CALIFORNIA EV - Motorcycle MOTO GUZZI - Free user manual and instructions

USER MANUAL CALIFORNIA EV MOTO GUZZI

The illustrations and description in this booklet are indicative only and the manufacturer reserves itself the right to introduce any modification it may deem necessary for better performance or for constructive or commercial reasons without prior notice.

First of all we wish to thank you for choosing this motorcycle of our production.

By following the instructions outlined in this manual you will ensure your bike a long and troublefree life.

Before riding, please read thoroughly this manual in order to know your motorcycle's features and how to operate it safely.

All major checking and overhaul jobs are best carried out by our dealers who have the necessary facilities to quickly and competently repair your Moto Guzzi.

Repairs or adjustments by any other than a Guzzi dealer during the warranty period could invalidate the warranty right.

Monsieur:

IMPORTANT - The text is supplemented with schematic illustrations for quick reference and better understanding of the subjects concerned.

This manual contains some special remarks:

Accident prevention rules for the mechanic and for the personnel working nearby.

Possibility of damaging the motorcycle and/or its components.

Additional information concerning the job being carried out.

11 Specifications
20 Frame and engine numbers
24 Instruments and controls
56 Riding your motorcycle
63 Running-in
66 Maintenance and adjustments
84 Removing the wheels
97 Service schedule
100 Cleaning - storing
104 Cleaning the windscreen (if mounted)
106 Lubrication
118 Valve gear
122 WEBER injection- ignition system (I.A.W. 15M)
142 Electrical equipment
163 Wiring diagram

INDEX

Transmission secondaria

4-stroke, twin cylinder

Cylinder configuration 90° V-twin

Bore: 92 mm

Stroke: 80 mm

Capacity: 1064 cc

Compression ratio: 9.5:1

Max. torque: 9.6 kgm (94 Nm) at 5000 rpm

Max. power: CV 73,5 (Kw 54) at 6400 rev/min

Timing system

With rods and rockers and 2 valves per cylinder. One camshaft in the crankcase driven by duplex chain with automatic chain tensioner.

Feed system

Indirect electronic injection, timed sequential MAGNETI MARELLI IAW 15M "Alfa-N" system, 2 throttle valves 40mm with Weber IW031 injectors, electric pump with pressure regulator, digital control of optimised injection times.

Exhaust system

In stainless steel - 2 pipes connected to an expansion chamber and two silencers.

Lubrication

Pressure fed by gear pump

Wire mesh and cartridge filters on oil sump

Normal lubrication pressure 3.8 ÷ 4.2 ~kg / cm^2 (pressure valve on oil sump).

Low oil pressure sensor (electrical) on crankcase.

Generator / Alternator

On front of crankshaft.

Output power: 350W at 5000 rev./min. (14V - 25A).

Ignition

"MAGNETI MARELLI" Inductive discharge digital electronics.
Spark plugs: NGK BPR 6 ES.
Spark plug gap: 0.7 mm
2 ignition coils . mounted on frame.

Starter

Electric starter motor 12V-1,2 Kw with electromagnetic ratchet control. Ring gear on the flywheel. START «(?)» push-button on right handlebar.

Transmission

Clutch

Dry, twin driven plates. Located on engine flywheel.

Clutch lever on left handlebar.

Primary drive

With helical gears, 1:1.2353 (Z=17/21).

12

Gearbox

5-speed, front engaging, constant mesh.

Incorporated Cush drive

Control pedal on left side of machine.

Gear ratios:

1st 1:2 (Z=14/28)

2nd 1:1.3889 (Z=18/25)

3rd 1:1.0476 (Z=21/22)

4th 1:0.8696 (Z=23/20)

5th 1:0.7500 (Z=28/21)

Final drive

Cardan shaft with gears

Overall gear ratios (engine-wheel)

1st gear = 1:10,1912

2nd gear = 1: 7,0772

3rd gear = 1 : 5,3382

4th gear = 1 : 4,4309

5th gear = 1 :3,8217

Frame

High tensile stress modular duplex tubular cradle.

Suspension

Front: «MARZOCCHI Ø 45 mm» hydraulic telescopic fork, with separate adjustment of hydraulic damping during rebound and compression.

Rear: swinging fork with two adjustable hydraulic shockabsorbers in the hydraulic damping during rebound.

Wheels

Spoked with Tubeless rims in sizes:

• Front: 18"x2.50 - MT
  Rear: 17"x4.00 - MT

Tyres

• Front: 110/90 - 18 - 61V
  Rear: 150/70 - 17 - 69V

Brakes

Integral braking system with braking correction and delay valve.
Front: "BREMBO" semi-floating stainless steel disc with fixed calliper and 4 differentiated pistons. Hand lever control located on the right side of the handlebars. Hydraulic transmission independent from the rear brake;
- disc 320 mm;
- brake cylinder 30/34 mm;
- master cylinder 13 mm.

Rear: fixed disc with floating calliper and 2 parallel pistons. Pedal lever control located in the centre on the right side of the vehicle;

• disc 282 mm;
• brake cylinder 30/32 mm;
• master cylinder 16 mm.

The rear brake is connected by a hydraulic circuit to the left front brake; the left front brake has the same dimensions as the right front brake controlled by the brake lever.

Dimensions and weight

Wheelbase 1,560 m

Overall length 2,380 m

Overall width 0,815 m

Height (without screen) 1,150 m

Driver's seat height 0,760 m

Weight (dry) 251 kg

Performance

Max. speed without accessories with one rider: 200 Km/

h. Fuel consumption: 5 lt/100 km (CUNA standards).

N.B. - On request the motor vehicle can be equipped with a windshield which allows com

fortable driving, and large capacity removable sidebags.

These items do however after the aerodynamic features of the bike; it is advisable therefore not to exceed 130 kph especially when the bike is fully loaded.

