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    Cagiva T4-500 1987 Factory Service Repair Manual

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    The Cagiva T4-500, produced in 1987, is a versatile dual-sport motorcycle, embodying Italian design and a focus on robustness for both on-road touring and capable off-road performance. With its single-cylinder,...
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    Tipo: Motorcycle
    Proveedor:
    SKU: 146127
    The Cagiva T4-500, produced in 1987, is a versatile dual-sport motorcycle, embodying Italian design and a focus on robustness for both on-road touring and capable off-road performance. With its single-cylinder, four-stroke engine displacing approximately 478 cc and an estimated 30-35 horsepower, it offers a balanced blend of power and manageable handling. This model was a key player in the adventure motorcycle segment during its production era, appealing to riders who valued a machine that could reliably tackle diverse terrains. Its design philosophy emphasized durability and a distinctive aesthetic, setting it apart from competitors like the Honda Transalp and Yamaha Tenere of the period. This comprehensive factory service repair manual provides essential information for the maintenance, troubleshooting, and repair of your Cagiva T4-500. Covering all major systems, including detailed procedures for the engine, fuel, ignition, transmission, suspension, brakes, and electrical systems, this guide is designed for both professional mechanics and DIY enthusiasts. It offers step-by-step instructions for disassembly, assembly, adjustments, and routine maintenance, along with diagnostic guidance for common issues. By utilizing the detailed technical specifications and repair instructions within this manual, owners and technicians can ensure the optimal performance and longevity of their 1987 Cagiva T4-500.
    🏷️ Basic Information
    Identification
    Make:
    Cagiva
    Model:
    T4-500
    Year:
    1987
    Product Type:
    Factory Service Repair Manual
    👋 Introduction
    Market Position
    Segment:
    Dual-sport / Adventure Motorcycle
    Target Market:
    Motorcyclists seeking a capable off-road and on-road touring machine
    Competitive Analysis
    Key Competitors:
    Honda Transalp, Yamaha Tenere, Suzuki DR-Z, BMW GS series (though often larger displacement)
    Key Features
    Design Philosophy:
    Robustness, versatility, capable off-road performance with touring comfort
    Distinctive Features:
    Italian design influence, often featuring distinctive styling and handling characteristics
    📋 Manual Details
    Coverage Areas
    Primary Coverage:
    Repair, maintenance, adjustments, disassembly, assembly, checks
    Target Audience:
    Mechanics and DIY persons
    Page Count
    Estimated Page Count:
    Varies (typical for this era, often 200-400 pages)
    Manual Type
    Type:
    Service and Repair Manual
    Language
    Language:
    English (assumed based on common practice for this market)
    Format
    Format:
    Printed (typical for factory manuals of this era, digital formats may exist)
    📖 Manual Coverage
    Systems Covered
    Engine:
    Detailed disassembly, assembly, troubleshooting, tuning, specifications
    Fuel System:
    Carburetor(s) (likely Dell'Orto or similar), fuel pump, fuel lines, fuel tank maintenance and repair
    Ignition System:
    Ignition coil, spark plugs, CDI unit, timing adjustments
    Transmission:
    Gearbox disassembly, assembly, inspection, oil change procedures, clutch operation
    Suspension:
    Front forks (likely Marzocchi or similar), rear shock absorber(s), linkage, preload adjustments, seal replacement
    Brakes:
    Front and rear brake systems (likely disc brakes), caliper overhaul, pad replacement, bleeding procedures, master cylinder
    Electrical System:
    Wiring diagrams, lighting, battery, charging system (alternator/stator), starter motor, fuses, relays
    Cooling System:
    Air cooling (typical for this model)
    Exhaust System:
    Muffler and header pipe inspection and replacement
    Wheels And Tires:
    Tire pressure, wheel bearing inspection, spoke tensioning (if applicable), rim maintenance
    Frame And Bodywork:
    Chassis inspection, fairing removal and installation, seat, fuel tank mounting
    Controls:
    Throttle cable adjustment, clutch cable adjustment, brake lever adjustment, shifter linkage
    Procedures Included
    Maintenance:
    Regular service checks, oil changes, filter replacements, chain adjustment, lubrication points
    Troubleshooting:
    Diagnostic procedures for common and uncommon issues, fault finding charts
    Repair:
    Step-by-step instructions for component repair and replacement
    Disassembly Assembly:
    Complete guide to taking apart and reassembling major and minor components
    Adjustments:
    Carburetor synchronization, ignition timing, clutch and brake free play
    Technical Depth
    Depth:
    Comprehensive, covering routine maintenance to full engine and transmission rebuilds
    📊 Manual Specifications
    File Format
    Digital Format:
    PDF (potential for scanned or transcribed format)
    Print Quality
    Print Quality:
    High-resolution images and clear text (typical for factory originals)
    Binding Type
    Binding:
    Stapled or perfect bound (for printed versions)
    Paper Type
    Paper Type:
    Durable, often coated paper to withstand shop use
    ⚙️ Engine Specifications
    Primary Engine
    Configuration:
    Single-cylinder, four-stroke
    Displacement:
    478 cc (approximate, actual may vary slightly based on bore/stroke) - '500' in model name often denotes approximate cubic capacity.
