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SERVICE MANUAL /Elefant 650 USA

1. P 1 Slide 60 3 2 Needle S 18 2 2 tacca 3 Pilot jet 65 4 Needle valve 250 5 Float tipo 10 gr 6 Main jet 130 horiz 132 vert 7 Needle jet E o 265 AB 8 Choke jet 75 9 Acceleration pump jet 35 Delivery of pick up pump 5 cm 0 5 4 times Float level 17 5 18 5 mm LLL DN ENGINE OVERHAULING Float level e Place vertically the carburetor on a flat surface e By means of a caliper check that distance is 17 5 v 18 5 mm 0 6889 0 7283 Accelerating pump fuel delivery e Connect carburetor to a petrol tank e Use a funnel and graduated test tube to collect petrol e Rhytmically open and close 4 times with few seconds interval the e y carburetor slide The amount of petrol collected in the test tube must be 4 c c 0 5 e If adjustment is needed act on adjustment screw Turn it clock wise to reduce gas delivery Turn it anticlockwise to increase gas delivery CAUTION Do not remove the adjustment screw of the acceleration pump stroke 49826 G 21 Lo ENGINE RE ASSEMBLY H H 2 Valves H Lower rocker arm H 3 Camshaft H 5 Upper rocker arm H 6 Valve covers H 7 Mainshaft H 7 H 7 Shift forks H 7 Selector drum H 8 Shift forks shafts H 8 Cranksha
2. N 49826 mm ENGINE RE ASSEMBLY a e Temporarily mount camshaft supporting caps e Check that there is no play between rocker arm sliding shoe and cams returning cap can still be rotated by hand e If too tight or too loose check the tolerances with a feeler gauge e Different returning caps thicknesses are supplied as spare parts to ad just play e Use micrometer and returning cap holding tools for accurate measure ment NN m N 49826 ENGINE RE ASSEMBLY Upper rocker arm e Place opening arm and adjust side play in the same way of lifting or lo wer rocker arm with the help of shaft tool Ze 42405 e Substitute shaft tool by rocker arm tool with the hole facing outwards e Temporary mount camshaft supporting caps so camshaft is supported at both ends e Chech play between rocker arm slide shoe and pushing cap using a feeler gauge Service tolerance 0 10 mm 0 0039 in e Different pushing cap thicknesses are available to adjust play 49826 mm H 6 LEAGIVA E Jesse pin i EE EE GE SE de caps 2 e o o lt c Z O c ing si e Tight allen bolts of camshaft support 49826 Valve covers e Tight allen bolts of valve covers N B 5 ae ENGINE RE ASSEMBLY Mainshaft e Place Mainshaft on left side center case complete with g
3. N 49826 HYDRAULIC CONTROL CLUTCH RELEASE Hydraulic clutch fluid drain e Attach a clear plastic hose into the bleed valve on clutch cover and turn the other end inside a container Loosen bleed valve so fluid begins to drain e Remove container cap and rubber diaphragm WARNING Since the hydraulic clutch fluid is brake fluid it may cause irritation Avoid contact with skin or eyes In of contact flush thoroughly with water and cali a doctor if your eyes were exposed Hydraulic clutch master cylinder overhaul e Check that piston and cylinder surfaces are perfectly smooth e Replace seals if necessary e Clean thoroughly Hydraulic clutch piston overhaul e Check that piston and cylinder surfaces are perfectly smooth e Replace seals if necessary e Clean thoroughly N 49826 LL iis HYDRAULIC CONTROL CLUTCH RELEASE Changin the clutch fluid The clutch fluid should be checked and changed in accordance with the Periodic Maintenance Chart and whenever becomes contaminated with dirt or water Use only DOT 4 brake fluid from a sealed con CAUTION a Handle brake fluid with care because it can da mage paint and instrument lenses Never allow contaminants dirt water etc to enter the brake fluid reservoir Bleeding the clutch e Attach a clear plastic hose to the bleed valve on the clutch cover and run the other end of the hose into a container e R
4. Clutch lever adjustment Allow lever play of 1 1 5 mm 0 4 0 6 inch Act on allen bolt to set proper play Drive chain adjustment e Setthe motorcycle on its stand e Rotate the wheel to find the position where the chain is tightest and check the vertical movement shown on figure If chain slack is more or less adjust the chain To adjust the chain Loosen wheel axle nut 1 e If chain is too tight back out the left and right chain adjusting bolt 2 evenly and kick the wheel forward until the proper chain slack is reached f chain is too loose turn in the left and right chain adjusting bolt 2 evenly until the drive chain has the correct amount of slack e Tighten wheel axle nut Note To keep the chain and wheel aligned turn adjusting bolts 2 evenly Wheel alignment can also be checked using the straightedge or string method W ARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Take care not to damage the brake hose Damaging the brake line greatly reduces the brake line strength and causes brake fluid leakage resulting in the loss of brake control III H 49826 ADJUSTMENTS Spark Arrester Cleaning U S model This motorcycle is equipped with a Spark Arrester approved for off road use by the U S Forest Service It must be properly maintained to ensure its efficiency in a
5. e Pull out cylinder head tap slighty if ne ded with rubber or plastic hammer ji ur EE ER 49826 EE ENGINE DISASSEMBLY 8 Sj Cylinder e Remove cylinder tap it slightly if necessary Hold piston to avoid hitting crankcase and possible damage e Place clean rag under the piston clogging crankcase opening to avoid dropping foreing parts e Remove piston pin retaining rings WARNING These rings are highly compressed in the ring groove and may fly out with considerable force when pried out of the groove Safety glasses or goggles must be worn while remo ving or installing retaining rings e Holding up piston pull out pin with the help of another soft aluminum pin and a hammer e f piston pin is too tight use a piston pin puller Note Mark each piston up on its position V or H and an arrow to in dicate direction 49826 ENGINE DISASSEMBLY e To remove ignition side cover loosen allen bolts and remove cover by using pullers 42416 e Remove jacks from pick up connector by using pullers 42413 e Remove pick up bolts and pick up backing plate e Bend back tab on washer of alternator nut QUEUE 5 N 49826 ENGINE DISASSEMBLY e Lock alternator by means of tool 42652 and remove nut e Remove washer aiternator and woodroof key e Re
6. Lock bolts to 24 Nm 2 5 18 08 Ib ft m CAGIVA VA GAN N 49826 ths H 26 ENGINE RE ASSEMBLY e Place belts side covers and tighten bolts e Carefully clean the spark plugs and check electrodes gap 0 6 mm 0 0236 in e Install the spark plugs and torque at 18 Ibs f 2 5 H 27 SUSPENSIONS AND WHEEL EELLETEEEEEEEIETITEHEETEEETIDETTTETEUIRETETRUTREETER ERREUR HEERREHRRREHENSEERNEREREREENNNEERENEBREERRENRRBRERERERNEE 2 L3 1 3 1 3 1 4 L L 7 L 1 10 1 10 1 11 1 12 112 1 12 N 49826 1 Front suspension Front forks removal Oil seal dust seal Inspection Inner tube Oil change Rear suspension Swing arm Wheels tires Wheel rim Front wheel removal Rear wheel removal Wheel bearings Bearing replacement Wheel bearings installation SUSPENSIONS AND WHEELS Front suspension Front suspension is of the hydraulic type with double damping effect Front fork consist of the fork legs connected to the frame head pipe by the stem base 1 and stem head bracket 2 Jt accomplishes shock absortion through spring action and resistance to the flow of the oil forced into the cylinder by tube movement Each fork leg isatelescopic tube including an inner tube 3 outher tube 4 cylinder and piston unit 5 and cylinder base 6 The inner tube
7. 17 or 130 80 17 Brake Front anaa ai Single drilled floating disc 260 mm 10 2 in Brembo Single drilled disc 240 mm 9 44 in Brembo Rims in light alloy Front error 21 1 85 17 2 75 Suspension type Front Telescopic fork Heat Soft Damp type box sectionaluminium swingarm single shock DIMENSIONS Maximum lenght 2250 mm 88 6 in Wheel base sedie 1530 mm 60 2 in Maximum height 1250 49 2 Ground clearance 250 mm 9 8 in Seat LE 880 mm 34 6 in Gas tank total capacity 17 5 Its 4 6 gals HOSBIVB EE Enos ER 5 Its 1 3 gals Diy WIG itte M 184 5 Kg 406 7 ibs FLUIDS AND GREASE IS Type of fluid Capacities CASO 94 98 octane rate 17 5 Its 4 6 gals Engine oil and filter CASTROL GTX2 or equivalent 3 3 Its 3 5 US qts Front fork dd Geer SAE 15 0 5 Its 0 53 US qt Front rear brake circuits DOT 4 CASTROL Disc Brake Fluid anti vapourlock Hydraulic clutch DOT 4 CASTROL Disc Brake Fluid p Drive chain E CASTROL GTX2 or equivalent d Tachometer Speedmeter CASTROL LM Grease or equivalent A 49826 TORQUE ENGINE TORQUE
8. SERVICE MANUAL Elefant 650 USA a 9 D I D z D ate ze 4 B d 2 2 0 Mr P gt E a H d 9 oe LEID mm Gel S eg 3 B ML e caes eee e mei im LEE n eom o non n d v K sse _ E 5 e N d DH A To e EE E E E S SERVICE MANUAL Elefant 650 USA Copyright by CAGIVA Motor Italia S p A 21100 Schiranna Varese Italy 1 Edizione Printed in Italy Stampato N Print No 49826 Elaborazioni Tecniche D LUGO MAII JUIN CAGIVA Motor Italia S p a and CAGIVA North America accepts no liability for any inaccuracies or omissions in this publication although every possible care has been taken to made it as complete and accurate as possible All procedures and specifications subject to change without paoe notice and may not apply to e country ELEFANT 650 SERVICE MANUAL 1986 by CAGIVA Motor Italia S p A 1st edition JANUARY 1986 All rights reserved any reprinting or unauthorized use without the written permission of CAGIVA Motor Italia S p A or CAGIVA North America Inc is expressely prohibited Printed in Italy 49826 iE dE Du DD AAA AAAS pn N EMISSION CONTROL INFORMATION To protect the Environment in wich we al
9. e Remove sparkplug cables Drain engine oil Disconnect all electric cables pick up alternator electric start motor and neutral light wire Remove head steady Placea hydraulic jack under the engine sump remove engine top rear mounting bolt Remove swingarm pivot bolt and remove engine from frame Place engine on stand LLL E 7 N 49826 ENGINE DISASSEMBLY F 2 F 3 Camshaft driving belts and pulleys F 15 Primary trasmission pinion F 4 Cylinder head F 16 Center crankcases F 5 Cylinder and piston E17 Oil pressure adyusting valve F 6 Ignition cover F 18 Camshaft driving shaft F 6 Pick up back plate F 18 Crankshaft E Alternator rotor F 18 Shift fork rod Ej Ignition flywheel 8 Selector drum F 8 Camshaft driving gear F 19 Shift forks F 9 Starter gears F 19 Countershaft F 10 Starter motor F 19 Mainshaft 10 Countershaft sprocket F 20 Valve covers F 11 Shift mechanism F 20 Upper rocker arms F 11 Clutch cover F 21 Valves F A2 F 13 Clutch F 22 Camshaft F 14 Oil pump F 23 Lower rocker arms N 49826 d ENGINE DISASSEMBLY Engine Lubrication System Oil filler cap Oil level indicator Drain plug Scr en filter Oil filter cartridge Oil pressure switch NOM amp WH ch Oil cooler Oil change oil e Remove clean and install screen filter Change oil cartdrige e Fill up with
10. servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles kno wingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance war aan under this title floowing its sale and delivery to the ultimate purchaser NOTE The phrase remove or render inoperative any device lt Or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of devices Or elements of design in order to perform maintenance 2 Tampering could include A Maladjustement of vehicle components such that the emission standards are exceeded B Use of replacement parts or accessories wich adversely the performance or dura bility of the motorcycle C Addition of components or accessories that result in the vehicle SE the stan dards D Permanently removing disconnecting or rendering inoperative any component or ele ment of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION 49826 SOURIS ePID TAMPERING b aK WITH NOISE CONTROL SYSTEM PROHIBITED Federal Law prohibits the following acts or the causing thereof 1 The removal or rende
11. 650 1100 1900 3000 6300 9500 12500 15600 19000 P396 LB A c Lu Ly o c o o J 2 3 Master cylinder cup and dust Seal replace Brakes and clutch Caliper piston and dust seal replate 2 years Brake hose replace Gg Clutch hose 4 years replace Es bei In the interest of safety we recommend these items be serviced only by an authorized CAGIVA dealer dq For higher odometer readings repeat at the frequency interval established here c 2 enaa N 49826 ADJUSTMENTS i D 2 D 3 D 4 4 D 4 D 5 D 6 QUART Carburetor synchronization Idle adjustmen Throttle cable adjustment Choke cable adjustment Front brake lever adjustment Hydraulic clutch lever adjustment Drive chain adjustment Steering head bearings play adjustment um 49826 ADJUSTMENTS Carburetor synchronization Carburetors must be adjusted to open and close simultaneously Note Value clearance spark plugs and ignition must be set properly before synchronizing the carburetors A Idle Speed 1 Warm up engine 2 Stop engine 3 Install vacuum Gauge Note Insure the gauge does not leak Leaking will result in improper adjustment 4 Start engine and leave it at idle speed 5 Turn carburetors slide adjusting bolt 1 until mercury columns from va cuum gage are even 6 Turn adjusting bolt of both carburet
