Target Audience:
Professional technicians and experienced DIY enthusiasts undertaking comprehensive repairs, maintenance, and restoration of the Cagiva T4-500 E 1987.
Value Proposition:
Provides a single, authoritative source of information equivalent to factory service manuals, covering all aspects of repair and maintenance for a specific model year.
Instructional Method:
Numbered instructions, detailed sub-steps, notes, cautions, warnings, and bold figure numbers for clear guidance.
Visual Aids:
Detailed illustrations, drawings, photos, and enlarged inset diagrams for precise part identification and procedure clarity.
Organization:
Numbered table of contents for quick information retrieval.
Delivery:
Instant Download, eliminating shipping costs and waiting times.
Covered Systems:
Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Clutch, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Chassis, Bodywork, Troubleshooting, Wiring Diagrams
Estimated Page Count:
Detailed page count not specified, but described as 'very detailed' and containing 'everything you will ever need to repair, maintain, rebuild, refurbish or restore.'
Type:
Full Service Repair Manual
Engine Mechanical:
Detailed information on engine disassembly, inspection, repair, and reassembly for the T4-500 E engine.
Fuel System:
Covers carburetor adjustment, cleaning, fuel tank, fuel lines, and fuel pump diagnostics and repair.
Ignition System:
Includes ignition timing, spark plug specifications, coil testing, and troubleshooting of ignition components.
Transmission Drivetrain:
Detailed procedures for transmission disassembly, inspection, repair, clutch replacement, and final drive maintenance.
Suspension Steering:
Covers front and rear suspension component inspection, replacement, and steering system maintenance.
Braking System:
Includes brake fluid specifications, pad/shoe replacement, caliper/master cylinder overhaul, and bleeding procedures.
Electrical System:
Comprehensive coverage with detailed wiring diagrams, component testing, and troubleshooting for electrical faults.
Chassis Bodywork:
Information on frame inspection, body panel removal/installation, and related hardware.
Routine Maintenance:
Covers oil changes, filter replacements, chain adjustment, lubrication points, and general inspection schedules.
Diagnostic Procedures:
Detailed troubleshooting guides for common and uncommon issues, including step-by-step diagnostic trees.
Rebuild Procedures:
In-depth instructions for rebuilding major components such as the engine, transmission, and carburetors.
Electrical Troubleshooting:
Specific procedures combined with wiring diagrams to diagnose and repair electrical system problems.
Depth Of Coverage:
Professional technician level, with adequate data for advanced DIY mechanics. Covers everything from basic maintenance to complete rebuilds and complex diagnostics.
Engine Type:
Air-cooled, 4-stroke single-cylinder (common for this era of Cagiva dual-sport, though precise configuration might vary slightly depending on specific T4-500 E variants).
Displacement:
Approximately 478cc (based on '500' designation, typically a 478cc single cylinder for this model).
Bore X Stroke:
Specific bore and stroke values would be detailed within the manual, but generally in the range of 86mm x 84mm for a 478cc single.
Compression Ratio:
Typically around 9.0:1 to 9.5:1 for this type of engine, as detailed in the manual.
Horsepower:
Estimated 30-35 HP at 6,000-6,500 RPM, actual figures in manual.
Torque:
Estimated 35-40 Nm at 4,500-5,000 RPM, actual figures in manual.
Carburetion:
Likely a single Dell'Orto PHM 40 or similar high-quality carburetor, with detailed tuning and rebuilding procedures.
Fuel Capacity:
Typical capacity for this era dual-sport is around 17-20 liters (4.5-5.3 US gallons), exact figure in manual.
Transmission Type:
5-speed constant mesh, sequential manual transmission.
Optional Transmission:
N/A (Typically no automatic or other transmission options for this model).
Clutch Type:
Wet, multi-plate clutch operated by cable.
Gear Ratios:
Specific gear ratios for each speed are detailed in the manual.
Final Drive:
Chain drive with specific adjustment and maintenance procedures.
Length:
Approximate length of 2200mm, exact specifications in manual.
Width:
Approximate width of 850mm, exact specifications in manual.
Height:
Approximate seat height of 860mm, exact specifications in manual.
Dry Weight:
Around 170-180 kg (375-397 lbs) dry weight, exact figure in manual.
Gross Vehicle Weight Rating:
Specific GVWR would be listed in the manual.
Safety Ratings:
Motorcycles of this era did not have standardized crash test ratings like cars. Safety features are focused on mechanical integrity and rider control.
Braking System Type:
Front: Single disc brake. Rear: Drum brake or possibly a second disc brake depending on specific T4-500 E sub-model, with manual detailing specific components and fluid.
Suspension Performance:
Adjustable suspension components (e.g., preload on rear shock, potentially rebound on front forks) contribute to stability and control, with adjustment procedures in the manual.
Lighting System:
Headlight, tail light, brake light, turn signals, and instrument cluster illumination, with wiring diagrams for troubleshooting.
Infotainment System:
N/A (Motorcycle of this era did not feature infotainment systems).
Driver Assistance Features:
N/A (Motorcycles of this era did not feature driver assistance systems).
Connectivity Options:
N/A (Motorcycles of this era did not feature connectivity options).
Instrument Panel:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights for neutral, turn signals, oil pressure, high beam.
Oil Change Interval:
Typically every 3,000-5,000 km (1,800-3,000 miles) or annually, specific interval in manual.
Air Filter Cleaning:
As required, depending on operating conditions, with detailed cleaning and replacement instructions.
Spark Plug Replacement:
Recommended every 6,000-10,000 km (3,700-6,200 miles), with specific plug type and gap in manual.
Chain Lubrication Adjustment:
Regularly, every 500-1,000 km (300-600 miles) and before long trips, with specific tension specifications in manual.
Engine Oil Type:
SAE 20W/50 or 10W/40 motorcycle-specific oil meeting JASO MA specifications, exact grade and API rating in manual.
Engine Oil Capacity:
Approximately 2.0-2.5 liters with filter change, exact capacity in manual.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic fluid, check manual for specific recommendation.
Fork Oil Type:
Specific viscosity fork oil (e.g., SAE 10W or 15W) detailed in manual, with capacity per fork leg.
Common Wear Items:
Clutch wear, carburetor jetting issues, electrical connections degradation over time, fork seal leaks are common on bikes of this age.
Carburetor Tuning:
Diaphragm wear or hardening, jet blockages, and float level adjustments are frequent maintenance points.
Electrical Corrosion:
Connectors and grounds can corrode over time, leading to intermittent electrical issues. Manual's wiring diagrams are crucial.
Cagiva Heritage:
Cagiva was an Italian motorcycle manufacturer known for its off-road and dual-sport motorcycles, often incorporating innovative designs and partnerships.
T4 Series Evolution:
The T4 series represented Cagiva's foray into the competitive dual-sport market, offering robust performance for both on-road and light off-road use. The 'E' likely denotes an electric start version.
Production Period:
The T4-500 E was produced in the late 1980s. Specific production run dates are typically found within historical resources rather than service manuals.
Manufacturing Location:
Cagiva motorcycles were manufactured in Italy.
