User Manuals: Cagiva Navigator Motorcycle engine

User Manuals: Cagiva Navigator Motorcycle engine

Manuals and User Guides for Cagiva Navigator Motorcycle engine. We have 1 Cagiva Navigator Motorcycle engine manual available for free PDF download: Workshop Manual

Cagiva Navigator Workshop Manual

Cagiva Navigator Workshop Manual (408 pages)

Brand: Cagiva | Category: Motorcycle | Size: 23.4 MB

Table of Contents

Workshop Manual
1
General Repairing Rules
2
Identification Data
3
Table of Contents
4
General Information
5
Dimensions and Weights
7
General Information
7
Maintenance
10
Maintenance
11
- Fuel Tank Removal
  12
- Maintenance and Tuning
  12
- Air Filter
  14
- Spark Plugs
  15
- Carbon Deposits
  17
- Heat Grade Code
  17
- The Condition of the Electrodes
  17
- The Gap between the Spark Plug Electrodes
  17
- Front Cylinder
  18
- Valve Tappet Clearance Adjustment
  18
- Rear Cylinder
  19
- Intake Valve Pads Selection Table
  22
- Exhaust Valve Pads Selection Table
  23
- Engine Oil and Oil Filter
  24
- Engine Oil Change
  24
- Fuel Tubing
  24
- Torque Pressure
  24
- Minimum Tickover
  25
- Oil Capacity
  25
- Oil Filter Substitution
  25
- Accelerator Cable Play
  26
- Synchronisation of the Carburettors
  26
- Clutch
  27
- Cooling System
  27
- Engine Coolant Change
  28
- Radiator Tubes
  29
- Transmission Chain
  29
- Chain Adjustment
  30
- Cleaning and Lubrication
  30
- Brake Fluid Level Check
  31
- Brake Pads
  31
- Brakes
  31
- Brake Pedal Height
  32
- Bleeding the Air from the Braking System
  33
- Condition of the Tread
  34
- Steering
  34
- Tyre Pressures
  34
- Tyres
  34
- Compression Specification
  35
- Compression Test
  35
- Compression Test Procedure
  35
- Low Oil Pressure
  36
- Oil Pressure Specification
  36
- Oil Pressure Test
  36
- Oil Pressure Test Procedure
  36
- Specifications
  37
- Technical Data
  37
- Tyre Pressures
  43
- Injection - Air Intake System
  46
- Maintenance Precautions
  47
Connectors/Couplings
47
Injection - Air Intake System
47
- Ecm/Various Sensors
  48
- Fuses
  48
- Electrical Circuit Testing Procedure
  49
- Open Circuit Tests
  49
- Continuity Test
  50
- Short Circuit Tests
  51
- Voltage Test
  51
- Use of the Tester
  52
- Fi System Technical Characteristics
  53
- Intake Air System Technical Characteristics
  64
- Position of the Fi System Components
  65
- Fi System Diagram
  66
- Fi Electrical System Diagram
  67
- Auto-Diagnostic Function
  68
  - User Mode
    68
  - Dealer Mode
    69
- Security Function
  71
- Butterfly Body
  94
  - Butterfly Body Removal
    95
  - Check
    101
  - Cleaning the Carburettor
    101
  - Carburettor Reassembly
    102
  - Air Screw Adjustment
    109
  - Fuel Injector Assembly
    109
  - Fuel Injector Check
    109
  - Fuel Injector Removal
    109
  - Choke Adjustment
    110
  - Calibration Accessory
    111
  - Carburettor Synchronisation
    111
  - Butterfly Valve Synchronisation
    112
  - Throttle Lever Play
    114
  - Throttle Position Sensor Adjustment (Tps)
    114
  - Choke Cable Adjustment
    115
  - Major Adjustments
    115
  - Throttle Cable Adjustment
    115
  - Ckp Sensor Check
    116
  - Iap Sensor Check
    116
  - Iap Sensor Removal/Reassembly
    116
  - Tp Sensor Check
    116
  - Ap Sensor Removal/Reassembly
    117
  - Ect Sensor Check
    117
  - Iat Sensor Check
    117
  - Iat Sensor Removal/Reassembly
    117
  - Engine
    120
  - Engine Central Part
    121
  - Engine Components that Can be Removed Without Removing the Engine
    121
  - Engine Left Side
    121
  - Engine Right Side
    121
  - Removing the Engine
    122
  - Exhaust Silencer Removal
    124
  - Installation of the Engine into the Frame
    131
  - Disassembling the Engine
    138
  - No. 1 (Front) Cylinder
    139
  - No. 2 (Rear) Cylinder
    142
  - Assembling the Engine
    158
  - Driven Plates
    172
  - Driving Plates
    172
  - Front No. 2 Valve Motion Idler Gear/Sprocket
    184
  - No. 1 (Front) Timing Chain Tension Adjuster
    186
  - Rear No. 2 Valve Motion Idler Gear/Sprocket
    188
  - No. 2 (Rear) Timing Chain Tension Adjuster
    189
  - No. 2 (Rear) Camshafts
    193
  - Camshaft/Cylinder Head
    199
- Description of the Valve Gear System
  201
  - Front Camshafts
    203
  - Precautions for Installation
    203
