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    Cagiva T4 350 T4 500 Workshop Service Repair Manual

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    This document serves as a comprehensive workshop service repair manual for the T4 350 and T4 500 dual-sport/adventure motorcycles, produced from 1987 onwards. These versatile Italian-engineered machines, often featuring robust...
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    Typ: Motorcycle
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    Art.-Nr: 121195
    This document serves as a comprehensive workshop service repair manual for the T4 350 and T4 500 dual-sport/adventure motorcycles, produced from 1987 onwards. These versatile Italian-engineered machines, often featuring robust Rotax engines, were designed for both on-road versatility and off-road capability. This manual provides detailed information essential for understanding, maintaining, and repairing these iconic motorcycles, ensuring their continued performance and reliability. The scope of this manual encompasses all critical aspects of the T4 series, including detailed procedures for engine rebuilding, powertrain systems, chassis and suspension components, and electrical systems. It offers step-by-step instructions, troubleshooting guides, and technical specifications, along with crucial safety guidelines. Whether you are a dedicated owner or a professional technician, this resource is designed to facilitate efficient and accurate maintenance and repair, covering everything from routine servicing to in-depth diagnostics and component overhauls.
    🏷️ Basic Information
    Identification
    Make:
    Cagiva
    Model:
    T4 350
    Model Variant:
    T4 500
    Vehicle Type:
    Dual-Sport / Adventure Motorcycle
    Codes
    Engine Code Common:
    Rotax 2-valve (350cc/500cc variants)
    Chassis Code Common:
    T4
    👋 Introduction
    Market Position
    Positioning:
    Specialized service manual for a niche European dual-sport motorcycle, catering to owners and independent workshops.
    Competitive Analysis
    Comparison:
    Distinguishes itself from generic manuals by offering make, model, and year-specific information for the Cagiva T4 series. Emphasizes its completeness for all repair and maintenance needs.
    Key Features
    Value Proposition:
    Provides a singular, authoritative source for repair, maintenance, and diagnostics, saving time and money compared to sourcing information from multiple disparate sources. Instant download ensures immediate access to critical repair data.
    Diagrams:
    Includes step-by-step diagrams which are crucial for understanding complex mechanical and electrical procedures.
    📋 Manual Details
    Coverage Areas
    Models Covered:
    Cagiva T4 350, Cagiva T4 500
    Years Covered:
    1987 Onwards
    Page Count
    Estimated Page Count:
    Detailed (Exact count not specified but described as comprehensive)
    Manual Type
    Type:
    Workshop Service Repair Manual
    Language
    Language:
    English
    Format
    Digital Format:
    PDF (Instant Download)
    Compatibility:
    PC/MAC Compatible
    Features
    Viewing Options:
    Printable (select pages or entire manual), Screen Viewable, Zoom In/Out
    📖 Manual Coverage
    Systems Covered
    Powertrain:
    Engine, Fuel System, Lubrication, Clutch, Gearshift Linkage, Sub-transmission, Crankcase, Transmission, Crankshaft, Primary Shaft
    Chassis And Suspension:
    Front Wheel, Front Suspension, Rear Wheel, Rear Suspension, Hydraulic Brake System
    Electrical And Ignition:
    Battery, Charging System, Ignition System, Electric Starter, Switches, Electrical Diagrams
    General Maintenance:
    General Information, Inspection and Adjustment, Technical Features, Troubleshooting
    Procedures Included
    Repair And Rebuild:
    Engine Rebuilding, Cylinder Head/Valve procedures, Cylinder/Piston procedures, Clutch rebuild, Transmission rebuild, Crankshaft/Primary shaft procedures
    Maintenance:
    Routine Maintenance, Lubrication procedures, Inspection and Adjustment procedures, Fluid Capacities
    Diagnostics:
    Troubleshooting guides, Electrical troubleshooting with diagrams
    Installation:
    Engine Removal/Installation
    Technical Depth
    Depth:
    Comprehensive: Covers all workshop repair procedures from basic maintenance to complete engine rebuilding and electrical system diagnostics. Provides step-by-step diagrams and detailed instructions.