12. 960 gt lt E 9 o 2 bi Mi e pe 2 o o o no lt E 2 g 0 gt Te Ww X lt Eeo ae ge uw Se E DG e z y gt g Se e 0m 5 o C o o A H s gt pu c D gt Och S n om es base 5 7S o 2 e E eener 2 gt lt xs gt ma o o 5 gt Ox 208 099 D ooo g 7 5 S S 2 2 2 um e e e gt e e gt e We ners mere m SS Pai WEE m a me g Reesen wa SES m E o RS EE m ER um pa e x Sa Beer m eens acc FS Bereet ao m mM lee m PESE Ex EEN M pone abg he A Pa eee ne n S Bees ENGINE OVERHAULING Valve Valve seat assembly e Check that contact surface between valve and seat is 1 4 1 6 mm 0 0551 0 0629 in e f measured dimensions are off the limits grind the valve and seat Note To check the contact surface use Prussian blue Replacing valve guide Replacing valve guides if necessary must be done before valve seat is ground since the valve stem hole in valve guide is the basis from which all seat grinding is done Valve stem valve guide clearances are listed in G 21 If value stems and or guides are worn beyond service wear limits new parts must be instal led To replace valve gui
13. CAUTION j Charging the battery at a rate higher than speci fied above could ruin the battery Charging at a hi gher rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active meterial Deposits will accumulate and can cause internal shorting e Measure the specific gravity of the electrolyte and use the graph Fig K2 to determine the percentage of discharge Multiply the capacity of the battery by the percentage of discharge to find the amount of di scharge in ampere hours Use this figure in the formula below to com pute charging time Because the battery gives off an explosive gas Because the battery gives J off an explosive gas ELECTRIC SYSTEM Amount of discharge AH 1 2 1 5 Charging current A 4 Charging time hours e Remove the caps from all the cells and begin charging the battery at the rate just calculated If a constant voltage charger is used the volta ge will have to be adjusted periodically to maintain charging current at a constant value rate to bring down the temperature and increase charging time proportionately e After charging check the electrolyte level in each celi If the level has dropped add distilled water to bring it back up to the upper level line e Check charging resuits by measuring the specific gravity of each cell and by measuring battery voltage Battery voltage of a 12 voi
14. Liz Me Us aS 1102 AH 30NI142 TVLNOZIHON 22140 ID TY VNIBOS 1102 AH YONA TILIA 183A THI IY VNIBOS YOLLANDI 1431 NIE AWW S 301L 02 3v Give 350 3401070934 ruaisn3 u31sviS 01092105 AM 38011083131 BOLOW ONILMVIS AAT ONIMOLONW amp 92192 2 S 92 92 Ju 3 430 Nf e iuvis kx ROLL LHO HOLIMS 3AVIHO H YYFLNI 1 179 vaaliva M 2 CAGIVA 2 49826 N ELECTRIC SYSTEM HTTETETETTECLLTEEETETLUTT TETTTTTTTTTTT T TET TR TT EEZEEEEFEREERE GT TG G GT Ignition system wiring diagram TO THE R H COMMUTATOR 36 37 PICK UP HORIZONTAL CYLINDER VERTICAL CYLINDER ELECTRONIC BOX ELECTRONIC BOX 38 HORIZONTAL CYLINDER HN COIL VERTICAL CYLINDER HV COIL Wy WM N AN Cr 7 ar SPARK PLUG SPARK PLUG Wire color codes COLOUR GREEN BLACK L T BLUE RED BLACK COLOUR COLOUR 25 hiana 36 o 20 WHITE 31 YELLOW GREEN 42 YELLOW GREEN a 55 _ WHITE BLUE M 3 N 49826 II ELECTRIC SYSTEM H IUIIITIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII III IR III IR RI INN Battery 1 Hydrometer The battery supplies the current to the starter motor and serves as a back up source of power to operate the electrical equipment whenever the engi ne is turning over too slowly for the al
15. PART 6 METRIC ENGLISH REMARK THREAD DIAMETER Kg m ft lbs AND PITCH CYLINDER HEADS FIXING NUTS ER 25 5 5 CONROD CAPS FIXING SCREWS 6 5 7 0 10 1 0 PRIMARY TRASMISSION GEARFIX NUT 11 12 775 487 Garg CLUTCH DRUM FIXING NUT 14415 101 108 5 20 P 1 0 TIMING SYSTEM SHAFT GEAR FIX NUT 4 29 14 10 TIMING SHAFT RING NUT 354 255429 215 P 1 0 ALTERNATOR ROTOR FIXING NUT T 7995 220 P 1 0 TIMING BELT STRETCHER FIX SCREW 25 18 0 8P125 OIL PUMP GEAR FIX NUT mE 242 5 14 5418 8P1 0 IGNITION SPARK PLUG 2 5 18 e D 14P 1 25 COVERS AND CRANKCASES BOLTS 084 67 6P10 COVERS AND CRANKCASES BOLTS 2 3 14 5422 o 8P125 CLUTCH CONTROL DISC FIX BOLTS 0831 647 6P10 N 49826 HA AMALIA 1727 TORQUE Lm E an CHASSIS TORQUE PART METRIC ENGLISH REMARK THREAD DIAMETER kg m ft Ibs AND PITCH FRONT AXLE 7 747 5 50 5 54 314P 15 REAR AXLE NUT 747 5 50 5454 P Q 16 P 1 5 REAR SHOCK ABOSORBER BOLTS A 29 M Q12P175 STEERING STEM HEAD BOLT ER 14 5 8Pi25 0 STEERING STEMLOCKNUT 2 0 445 25P1 FRONT FORK TOP PLUGS 25 18 E 238P 1 5 FRONT FORK DRAIN SCREWS TE 6P1 HANDLEBAR CLAMP BOLTS 2 14 5 1 25 ALLEN BOLT FROM BASE 01 5 11 6 1 DISC MOUNTING BOLTS FRONT a 14 5 E o 8P125 DISC MOUNTING BOLTS REAR 1 5 11 9 6
16. Place cover bolts and tighten on e Place clutch housing holding bolts and tighten on lock clutch housing by means of tool YY 42403 e Place clutch hub and clutch spring plate e Place locking washer and lock the clutch drum with tool xxv 42403 Li Lock the fixing nut to a torque of 136 Nm 14 or 101 2 161 E Sr Les SF y ee e Bend back the washer e By means of a screwdriver push the spring plate e Place clutch plates keeping in mind that the first plate to be placed is the special driven plate with bend teeth Bend teeth should be pointing to the outside The last plate to be placed is the special driving plate 4 ee il Z Ss YEE TII N 49826 H 14 ENGINE RE ASSEMBLY 1111111 Place the plate retaining circlip e Place clutch springs e Place clutch springs holding plate and tighten on bolts Place clutch plates cover and tight on bolts Duemsi MADE WM TAH j 4 4 S QE Sy 7 9 QULA H 15 N 49826 ENGINE RE ASSEMBLY Shift mechanism assembly e Place shift mechanism assembly e Place shift mechanism lever in center of selector drum e Tighten shift mechanism plate support e Place countershaft sprocket N 49826 ENGINE RE ASSEMBLY Place countershaft sprocket holding plate by sliding it thru shaft grooves and rotating inside slot u
17. SPECIFIC TOOLS Nr Code DUCATI Clutch drum locking wrench Rocker pin extractor Timing belt tensioner Wrench for cylinder head nut Alternator retain wrench for nut locking Crankshaft gear retaining wrench for nut locking Closing rocker amp spring assembling tool Protractor wheel Graduated disc bearing tool for advance checking with disc Tool for removal of connector pins Timing pulley nut locking wrench Timing pulley nut locking wrench Tool for removal of chain cover Rocker assembi pin Timing pulley retaining wrench Lower spacer Lower spacer Oil filter cartridge removing tool W 1 N 49826
18. Us UN a 49826 F 13 ENGINE DISASSEMBLY e Remove the 8 holding bolts and the clutch housing from primary gear Lock clutch housing by means of blocking tool yy 42403 Remove bushing 2 EL D 4 522 ye e Remove the clutch housing e Remove R H side cover DUE qi Wen Remove bushing F 14 N 49826 Wm ENGINE DISASSEMBLY e Remove Primary gear Bushing Oil pump C AUTION When removing oil pump watch out for bushings and rubber washers placed at rear of oil pump RU N 49826 M ENGINE DISASSEMBLY TTTTTTLLLTTLLLELLELLTT LTLTTTTTTETETETETETETTETETTETETTETE e Bend back tab on locking washer Hold crankshaft pinion by means of tool Yr 42409 and loosen up the nut e Remove pinion use puller CAUTION i Place an aluminum pad between crankshaft end and puller 4 Hold driving pullers by means of tool 7 42415 and use wrench 42414 to loosen nut z 651 N 49826 F 16 DEM ENGINE DISASSEMBLY e Remove First pulley and woodroof key Second pulley and woodroof key A Re va e Remove selector drum positioning pin assembly 2 e Hemove center crankcases bolts N 49826 B ENGINE DISASSEMBLY e Slightly tap with a plastic hammer crankshaft and mainshaft until
19. closing roc ker arm e Remove the two closing cap retainers e Remove cap e Remove valves QUU UU F 22 N 49826 3 ENGINE DISASSEMBLY e Remove camshaft CAUTION Watch for shims e Horizontal cylinder camshaft has two woodroof keys while vertical cylin der has only one e Hold the end of closing rocker arm spring by means of tool Ze and e Remove closing rocker arm shafts by means of tool 42404 N 49826 SER GE WE F ENGINE DISASSEMBLY 1111111111111111111111111111111111111111 e Remove rocker arms CAUTION Pay attention to side play shims When rea sembling must be in the same place unless play has to be corrected e Remove the valve guide oil seal F 24 ENGINE OVERHAULING 9900 G 2 Washing parts G 2 Assemblies G 3 Measuring the cylinder G 4 Measuring the piston G 5 Piston cylinder matching GP Piston pin G 5 Piston rings G 5 Piston ring piston ring groove clearance G 6 Piston ring end gap G 6 Piston pin Piston pin housing clearance G 6 Piston pin Con rod small end clearance G 7 Conrods G 7 Conrod small end plain bearing replacement G 7 Rod bearing insert G 8 Crankshaft G 8 Crankshaft truing G 8 Grinding the crankshaft pi
20. new oil to maximum level Start engine let it run for one minute and stop it Check oil level again and ad if needed o 4 CAUTION Oil level must be checked with motorcycle in vertical position and standing on both wheels UA N 49826 F 2 ENGINE DISASSEMBLY e sure that engine is properly installed on its support Remove spark plugs e Remove toothed belts covers e Loosen both belt tensioners and move them avay from belts e With a felt pen or similar marker mark rotation counterclockwise and the cylinder camshaft they drive V for vertical cylinder and H for horizontal cylinder 22 SN 277 ADT N 49826 ENGINE DISASSEMBLY e Remove the belt with your hands only do not try with any tool 5 CAUTION Sharp bending of toothed belt minimum bending radius is 0 78 in oil petrol solvents may cause permanent damage io the belts Pulley Removal e Hold pulley with tool Ze 42415 and loosen up holding nut with tool 42414 e Remove pulley woodroof key and guiding washer wd F 4 N 49826 ENGINE DISASSEMBLY Cylinder Head e Remove rubber back cap CAUTION Follow next steps only if engine is cold If engine is still warm due to the natural expansion of the aluminum the stress that cylinder studs have increases the torque needed to loosen cylinder head nuts
21. off set is not more than 0 05 mm 0 0020 in Note When installing shafts in truing stand adjust so centers are snug Shafts must turn freely but may not be loose in centers It shafts are loose or tight indicators will not read accura tely G 14 N 49826 EI NGINE OVERHAULING Oil seals replacement e Replace oil seals at every engine overhauling e When replacing oil seals be sure that new seals are introduced perpen dicular to its housing e When new oil seal is in its place lubricate oil seal lip with a little oil or high temperature grease to reduce rubber to metal friction Note Replace any oil or grease seals that were remo ved with new ones as removal generally dama ges seals Seals should be pressed into place using a sui table driver which contacts evenly with the side of the seal until the face of the seal is even with the end of the hole Bearings e Before checking bearings wash them thoroughly with solvent and dry with compressed air Do not use compressed air to spin the bea rings dry This causes damage to the bearing surfaces CAUTION e To check bearings lightly oi them and rotate slowly the inner ring by hand If hard spots excesive play or uneven rotation is found replace bearings Note Main bearings must always be replaced both at the same time and installed with the thicker part of the outside rac
22. switch is actioned by the lever and it is placed in master cylinder bracket Rear brake light switch is hydraulic pressure actioned and is placed in the rear master cylinder Each switch turns on the brake light Due to the fact that the components of the disc brake the disc and pads are in direct contact with the air flow past the motorcycle excelent dissipation of the heat from brake friction is obtained and minimizes the possibility of brake fade common to drum brakes The automatic wear adjustment mechanism of the rear caliper i is the same of the front caliper and caliper operation is the same as for the front caliper QUII BRAKES Brake pads removal e Remove the guard cap e Remove pads pin holder e Remove the pads Pad wear e Inspect the pads for wear Service limit 4 mm 0 16 in Pad cleaning Be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Replace the pads with new ones if they cannot be cleaned sati sfactorily Pad installation e if a new thicker pad is installed push the caliper pistons in their hou sings by means of a soft end tool Note Do not use hard surface tools they could cause damage in brake pistons and resault in hazardous braking situations e Install new brake pads e install anti rattle spring blade and holder pin e Bleed the brake if required e 2 e P
