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Cagiva T4-350 R-E T4-500 E 1987 Workshop Service Repair Manual

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The T4, produced in 1987, is a versatile dual-sport motorcycle designed for both on-road and off-road adventures. Building on Italian heritage and off-road expertise, the T4 series offered robust performance...
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Cagiva T4-350 R-E T4-500 E 1987 Workshop Service Repair Manual
The T4, produced in 1987, is a versatile dual-sport motorcycle designed for both on-road and off-road adventures. Building on Italian heritage and off-road expertise, the T4 series offered robust performance for its era, competing with models like the Honda Transalp and Yamaha Tenere. Available in variants such as the T4-350 R-E and T4-500 E, these motorcycles feature air-cooled, SOHC engines, a 5-speed transmission with a wet multi-plate clutch, and a chain final drive, making them capable machines for diverse riding conditions. This Workshop Service Repair Manual provides comprehensive guidance for the T4 models, covering essential maintenance procedures, detailed troubleshooting steps, and in-depth repair instructions. It encompasses all major systems, including the engine, transmission, chassis, brakes, and electrical components, offering clear direction for tasks ranging from routine oil changes and filter replacements to complete engine overhauls and carburetor rebuilds. This manual serves as an indispensable resource for owners and technicians alike, ensuring the T4 remains in optimal condition and performance throughout its service life.
🏷️ Basic Information
Identification
Make:
Cagiva
Model:
T4
Year:
1987
Engine Variants Covered:
T4-350 R-E, T4-500 E
Codes
Product Code:
Cagiva_T4_1987_WSM
👋 Introduction
Market Position
Segment:
Dual-sport / Adventure Motorcycle
Target Audience:
Owners and technicians requiring in-depth maintenance and repair information
Competitive Analysis
Competitors 1987:
Honda Transalp, Yamaha Tenere, Suzuki DR Series, BMW GS Series
Key Features
Vehicle Type:
Dual-purpose motorcycle designed for both on-road and off-road riding
Manual Value Proposition:
Essential tool for maintaining the longevity and performance of the Cagiva T4 models
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service Repair
Secondary Coverage:
Maintenance, Troubleshooting, Repair
Page Count
Estimated Pages:
Detailed (Exact count not specified in product info, but typical for a comprehensive workshop manual)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
Likely English (standard for international manuals, but confirm with seller if critical)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, tuning, lubrication, cooling, and fuel systems
Transmission:
Gearbox inspection, maintenance, repair, and clutch operation
Chassis:
Frame inspection, suspension (front and rear), steering system, and wheel bearings
Brakes:
Brake system inspection, hydraulic system, brake pad/shoe replacement, and caliper service
Electrical:
Wiring diagrams, ignition system, lighting, charging system, starter motor, and battery service
Fuel System:
Carburetor adjustment and overhaul, fuel lines, and fuel tank maintenance
Exhaust System:
Exhaust pipe and muffler inspection and replacement
Bodywork:
Body panel removal and installation, fairings, seat, and basic trim components
Procedures Included
Maintenance:
Regular service checks, oil changes, filter replacements, chain adjustment, and spark plug service
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly
Engine Overhaul:
Detailed instructions for complete engine rebuilds
Suspension Service:
Fork seal replacement, shock absorber servicing, and linkage lubrication
Carburetor Rebuild:
Jetting adjustments, float bowl service, and diaphragm replacement
Technical Depth
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and transmission rebuilds
Diagnostic Coverage:
Includes detailed troubleshooting guides and diagnostic flowcharts
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Typically searchable text within PDF for easy navigation (depends on original scan quality)
Print Quality
Quality:
