Segment:
Dual-sport / Enduro motorcycle
Target Audience:
Do-it-yourselfer and experienced mechanics
Key Competitors Era:
Other 500cc dual-sport and enduro motorcycles from brands like Yamaha (XT500/Tenere), Honda (XR500), Suzuki (DR500), Kawasaki (KLR500/KLR600)
Manual Benefit 1:
Cost-effective way to maintain and repair the vehicle
Manual Benefit 2:
Provides OEM-level detail for accurate repairs
Manual Benefit 3:
Enables user to print only necessary pages for convenience
Delivery Method:
Instant PDF download after purchase
Primary Coverage:
Complete Workshop Service and Repair
Vehicle Variants Covered:
All styles of the 1988 Cagiva T4-500 R-E
Estimated Page Count:
Hundreds of pages (exact count not specified but implied to be substantial for a full workshop manual)
Manual Type:
Factory Service Repair Manual
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of engine components
Fuel System:
Carburetor tuning, cleaning, and overhaul; fuel pump and lines
Ignition System:
Ignition timing, component testing (CDI, coil), spark plugs
Electrical System:
Wiring diagrams, troubleshooting, component testing (lights, starter, battery, charging system)
Transmission:
Clutch operation, gearbox disassembly and assembly, gear selection
Suspension:
Front fork service (oil, seals, springs), rear shock absorber adjustment and service
Brakes:
Front and rear brake system service (hydraulic, caliper, master cylinder, pads, fluid)
Wheels And Tires:
Tire pressure, wheel bearing service, spoke tensioning (if applicable)
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fenders
Cooling System:
Coolant specifications, radiator, hoses (relevant if liquid-cooled; assuming air-cooled based on general T4-500 knowledge but manual will clarify)
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points
Troubleshooting:
Diagnostic procedures for common and complex issues, including electrical faults
Repair Procedures:
Step-by-step instructions for virtually all mechanical and electrical repairs
Disassembly Reassembly:
Complete breakdown and rebuilding guidance for all major vehicle systems
Electrical Diagnostics:
Detailed troubleshooting steps and wiring diagrams for the electrical system
Component Testing:
Specific procedures for testing ignition, electrical components, and mechanical parts
Depth:
Comprehensive (from basic maintenance to complete engine rebuilds and advanced electrical diagnostics)
Detail Level:
Step-by-step instructions with detailed substeps, notes, cautions, and warnings
Illustrations:
Hundreds of photos and illustrations, detailed drawings, and enlarged insets
Engine Type:
Four-stroke, single-cylinder (likely Rotax-derived or similar, common for Cagiva at the time)
Displacement:
Approx. 478cc (500cc class designation)
Bore X Stroke:
Specifics detailed in manual (e.g., ~87mm x 82mm, common for this engine family)
Cooling System:
Likely Air-cooled (manual will confirm)
Valve Train:
SOHC, 2 valves per cylinder (typical for this era and configuration)
Horsepower Estimate:
~30-35 HP (typical for the class and engine design, precise figures in manual)
Torque Estimate:
Specifics detailed in manual
Carburetor:
Single or dual carburetor setup (e.g., Dell'Orto PHF or similar, manual will specify model and size)
Fuel Type:
Unleaded gasoline (manual will specify octane rating)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Starter Type:
Electric Start (R-E designation)
Braking System Front:
Single or dual disc brake with hydraulic actuation
Braking System Rear:
Drum brake or single disc brake with hydraulic actuation (manual will confirm)
Lighting:
Headlight, taillight, brake light, turn signals (standard for the era)
Oil Change Interval:
Specified in manual, typically every 2,000-3,000 km or annually.
Spark Plug Replacement:
Specified in manual, often around 5,000-10,000 km.
Chain Adjustment Interval:
Regularly checked, adjustment as needed based on slack.
Engine Oil Type:
SAE 10W-40 or 20W-50 motorcycle specific oil (manual will confirm viscosity and API classification).
Engine Oil Capacity:
Specified in manual (typically around 1.5-2.0 liters).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (manual will specify).
Fork Oil Type:
Specific weight (e.g., SAE 10W) and volume for front forks (details in manual).
Carburetor Fouling:
Common with age and infrequent use, requiring cleaning and tuning.
Electrical Connections:
Corrosion or degradation of electrical connectors due to age and environmental exposure.
Suspension Seals:
Wear and tear on fork seals leading to leaks, a common issue on older bikes.
Charging System:
Potential issues with stator or regulator/rectifier, common on older electrical systems.
Cagiva History:
Cagiva was an Italian motorcycle manufacturer known for its range of street, off-road, and racing bikes. Founded by Claudio Castiglioni, they often utilized engines from other manufacturers or developed their own.
T4 Series:
The T4 series was Cagiva's entry into the dual-sport and enduro market, offering a balance between on-road usability and off-road capability. The 'R-E' designation signifies the inclusion of an electric starter.
Production Period:
Mid to late 1980s for this specific model variant.
