Cagiva Navigator - Repair, Service and Maintenance Manual

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CAGIVA NAVIGATOR - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual, to Cagiva Navigator


CONTENTS:


GENERAL DESCRIPTION  A-1

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

MAINTENANCE  B-1

- Spark plugs  B-7
- Transmission chain  B-21
- Cooling system B-19
- Compression test  B-27
- Oil pressure check  B-28
- Technical data  B-29
- Air filter  B-6
- Brakes  B-23
- Clutch  B-19
- Throttle cable play  B-18
- Valve clearance  B-10
- Engine oil and oil filter  B-16
- Maintenance and tuning  B-4
- Tyres  B-26
- Oil pressure test procedure  B-28
- Compression test procedure  B-27
- Tickover  B-17
- Balancing of the carburettors  B-18
- Fuel tank removal B-4
- Steering  B-26
- Fuel tubing  B-16

AIR INTAKE AIR INJECTION SYSTEM  C-1

- Air intake system – technical characteristics  C-20
- FI system – technical characteristics  C-9
- Malfunction codes  C-30
- Injection time compensation (volume) C-10
- Connectors/couplings C-3
- Injection stop check C-10
- Fuel injection check C-67
- Fuel pump check  C-49
- Fuel pressure check  C-48
- Butterfly body  C-52
- FI system diagnostics C-28
- ECM/various sensors  C-4
- ECM (FI unit test)  C-14
- Auto-diagnostic function  C-24
- Security function C-27
- Fuses  C-4
- Throttle lever play  C-72
- Throttle position sensor adjustment (TPS)  C-72
- Fuel injector  C-12
- Carburettor system C-64
- Dealer mode C-25
- Electric fuel pump  C-11
- FI system – position of the parts  C-21
- Maintenance precautions  C-3
- Electrical system test procedures  C-5
- Auto-diagnostic procedure  C-29
- Cleaning the carburettor C-59
- Throttle cable adjustment  C-73
- Choke adjustment  C-68
- Fuel pressure adjustment C-12
- Butterfly body removal  C-53
- FI system electrical diagram  C-23
- FI system diagram C-22
- Sensors  C-16
- Sensors  C-74
- Balancing of the carburettors  C-69
- Injection synchronisation  C-15
- Fuel pump control system  C-13
- Incoming fuel feed system  C-11
- Carburettor disassembly  C-56
- Carburettor disassembly  C-60
- Air filter disassembly  C-51
- Use of testers  C-8

ENGINE  D-1

- Camshaft/cylinder head  D-81
- Cover/gearchange/crankshaft/connecting rod  D-151
- Cylinder/piston  D-105
- Engine components that can be removed without removing the engine  D-3
- Cylinder/piston test  D-108
- Camshaft/cylinder head check and maintenance  D-90
- Seat bearings check and maintenance  D-163
- Gearchange pre-selector assembly check and maintenance D-146
- Clutch cover/water pump check and maintenance  D-125
- Clutch/disengage assembly check  D-117
- Timing system description  D-83
- Bowl filter/oil pressure regulator  D-172
- Oil filter  D-177
- Clutch  D-114
- Oil spray/piston oil cooling  D-177
- Primary drive gear/ N° 1 intermediate gear shaft timing
- pinion sprocket  D-129
- Camshaft installation  D-102
- Crankshaft/connecting rod/gearbox installation  D-168
- Clutch disengagement device installation  D-122
- Clutch installation  D-119
- Gearchange pre-selector group installation  D-148
- Engine/frame installation  D-13
- Piston/cylinder installation  D-111
- Water pump/clutch cover installation D-127
- Oil pressure switch/oil cooler  D-175
- Water pump/clutch cover  D-123
- Oil pump  D-170
- Gearchange pre-selector  D-143
- Oil pressure  D-177
- Crankshaft thrust play adjustment D-167
- Camshaft removal  D-88
- Cylinder/piston removal D-106
- Clutch disengagement device removal  D-116
- Engine removal and installation  D-4
- Clutch removal  D-115
- Gearchange pre-selector group removal  D-144
- Starter motor removal  D-142
- Water pump/clutch cover removal  D-124
- Timing synchronisation diagram  D-86
- Engine lubrication system diagram  D-178
- Engine lubrication system  D-169
- Engine lubrication system  D-179
- Engine disassembly/assembly  D-20
- Timing distribution table  D-87

SUSPENSION AND WHEELS  E-1

- Removal/check of the rear suspension compensator assembly  E-21
- Front fork assembly E-12
- Assembly of the rear suspension compensator assembly  E-23
- Support tube sliding assembly - reassembly E-9
- Steering assembly E-16
- Spring pre-load adjustment  E-21
- Front fork assembly overhaul  E-7
- Front wheel  E-3
- Rear wheel  E-17
- Support tube sliding assembly removal  E-8
- Handlebar removal  E-13
- Steering removal  E-13
- Front suspension E-6
- Chain, crown wheel and pinion wheel overhaul  E-18
- Rear wheel  E-17
- Rear fork removal E-23
- Rear suspension  E-20
- Frame  E-25

BRAKES F-1

- Brake pump check  F-11

- Brake pump check  F-15
- Brake pad wear check F-4
- Brake discs F-4
- Front brake  F-3
- Rear brake  F-3
- Brake pump assembly and installation F-11
- Brake pump assembly and installation F-15
- Front brake pincer removal and reassembly  F-8
- Rear brake pincer removal and reassembly  F-9
- Front brake pump removal and reassembly F-10
- Rear brake pump removal and reassembly  F-13
- Brake fluid substitution  F-6
- Bleeding air from the braking circuit  F-7

ELECTRICAL SYSTEM  G-1

- Maintenance precautions  G-5
- Initial charge  G-38
- Ignition/side stand security system movement check  G-18
- Starter relay check  G-17
- Switches  G-37
- Lights G-33
- Maintenance G-39
- Starter motor assembly  G-16
- Charging operations  G-40
- Starter motor removal and disassembly G-15
- Starter system and side stand security system disassembly  G-12
- Ignition system  G-21
- Charging system  G-7
- Instrumentation  G-28

ENGINE COOLING  H-1

- Cooling system H-3
- Engine coolant  H-5
- Radiator and coolant tubes  H-6
- Cooling fan  H-9
- Thermal fan switch  H-10
- Coolant temperature sensor H-12
- Thermostat  H-13

SPECIFIC TOOLS AND EQUIPMENT I-1

TORQUE PRESSURES L-1