Refuelings

Part	Litres	Recommended product
Fuel tank (reserve approx 4 lt.)	approx. 19	Super petrol (97 NO-RM/min.) Unleaded petrol (95 NO-RM/min.)
Oil sump	3	Olio "Agip 4T SUPER RACING SAE 20W/50"
Scatola cambio	0,750	Olio "Agip Rotra MP SAE 80 W/90"
Scatola trasmissione(lubrificazione copbia conica)	0,250 of which 0,230 0,020	"Agip Rotra MP SAE 80 W/90" "Agip Rocol ASO/R" or "Molykote tipo A"
Front forks (for leg)	0,485	Shock - Absorbers oil (SAE 10)
Front and rear brake circuits	--	"Agip Brake Fluid - DOT4"

14 CHARACTERISTIQUES GENERALES

Moteur

1. Gang = 1:2 (Z = 14/28)
2. Gang = 1:1,3889 (Z = 18/25)
3. Gang = 1:1,0476 (Z = 21/22)
4. Gang = 1:0,8696 (Z = 23/20)
5. Gang = 1:0,7500 (Z = 28/21)

Sekundärtrieb

1. Gang = 1:10,1912
2. Gang = 1: 7,0772
3. Gang = 1: 5,3382
4. Gang = 1: 4,4309
5. Gang = 1: 3,8217

Fahrgestell

FRAME AND ENGINE NUMBERS (fig.2)

The frame number is stamped on the downtube; this number is entered in the motorcycle's log-book and is thus used to identify the vehicke for legal purposes. The engine number is stamped on the crankcase.

NUMEROS D'IDENTIFICATION (fig. 2)

Use of spares which are not approved will invalidate warranty rights.

Pieces détachées

1 Key switch for devices and steering lock.
Position OFF «» vehicle stationary. Key removable (no contact).
Position ON «Q» vehicle ready to be started.
All circuits are on. Key not removable.
Position LOCK «O» steering locked. Engine off, no contact, key removable.
Position P «P» steering locked. Engine off; with switch «A» of fig. 5 in position «E» the parking light is on. Key removable.

APPAREILS DE CONTROLE ET COMMANDE

In order to use the steering lock mechanism, proceed as follows:

Turn the handlebars to the left.
Press the key downwards and release it, then turn it in an anticlockwise direction to the LOCK «@» or P «P» position.

WARNING: Never turn the key to position LOCK «» or P «» when the engine is running.

2 Odometer, tachometer.
3 Rev counter.
4 Pilot light (green) «Neutral». Lights up when the gearbox is in neutral.
5 Pilot light (red) for generator current output. Should go out when the engine reaches a certain number of revs.
6 Petrol tank reserve pilot light (orange).
7 Pilot light (green) for flashing indicators.
8 Oil pressure pilot light (red). Goes out when the oil pressure is sufficient to ensure engine lubrication.
9 Pilot light (blue) for main beam.

10 Partial rev counter zeroing.

Light switches (figs. 4 and 5)

Are fitted to the sides of the handle-bars.

Switch «A» (fig. 5)

Position « lights off.
Position parking lights on.
Position « twin-filament headlamp on.

Switch A (fig.4)

With switch «A» (lights) of fig. 5 in position «杂 »

Position «D» dipped beam.
Position main beam.
Position « 口 » flashing light control.

Horn button, passing and direction indicators (fig. 4)

These are mounted on the left handlebar:

Push-button B (▶) sounds the electric horn when pressed.

Push-button C:

position > for right turn signals control.
position for left turn signals control.
press the switch to disconnect flashers.

Starter button and engine stop switch

(fig. 5)

These are mounted on the right handlebar.

With the key «1» in fig. 3 position ON « », the vehicle is ready for starting. To start the engine:

check that switch «B» is in position (run);
■ pull the clutch lever in to disengage the clutch fully;
if the engine is cold, put the «CHOKE» control «D» in the starting position «1» (see fig. 4);
press the starter button «C» «(?)» (start).
To stop the engine in case of emergency:
turn the switch to position (off).

Once the engine has stopped, turn the key switch (fig. 3) anti-clockwise until OFF «»; remove the key from the switch.

Before start, put switch «B» in (RUN) position.

Manopola comando gas («D» di fig. 5)

The throttle control is on the right handlebar; turning the twist-grip towards the rider opens the throttle, turning it away from the rider closes it.

This is on the left handlebar and is only to be used when starting or changing gear.

Leva commande freno anteriore destro

(«E» di fig. 5)

Brake lever, r/h front brake

(«E» in fig. 5)

This is on the right handlebar and controls the master cylinder of the right front brake.

The «CHOKE» is on the left handlebar and is used for cold starts.

Position 1 CHoke on; starting position.
Position «2» CHOKE off; engine running.

Brake pedal for left front brake and rear brake («A» in fig. 16)

This is centrally located on the right side of the vehicle and is linked to the master cylinder by a tierod; this pedal operates the front left and rear brakes together.

This is a double rocker arm type, situated on the left of the motorcycle:

1st gear: push front pedal down;

2nd, 3rd, 4th, 5th gears: push rear pedal down;

neutral: between 1st and 2nd gears.

WARNING! Before changing gear disengage the clutch fully.

To open, turn the key anti-clockwise.

N.B. Fuel spillage caused during refuelling should be cleaned immediately to prevent damage to the fuel tank paintwork.

WARNING: after each refueling always check the cap for being well positioned and closed.

The vehicle is provided with an electric cock «A» fitted on the left side under the tank, which operates automatically, cutting off fuel flow to the throttle unit when the engine is not running.

It comes into play when the key of the change-over switch «1» on Fig. 3 is in its ON position «@».

Should the cock not be working properly, first check the condition of the fuse «1» on Fig. 9.

This is located on the right side. To enter it is necessary to remove the side cover and possibly the front saddle.

The terminal board has 6 fuses.

Before changing a burnt fuse, trace and repair the cause of the trouble.

Fuse «1»: battery recharge (30A).

Fuse «2»: key switch (15A).