23. the relationship between the speci fic gravity of the solution at 20 C 68 F and the percentage of battery char ge Since specific gravity varies with temperature and since the tempera ture of the solution being checked is likely to be other than 20 C 68 F the formula given below should be used to compute the equivalent specific gravity for any temperature When the temperature goes up the specific gravity goes down and vice versa Specific Gravit Initial charge New batteries for CAGIVA motorcycles are dry charged and can be used directly after adding the electrolyte However the effect of the dry charge deteriorates somewhat during storage especially if any air has entered the battery from imperfect sealing Therefore it is best to give the battery an initial charge before using it in order to ensure long battery life WARNING or open flame away from the battery char ging e Pour a 1 280 specific gravity at 20 C or 68 F sulphuric acid solution into each cell of the battery up to the upper level line e Let the battery stand for 30 minutes adding more acid if the level drops during this time Note 1 If the temperature of the solution is over 30 C 85 F cool the solution before pouring it into the battery 2 After pouring the acid into the battery start charging the battery within 12 hours e Leaving the caps off the cells connect the battery to a charger set the charging rate at 1 10
24. they have worn past the ser vice limit replace them with new ones Service limit thickness 3 3 mm 0 1299 in CAUTION If new dry steel plates and friction plates are x installed apply engine oil on the surfaces of each plate to avoid clutch plate seizure e Check that clutch spring free length is at least 41 mm 1 6142 in If shorter replace with new springs G 16 N 49826 ENGINE OVERHAULING i Gearbox e Check that engaging dogs edges in gears are still sharp e Check that idling gears freely rotate in the shafts and a side tolerance below 0 10 mm 0 0039 in e Shaft threads and sliding slots must be in good conditions e Check that sliding slots are within manufacturer s tolerances Service width 8 0 8 09 mm 0 3150 0 3185 in Service limit 8 19 mm 0 3224 in N 49826 G 17 CAGIVA ENGINE OVERHAULING Shafts bushings e Check that all shaft bushing assemblies are within the tolerances speci fied by the manufacturer Tolerance 0 02 0 03 mm 0 0008 0 0012 in Service limit 0 10 mm 0 0039 in 7 49826 e G 18 N ENGINE OVERHAULING Carburetor overhauling e Throughly wash with solvent an dry with compressed air all carburetor components CAUTION Do not ramane the adjusting screw 1 of accelerating pump Every carburetor has been individually test
25. wear or damage Check that belts are in perfect conditions although it is advisable to chan ge them at every overhaul Check if the ball bearing belt tensioner turns freely without excessive play SO Free wheel and starting mechanism Make sure that the free wheel works properly and that roller tracks are free of wear signs or any other damages Check that all gears are in good conditions N 49826 e ENGINE OVERHAULING Crankshaft assembly e Check that conrod cap centering pins are fitted e Apply a liberal amount of engine oil to the connecting rods and caps and make sure that both are marked with the same number e Bolt on caps to connecting rods using brand new bolts Note Carefully grease bolts on thread and cap to ensure that the tightening torque applied is not lost in thread or cap fric tion e Apply tightening torque of 64 Nm 6 5 or 47 01 Dit e Check connecting rod side play by means of a feeler gauge Side play 0 15 0 35 mm 0 0059 0 0138 in Crankcases e Carefully check visually crankcase e Check for flatness on a surface plate e Check that bearings and bushings are in good condition Note If bearings of bushings need to be changed always replace both bearings of a set e Check that lubrication conduits are not obstructed Check of shaft e To check if shafts are bent place them in a truing stand e With the help of a dial gauge check that shafts
26. 1 FRONT CALIPER MOUNTING BOLTS 4 0 29 Q10P15 sun ee um ee ee ANA REAR CALIPER MOUNTING BOLTS 40 29 8P125 NOTE Marks used in Remark e Apply a non permanent locking agent to the threads Apply a liquid gasket to the threads or washer B 2 N 49826 TORQUE The table below relating tightening torque to thread diameter and pitch lists the basic torque for the bolts and nuts used on CAGIVA Motorcycles However the actual torque that is necessary may vary amount bolts and nuts with the same thread diameter and pitch The bolts and nuts listed on Pg B 1 vary to a greater or lesser extent from what is given in this table Refer to this table for only the bolts and nuts not included in the table on Pg B 1 All of the values are for use with dry solvent cleaned threads COARSE THREADS LEE Eben DIA mm PITCH KGM FT LBS 5 0 80 0 85 0 50 30 43 in lbs rJ c 6 1 00 0 60 0 90 52 78 in lbs 8 1 25 1 6 22 11 5 16 0 x M cl 10 1 50 3 1 42 o 22 30 12 1 75 54 7 5 39 54 14 2 00 8 8 11 5 60 83 16 200 13 0 18 0 94 130 18 2 50 180 225 130 181 20 2 50 26 35 188 253 FINE THREADS e 5 H DIA mm PITCH mm KG M FT LBS 5 0 50 0 35 0 50 30 43 in Ibs _ nne a a RE 6 0 75 0 60 0 80 52 69 in Ibs i _ B 1 00 14 19 10 0 13 5 10 1 25 26 3
27. 2344 LLIWB3INI i Sech nr 390191430 d 11313 N39 11313 7991432 LCE Aen DE 8 EMT A H bd Ge 1NQH4 2959 6 2 6 SIHIN SIN JAMYISN ie 0t hHiS WATT 9 29 550 ES vl gt vv v 999 pa 59 Q 1431 170919 ecl eleva elo NIS Z3NlQ s Lf i i Grae oo eR me 7 Ears NPG Sire SE Ee EH EH ESCM 30 E DEE Las D ja RES z st er 2 ee ee eee E Zi a REES EG s 3 p d Wee PEN N EA G ee Ee ee E ee ee pr d E H tooo eee kum wei ae pou E SES NGANA TO EN Eer 8 ioi LAAT 1504 ONITYNY4 E peces ANE nan eee ND 8 EE OE Poona es en Ie oe peti a xb xi gt gt aas 4 DUET SESS NUN d Ee Ep TII au TT poem oe enne 1 po gt a EET cu pe RECS WOLUNG 4 OWT TOY JH ENEE e 3 s INV 330113 0M4 i ml gb RA p SCH se e Mau AMOI 1YNDIS NAN i X30 2390 NO Vaud SHOE 15 d UO LYDIGNI MOLIMS ZE aHomadis de30 31103 YYJINI WYWu9YIG 219193193 JHL 1504 401 3unsS3Ud NO 01710 SS3ud od nias Mtd Waves v3130Nv9 V130NY2
28. 5 19 0 25 a ME ON 12 1 50 45 62 33 45 14 1 50 74 102 84 74 16 1 50 115 2160 83 116 18 1 50 17 0 23 123 166 20 1 50 23 33 166 239 MIT mmm 49826 ERE MAINTENANCE PERIODIC MAINTENANCE CHART Odometer Reading Km mi Refer sET 500 1000 1500 3000 5000 10000 15000 20000 25000 30000 UP 350 650 1100 1900 3000 6300 9500 12500 15600 19000 P 9 Every Operation A 2 Valve clearance check H 5 pe Driving belt tension check Hog Cylinder head nuts check Fuel lines clean carburetor Check synchronization Ca Spark plug clean and gap Air filter clean Air filter replace EMISSION RELATED CA Carburetor Idle speed Dy Engine oil Change 1 year Evaporative emission control System California only Be a M 4 Battery electrolyte level check a Engine oil level Check B Cil filter replace A Brake pad wear check Brake fluid check Month NON EMISSION RELATED D D 2 year r pr N 49826 g Brake fluid change s Brake light switch check MAINTENANCE PERIODIC MAINTENANCE CHART Whichever gt Odometer Reading Km mi comes Refer v SET 500 1000 1500 3000 5000 10000 15000 20000 25000 30000 o UP 350
29. 826 Ze ENGINE OVERHAULING Note Be sure to install the rings so that the mark is on the top side of the piston Piston ring end gap Position piston ring inside of the bottom end of the cylinder the cylinder e Use feeler gauge to check piston ring gap Top Piston ring Standard 0 25 0 40 mm 0 0098 0 0157 in Service limit 1 20 mm 0 047 in Middle Piston ring Standard 0 25 v 0 40 mm 0 0098 0 0157 in Service limit 1 20 mm 0 047 Bottom Piston ring Standard 0 20 0 35 mm 0 0079 0 0138 in Service limit 1 20 mm 0 047 Piston pin Piston pin housing clearance Service limit 0 05 mm 0 0020 in Piston pin Con rod small end bushing clearance located e Push the ring with the piston crown no more than 10 mm 0 4 in inside Standard clearance 0 002 0 013 mm 0 00007 i 0 00051 A CS Standard clearance 0 006 0 029 mm 0 00023 0 00114 in I eem sm Service limit 0 05 mm 0 0020 in BGAN G6 49826 eon ENGINE OVERHAULING H 111111 HERR RERN Conrods The conrod small end bushing must be in good conditions and firmly set in its housing Remove the connecting rod big end bearing inserts Select an arbor of the same diameter as the connecting rod big end and of optional length and insert it through the big end of the connecting
30. E EEE EEE ERE E TRRREERHTREERETREERERRREERHHEERENHRERERERHNRNHEEREESESEEREERBERERERREREEE Summary Specifications Torque Maintenance Adjustments General operations Engine disassembly Engine overhauling Engine re assembly Suspension and wheels Hydraulic control clutch release Brakes Electric system Troubleshooting guide Specific tools SS Sr o E OD am Dom Se MAE 49826 SPECIFICATIONS ENGINE Compression oiii Horse power r p m Max engine speed LubricatiOn an Welt lo E ele DEE Alternator a Ignition module Autom advanced anuon timing SPAM PIUGS E Electrode gap PPA Head lamp bulbs Rear parking light bulbs Turning light uideo Tail light bulbs Twin cylinder 90 L 4 stroke Desmo SOHO air cooled 649 6 c c 82x61 5 mm 10 1 vod 57 5 CV 42 3 Kw 7500 r p m Em 8 500 r p m By gear pressure pump Wet sump Dell Orto PHF 36 x2 Ducati Electronic Ducati or Saprisa Alternator 12 V 300 W BOSCH Motoplat 5 1700 r p m 25 2600 r p m 32 over 2900 r p m CHAMPION L 82 YC 0 6 0 7 mm 0 023 0 028 in 12V 14Ah 12 V 55 60 W 12V 5W 12V 21W Double filament 12 V 21 5 W Stop Plate lights A1 N 49826 SPECIFICATIONS FLLEEEEREEEEEDLDEETEE
31. ITEREITERITRRITEEEETRRTRRRIRRETRRRE UTERE RRERRERIRRRER GER RRRRERRRRREREREREEBREERRERERRE DESMODROMIC VALVE GEAR SYSTEM Your CAGIVA motorcycle features the famous DUCATI Desmo dromic valve gear system The Desmodromic valve gear sy stem ensures high performances over the entire speed range Rocker arms to valves clearance inlet and exhaust valves Opening rocker arm 0 10 mm 0 0039 in Closing rocker arm 0 00 0 02 mm 0 0 00078 The Desmodromic Valve Gear System 1 Opening rocker arm upper 2 Opening rocker arm adjuster 3 Split sn 4 Closing rocker arm adjuster 5 Return spring 6 The camshaft is belt driven and valve timing is Closing rocker arm lower 7 Camshaft 8 Valve TRANSMISSION Transmission 5 speed constant mesh Clutch WOO siii a Multiplate dry clutch hydraulically operated Primary drive Pr Helical gears 36 71 Final drive O ring chain 5 8 x 3 8 Final Fallo dn 14 44 Gear ANOS o ak aba 1st 14 43 2nd 20 37 ard 24 32 4th 27 29 5th 29 27 Overall Drive Ratio 5th gear 0 173 2 49826 SPECIFICATIONS e db FRAME Type Seed Double down tube cradle 4130 box section tube ac ERES 20 30 Steering angle eU aka 35 to either side preci er M 114 mm 4 49 in Tire SIZE te E 90 90 21 abri T 130 90
32. arged battery not in use loses its charge after 2 to 7 days or if the specific gravity drops markedly the battery is defective The self di scharge rate of a good battery is only about 1 per day RU ELECTRIC SYSTEM AYIIFTITETEEDTEITISIEITEDETEHITEHERRETEETSEEERERESEETEEEIS RES EERR HRERRHERRRRREERR iii Table K1 Battery Troubleshooting Guide Good Battery Suspect Battery white sulphated plates broken or corroded chocolat color gray Plates None or small amount sediment up to plates causing short Replace Sediment above 12 volts below 12 volts Test charge Voltage above plates below top of plates Fill and test charge Electrolyte Level below 1 100 or difference of more that 0 020 between two cells above 1 200 in all cells no two cells more than 0 020 different Specific Gravity Test charge Generator The generator is placed on the left hand side of the engine The stator coil is mounted in the alternator cover while the rotor is secured to the left end of the crankshaft and rotates at engine r p m Permanent magnets in the rotor supply the magnetic field for the stator coil so that no slip rings or brushes are necessary making the alternator practi cally maintenance free Power out put is 12 Volts 300 watts Do not allow the rotor to suffer sharp impacts CAUTION such as striking it with a hammer or letting i
