1994–2008 Cagiva Mito 125, Evolution 500 Workshop Manual (P/N 68543)

• Covers Mito 125 models with and without fairing, including engine removal, crankcase separation, and repair of the seven-speed gearbox and wet clutch.
• Fuel-system coverage includes Dell’Orto PHBH 28 RD carburetor disassembly, float-level and jet checks, and intake reed-valve inspection.
• C.T.S. (Cagiva Torque System) exhaust-valve procedures address carbon buildup, control-cable tension, valve reassembly, and end-of-stroke clearance.
• Details Marzocchi fork overhaul, SOFT DAMP rear-linkage inspection, swingarm-pivot service, and wheel-bearing replacement.
• Brembo brake repair coverage includes front and rear calipers, master cylinders, pad replacement, disc inspection, and hydraulic-system bleeding.
• Electrical fault tracing uses the wiring diagram, component key, wire-color coding, and alternator, regulator, and starter checks.

Factory Mito Documentation and Workshop Scope

This 184-page PDF set contains Cagiva’s English-language Mito workshop manual, P/N 68543, first edition marked 10-90. An introduction and 11 section files document the liquid-cooled, single-cylinder two-stroke configuration with separate oil injection.

Bodywork procedures distinguish the faired version’s access requirements and cover the seats, fuel tank, exhaust, and engine connections. Factory Troubles and remedies charts link hard starting, abnormal engine noise, clutch slip or drag, gear-selection faults, and overheating to possible causes and corrective work.

Engine and Component Specifications

The technical data section details cylinder-piston assembly charts for matching graded pistons and NIKASIL-coated cylinders, with mating clearances and wear limits. Bottom-end inspections cover con-rod big-end radial play, rod bending, and crankshaft runout. A separate selection table matches the connecting-rod small end to the appropriate needle cage.

Clutch pack data covers friction-disc thickness, plate distortion, basket clearance, and spring service limits. Transmission repair information adds shift-fork measurements, shaft inspection dimensions, and endplay and shimming checks. The Balance countershaft phasing drawing shows the gear-timing relationships used during reassembly.

The manual flags two specific assembly risks: turning the cylinder during removal can damage the piston rings, while poor sealing between the crankcase halves can cause engine or gearbox seizure.

Fuel, Lubrication, and Cooling-System Service

The carburetor pages identify the power-jet configuration and include an exploded view with a component specification table. The Correction factor of the main jet chart accounts for temperature and altitude changes; separate adjustment sections address idle mixture and intermediate-throttle operation.

Mikuni oil-pump coverage includes installation and delivery adjustment, rather than internal pump rebuilding. Cooling-system repair covers draining and refilling, radiator and hose inspection, thermostat removal, and water-pump drive and seal service. The Cooling system drawing shows the radiator-bypass arrangement and the relationship between the pump, expansion tank, thermostat, and temperature-sensing components.

Chassis and Electrical Repair Details

The fork section distinguishes the compression and rebound damper assemblies, including their different installation positions. Rear-linkage checks distinguish allowable axial movement from radial wear.

Rear-shock coverage includes spring-length, shaft-condition, leakage, and ball-joint checks. The gas-pressurized damper must not be opened; internal wear or substantial leakage calls for replacement rather than a hydraulic rebuild.

Kokusan ignition timing and EFEL starter servicing receive separate attention. Starter information includes brush and insulation checks, plus free-running and loaded test specifications. The Checking the recharge system on vehicle chart accompanies on-bike charging-system diagnosis.

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

Working on high-revving two-stroke engines requires precision; follow the manual’s torque specifications and safety procedures.