Fuse «3»: driving beam, traffic beam, horn (15A).

Fuse «4»: direction indicators, parking lights (5A).

Fuse 5 ECU (5A).

Fuse «6»: Pump, coils, injectors (10A).

TABELLA FUSIBILI (FUSES)
F1 = 30A	F2 = 15A	F3 = 15A	F4 = 5A	F5 = 5A	F6 = 10A
+ -	-	-	←	-	POMPA PUMP
RICARICA BATTERIA	COMMUTATORE A CHIAVE	L. ABB / ANAB AVV. ACUST.	INDIC. DIREZ. L. POSIZIONE	ECU	POMPA BOBINE INIETTORI
BATTERY RECHARGER	KEY SWITCH	L. HB / LB HORN	DIREC. INDIC. DIPPED L.	ECU	PUMP COIL INJECTORS

It is fitted between the frame and steering joke on the left hand side.

To harden or loosen the steering, turn in or out the knob «A».

It adds to steering accuracy and stability for improved handling under any conditions.

10

Side bags and top-case (optional)

(fig. 11)

To release the sidebags and the top-case from the supports, pull lever «A» of the clamping device after having released the lock using its key. To open the lids, lift lock «B» after having released it with its key.

N.B.-The maximum load for each side bag is 10 kg.; loads should be equally distributed between the two bags.

The maximum load allowed for the top-case is 5 kgs.

Sacoches laterales et top-case (en option) (fig. 11)

The driver's saddle is clamped by device «A» operated by means of a flexible transmission by the «B» lever, inserted in the helmet carrier device «C». To unclamp the saddle it is necessary to pull lever «B» downward after having released it by turning helmet carrier lock «C». To clamp the saddle, it must be placed in its seat on the frame, pressed on, then lock lever «B». The passenger's seat is fixed in place.

The helmet can be left with the motorcycle, using the helmet holder with lock «C».

N.B. - never leave the helmet in the holder when the motorcycle is running, as it may interfere with the moving parts.

Documents and objects holder

(«A» in fig. 13)

To gain access remove the driver's seat (see Fig. 12).

Dispositif porte-casque (fig.12)

The motorcycle is fitted with a side stand for parking. When the side stand is in use (i.e. in the out position) it activates a microswitch «B» controlling a relay which disenables to the starter motor; it is therefore not possible to start the vehicle with the side stand in use.

that there is sufficient fuel in the tank;
that the engine oil is on the right level;
the ignition key is in position ON «Q» (see fig. 3);
that the following warning lights are on:
- red warning lights: oil pressure and generator;
— green warning light: «NEUTRAL» indicator;
that the «CHOKE» control lever is in the starting position (if the engine is cold) («1», fig. 4);
that switch B (fig. 5) is in position (run).

Once the engine has started, and before putting the «CHOKE» lever back to its normal running position («2» in fig. 4), allow the engine to idle for a few seconds in summer or a few minutes in winter.

UTILISATION DU MOTOCYCLE

ATTENTION! - If the «green» warning light does not come on when the ignition switch is on (see ON «♀» in fig. 3) this means that a gear is engaged; starting the vehicle in this condition could be dangerous.

Before starting, always check that the engine is in «neutral».

Warm start

Follow the same procedure as that for the cold start but without the «CHOKE» control in the start position («1», fig. 4).

WARNING! - The starter motor should not be operated for more than 5 seconds; if the engine doesn't start, wait for 10 seconds before the following starting operation. Anyway act on the starter button C «①» in fig. 5 only with the engine completely stopped.

On the way

To change gear, shut the throttle, disengage the clutch fully and engage the next gear; then engage the clutch gradually while opening the throttle.

The gear change pedal should be operated firmly and surely.

When changing down use the brakes gradually and close the throttle gradually to avoid over-reving the engine, when releasing the clutch lever.

Stopping the motorcycle

Close the throttle and use the brakes; just as the vehicle is about to stop disengage the clutch. These three operations should be carefully coordinated to maintain full control of the vehicle.

When slowing down in normal conditions, use the gearbox to provide engine braking to slow the vehicle; take care not to over-reving the engine. Use the brakes (especially the front brake) with particular care when roads are slippery or wet.

To stop the engine, turn the ignition switch till the position OFF «» (see fig. 3).

Parking

On badly lit roads, leave the parking lights on.
Turn the key switch to position P «P» (see figure 3), and the light switch «A» in fig. 5 to position «≥«; and remove the key from the switch.

IMPORTANT

Do not leave the switch to « ≥ 0.5 » for long odds or the battery will run down.

Arrêt

The recommendations below should be followed when running-in:

Before riding, run the engine at low revs until it has warmed up.
- Do not exceed the rpm shown in the table; it is also advisable to run the engine at varying speeds rather than at a constant speed.
Before stopping reduce the speed gradually to avoid subjecting components to sudden changes in temperature.
Remember that components need several thousand kilometers before they are properly bedded in; care taken in this period will ensure prolonged vehicle life.

After the first 500÷ 1500 km

Change the engine oil.
Should the oil level drop to the minimum level before the first 500 ÷ 1500 kilometers have been completed then carry out a complete oil change rather than just topping up. Recommended oil: «Agip 4T SUPER RACING SAE 20W/50».
Replace gear lubrication oil.
Replace transmission box lubrication oil.
Check that all nuts and bolts are tight.
Check rocker clearance.
Check tyre pressures.

BREAKING-IN RPM

Kilometers	Max. RPM
From 0 to 1000	5000
From 1000 to 2000	6000
From 2000 to 4000	Gradually increase rpm until maximum permissible is reached.

64 RODAGE

Adjusting the clutch lever (fig. 15)

There should be 3 ÷ 4 mm of free play at the lever; turn the adjuster screw «A» to obtain the desired play.

Play can also be adjusted on the cable adjuster «B» located on the right side of the gearbox. First loosen the lock nut «C» and then adjust.