33. bolt on crankcase Note Clutch fluid is DOT 4 WARNING Clutch fluid can cause eye irritation In case of contact with eyes flush with plenty of water and get medical attention KEEP BRAKE FLUID OUT OF REACH OF CHILDREN Tachometer driving cable removal With a pair of pliers loosen up knurled ring nut Pull out driving cable Carburetors removal Remove throttle cable from throttle grip on handlebar by pulling down the rubber cover placed underneath the throttle grip Remove air filter rubber hose from both carburetors Remove chocke from carburetors Loosen clamps and pull carburetors out 49826 DULL DD GENERAL OPERATION Shift pedal linkage removal Remove bolt from shift pedal e Remove shift linkage short lever from shift axle Drive chain removal Set motorcycle on its stand e Turn rear wheel until master link is on rear sprocket e Remove master link clip e Remove master link Turn wheel backwards until chain lays completly on the ground W ARNING 2 your fingers out of the chain and sprockets when rear wheel is moving Serious phisical damage can be obtained if catched by chain and sprockets C AUTION When chain is mounted back be sure that the master link clip is mounted with its closed end pointing to the direction of the chain movement i gt E 6 igaara a N 49826 GENERAL OPERATION H Engine removal from frame
34. ccordance with the periodic Maintencance Chart CAUTION The spark Arrester must be installed correctly and functioning properly to provide adeguate fire protection WARNING W avoid burns wear gloves if Spark Arrester is hot Remove Spark Arrester mounting bolts 1 4 e Pull cover 2 and plates 3 out of the muffler e Clean carbon particles Install spark arrester W ARNING da Never run the engine without Spark Arrester near combustible materials hot particles may start a fire Do not run the engine in a closed area Exhaust gases contain carbon monoxide a colorless odorless poisonous gas Breathing exhaust gas leads to carbon monoxide poisoning asphyxiation and death Wa 49826 ADJUSTMENTS IIIIIIIIIIIIIIIIIIIIIIIIIIUIIIIIIUIIIIUIIIIIRIIR III DI UI DI DIDIER ENER E REDER RRE RERRRRRRR Steering head bearings play adjustment For safety the steering should always be kept adjusted so that the handlebar will turn freely but have no play If the steering is too tight it will be difficult to turn the handlebar quickly the motorcycle may pull to one side and the steering stem bearings may become damaged If the steering is too loose the handlebar will vibrate and the motorcycle will be unstable and difficult to steer in a straight line To check the steering adjustment Set the motorcycle on a center stand e Lift the front wheel off the ground e From the straight forwar
35. ck Spark plugs are tight Valves seat properly Piston rings worn out Check stop run switch Ignition wires not properly pluged Clear or replace spark plug check electrode gap Check ignition coil wires or replace it Check pick up wires replace if required N 49826 y 14 TROUBLESHOOTING GUIDE Lights do not work properly CAUSE REMEDY Battery is down or often runs down Check battery condition and charging circuit Check rectifier regulator If defective must be replaced To check if charging circuit works procede as follows e Disconnect the wire from terminal of the battery and place a direct current ammeter between terminal and wire possibly with O in center e Stait engine until a spead in 5 000 is reached The ammeter must read the following values a max current 10 A if the battery is almost dead b min current 1 A if the battery is fully charged Test must be carried out with lights off The ammeter must be connected al ways with the engine off Electrical consumption test e Make sure that all the bulbs work a with low beam lights on the ammeter must read zero at approx 2 200 r p m b with lights off the ammeter must read zero at approx 1 000 r p m Ignition switch is off but battery quickly goes dead Check that no ground contact is in the system 1111121112111211 000 N 2 N 49826 TROUBLESHOOTING GUIDE Engine
36. contact with skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed N 49826 mmm BRAKES Caliper overhaul e Remove fluid hose e Remove caliper from support e Dissasamble caliper by removing the allen bolts e Clean thoroughly To clean calipers use only isopropyl alcohol or ethyl alcohol Gasoline motor oil or any ot her petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually reach and break down the rubber used in the disc brake e Use aire compressed to remove pistons e Check that piston and cylinder surfaces are perfectly smooth e Reasemble WARNING Compressed air can possibly forcibly eject the pistons from the calipers Rap a shop towel around the caliper before applying compres sed air AUAM N 49826 BRAKES Mastercylinder overhaul e Push piston with a thin rod to relieve presure from snap ring e Remove snap ring e Slowly pull out rod until piston comes out of master cylinder pushed by internal spring e Clean thoroughly CAUTION To clean master cylinders and pistons use dech only isopropyl alcohol or ethyl aicohol Gasoli ne motor oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually r
37. crankcase split is obtained CAUTION When crankcases split is obtained watch care fully not to lose or misplace the shims from Crankshaft Mainshaft Countershaft Selector drum Do not under any circumstances use a screwdriver or other tool to pry the cases apart This will ruin the cases e Remove oil pressure adjustment valve and spring Lei i N 49826 F 18 ENGINE DISASSEMBLY e Remove camshaft driving shaft CAUTION Watch for the shims do not loose or misplace e Remove crankshaft by means of slightly tapping with a plastic hammer CAUTION Watch for shims do not loose or misplace e Remove shift fork rods and move away shift forks from selector drum e Remove selector drum N 49826 E J d i ENGINE DISASSEMBLY e Remove mainshaft watch for shims Keep them in same position III F 20 N 49826 Per st E ENGINE DISASSEMBLY CAUTION When disassembling cylinder head compo nents mark them appropriately to be able to reassemble them in their previous position e Loosen bolts and remove valve covers e Loosen bolts and remove camshaft supporting cap e Remove the rocker arms When removing rocker arm shims avoid dama CAUTION ging or scratching seat surface N 49826 M sra ENGINE DISASSEMBLY e Turn camshaft and with the aid of a screwdriver hold up the
38. d position of the handlebar slowly push the handlebar to either side be sure that the cables and wiring harness do not interfere handlebar movement If the handlebar begins to turn by the action of gravity and continues moving until the ridge on the stem base stops against the stop rod on the frame the steering is nof too tight e If the handlebar does not begin to turn by the action of gravity the steering is too tight necessitating adjustment Squat in front of the motorcycle and grasp the lower ends of the front fork Push and pull the fork end back and forth If play is felt the steering is too lose necessitating adjustment To adjust the steering e Loosen stem head bolt Adjust play acting on steering stem locknut using the stem nut wrench e Loosen top triple clamp allen bolts Tight on stem head bolt Tight on allen bolts ae N 49826 D 6 icaervaj t GENERAL OPERATION E 2 Seat Removal E2 Side covers removal E 2 Air scoops removal E 2 Gas tank removal E 3 Battery removal E 3 Air filter box removal E 3 Silencer removal E 4 Subframe removal E 4 Exhaust removal 5 cooler hoses removal D E 5 Clutch cable removal E 5 Hydraulic clutch fluid hose removal E 5 Tachometer driving cable removal E 6 Carburetor removal E 7 Shift pedal linkage removal E 7 Drive chain removal E 8 Engine removal from frame GENERAL OPERATION Seat Removal e Loos
39. des act as follows 1 Heat up slowly and evenly the cylinder head till reaching 150 160 C 302 320 F 2 Tap guides from combustion chamber towards outside using drift pin shown 3 Let cylinder head and valve guides coo down to room temperature 4 Inspect the inside diameter where the valve guide fits in the head and the seat that the shoulder of the valve guide abuts These must be free of scores burrs and foreign material If necessary ream the insi de diameter to the next oversize The interference measured cold between the valve guide and the seat must be 0 04 0 05 mm 0 0016 0 0020 in mE Note Over size outside valve guide diameter are available in the following sizes 0 03 mm 0 0012 in 0 06 mm 0 0024 in 0 09 mm 0 0035 in 5 Heat up slowly and evenly the cylinder head till untill 150 166 C 302 v 320 F are reached 6 Lubricate the outside of the new valve guide with white lead or anti seize compound Using the drift pin quickly and carefully install the new guide Make sure it is driven fuily home 7 Allow the cylinder head to slowly cool WARNING Avoid to touch cylinder head with bare hands CAGIVA N 49826 G 11 ENGINE OVERHAULING Replacing valve seat If valve seat replacement is required act as follows 1 Mill the old valve seats C AUTION Be carefull not to damage the head Check valve seat housing on cylinder head and choose
40. e facing away from the crankshaft It s advisible to replace main bearings at every engine overhouling e Oil the bearings liberally when installing Bearings replacement To replace bearings aci as follows 1 Heat up crankcases in oven until reaching 100 C 212 F 2 Remove old bearings by means of a suitable Driver 3 While crankcase is still hot install the new bearings perfectly in squa re with the housing axis CAUTION When installing a ball bearing the outer bea be pushed by a suitable driver This prevents severe stress on the ball and races and pre vents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft 4 Live engine to cool down to room temperature and check if bearing is tightly fixed to the crankcase N 49826 ring race which is affected by friction should G 15 Ou CAGIVA ENGINE OVERHAULING Oil pump Carry out the following checks play between gear teeth does not exceed 0 10 mm 0 0039 in play between gears and pump body does not exceed 0 10 mm 0 0039 in play between gears and cover does not exceed 0 07 mm 0 0028 in the pump cover is free of dents scores or any damage Clutch assembly e Make sure that all clutch assembly components are in perfect condition e If clutch plates show signs of damage or if
41. e disc does not touch the ground 49826 Ill CAGIVA 1 11 SUSPENSIONS AND WHEELS Wheel bearings A wheel bearing is fitted in both sides of hub Since worn wheel bearings will cause play in the wheel vibration and in stability they should be changed Bearing replacement e Insert a metal rod into the hub from the top side and remove the bottom side bearing by tapping evenly around the bearing inner race e Remove the remaining bearing by tapping evenly around the bearing in ner race Wheel bearings Installation e Before installing the new bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bea rings Install them using the bearing driver so that the bearings are placed per fectly in axis with wheel axle N 49826 UNI 1 12 HYDRAULIC CONTROL CLUTCH RELEASE 1111020012000 510111101 J 1 Hydraulic clutch description J 2 Hydraulic clucth fluid drain J 2 Master cylinder overhaul J 3 Fluid change J 3 Bleeding Hydraulic clutch The Elefant 650 has a hydrally operated clutch The clutch system has to be inspected periodically for fluid level and leakage The hydraulic clutch system is composed of the following parts e Master cylinder with fluid reservoir and clutch lever placed on handlebar Hydraulic line e Clutch piston placed on clutch cover p Ut J CAGIVA
42. e inner and outer tubes and pump them back and forth manually to check for smooth operation If the inner tube is bent or badly creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube To ckeck inner tube bending install both inner tubes in lower triple clamp and check for distances A B 0 10 A B x 0 0039 in QULA AF ANON SUSPENSIONS AND WHEEL Oil change e Place motorcycle on a center stand e Remove the handle bar off the stem head e Remove the drain screw from the lower end of the outer tube e Pump out the oil by repeatedly compressing and extending the front fork e Wash the drain screws and place them on the outer tube Tighten Screws e Place a jack or stand under the engine so taht the front wheels is raised off the ground e Remove the top fork caps and pour in the type and amount of oil specified in table e Install fork caps and tight e Install the handlebar Remove jack from under the engine Fork oil 500 cc or 30 5 cu in per fork leg Oil type SAE 15 fork oil TULLIUM 49826 SUSPENSIONS AND WHEELS Rear suspension The rear suspension is the Cagiva Soft Damp system and it is of the swingarm type controlled by a single schock absorber The shock absorber is pressurize and has a hydraulic spring adjuster so that the spring can be adjusted for different road and loading conditions WARNING This shock absorbe
