fixing screw M6x30 10 - 12 Nm (7.37 - 8.85 lb...
Page 206 California 1400 Engine • Saddle removal; • Battery removal; • Removal of steering column fairings; • Removal of tank cap cover; • Tank removal; • Removal of side fairings; • Removal of silencers; • Removal of starter motor cover; •...
Page 207 California 1400 Engine • Remove the front bracket with silent block from the lower part paying atten- tion not to damage the alternator cover. • Remove the three upper screws of the alternator cover. • Remove the central screws of the al- ternator cover.
Page 208 California 1400 Engine • Remove the lower screws of the alter- nator cover. • Remove the alternator cover by pulling it off from the lower part, paying atten- tion not to damage it. • Loosen the screw. • Loosen the nut and undo the set screw so that the alternator slides.
Page 209: Removing The Generator
California 1400 Engine 020677Y Generator belt tensioner, lever for belt tensioning • Tighten the belt to a torque of 50 Nm (36.88 lb ft). • Tighten the adjuster and tighten the locknut. Removing the generator • Remove the screw. •...
Page 210: Installing The Generator
California 1400 Engine • Remove the belt and the alternator with pulley. Installing the generator • Insert the alternator as shown in the figure • After correctly inserting the belt, on the pulleys tighten the screw with the rela- tive nut •...
Page 211 California 1400 Engine • Using the belt tensioning tool, tension the belt to the prescribed torque and tighten the set screw. • Remove the belt tensioning tool. • Lock the set screw in position by screwing the lock nut. Specific tooling 020677Y Generator belt tensioner, lever for belt tensioning •...
Page 212: Starter Motor
California 1400 Engine • Insert the central screws • Insert the lower screws • Tighten all the screws of the cover Starter motor TARTER MOTOR pos. Description Type Quantity Torque Notes Starter motor fixing screws M8x75 25 Nm (18.44 lb ft)
Page 213 California 1400 Engine Removing the starter motor • Undo and remove the two screws and collect the washers. • Slide off the starter motor. Clutch side Disassembling the clutch ENG - 213...
Page 214 California 1400 Engine LUTCH pos. Description Type Quantity Torque Notes Flywheel on crankshaft fixing screw M8x25 42 Nm (30.98 lb ft) Loctite 243 Clutch external flange fixing screw on flywheel M7x16 20 Nm (14.75 lb ft) Loctite 243 Start-up crown fixing screw on flywheel M6x12 10 Nm (7.37 lb ft)
Page 215 California 1400 Engine 17.Thrust cylinder 18.Clutch control cylinder 19.TE flanged screw • Remove the complete gearbox. • Undo and remove the six screws (1). • Remove the start-up crown gear. • Remove the clutch bell and the friction disc by undoing the six screws (2).
Page 216 California 1400 Engine • Remove the retainer ring. • Remove the clutch pressure plate. • Unscrew and remove the six screws. • Remove the clutch plate. CAUTION DURING REMOVAL/FITTING OF THE SCREWS DO NOT USE WASHERS IF PREVIOUSLY INSTALLED. See also...
Page 217 California 1400 Engine Checking the clutch actuator If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod. Measure as follows: • Fit the new clutch on the crankshaft. • Fit the clutch control bowl in the gear- box.
Page 218 California 1400 Engine • Place the clutch pressure plate. • Fit the tool to centre and compress the plate. • Fully tighten the two centring tool screws. Specific tooling 020672Y Clutch spring centre and pusher • Once the centring tool is fitted, lock the plate with the snap ring.
Page 219 California 1400 Engine • Insert the friction disc in the cap by matching the centring with the slot in the cap. • Fit the clutch bell. • Place the starter sprocket. • Tighten the six screws to the prescri- bed torque operating diagonally and in stages.
Page 220 California 1400 Engine Heads YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special aesthetic head cover fixing screw 8 Nm (5.90 lb ft) Locked with cross sequence Special head cover screw 8 Nm (5.90 lb ft) Locked with cross...
Page 221 California 1400 Engine YLINDERS TIMING pos. Description Type Quantity Torque Notes Camshaft / rocker support fixing screws M8x30 16 - 18 Nm (11.80 - 13.28 lb ft) Nut for tie rod M10x1.25 Pretorque 15 Nm (11.06 lb ft) Final torque 42 Nm (30.98 lb ft)
Page 222 California 1400 Engine 9. Intake and exhaust com. rockers 10.Rocker adjustment nut 11.Adjustment screw 12.Intake and exhaust com. rockers 13.5.3x10x0.5 spring washer 14.Complete breather cover 15.Screw 16.Plate 17.TE flanged screw M6x25 18.Cup spring 19.Shim washer 20.Shim washer 21.Roller 22.Nut M10x1.25 6H 23.Flanged screw M6x120...
Page 223 California 1400 Engine BE CAREFUL NOT TO INVERT TWO SPARK PLUG CAPS. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings. • Remove the head cover together with the gaskets. • Remove the two spark plugs.
Page 224: Removing The Cylinder Head
California 1400 Engine Removing the cylinder head • Undo and remove the two fixing screws of the pliers of the blow-by. • Remove the pliers of the blow-by pay- ing attention not to damage the seal ring. • Undo the external fixing screws of the head.
Page 225 California 1400 Engine • Discharge the left chain tensioner from the oil pressure undoing the screw shown. • With the help of a screwdriver act on the chain tensioner slider so as to dis- charge the thrust of the tensioner and simultaneously insert a pin in said hole so as to block the return.
Page 226 California 1400 Engine • Undo the nuts securing the cam tower and the head unit. • Remove the complete head of the cam tower timing system. • Undo the fixing screws of the rocker bridge • Remove the rocker bridge.
Page 227: Cylinder Head
California 1400 Engine • Use the screws as shown in the figure to extract the cam tower. • Remove the timing system cam tower complete with the camshaft. See also Removing the head cover Cylinder head key: ENG - 227...
Page 228 California 1400 Engine 1. Rockers. 2. Hydraulic tappets with rollers. 3. Camshaft. Removing the overhead camshaft • Using the special tool hold the cam- shaft. Specific tooling 020953Y Cam shaft lock for fixing • Unscrew and remove the camshaft fix- ing screw.