Adjusting the brake pedal of rear and left-hand front brakes (fig. 16)

To vary the position of the control pedal «A», do the following:

remove the split pin «B», pull out the pin «C», loosen the counter-nut «D» and tighten or back off the fork «E» until obtaining the desired position of the control pedal;
replace the pin «C» with the relative split pin «B».

Checking brake pads wear

Check the thickness of the brake pads every 3000 km:

Wear limit 1.5mm

If the pads are below the wear limit they should be changed.

There is no need to bleed the brakes when the new pads have just been fitted; pumping the brake lever a few times will return the caliper pistons to their normal position.

When changing the pads, also check the flexible hoses; if damaged they should be replaced immediately.

N.B. - Use the brakes with moderation for the first 100km after fitting new brake pads, to allow the pads to get properly bedded in.

Checking brake disks

The brake disks must be perfectly clean, with no oil, grease or other dirt on them. They should also show no signs of scoring.

The torque wrench setting of the screws that fix the disk to the hubs is 3 ÷ 3,2 kgm.

IMPORTANT! - Do not change the braking system components and the rear suspension assy. These components must be replaced with original spare parts only and the operation must be done by authorized technicians only.

Checking the brake fluid in the master cylinder reservoir (figs. 17 and 18)

To ensure efficient operation of the brakes:

1 Make frequent checks of the fluid level in the front «A» in fig. 17 and rear «B» in fig. 18 reservoirs. The level should always be above the minimum mark on the reservoirs.
2 Top up the brake fluid when necessary or at regular intervals. Only use recommended brake fluid in sealed containers for topping up.

Fluid containers should only be unsealed immediately before they are about to be used.

3 The fluid in the brake reservoirs should be changed completely after about every 20,000km or at least once a year.

To ensure efficient braking there should be no air bubbles in the brake circuit; if the brake lever has too much travel or a spongy action, this means that there are bubbles in the brake circuit.

When flushing the Brake circuits, only use fresh brake fluid.

Never use alcohol for flushing or compressed air for drying; we recommend the use of «trichloroethylene» for metal parts.

Never use mineral oils or greases for lubricating parts. If no suitable lubricant is available, we recommend the light greasing of the rubber and metal parts with brake fluid.

Recommended fluid «Agip Brake Fluid DOT 4».

IMPORTANT. Fluid should be handled with care, as it may dissolve paintwork.

These operations are best carried out by an authorized dealer.

17

18

Adjustable telescopic fork adjustment

(fig. 19)

The motorcycle is equipped with a hydraulic telescopic fork with separate adjustment of shock-absorbers during rebound and compression.

Hydraulic damping can be adjusted by using the setting handles «A» and «B».

The left setting handle «A» adjusts the hydraulic damping during rebound; the right setting handle «E» controls damping during compression.

Both setting handles have 15 adjustment positions (notches); turning them clockwise (+) increases damping and decreases it in the opposite direction (-).

N. B.: Do not force the setting handles beyond the limit positions.

Rear shock-absorber adjustment

(fig. 20)

The motorcycle is equipped with shock-absorbers with adjustment of hydraulic damping during rebound.

To adjust hydraulic braking in extension, work on the ring nut «A».

Turn it counter-clockwise ( HARD) to increase, clockwise ( SOFT) to decrease.

N.B.: To ensure good motorcycle stability, it is recommended to make sure that both shock-absorbers are adjusted to the same position.
IMPORTANT - do not change the braking system components and the rear suspension assy. These components must be replaced with original spare parts only and the operation must be done by authorized technicians only.

To ensure safe riding, the steering should be adjusted to allow free movement of the handlebars without any play.

■ loosen the steering head fixing bolt «A»;
undo the steering head nut «B»;
turn the adjuster nut «C» to take up any play.

When play has been adjusted tighten the nut «B» and the steering head fixing bolt «A».

It is recommended to perform the operation described above at our dealer locations.

21

Remove the wheel as follows:

place the machine securely on its centre stand, place a support under the engine base in order to lift the wheel from the ground;
undo the bolts «A» holding the brake calipers to the fork legs and remove the calipers complete with hoses;
■ loosen the pinch bolts «B»;
■ unscrew and remove the wheel spindle «C» paying attention to the position of the spacer «D», then remove the wheel;

DEMONTAGE DES ROUES DU VEHICULE

Roue AV (fig. 22)

refitting the wheel is the reverse of the above procedure; care should be taken to fit the spacer in the correct position; pump the brake lever and pedal a few times to return the caliper pistons to their normal position.

WARNING FOR WHEELS WITH SPIKES

At each maintenance control, check for integrity and tension of the wheel spokes.

A wrong spoke tension or the breakage of one or more spokes may affect the wheel, thus compromising the vehicle safety and stability.

Always respect the maximum tolerated load specifications.

The non observance of the requirements for tyres pressure or load limits can affect the handling, operation and control of the motorcycle. The max. allowed weight supported by this motorcycle is 200 kgs (passengers + luggage + accessories).

Divided up as follows:

• Front axle 52 kg.
  Rear axle 148 kg.

Rear wheel (fig. 23)

To disassemble the rear wheel from the fork arm and gearbox, do the following:

place the vehicle on the middle kick-stand;
remove the left muffler;
■ unscrew the lock screw-pin «A» for the calliper plate «B»;
disassemble the brake calliper «C» from the calliper plate «B»;
■ unscrew the nut «D» with washer «E» on the housing side pin
■ loosen the pin lock screw «F» on the fork arm;
remove the pin «G» from the housing, from the hub and from the fork arm;
remove the calliper plate «B»

■ tilt the vehicle on the right side enough to be able to pull the wheel off the fork, arm and transmission housing.

To replace the wheel, reverse the disassembly order remembering to insert the calliper plate on the stop «A» of the left arm of the swinging fork.

Tyres are among those machine components which require regular checking.

Machine stability, rider comfort and safety all depend on good tyre condition.

Do not use tyres with less than 2mm of tread.

