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1988 Cagiva T4-500 R-e Workshop Service Repair Manual

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The 1988 Cagiva T4-500 R-e is a dual-sport motorcycle renowned for its robust design and off-road capabilities. As an Italian-manufactured machine, it represents a blend of performance and durability characteristic...
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Type: Motorcycle
Vendor:
Sku: 146541
1988 Cagiva T4-500 R-e Workshop Service Repair Manual
The 1988 Cagiva T4-500 R-e is a dual-sport motorcycle renowned for its robust design and off-road capabilities. As an Italian-manufactured machine, it represents a blend of performance and durability characteristic of its era. This model is engineered for versatility, suitable for both on-road commuting and adventurous trail riding, offering riders a capable and engaging experience. Its 4-stroke, single-cylinder, liquid-cooled engine, estimated to produce 30-35 HP, provides reliable power, complemented by a 6-speed transmission and chain drive for efficient power delivery. The T4-500 R-e features hydraulically actuated disc brakes front and rear for effective stopping power. This comprehensive factory service repair workshop manual provides essential information for the maintenance and repair of your 1988 Cagiva T4-500 R-e. It covers a wide array of critical systems, including detailed procedures for engine overhaul, fuel system adjustments, ignition system troubleshooting, cooling system maintenance, transmission and drivetrain servicing, suspension system repairs, braking system overhauls, and electrical system diagnostics. The manual includes routine maintenance schedules, troubleshooting guides, component rebuild instructions, and precise tightening specifications. With hundreds of detailed illustrations and step-by-step instructions, this manual is an indispensable resource for do-it-yourself enthusiasts and professional mechanics seeking to preserve the performance and longevity of their motorcycle.
🏷️ Basic Information
Identification
Make:
Cagiva
Model:
T4-500 R-e
Year:
1988
Vehicle Type:
Dual-sport Motorcycle
👋 Introduction
Market Position
Target Audience:
Do-it-yourself enthusiasts and experienced mechanics alike.
Value Proposition:
Inexpensive way to maintain and repair the vehicle, saving on professional service costs.
Key Features
Detail Level:
Highly detailed factory service repair manual.
Instruction Style:
Step-by-step instructions with detailed illustrations.
📋 Manual Details
Coverage Areas
Manual Title:
1988 Cagiva T4-500 R-e Workshop Service Repair Manual
Language:
English
Manual Type:
Factory Service Repair Workshop Manual
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly procedures.
Fuel System:
Carburetor tuning, cleaning, and overhaul; fuel tank inspection and repair; fuel line maintenance.
Ignition System:
Spark plug specifications, ignition timing adjustment, CDI unit troubleshooting.
Cooling System:
Radiator and fan inspection, coolant fluid specifications and flushing.
Transmission And Drivetrain:
Gearbox disassembly, inspection, and repair; clutch operation and adjustment; chain and sprocket maintenance.
Suspension System:
Front fork overhaul, rear shock absorber inspection and adjustment, linkage maintenance.
Braking System:
Front and rear brake caliper overhaul, master cylinder inspection, brake pad replacement, hydraulic system bleeding.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier) testing, lighting system troubleshooting.
Frame And Bodywork:
Frame inspection for damage, body panel removal and installation, seat and fairing maintenance.
Wheels And Tires:
Tire pressure specifications, wheel bearing inspection, spoke tensioning (if applicable).
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning.
Troubleshooting Guides:
Diagnostic charts and steps for common performance issues and component failures.
Component Rebuilds:
Detailed instructions for rebuilding carburetors, brake calipers, and suspension components.
Diagnostic Procedures:
Methods for checking ignition, fuel delivery, and electrical system integrity.
Tightening Specifications:
Torque values for critical fasteners across all systems.
Technical Depth
Depth Of Information:
Comprehensive, covering everything from basic maintenance to complete engine and chassis teardown and rebuild.
Illustrations:
Hundreds of detailed illustrations and photos guiding each procedure.
Disassembly Level:
Based on complete disassembly of the machine, providing intimate detail.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Compatibility:
Compatible with all PC-based Windows operating systems and macOS.
Printability:
All pages are printable.
Searchability:
Assumed to be text-searchable within the PDF, enhancing user experience.
Print Quality
Image Resolution:
High quality, suitable for detailed viewing of illustrations and text.
Completeness:
100% complete and intact.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, single-cylinder
Displacement:
Approx. 478cc (based on T4 500 model lineage)
Bore X Stroke:
Specifics to be detailed in manual (typical for this era around 80mm x 94mm)
Cooling System:
Liquid-cooled (Radiator and fan)
Performance
Horsepower:
Estimated 30-35 HP (specifics in manual)
Torque:
Estimated 30-35 Nm (specifics in manual)
Fuel System
Carburetor Type:
Single Mikuni carburetor (likely 34mm or 36mm, to be confirmed in manual)
Fuel Type:
Unleaded gasoline (recommendation to be in manual)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
Chain drive
📐 Dimensions
Exterior
Wheelbase:
Approx. 1450 mm (to be confirmed in manual)
Seat Height:
Approx. 860 mm (to be confirmed in manual)
Weights
Dry Weight:
Approx. 150 kg (to be confirmed in manual)
🛡️ Safety Features
Active Features
Braking System Description:
Hydraulically actuated disc brakes front and rear.
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer, odometer, and basic indicator lights (turn signals, neutral, high beam).
Driver Assistance
Safety Features:
None beyond standard braking and lighting systems, as this is a 1988 motorcycle.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Recommended every 3,000 - 5,000 km or annually (specifics in manual).
Air Filter Cleaning:
Recommended every 3,000 - 6,000 km or as needed based on riding conditions.
Chain Lubrication Adjustment:
Recommended every 500 - 1,000 km and after washing or riding in rain.
Fluid Specifications
Engine Oil Type:
Typically SAE 10W-40 or 20W-50 motorcycle-specific oil (check manual for exact API/JASO rating).
Coolant Type:
Ethylene glycol-based antifreeze coolant (e.g., 50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (check manual).
Known Issues
Common Wear Items:
Clutch wear, carburetor jetting sensitivity, suspension seal leaks, potential electrical connector corrosion due to age.
Carburetor Tuning Quirks:
May require precise jetting and pilot screw adjustment for optimal performance, especially at different altitudes.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Cagiva is an Italian motorcycle manufacturer.
Model Evolution
T4 Series Context:
The T4 series was Cagiva's line of dual-sport motorcycles, known for their off-road capability and robust design, often utilizing Rotax engines in earlier models, though this 500cc likely features a Cagiva or licensed Italian engine.
Production
Production Era:
Late 1980s to early 1990s for the T4 series.
🏆 Awards & Recognition
Recognitions
Historical Market Reception:
Cagiva models of this era were generally well-regarded for their styling and off-road prowess, though market share varied by region.
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