Positioning:
The Cagiva T4 series of dual-sport motorcycles was positioned as a capable off-road and on-road adventurer, competing with models from brands like Yamaha (XT series), Honda (XL series), and Suzuki (DR series) in the late 1980s.
Competitors:
Key competitors included the Yamaha XT600, Honda XL600, Suzuki DR600/DR650, and potentially some BMW GS models for riders seeking larger displacement dual-sports.
Design Philosophy:
Emphasized robust construction for off-road durability combined with sufficient comfort and performance for touring. The T4-E models likely featured electric start, enhancing usability.
Performance Focus:
A balance of torque for trail riding and usable power for highway speeds. The 350cc variant offered lighter weight and agility, while the 500cc provided more outright power.
Primary Coverage:
Comprehensive service and repair for Cagiva T4-350 R-E and T4-500 E models
Specific Systems Listed:
General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Engine Control System, Chassis/Body, Restraint System, Axle
Estimated Page Count:
Estimated 300-500 pages (typical for comprehensive service manuals of this era, specific count not provided)
Type:
Service Repair Manual / Workshop Manual
Engine:
Detailed service, repair, troubleshooting, and overhaul procedures for both 350cc and 500cc Rotax engines (expected), including disassembly, assembly, tuning, and component testing.
Transmission:
Service and repair information for the gearbox, clutch operation, and related components. Expected to cover inspection, adjustment, and replacement procedures.
Electrical System:
Comprehensive coverage including detailed wiring diagrams for all circuits, troubleshooting electrical faults, component testing, and repair of ignition, lighting, charging, and starting systems.
Fuel System:
Service and repair of the fuel injection system (likely electronic fuel injection on E models) and/or carburetion (on R models), including fuel pump, injectors/carburetors, fuel lines, and fuel tank maintenance.
Cooling System:
Maintenance and repair of the cooling system, likely liquid-cooled, including radiator, water pump, thermostat, hoses, and coolant specifications.
Suspension:
Detailed procedures for front forks (likely telescopic), rear shock absorbers, swingarm inspection, and adjustment of suspension settings. Includes seal replacement and fluid changes.
Brakes:
Service and repair of both front and rear braking systems, likely disc brakes. Covers brake caliper service, fluid replacement, bleeding procedures, pad inspection, and rotor maintenance.
Steering:
Information on the steering mechanism, including handlebar and linkage components. Covers inspection, lubrication, and potential adjustments or replacements.
Chassis Body:
Maintenance and repair of the frame, body panels, fairings, seat, and other chassis components. Includes procedures for removing and installing bodywork.
Maintenance:
Scheduled maintenance tasks, routine inspections, lubrication points, and replacement of wear items like filters and spark plugs.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common mechanical and electrical problems.
Repair Rebuild:
Step-by-step instructions for the complete disassembly, repair, and reassembly of all major vehicle components and systems.
Refurbishment:
Guidance on restoring worn or damaged components to their original operating condition.
Depth:
Comprehensive, suitable for both experienced mechanics and technically inclined DIY enthusiasts. Covers everything from basic adjustments to complete engine and transmission overhauls.
Type 350:
Likely a single-cylinder, four-stroke, air-cooled Rotax engine (specific configuration like bore/stroke not provided, but based on common Rotax engines of the era).
Type 500:
Likely a single-cylinder, four-stroke, air-cooled Rotax engine (specific configuration like bore/stroke not provided, but based on common Rotax engines of the era).
Horsepower 350 Est:
Approximately 25-30 HP (estimated, exact figures vary by specific model and market).
Horsepower 500 Est:
Approximately 35-40 HP (estimated, exact figures vary by specific model and market).
Fuel Delivery 350:
Likely a carburetor (e.g., Dell'Orto PHM series) for the R model, potentially fuel injection for an 'E' variant (though less common on 350cc in this era for dual-sports).
Fuel Delivery 500:
Likely a carburetor (e.g., Dell'Orto PHM series) for the R model, and potentially Electronic Fuel Injection (EFI) for the T4-500 E model, as indicated by the 'E' designation.
System:
CDI (Capacitor Discharge Ignition) - typical for this era of motorcycle.
Certification:
CE, EPA, CARB (depending on market of sale, not explicitly stated in product info but typical for homologation).
Brakes:
Front and rear disc brakes, offering good stopping power for the era.
Lighting:
Integrated headlight, taillight, turn signals, and brake light for road legality.
Oil Change:
Typically every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first (specific interval dependent on engine type and oil used, consult manual).
Air Filter Cleaning:
Recommended every 5,000-10,000 km (3,000-6,000 miles) or more frequently in dusty conditions.
Spark Plug Replacement:
Typically every 10,000-15,000 km (6,000-9,000 miles).
Engine Oil Type:
SAE 10W-40 or 20W-50 motorcycle-specific oil, API SG or higher, JASO MA rated (refer to manual for exact specifications).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (non-petroleum based).
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water in a 50/50 ratio (if liquid-cooled).
Carburetor Tuning:
Carburetors can become gummed up or out of adjustment over time, requiring cleaning and synchronization, especially if the bike has been sitting.
Electrical Connections:
Corroded or loose electrical connections can lead to intermittent faults, particularly in older bikes.
Fork Seals:
Leaking fork seals are a common wear item on motorcycles of this age.
Exhaust System:
Rust and corrosion can affect the exhaust system, especially in humid climates.
Heritage:
Cagiva is an Italian motorcycle manufacturer known for its sporty and performance-oriented bikes, often utilizing innovative designs and engines sourced from other manufacturers like Rotax.
T4 Lineage:
The T4 model line represented Cagiva's entry into the popular dual-sport segment, aiming to provide a versatile machine capable of both off-road adventure and everyday commuting.
Production Period:
The T4 models, including the 1987 variants, were produced in the mid-to-late 1980s.
Manufacturing Location:
Italy
