Cagiva Navigator Instruction manual

1
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

2
Introduction
This publication is intended for CAGIVAWorkshops 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.

3
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
2
4
1

4
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

A.1
GENERAL INFORMATION
A
Section

A.2
GENERAL INFORMATION
Dimensions and weight .......................................................... A-3
Engine unit ............................................................................. A-3
Transmission unit ................................................................... A-3
Frame..................................................................................... A-4
Front suspension.................................................................... A-4
Rear suspension .................................................................... A-4
Wheels and brakes ................................................................ A4
Electrical system .................................................................... A-4
Instrument panel .................................................................... A-4
Fuel/oil/coolant/fork oil capacity ............................................. A-4

A.3
GENERAL INFORMATION
DIMENSIONS AND WEIGHTS
Overall length .......................................................................... 2168 mm
Overall width ........................................................................... 790 mm
Overall height .......................................................................... 1290 mm
Wheelbase .............................................................................. 1530 mm
Ground clearance.................................................................... 180 mm
Seat height .............................................................................. 850 mm
Dry weight ............................................................................... 222 kg
ENGINE UNIT
Type ............................................................................................ Liquid cooled, DOHC, TSCC four stroke
Number of cylinders .................................................................... 2
Bore............................................................................................. 98,0 mm
Stroke.......................................................................................... 66 mm
Displacement .............................................................................. 996 cm3
Compression ratio ....................................................................... 11.3 : 1
Fuel feed system......................................................................... Injection
Air filter ........................................................................................ Non woven synthetic material
Starter system ............................................................................. Electric
Lubrication system ...................................................................... Wet sump
TRANSMISSION UNIT
Clutch .......................................................................................... Wet multi-plate type
Gearbox ...................................................................................... 6 speed constant mesh
Gear change ............................................................................... 1 down, 5 up
Primary reduction ........................................................................ 1.838 (57/31)
Final reduction............................................................................. 2.562 (41/16)
Gear ratios, 1a ............................................................................ 2.666 (32/12)
2a .................................................................. 1.933 (29/15)
3a .................................................................. 1.500 (27/18)
4a .................................................................. 1.227 (27/22)
5a .................................................................. 1.086 (25/23)
6a .................................................................. 1.000 (24/24)
Transmission chain ..................................................................... 5/8” x 5.16”
NAVIGATOR
2168
790
1290
1530
180
850

A.4
GENERAL INFORMATION
FRAME
Type ........................................................................................... Rectangular and square box section tubular framework
in highly resistant steel with box-type strengthening
supports at the fork fulcrum attachment.
FRONT SUSPENSION
Type ........................................................................................... Conventional advanced pivot hydraulic telescopic fork
with45mmdiametertubes.Telescopicmovement150mm.
Steering angle ............................................................................ 32° (left and right)
Steering head angle ................................................................... 25°
Trail ............................................................................................ 110 mm
REAR SUSPENSION
Type ............................................................................................Single hydraulic shock absorber progressively damped
with external pre-load adjustment of the spring and
extensionofthehydraulicbrakingeffect.Wheeltravel160mm.
WHEELS AND BRAKES
Front brake................................................................................. Twin disc
Rear brake ................................................................................. Single disc
Front tyre.................................................................................... Metzeler ME Z4 C – 110/80 – 18”
Rear tyre .................................................................................... Metzeler ME Z4 – 150/70 – 17”
ELECTRICAL SYSTEM
Transistorised electronic ignition
Ignition phase............................................................................. 3° before T.D.C. at 1300 rpm
Spark plugs ................................................................................ NGK CR8EK or DENSO U24ETR
Battery........................................................................................ 12v 10Ah
Generator ................................................................................... Three phase AC generator
Fuses ......................................................................................... 30/30/15/15/15/10/10A
Headlight unit ............................................................................. Main beam: condenser halogen bulb H1 12v-55w
Dipped beam: polyellipsoidal bulb H3 12v-55w
Sidelight ..................................................................................... 12v 5w
Direction indicators..................................................................... 12v 10w
Number plate light ...................................................................... 12v 5w
Brake/tail light............................................................................. 12v 21/5w
INSTRUMENT PANEL
Instrument bulb .......................................................................... 12V 1.2W
Warning lights ............................................................................ 12V 2W
FUEL/OIL/COOLANT/FORK OIL CAPACITY
Fuel tank ..................................................................................... 20 L
Engine oil: oil change .................................................................. 3100 ml
oil change with filter ................................................ 3300 ml
overhaul .................................................................. 3600 ml
Engine coolant ............................................................................ 2000 ml
Fork oil (each tube) ..................................................................... 680 ml

B.1
MAINTENANCE
B
Section

B.2
MAINTENANCE
Maintenance and tuning......................................................... B-4
Compression check................................................................ B-23
Oil pressure check ................................................................. B-24
Technical data ........................................................................ B-25

