cagiva_navigator.pdf

Workshop Manual

NAVIGATOR

MVAGUSTA MOTORCYCLES S.p.A.

Via G. Macchi , 144 (Schiranna)

21100 VARESE - ITALY

1st Edition

Printed in Italy

Print no. - 8A0095860

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.

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.

Contents

Section Page

General information ..................................................................... A 5

Maintenance ............................................................................................ B9

Injection - Air intake system ........................................................ C

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

GENERAL INFORMATION

Section

A.1

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