CAGIVA T4 350 T4 500 Workshop Repair Manual All 1987 ONWARDS ModelS COVERED

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The Cagiva T4 350 and T4 500 models, produced from 1987 onwards, represent Cagiva's robust entry into the dual-sport and enduro motorcycle market. Known for their Italian engineering and off-road...

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Tipo: Motorcycle

Proveedor:

SKU: 125863

Etiquetas: 1987 Cagiva Motorcycle Motorcycles T4 T4 350 T4 500

Variantes de producto

Descripción

The Cagiva T4 350 and T4 500 models, produced from 1987 onwards, represent Cagiva's robust entry into the dual-sport and enduro motorcycle market. Known for their Italian engineering and off-road heritage, these motorcycles blend capable performance with road-legal features, making them versatile for various riding conditions. The T4 series is recognized for its durable construction and reliable engines, designed to withstand demanding use. This manual covers both the 350cc and 500cc variants, providing essential information for owners and technicians alike. This comprehensive Workshop Service Repair Manual offers detailed guidance for the maintenance, repair, and troubleshooting of your Cagiva T4 350 or T4 500. It covers all major systems, including the engine, fuel system, ignition, transmission, suspension, brakes, and electrical components. With step-by-step procedures, detailed illustrations, and critical technical specifications, this manual empowers you to perform routine servicing, complex repairs, and diagnostics. Its purpose is to ensure the longevity and optimal performance of your motorcycle, providing expert-level information for owners and independent repair professionals.

🏷️ Basic Information

Identification

Make:

Cagiva

Model:

T4 350 / T4 500

Model Variants:

T4 350, T4 500

Covered Years:

1987 Onwards

Codes

Manual Product Code:

CAGIVA-T4-350-500-WSM

👋 Introduction

Market Position

Target Audience:

Owners of Cagiva T4 350 and T4 500 motorcycles, independent repair shops, and motorcycle enthusiasts undertaking their own maintenance and repairs.

Competitive Analysis

Value Proposition:

Provides comprehensive, expert-level technical information essential for maintaining and repairing specific Cagiva models, offering significant cost savings compared to dealership service.

Key Features

Key Manual Benefits:

Instant download, detailed illustrations, step-by-step procedures, comprehensive specifications, and troubleshooting guidance.

📋 Manual Details

Coverage Areas

Primary Market:

Global (English Language)

Page Count

Estimated Page Count:

Likely 300-500 pages (typical for comprehensive workshop manuals)

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Detailed coverage of both 350cc and 500cc engine variants, including disassembly, assembly, tuning, and troubleshooting.

Fuel System:

Carburetor systems (likely Dell'Orto or similar), fuel lines, fuel pump, and fuel tank maintenance and repair.

Ignition System:

Ignition coil, spark plugs, timing, CDI unit, and related wiring.

Transmission Drivetrain:

Clutch operation, gearbox internals, gear shift mechanism, final drive and chain maintenance.

Suspension:

Front forks (likely conventional or upside-down), rear shock absorber(s), linkage systems, and associated adjustments.

Brakes:

Front and rear brake systems (likely disc brakes), caliper service, master cylinder overhaul, fluid replacement, and bleeding procedures.

Electrical System:

Wiring diagrams, battery maintenance, lighting circuits, starter motor, alternator/stator, and instrument cluster.

Cooling System:

Liquid cooling system components (radiator, fan, hoses, water pump), coolant replacement, and leak detection.

Exhaust System:

Exhaust pipes, mufflers, and emission control components (if applicable).

Frame Chassis:

Frame inspection, fork yokes, steering head bearings, and general chassis integrity checks.

Bodywork Trim:

Fairings, fuel tank, seat, fenders, and other cosmetic components removal and installation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks, brake pad inspection, and coolant checks.

Troubleshooting:

Diagnostic procedures for common starting issues, engine performance problems, electrical faults, and braking system anomalies.

Engine Rebuild:

Complete engine overhaul instructions, including piston, ring, cylinder, valve, and crankshaft service.

Suspension Service:

Fork seal replacement, oil changes, rear shock absorber service and adjustment.

Brake System Repair:

Brake caliper rebuilding, master cylinder replacement, brake line flushing and bleeding.