Incorrect tyre pressures can cause instability and excessive tyre wear.

Tyre pressures:

■ front wheel: with one or two riders 2.3 BAR.
rear wheel: with one rider 2.5 BAR; with two riders 2.9 BAR.

The values indicated refer to normal use (tour

ism). For use at continuous maximum speed,

on the motorway, it is recommended to increase the pressure in the front wheel by 0.2 BAR.

IMPORTANT!

If a tyre needs replacing, use the same make

and type as the first-equipment tyre. Tyre pressure should be measured when tyres are cold.

Pneus

This machine is fitted with cast, aluminum alloy rims; even though these are very strong they can be damaged both aesthetically and mechanically by the use of incorrect tools when removing and fitting tyres. Tyre levers should not have sharp edges or ribbing in those places where they come into contact with the rim; lever contact surfaces should be smooth and edges should be rounded. Use of a suitable commercially available lubricant facilitates tyre removal and fitting therefore making strenuous use of the levers unnecessary. It is important to ensure that the tyre beads settle properly into the centre rim groove.

Some tyres have an arrow moulded on the sidewall, in these cases the tyres should be fitted as follows:

■ rear wheel: arrow pointing in the direction of rotation;

■ front wheel: arrow pointing against the direction of rotation.

N.B. - These instructions should be followed unless otherwise directed by the tyre manu- er.

PROGRAMMADIMANUTENZIONE

MILEAGE COVERED ITEMS	1000 mi. (1500 Km)	6000 mi. (10000 Km)	12000 mi. (20000 Km)	18000 mi. (30000 Km)	24000 mi. (40000 Km)	30000 mi. (50000 Km)
Engine oil	R	R	R	R	R	R
Oil filter cartridge	R	R	R	R	R	R
Wire gauze oil filter	C	C	C	C	C	C
Air filter		R	R	R	R	R
Fuel filter			R		R
Spark plugs	A	R	R	R	R	R
Rocker clearance	A	A	A	A	A	A
Carburetion	A	A	A	A	A	A
Nuts and bolts	A	A	A	A	A	A
Fuel tank, cocks filters and pipes		A		A		A
Gear box oil	R	R	R	R	R	R
Rear drive box oil	R	R	R	R	R	R
Wheel and steering bearings			A		A
Fork legs oil	R		R		R
Starter motor and generator			A		A
Brake systems fluid	A	A	R	A	R	A
Brake pads	A	A	A	A	A	A

KEY: A = Inspections - Adjustments - Possible replacements - Servicing. / C = Cleanings. / R = Replacements.
Occasionally, check the electrolyte level in battery, lubricate joints and cables; every 1000 km (600 miles) check the engine oil level.
In any case, replace the motor oil, the oil filter and the brake fluid, oil at least once a year.
Periodically check the tension of the wheel spokes.

PROGRAMME D'ENTRETIEN

Preparations for washing

Before washing the vehicle, the following parts should be covered with a waterproof material: the rear part of the silencers, the clutch and brake levers and pedals, the throttle twist-grip, the left-hand light switch, the ignition key switch, the shaft with driving couplings.

Washing

Avoid spraying water too much pressure on the instruments and the front and rear hubs.

Drying

Remove the protective coverings.

Thoroughly dry the vehicle.

Test the brakes before using the vehicle.

N.B. - To clean the painted parts of the engine unit (engine, gearbox, transmission box, etc.)

the following products may be used: diesel oil, petrol or water-based neutral detergents for car cleaning.

These products should be washed off immediately with water; do not use water at high temperatures or pressures.

NETTOYAGE - LONGUE INACTIVITE

Nettoyage

If the vehicle is to remain idle for a considerable period of time (e.g. for the winter period) it should be stored in the following way:

clean the vehicle thoroughly;
empty the fuel tank and feeding system. If left for a long time, the fuel will evaporate leaving incrustation and residue;
remove the spark plugs and put a few drops of SAE 30 oil into the cylinder. Turn the crankshaft for a few revolutions and then replace the spark plugs;
reduce the tyre pressures by 20% ;
position the vehicle so that its wheels are not touching the ground;
Smear a layer of oil on unpainted parts to prevent rust;
remove the battery and store in a dry place away from the direct sunlight and where there is not danger of frost; check the battery charge once a month;
cover the vehicle but in such a way that the air can circulate.

Longue inactivité

CLEANING THE WINDSCREEN (if mounted)

The windscreen can be cleaned using most of the soaps, cleaners, waxes and polishes commercially available for glass and plastic.
The following precautions should be taken:
do not wash or polish the windscreen in direct or strong sunlight or when temperatures are high;
under no circumstances use solvents, lyes or similar products;
■ do not use abrasive substances, pumice, sand/ emery paper, files, etc.;
■ wash all dust and dirt away before polishing. Small superficial scratches can be removed using a mild polish;
paint or sealing compound can be removed before harden by using diesel, isopropylic alcohol or butyl cellosolvent (do not use methyl alcohol);
- use soft cloths, sponges,chyam leathers or cotton wool; do not rub too hard. Do not use paper towels or man-made fibre cloths as they tend to scratch the windscreen.
Deep scratches cannot be removed by hard rubbing or the use of solvents.

Checking the oil level (fig. 24)

Check the crankcase oil level every 1000 km; the oil should reach the «Max» mark on the dipstick «A». If the oil is below this level, top up with the recommended type and grade of oil.

The oil level check should be carried out

after the engine has run for a few minutes: the ck plug «A» should be screwed fully home.

LUBRIFICATION

Oil change (figs. 24 & 25)

The oil should be changed after the first 500 ÷ 1500 km and every 10000 km thereafter. Change the oil when the engine is warm.

Allow the sump to drain fully before filling with new oil. «A» Oil filler plug with dipstick (fig. 24);

"B" Oil drain plug (fig. 25).

Oil required: 3 litres of «Agip 4T SUPER RACING SAE 20W/50».