  - Rear Camshafts
    203
  - Valve Timing Diagram
    204
  - Valve Timing Chart
    205
  - No. 1 (Front) Camshafts
    206
- Removing the Camshafts
  206
- Cam Wear
  208
- Checking and Servicing the Camshafts and the Cylinder Head
  208
  - Camshaft Journal Wear
    209
  - Camshaft Gears and Automatic Decompressor
    210
  - Camshaft Runout
    210
  - Timing Chain Guide and Chain Stretcher
    210
  - Timing Chain Tension Adjuster
    210
  - Cylinder Head
    211
  - Cylinder Head Distortion
    212
  - Valve Head Radial Runout
    212
  - Valve Seal Surface Wear
    212
  - Valve Stem Runout
    212
  - Valve Guide Servicing
    213
  - Valve Stem Deflection
    213
  - Valve Stem Wear
    213
  - Valve Seat Servicing
    214
  - Valve Seat Width
    214
  - Valve Spring
    216
  - No. 2 Valve Motion Idler Gear/Sprocket Thrust Clearance
    217
  - Cylinder Head Assembly
    218
  - Camshaft Position Sensor
    219
  - Exhaust Pipe
    219
  - Intake Pipe
    219
- Installing the Camshafts
  220
  - No. 1 (Front) Camshaft
    220
  - No. 2 (Rear) Camshaft
    221
  - Cylinder/Piston
    223
  - Cremoving the Cylinder and the Piston
    224
  - No. 1 (Front) Cylinder and Piston
    224
  - No. 2 (Rear) Cylinder and Piston
    225
  - Checking the Cylinder and the Piston
    226
  - Cylinder Barrel
    226
  - Cylinder Block Distortion
    226
  - Piston Diameter
    226
  - Piston Ring/Piston Groove Clearance
    227
  - Piston/Cylinder Clearance
    227
  - Piston Pin and Piston Pin Bore
    228
  - Piston Ring Free End Gap and Piston Ring End Gap
    228
  - Installing the Piston and the Cylinder
    229
  - No. 1 (Front) Piston and Cylinder
    230
  - No. 2 (Rear) Piston and Cylinder
    231
- Removing the Clutch
  233
- Removing the Clutch Throw-Out
  234
- Checking the Clutch and the Throw-Out
  235
  - Clutch Driving Plates
    235
  - Clutch Bearing
    236
  - Clutch Driven Plates
    236
  - Clutch Spring Free Length
    236
  - Clutch Throw-Out
    236
- Installing the Clutch
  237
- Installing the Clutch Throw-Out
  240
- Removing the Primary Driving Gear and the No. 1 Valve Motion Idler Gear/Sprocket Shaft
  248
- Assembling the Primary Driving Gear
  250
- Checking and Servicing the Primary Driving Gear
  250
- Disassembling the Primary Driving Gear
  250
- Fitting the Primary Driving Gear and the No. 1 Valve Motion Idler Gear/Sprocket Shaft
  251
- Starting System/Generator/Crankshaft Position Sensor
  252
- Removing the Starting Torque Limiter, the Generator and the Crankshaft Position Sensor
  253
- Checking and Servicing the Starting Torque Limiter, the Generator and the Crankshaft Position Sensor
  255
- Installing the Starting Torque Limiter, the Generator and the Crankshaft Position Sensor
  258
- Checking and Servicing the Starter Motor
  260
- Installing the Starter Motor
  260
- Removing the Starter Motor
  260
  - Gear Preselector
    261
  - Removing the Gear Preselector Assembly
    262
  - Checking and Servicing the Gear Preselector Assembly
    264
  - Fitting the Gear Shaft/Arm
    264
  - Removing the Gear Shaft/Arm
    264
  - Checking the Gear Shaft Hole
    265
  - Replacing the Oil Seal
    265
  - Installing the Gear Preselector Assembly
    266
  - Crankcase/Gearbox/Crankshaft/Connecting Rod
    269
- Checking and Servicing the Transmission
  271
- Fork-Groove Play
  271
- Removing the Transmission, the Crankshaft and the Connecting Rod
  271
- Driving Shaft
  273
- Checking and Servicing the Connecting Rod Bearings/Crankpins
  278
- Checking the Connecting Rod and the Crankshaft
  278
- Checking and Servicing the Crankshaft Bearings
  281
  - Bearing Selection Table
    282
  - Replacing the Crankshaft Bearings
    282
  - Selecting the Crankshaft Bearings
    282
- Adjusting the Crankshaft Thrust Clearance
  285
- Installing the Transmission, the Crankshaft and the Connecting Rod
  286
- Engine Lubrication System
  287
- Oil Pump
  288
- Oil Sump Filter/Oil Pressure Regulator
  290
- Oil Pressure Switch/Oil Cooler
  293
  - Checking and Cleaning the Oil Cooler
    294
  - Checking the Oil Cooler Pipes
    294
- Oil Filter
  295
- Oil Pressure
  295
- Piston Cooling Oil Jet/Oil Nozzle
  295
  - Engine Lubrication Chart
    296
  - Oil Sump
    296
- Engine Lubrication System
  297
- Suspensions and Wheels
  300