Digital download, print quality depends on original source material and scanning process
Binding Type
Type:
N/A (Digital PDF)
Paper Type
Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type 350:
4-stroke, SOHC, 2-valve per cylinder, Air-cooled
Engine Type 500:
4-stroke, SOHC, 2-valve per cylinder, Air-cooled
Displacement 350:
Approximately 349cc (specific bore/stroke may vary)
Displacement 500:
Approximately 478cc (specific bore/stroke may vary)
Performance
Horsepower 350:
Estimated 28-30 HP (at crankshaft, typical for the era)
Horsepower 500:
Estimated 35-38 HP (at crankshaft, typical for the era)
Torque:
Not specified in product info, but would be characteristic of a mid-size dual-sport
Fuel System
Carburetion:
Single or Twin Carburetors (likely Mikuni or Dell'Orto, specific model depends on variant)
Fuel Type:
Unleaded Gasoline (RON 91 or higher recommended)
Ignition
Ignition System:
CDI (Capacitor Discharge Ignition)
Lubrication
Oil Type:
JASO MA certified 4-stroke motorcycle oil (e.g., SAE 10W-40 or 20W-50, refer to manual for exact spec)
🔧 Transmission
Standard
Type:
5-speed constant mesh sequential gearbox
Optional
Type:
N/A (Typically single transmission option per model variant)
Features
Clutch:
Wet multi-plate clutch
Final Drive:
O-ring sealed chain drive
📐 Dimensions
Exterior
Wheelbase:
Approx. 1450 mm (57.1 inches) - subject to specific model variant
Seat Height:
Approx. 850 mm (33.5 inches) - subject to specific model variant
Weights
Dry Weight 350:
Approx. 145 kg (320 lbs)
Dry Weight 500:
Approx. 155 kg (342 lbs)
Fuel Capacity:
Approx. 16 Liters (4.2 US Gallons) - subject to specific model variant
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycle safety standards differ from automobiles; manual will focus on mechanical safety)
Active Features
Braking System:
Disc brakes front and rear (specific caliper/rotor sizes not provided in product info)
Suspension:
Robust dual-purpose suspension for varied terrain control
Passive Features
Lighting:
Headlight, taillight, turn signals for visibility
💡 Technology Features
Infotainment
System:
N/A (This is a 1987 motorcycle, infotainment systems were not applicable)
Driver Assistance
Features:
N/A (Motorcycle, no electronic driver assistance systems)
Connectivity
Features:
N/A (Motorcycle, no connectivity features)
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000 - 5,000 km (1,800 - 3,000 miles) or annually, refer to manual for exact interval and oil capacity.
Air Filter Cleaning:
Check every 5,000 km (3,000 miles), clean or replace as needed.
Spark Plug Replacement:
Typically every 10,000 - 15,000 km (6,000 - 9,000 miles).
Chain Maintenance:
Lubricate and adjust chain every 1,000 km (600 miles) or more frequently if ridden in adverse conditions.
Fluid Specifications
Engine Oil:
SAE 10W-40 or 20W-50, API SG or higher, JASO MA certified (verify in manual for exact viscosity and spec).
Brake Fluid:
DOT 3 or DOT 4 (confirm with manual, as DOT standards can vary).
Coolant:
N/A (Air-cooled engine)
Known Issues
Carburetor Tuning:
Carburetors can require periodic adjustment and cleaning due to age and fuel quality variations.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent issues.
Suspension Seals:
Fork seals and rear shock bushings can wear over time, requiring replacement.
Exhaust Leaks:
Gaskets and seals in the exhaust system may require periodic inspection and replacement.
📚 Vehicle History
Brand Heritage
Manufacturer:
Cagiva, an Italian motorcycle manufacturer known for its performance and racing heritage.
Model Evolution
T4 Series:
The T4 series represented Cagiva's entry into the growing dual-sport market of the late 1980s, building on their off-road expertise.
Engine Development:
Engines likely derived from Cagiva's existing single-cylinder or parallel-twin platforms, adapted for dual-sport use.
Production
Production Period:
The T4 series was produced throughout the late 1980s and early 1990s.
🏆 Awards & Recognition
Recognitions
Motorcycle Industry:
Cagiva models often received praise for their performance and Italian styling, though specific awards for the T4 series are not widely documented.
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