Page 229 California 1400 Engine • Remove the camshaft from its seat. • Remove the hydraulic tappets with roll- ers from their seats. See also Removing the rocker arms Removing the rocker arms • Undo the fixing screws of the rocker bridge •...
Page 230: Removing The Valves
California 1400 Engine • Remove the rockers. See also Removing the cylinder head 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.
Page 231: Checking The Cylinder Head
California 1400 Engine 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 between them and the stem cannot be elim- inated by simply replacing the valves.
Page 232: Installing The Valves
California 1400 Engine OUTLET VALVE SEAT DETAIL DRAWING - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45° milling cutter and then grind. - Replace the head in case of excessive wear or damage.
Page 233 California 1400 Engine Installing the rocker arms • Insert the roller hydraulic tappets. • Fit the camshaft • Place the half spheres (1) into the ap- propriate seats (2) of the rocker. • Place the two rocking levers in the cam tower seats.
Page 234 California 1400 Engine Installing the overhead camshaft Installing the overhead camshaft • Insert the roller hydraulic tappets mak- ing sure that the roller (1) in the appro- priate milling (2) of the cam tower coincides. • Position the cam shaft paying attention to the direction.
Page 235 California 1400 Engine • Remove the bushing so as to be able to fix the tool. • Be careful when removing it not to damage it. Specific tooling 020953Y Cam shaft lock for fixing • Tighten the camshaft fixing screw.
Page 236 California 1400 Engine Timing IMING SYSTEM pos. Description Type Quantity Torque Notes Idle shaft flange fixing screws M6x14 7 - 8 Nm (5.16 - 5.90 lb ft) Loctite 542 only on through hole Bearing on idle shaft fixing screw M6x16 8 - 10 Nm (5.90 - 7.37 lb ft)
Page 237 California 1400 Engine • Using the special tool, remove the tim- ing system gear. Specific tooling 12.91.36.00 Tool to remove the flywheel-side flange • Remove the tone wheel. • Recover the cotter and the shim wash- ENG - 237...
Page 238 California 1400 Engine • Undo and remove the timing sensor fixing screw. • Remove the timing sensor and its O- Ring See also Removing the generator Service shaft removal • Remove the tone wheel. • Remove both cylinders. • Undo and remove the two screws.
Page 239 California 1400 Engine Removing the phonic wheel Installing the service shaft • Place the service shaft bearing (if pre- viously removed) on the crankcase. • Fix it to the seat with the lock washer and screw. • Fit the timing chains according to the references marked at the removal phase.
Page 240 California 1400 Engine • Undo and remove the two M6 flanged screws. • Tighten the cap with the two original TBEI screws. Installing sliders • Fit the crankshaft and the service shaft on the crankcase. • Fit the fixed chain sliders and tighten the fixing screws.
Page 241 California 1400 Engine Cam timing • Fit the crankshaft and the service shaft on the crankcase. • Fit the cylinders. • Turn the crankshaft until the left cylin- der piston reaches the top dead centre (TDC). • Fit the cotter and the shim washer on the service shaft.
Page 242 California 1400 Engine • After shimming the timing sensor prop- erly, proceed to fit it. • Fit the washer and tighten the timing system gear fixing nut of the service shaft. • Place a new gasket between the crank- case and the oil pump.
Page 243 California 1400 Engine • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear.
Page 244 California 1400 Engine Measuring air gap • Undo the screw and remove the engine speed sensor. • Space the sensor with a 1 mm (0.0394 in) thick adjustment plate. • Measure the distance between the engine speed sensor and the tone wheel. If the distance measured is: - 0.55 - 0.7 mm (0.0216 - 0.0275 in), the 1 mm (0.0394 in) adjustment plate must be replaced with a...
Page 245 California 1400 Engine Cylinder-piston assembly ISTON CYLINDER pos. Description Type Quantity Torque Notes Tie rod on crankcase M10x1.25 5 Nm (3.69 lb ft) Right tensioner cover M30x1.5 40 Nm (29.50 lb ft) Left tensioner cover M20x1.5 30 Nm (22.13 lb ft)
Page 246 California 1400 Engine key: 1. Right cylinder 2. Piston 3. Screw 4. Top piston ring 5. Middle piston ring 6. Oil scraper piston ring 7. Pin 8. Retainer ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket 13.Left cylinder 14.Washer...
Page 247 California 1400 Engine • Remove the two dowel pins on the stud bolts. • Remove the two gaskets between the crankcase and the cylinder. • Cover the crankcase opening with a clean cloth. See also Removing the cylinder head Disassembling the piston...
Page 248 California 1400 Engine • The reference on the piston ring must be facing the piston crown. • Fit the piston rings on the piston: - the oil scraper in the lower slot; - the thicker smooth ring in the intermediate slot; - the less thick smooth ring in the upper slot.
Page 249 California 1400 Engine Installing the cylinder RIGHT CYLINDER • Fit the piston. • Remove the cloth used to prevent for- eign bodies from getting into the crank- case. • Turn the rings so that the coupling ends are 120 degrees from each other.
Page 250 California 1400 Engine • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner and the chain tensioner cap temporarily and keep the chain taut on the service shaft. LEFT CYLINDER • Fit the piston.
Page 251: Installing The Cylinder Head
California 1400 Engine DURING THIS OPERATION, PAY ATTENTION NOT TO DAMAGE THE PISTON. Specific tooling 020674Y Piston ring clamp 020716Y Connecting rod locking • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft.
Page 252 California 1400 Engine • Fit a new O-ring in the spark plug hole. • Fit the complete cam cap. • Fix the cam cap with the four nuts on the stud bolts. • Fix the head with the two screws.
Page 253 California 1400 Engine • Screw two screws in the threaded holes of the timing system upper gear. • Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain. • Place the gear in the chain.
Page 254 California 1400 Engine • Screw two screws in the threaded holes of the timing system upper gear. • Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain. • Place the gear in the chain.
Page 255 California 1400 Engine Installing the head cover • Replace the gaskets and install the head cover. • Replace the four rubber rings. • Tighten the four screws to the prescri- bed torque. • Position the two plug caps of the spark plug.
Page 256 California 1400 Engine Removing the crankshaft • Remove the clutch. • Remove the tone wheel and the oil pump gear. • Working from the generator side, un- screw and remove the nut. • Remove both gears. • Remove the connecting rods.