    Bore X Stroke:
    Data not explicitly provided, but typical for this displacement range.
    Compression Ratio:
    Data not explicitly provided, but typically around 9-10:1 for this era.
    Cooling System:
    Air-cooled
    Performance
    Horsepower:
    Estimated 30-35 HP (actual figures often vary by market and tuning)
    Torque:
    Estimated 30-35 Nm (actual figures often vary by market and tuning)
    Fuel System
    Carburetion:
    Single carburetor, likely Dell'Orto PHM 38 or similar.
    Fuel Type:
    Unleaded gasoline (petrol)
    🔧 Transmission
    Standard
    Type:
    5-speed manual transmission
    Optional
    Gearbox Type:
    Not applicable (standard manual)
    Features
    Clutch:
    Wet multi-plate clutch
    Final Drive:
    Chain drive
    📐 Dimensions
    Exterior
    Length:
    Data not explicitly provided, typical for dual-sport of this era.
    Width:
    Data not explicitly provided, typical for dual-sport of this era.
    Height:
    Data not explicitly provided, typical for dual-sport of this era.
    Weights
    Dry Weight:
    Approx. 160-170 kg (unladen)
    Wet Weight:
    Approx. 180-190 kg (with fluids)
    Fuel Capacity:
    Approx. 16-20 Liters
    🛡️ Safety Features
    Ratings
    Crash Safety:
    N/A for motorcycles of this era; focus on rider protection and vehicle handling.
    Active Features
    Braking System:
    Disc brakes front and rear (typically single disc front, single disc rear)
    Lighting:
    Headlight, taillight, brake light, turn signals
    Passive Features
    Chassis Design:
    Steel frame for durability and handling
    Handguards:
    Often fitted as standard or common aftermarket addition for protection.
    💡 Technology Features
    Infotainment
    Infotainment System:
    Not applicable (analog gauges, no modern infotainment)
    Driver Assistance
    Assistance Features:
    Not applicable (no electronic rider aids)
    Connectivity
    Connectivity Options:
    Not applicable
    🔧 Maintenance
    Service Intervals
    Oil Change:
    Every 3,000 - 5,000 km (or annually)
    Air Filter:
    Inspect every 3,000 km, clean/replace as needed
    Spark Plug:
    Replace every 6,000 - 10,000 km
    Chain Lubrication Adjustment:
    Every 1,000 km or after riding in wet conditions
    Fluid Specifications
    Engine Oil Type:
    SAE 10W-40 or 20W-50 Motorcycle-specific (API SG or higher recommended)
    Engine Oil Capacity:
    Approx. 1.5 - 2.0 Liters (check dipstick/sight glass)
    Brake Fluid Type:
    DOT 3 or DOT 4 (check manual for specific recommendation)
    Transmission Oil Type:
    SAE 80W-90 Gear Oil
    Known Issues
    Electrical Connections:
    Corrosion in connectors, grounding issues due to age
    Carburetor Performance:
    Gumming of jets if fuel is left standing, need for periodic cleaning and adjustment
    Suspension Seals:
    Fork seal leaks, rear shock absorber wear
    Exhaust Leaks:
    Gasket failures at header pipe to engine connection
    📚 Vehicle History
    Brand Heritage
    Cagiva Legacy:
    Cagiva is an Italian motorcycle manufacturer founded in 1978, known for its range of street bikes, off-roaders, and racing heritage.
    Model Evolution
    T4 Series:
    The T4-500 was part of Cagiva's early exploration into the dual-sport market, offering a blend of Italian design and utilitarian functionality.
    Production
    Production Era:
    Mid to late 1980s
    Manufacturing Location:
    Italy
    🏆 Awards & Recognition
    Recognitions
    Model Awards:
    Not specifically documented major awards, but appreciated for its ruggedness and capability in its segment.
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