43. e side allen bolts e Lift seat Side covers removal e Remove bolts and pull out side covers Air scoops removal e Remove fixing bolts to gas tank and pull them forward Gas tank removal Be sure that both gas valves are closed e Remove gas hoses Remove the rear gas tank fixing bolt Lift rear of gas tank and slide it backwards WARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch off Do not smoke or allow flames or sparks the area where the motorcycle is parked Battery removal Remove seat and side panel Remove negative wire e Remove positive wire Remove rubber clamp WARNING The battery contains sulfuric acid Avoid contact with skin eyes or clothing f e E 2 CAGIVA N 49826 GENERAL OPERATION Antidot X External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water and get prompt medical attention KEEP OUT OF REACH OF CHILDREN Batteries produce explosive gases Keep sparks flames and cigarettes away Always protect eyes when working near batteries Air filter box removal i Remove fixing bolts on R H side air filter to frame rubber hose clamp Loosen crankcase breather rubber hose clamp Remove air filter box pulli
44. each and break down the rubber used in piston or disc brake e Check that piston and master cylinder surfaces are perfectly smooth e Reasemble Fluid change The brake fluid should be checked and changed in accordance with the Periodic Maintenance Chart and whenever becomes contaminated with dirt or water Don t change the fluid in the rain or when a strong wind is blowing CAUTION Use only DOT 4 brake fluid from a sealed con tainer Never use old brake fluid Never allow contaminants dirt water etc to enter the brake fluid reservoir Handle brake fluid with care because it can da mage paint and instrument lenses Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fiuid WARNING Do not mix two types of fluid for use in the bra ke This lowers the brake fluid boiling point and could cause the brake to be ineffective it may also cause the rubber brake parts to dete riorate JL LU LU A A AA TAA AU N 49826 BRAKES Refiling the brake lines e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container Remove the reservoir cap and remove the rubber cap on the bleed valve Open the bleed valve counterclockwise to open and pump the brake lever or pedal until all the fluid is drained from the line e Close the bleed valve and fill the reservoir with fresh brake
45. ears and JA e shims ff i D if nf A ge UN S Countershaft e Place Countershaft assembly Shift forks e Place shift forks page e EK t ES Mi E eu COMI E Ean f gie Dee d A Selector Drum e Place Selector Drum N 49826 QULA ENGINE RE ASSEMBLY Shift forks shaft e Place shift forks ends in selector drum slots e Place shift forks shafts Crankshaft e Place crankshaft with shims tapping sligthly with a rubber or plastic hammer Camshaft driving shaft e Place camshaft driving shaft with shims in its bearing Oil pressure adjusting valve e Place oil pressure adjusting valve and spring 22 4 N 49826 f ENGINE RE ASSEMBLY Crankcases sure that the shim adjustment washers have been positioned on D shafts and selector drum e Place new center case gasket using some grease to keep it in place Check that crankcase centering bushings are in place e Join the two crankcases taking care that all shafts are correctly placed in their housings e Tap a few times with a plastic hammer to make sure that the parts are matched correctly DULUTH D DLE H 9 N 49826 ENGINE RE ASSEMBLY Tighten thoroughtly and progressively crankcase bolts Check that crankshaft rotates freely but with no side play Check that gearbox shafts have an axial p
46. ed for better perfor mance To clean all carburetor conduits or Jets use only compressed air If any metal wi re or hard rod 1 used damage can occur to soft conduit or jets walls changing air or gas flow causing carburation variatio e Replace any O ring or plastic plug if damaged or deteriorated e Check for signs of wear in carburetor slide needle or needle jet f carburetor slide sticks wide open check for dents or scraps in slide or carburetor body Operation with damaged sticking carburetor slide could result in an unsafe riding condition For US model only e To remove the air screw 2 punch and pry off the plug with an awl or other suitable tools e Turn in the air screw and count the number of turns until it seats fully but not tightly and then remove the pilot screw Note This is to set the pilot screw on its original position when assembling e When installing the pilot screw and plug do as follows o Tum in the air screw fully but not tightly and back it out the same number of turns counted during disassembly o Install a new plug in the pilot screw hole A Failure to adhere to this operating procedure could cause emission limits to be exceeded See the warning about tampering on page 2 of this Manual i Na CAGIVA G 19 N 49826 ENGINE OVERHAULING Dell Orto 36 DD PHF 36 DD gt
47. emove the reservoir cap and the rubber cap e Fill up master cylinder reservoir with brake fluid e Open the bleed valve counterclockwise to open apply the clutch by the lever close the valve with the clutch held applied and then quickly release the lever Repeat this operation until clutch line is filled and fluid starts coming out the plastic hose Replenish the fluid in the reservoir as often as necessary to keep it from running completely out e When pulling the clutch lever becomes hard repeat operation until the clear plastic hose is free of air bubbles Gaara N 49826 BRAKES v d LEET NISNBEENAITIIHIIIIHILIHIIIIIIIIIHIITIIIITIIIIIIIIIIIIIITIIIII I L 1 Brake system L 2 Brake pads removal L 3 Brake disc L 3 Brake fluid drain L 4 Caliper overhaul L 5 Brake master cylinder overhaul L 6 Fluid change L 6 Bleeding the brake Brake system A hydraulic disc brake is used on each wheel for superior braking performance and high reliability The major components of each disc breake are the brake lever front or the brake pedal rear master cylinder brakeline caliper assembly and disc The brake lever is pulled or the brake pedal is pushed to move a piston in the master cylinder and pressurize the brake fluid mE Fluid pressure is trasmitted through the brake line to operate the caliper The caliper grips the disc attached to the wheel slowing wheel rotation Front brake light
48. erclockwise and close the bleed valve Then release the lever or pedal Repeat this operation until no more air can be seen coming out into the plastic hose Check the fluid level in the reservoir every so often replenishing it as necessary e When air bleeding is finished check that the brake fluid is filled to the upper level line marked in the reservoir 49826 ELECTRIC SYSTEM te M 2 Wiring Diagram M 3 Ignition system wiring diagram M 4 Battery M 6 Generator M 6 Fuse box M 7 Regulator rectifier M 7 Ignition coil test M 7 Pick up test M 8 Spark plugs M 8 Spark plug caps M 8 Start M 9 Ignition timing advance inspection Wire color codes R POS COLOUR 56 GREEN BLACK i a 58 59 P 62 YELLOW RED GREEN WHITE BLACK YELLOW GREEN YELLOW GREEN AU N 49826 ui jer H gt 9 LE Q uJ 4 MES SL Ae 9574 ea 4X N 5 y EL 5 6 oz 1431 TINIIS ML i 9t ev 04 we 2340 EIST CU Be 3 Ke e IONI X08 21 0912372 2150412313 d 1 Lapide YIONTAD WALA YONA TwiNDZIHOH 33997713 199915 NYAL 091150099 AAY way e d Ald FWOLLYFA ONUNDU 1NOZZI40 OYONING 39
49. fits into the outer tube altering its position in the outer tube as the tube arrangement absorbs shocks The cylinder is fixed to the bottom of the outer tube and the piston equipped with a piston ring is secured to the top of the cylinder The collar 7 coupled with a return control valve 8 fixed in the lower end of the inner tube forms the upper part of the lower chamber and toghether with the piston helps seal the upper chamber The collar and cylinder base configuration function to form an oil lock at the end of the compression stroke to prevent the inner tube from striking the bottom Taper on damping rod at piston side bring about on oil lock at the end of the extension stroke to prevent the inner tube from striking the top The front fork legs of this model contains springs only as suspending element Springs Since the spring becomes shorter as it weakens check its free length A to determine its A condition If the spring of either fork leg is shorter than the service limit it must be replaced if A the length of a replacement spring and that of remaining spring vary greatly the remainaing Y spring should also be replaced in order to keep the fork legs balanced for motorcycle stability For spring free length service limit A 520 mm 20 47 in NNN SUSPENSIONS AND WHEEL Fron forks removal e Remove wheel as described in page 1 10 e Remove front brake hose clamp and speedometer driving cable clamp Re
50. fluid e Open the bleed valve apply the brake by the brake pedal or lever close the valve with the brake held applied and then quickly release the lever or pedal Repeat this operation until the brake line is filled and fluid starts coming out of the plastic hose Replenish the fluid in the reservoir as often as necessary to keep it from running completely out Bleeding the brakes If the brake fluid has just been changed or the lever or pedal feels soft or spongy air has entered the brake lines and has to be removed e Remove the reservoir and check that there is plenty of fluid in the reservoir The fluid level must be checked several times during the bleeding operation and replenish as necessary If the fluid in the Reservoir runs completely our any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e With the reservoir cap off slowly pump the brake lever or pedal several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir This bleeds the air from the master cylinder end of the line e Install the reservoir cap and connect a clear plastic hose to the bleed valve at the caliper running the other end of the hose into a container Pump the brake lever pedal a few times until it becomes hard and then holding the lever squeezed or the pedal pushed down quickly open turn count
51. ft H 8 Camshaft driving shaft H 8 Oil pressure adjustment valve H 9 Crankcase H 12 Crankshaft primary transmission pinion _ H 12 Oil pump H 13 Clutch assembly H 15 RH side cover H 16 Shift mechanism assembly H 16 Countershaft sprocket 17 Starter motor H18 Starter gears H 18 Camshaft driving gear H 20 Ignition flywheel H 20 Alternator rotor H 21 Pick up back plate H 22 Ignition cover H 22 Piston and cylinder H 24 Cylinder head H 25 Camshaft timing H 1 N 49826 ENGINE RE ASSEMBLY Valves e Install oil seal e Install valve e Place the lower rocker arm and spring in valve spring compressor too 742410 e Place the lower rocker arm spring spring compressor in cylinder head and hold in place by means of shaft tool Y 42405 fl reiner 49826 i H B m ENGINE RE ASSEMBLY e Shim the sides of rocker arm and bring it to perfectly centered position respect to valve stem The rocker arm must be free to move with no axial play e Remove shaft tool 42405 and replace by the rocker arm shaft with the hole facing outwards e Unlock the spring and remove the spring compressor tool e Place the camshaft inserting the woodroof key of the tachometer driving gear only in the cylinder head of horizontal cylinder e camshaft and with the aid of a screw driver lift the rocker arm end that features a sliding shoe e Place e return cap and cap retainers
52. get pinched crimped or melted shut by contact S specific gravity at the present temperature with the hof muffler if battery gases cannot escape through this Sog specific gravity at 20 C hose they will explode the battery Ses specific gravity at 68 F 7 DON T INSTALL THE BATTERY BACKWARDS The negative side t present temperature of solution is grounded Generally speaking a battery should be charged if a specific gravity reading shows it to be discharg Electrolyte ed to 50 or less of full charge The electrolyte is dilute sulphuric acid The standard specific gravity of the electrolyte is 1 280 at 20 C 68 F The water in this solution changes to a gaseous mixture due to chemical action in the battery and escapes which Specific Gravity Battery Charge Relationship concentrates the acid in a charged battery Consequently when the level of the electrolyte becomes low only distilled water shoul be added If sulp K2 huric acid is added the solution will become too strong for proper chemical action and will damage the plates Metal from the damaged plates collects in the bottom of the battery This sediment will eventually cause an internal short circuit The specific gravity of the electrolyte is measured with a hydrometer and is the most accurate indication of the condition of the battery When using the hydrometer read the electrolyte level at the bottom of the meniscus cur ved surface of the fluid Fig K2 shows