Changing the filter cartridge and cleaning the mesh filter (fig. 25)

After the first 500 ÷ 1500 km (first oil change) and afterward every 10,000 km, replace the filtering cartridge «A» by doing the following:

■ unscrew the drain plug «B» and allow the sump oil to drain off fully;
undo the screws and remove the sump cover «C» from the crankcase: this assembly includes the filter cartridge «A», the mesh filter «D» and the oil pressure valve «E».
■ When changing the filter cartridge «A» it is also a good idea to remove the mesh filter «D» and wash it in petrol; dry by blowing with compressed air. Blow the oil ducts in the sump out with compressed air and refit the mesh filter.

Do not forget to fit a new sump gasket when refitting the sump.

It is recommended to perform the operation described above at our dealer locations.

Checking the oil level (fig. 26)

Check the oil level every 5000km ; the oil should just reach the level plug hole «B».

If the oil is below this level top up with the recommended grade and type of oil.

Oil change

The gearbox oil should be changed after the first 500-1500 Km and then every 10.000 Km. Drain the oil when the gearbox is warm as the oil is more fluid and drains more easily.

Allow the gearbox to drain fully before filling with new oil. «A» Filler plug.

Oir required: 0.750 litres of Agip Rotra MP SAE 80W/90.

Rear transmission box lubrication

(fig. 27)

Checking the oil level

Check the oil level every 5000km ; the oil should just reach the level plug hole «A».

If the oil is below this level top up with the recommended grade and type of oil.

Oil change

The transmission box oil should be changed after the first 500-1500 Km and then every 10.000 Km.

«B» Bouchon de niveau.

Bouchon de vidange.

Drain the oil when the box is warm as the oil is more fluid and drains more easily.

Allow the box to drain fully before filling with new oil.

Front fork oil change.

After the first 500 ÷ 1500 Km and afterwards every 20.000 km or at least once a year.

About 0.485 litres of oil is needed for the «MARZOCCHI (SAE 10)» shock absorbers.

These operations are best carried out by an authorized dealer.

Greasing

To grease:

■ steering bearings;
■ swinging arm bearings;
control rod joints;
side stand fittings;
Use: «Agip Grease 30».

The clearance between rocker arms and valves should be checked and adjusted after the first 500 ÷ 1500 km and every 10000 thereafter or if the valve gear becomes excessively noisy.

Adjustment should be carried out with the engine cold and the piston at TDC in the compressions phase (valves closed).

Remove the rocker box cover and proceed as follows:

1 loosen nut «A».
2 turn the adjuster screw «B» to obtain the clearances:

DISTRIBUTION

• intake valve 0.10 mm;
  *■ exhaust valve 0.15 mm.

Use a suitable feeler gauge «C» to measure the clearances.

Remember that if the clearances are greater than those specified, valve gear will be noisy; if the valves donor close fully this can cause problems such as:

loss of compression;
■ engine overheating;
- valve burn-out, etc.

It is recommended to perform the operation described above at our dealer locations.

• USA version:

■ intake valve: 0.05 ~mm ;
exhaust valve: 0.10 ~mm ;

In the Weber injection-ignition system type "alfa/N" the engine speed and the throttle position are used to measure the quantity of sucked air; when the quantity of air is known, measure the fuel quantity in relation with the desired strength. Other sensors in the system allow to adjust the main operation, on particular condition. Moreover, the engine speed and the throttle angle allow to calculate the optimal ignition advance on every operation condition. The quantity of air sucked from each cylinder per cycle, depends on the air density in the suction manifold, on the single displacement and on the volume efficiency. The volume efficiency is experimentally calculated on the whole operation field of the motor (rpm and engine load) and is stored in the electronic unit. The control of the injectors, each cylinder, is "time-sequenced", i.e. the two injectors are controlled on the basis of the suction sequence, while the delivery can already begin, for each cylinder, from the expansion phase until the suction phase, already begun. The timing for the initial delivery is contained in the electronic unit.

Static inductive-discharge ignition with dwell control provided by the power module (in-built in the electronic box) and ignition advance mapping stored in the electronic box. The coils receive the control inputs from the I.A.W. 15M unit (that calculates the ignition advance) via the power modules.

Description of the system

Fuel circuit

The fuel is injected along the suction pipe of every cylinder, in the upper side of the suction valve.

It includes: tank, pump, filter, pressure adjuster, electroinjectors.

Sucked air circuit

The circuit includes: air filter, suction pipe, floated casing.

Downstream the throttle valve is installed the plug for the pressure adjuster.

The potentiometer for the throttle position is assembled on the throttle shaft.

The absolute pressure sensor (integrated in the electronic unit) and the air temperature sensor are installed upstream thethrottle valve.

Control circuit

With this circuit, the electronic unit detects the engine conditions and the performance of the fuel exhaust and the ignition advance.

It includes: battery, ignition switch, two relais,electronic unit with max. pressure sensor integrated, ignition unit, airtemperature sensor, throttle position potentiometer, two injectors, oil temperature sensor,injection timing/RPM sensor.

Description de l'installation

Circuit essence

When the engine is in standard thermic conditions, the 15M I.A.W. unit calculates the phase, the injection time, the ignition advance, only by interpolation on the corresponding stored presettings, according to rpm and throttle position.

The resulting amount of fuel is delivered to the two cylinders with two subsequent injections.

The count of the initial delivery moment, for each cylinder, is made by means of a presetting that depends on the number of revolutions.

Starting phase

When the ignition switch is in operation, the 15M I.A.W. unit feeds the fuel pump for few time and detects the throttle angle and the temperature of the engine.

After starting the engine, the unit receives the revolution and phase signals, which allow it to control the injection and the ignition.

To make the starting phase easy, an enrichment of the main quantity, upon the oil temperature, is performed. After the starting phase, the unit begins the check of the advance.

Acceleration operation

During acceleration, the system increases the delivered fuel quantity, in order to obtain the best way of guide.

