CAGIVA Super CITY 125 Service-Reparaturhandbuch ab 1991

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🏷️ Basic Information Identification Make: Cagiva Model: Super City 125 Model Code: N/A (Specific internal Cagiva code might exist, but not typically advertised) Generation Generation Designation: First Generation (Launched in...

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Typ: Motorräder

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Art.-Nr: 602720

Stichworte: 1991 Cagiva City Motorcycle Motorcycles Super CITY 125

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Beschreibung

🏷️ Basic Information

Identification

Make:

Cagiva

Model:

Super City 125

Model Code:

N/A (Specific internal Cagiva code might exist, but not typically advertised)

Generation

Generation Designation:

First Generation (Launched in late 1980s/early 1990s)

Generation Years:

1991 Onward (Manual covers this model from 1991 onwards, implying potential minor updates)

Codes

Vin Code Prefix:

2C9 (For Italian manufactured Cagiva motorcycles)

👋 Introduction

Market Position

Market Segment:

Lightweight sport/commuter motorcycle, popular in Europe for its nimble handling and spirited performance for its class.

Target Audience:

Young riders, urban commuters, enthusiasts seeking an affordable and engaging entry-level sportbike.

Competitive Analysis

Key Competitors:

Yamaha DT 125, Aprilia AF1 125, Honda NSR125, Suzuki RG125, Gilera SP01 125.

Key Features

Engine Type:

High-revving liquid-cooled two-stroke single-cylinder engine, known for strong power output in its displacement class.

Design Philosophy:

Sporty styling inspired by larger Cagiva racing motorcycles, coupled with practical commuter capabilities.

Handling:

Agile and responsive chassis, often featuring adjustable suspension components for a sporty feel.

📋 Manual Details

Coverage Areas

Coverage Areas:

Complete service and repair for the Cagiva Super City 125 motorcycle from 1991 onwards.

Page Count

Page Count:

Estimated 300-400 pages (typical for a comprehensive service manual of this era)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English (Likely origin, but Italian and other languages may exist for regional releases)

Format

Format:

Printed Book (Digital PDF versions are common aftermarket offerings)

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly of the 125cc two-stroke engine.

Fuel System Service:

Carburetor tuning, cleaning, and rebuilding (likely Dell'Orto PHBH or similar), fuel tank, fuel lines, and petcock maintenance.

Ignition System Diagnostics:

CDI ignition system testing, spark plug selection, timing adjustments, and troubleshooting.

Exhaust System Maintenance:

De-carbonizing expansion chambers, muffler packing replacement, and leak checking.

Cooling System Service:

Liquid-cooled systems: radiator maintenance, coolant flushing, water pump inspection and seal replacement.

Transmission Repair:

Gearbox disassembly, inspection of gears and shift drum, clutch service (wet multi-plate), and gearbox oil change.

Chassis And Frame Inspection:

Frame integrity checks, swingarm bearing service, steering head bearing adjustment and replacement.

Suspension Service:

Front fork overhaul (seal replacement, oil viscosity and level), rear shock absorber inspection and replacement.

Braking System Maintenance:

Hydraulic front and rear brake systems: caliper overhaul, master cylinder servicing, brake pad replacement, fluid bleeding, and line inspection.

Wheel And Tire Service:

Wheel bearing replacement, spoke tensioning (if applicable), tire mounting and balancing, and valve stem replacement.

Electrical System Troubleshooting:

Wiring diagrams, lighting circuits, battery maintenance, starter motor, horn, and indicator system checks.

Bodywork And Trim Repair:

Fairing removal and installation, seat, tank cover, and panel fitment.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain adjustment and lubrication, brake adjustments.

Diagnostic Procedures:

Troubleshooting guides for common starting, running, and electrical issues based on symptom analysis.

Component Replacement:

Detailed step-by-step instructions for replacing major and minor components.

Rebuild Instructions:

Comprehensive rebuild procedures for the engine, carburetor, brake calipers, and master cylinders.

Wiring Diagrams:

Foldout wiring diagrams illustrating the complete electrical system.

Technical Depth

Technical Depth:

Comprehensive, covering everything from basic rider maintenance to full engine and chassis rebuilds.

Diagnostic Tools Required:

Specifies required tools for diagnostics, including feeler gauges, torque wrenches, multimeter, compression tester.

Torque Specifications:

Detailed torque values for all critical fasteners across all systems.

Tolerances And Clearances:

Precise measurements for engine component clearances, bearing play, and other critical tolerances.

📊 Manual Specifications

File Format

File Format:

Likely printed paper. If digital, typically PDF.

Print Quality

Print Quality:

Typically black and white line drawings and diagrams. Text clarity is paramount.

Binding Type

Binding Type:

Stapled or perfect bound paperback for printed versions.