53. gh tech bikes and therefore repair and maintenance techniques suitable for less sophisticated motorcycles may not be appropriate to these fine hand crafted machines If you have any question regarding any of the procedures in this Manual it is essential that you consult a factory trained CAGIVA mechanic In addition to the information given in this Service Manual Service Bulletins are issued to CAGIVA Dealers from time to time which cover interim engineering changes and supplementary information Service Bulletins should be consulted for complete infor mation on the models covered by this manual Important Notice Read this manual carefully and pay special attention to statements proceeded by the following words WARNING Indicates a possibility of severe personal injury or loss of life if instruction are not followed Indicates a possibility of personal injury or equipment dama i ge if instructions are not followed NOTE Give helpful information Replacement Parts When replacement parts are required use only genuine CAGIVA parts or parts with equivalent characteristics including type strength and material Failure to do so may result in product malfunction and possible injury to the operator and or passenger I DLL D 49826 i ATED A i i 1 t 4 4 E z E er ri E gt E QULA N 49826 zeen TN NINDA KANAAN NA EE EDUL
54. ics CAUTION grinding must be followed by heat treating sulphurnitriting at 550 C 8 N 49826 SE ME Ek E CHE e E Zo ANA Ax 5 c i E t S e LIII LL E zm 5 5 o 8 KZ no ee 5 T3 5 Go E 5 b T C 2 So oc GH co c as o Aia Ss ees OE Ww Oc t E C O o e 6 9 9 9 9 2 gt e ZS 2 5 8 M E ari UO 0 g _ D E e E E e o One OTD lt UO L EI e coc 9 cO E a 990 8 5 bomo D ue om i 2 a C E oof o E ot 2 amp O pad O i X noH c Je man Soe a 6 2 amp Ae E8882 2 5 S2 5 ox x Q 2 ZE OW 9 c o ESPERE 5 L gt gt zcOosoo 2 e e o o O e e z HHH paire or eter abani iere s Mem o tan aga ar pm in c e eme 0 So 5 O o ae cm X ID gt EET gt e un o Aa eo o a C o E So t De E _ ag 9 0 gt V nm t 2 Et re gt lt t c Qc O c Rat o O Q o o OO c 9 T En amp o S 86 TF o
55. id of a micrometer check the ovalization max admited 0 01 mm or 0 0004 in and taper max admited 0 01 mm or 0 0004 in i x MOURA LS E ens Crankshaft truing e Install Crankshaft in Flywheel Truing Stand e Place dial gauges in the center of main bearings housing Turn flywheels slowly and observe the movement of indicator pointers Max admited difference between the two readings 0 02 mm or 0 0008 i P Note When installing crankshaft in truing stand adjust so centers are snug Wheels must turn freely but m shafts may not be loose in centers If crankshaft E is loose or tight indicators will not read p accurately KS e Remove the screw on caps and carefully clean the lubrication channels S e Place few drops of Loctite 242 on the plug that closes the inner hole of the crank pin and place back the plug e The other three threaded caps are already fitted with an insert of self a locking mater al Grinding the Crank pin e If crank pin is damaged or worn out grinding must be performed at a specialiced workshop e Original crank pin diameter is 40 008 40 020 mm or 1 5751 1 5755 in e The diameter can be reduced by grinding 0 25 mm 0 0098 in or 0 50 mm 0 0197 in Note It is absolutly necessary that crank pin flywheel radius be a maximum of 1 5 mm 0 059 in aset To restitute crank pin surface characterist
56. l live Cagiva has incorporated Crankcase Emissions 1 and Exhaust Emissions 2 Control Systems in compliance with applicable regulations of The United States Environmental Protection Agency 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the va pors are routed to the combustion chamber through the air cleaner and the carburetor 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle 3 Evaporative Emissions Control system those motorcycles sold in California are equipped with an evaporative emissions control system See the California Supplement to this Manual The Clean Air Act wich is a Federal Law covering Motor Vehicle Pollution contains what is com monly referred to as the Act s Tampering Provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing
57. lay of 0 0 20 mm 0 0 0079 in If axial play is greater adjust by means of adjusting shims e Check that all assembled parts rotate freely NS RI Y m d CAGIVA N 49826 H 10 ENGINE RE ASSEMBLY e Place key and inner pulley on camshaft driving shaft e Place key and outside pulley on camshaft driving shaft e Lock pulleys by means of tool YF 42415 and tight on throughly self loc king nut using wrench yy 42414 QUAL H 11 N 49826 ENGINE RE ASSEMBLY PEEELP ELE TCCD EC TELE CPE EE DEER D ERE ELE EERE EERE CERES R RRR RRR SRR Crankshaft primary transmission pinion e Place woodroof key and pinion on crankshaft Place the locking washer lock the gear by means of tool 42409 and tighten the fixing nut to a torque of 90 Nm 10 Kgm or 72 33 lb ft e Bend locking washer tab e Place reference bushings and 0 rings the crankcase e Completely fill the oil pump wit engine oil and place it on the crankcase N 49826 H 12 ill UAN A ANAA AA ANA AA ANA AA A ANANA AA ANA NANA NANA NANA NADA ENGINE RE ASSEMBLY TIT iret titi titi etter tite TTL TT TET TETETETETEIITITIEUIT gt Thoroughly tighten oil pump fixing bolts e Place bushing on mainshaft Place primary gear e Place bushing on mainshaft QUAL H 13 N 49826 ENGINE RE ASSEMBLY e Place gaskets and primary transmission cover e
58. misses or produces low power ES CAUSE REMEDY Petrol flow to carburetor not steady Check carburetor inlet screen filter fuel valve filter gasoline hoses Main jet is partially obstructed Blow with compressed air The slide of either Sep or both carburetors Adjust valve acting en cable does not open fully _ adjusting screw Poor quality gasoline Replace petrol Unsuitable type of spark plugs Check for the right heat range Loose spark plug Tighten spark plug to recommended Ignition coil spark plug wire shorted Change it Spark plug electrode gap Check it birty spark plug electrodes Clean them IC unit defective Change it Defective ignition col Replace it Defective ignition pick up Replace it Generator stator coil Replace it Cloged muffler Replace it Cloged Spark Arrester Clean it Start motor does not run a i T er CAUSE REMEDY Dead battery Check and charge battery Defective start motor button Replace it Defective starter relay Replace it Defective start motor Replace it 826 arva 49 n N tima emm M No OO O O P WON Nr Code CAGIVA 42403 42404 88713 0146 88713 0120 88713 0748 88713 0718 88713 0710 88713 0137 88713 0143 98112 0002 88713 0123 88713 0114 88713 0139 88713 0711 88713 0144 88713 0262 88713 0711 0675 03210
59. move front brake caliper Loosen top and bottom steering stems bolts e Slide down both fork legs e Remove fork leg caps e Remove spring e Drain oil from fork leg Remove allen bolt from base of outer tube Note If allen bolt can t be removed because the damping shaft turns introduce thru the opening of the inner tube a long rod with a flattened head to block the damping rod and prevent it from rotating e Pull apart both inner and outer tubes Oil seal dust seal Oil is prevented from making out by the seal wich is fitted at the upper end of the outer tube A dust seal on the outside of the tube keeps dirt and water from entering and damaging the oil seal and tube surface Inspection Inspect the oil seal and dust seal for any signs of deterioration or damage and replace them if necessary Replace the oil seal with a new one whenever if has been removed N 49826 13 SUSPENSIONS AND WHEELS Inner tube A bent dented scored or otherwise damaged inner tube will damage the oil seal causing oil leakage A badly bent inner tube may cause poor nanang inner tube damage Visually inspect the inner tube and repair any damage If the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced Temporarily assemble th
60. move ignition flywheel and idling gears e Remove the two needie bearings N 49826 NA ENGINE DISASSEMBLY e Remove steel bushing and washer e Straighten up locking washer and remove nut from camshaft driving shaft by locking gear with a rod thru gear holes e Hemove gear i CEPR PEN 49826 S Pa ENGINE DISASSEMBLY e Remove camshaft driving pinion from crankshaft e Remove woodroof key from crankshaft F 10 N 49826 ENGINE DISASSEMBLY NANA NAN NAN NANA NAN ANAN NAN ANA NAN AAN NAN ANAN NR ANNA e Remove starter motor To remove countershaft sprocket Remove bolts e Rotate holding plate until aligned with countershaft grooves and slide it out e Pull out countershaft sprocket i F 11 do N 49826 ENGINE DISASSEMBLY e Remove bolts of shift mecanism support e Pull out shift mecanism assembly zu SS e Remove clutch side cover tapping with plastic hammer if necessary DUCATI Ma M TAL Remove Clutch spring bolts e Clutch springs TIT F 12 N 49826 H ENGINE DISASSEMBLY e Clutch plates retaining circlip e Clutch plates e Bend back tab of locking washer e Lock clutch hub by means of blocking tool 5 42403 and loosen nut e Remove Clutch hub nut yr Locking washer Clutch hub and inner spring plate Washer m di
61. n G 9 Matching conrod and conrod bearings G 10 Cylinder head G 10 Valve seat G 10 Valve guide G 10 Valves mE G 11 Valve valve guide assembly G 11 Valve valve seat assembly G 11 Replacing valve guide G 12 Replacing valve seats G 12 Rocker arms G 12 Rocker arm spring G 13 Rocker arm Rocker arm shaft assembly G 13 Camshafts and bearings G 13 Pulleys Belts Tensioners G 13 Free wheel and starting mechanism G 14 Crankshaft assembly G 14 G 14 Check of shaft G 15 Oil seal replacement G 15 Bearings G 16 Oil pump G 16 Clutch assembly G 17 Gearbox G 18 Shafts plain bearings G 19 Carburetor overhauling G 21 Float level G 21 Accelerating Pump fuel delivery 49826 ENGINE OVERHAULING Washing engine parts To remove carbon deposits and dirt a high flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in North America is stoddard solvent generic name Note Always follow manufacturer and container directions regarding the use of any solvent WARNING Commercial solvents are flammable and can be explosive under certain conditions Do not smoke or allow flames or sparks in the area where the engine parts are washed Solvents may cause eye irritation In case of contact flush thoroughly with water and call a doctor Dry washed components thourghly and dry with compressed air CAUTION x Do not use compres
62. ng it up Silencer removal e Disconnect electrical wires going to tail lights fuse box and starter relay e Loosen both exhaust to silencer clamps e Remove the two fixing bolts and remove silencer Subframe removal Remove the aluminum support of passenger s footrest Remove the four fixing bolts Remove subframe k CAUTION When reassembling be sure that top left side fixing bolt is also attached to the two ground wires N 49826 GENERAL OPERATION Removal of the bolted section of main frame e Remove skid plate Remove all fixing bolts Remove bolted section Note Note that rear brake pedal and master cylinder will remain attached to the bolted section Exhaust removal Remove the nuts from the header section ring nut e Remove header sections WARNING Do not touch exhaust pipes or silencers unless cold Oil cooler hoses removal Remove oil pressure switch wires Remove oil pressure switch Remove the banjo bolt at crankcase Remove banjo bolts in cylinder heads and hoses Note Carefully remove gaskets so can be used when assembling the engine N 49826 GENERAL OPERATION Hydraulic clutch fluid hose removal Fit an appropriate length of clear plastic tubing over bleeder valve loosen it remove cover from handlebar container and let drain the fluid in appropriate container Remove the banjo
63. ntil facing threaded holes on countershaft sprocket e Tighten bolts by meaning of service tool e Place starter engine gasket engine starter and thoroughly tighten the bolts QUALIA AAA H 17 N 49826 M ENGINE RE ASSEMBLY Storter gears e Place starter idling gears and shims e Place snap ring e Place camshaft driving pinion on crankshaft e Place key and camshaft driving gear TES ES nye gt tA lt i S A N ER e d p E Sc SEEN 2 ESS TE YALAN CF 2 m CAGIVA ENGINE RE ASSEMBLY e Place countershaft driving gear so the mark on it faces the mark on the crankshaft driving pinion e Place locking washer and tight on nut with a torque of or 28 93 Ibs ft Bend washer tab e Place steel bushing and washer on crankshaft e Place the two needle bearings H 19 ENGINE RE ASSEMBLY Ignition flywheel e Place the ignition flywheel and freewheel assembly including starting M Q LSS Fo See ANA D 1 gt idling gear SS Note The ignition flywheel must be placed with the mark facing the key slot e Place key and the generator rotor e Place locking washer lock the rotor by means of tool r 42652 and tigh ten fixing nut to a torque of 108 Nm 11 79 56 lb ft Bend locking washer N 49826 H 20 ENGINE RE ASSEMBLY e Place pick up back plate and the fixing bolts tigh