This condition is detected when the throttle angle variation reaches appreciable values, the enrichment factor is determined upon the oil and air temperatures.

ATTENZIONE!

In order not to cause damages to the electronic ignition system, follow the precautions hereunder:

in case of battery removal or refitting, be sure that the ignition switch is in position OFF «»;
do not disconnect the battery with engine on;
be sure of the perfect efficiency of earth cables of electronic boxes;
do not electric weld on the vehicle;
do not use other electric devices for starting;
to avoid either malfunctioning or inefficiencies of the ignition system, the spark plug wire connections (spark plug cap) and the spark plugs must be of the recommended type (as original equipment);
do not make any plug current check if the original spark plug cap are not fitted otherwise the electronic power box would be irreparably damaged;

in case of assembling of antitheft devices or other electric devices, absolutely do not touch the electric ignition/injection system.

In the electronic injection/ignition system is not possible to adjust the carburattor setting (air/gasoline ratio).

IMPORTANT!

Do not adjust the mechanical and electronic components in the electronic injection/ignition system.

Any adjustment or maintenance work should be carried out at the dealer's workshop.

Adjusting the idle setting

Recommended minimum rpm: 1050÷ 1150 rpm.

N.B. - The idle setting should be adjusted when the engine is at running temperature.

These operations are best carried out by an authorized dealer.

Réglage du ralenti

Fuel filter replacement

(«A», fig. 29)

The filter is provided with a filtering element made of paper, with 1200~cm^2 surface, and 10~ m ; filtering power: it is necessary due to the high sensibility of injectors to foreign elements.

The filter is assembled under the fuel tank between the pump and the pressure adjuster and on the external cover there is an arrow showing the direction of the fuel. Every 20,000 km it is necessary to replace it..

To change the fuel filter, it is advised to use an authorized dealer.

Check the air filter every 5000km and clean by blowing with compressed air; change every 10.000km .

This filter is mounted in a special case above the motor group, the saddle and fuel tank must be removed in order to have access to it.

For the above operations it is advisable to apply to a Moto-Guzzi dealer.

Use the following types of spark plug:

NGK BPR 6 ES

Spark plug gap: 0.7mm

Periodically remove the spark plugs for cleaning and checking.

Refit the plugs by hand taking care not to cross thread them, they should screw home easily; it is then recommended to tighten them manually for some turns and to use the provided suitable key, in order to lock them when the engine is cold.

Bougies (fig. 31)

Even if used plugs appear to be in good condition, they should be replaced every 10.000km .

N.B. - Values lower than 0.7mm can compromise the engine life.

WARNING! To avoid either malfunctioning or inefficiencies of the ignition system, the spark plug wire connections (spark plug cap) and the spark plugs must be of the recommended type (as original equipment). Do not make any plug current check if the original spark plug cap are not fitted otherwise the electronic power box would be irreparably damaged. Bear in mind that this also applies to any vehicles equipped with the electronic ignition systems listed below.

The electrical equipment consists of the following:
Battery.
Starter motor with electro-magnetic ratchet.
Generator-alternator fitted to the front of the crankshaft.
Fuel reserve signal device.
Light switch.
Ignition coil.
Electronic control unit (I.A.W. 15 M).
Phase and revolution sensor.
Side-stand microswitch.
Voltage regulator.
Fuse box.
Electronic control unit.
Pump control microswitch, coils, electro-injectors.
Starter microswitch.
■ Headlight.
Tall light.
Direction indicators.
■ Selector indicators.
Light direction indicator, horn and headlamp flasher switch.
Hazard warning lights, switch.
Starter and stop device.
Electric horns - Horn switch.
Warning lights on instrument panel for: neutral indicator (green), side lights on (green), oil pressure (red), main beam (blue), generator (red), fuel reserve (orange), direction indicators (green).

INSTALLATION ELECTRIQUE

The 12 V/30 Ah battery is charged by the generator. To gain access to the battery:

remove the saddle;
lift out the tool box.

Battery maintenance Batteries which are already in service (i.e. dry batteries which have been filled, activated and charged) should be maintained as follows:

top up with distilled water (never use acid) so that the liquid level is 5mm over the top of the plates;
■ battery terminals should be kept tightened, clean and greased with Vaseline;
- keep the top of the battery clean, avoid spillage of electrolyte as this will reduce insulation and will corrode the battery holder and cover;
check that the charging equipment is not under or overcharging the battery; battery liquid specific gravity should be 1.24÷ 1.27 .If this is not the case it will be necessary to check the insulation and efficiency of charging and starting equipment;
■ batteries which are stored should be charged at regular intervals at 1/10th of capacity, should be kept topped up and with a specific gravity of 1.27 at 25^
the battery should be clamped firmly in place complete with anti-vibrations devices.

Batterie

N.B. - In tropical climates (avarege temperature

above 33^) electrolyte specific gravity should be

ed to 1.23.

Important

A kinked or twisted breather tube may lead to overpressure and damage battery.

Warning

The battery contains sulfuric acid (electrolyte).

Avoid contact with skin and eyes as it may cause severe burns.

If you spill some electrolyte on your skin, wash the affected area with abundant water.

If some electrolyte gets into your eyes, wash with running water for at least 15 minutes and seek medical advise without delay.

Warning

Batteries develop explosive gases: keep them away from heat sources and flames.

Charge the battery in a ventilated room.

Always wear protective goggles and gloves when working near the battery.

Warning

Keep the battery out of the reach of children.

The battery has a 12 voltage, a 16 Ah capacity and is charged by the alternator.

To gain access to the battery:

Remove the saddle;
Lift out the tool box;

The battery is the hermetic type (maintenance-free) and does not need to be checked.

Instructions for recharging

To recharge the battery, use a costant voltage charger set to 14.7 ÷ 15V at 25^ .

ing

Contains toxic materials (Pb and H_2SO_4

Extremely high current, avoid short circuit. DO NOT charge in a gas tight container.

Sealed Lead Battery.