Paper Type

Paper Type:

Durable, matte paper stock suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, two-stroke, single-cylinder

Bore X Stroke:

Approximately 56 mm x 50.6 mm (typical for this class, check manual for exact spec)

Displacement:

124.6 cc (125cc)

Compression Ratio:

Approximately 7.5:1 to 8.5:1 (check manual)

Valve Train:

Reed valve induction (typical for 2-stroke)

Performance

Horsepower:

Estimated 28-32 HP at 9,000-10,000 RPM (Varies by market and specific tuning)

Torque:

Estimated 18-20 Nm at 8,000-9,000 RPM (Varies by market and specific tuning)

Fuel System

Carburetor Model:

Typically Dell'Orto PHBH 28/30mm or Mikuni VM28 (check manual for exact fitment)

Fuel Type:

Unleaded gasoline (RON 95 or higher) with 2-stroke oil pre-mix or automatic oil injection system.

Oil Type:

High-quality 2-stroke engine oil (JASO FD, API TC rated)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet, multi-plate

Features

Final Drive:

Chain drive

Gear Ratios:

Specific ratios detailed in the manual, crucial for performance tuning.

📐 Dimensions

Exterior

Length:

Approx. 1980 mm (check manual)

Width:

Approx. 780 mm (check manual)

Height:

Approx. 1100 mm (check manual)

Wheelbase:

Approx. 1340 mm (check manual)

Weights

Dry Weight:

Approx. 130 kg (check manual)

Fuel Tank Capacity:

Approx. 12 liters (check manual)

Oil Tank Capacity:

Approx. 1.5 liters (for automatic oil injection models)

🛡️ Safety Features

Ratings

Safety Standards:

Conforms to European safety standards of the era. Specific crash ratings not typically applied to motorcycles of this period.

Active Features

Braking System:

Front: Single disc with hydraulic caliper. Rear: Drum or disc brake (check specific model variant).

Lighting:

Halogen headlight, tail light, brake light, turn signals.

Passive Features

Frame Construction:

Steel perimeter or trellis frame for rigidity and rider safety.

Tire Specification:

Front: 100/80-17, Rear: 130/70-17 (typical, check manual for exact fitment and approved brands).

💡 Technology Features

Infotainment

Infotainment System:

Not applicable for this era of motorcycle; focus is on mechanical and electrical functionality.

Driver Assistance

Rider Aids:

No electronic rider aids (ABS, traction control) are present on this model.

Connectivity

Connectivity Features:

Not applicable.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km or annually (refer to manual for precise intervals based on usage).

Spark Plug Check:

Every 5,000 km.

Air Filter Cleaning:

Every 3,000 km or as needed in dusty conditions.

Chain Lubrication Adjustment:

Every 500-1,000 km and after washing or rain.

Coolant Flush:

Every 2 years or 20,000 km.

Fluid Specifications

Engine Oil Type:

2-stroke premix oil (JASO FD, API TC) or dedicated 2-stroke injector oil.

Gearbox Oil Type:

API GL-4 or GL-5, SAE 75W/90 or 80W/90 hypoid gear oil. Capacity: ~1.0-1.2 Liters (check manual).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific recommendation).

Coolant Type:

Ethylene glycol based antifreeze coolant mixed 50/50 with distilled water.

Known Issues

Carburetor Tuning:

Sensitivity to altitude and temperature changes, requiring periodic adjustment or re-jetting for optimal performance.

2-Stroke Engine Wear:

Piston ring and cylinder wear can occur with high mileage or poor lubrication, necessitating rebuilds.

Electrical Connections:

Corrosion or loose connections in the wiring harness, particularly on older models, can lead to intermittent electrical faults.

Clutch Slippage:

Wear on clutch plates or incorrect adjustment can lead to clutch slippage, especially under heavy load.

Suspension Leaks:

Front fork seals can degrade over time, leading to oil leaks. Rear shock absorbers may lose damping effectiveness.

📚 Vehicle History

Brand Heritage

Brand Origin:

Cagiva is an Italian motorcycle manufacturer founded by the Castiglioni brothers in 1978, acquiring brands like Husqvarna and MV Agusta.

Brand Focus:

Cagiva was known for its sporty, often Italian-designed motorcycles, including dirt bikes, street bikes, and sportbikes.

Model Evolution

Development Context:

The Super City 125 was part of Cagiva's strategy to offer competitive 125cc performance motorcycles, often featuring performance-oriented two-stroke engines.

Design Inspiration:

Likely drew design cues from Cagiva's successful racing efforts and larger displacement sportbikes of the era.

Production

Manufacturing Location:

Primarily Italy.

Production Period:

1990s, with specific model year updates within the '1991 Onward' range covered by the manual.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific industry awards for the Super City 125 are not widely documented. Its reputation is built on performance and handling in its class.

Ratings

Owner Reviews:

Generally positive for its class, praised for spirited performance and agile handling, though reliability can be a concern with age without proper maintenance.