Electrical Diagnostics:

Tracing electrical faults, component testing, and wiring harness repair.

Carburetor Tuning:

Synchronization, jetting adjustments, idle speed settings, and cleaning procedures.

Wheel Tire Service:

Tire changing, wheel balancing, and spoke tension adjustment (if applicable).

Torque Specifications:

Detailed torque values for all critical fasteners across all systems.

Technical Depth

Depth Of Information:

Comprehensive, from basic maintenance to full engine and transmission rebuilds, suitable for experienced mechanics and dedicated DIY enthusiasts.

Diagnostic Capabilities:

Includes diagnostic flowcharts and troubleshooting guides for identifying and resolving mechanical and electrical issues.

Exploded Views:

High-quality exploded views and diagrams for easy identification of parts and understanding of assembly sequences.

Step By Step Instructions:

Detailed, sequential instructions for each repair and maintenance procedure.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality Suitability:

Optimized for digital viewing; printable pages may vary in quality depending on user's printer.

Binding Type

Binding Type:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

Compatibility

Operating Systems:

PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, 10, 11; macOS)

Searchability

Text Searchability:

Likely searchable PDF if text layer is present, enabling quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, air-cooled (or possibly liquid-cooled for later models), single-cylinder (for 350) and potentially twin-cylinder (for 500 - though T4 500 usually refers to a single).

Engine Capacity 350:

Approximately 350cc

Engine Capacity 500:

Approximately 500cc (likely a larger displacement single)

Performance

Power Output 350:

Estimated 25-30 HP (subject to specific tuning and model year)

Power Output 500:

Estimated 30-35 HP (subject to specific tuning and model year)

Fuel System

Carburetor Type:

Likely single Dell'Orto PHF or PHBH series carburetor for both models, possibly with different jetting.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh gearbox

Optional

Clutch Type:

Wet multi-plate clutch

Features

Final Drive:

Chain drive

📐 Dimensions

Exterior

Frame Type:

Steel semi-double cradle frame

Weights

Dry Weight 350:

Approx. 145 kg (subject to specific model variant)

Dry Weight 500:

Approx. 150 kg (subject to specific model variant)

🛡️ Safety Features

Ratings

Safety Features:

Reflective elements on tires/bodywork, standard braking systems. Manual focuses on mechanical safety aspects of maintenance.

Active Features

Braking System Type:

Front and Rear Disc Brakes

💡 Technology Features

Infotainment

Instrument Cluster:

Basic analog speedometer, tachometer (if equipped), odometer, trip meter, and indicator lights.

Driver Assistance

Not typically equipped on models of this era.

Connectivity

Wiring Harness:

Focus on robust, albeit sometimes aged, electrical systems; manual details wiring for diagnostics and repair.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000 - 5,000 km or annually, check manual for exact specs.

Valve Clearance Check:

Often at 6,000 - 10,000 km intervals, crucial for engine performance.

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-40 or 20W-50 motorcycle specific oil.

Brake Fluid Type:

DOT 4 recommended for hydraulic brake systems.

Coolant Type:

Ethylene glycol based anti-freeze and coolant mixture (50/50 with distilled water).

Known Issues

Common Problems Documented:

Potential carburetor tuning issues, electrical connection corrosion, and wear on common parts like brake pads and chain/sprockets. The manual addresses these.

Parts Information

Component Identification:

Manual provides detailed diagrams for identifying and sourcing replacement parts.

📚 Vehicle History

Brand Heritage

Manufacturer:

Cagiva Motorcycles, an Italian manufacturer known for its sport and off-road motorcycles.

Model Evolution

T4 Series Context:

The T4 series represented Cagiva's entry into the dual-sport/enduro market, blending off-road capability with road-legal features.

Production

Production Period:

Mid-1980s through the 1990s, with '1987 Onwards' indicating a broad coverage.

🏆 Awards & Recognition

Recognitions

Manufacturer Awards:

Cagiva has a history of success in off-road racing, lending credibility to the T4's design and engineering.

Ratings

Durability Reputation:

Reputation for robust engines and chassis, particularly in off-road applications. Manual helps maintain this.