B.3
MAINTENANCE
Check ■Substitution ●First Every Every Every Every Every
1000 km 1000 km 6000 km 12000 km 20000 km 24000 km
Engine oil Check level ■
Engine oil Substitute ●●
Engine oil filter Substitute ●●
Coolant Check level ■■
Coolant Substitute
Every 2 years
Valve tappet clearance adjustment Check/adjust ■
Timing chain tension Check/adjust ■■
Synchronisation butterfly valves Check/adjust ■
Spark plugs Check/substitute ■■●
Fuel filter Substitute ●
Air filter Check/substitute ■●
Fuel feed system Check ■
Brake fluid Check level ■■
Brake fluid Substitute
Every 2 years
Brake disc pads Check ■
Brake discs Check ■
Braking system Check ■
Braking system Bleed air Every 20000 km/every 2 years
Accelerator control Check/adjust ■■
Clutch control Check ■■
Steering Check bearing play ■■
Fork Substitute oil
Every 2 years
●
Secondary transmission chain Check tension/lubrication ■■
Crown and pinion, chain Check/substitute ■
Tyres Check pressure/substitute ■■
Screws and bolts Check for tightness ■■
Fuel tubing Substitute
Every 4 years
Clutch cover screws Check for tightness ■
Rear wheel bearings Check ■

B.4
MAINTENANCE
MAINTENANCE AND TUNING
This section describes the servicing procedures for each part of pe-
riodical maintenance.
FUEL TANK REMOVAL
To complete this operation it is necessary to previously remove the
seat.
• Remove the complete fuel tap assembly by unscrewing the three
screws 1 indicated in the figure.
• Extract the flange 2 of the petrol covers.
• Remove the six screws 3using an 8mm spanner.
• Extracttheplate4payingattentiontothe two washers underneath.
• Remove the tank cover 5by unscrewing the two screws 6.
• Removethewindshield7byunscrewingthethreescrews8shown
in the figure.
2
1
4
3
5
6
8
7
8

B.5
MAINTENANCE
• Remove the fairing by unscrewing the five screws 1. There is one
front screw and four screws highlighted in the figure.
• Remove the front protection by unscrewing the two lower screws
2, as shown in the figure.
• Disconnect the indicator connectors. One is indicated in the figure
and the other is on the opposite side of the machine.
• Disconnect the fuel tubes from the left fuel tank. The fuel tubes
are attached to the fuel tank by rapid attachments and their re-
moval automatically blocks the exit of fuel. It is necessary to push
the lever 3and slide out the elbow union 4to disassemble it. Be-
fore effecting reassembly, check that the small pin 4is completely
extended. If it is not in position, push on the lever 3to bring it into
position.
• Disconnectthereservefuelsensorconnectorattachedtotheright
fuel tank.
1
1
2
34

B.6
MAINTENANCE
• Slacken and remove the two tank union clamps 1. One is situated
at the front of the vehicle and the other at the back of the tank.
• Finally, remove the two fixing screws 2. Disconnect the overflow
tube from the left fuel tank.
AIR FILTER
Check every 6000 km (or 6 months)
Substitute every 12000 km (or 12 months).
• It is necessary to remove the fuel tanks before removing the air
filter.
• Carefully eliminate dust and dirt from the filter element by using
compressed air.
The compressed air must be blown from the exterior of
the filter element. If compressed air is used internally, the
dust and dirt will be pushed into the pores of the filter
thereby reducing the flow of air to the same element.
• To assemble a clean or new filter element, carry out the operation
of disassembly in the reverse order.
Should the motorcycle be used frequently on dusty roads,
the filter element must be cleaned more frequently. The
use of the engine without a filter or with a broken filter
element will certainly shorten the life of the engine. Check
that the air filter is always in good condition. The long life
of the engine depends a lot on this component!
1
1

B.7
MAINTENANCE
SPARK PLUGS
Check every 6000 km (or 6 months)
Substitute every 12000 km (or 12 months)
After the first 1000 km it is necessary to remove the spark plugs,
clean them and check the distance between the electrodes (0.6÷0.7
mm).
REMOVAL OF SPARK PLUG N° 1 (FRONT)
• Remove the sump guard by unscrewing the two screws 1. One
screw is indicated in the figure whilst the other screw is on the
other side.
• Disconnect the fuel tubes.
• Remove the left side protection of the radiator.
• Remove the lower radiator fixing and its spacer. Unhook the radia-
tor from its mountings.
• Pushtheradiatordownsothat there is access to the forward spark
plug.
• Remove the spark plug insulated cap.
• Unscrew the spark plug as shown in the figure.
During this operation, pay attention to the front mudguard.
Place a piece of cloth between the radiator and the mud-
guard as shown in the figure.
1

B.8
MAINTENANCE
Be careful to not damage the finning of the radiator.
The radiator and engine can provocate serious burns when
they are hot. Wait until the radiator and the engine are cool
enough to be touched before carrying out this operation.
REMOVAL OF SPARK PLUG N° 2 (REAR)
• Remove the seat.
• Remove the seat compartment by unscrewing the eight screws 1.
Six of theses screws are shown in the figure.
• Unhook the rubber mountings of the fuel filter.
• Remove the spark plug insulated cap.
• Remove the spark plug.
1