Page 257 California 1400 Engine • Collect the shim washer from inside the crankcase. See also Disassembling the clutch Removing the phonic wheel Disassembling the connecting rod RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws M10x1 Pre-torque 40 Nm (29.50 lb ft) Final torque 80 Nm (59.00 lb ft)
Page 258 California 1400 Engine • Remove both heads. • Remove the cylinders and the pistons. • Remove the oil sump. • Undo the coupling screws (A) inside the crankcase and remove the con- necting rods (B). See also Removing the flywheel...
Page 259 California 1400 Engine Specification Desc./Quantity Balance with a 1601 g (56.47 oz) +/- 0.25% weight fitted on the crankpin (B). Maximum imbalance allowed for each shoulder: 2 g (0.07 oz). Crankshaft selection colour (2) green Type 2 to be used with green connecting rods.
Page 260 California 1400 Engine CONNECTING ROD BUSHING THICKNESS Specification Desc./Quantity Regular 'Blue' connecting rod bearing (production) 1.539 - 1.544 mm (0.06059 - 0.06079 in) Regular 'Red' connecting rod bearing (production) 1.535 - 1.540 mm (0.06043 - 0.06063 in) CRANKPIN DIAMETER (B) Specification Desc./Quantity...
Page 261 California 1400 Engine Assembling the connecting rod • Lubricate the crankpin on which the connecting rods are to be fixed. • If the connecting rods are not replaced, be careful not to interchange the right connecting rod with the left one and vice versa.
Page 262 California 1400 Engine Installing the crankshaft • Fit the shim washer inside the crank- case with the chamfered side facing the generator side. • Lubricate the crankshaft bushing on the crankcase, generator side. • Use the sealing ring fitting tool on the flywheel-side flange to fit the sealing ring on the flange.
Page 263 California 1400 Engine • Place the flywheel-side flange on the crankshaft and check if the dowel pin with the O-ring is correctly placed. • Apply Teflon tape on the two lower fix- ing screws at the back in order to pre- vent oil leaks.
Page 264 California 1400 Engine Refitting the crankcase halves In case the lubrication jets are removed, replace them with two new of the same type. Check that the O-ring is fitted on the jets. Do not interchange them upon refitting because they have a different length.
Page 265 California 1400 Engine IL PUMP pos. Description Type Quantity Torque Notes Oil pump fixing screws M6x45 9 11 Nm (6.64 8.11 lb ft) Loctite 243 Low nut for oil pump M6x0.75 8 Nm (5.90 lb ft) Loctite 243 IL SUMP COMPONENTS pos.
Page 266 California 1400 Engine pos. Description Type Quantity Torque Notes Mesh type oil filter fixing screw M6x14 6 Nm (4.42 lb ft) Oil filter 15 Nm (11.06 lb ft) Engine oil RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75 10 Nm (7.37 lb ft)
Page 267 California 1400 Engine Conceptual diagrams The oil pump is operated by the gear (10) which receives the motion directly from the crankshaft. The gear (10) is mounted on the shaft (8), on which two rotors are fitted: one for engine cooling (7) and another for lubrication (6).
Page 268 California 1400 Engine 2. Oil delivery pipe to heads 3. Oil delivery pipe to radiator 4. Oil pump body 5. Oil pump gasket 6. Rotor for lubrication 7. Rotor for cooling 8. Rotor control shaft 9. Oil pump cover 10.Oil pump control gear 11.Lubrication oil intake filter...
Page 269: Oil Pump
California 1400 Engine 8. Flywheel-side 9. Piston cooling jets 10.Auxiliary shaft 11.Chain tensioner 12.Camshaft 13.Hydraulic tappet with roller 14.Rocker axes Oil pump Removing • Bring the left cylinder piston to the TDC in combustion phase. • Mark a reference on the oil pump control gear and another on the driven gear so as to place them correctly again upon refitting.
Page 270 California 1400 Engine • Drain the engine oil. • Remove the generator and the timing system cover. • Unscrew and remove the nipple. • Collect the gasket. • Unscrew and remove the three screws. • Remove the oil pump. •...
Page 271 California 1400 Engine Installing • Place a new gasket between the crank- case and the oil pump. • Fit the oil pump. • Tighten the three oil pump fixing screws. • Place the driving pin on the oil pump shaft.
Page 272 California 1400 Engine • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear.
Page 273 California 1400 Engine Removing the oil sump key: 1. Flange 2. Pressure adjuster valve 3. Flange inlet pipe 4. Pump inlet pipe 5. Pump inlet filter 6. Oil filter 7. Cartridge-type oil filter 8. Joint 9. Special gasket 10.Exhaust cap 11.Oil sump gasket...
Page 274 California 1400 Engine • Unscrew and remove the oil level plug and collect the O-Ring. • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Unscrew and remove the four screws. • Remove the pump inlet filter.
Page 275 California 1400 Engine • Unscrew and remove the filter fixing screw. • Remove the filter. • Remove the overpressure valve. Refitting the oil sump • Position the gasket of the overpressure valve. ENG - 275...
Page 276 California 1400 Engine • Apply threadlock on the overpressure valve. • Tighten it to the prescribed torque. • Make sure that the OR is in good con- dition, otherwise replace it. • Position the joint. ENG - 276...
Page 277 California 1400 Engine • Insert the joint in the oil sump, making sure the OR is in good condition. • Replace the OR if necessary. • Place a new gasket between the crank- case and the flange. • Insert the flange, the intake filter.
Page 278 California 1400 Engine • Fit the filter and tighten it to the speci- fied torque. • Place the oil sump. • Tighten the fourteen screws to the pre- scribed torque. • Add engine oil up to the correct level. Blow-by The Blow By system allows for oil vapours to be recycled.
Page 279 California 1400 Engine The oil vapours coming from the joints (1) and (2), are filtered and enter into the filter box through the joint (4)(5), while the liquid portion returns to the oil sump by means of the joint (3).
Page 280 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 281 California 1400 Power supply Circuit diagram key: 1. Fuel tank 2. Throttle body 3. Fuel filter 4. Fuel delivery pipe 5. Fuel pump unit Injection P SUPP - 281...
