Cagiva Navigator 1000 service ...

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Workshop Manual
NAVIGATOR
Copyright by
MVAGUSTA MOTORCYCLES S.p.A.
Via G. Macchi , 144 (Schiranna)
21100 VARESE - ITALY
1st Edition
Printed in Italy
Print no. - 8A0095860
1
Introduction
This publication is intended for CAGIVA Workshops and is designed to help authorized
personnel in service and repair operations. Familiarity with the specifications provided
herein is a key factor in ensuring effective training of operators.
To make the manual easy to understand, the different paragraphs are identified by
icons that point out the subjects being dealt with.
Notes having special meanings are marked with the following symbols:
Accident-prevention rules for the operator and other people working close by.
There is a possibility that the vehicle and/or its components may be damaged.
Further information on the operation being performed.
Tips
To avoid problems and obtain the best possible results, CAGIVA recommends observ-
ing the following general rules:
- Before carrying out any repairs, evaluate the customer’s report of the vehicle’s mal-
function and ask any questions that may help clarify the nature of the problem.
- Clearly identify the causes of the malfunction. This manual provides the fundamen-
tals of troubleshooting, which the operator will complete with his personal experience
and the participation in the periodic training courses organized by CAGIVA.
- Make a rational plan of the repair so as to avoid wasting time in collecting spares,
preparing tools, etc.
- Only perform the operations that are required to reach the part to be repaired. Helpful
guidelines are provided in the disassembling and removing procedures described in
this manual.
General repairing rules
1 Always replace gaskets, sealing rings and cotter pins with new ones.
2 When loosening or tightening nuts or screws, always begin with the largest, or with
the one at the centre. Tighten with the prescribed torques using a crosswise pattern.
3 Always mark the parts and positions that might be exchanged when reassembling.
4 Use genuine CAGIVA spares, and lubricants of the recommended brands.
5 Use special tools as specified.
6 Consult the Technical Circulars, as they may contain updated information on adjust-
ing and service procedures.
2
IDENTIFICATION DATA
The vehicle is identified by the following:
- Motorcycle serial number (1) on the right side of the head tube.
- Engine serial number (2) on the lower part of the right-hand crankcase half.
- Colour code on plate (3) inside the glove compartment under the saddle.
- Homologation data on the plate applied to the frame lower tube, next to the steering
head tube.
When ordering spares, always mention the motorcycle and engine serial numbers and
the colour code.
3
1
4
2
3
Contents
Section Page
General information ..................................................................... A 5
Maintenance
............................................................................................
B9
Injection - Air intake system ........................................................ C
45
Engine ......................................................................................... D
119
Suspensions and wheels ............................................................ E
299
Brakes
......................................................................................................
F
324
Electrical equipment .................................................................... G
338
Engine cooling ............................................................................. H
376
Specific tooling ............................................................................ I
390
Tightening torques....................................................................... L
394
Index
.........................................................................................................
M
400
4
GENERAL INFORMATION
Section
A
A.1
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