Cagiva Mito 125 Workshop Manual, 1994–2008 (P/N 68543)

Cagiva’s English-language Mito 125 workshop manual, P/N 68543, is the first edition marked 10-90. It covers faired and unfaired versions with a liquid-cooled, single-cylinder two-stroke engine and separate oil injection.

Chapter Files and Wiring Diagram Readability

Search and navigation: Use the printed contents and index to locate sections. The PDFs have no built-in text search or bookmarks. Small wire numbers in the main wiring diagram need magnification, and a few remain faint when enlarged.

The ZIP contains 184 pages across 12 printable PDFs. The total includes the six-page introduction with the cover and title page, plus 178 pages across 11 chapter files.

Engine Overhaul, Chassis Service, and Electrical Tests

This is a selection of workshop topics. The manual also covers drive-chain tension and headlamp aiming.

• Engine and gearbox: Engine removal, crankcase separation, and disassembly, inspection, and reassembly of the gearbox and wet clutch.

• Carburetor and intake: Dell’Orto PHBH 28 RD carburetor service with jet and float-level checks, plus inspection of the intake reed valve.

• Cagiva Torque System (C.T.S.): Exhaust-valve carbon removal, control-cable tension adjustment, valve reassembly, and end-of-travel clearance checks.

• Cooling system: Coolant draining and refilling, radiator and hose inspection, thermostat removal, and water-pump drive and seal service.

• Suspension and wheels: Marzocchi fork overhaul, SOFT DAMP rear-linkage inspection, swingarm-pivot service, and front and rear wheel-bearing replacement.

• Brembo brakes: Front and rear caliper and master-cylinder overhaul, pad replacement, disc inspection, and hydraulic-system bleeding.

• Electrical diagnosis: Wiring diagram with a component key and wire-color codes, plus alternator, regulator, and starter checks.

Cagiva wrote this manual for authorized workshop personnel and assumes familiarity with workshop measurements and special tools.

Bodywork Access and Fault Diagnosis

The faired version has separate procedures for removing the headlight and lower fairings. Other access procedures cover the seats, fuel tank, exhaust, and engine connections.

The troubleshooting charts help narrow down hard starting by separating compression, ignition, and fuel faults. They also cover abnormal engine noise, clutch slip or drag, gear-selection faults, and overheating.

Piston, Crankshaft, and Gearbox Overhaul

The cylinder-piston tables match graded pistons to NIKASIL-coated cylinders. A separate table matches the connecting-rod small end to the correct needle bearing cage. Bottom-end checks cover big-end radial play, connecting-rod bending, and crankshaft runout.

Clutch inspection covers friction-disc thickness, plate distortion, basket clearance, and spring service limits. Gearbox checks include shift-fork and shaft measurements, endplay, and shimming. A balance-shaft timing drawing shows how the gear marks line up during reassembly.

For a crankshaft-only repair, the disassembly section identifies when the gear clusters can stay in the right crankcase half. Turning the cylinder during removal can damage the piston rings, and a poor seal between the crankcase halves can lead to engine or gearbox seizure.

Fuel Metering, Oil Injection, and Cooling

The carburetor exploded view and component table identify the power-jet configuration. A main-jet correction chart accounts for temperature and altitude. Separate sections cover idle mixture and part-throttle adjustment.

Mikuni oil-pump service is limited to installation and delivery adjustment. The cooling-system drawing shows the radiator bypass and how the pump, expansion tank, thermostat, and temperature-sensing components connect.

Fork and Rear Shock Service

The fork section shows which leg takes the compression damper and which takes the rebound damper. Rear-linkage checks distinguish normal axial movement from radial wear.

The rear shock section covers spring length, shaft condition, leakage, and ball-joint play. Keep the gas-pressurized damper sealed. Internal wear or substantial leakage calls for replacement.

Ignition, Charging, and Starter Checks

The electrical section covers Kokusan ignition timing and includes an on-bike charging test chart. The alternator and regulator checks help distinguish a charging-system fault from a battery problem.

EFEL starter servicing covers brush wear and insulation checks, with specifications for free-running and loaded tests.

Maintenance Schedule, Torque Tables, and Special Tools

Reference pages provide the mileage-based maintenance schedule, fluid capacities, and separate engine and chassis torque tables. The illustrated tool list identifies the crankcase splitter 800033048, right-side crankshaft installer 800033047, and ignition timing tool 800048803 for planning the work. Follow the manual’s torque specifications and safety procedures during engine work.

Selected Piston Fit and Brake Disc Limits

At a stabilized temperature of 68°F, the cylinder-piston matching section gives a preferred clearance of 0.00157 ± 0.00019 in. and a wear limit of 0.00275 in.

The brake section gives a minimum thickness of 0.13 in. for both discs. The rear disc distortion limit is 0.011 in. with the disc mounted on the wheel.