Description
This 140 page, 1985 – 1987 Cagiva Alazzurra 350 650 Motorcycle Service Manual is a reproduction of the original out of print manual. It 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, high tech motorcycles 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. This CAGIVA motorcycle features the famous DUCATI Desmodromic valve gear system. The Desmodromic valve gear system ensures high performances over the entire speed range. This manual explains how to inspect and adjust the rocker arms to valve clearances (inlet and exhaust valves). This manual also includes a Camshaft Belt Tension Service Bulletin from CAGIVA.
1985 – 1987 Cagiva Alazzurra 350 650 Motorcycle Service Manual Models Covered
1985 Cagiva Alazzurra 650 repair
1985 Cagiva Alazzurra 350 repair
1986 Cagiva Alazzurra 650 repair
1986 Cagiva Alazzurra 350 repair
1987 Cagiva Alazzurra 650 repair
1987 Cagiva Alazzurra 350 repair
1985 – 1987 Cagiva Alazzurra 350 650 Motorcycle Service Manual Table of Contents
Specifications
Torque Values for Engine and Chassis
Maintenance
Adjustments
General operations
Engine disassembly
Engine overhauling
Engine re-assembly
Suspension and wheels
Hydraulic control clutch release (Alazzurra 650)
Brakes
Electric system
Troubleshooting guide
Specific tools
1985 – 1987 Cagiva Alazzurra 350 650 Motorcycle Service Manual Index of Topics
Carburetor synchronization
Idle adjustment
Throttle cable adjustment
Choke cable adjustment
Front brake lever adjustment
Cluth cable adjustment (Alazzurra 350)
Hydraulic clutch lever adjustment (Alazzurra 650)
Drive chain adjustment
Steering head bearings play adjustment
Side stand switch adjustment
Fairing removal
Seat removal
Side covers removal
Tail fairing
Battery removal
Gas tank removal
Carburetors removal
Exhaust pipe removal
Drive chain removal
Shift pedal linkage removal
Tachometer driving cable removal
Clutch cable removal (Alazzurra 350)
Hydraulic clutch fluid hose removal (Alazzurra 650)
Engine removal from frame
Camshaft driving belts and pulleys
Cylinder head
Cylinder and piston
Ignition cover
Pick-up bock plate
Alternator rotor
Ignition flywheel
Camshaft driving gear
Starter gears
Starter motor
Countershaft sprocket
Shift mechanism
Clutch cover
Clutch
Oil pump
Primary transmission pinion
Center crankcases
Oil pressure adjusting valve
Camshaft driving shaft
Crankshaft
Shift fork rod
Selector drum
Shift forks
Countershaft
Mainshaft
Valve covers
Upper rocker arms
Valves
Camshaft
Lower rocker arms
Washing parts
Assemblies
Measuring the cylinder
Measuring the piston
Piston-cylinder matching
Piston pin
Piston rings
Piston ring-piston ring groove clearance
Piston ring end gap
Piston pin – Piston pin housing clearance
Piston pin – Con-rod small end clearance
Conrods
Conrod small-end plain bearing replacement
Rod bearing insert
Crankshaft
Crankshaft truing
Grinding the crankshaft pin
Matching conrod and conrod bearings
Cylinder head
Valve seat
Valve guide
Valves
Valve-valve guide assembly
Valve-valve seat assembly
Replacing valve guide
Replacing valve seats
Rocker arms
Rocker arm spring
Rocker arm – Rocker arm shaft assembly
Camshafts and bearings
Pulleys – Belts – Tensioners
Free wheel and starting mechanism
Crankshaft assembly
Crankcases
Check of shaft
Oil seal replacement
Bearings
Oil pump
Clutch assembly
Gearbox
Shafts plain bearings
Carburetor overhauling
Float level
Accelerating Pump fuel delivery (Alazzurra 650)
Valves
Lower rocker arm
Camshaft
Upper rocker arm
Valve covers
Mainshaft
Countershaft
Shift forks
Selector drum
Shift forks shafts
Crankshaft
Camshaft driving shaft
Oil pressure adjustment valve
Crankcase
Crankshaft primary transmission pinion
Oil pump
Clutch assembly
RH side cover
Shift mechanism assembly
Countershaft sprocket
Starter motor
Starter gears
Camshaft driving gear
Ignition flywheel
Alternator rotor
Pick-up back plate
Ignition cover
Piston and cylinder
Cylinder head
Camshaft timing
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
Hydraulic clutch description
Hydraulic clutch fluid drain
Master cylinder overhaul
Fluid change
Bleeding
Brake system
Brake pads removal
Brake disc
Brake fluid drain
Caliper overhaul
Brake master cylinder overhaul
Fluid change
Bleeding the brake
Wiring Diagram
Ignition system wiring diagram
Battery
Generator
Fuse box
Regulator rectifier
Ignition coil test
Pick-up test
Spark plugs
Spark plug caps
Start
Ignition timing advance inspection
Troubleshooting Issues
Engine doesn’t start, starting difficult
Lights do not work properly
Engine misses or produces low power
Start motor does not run