64. ors same number of turns until idling speed is reached ama un Idle speed 9004100 r p m 7 Check for same height on vacuum Gauge Q WARNING Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas Do not exceed 4000 rpm with gauges attached to carbs Do not make sudder rpm increases with gauges attached Uo D 2 CAGIVA N 49826 ADJUSTMENTS i TTT OTTO B Throttle cable adjustment Once idle speed is set gradually accelerate up to 3 000 to 4 000 r p m and check mercury columns in vacuum gauge If uneven adjust cable play by turning the cable adjuster of carburetor with higher mercury column Rev the engine up to 4 000 r p m for a fraction of a second two or three mi vdd eun times and check the synchronization again from idle speed Tighten locknut Adjust cable play by acting on cable adjuster at throttle control nut until 2 3 mm 0 078 0 12 in of play at the throttle grip is obtained Tighten the locknut WARNING J Do not exceed 4 000 r p m with gauges attached to carbs Do not make sudden pm increases with gauges attached 49826 3 ADJUSTMENTS Chocke cable adjustment Allow a free of 2 5 4 mm O 1 0 16 in Act on cable nut adjuster and tighten locknut Front brake lever adjustment Allow a free play of 1 1 5 mm 0 4 0 6 inch Act on allen bolt to set proper play
65. r contains highly compressed nitrogen gas Read and understand the following information before handling the shock absorbe rs The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling Do not tamper or attempt to open the cylinder assembly Do not subject shock absorber to an open flame or other high heat This may cause the unit to explode due to eccessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance i L N 49826 SUSPENSIONS AND WHEEL UNO ITT Shock absorber disposal steps e Remove valvecap 1 Release gas pressure by acting on air valve 2 CAUTION Wear eye protection to prevent eye damage from escaping gas Swingarm e Place motorcycle on a center stand and remove rear wheel and shock absorber connecting rods to swingarm e Remove swingarm nut and pivot bolt by means of a hammer and a drift pin Remove swingarm e Check needle bearings and pivot bolt runout When reassembling check side play of swingarm if necessary ad or remove shims internaly or externally e Lubricate oil seals lips and bearings with grease AUTUMNI 49826 eaaa SUSPENSIONS AND WHEELS Shock absorber removal e Place motorcycle on a center stand e Remove shock absorber bottom nut and boit Remove rear subframe as indica
66. ring inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or elivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been remo ved or rendered inoperative by any person a Among those acis presumed to constitute tampering are the acts listed below 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance ores RINK N 49826 o ee N NGA IIIIIIIIIIIIIIIIIIIIIIIT III III EIER IR III DIDAAR DEED EU D DD DER ED RER REDER RRER Foreword This manual was written by CAGIVA Motor Italia S p a primarily for use by CAGIVA dealers and their qualified mechanics It is not possible to put an entire mechanic s education into one manual so it is assumed that persons using this book to perform maintenance and repairs on CAGIVA motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology Repairs or service attempted without such knowledge will very likely not only cause expensive damage to the motorcycle but will render it unfit for service and unsafe The Alazzurra motorcycles are high performance hi
67. rod Select an arbor of the same diameter as the piston pin and 100 mm 3 93 in long and insert it though the small end of the connecting rod bushing On a sur ace plate set the big end arbor on V blocks so that the connecting rod is perpendicular to the surface plate Using a height gauge or dial gauge measure the difference in the height of the small end arbor above the surface plate pu If the measurement exceeds the service limit replace the connecting rod Service limit 0 05 mm 0 0020 in Connecting rod small end plain bearing replacement To replace small end bearing use a Piston pin bushing tool and a hydraulic press Mounting interference between bushing and connecting rod small end must be 0 052 0 095 mm 0 0020 0 0037 in Drill an oil hole in bushing aligned with oil hole in rod Rebore bushing to 18 006 18 024 mm 0 7088 0 7096 in Connecting rod bearing insert It is a good practice to replace connecting rod bearing inserts at each engi ne overhaul Replacement bearing inserts are supplied ready for mounting and do not need to be adjusted with scrapers or emery cloth If crankshaft pin has been ground use bearing inserts supplied as spare parts with internal diameter reduced of 0 25 mm 0 0098 in or 0 50 mm 0 0197 in d N 49826 ENGINE OVERHAULING Crankshaft e Examine crankshaft pin to see that it is not pitted scored indented With the a
68. sed air to spin the bearings dry This causes damage to the bearing surfa ces i Do not wash oil seals and other rubber components with solvent as chemical action will damage rubber characteristics and replacement will be needed Note All gaskets seals and O rings should be replaced when an engine is overhauled All gasket surfaces oil seal lips and O rings must be cleaned Assemblies For a good and efficient engine operation it is essential that all assemblies are within the tolerances prescribed by the Manufac turer WI tolerances are too close damaging seizures may occure as soon as heat builds up in engine If tolerances are too big vibrations may appear mecanical noise increase and moving parts wear accelerate G2 N 49826 ENGINE OVERHAULING Measuring the cylinder Check that cylinder walls are perfectly smooth Measure cylinder bore at three different heights and two different directions at 90 to obtain taper and ovalization values Max taper Max bore min bore at different heights 0 05 mm 0 002 in Max outof round Max bore min bore at same height 0 05 mm 0 002 in if cylinder has suffered damage or excessive wear the cylinder must be replaced The Patented GILNISIL coating has exceptional antifriction and antiwear properties but as most electrolitical coatings cannot be rebored All cylinders are marked with a letter indicating the measurement family
69. ston rings are carefully compressed with the fingers If piston rings are not compressed properly when mounting the cylinder they can be bro ken due to their brittleness QUII H 23 N ENGINE RE ASSEMBLY Cylinder head e Place the three O rings on vertical cylinder head e Place the three O rings on horizontal cylinder head E Push down pistons so they are not at T D C so that they will not touch the valves e Install the cylinder heads e Tighten head bolts on a Cross pattern to a torque of 34 Nm 3 5 25 31 Ib ft using special wrench 42407 E N 49826 H 24 ENGINE RE ASSEMBLY Camshaft timing e Place rubber back cap and tighten bolts e Place guiding washer key and pulley on camshaft e Lock pulley by means of tool 71 42415 and tighten self locking nut using tool Yg 42414 e Turn camshaft until ref mark on pulley faces ref mark on crankcase SING NG SA EM K 44 25 49826 x 3 H H B H ENGINE RE ASSEMBLY e Turn camshaft until ref mark in pulley face ref mark in rubber back cap e Place toothed belts by only means of your hands e If previously disassembled belts are used place them according to marks Note It is recommended to change belts at every engine over haul e To tighten belt tensioner apply dynamometric stretcher yx 42406 and pull it to the ref mark
70. t fall on a hard surface Such a shock to the ro tor can cause the magnets to loss their magne tism Fuse box The fuse box is fixed to the left hanside of the motorcycle just besides TUE the battery y To reach it remove right side pannel Before replacing a damaged fuse look for the cause of the damage Always replace fuses with others of some am perage CAUTION N 49826 ELECTRIC SYSTEM Regulator rectifier The charging system consists of an alternator and regulator rectifier The regulator is an aluminum box placed under the gas tank The alternator generates the current required by the electrical circuits The generated current is a three phase alternating current AC which is chan ged to direct current DC and controlled by a solid state regulator rectifier to supply an even voltage to the circuit components There are a number of important precautions that are musts wnen servi cing the charging system Cautions that are applied to the individual sec tions are mentioned in each section Failure to observe these rules can re sult in serious system damage Learn and observe all the rules below When handling the regulator rectifier observe the following to avoid damage to the regulator recti j fier Charging System K3 1 Do not reverse the battery lead connections This will burn out the zener diode 2 For the regulator rectifier to function properly the bat
71. t battery directly after the completion of charging should be 15 to 16 volts and the specific gravity of the electrolyte should be more than 1 250 If the volta ge is lower than this the battery is not completely charged or can no longer take a full charge If the specific gravity of any one cell is lower than 1 250 there may be damage in the cell If the temperature of the electrolyte rises above 45 115 F during charging reduce the charging Test charging When the battery is suspected of being defective first inspect the points noted in the table below The battery can be restored by charging it with the ordinary charge If it will take a charge so that the voltage and specific gravity come up to normal it may be considered good except in the follo wing case if the voltage suddenly jumps to over 13 volts just after the start of char ging the plates are probably sulphated A good battery will rise to 12 volts immediately and then gradually go up to 12 5 13 volts in about 30 to 60 minutes after charging is started If one cell produces no gas bubbles or has a very low specific gravity it is probably shorted If there does not appear to be enough sediment to short the plates but one cell has a low specific gravity after the battery is fully charged the trouble may be just that there is insufficient acid in that cell In this instance only sulphuric acid solution may be added to correct the specific gravity If a fully ch
72. t be aligned with the white timing arrow e Above 2 900 r p m the advanced timing mark must be aligned with the white timing arrow Timing Advancing Advance begins 1 700 r p m Full advance 2 900 r p m Note If the timing is not correct check the pick up to ignition flyw heel gap Follow the same procedure for vertical cylinder Electric starter engine Engine type SJCE e Power output 367 W 12 volts e Spinning sense anticlokwise e Pinion retaining nut torque 22 Nm 2 2 Kg m 15 9 Ibs ft N 49826 mm 1 i t i TROUBLESHOOTING GUIDE N 1 Engine doesn t start starting difficult N 2 Lights do not work properly N 3 Engine misses or produces low power Start motor does not run N Engine Doesn t Start Starting Difficulty CAUSE REMEDY EE Stop Run switch in OFF position Gear engaged tank to carburetor gasoline hoses obstructed or clog Carburetor inlet filter screen clog Gas tank fuel valve fiiter obstructed Jammed Carburetor float Punctured float Obstructed jet Dirty or defective No compression No spark No spark on only one spark plug Switch to RUN position Shift to neutral Blow with compressed air Remove the screen and blow with compressed air Remove filter and blow with compressed air Remove the float bowl and clean Change it To clean passage apply strong air jet Clean or replace Check electrode gap Che
73. ted in page E 4 e Remove shock absorber bottom nut and bolt e Remove hydraulic spring preload adjuster from frame e Remove shock absorber top fixing nut and bolt e Remove shock absorber 49826 SUSPENSIONS AND WHEEL Wheels tires The tires are designed to provide good traction and power transmission during acceleration and braking even on bad surfaces To do this they must be inflated to the correct pressure and not overloaded If the tires are inflated to too high a pressure the ride is tough the center portion of the tread wears quickly and the Cold tire 28 4 2 0 pressures PSI Kg cm tires are easily damaged and handling is poor In addition heat builds up at high speeds and tire life is greatly shortened 90 90 21 54S 130 80 17 65 25 6 1 8 PIRELLI MT40 MT40 METZELER ENDURO ENDURO If inflation pressure is too low the shoulder portions wear quickly the cord suffers damage fuel consumption is high 90 90 S 21 130 90 S 17 10r2 Persons Kd 25 6 1 8 31 3 2 2 WARNING Operation with excessively worn tires is hazardous and will adversely affect traction and handling Proper wheel balance is necessary for sate stable handling of the motorcycle Wheel balancing is necessary after tire repair or replacement When replacing tires mount new tire in the position indicated by arrow for proper rota
