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...
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
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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