Page 282 California 1400 Power supply Diagram key: 1. Control unit position 2. Instrument panel 3. Ignition switch 4. Battery 5. Fuel pump 6. Throttle valve position sensor 7. Air pressure sensor and intake air 8. Injectors 9. Engine temperature sensor 10.Crankshaft position sensor 11.Gear sensor...
Page 283 California 1400 Power supply 13.Lambda probe ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date NOTE THE FIGURE ONLY SHOWS THE ICON THAT APPEARS IN THE NAVIGATOR.
Page 284 California 1400 Power supply Navigator characteristic P.A.D.S. characteristic Unit of measurement Throttle grip opening percentage Throttle grip opening percentage Throttle valve position potentiom- Throttle valve position potentiom- ° eter 1 eter 1 Throttle position correction Throttle position correction ° Left cylinder ignition advance Left cylinder ignition advance °...
Page 285 California 1400 Power supply DEVICES ACTIVATION Navigator characteristic P.A.D.S. characteristic Description / Value Right cylinder central coil Right cylinder central coil Left cylinder central coil Left cylinder central coil Right cylinder side coil Right cylinder side coil Left cylinder side coil...
Page 286 Moto Guzzi Controllo Moto Guzzi Controllo Present/Not present Present/Not present Trazione (in turn) Trazione (in turn) Moto Guzzi Quick Shift Moto Guzzi Quick Shift Present/Not present Present/Not present Present/Not present Present/Not present Front brake lever Front brake lever...
Page 287 California 1400 Power supply ERRORS screen page This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). ERRORS DISPLAY Navigator P.A.D.S. Navigator Description / Value P.A.D.S Description / Value...
Page 288 California 1400 Power supply Navigator P.A.D.S. Navigator Description / Value P.A.D.S Description / Value characteristic characteristic Left cylinder Left cylinder Short circuit to positive Short circuit to positive lambda probe lambda probe Heating left cylin- Heating left cylin- Short circuit to positive/ short circuit to...
Page 289 California 1400 Power supply Navigator P.A.D.S. Navigator Description / Value P.A.D.S Description / Value characteristic characteristic Cylinder manifold Cylinder manifold Pressure too high/pressure too low Pressure too high/pressure too low intake pressure intake pressure error error Manifold pres- Manifold pres-...
Page 290 California 1400 Power supply Navigator P.A.D.S. Navigator Description / Value P.A.D.S Description / Value characteristic characteristic NQS - No Dash- NQS - No Dash- Signal absent Signal absent board Node board Node NQS - Dash- NQS - Dash- Intermittent signal or communication er-...
Page 291 INDEX OF TOPICS SUSP USPENSIONS...
Page 292: Removing The Front Wheel
California 1400 Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Brake discs fixing screws M8x22 25 Nm (18.44 lb ft) Wheel axle 80 Nm (59.00 lb ft) Removing the front wheel • Working from both sides, undo and re-...
Page 293 California 1400 Suspensions • Hold the motorcycle front section. • Loosen the screw on the wheel axle clamp. • Undo and remove the wheel axle. • During the pin extraction operation, support the wheel and then remove it. Checking the front wheel FRONT WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel.
Page 294 California 1400 Suspensions • Replace both wheel bearings. RADIAL AND AXIAL CLEARANCE CHECK • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: •...
Page 295 California 1400 Suspensions FRONT WHEEL REMOVAL • Remove the spacer. • Undo and remove the six fixing screws (1) of the tone wheel and the front disc. • Remove the tone wheel and the front disc. SUSP - 295...
Page 296 California 1400 Suspensions • Working on the opposite side remove the spacer. • Remove the dust gaiter. • Undo and remove the six fixing screws (2) of the front disc and remove it. • Remove the Seeger ring. • Using the special tool remove the bear- ing and the spacer.
Page 297 California 1400 Suspensions • After removing the bearing (3) and the spacer (4), operate from the opposite side and remove the bearing (5). SUSP - 297...
Page 298 California 1400 Suspensions Handlebar REMOVAL OF COMMANDS TO HANDLEBAR • Undo and remove the two fixing screws of the clutch pump bracelet. • Remove the pump. • Undo and remove the three fixing screws of the left switch. • Remove the switch.
Page 299 California 1400 Suspensions • Undo and remove the two fixing screws of the right switch. • Remove the switch. Removing • Undo and remove the four fixing screws of the handlebar bracelet. • Remove the handlebar. SUSP - 299...
Page 300 California 1400 Suspensions Front fork pos. Description Type Quantity Torque Notes Lower suspension bars fixing screws M5x50 6 Nm (4.42 lb ft) SUSP - 300...
Page 301: Removing The Fork Legs
California 1400 Suspensions TEERING pos. Description Type Quantity Torque Notes Screws fixing forks to plate M8x35 25 Nm (18.44 lb ft) Lower ring nut 50 Nm (36.87 lb ft) Pretightening to 60 Nm (44.25 lb ft) Upper cover 100 Nm (73.76 lb ft) Removing the fork legs •...
Page 302 California 1400 Suspensions Draining oil • Lock the stanchion in a vice with the specific tool. Specific tooling 020951Y Stanchion support • Unscrew the upper cap of the stan- chion. • Using the special tool to hold the locked preloading pipe.
Page 303 California 1400 Suspensions • Remove the spring. • Pour the oil inside a container of ade- quate capacity. Disassembling the fork • Discharge all the oil from the sleeve. • Tighten the wheel holder sleeve in a vice. • Apply the specific wrench on the ring nut of the piston.
Page 304 California 1400 Suspensions • Remove the retainer ring. • Take out the sleeve from the stem us- ing the stem as a hammer puller. • Remove all components of the stanchion. Checking the components Stem Check the sliding surface for scorings and/or scratches.
Page 305 California 1400 Suspensions 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. CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SUR- FACE.
Page 306 California 1400 Suspensions • O-Ring on the cap. Reassembling the fork • Lock the sleeve in the vice. • Lubricate the stanchion sliding edges with fork oil or grease for seals. • Install the lower and upper bushing on the stanchion, the dust scraper, the seal ring and the washer.
Page 307 California 1400 Suspensions • Insert the retainer ring in its position. • Fit the dust gaiter with the specific tool. Specific tooling AP8140146 Weight • Insert the pumping member in the sleeve. • Install the lock key of the piston.
