2001–2013 Moto Guzzi California EV / Special / Sport / Jackal / Stone Service Manual (P/N 3 92 01 01, 03 90 00 70)

• 10-PDF Moto Guzzi technical set centered on the 511-page Workshop Manual, publication code 03 92 01 01, printed in Italy in April 2002. It identifies California EV 1997–2000, California EV 2001, first- and second-series California Special configurations, California Special Sport, California Jackal, and California Stone.
• Covers engine/gearbox removal, cylinder-head and timing service, cylinder and piston inspection, clutch repair, crankshaft and connecting-rod checks, gearbox overhaul, and rear-drive housing and shaft work.
• Details both front-axle arrangements, wheel overhaul and spoke adjustment, model-specific Marzocchi fork repair, swingarm and shock service, steering, controls, and chassis inspection.
• Separates the integral EV/Special/Special Sport braking system from the conventional Jackal/Stone circuits, with dedicated caliper, master-cylinder, disc, pad, brake-power-limiter, fluid replacement, draining, and bleeding coverage.
• Documents the Magneti Marelli IAW 15M fuel-injection and ignition system, including throttle-body adjustment, ECU reset, sensor and actuator fault isolation, injectors, coils, fuel-pump relay, RPM/TDC sensor, and CO setup.
• Provides model-specific wiring diagrams, electrical tests, factory special-tool numbers, scheduled-maintenance data, torque tables, fluid specifications, inspection limits, and exploded parts views.

Model and Chassis-Break Coverage

The workshop manual is written around the 1064cc, 90-degree V-twin California platform, but it does not treat every version as mechanically identical. Front-wheel service is divided between an earlier axle retained by an external nut and a later axle threaded into the left fork leg. The change is identified at EV chassis KD115426/KD115427, Jackal KD152328/KD152329, and Special KD131644/KD131645. EV 2001, Stone, and Special Sport use the threaded-leg arrangement from initial production.

The suspension material separates the adjustable inverted Marzocchi fork on EV and early Special models from the non-adjustable fork used on Jackal, Stone, later Special, and Special Sport. It also distinguishes BBS tubeless spoked wheels, later steel-rim spoked wheels, and the different rear-shock configurations. Coverage is limited to these early California versions and the included 2001–2002 catalogs, not the complete California range through 2013.

On EV, Special, and Special Sport models, the rear pedal operates the rear and left-front calipers while the right-front caliper remains on the hand lever. Jackal and Stone use separate front and rear circuits, so their bleeding and component-service sections are kept distinct.

California EV motorcycles built from 1997–2000 through chassis KD115749 use the larger P08 ignition/injection ECU. Moto Guzzi directs service work on that system to separate workshop publication 29 92 01 60, which is not included. The IAW 15M diagnostic chapter in this set should not be substituted for the P08 manual.

Repair and Diagnostic Depth

Engine coverage extends from lubrication and pressure checks to engine/gearbox removal, head and valve-gear repair, cam timing, cylinder and piston selection, clutch overhaul, alternator and flywheel work, and crankshaft/connecting-rod inspection and balancing. The drivetrain chapters add gearbox disassembly, shaft and selector shimming, bench reassembly, final-drive bearing service, pinion setup, and gear-tooth contact checks.

The tool table identifies factory equipment such as gearbox support 14 92 96 00, cam and ignition degree wheel 19 92 96 00, flywheel/starter-ring lock 12 91 18 01, clutch assembly tool 30 90 65 10, and secondary-shaft lock 12 90 71 00.

IAW 15M diagnosis covers the fuel pump, filter and regulator, throttle bodies, injectors, relays, ECU, temperature sensors, throttle-position potentiometer, coils, and timing/RPM pickup. Factory procedures address ECU error reset, sensor and actuator circuits, cylinder synchronization, idle and CO checks, and USA/SGP/CAN evaporative-emission equipment.

Electrical references include the EV 2001/Stone/Special Sport system diagram, the separate EV 1997–2000 diagram, California Special and Jackal diagrams, IAW 15M circuit keys and diagnostic connections, and alternator/regulator wiring and tests. Starter, lighting, dashboard, handlebar controls, side-stand switch, fuse board, and battery variants have dedicated repair sections.

Included Publications and Scope Notes

The archive contains 1,681 PDF pages in 10 files. The Workshop Manual accounts for 511 pages. Owner’s Manuals comprise EV (publication code 03 90 00 70), 166 pages; Special/Special Sport (03 90 00 65), 155; and Stone (03 90 00 75), 160. Parts material comprises EV/EV Touring (catalog code 03 92 00 70), 146 pages; Special/Special Sport/Aluminium (03 92 00 65), 157; California Sport 2001–2002 (GU011), 48; Stone/Stone Metal (03 92 00 75), 143; California Stone 2001–2002 (GU012), 53; and a second 142-page copy of the Stone/Stone Metal catalog. The two Stone/Stone Metal files reproduce the same catalog apart from one section-marker page, leaving 1,539 non-duplicate pages.

The workshop manual is in English, German, and Dutch. The full owner’s manuals and full-format parts catalogs use Italian, English, French, and German; compact catalogs GU011 and GU012 use French item descriptions with part numbers and exploded views.

The parts books cover EV/EV Touring, Special, Special Sport, Aluminium, Stone, and Stone Metal. Later catalogs identify standard- and hydraulic-tappet-engine parts, but the April 2002 workshop manual has no hydraulic-tappet repair chapter. No separate Jackal parts catalog is included.

Two repair traps are specifically documented. Spoke tension is not to be adjusted with the tire installed because damaged nipple covers can puncture the tube. On linked-brake models, the brake-power limiter is matched to the rear-shock characteristics, and shocks with different specifications can compromise pressure distribution. Secure the motorcycle properly and isolate the electrical system where required before fuel, brake, or major chassis work.