CagivaNavigator

1WorkshopManualNAVIGATORCopyrightbyMVAGUSTAMOTORCYCLESS.p.A.ViaG.Macchi,144(Schiranna)21100VARESE-ITALY1stEditionPrintedinItalyPrintno.-8A00958602IntroductionThispublicationisintendedforCAGIVAWorkshopsandisdesignedtohelpauthorizedpersonnelinserviceandrepairoperations.Familiaritywiththespecificationsprovidedhereinisakeyfactorinensuringeffectivetrainingofoperators.Tomakethemanualeasytounderstand,thedifferentparagraphsareidentifiedbyiconsthatpointoutthesubjectsbeingdealtwith.Noteshavingspecialmeaningsaremarkedwiththefollowingsymbols:Accident-preventionrulesfortheoperatorandotherpeopleworkingcloseby.Thereisapossibilitythatthevehicleand/oritscomponentsmaybedamaged.Furtherinformationontheoperationbeingperformed.TipsToavoidproblemsandobtainthebestpossibleresults,CAGIVArecommendsobserv-ingthefollowinggeneralrules:-Beforecarryingoutanyrepairs,evaluatethecustomer’sreportofthevehicle’smal-functionandaskanyquestionsthatmayhelpclarifythenatureoftheproblem.-Clearlyidentifythecausesofthemalfunction.Thismanualprovidesthefundamen-talsoftroubleshooting,whichtheoperatorwillcompletewithhispersonalexperienceandtheparticipationintheperiodictrainingcoursesorganizedbyCAGIVA.-Makearationalplanoftherepairsoastoavoidwastingtimeincollectingspares,preparingtools,etc.-Onlyperformtheoperationsthatarerequiredtoreachtheparttoberepaired.Helpfulguidelinesareprovidedinthedisassemblingandremovingproceduresdescribedinthismanual.Generalrepairingrules1Alwaysreplacegaskets,sealingringsandcotterpinswithnewones.2Whenlooseningortighteningnutsorscrews,alwaysbeginwiththelargest,orwiththeoneatthecentre.Tightenwiththeprescribedtorquesusingacrosswisepattern.3Alwaysmarkthepartsandpositionsthatmightbeexchangedwhenreassembling.4UsegenuineCAGIVAspares,andlubricantsoftherecommendedbrands.5Usespecialtoolsasspecified.6ConsulttheTechnicalCirculars,astheymaycontainupdatedinformationonadjust-ingandserviceprocedures.3IDENTIFICATIONDATAThevehicleisidentifiedbythefollowing:-Motorcycleserialnumber(1)ontherightsideoftheheadtube.-Engineserialnumber(2)onthelowerpartoftheright-handcrankcasehalf.-Colourcodeonplate(3)insidetheglovecompartmentunderthesaddle.-Homologationdataontheplateappliedtotheframelowertube,nexttothesteeringheadtube.Whenorderingspares,alwaysmentionthemotorcycleandengineserialnumbersandthecolourcode.32414ContentsSectionPageGeneralinformation.....................................................................A5Maintenance............................................................................................B9Injection-Airintakesystem........................................................C45Engine.........................................................................................D119Suspensionsandwheels............................................................E299Brakes......................................................................................................F324Electricalequipment....................................................................G338Enginecooling.............................................................................H376Specifictooling............................................................................I390Tighteningtorques.......................................................................L394Index.........................................................................................................M400A.1GENERALINFORMATIONASectionA.2GENERALINFORMATIONDimensionsandweight..........................................................A-3Engineunit.............................................................................A-3Transmissionunit...................................................................A-3Frame.....................................................................................A-4Frontsuspension....................................................................A-4Rearsuspension....................................................................A-4Wheelsandbrakes................................................................A4Electricalsystem....................................................................A-4Instrumentpanel....................................................................A-4Fuel/oil/coolant/forkoilcapacity.............................................A-4A.3GENERALINFORMATIONDIMENSIONSANDWEIGHTSOveralllength..........................................................................2168mmOverallwidth...........................................................................790mmOverallheight..........................................................................1290mmWheelbase..............................................................................1530mmGroundclearance....................................................................180mmSeatheight..............................................................................850mmDryweight...............................................................................222kgENGINEUNITType.......................