Page 308 California 1400 Suspensions • Tighten the piston fixing screws in the fork end to the prescribed torque. Filling oil • Place the sleeve upright in a vice fitted with protection shoes. • Compress the sleeve in the stem. Place a support under the stem in order to leave it compressed.
Page 309 California 1400 Suspensions 612 cm³ (37.35 cu.in) (for each stem) Oil level (from sleeve rim, without the spring and with pumping member fully down) 110 mm (4.33 in). • Insert all components in the piston. • Fit the spring. •...
Page 310: Installing The Fork Legs
California 1400 Suspensions • Screw the upper cap on the pumping member pin. • Position the stanchion in a vice by means of the special tool, keeping the forks in a vertical position. • Tighten the cap to the prescribed tor- que.
Page 311 California 1400 Suspensions • Mount the front wheel. • Before tightening torque the clamp screw, turn the fork a few trips in order to perfectly align the sleeve. Removing • First remove the handlebar, the front wheel. • Working from both sides undo the screws fixing the upper plates to the forks.
Page 312 California 1400 Suspensions • Remove the upper plate. • Remove the OR from the forks and the upper cover. • Undo and remove the screws fixing the lower plate to the fork. SUSP - 312...
Page 313 California 1400 Suspensions • Retrieve the safety plate. • Using the special tool loosen the upper ring nut (1) and the lower ring nut (2). • Retrieve the rubber spacer (3) placed between the two ring nuts. • Be careful to properly hold the lower plate.
Page 314 California 1400 Suspensions • Remove the spacer located in the low- er plate. • Remove the axial ball bearing (5)(6). • Remove the lower plate. • Working from both sides, undo and re- move the two fixing screws of the fork lower cover.
Page 315 California 1400 Suspensions Steering bearing TEERING pos. Description Type Quantity Torque Notes Screws fixing forks to plate M8x35 25 Nm (18.44 lb ft) Lower ring nut 50 Nm (36.87 lb ft) Pretightening to 60 Nm (44.25 lb ft) Upper cover 100 Nm (73.76 lb ft)
Page 316 California 1400 Suspensions • Adjust the preloading of the steering bearings by tightening the lower ring nut to the prescribed torque. • Turn the steering 3-4 times completely from right to left and then check correct tightening torque of such ring nut.
Page 317 California 1400 Suspensions Disassembling • Using the special tool remove the up- per bearing. • Subsequently, after removing the up- per bearing hit it from bottom upwards, using the appropriate tool, to extract the lower one. Assembling • Using the special tool install the two bearings, first the lower then the upper one.
Page 318 California 1400 Suspensions • Assemble the components from (1) to (5). • Insert the upper oil seal and make sure the straight section of the column (A) is secured. • Tighten the ring nut (6) to the specified torque before the dust gaiter (5), then unscrew the abovementioned ring nut and retighten it.
Page 319: Removing The Rear Wheel
California 1400 Suspensions Rear EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel pin 100 Nm (73.76 lb ft) Tone wheel flange screws M8x20 25 Nm (18.44 lb ft) Wheel axle nut M25x1.5 100 Nm (73.76 lb ft) Removing the rear wheel •...
Page 320: Checking The Rear Wheel
California 1400 Suspensions • Remove the pin and remove the rear wheel. Checking the rear wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS. REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel.
Page 321 California 1400 Suspensions ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE. • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: •...
Page 322 California 1400 Suspensions • Remove the left spacer. • Remove the right spacer. • Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless. If one or both bearings do not fall within the control parameters: •...
Page 323 California 1400 Suspensions • Unscrew and remove the five screws (1). • Remove the flange paying attention to the spacer. • Remove the flexible coupling disc. • Operating from the opposite side undo and remove the six fixing screws (2) of the tone wheel.
Page 324 California 1400 Suspensions • Remove the dust gaiter and the seeger ring locking the bearings. • Undo and remove the six fixing screws of the rear disc. • Remove the rear disc. SUSP - 324...
Page 325 California 1400 Suspensions • using the special tool, remove the bearings. • After removing the bearing (3) and the spacer (4), operating from the opposite side and using the special tool, remove the bearing (5). SUSP - 325...
Page 326: Installing The Rear Wheel
California 1400 Suspensions Installing the rear wheel • To install the rear wheel carry out the operations described for disassembly in reverse order, paying particular at- tention to the type of flange mounted. In fact, depending on this it may or may...
Page 327 California 1400 Suspensions EAR SHOCK ABSORBERS pos. Description Type Quantity Torque Notes Pins 40 Nm (29.50 lb ft) Shock absorber fixing screws M6x14 10 Nm (7.37 lb ft) Removing • The following procedure refers to one single shock absorber, but is valid for both.
Page 328 California 1400 Suspensions ONLY FOR THE CUSTOM VERSION The following procedure is described for one single shock absorber, but is valid for both. • Remove the footrest mounting. • As for the Touring version, unscrew and remove the two fixing screws of the shock absorber.
Page 329 INDEX OF TOPICS CHAS HASSIS...
Page 330 California 1400 Chassis Swinging arm WINGARM pos. Description Type Quantity Torque Notes Swingarm pin 60 Nm (44.25 lb ft) Preloading bushing 10 Nm (7.37 lb ft) Clamp screws M6x25 10 Nm (7.37 lb ft) Removing • First remove the rear wheel.
Page 331 California 1400 Chassis • Remove the clamp that fixes the dust gaiter (3) to the swingarm. • Unscrew and remove the pin, making sure that the swingarm does not fall. Cardan shaft CHAS - 331...
Page 332 California 1400 Chassis Removing • First remove the swingarm. • Remove the rubber protection. • Using a screwdriver, remove the uni- versal joint. • Remove the cardan shaft. Checking Carefully check: The splines on the cardan shaft (1) must be intact, free from grain or dents.
Page 333: Side Stand
California 1400 Chassis In the figure are shown two worn toothing profiles: • Profile (3) shows acceptable wear, the cardan shaft should not be replaced. • Profile (4) shows unacceptable wear, the cardan shaft must be replaced. Stand TAND pos.
