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