Vehicle Type:
Dual-purpose motorcycle (Enduro/Adventure)
Target Audience:
Off-road enthusiasts, adventure riders, owners seeking detailed maintenance and repair information
Comparable Models:
Honda Transalp, Yamaha Tenere, BMW GS series (of similar displacement and era)
Manual Usability:
Presented in an easy-to-read PDF format, facilitating quick access to specific information for diagnostics and repairs.
Manual Utility:
A comprehensive resource for all maintenance and repair needs, empowering owners and technicians alike.
Professional Grade:
Utilizes the same detailed procedures and specifications that professional mechanics rely on, ensuring accurate and effective work.
Engine:
Complete engine overhaul, tuning, diagnostics, components (e.g., cylinder head, pistons, crankshaft, valve train, cooling system, lubrication system)
Fuel System:
Carburetor (e.g., Dell'Orto, Mikuni), fuel pump, fuel lines, filters, fuel tank maintenance and repair
Ignition System:
Ignition coil, spark plugs, CDI unit, wiring, timing adjustments
Transmission:
Gearbox overhaul, clutch operation, shift mechanism, lubrication
Chassis Frame:
Frame inspection, straightening, repair procedures
Suspension:
Front forks (e.g., telescopic, inverted), rear shock absorbers, linkage systems, swingarm, bearings, seals
Brakes:
Hydraulic systems (front and rear), caliper service, master cylinders, brake lines, pads, discs, bleeding procedures
Electrical System:
Wiring diagrams, battery, starter motor, alternator, lighting system, switches, fuses, relays, instrumentation
Exhaust System:
Exhaust pipes, mufflers, mounting, inspection
Wheels Tires:
Wheel bearing service, spoke tensioning, tire mounting and balancing
Bodywork:
Fairings, fuel tank, seat, fenders, body panel removal and installation
Controls:
Throttle, clutch, brake levers, foot controls, cable adjustments
Preventative Maintenance:
Regular service checks, lubrication points, filter replacements, chain adjustment
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides
Repair Procedures:
Step-by-step instructions for disassembly, reassembly, and repair of all major components
Adjustment Procedures:
Carburetor synchronization, ignition timing, valve clearance adjustment, cable slack adjustment
Diagnostic Troubleshooting Charts:
Flowcharts and tables to identify causes of problems
Torque Specifications:
Detailed torque values for critical fasteners across all systems
Depth:
Comprehensive (covers routine maintenance to complete engine and transmission rebuilds)
Professional Standard:
Designed for use by professional mechanics, offering the same level of detail as OEM manuals
Engine Type 350:
4-stroke, single-cylinder, liquid-cooled (likely Rotax-derived or similar OEM)
Engine Type 500:
4-stroke, single-cylinder, liquid-cooled (likely Rotax-derived or similar OEM)
Bore Stroke 350 Approx:
Approx. 78 mm x 68 mm (typical for 350cc singles)
Bore Stroke 500 Approx:
Approx. 86 mm x 86 mm (typical for 500cc singles)
Horsepower 350 Approx:
Approx. 30-35 HP (depending on tuning and specific model variant)
Horsepower 500 Approx:
Approx. 40-45 HP (depending on tuning and specific model variant)
Torque 350 Approx:
Approx. 25-30 Nm (depending on tuning and specific model variant)
Torque 500 Approx:
Approx. 35-40 Nm (depending on tuning and specific model variant)
Carburetion 350:
Single Dell'Orto PHF 36 or similar
Carburetion 500:
Single Dell'Orto PHF 36/40 or similar
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Cooling System:
Liquid-cooled with radiator and fan
Lubrication System:
Wet sump
Oil Capacity Approx:
Approx. 1.5 - 2.0 Liters (check manual for exact spec)
Recommended Oil Viscosity:
10W-40 or 20W-50 (depending on climate, refer to manual)
Recommended Oil Standard:
API SG or higher, JASO MA
Crash Safety Rating:
N/A (Motorcycles typically do not have standardized crash test ratings like cars)
Braking System:
Front: Single Disc Brake with dual-piston caliper; Rear: Single Disc Brake with single-piston caliper
Tire Size Front:
e.g., 90/90-21 or 1.60 x 21 rim
Tire Size Rear:
e.g., 120/90-17 or 2.15 x 17 rim
Lighting System:
Halogen headlamp, LED taillight, turn signals
Frame Construction:
Steel frame (e.g., tubular, duplex cradle)
Oil Change Interval:
Every 3,000 - 5,000 km or 6 months (refer to manual for specific recommendation)
Air Filter Cleaning Interval:
Every 3,000 - 6,000 km or as needed based on operating conditions (refer to manual)
Spark Plug Replacement Interval:
Every 8,000 - 12,000 km (refer to manual for type and gap)
Valve Clearance Check Interval:
Every 8,000 - 12,000 km (critical for performance and engine longevity)
Chain Lubrication And Adjustment Interval:
Every 500 - 1,000 km or after riding in wet conditions
Coolant Type:
Ethylene glycol-based antifreeze/coolant (50/50 mix with distilled water)
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Common Wear Items:
Clutch plates, fork seals, wheel bearings, chain and sprockets, brake pads
Carburetor Issues:
Can require frequent cleaning and tuning, especially if fuel is left in the system for extended periods. Jetting may need adjustment for altitude or modifications.
Electrical Gremlins:
Older electrical systems can be prone to corrosion on connectors, leading to intermittent faults. Proper dielectric grease application is beneficial.
Cagiva Origin:
Italian motorcycle manufacturer, known for performance and design, often using Austrian Rotax engines in this era.
T4 Introduction:
The T4 model was Cagiva's entry into the dual-sport/adventure segment, offering a balance of off-road capability and on-road comfort for touring.
Engine Source:
Often utilized Rotax engines, renowned for their reliability and performance in off-road applications, in the 350 and 500cc displacements.
Production Period:
From 1987 onwards, with potential updates and variations in subsequent years.
Manufacturing Location:
Italy