Page 334 California 1400 Chassis • Unscrew and remove the three screws. • Remove the side stand. Exhaust UEL TANK pos. Description Type Quantity Torque Notes Front fixing screw M8x16 25 Nm (18.44 lb ft) Rear fixing screw M6x25 10 Nm (7.37 lb ft)
Page 335 California 1400 Chassis Removing the manifold - tail pipe • The following procedure applies to both exhausts. • Loosen and remove the three fixing screws of the heat shield. • Remove the heat shield. • Loosen the side clamp. •...
Page 336 California 1400 Chassis • Undo and remove the two nuts on the exhaust stud bolts of the head. • Remove the exhaust manifold. CHAS - 336...
Page 337 California 1400 Chassis Engine oil cooler IL RADIATOR pos. Description Type Quantity Torque Notes Screws fixing oil radiator to chassis M6x25 10 Nm (7.37 lb ft) Screws fixing electric fan to oil radiator 4,2x20 2.5 Nm (1.84 lb ft) CHAS - 337...
Page 338 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 339 California 1400 Braking system ABS B RAKING YSTEM pos. Description Type Quantity Torque Notes ABS control unit lower cover fixing screws 6 Nm (4.42 lb ft) ABS control unit support plate fixing screws M6x25 10 Nm (7.37 lb ft) ABS control unit support plate fixing screws M6x16 10 Nm (7.37 lb ft)
Page 340 California 1400 Braking system key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Start-up relay 6. ECU 7. Instrument panel 8. K line (diagnosis) 9. Starter motor 10.Fuses ABS control unit pin out key:...
Page 341 California 1400 Braking system Front speed sensor ground PIN 13 Front speed sensor signal PIN 14 Vehicle identification (2) PIN 15 Serial K line for diagnostics PIN 16 Battery power PIN 18 Foreword key: 1. Rear brake calliper 2. Modulator 3.
Page 342 California 1400 Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit BRAK SYS - 342...
Page 343 California 1400 Braking system 5. Rear brake pump 6. Rear brake pedal control 7. ABS control unit 8. Rear brake calliper 9. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open) 11.Humidifier 12.Rear brake circuit intake solenoid valve (normally open) 13.Rear brake exhaust circuit solenoid valve (normally closed)
Page 344 California 1400 Braking system D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider.
Page 345 California 1400 Braking system Riding with an active ABS system • At engine starter, the ABS warning light (5) on the instrument panel (4) flashes until the vehicle exceeds 5 km/h (3.1 mph). If the ABS warning light remains on when the...
Page 346 California 1400 Braking system - error code 5D93 requires some minutes before it is diagnosed during the given time: the ABS warning light ABS keeps flashing. ABS FAULTS - GUIDE TO THE DIAGNOSIS 1. ABS WARNING LIGHT ON 2. CONNECT DIAGNOSTICS INSTRUMENT DOES THE DIAGNOSTICS INSTRUMENT COMMUNICATE? (NO, go to 3;...
Page 347 California 1400 Braking system P.A.D.S./Navigator characteristic Value/example Unit of Notes measure ment Software version Vehicle code The vehicle code stored in the control unit is read. Vehicle identification according to A different type of vehicle is associated with each state of Pins 2 and 15 configuration of PIN 2 and PIN 15 connections or the injection control unit vehicle code reader.
Page 348 California 1400 Braking system ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. ACTIVATION P.A.D.S./Navigator characteristic Value/example Unit of Notes measure ment Front brake bleeding procedure...
Page 349 California 1400 Braking system ERRORS screen page This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). ERRORS P.A.D.S./Navigator characteristic Value/example Unit of Notes...
Page 350 California 1400 Braking system P.A.D.S./Navigator characteristic Value/example Unit of Notes measure ment Rear speed sensor: excessive meas- Faulty sensor or tone wheel with wrong number of ured speed 5DA5 teeth or wrong tyre size Control unit: missing valve calibra- Possible control unit fault...
Page 351 California 1400 Braking system ADJUSTMENTS P.A.D.S./Navigator characteristic Value/example Unit of Notes measure ment Coding (1) Used for re-coding the control unit or coding a new one. Coding (2) The identification of the vehicle is carried out based on the injection control unit reading.
Page 352 California 1400 Braking system • Disconnect the ABS control unit con- nector. • Remove the ABS control unit. INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR • Check the initial position of the lever that couples the connector. • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5...
Page 353 California 1400 Braking system IT IS ADVISABLE TO CREATE A TEMPLATE TO CHECK THE CORRECT CONNECTOR IN- SERTION. • Fit the protection casing. Component maintenance The vehicle is fitted with a two-channel ABS sys- tem, i.e. it works on both the front and the rear wheel.
Page 354 California 1400 Braking system Disc Inspection REAR CAUTION THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI- FICATIONS OF THE SYSTEM. • The following operations are to be car- ried out with brake disc fitted on the wheel.
Page 355: Front Brake Pads
California 1400 Braking system Disc oscillation tolerance: 0.15 mm (0.0059 in), with respect to the wheel centre line. Front brake pads Removal • Undo and remove the two screws. • Slide off the brake calliper from the disc. • Turn the pins and remove both split pins.
Page 356 California 1400 Braking system • 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.
Page 357 California 1400 Braking system Rear brake pads Removal • Remove the lock and remove the pin. BRAK SYS - 357...
Page 358 California 1400 Braking system • 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. Installing • Insert two new pads, placing them so that the holes are aligned with the cal- liper holes.
Page 359 California 1400 Braking system Bleeding the braking system VEHICLE PREPARATION • It is important to check that there is always enough brake fluid in the reservoir. • Using a bleed device facilitates these operations while, in the meantime, the "Brake fluid replacement"...
Page 360 California 1400 Braking system REPLACE THE ABS CONTROL UNIT VEHICLE PREPARATION • Connect the bleed bottle to the bleed screws of the front and rear callipers and open it. • Fully press down the lever and the brake pedal and fix them into position with the respective locking devices.
Page 361 California 1400 Braking system • Check the stroke and the sensitivity of both the lever and the brake pedal. • If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in the braking system and if everything is ok, continue bleeding operations using Navigator as described.
Page 362 California 1400 Braking system BLEEDING SYSTEM WITH DIAGNOSTICS INSTRUMENT This type of bleeding has to be carried out if after all the checks the brake lever and the pedal are still spongy. The operations described here are valid for both systems even though the description refers to the front system.
