ri)COUCO TEU Workshop Manual MITO Copyright by Stampato N° - Print No. - Imprimé N. - Druckschriff Nr. - Documento N°: 68543 Elaborazioni Tecniche D.E.Ca. - LUGO ANAM LULU art. N. 68543Foreword This publication intended for CAGIVA Workshops has been prepared for the purpose of helping the authorized personnel in the maintenance and repair work of the motorcycles herewith dealt with. The perfect knowledge of the technical data contained herein is essential for a more complele professional raining of he operator. The paragrophs have been completed wilh schematic illusotions evidencing the subject concemed, in order to enable a more immediate understanding. This manual contains information with particular meanings ‘Accident prevention rules for the operator and for the personnel working near by. [Ey Possibility of damaging the vehicle and/or its components. {5 Additional information concerning the operation under way. Useful suggestions CAGIVA sugges!s, in order to prevent troubles and in order to have an excellent final result, to generically comply with the following instructions: = incase of repair work, weigh the impressions of the Customer who complains about the improper operation of the motorcycle, and formulate proper clearing questions about the symptoms of the trouble — detect clearly the cause of the trouble. This manual gives the theoretical bases which however shall be integrated by the personal experience and by the attendance to taining courses periodically organized by CAGIVA. = rationally plan the repair work in order to prevent dead time as for insiance procurement of spare pars, tool preparation, el — reach the component fo be repaired and perform only the required operations In this connection, i! will be useful to consult the disassembly sequence contained in this monual, General instructions for repair work ‘Always replace the seal rings and split pins with new components When loosening or tightening nuts or bolts, clways start from the bigger ones or from the center. Lock ot the prescribed torque wrench seting following a crossed run Always earmark the components or positions which could be mistaken one for nother at the time of assembly. Use original CAGIVA spare parts and the lubricants of the recommended brands Use special tools, where specified Consul the Service Bulletins os they may contain updated adjustment dota ond repair methodologies. OUR oO Ko QI art. N, 68543 (10-90)BEWARE! The bike is equipped wih seporale lubrication ond warming light for ol reserve. For a correct operation of the motorcycle ahways make sure that, by turning the key to position «ON», the oil warning light goes «ON» together with the neutral warning light; when you go into a gear both of them will come OFF. JIN cAuTion FUEL — With temperature lower than -5°C fill p the fuel tank with 1% mixture rather than petol only. —Do not start engine with battery disconnected from connection cables of electric system; warn, lights and parking lights should be damaged. MAA Part. N. 68543 (10-90)EOCEEEENMU EE AUUMUUOUENUOUOUUUSEUEUEOOUUUEEEEEOUAOLET Tc mt QA 168543 (10-90)UEC nan Summary 8 General Maintenance ri Troubles and remedies Adjustments General operations Engine disassembly Engine overhauling Engine reassembly Suspensions ond wheels Brakes Electric system Engine cooling system C.1.S. exhaust valve Spectfic tools Torque wrench settings Analytical index NxZOZER--rTOmmooers MACMALLNAGENERAL au TO Engine AZ Fuel feeding AZ Lubrication AZ Cooling AZ Ignition AZ Storing AZ Transmission AZ Brakes AZ Frame AZ Suspensions AZ Wheels AZ Tyres AZ Electric system AB Performances Ag Weights AB Overall dimensions AB Supply AB HNN art. 10-90),GENERAL EEL un ENGINE Single-cylinder, to-stoke engine, wihlamellor suction ond lectonic contol C.TSS. valve on the exhoust system, Bore 2.204 in Sroke 1.992 in Copocity 7.602 cusin Compression ratio (wih closed lights 63:1 FUEL FEEDING Intake setting by lomeliar valve DISTRIBUTION DIAGRAM, TRANSFER: 124° EXHAUST: ‘Wih closed valve 170° With open vale 192° Carburetor Del'Grio PHBH 28 RD LUBRICATION ENGINE Through variable delivory pump. SHIFTING and MAIN TRANSMISSION Through the cil conicined in the engine block. cOOUNG Wih liquid ciculotion rough a pump. Big bert radioor,constoined to the Feme. IGNITION Electronic, Moke KOKUSAN Ignition advance: 14° 30 before D.C. (comesponding to 0.039 in. of piston sroke before T.D.C) Spark plug type CHAMPION NaC Electrode gop. 0.019 in STARTING Elec TRANSMISSION ‘Cluster constantmesh gears Frimory roio 2 20/65=1:3.25 Gear ratios Is 2797 2nd 1.857 3rd val ah 1,142 Sh 01956 oh 0/863, 7h 0.818 Final dive ratio 3.071 Gearing chain Totol ratios Is 27.228 2nd 18/538 ard 14,092 ah 11,408 Sh 91548 oh 8,621 7h 8,167 Oita multidise clutch type. Part. N. 68543 (10-90) m1 BRAKES Front brake Feforated