Must be recycled or disposed of properly.

The operations are best carried out by an authorized dealer.

Batterie version USA;SGP;CAN

To change the bulbs, unscrew the retaining screw «A» under the headlight unit; remove the light unit and remove the lamp holder.

N.B.-When changing the headlight bulb (main/

dipped beams) take care not to touch the

part of the bulb with your fingers.

Unscrew the screws "A" which attach the reflector to the light body; at the same time press the lights inward while rotating them and unscrew them from the light-sockets.

Front and rear direction indicators

(figs. 32-33)

Undo the screws «D» holding the reflector to the direction indicator unit. To remove the bulb from the bulb holder, press in and turn.

N.B. - Do not overtighten the reflector retaining screws as this will break the reflector.

Dismantle the head lamp;
Take out the three screws «A» which fasten the lower cover «B»;
Take out the lower cover «B»;
Take out the lamp holder and replace the lamp.

Adjusting the headlight beam (fig. 36)

The headlight beam should always be kept adjusted at the correct height to ensure good visibility and to avoid dazzling on coming traffic. Fot its vertical orientation, loosen two screws «C» that fix the headlight, and move it manually upwards or downwards until the prescribed height.

60/55 W
4 W
5/21 W
10W
3W
1,2 W

Bulbs

Headlight:

Dipped and main beam 60/55 W
Side/parking lights 4 W

Tall light:

Number plate, stop light 5/21 W
Direction indicators 10 W
Speedo, rev. counter warning lights 3 W
Instrument panel warning lights 1.2 W

Ampoules

Phare avant:

Key to wiring diagram

1 Driving beam 60 W (H4 halogen with traffic beam)
2 Parking light 4W
3 Traffic beam 55 W (H4 halogen with driving beam)
4 way Amp connector for front lamp
5 Front direction indicator 10 W, RH
6 2-way Cannon connector for front direction indicator, RH
7 Front direction indicator LH 10 W
8 2-way Cannon connector for front direction indicator, LH
9 Instrument panel
10 10-way A Pakard connector (instrument panel)
11 10-way B Pakard connector (instrument panel)
12 Switch for oil pressure
13 Idle switch
14 Switch for fuel level
15 Horn tone L
16 Horn tone H
17 10-way Pakard connector (device LH)
18 LH control device: lights, direction indicators, horn
19 Alternator 12V 350 W
20 Voltage regulator
21 Intermittence
22 Lights relay (MINIRELAY N.A.)
23 Start relay (MINIRELAY SHUNTING)
24 Starter
25 Battery 12V 30Ah
25 Battery 12V 16Ah (USA,SGP,CAN)
26 Rear Stop switch
27 3-way Cannon connector for direction indicators and rear Stop
28 2-way Cannon connector for rear position
29 Rear direction indicator 10 W, LH
30 Rear direction indicator 10 W, RH

31 Rear stop light 21 W (with parking light)
32 Rear parking light 5 W (with STOP light)
33 Number plate light 5 W (with number plate type USE, optional)
34 Solenoid valve (electric tap)
35 Safety fuses range (see table)
36 Safety relay for side stand (MINIRELAY N.A.)
37 2-way Cannon connector for side stand
38 Safety switch for side stand
39 RH control device, (Ign.-Run, Start, lights)
40 10-way Pakard connector (controls device, RH)
41 Front Stop switch
42 Key ignition switch
43 4-way AMP connector
44 Electronic unit IAW 15M
45 Air temperature sensor
46 3-way diagnosis AMP connector
47 LED diode for warning lamp (UNASSEMBLED)
48 Cilynder ignition coil AT, LH (BAE850AK)
49 Cilynder ignition coil AT, RH (BAE850AK)
50 Power relay for injection (MINIRELAY N.A.)
51 Safety diode
52 Electronic unit relay ECU (MINIRELAY N.A.)
53 Pompe du carburant
54 Injector, LH (IV031)
55 Injector, RH (IV031)
56 Timing sensor (SEN813)
57 Motor oil temperature sensor (NIC WTS05)
58 Throttle potentiometer (PF3C)
59 Max. pressure sensor inside the electronic unit ECU
60 1-way AMP connector (key closed supply)
61 1-way AMP connector (RPM sensor in the injection side)

164 SCHEMA INSTALLATION ELECTRIQUE

F1 Battery recharge (30A)
F2 Key switch (15A)
F3 Driving beam, traffic beam, horn (15A)
F4 Direction indicators, Parking lights (5A)
F5 ECU (5A)
F6 Pump, coils, injectors (10A)

FUSEES

Bianco-Marrone = White-Brown

Nero-Grigio = Black-Grey

Rosso-Bianco = Red-White

Rosso-Blu = Red-Blue

Rosso-Verde = Red-Green

Marrone-Nero = Brown-Black

Bianco-Blu = White-Blue

Bianco-Verde = White-Green

Arancio = Orange

Azzurro = Azur

Bianco = Blanc

Giallo = Jaune

Grigio = Gris

Marrone = Marron

Nero = Noire

Rosa = Rose

Rosso = Rouge

Verde = Vert

Viola = Violet

Marrone-Nero = Marron-Noire

Bianco-Blu = Blanc-Bleu

Bianco-Verde = Blanc-Vert

Arancio = Orange

Azzurro = Hellblau

Bianco = Weiss

Giallo = Gelb

Grigio = Grau

Marrone = Braun

Nero = Schwarz

Rosa = Rosa

Rosso = Rot

Verde = Grün

Viola =Violett

Bianco-Azzurro = Weiss-Hellblau

Bianco-Giallo = Weiss-Gelb

Bianco-Marrone = Weiss-Braun

Bianco-Nero = Weiss-Schwarz

Blu-Nero = Blau-Schwarz

Giallo-Nero = Gelb-Schwarz

Nero-Grigio = Schwarz-Grau

Rosso-Bianco = Rot-Weiss

Rosso-Blu = Rot-Blau