B.9
MAINTENANCE
HEAT GRADE CODE
• Check the heat grade code of the spark plug.
The type “R” spark plug has a resistor on the central electrode to
avoid radio disturbance.
CARBON DEPOSITS
• Check the spark plugs for carbon deposits. If there are deposits,
use the appropriate machine or a pointed tool to eliminate them.
Take care in using the pointed tool.
THE GAP BETWEEN THE SPARK PLUG ELECTRODES
• Measure the gap between the spark plug electrodes using feeler
blades. Adjust the gap if it is not correct, using the following infor-
mation:
Specific tool: 800096651: Feeler gauge
800096872: Feeler gauge
Standard
Normal gap between the electrodes of the spark plug A: 0,6÷0,7 mm
THE CONDITION OF THE ELECTRODES
• Controllare se gli elettrodi sono usurati o bruciati. Se essi fossero
estremamente usurati o bruciati,sostituire la candela.
Sostituire la candela anche in caso di rottura dell’isolante o dan-
neggiamento della filettatura.
When a spark plug substitution is made, check the pitch
size and the length of the thread. If the threading is too
short, carbon residues will be deposited on the threading
of the cylinder head thereby possibly causing damage to
the engine.
REPLACING THE SPARK PLUG AND INSULATED CAP
Carefully screw the spark plug into place by hand before
tightening with a plug spanner. This is to avoid damage to
the aluminium threading.
• Manually screw in the spark plugs into the cylinder heads and
tighten them to the specific torque.
Torque pressure
Spark plug: 11 N·m (1,1 kg-m)
NGK CR8EK
DENSO U24ETR
A A

B.10
MAINTENANCE
When the front and rear spark plug insulated caps are pushed on,
turn the triangular signs on the insulated caps Atowards the ex-
haust side of the cylinders.
VALVE TAPPET CLEARANCE ADJUSTMENT
Check every 24000 km (or every two years)
• Remove the seat.
FRONT CYLINDER
• Remove the spark plug as described in page B-7.
• Remove the front cylinder head valve cover 1by unscrewing the
four screws 2shown in the figure.
When removing the valve cover, be careful that the locat-
ing pins or the gasket do not fall to the ground or inside
the cover opening.
The valve tappet clearances vary between the inlet and the exhaust
valves.
The valve tappet clearance adjustment must be checked and ad-
justed:
1) During periodical maintenance.
2) When tappet maintenance is carried out.
3) When the camshafts are removed for maintenance.
Valve tappet clearances (cold):
Inlet : 0.10 - 0.20 mm
Exhaust : 0.20 - 0.30 mm
* Valve tappet clearances must be checked when the piston is in
the top dead centre (T.D.C.) position of the compression cycle.
* The inlet and exhaust cams of the front cylinder in position A indi-
cate that the front piston is in the top dead centre (T.D.C.) position
of the compression cycle.
* The inlet and exhaust cams of the rear cylinder in position B indi-
cate that the rear piston is in the top dead centre (T.D.C.) position
of the compression cycle.
* Specified valve tappet clearances are with a COLD engine.
* Use a 17 mm spanner to turn the camshaft when checking the
valve tappet clearances. The camshaft must be turned in the di-
rection of normal engine operation. Both spark plugs must be re-
moved.
IN.
EX.
A
1
2

B.11
MAINTENANCE
• Remove the plug of the generator cover 1and the timing cover
inspection plug 2.
• Turn the engine camshaft to bring the piston of the N° 1 cylinder
(front) to the top dead centre (T.D.C.) position of the compression
cycle. Align the “F/T” line on the generator rotor with the timing
inspection hole line and bring the camshafts to the indicated posi-
tion in page B- 10.)
• To check the valve tappet clearances of the N° 1 cylinder (front),
insert a feeler gauge between the valve stem and the cam. If the
clearance is not correct, adjust it within the specified range.
REAR CYLINDER
• Remove the seat, the seat compartment and the spark plug as
described in page B-8.
• Remove the left and right hand side panels by unscrewing the two
screws.
• Disconnect the oil vapour tube from the left hand side of the ma-
chine.
21

B.12
MAINTENANCE
• Unhook the rear brake fluid chamber by unscrewing the screw
shown in the figure.
• Disconnect the electrical connector of the camshaft position sen-
sor.
• Remove the sensor by unscrewing the two relative screws.
• Disassemblethefuelfilterfromitssupportsanddisconnectitfrom
the fuel tubes, taking care to not spill any fuel.
Place a cloth underneath the fuel filter.
• Disassemble the expansion tank cover assembly.
• Remove the rear cylinder head valve cover by unscrewing the
four relative screws shown in the figure.
• Rotate the crankshaft 270° (3/4 of a turn) to bring the piston of N°
2 cylinder (rear) to T.D.C. of the compression cycle. Align the “R/
T” line on the rotor of the generator with the counter-line of the
timing synchronisation inspection hole and bring the camshafts in
the position indicated at page B-7.