- Front Wheel
  301
Front Wheel Removal
301
Suspensions and Wheels
301
- Front Wheel Bearing Substitution
  302
- Front Wheel Overhaul
  302
- Bent Wheel Spindle
  303
- Wheel Assembly
  303
- Front Fork Removal
  304
- Front Suspension
  304
  - Fork Assembly Overhaul
    305
  - Support Tube Sliding Assembly Removal
    306
  - Support Tube Sliding Assembly – Reassembly
    307
  - Fork Assembly – Reassembly
    310
  - Steering Reassembly
    314
- Rear Wheel
  315
  - Rear Wheel Removal
    315
  - Chain, Crown Wheel and Pinion Wheel Overhaul
    316
  - Crown Wheel Substitution
    316
  - Rear Wheel Overhaul
    316
  - Pinion Wheel Substitution
    317
  - Substitution of the Chain
    317
  - General Check of the Shock Absorber
    318
  - Rear Shock Absorber Removal
    318
- Rear Suspension
  318
- Frame
  323
- Reassembly - Compensator Assembly
  321
- Frame Substitution
  323
Brakes
326
- Brake Pad Wear Check
  327
- Disc Brake
  327
- Front Brake
  328
- Rear Brake
  328
- Brake Fluid Substitution
  329
- Front Brake Pincer Assembly Removal
  331
- Rear Brake Pincer Removal
  332
- Front Brake Pump Assembly Removal
  333
- Brake Pump Reassembly
  334
- Rear Brake Pump Removal
  335
- Electrical Equipment
  338
Electrical Equipment
340
- Colour Legends
  341
- Electrical Wiring System Diagram
  341
- Connecting Terminals
  342
- Connectors
  342
- Precautionary Maintenance Advice Connectors
  342
- Semiconductor Parts
  342
- Charging the Battery
  343
- Charging System
  344
- Function of the Rectifier
  344
- Diagnostics
  346
- The Battery Discharges Rapidly
  346
- Battery Current Leakage Test
  347
- Charge Output Test
  347
- Generator Winding Resistance Test
  348
- Rectifier Test
  348
- Testing the Generator Performance in the Absence of a Charge
  348
- Starter System and Side Stand/Ignition Security System
  349
  - Starter System Description
    349
  - Side Stand/Ignition Security System Description
    350
  - The Starter Motor Does Not Turn
    351
  - Brushes
    352
  - Starter Motor Check
    352
  - Starter Motor Removal and Disassembly
    352
  - Commutator
    353
  - Oil Seal Check
    353
  - Rotor Winding Check
    353
  - Starter Motor Reassembly
    353
  - Starter Relay Check
    354
  - Diode
    355
  - Testing the Parts of the Side Stand/Ignition Security System
    355
  - Gearchange Position Switch
    356
  - Side Stand Switch
    356
  - Injection Relay and Fuel Pump Relay
    357
  - Crankshaft Position Sensor
    358
  - Engine Coolant Temperature Sensor
    358
- Ignition System
  358
  - Throttle Position Sensor
    358
  - Worn or Non-Firing Spark Plugs
    360
  - Peak Voltage of the Primary Winding of the Ignition Coil
    361
  - Test
    361
  - Ignition Coil Resistance
    362
  - Circuit Tester Dial Indication
    363
  - Crankshaft Position Sensor Resistance
    364
- Instruments
  365
  - Engine Coolant Temperature Sensor and Indicator Check
    367
  - Fourth Phase
    367
  - Second Phase
    367
  - Third Phase
    367
  - Oil Pressure Warning Light Test
    369
  - Speedometer Check
    369
  - Speedometer Sensor Check
    369
  - Halogen Lamp Substitution
    370
  - Headlight
    370
- Lights
  370
  - Front Direction Indicator Bulb Substitution
    371
  - Instrument Panel Bulb Substitution
    371
  - Rear Light and Rear Direction Indicator Bulb Substitution
    371
  - Headlight Beam Adjustment
    372
  - Direction Indicator Relay
    373
  - Fuel Pump Relay
    373
  - Starter Relay
    373
  - Ignition Switch
    374
  - Light Commutator
    374
  - Light Switch
    374
- Switches
  374
- Engine Cooling
  377
- Cooling System
  378
Engine Cooling
378
- Construction
  379
- Engine Coolant
  380
  - Engine Coolant - Radiator and Tubes
    381
  - Radiator Cap Check
    382
  - Cooling System Tubes Check
    383
  - Radiator Check and Cleaning
    383
  - Radiator Mounting Bolt
    383
- Cooling Fan
  384
  - Fan Mounting Bolts
    384
  - Radiator Mounting Bolts
    384
  - Cooling Fan Thermal Switch
    385
- Engine Coolant Temperature Sensor
  387
- Temperature Sensor Specification
  387
- Thermostat
  388
- Water Pump
  389
Specific Tooling
391
Specific Tooling
392
- Torque Pressures
  395
- Exhaust System
  399
- Index
  401
Index
402

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