    📊 Manual Specifications
    File Format
    Format:
    PDF
    Searchability:
    Likely text-searchable PDF, facilitating quick information retrieval.
    Print Quality
    Quality:
    High Resolution (implied by zoom functionality and detailed diagrams)
    Binding Type
    Binding:
    N/A (Digital Product - Instant Download)
    Paper Type
    Paper Type:
    N/A (Digital Product - Instant Download)
    Delivery
    Delivery Method:
    Instant Download via Email Link
    ⚙️ Engine Specifications
    Primary Engine
    Type:
    Four-stroke, Air-cooled, Single Cylinder (typically Rotax-derived)
    Displacement 350:
    Approximately 348cc
    Displacement 500:
    Approximately 478cc
    Valve Train:
    2-valve SOHC
    Performance
    Horsepower 350:
    Est. 25-30 HP (Varies by specific model year and tune)
    Horsepower 500:
    Est. 30-35 HP (Varies by specific model year and tune)
    Torque:
    Specific torque figures not provided but expected to be adequate for dual-sport use.
    Fuel System
    Carburetion:
    Single Carburetor (e.g., Dell'Orto PHM series or Mikuni)
    Fuel Type:
    Unleaded Gasoline
    Lubrication
    System Type:
    Wet Sump
    Oil Capacity:
    Typically around 1.5-2.0 liters (Specifics in manual)
    Oil Specification:
    Refer to manual for specific viscosity (e.g., SAE 10W-40 or 20W-50) and API classification.
    🔧 Transmission
    Standard
    Type:
    5-Speed Manual
    Optional
    Transmission Options:
    N/A (Standard 5-speed)
    Features
    Clutch Type:
    Wet Multi-plate
    Drive Type:
    Chain Drive
    📐 Dimensions
    Exterior
    Wheelbase:
    Varies by model, but typically around 1450-1480 mm
    Weights
    Dry Weight:
    Approximately 140-155 kg (Varies by model and equipment)
    Fuel Tank Capacity:
    Approximately 16-18 Liters
    🛡️ Safety Features
    Active Features
    Braking System:
    Hydraulic Disc Brakes (Front and Rear)
    Suspension Front:
    Telescopic Forks (Likely Marzocchi or similar, with adjustable preload on some models)
    Suspension Rear:
    Monoshock Swingarm with Linkage (Likely PDS or similar)
    Passive Features
    Lighting:
    Halogen Headlight, Taillight, Turn Signals
    💡 Technology Features
    Infotainment
    Infotainment System:
    N/A (Basic motorcycle instrumentation)
    Driver Assistance
    ABS:
    N/A (Anti-lock Braking System not typically fitted to models of this era)
    Connectivity
    Connectivity Features:
    N/A
    Lighting Technology
    Headlight Type:
    Halogen
    🔧 Maintenance
    Service Intervals
    Oil Change:
    Refer to manual for specific mileage/time intervals (typically 3000-5000 km)
    Valve Adjustment:
    Refer to manual for specific mileage/time intervals (e.g., every 6000-10000 km)
    Spark Plug Replacement:
    Refer to manual for specific mileage/time intervals
    Fluid Specifications
    Brake Fluid:
    DOT 3 or DOT 4 (Check manual for specific type and flush interval)
    Coolant:
    N/A (Air-cooled engine)
    Known Issues
    Common Wear Items:
    Clutch wear, suspension seals, carburetor tuning, electrical connections corrosion (common for bikes of this era).
    Common Issues
    Specific Notes:
    The Rotax engines are generally robust but require proper maintenance. Carburetor synchronization and cleaning are key for smooth running. Electrical system checks are vital due to age and potential exposure to elements.
    📚 Vehicle History
    Brand Heritage
    Manufacturer Origin:
    Cagiva is an Italian motorcycle manufacturer.
    Model Evolution
    Development:
    The T4 series was Cagiva's entry into the popular dual-sport market, often utilizing reliable Rotax engines, known for their robustness in off-road applications. They were designed for versatility, capable of both on-road commuting and off-road trail riding.
    Production
    Production Period:
    1980s and 1990s
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