Page 363 California 1400 Braking system • 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 con- tainer to collect the fluid.
Page 364 California 1400 Braking system • 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.
Page 365 INDEX OF TOPICS BODYW ODYWORK...
Page 366 California 1400 Bodywork EAR MUDGUARD pos. Description Type Quantity Torque Notes Front fixing screws M8x20 25 Nm (18.44 lb ft) Upper fixing screw M8x16 25 Nm (18.44 lb ft) Side cover fixing screws M5x9 6 Nm (4.42 lb ft) BODYW - 366...
Page 367 California 1400 Bodywork NDER ADDLE pos. Description Type Quantity Torque Notes Lower saddle compartment closing fixing 6 Nm (4.42 lb ft) screws Fixing screw closing upper and lower saddle M5x20 3 Nm (2.21 lb ft) compartment stainless steel ENTRAL BODYWORK pos.
Page 368 California 1400 Bodywork ANK COVER pos. Description Type Quantity Torque Notes Fairing fixing screws M5x10 6 Nm (4.42 lb ft) Dashboard fixing screw M5x16 5 Nm (3.68 lb ft) UEL TANK pos. Description Type Quantity Torque Notes Front fixing screw M8x16 25 Nm (18.44 lb ft)
Page 369 California 1400 Bodywork pos. Description Type Quantity Torque Notes Fuel pump fixing screw M5x20 6 Nm (4.42 lb ft) Fuel level sensor fixing nuts 5 Nm (3.69 lb ft) Screw fastening cap flange to tank M5x16 6 Nm (4.42 lb ft) EADLAMP pos.
Page 370 California 1400 Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws M5x12 4 Nm (2.95 lb ft) Engine guard (IF APPLICABLE) NGINE GUARD KIT pos. Description Type Quantity Torque Notes Engine guard upper fixing screws 50 Nm (36.2 lb ft) Engine guard lower retainer nut 50 Nm (36.2 lb ft)
Page 371 California 1400 Bodywork • The following procedure is described for one single engine guard, but is valid for both. • Unscrew and remove the screw indi- cated in the figure. • Position engine guard and secure it with the screw provided in the kit.
Page 372 California 1400 Bodywork • Rotate the engine guard to the left and secure it with the screw from the kit. • Finally replace the lower screw of the engine guard with the one supplied in the kit. • Tighten all screws to torque.
Page 373 California 1400 Bodywork IDE BUMPERS KIT pos. Description Type Quantity Torque Notes Bumpers front fixing screw M8x70 24 Nm (17.4 lb ft) Bumpers central fixing screw M8x25 24 Nm (17.4 lb ft) Bumpers rear fixing screw M8x50 24 Nm (17.4 lb ft)
Page 374 California 1400 Bodywork pos. Description Type Quantity Torque Notes Luggage rack upper fixing screws M8x25 25 Nm (18.4 lb ft) Luggage rack side fixing screws M8x20 25 Nm (18.4 lb ft) • First remove the rear handle. Working on both sides of the bike: •...
Page 375 California 1400 Bodywork INSTALLATION OF LUGGAGE RACK ON BIKE WITH PANNIERS • First remove the cases and the rear handle. Working on both sides of the bike: • Screw the spacer (1) into the bike frame. • Remove the screw (2).
Page 376: Instrument Panel
California 1400 Bodywork Instrument panel • Undo and remove the two front fixing screws of the instrument panel; during operation, take care to support it ade- quately. • Undo and remove the three fixing screws (1). • Remove the rear cover.
Page 377 California 1400 Bodywork • Disconnect the front headlamp con- nectors. • Unscrew and remove the fixing screw behind the headlight assembly. • Undo and remove the two side fixing screws. • Be careful to adequately support the headlight assembly before removing the screws.
Page 378 California 1400 Bodywork Additional lights • Undo and remove the three lower fixing screws (1) taking care to properly sup- port the additional headlamps. • Remove the two connectors (2) from the bulkhead, pulling slightly. • Disconnect the additional light connec- tors.
Page 379 California 1400 Bodywork Footrest • The following procedure is described for one single footrest, but is valid for both. • Disconnect the stop light connector. • Undo and remove the three fixing screws (1). NOTE BEFORE PROCEEDING WITH THE LEFT FOOTREST RE- MOVAL, DISCONNECT THE GEAR TIE ROD.
Page 380 California 1400 Bodywork • Remove the fixing clamp of the stop light switch (3). • Undo and remove the two fixing screws (2). • Remove the switch. • Unscrew and remove the fixing screw of the brake lever. • Remove the brake lever.
Page 381 California 1400 Bodywork GEAR LEVER REMOVAL • To remove the gear lever, unscrew the screw shown in the figure. PASSENGER FOOTREST • Unscrew and remove the four screws (1). • Unscrew and remove the rear screw. • Remove the passenger footrest.
Page 382 California 1400 Bodywork Side body panels • Operating from both sides, unscrew and remove the fixing screw. • Remove the side fairing. SADDLE RELEASE CONTROL REMOVAL • Remove the fork spring. • Disconnect the saddle release cable. • Remove the cable support plate.
Page 383 California 1400 Bodywork • Remove the ignition switch assembly. License plate holder • Disconnect the light connector located under the rear mudguard. • Undo and remove the two fixing screws of the license plate support. • Remove the license plate support.
Page 384 California 1400 Bodywork Rear mudguard • First remove the rear handle. • Disconnect the connector of the li- cense plate light. • Unscrew and remove the lower fixing screw. See also Rear grab rail • Working from both sides, release the two side locks.
Page 385 California 1400 Bodywork • Undo and remove the turn indicator fix- ing screws. • Remove the wiring by its fasteners. • Remove the turn indicator. BODYW - 385...
Page 386: Fuel Tank
California 1400 Bodywork Fuel tank During the removal and refitting of the tank be very careful, in fact two types can be found: 1. Model "1" 2. Model "2" (Tank fitted on the USA version) In this case the difference is the number of breath- er pipes that are on the fuel pump side.
Page 387 California 1400 Bodywork • Undo and remove the two fixing screws of the tank cap cover. • Remove the cover. • Disconnect the two connectors of the fuel level sensor. • Working from both sides, undo and re- move the two side screws.