fixed dsc, wih hycrauke contol and floating caliper. Disc dometer 12:59n Broke caliper BREMBO Pod oreo 6.076 qin Rear brake Perforated fied disc, with hydraulic control and fixed caliper. Dise diameter 9.085 in. Brake caliper BREMBO Pod area 3.41 sqin FRAME Double crossmember with extuded tubulor end akmminium meld ors; rear tolpiece wih square steel pipes, Steering angle 30° for side Steering axis ongle 25° Fron! fork coster 3.858 in ‘SUSPENSIONS Front suspension Telehyckouic fork wih possible odjusiment of the inner sexing preload Producer MARZOCCHI legs diometer 1.496 in Fron! wheel bump poston fon the siding xs) 4.842 in Rear suspension Light alloy looting fork with “bonana” shaped 8H. arm. Progressive leverage suspension SOFT DAMP system) and hydraulic mono- dere wish sping The sing rood con be ode Damper make MARZOCCHI Reor wheal verical rave 5.255 in WHEELS Three-poke light alley front in Make GRIMECA Dimensions 2.75017" Threespoke light ally rear ‘im Make GRIMECA Dimensions 4,017" TyREs Front "| Manutocturer ond ype PYRE TUBELESS MT7S Dimensions 100/80:17" Monufocturer ond type ‘MICHEUN TUBELESS RADIAL Dimensions M0/70R17 lflion pressure in cold condion| dhiver only 26 2.0 bor PRE; 1 bor MICHELIN wth posterger 2.1 bor PRE! 2,0 bor MICHELIN to 28 TsPIRELLI TUBELESS MT75 140/70817" Manufocturer and type MICHEUN TUBELESS RADIAL Dimensions 150/602R17" Inflation pressute (in eold condition} diver only 2,1 bor PEL; 2,0 bor MICHEUN wih passenger 2,3 bor PRELU 2,2 bor MICHEUN (+) In otemotive, PIRELL ond MICHELIN on mode! without fairing. MICHELIN on model with fairing ELECTRIC SYSTEM The ignition system is composed by: = Generator: 12V-120W fer a ful batery recharge: = Seating motor 1 2V-500W:; ~ Electronic coi ~ Elecronic device = Voliage rectifier; = Solenoid stoner: = Storing coatol system; = Igriion spark plug, ‘OVERALL DIMENSIONS mm (in.) GENERAL VODDEDEU EEE E ELLE EEE The electronic contol of the exhaust vahe is composed by the fallowing pars = Opering valve contol system; = Volve contol motor 12V.3,3 W. The components of the electic system re ~ Double headlight with blue lamps 12V'25/25W ond parking igh bulbs 12V-5W; Dashboard with inshuments bulbs 12V-2W end warning lights 12V41,2W; ~ Blinker wit bulb 12V-10W; ~ Battery 12V-9A; = NO. 4 fuses 15A, wo sporefuses; ~ Taillight wih sop light 12V-2 1WV and parking light bulb 12¥-5W. PERFORMANCES Max. oct speed 96.1 mile/h Fuel average consumption 9.3 mile/| WEIGHTS Toto! dry wheight (model with faring) 20675 Ib. del without airing] 259.04 Ib. 670 (2637), 130 (44.48) x 1280(54.39) | 2000178. ‘suPpLY TPE uantiry (ites) Fool tank Supe uel 98-100 ON [mnie 13 Reserve {worning lamp comes ON} 4 Fuel mine oi AGP ZT RACING PLUS. 1 Chonge gear and main ronsmision i ‘AGP F.1 SUPERMOTOROIL SAE 15050 0,800 Front fok oil Specie "MARZOCCHI" SAE 7,5 (see page| SI Cooling system fid AGP NUOVO PERMANENT EXTRA 15 Hydraulic broke fui Daive chain lubxicaion Flexible conaciions AGP BRAKE FLUID DOT 4 - ‘AGIP CHAIN AND DRIVE SPRAY - AGIP GREASE 30. = oO REMARK - At temperature lower than -5°C fill up the fuel tank with 1% mixture rather than petrol only. WARNING! - Use of additives in fuel or lubricants is not allowed. NIM IN. 68549 (10-90)MAINTENANCE HMA 1. 68543 (10-90)MAINTENANCE CUETO ELLE (1 = Replace the exhaust vale (replacement should be made every 10,000 kr. 1009 | 1500 |2000| 3000 | 4000 |5000|6000|7000 | 8000 | 9000 10000)! 1000)12000] Spork Bg © ols cy s Goorbox 3 s cr 8 c s Air fiter P Carburetor P Pc P Ceoning of exhaust opening, | oho P Pel , CCeoning of combustion chamber, Piston, pion rings P e P Citch oxtonby, ¢ c c c c @ Tyes ¢ ie ie ¢ € c Hyetoulic broke id a cle/clelelefe!e| ee] e|- b) - Intermediate operation at From te idling 10 1/5 approx. of he throfle vake whenever he mixue stengh ish 'be changed, 0 valve iso be fited with o smaller ont exhaust o enrich, sp. greater fer @ mixtue leaning. From 1/5 to 4/5 cf the trotle opening, the valve is moinly metered by the conical needle fited on the valve and clomped in cn intemediote groove. Were the mixture srenght to be chonged; then the conical needle isto be Tewered for micure leaning sp. hited up for envichmen, while waryingthe fixing Reich «)- Full-power 3 During fullpower running the fue supply is generally metered by the fullpower ie Hence, fhe adjusmentis tobe corrected, fi giectefultpower etioenrich, asmaler fone to get mixture stenghh leaning. d)- Level ‘Moke sure thatthe float has the propertweight as sated on iis not warped and rotates freely on ils pin, Held the catoureter bedy inthe indicated positon so tht he rocker ‘rm ges in sigh touch withthe needle, and the needle with he seot. In thiseonditions, make cure that the two halFlloats are a! the requited height as fo the body love nl Part. N. 68543 (10-80) H_ 24,5+23,5 mm (0.96+0.92 in} Ht