74. ten the bolts only fin ger tight e With horizontal cylinder in T D C top dead center have the pick up re ference marks face the marks in ignition flywheel e Tight on pick up backing plate bolts e Plug in pick up cables e Make sure that the cables with the same letter O or V face each other e Gap between pick up and ignition flywheel higher step must be 0 50 v 0 55 mm 0 0197 0 0217 in CAUTION Never reverse ignition cable connector if mounting instructions are not carefully follo wed engine may fail to run properly LI 724 ENGINE RE ASSEMBLY Ignition cover e Place side cover and tighten bolts e Place piston so that the smallest indent faces towards the exhaust val ve e Hold piston and mount piston pin with the help of a plastic hammer 4982 MMMM ENGINE RE ASSEMBLY e Place piston pin snap rings in piston grooves x Do not reuse snap rings as removal weakens and deforms the snap ring It could fall out and score the cylinder wall e Place cylinder base gasket and vertical cylinder O Ring Note Place piston rings on piston with piston ring end openings at 120 in order to create a labyrinth e Lubricate cylinder with oil engine and insert piston in cylinder Note To insert piston in cylinder use universal a piston ring compressior adapter If piston ring compression adapter is not available cylinder is still possible to assemble if pi
75. ternator to supply sufficient power With proper care the battery can be expected to last several years but it may be completely ruined long before that if it is mistreated Following a few simple rules will greatly extend the life of the battery 1 When the level of the electrolyte in the battery is low add only di stilled water to each cell unti the level is at the upper level line marked on the outside of the battery Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery 2 Never add sulphuric acid solution to the battery This will make the electrolyte solution too strong and will ruin the battery within a very short time 3 Avoid quick charging the battery A quick charge will damage the battery plates m 4 Never let a good battery stand for more than 30 days without givint it a supplemental charge and never let a discharged battery stand without charging it If a battery stands for any length of time it slowly self discharges Once it is discharged the plates sulphate turn white and the battery will no longer take a charge 5 Keep the battery well charged during cold weather so that the o Celsius electrolyte does not freeze and crack open the battery The more Sop S 0 0007 t 20 discharged the battery becomes the more easily it freezes Erba 6 Always keep the battery vent hose free of obstruction and make Ses S 0 0004 t 68 sure it does not
76. tery must be charged to near capacity If the battery is badly discharged charge it befo re installing it in the motorcycle 3 Never remove the battery lead connections when engine is running regulator will suffer serious dammage Note Whe the battery load is 12 14 Volts the regulator out put will be of 4 2 Amps Battery Ignition coil test If the coil does not produce an adequate spark or if either the primary or secondary winding does not have the correct resistance replace the igni tion coil With the highest ohmeter range check for continuity Primary winding Low tension 8800 Q 20 Secondary winding High tension 40 Q 10 Pick up test Check if there is continuity with the Ohmmeter The resistance should be 220 Q 5 HN QUU N 49826 ELECTRIC SYSTEM Spark plug The spark plug ignite the fuel air mixture in the combustion chamber To do this effectivelyu and at the proper time the correct spark plugs must be used and the spark plugs must be kept clean and adjusted Recommended spark plugs are the Champion L82 YC or equivalent set to a 0 6 0 02 in gap If a spark plug of the wrong heat range is used the electrodes may not heat enough to keep all the carbon burned off but cool enough to keep from damaging the engine and the plug itself about 400 800 C 750 1450 F CAUTION Spark plug caps The carbon on the electrodes conducts electri city and can short
77. the battery capacity and charge it for 10 hours For example if the battery is rated at 12AH the charging rate would be 1 2 ampere If a constant voltage charger is used the voltage must be adjusted periodically to keep the current at a constant value CAUTION rate to bring down the temperature and increase the charging time proportionately e After charging check the electrolyte level in each cell H the level has dropped add distilled water to bring it back up to the upper level line e Check the results of charging by measuring the specific gravity of each cell and by measuring battery voltage Battery voltage of a 12 volt batte directly after the completion of charging should be 15 to 16 volts mixture of hydrogen and oxigen keep any sparks If the temperature of the electrolyte rises above 45 115 F during charging reduce the charging Ordinary charge WARNING mixture of hydrogen and oxygen keep any sparks or open flame away from the battery during char ging Ak e Clean off the battery using a solution of baking soda and water Make especially sure that the terminals are clean e lf the electrolyte level is low in any cell fill to over the lower level line but not up to the upper level line since the level rises during charging Figure the charging rate to be between 1 10 and 3 10 of battery capaci ty For example the maximum charging rate for a 12AH battery would be 12 x 3 10 which equals 3 6 amperes
78. the center electrode to ground by either coating the ceramic insulator or bringing across the gap Such short will pre vent an effective spark Carbon build up on the plug can also cause ot her troubles It can heat up red hot and cause preignition and knocking which may eventual ly burn a hole in the top of the piston Using the wrong type of spark plug can make the engine run too hot resulting in engine da mage or too cold with poer performance mis firing and stalling The standard plug has been selected to match the normal usage of this mo torcycle in combined street highway ri ding Special spark plug caps are used on this motorcycle These special caps must be used to avoid starting and running difficulties MIDUDD N 49826 M 8 im CAGIVA ELECTRIC SYSTEM erie Ignition timing advance inspection The ignition cover is provided with a clear plastic inspection window for the timing advance inspection with a strobe light To check timing advance proceed as follows e Connect a strobe light to the horizontal cylinder spark plug wire and to the battery in the manner prescribed by the manufacturer of the strobe light in order to check the ignition timing under operating conditions e Turn on the ignition switch and engine stop switch Start the engine and direct the strobe light at the timing marks e Below 1 600 r p m the first of the two fiming marks mus
79. the right oversize seat valve Assembly interference 0 11 0 16 mm 0 0043 wa 0 0063 in mE Note Oversized seat valves in the outside diameter of 0 03 mm 0 0012 in are supplied as spare parts 3 Evenly heat up cylinder head to a maximum of 180 v 200 356 392 F 4 Introduce new valve seats mE 5 Let the cylinder head cool down to room temperature 6 Grind the seats and grind the valves Rocker arms m e Check that the working areas are in perfect conditions with no signs of wear grooving or chrome coating damage or pealing e Check the condition of rocker arm bore and shaft Check that the working areas of the adjusters and return caps of the valves are perfectly flat and that there are not signs of wear Rocker arm spring EE SE E e Carefully check visually the closing rocker arm spring No signs of cracks deformation or slackenings must appear QUARTA G 12 N 49826 ENGINE OVERHAULING Rocker arm Rocker arm shaft assembly e Assembly tolerance must be 0 03 0 06 mm 0 0012 0 0024 in Service limit 0 08 mm 0 0032 in Camshaft and bearings 2 Check that the working surface of the cams scratched grooved or waviness E Check that lubrication conduits are free and clean Check camshaft bearings Pulleys belts and tensioners Check that pulleys have no signs of
80. they belong to Piston cylinder assemblies must always be performed with parts of same family WARN INEO EY OT ap av ar mr m 7 m S N 49826 G 3 CAGIVA ENGINE OVERHAULING i e Where carbon deposit is thick and hard it is advisable to scrape carbon off Use a putty knife or ground tip on an old file Use care to keep from scraping into aluminum of piston Place the pistons in GUNK HYDROSEAL or other carbon or gum dissolving agent until deposits are soft e Scrub piston dome to remove deposits e Wash piston in solvent and blow dry with compressed air e Clean piston ring grooves with a piece of compression ring ground to a chisel shape e Check piston diameter at 12 mm 0 47 in from the bottom of piston skirt using a micrometer m p EOM SOLL LED N 49826 ENGINE OVERHAULING Piston cylinder matching Standard clearance 0 02 0 04 mm 0 0008 0 0016 in Service limit clearance 0 14 mm 0 0055 in Piston pin T e Examine piston pin to see that it is not pitted or scored e If piston pin replacement is necessary also replace the piston pin bu shing Piston rings Examine piston rings to see that are not scored or damaged Piston ring Piston ring groove clearance Standard clearance _ 0 020 0 052 mm 0 0008 0 0020 in Service limit clearance 0 12 0 047 in 7 wana SS N 49
81. tion Maximum inflation pressure must not exceed specification located on tire side wall If a tire shows crosswise lines it means that the tire is worn to its limit Tire must be replaced immediately W Never clean or lubricate either tires tubes or rims with gasoline or oil because they will cause deterioration of the tire N 49826 IIIA Front wheel Rear wheel N 49826 1 10 Wheel rim Front wheel removal Rear wheel removal N y H SUSPENSIONS AND WHEEL Wheel rim are of a light alloy material If there is any doubt as to the condition of the wheel or if the wheel has received a heavy impact check the rim runout Carefully inspect the rim for small cracks dents bents or warp If there is any damage to the rim it must be replaced Rim sizes Front 1 85x21 Rear 2 75x17 Loose front wheel axle nut Loose front fork bottom bolts Place a jack or a stand under the engine so that the front wheel is raised off the ground Remove front wheel axle Remove front wheel Remove disc brake if necessary to replace wheel bearings Place motorcycle on a center stand Remove driving chain Loosen rear wheel axle nut Remove rear wheel axle Remove disc brake if it is necessary to replace wheel bearings C AUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so th
82. ump lever and or pedal until brake pads are against the disc Check the brake Install the guard cap WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pum ping the brake lever or pedal until the pads are against the disc The brake will not function on the first application of the lever or pedal if this is done New pads require a minimum break in distance CAUTION of 95 Kms 60 miles 11 49826 L 2 BRAKES Brake disc wear Measure the thickness of each disc at the point where it has worn the most Replace the disc if it has worn past the service limit Front and rear disc service limit 5 8 mm 0 2283 in Disc cleaning Poor braking can also be caused by oil on the disc Oil or grease on the disc must be cleaned off with trichloroethylene or a high flash point solvent Do not use on which will leave on oily residue Note Be sure that cooling holes of discs are clean Brake fluid drain _ e Attach a clear plastic hose to the bleed valve on the caliper and turn the other end of the hose into a container e Loosen bleed valve so fluid begins to drain e Remove container cap and rubber diaphragm e Pump with lever pedal brake to push brake fluid out of the line WARNING Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up immediately Brake fluid may cause irritation Avoid

SERVICE MANUAL /Elefant 650 USA

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