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CAGIVA Super CITY 125 Service Repair Manual 1991 Onward
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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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🏷️ 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.