Page 388 California 1400 Bodywork • Unscrew and remove the rear screw. • Slightly lift the tank so as to be able to reach the connector. • Disconnect the connector of the fuel pump. • Disconnect the fuel pipe. CAUTION PAY ATTENTION TO THE LEAKAGE OF FUEL EVEN IF IN A MINIMUM QUANTITY.
Page 389 California 1400 Bodywork Rear wheelhouse • First remove the control unit, license plate support and side panniers sup- port. • Working from both sides, undo and re- move the two side fixing screws. • Unscrew and remove the two rear screws.
Page 390 California 1400 Bodywork • Working from both sides, undo and re- move the two screws on the side of the rear shock absorber. • Undo and remove the fixing screws in the lower protection part of the ABS control unit.
Page 391: Front Mudguard
California 1400 Bodywork Front mudguard • Working from both sides, undo and re- move the two fixing screws (1). • Remove the front mudguard. Side panniers (IF APPLICABLE) • Open the top box using the key. • Undo and remove the four fixing screws (1), being careful to support the top box.
Page 392 California 1400 Bodywork • Remove the side top box. • Undo and remove the two bottom screws (2) and the side screw (3). • Remove the left support (1). • Repeat the same operations to remove the right support. •...
Page 393 California 1400 Bodywork IDE PANNIERS SUPPORT pos. Description Type Quantity Torque Notes Support fastening screws M8x16 25 Nm (18.1 lb ft) Support fastening screws M8x20 25 Nm (18.1 lb ft) THE FOLLOWING CHANGES ARE ONLY VAL- ID FOR THE USA VERSION MOTORCYCLE WITH CASES •...
Page 394 California 1400 Bodywork • Fix the reflectors (1) with the nuts (2) on the support (3). • Fix the support (3) by interposing it be- tween the license plate support (4) and the license plate holder (5). Pannier mounting The following steps are described for only one side of the frame but apply to both.
Page 395 California 1400 Bodywork Rear (ACCESSORY) pos. Description Type Quantity Torque Notes Top box attachment plate fastening screws M6x20 10 Nm (7.37 lb ft) • First install the luggage rack. • Secure the attachment plate (1) to the luggage rack (2) using the four screws (3) complete with pads (4), bushes (5), washers (6) and self-locking nuts (7).
Page 396 California 1400 Bodywork • Secure the cover (8) to the plate (1) using the four screws (9). Rear grab rail • First remove the saddle. • Undo and remove the three fixing screws (1) of the rear handle. • Remove the rear handle.
Page 397 California 1400 Bodywork Windscreen INDSHIELD KIT Position Description Quantity Windshield frame fixing screws kit (TBEI M6x20 stainless) Windshield frame-upper steering yoke fixing screws kit (TCEI M6x25 stainless) Frame-lower mounting bracket fixing screws (TSEI M6x40 stainless) Lower mounting bracket-lower steering yoke fixing screws (TBEI M6x20)
Page 398 California 1400 Bodywork the cable grommet in the right bracket (11). • Using the upper bayonet mount, con- nect the frame, complete with wind- shield, to the fasteners (2) which have just been assembled. • Secure the lower mounting bracket (5) to the lower steering yoke using the two screws (4).
Page 399 California 1400 Bodywork • Disconnect the two battery cables starting from the negative and then move to the positive. • Remove the battery. BODYW - 399...
Page 400 INDEX OF TOPICS PRE DE DELIVERY...
Page 401 California 1400 Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...
Page 402: Road Test
California 1400 Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 403 California 1400 Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
Page 404 California 1400 Pre-delivery Specific operations for the vehicle ANTI-THEFT DEVICE • Remove the left fairing. • Cut the indicated clamp and free the LED connector. • Take half of the adhesive backed foam in the anti-theft device kit and stick it to the bottom of the anti-theft control unit.
Page 405 California 1400 Pre-delivery • Install the left side fairing on the bike. (ACCESSORY) EATED HANDGRIPS KIT pos. Description Type Quantity Torque Notes Counterweighted fastening screws M6x30 10 Nm (7.37 lb ft) HEATED HANDGRIPS • Remove both side fairings first. LEFT HEATED HANDGRIP INSTALLATION •...
Page 406 California 1400 Pre-delivery • Collect the fixing screws (5) from the heatable handgrip (4). • Position the heatable handgrip all the way, taking care to align the holes on the grip with those on the handlebar, and screw in the fixing screws (5).
Page 407 California 1400 Pre-delivery • Insert and secure to the handlebar us- ing the screw (10), the spacer (8) and the counterweight (9). RIGHT HEATED HANDGRIP INSTALLATION • Remove the brake master cylinder first. • Remove the counterweight (2), undo- ing the screw (1).
Page 408 California 1400 Pre-delivery • Insert the heatable handgrip (5) in the handlebar and connect the gas cables which were removed from the block earlier. • Close the accelerator control block, taking care to insert the peg in the dedi- cated hole on the handlebar.
Page 409 California 1400 Pre-delivery • Insert and secure to the handlebar us- ing the screw (8), the spacer (10) and the counterweight (9). PRE DE - 409...
Page 410 ABS: 158, 340 Air filter: 59 Alternator: Battery: 112, 398 Brake: 355, 357 Brake pads: 355, 357 Brake pump: CAN line: 159 Cardan shaft: 331 Clutch: 149, 213, 217, 257 Coil: 138 Connectors: 153 Crankcase: 255, 264 Crankshaft: 240, 243, 255, 256, 258, 262 Cylinder: 42, 224, 227, 230, 231, 246, 247, 249, 251, 258 Desmodromic drum: 202 Display:...
Page 411 Identification: 9 Instrument panel: 376 Intake pressure sensor: 124 License plate holder: 383, 389 Luggage rack: Maintenance: 7, 54, 353 Maintenance Table: Mudguard: 384, 391 Oil filter: 58 Oil pressure sensor: 147 Oil sump: 273, 275 Primary shaft: 196, 201–203 Radiator: Rear wheel: 55, 319, 320, 326 Recommended products: 44...

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California 1400 my12

MOTO GUZZI California 1400 Instructions Manual

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3 Nm (2.21 Lb Ft)

6 Nm (4.42 Lb Ft)

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