Target Audience:
Owners and independent mechanics seeking to perform maintenance and repairs on the CAGIVA Super CITY 125.
Purpose:
Provides essential technical data and repair procedures often missing from owner's manuals, bridging the gap between DIY and professional service.
Completeness:
Covers a wide range of service and repair tasks, from routine maintenance to complex overhauls.
Clarity:
Detailed diagrams and step-by-step instructions enhance understanding and reduce errors.
Manual Type:
Service and Repair Manual
Language:
English (presumed, standard for most international manuals)
Format:
Digital (PDF likely), potentially physical print available
Estimated Page Count:
200-400 pages (typical for a comprehensive service manual of this era)
Engine Mechanical:
Full disassembly, inspection, and reassembly of the 125cc engine (cylinder, piston, crankshaft, connecting rod, valves, camshaft).
Engine Fuel System:
Carburetor servicing, tuning, and replacement; fuel tank, fuel lines, and petcock maintenance.
Engine Ignition System:
CDI unit, spark plug, ignition coil, timing adjustment procedures.
Engine Cooling System:
Radiator, coolant hoses, water pump maintenance and replacement (if liquid-cooled variant).
Transmission:
Gearbox operation, disassembly, inspection, and reassembly; clutch operation and adjustment.
Drivetrain:
Chain and sprocket maintenance, adjustment, and replacement; rear hub and axle.
Brakes:
Front and rear brake systems (likely drum or disc depending on variant), caliper/drum servicing, pad/shoe replacement, fluid bleeding, master cylinder and line maintenance.
Suspension:
Front fork servicing (oil changes, seal replacement), rear shock absorber maintenance and replacement.
Electrical System:
Wiring diagrams, battery maintenance, charging system (alternator/stator), lighting, horn, starter system, fuses.
Frame And Bodywork:
Chassis inspection, frame straightening (if applicable), body panel removal and installation, seat, handlebars, footpegs.
Scheduled Maintenance:
Oil changes, filter replacements, chain adjustments, spark plug service, brake checks, lubrication points.
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues.
Repair Procedures:
Step-by-step instructions for major component overhauls and replacements.
Technical Specifications:
Detailed torque values, clearances, fluid types and capacities, electrical resistance values.
Diagnostic Capabilities:
Includes procedures for diagnosing common mechanical and electrical faults, often with symptom-based troubleshooting guides.
Rebuild Instructions:
Comprehensive instructions for complete engine and transmission rebuilds.
Digital Format:
PDF (Portable Document Format) - Searchable text, high-resolution images.
Image Resolution:
High-resolution diagrams, illustrations, and photographs for clarity.
Physical Binding:
Spiral bound or saddle-stitched for lay-flat use (if physical copy)
Physical Paper:
Durable, coated paper to withstand workshop environments (if physical copy)
Engine Type:
Two-stroke, single-cylinder (common for 125cc bikes of this era)
Displacement:
125 cc (Cubic Centimeters)
Bore X Stroke:
Specific dimensions required from manual; typical for 125cc might be around 54mm x 54.5mm
Cooling Method:
Air-cooled or Liquid-cooled (depending on specific Super CITY 125 variant)
Compression Ratio:
Specific ratio required from manual; typically around 7.5:1 to 8.5:1 for 2-stroke
Horsepower Output:
Estimated 12-15 HP (horsepower) at specified RPM; precise figures in manual.
Torque Output:
Estimated 8-10 Nm (Newton-meters) at specified RPM; precise figures in manual.
Carburetor Type:
Likely a single, geared carburetor (e.g., Dell'Orto PHBH 28 or similar) or Mikuni.
Fuel Type:
Unleaded gasoline (RON 91 or higher, specified in manual)
Fuel Mixture:
Two-stroke oil/gasoline mixture ratio specified in manual (e.g., 1:50 or 1:40).
Transmission Type:
Constant mesh, 6-speed sequential gearbox.
Clutch Type:
Wet, multi-plate clutch, cable operated.
Gear Ratios:
Specific gear ratios for each speed provided in the manual.
Final Drive:
Chain drive (typically 520 or 525 pitch).
Overall Length:
Approx. 1900-2000 mm (exact in manual)
Overall Width:
Approx. 700-800 mm (exact in manual)
Seat Height:
Approx. 750-800 mm (exact in manual)
Dry Weight:
Approx. 110-125 kg (exact in manual)
Fuel Tank Capacity:
Approx. 10-12 Liters (exact in manual)
Wheelbase:
Approx. 1300-1350 mm (exact in manual)
Safety Features Overview:
Focus on mechanical reliability and rider input; no electronic safety aids typical for this era.
Brakes:
Effective braking system for its class (disc front, drum/disc rear).
Tires:
Appropriate tire selection for grip and stability is crucial; manual may offer recommendations.
Frame Construction:
Robust chassis designed for stability and rider feedback.
Instrument Cluster:
Analog speedometer, tachometer, odometer, and basic indicator lights (turn signals, neutral, oil level).
ABS:
Not equipped with ABS; standard braking system.
Charging Ports:
No USB or 12V charging ports.
Oil Change Interval:
Every 2,000-3,000 km or annually (specific interval in manual)
Spark Plug Replacement:
Every 4,000-6,000 km (specific gap and type in manual)
Air Filter Cleaning:
Every 2,000-4,000 km or as needed (specific procedure in manual)
Chain Lubrication Adjustment:
Every 500-1,000 km or after riding in wet conditions.
Engine Oil Type:
Specific 2-stroke engine oil (JASO FD, API TC, or equivalent), 1-liter capacity (exact in manual).
Gearbox Oil Type:
SAE 80W/90 hypoid gear oil, approx. 0.8-1.0 liter capacity (exact in manual).
Brake Fluid Type:
DOT 3 or DOT 4, depending on system specification (exact in manual).
Common Problems:
Carburetor jetting issues, CDI unit failures, exhaust port blockages (due to 2-stroke nature), clutch wear, front fork seal leaks.
Preventative Maintenance Focus:
Regular decarbonization of exhaust and cylinder ports, proper 2-stroke oil usage, and maintaining correct carburetor settings are key.
