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Cagiva T4-500 E 1987 Workshop Service Manual Repair

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This manual covers the T4-500 E, a dual-sport motorcycle produced in 1987. Known for its robust construction and versatility, the T4-500 E was designed to offer reliable performance both on...
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Type: Motorcycle
Vendor:
Sku: 156863
Cagiva T4-500 E 1987 Workshop Service Manual Repair
This manual covers the T4-500 E, a dual-sport motorcycle produced in 1987. Known for its robust construction and versatility, the T4-500 E was designed to offer reliable performance both on paved roads and off-road trails. Leveraging an engine likely derived from the Rotax 504 cc unit, this Italian-made machine was engineered for durability and capability, making it a capable companion for adventure riding and everyday use. Its design emphasized a balance of power and handling, characteristic of offerings during that era, which were often praised for their spirited performance and off-road prowess. This comprehensive workshop service manual provides detailed information for the mechanical repair, maintenance, and diagnostics of the 1987 T4-500 E. It covers all essential systems, including the engine, transmission, electrical components, and chassis, with in-depth procedures for overhaul, routine maintenance, and troubleshooting. The manual is intended for professional motorcycle technicians and experienced do-it-yourself mechanics, offering step-by-step instructions and diagnostic guidance to ensure the vehicle is maintained to the highest standards. With hundreds of pages of detailed content, this English-language manual is an invaluable resource for preserving the performance and longevity of your T4-500 E.
🏷️ Basic Information
Identification
Make:
Cagiva
Model:
T4-500 E
Year:
1987
Codes
Engine Code:
Likely derived from the Rotax 504 cc engine
👋 Introduction
Market Position
Target Audience:
Professional motorcycle technicians and experienced do-it-yourself mechanics.
Key Features
Content Focus:
Detailed repair procedures, diagnostic information, and maintenance schedules for the Cagiva T4-500 E.
Value Proposition:
Enables owners to perform a wide range of repairs and maintenance, saving on labor costs and ensuring proper upkeep of the vehicle.
📋 Manual Details
Coverage Areas
Primary Coverage:
Mechanical repair, maintenance, diagnostics, and electrical systems for the Cagiva T4-500 E (1987).
Page Count
Estimated Page Count:
Hundreds of pages (as indicated by product description)
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine:
Engine overhaul, carburetor tuning, cooling system, lubrication system, ignition system, exhaust system.
Transmission:
Gearbox disassembly, assembly, clutch operation, chain drive maintenance.
Electrical:
Wiring diagrams, lighting system, charging system, ignition system, starting system, troubleshooting electrical faults.
Chassis:
Frame inspection, suspension components (forks, rear shock), steering system, wheels, tires, brakes (front and rear).
Bodywork:
Fairings, fuel tank, seat, fenders, minor body panel adjustments.
Procedures Included
Maintenance:
Periodic maintenance charts, oil changes, filter replacements, spark plug service, chain adjustment, lubrication points.
Repair:
Step-by-step repair instructions for all major mechanical and electrical components.
Troubleshooting:
Diagnostic procedures for common issues and fault finding.
Overhaul:
Detailed procedures for engine and gearbox overhauls.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers from basic maintenance to full engine rebuilds.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Full Printable
Zoom Functionality:
Zoom IN/OUT enabled
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
Requirements
Software Requirements:
Adobe PDF Reader & WinRAR
Compatibility
Operating Systems:
All Versions of Windows & Mac
Delivery
Delivery Method:
Instant Download
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder
Displacement:
Approximately 478 cc (based on the Rotax 504 designation, though the T4-500 likely uses a slightly de-tuned version).
Bore X Stroke:
Specifics to be detailed within the manual, likely around 85mm x 84mm.
Cooling System:
Air-cooled (typical for this era and model type).
Performance
Horsepower:
Estimated 35-40 HP (precise figures in manual).
Torque:
Specific figures to be detailed within the manual.
Fuel System
Carburetion:
Likely a single Mikuni carburetor (e.g., VM34 or similar) or Dell'Orto PHM series.
Fuel Type:
Unleaded gasoline (91 RON or higher recommended).
Lubrication System
Oil Type:
Specific oil grade (e.g., SAE 10W-40 or 20W-50) and API classification to be confirmed in the manual.
Ignition System
Type:
Electronic ignition (CDI - Capacitive Discharge Ignition).
🔧 Transmission
Standard
Type:
5-speed constant mesh gearbox.
Clutch:
Wet, multi-plate clutch.
Final Drive:
Chain drive.
Features
Gear Ratios:
Specific gear ratios for each speed will be detailed in the manual.
Transmission Oil:
Manual will specify the type and capacity of transmission oil.
📐 Dimensions
Exterior
Wheelbase:
Approx. 1420 mm (55.9 inches).
Seat Height:
Approx. 860 mm (33.9 inches).
Weights
Dry Weight:
Approx. 165 kg (364 lbs).
Fuel Capacity:
Approx. 18 liters (4.75 US gallons).
🛡️ Safety Features
Active Features
Brakes Front:
Disc brake (single rotor, hydraulic actuation).
Brakes Rear:
Drum brake (mechanical actuation).
Passive Features
Frame Type:
Steel tube frame (typical for dual-sport motorcycles).
💡 Technology Features
Infotainment
Features:
None (basic motorcycle technology for its era).
Driver Assistance
Features:
None.
Connectivity
Features:
None.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000-5,000 km (or annually).
Spark Plug Service:
Every 6,000-10,000 km.
Chain Lubrication Adjustment:
Regularly, every 500-1000 km, depending on conditions.
Fluid Specifications
Engine Oil Grade:
Specified in manual, commonly SAE 10W-40 or 20W-50.
Brake Fluid Type:
DOT 3 or DOT 4, as per manual recommendation.
Known Issues
Electrical Connections:
Corrosion or loosening of electrical connectors, especially in humid environments.
Carburetor Tuning:
Can require periodic cleaning and adjustment due to fuel variations or age.
Suspension Seals:
Wear of fork seals and rear shock seals over time, leading to leaks.
Exhaust System:
Rusting or damage to the exhaust headers or muffler.
📚 Vehicle History
Brand Heritage
Manufacturer:
Cagiva is an Italian motorcycle manufacturer founded in 1978.
Model Evolution
Model Lineage:
The T4 series was Cagiva's line of dual-sport motorcycles, designed for both on-road and off-road use. The T4-500 E was an evolution of earlier models.
Production
Era:
Mid-to-late 1980s.
Engine Source:
Many Cagiva models of this era utilized Rotax engines, known for their reliability and performance in dual-sport applications.
🏆 Awards & Recognition
Recognitions
Awards:
No specific awards are commonly cited for this particular model, but Cagiva motorcycles of this period were generally well-regarded in their segment for performance and off-road capability.
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