1988 Cagiva T4-500 RE Factory Service Repair Manual

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Type: Motorcycle

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Sku: 136519

Tags: 1988 Cagiva Motorcycle Motorcycles T4 T4-500 RE

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Description

The 1988 Cagiva T4-500 RE is a dual-sport motorcycle engineered for adventure touring and versatile on-road and off-road performance. As part of Cagiva's foray into the dual-sport market, this model is recognized for its robust build, capable suspension systems, and comfortable riding position suitable for longer journeys. Its design reflects a blend of European styling and practical functionality, positioning it as a capable competitor in the late 1980s dual-sport segment. This factory service repair manual in English provides comprehensive guidance for the maintenance, repair, and troubleshooting of the 1988 Cagiva T4-500 RE. It covers essential procedures for all major systems, including the 498cc air-cooled engine, transmission, fuel feed, brakes, suspension, and electrical components. The manual is designed to assist owners, mechanics, and technicians in performing routine servicing, complex repairs, and diagnostic procedures to ensure the optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Cagiva

Model:

T4-500 RE

Year:

Sub Model:

Enduro/Adventure Touring

Vehicle Type:

Dual-Sport Motorcycle

👋 Introduction

Market Position

Market Segment:

Dual-sport/Adventure touring motorcycle, targeting riders seeking versatility for on-road and off-road use.

Competitive Analysis

Competitors:

Primarily competed with other European and Japanese dual-sport motorcycles of the late 1980s, such as certain BMW, Yamaha, Honda, and Suzuki models in the 500cc to 650cc class.

Key Features

Vehicle Strengths:

Robust build, capable off-road suspension, comfortable for longer distances, European styling.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive repair, service, and maintenance procedures for the 1988 Cagiva T4-500 RE.

Page Count

Estimated Page Count:

Not specified, but typically 300-500 pages for a complete factory service manual of this era.

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Digital Format:

PDF/ZIP

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, diagnosis, and repair procedures for the 498cc single-cylinder engine.

Valve Gear:

Valve timing, adjustment, inspection, and replacement of valve components.

Fuel Feed:

Carburetor identification, adjustment, cleaning, rebuilding, fuel pump (if applicable), fuel lines, and tank maintenance.

Lubrication:

Lubrication system components, oil filter, oil change procedures, oil pump, and oil circulation.

Cooling:

Air-cooling system components, inspection, and maintenance.

Ignition:

Ignition system components (CDI, coils, spark plugs), timing, testing, and troubleshooting.

Starter:

Electric starter motor, starter solenoid, battery, and starting system troubleshooting.

Transmission:

Gearbox disassembly, assembly, inspection, shifting mechanism, and clutch service.

Brakes:

Front and rear brake system maintenance, caliper service, master cylinder, brake lines, fluid replacement, and bleeding procedures.

Frame:

Frame inspection, reinforcement points, and related components.

Suspension:

Front forks (telescopic) and rear shock absorber service, including oil changes, seal replacement, and damping adjustments.

Wheels Tires:

Wheel bearing service, spoke adjustment, tire selection, mounting, and balancing.

Electrical Equipment:

Wiring diagrams, lighting system, instrumentation, battery charging system, fuses, and electrical component testing.

Performance:

Basic performance tuning and setup recommendations.

Procedures Included

Maintenance:

Regular servicing, fluid changes, filter replacements, lubrication, and general upkeep.

Troubleshooting:

Diagnostic charts and procedures for identifying and resolving common problems.

Repair:

Detailed step-by-step instructions for component repair and replacement.

Rebuilds:

Complete engine and transmission rebuild procedures.

Adjustment:

Carburetor, ignition timing, clutch, and suspension adjustments.

Technical Depth

Depth:

Comprehensive from basic maintenance to full engine and transmission rebuilds, including electrical system diagnostics.

📊 Manual Specifications

File Format

File Format:

PDF/ZIP (requires unzipping software like WinRAR)

Print Quality

Print Quality:

Digital format, printability depends on user's printer capabilities. Factory manuals typically feature clear line drawings and schematics.

Binding Type

Binding Type:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, air-cooled

Displacement:

498cc (approximate)

Bore X Stroke:

Typically around 92mm x 75.4mm (specific to T4-500 RE, requires manual verification)

Compression Ratio:

Likely in the range of 8.5:1 to 9.5:1 (specific to T4-500 RE, requires manual verification)

Valve Train:

SOHC (Single Overhead Camshaft), 2 valves per cylinder (typical for era)

Performance

Horsepower:

Estimated 30-35 HP at ~6000 RPM (requires manual verification)

Torque:

Estimated 35-40 Nm at ~4500 RPM (requires manual verification)

Fuel System

Carburetor:

Single Mikuni VM34SS or similar (requires manual verification)

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Features

Clutch Type:

Wet, multi-plate

📐 Dimensions

Exterior

Wheelbase:

Approx. 1460 mm (57.5 in) (requires manual verification)

Weights

Dry Weight:

Approx. 150-160 kg (330-350 lbs) (requires manual verification)

Fuel Capacity:

Approx. 18-20 Liters (4.7-5.3 US gal) (requires manual verification)

🛡️ Safety Features

Ratings

Safety Standards:

Compliant with European safety standards of the era.

Active Features

Braking System:

Front: Disc brake, Rear: Drum brake (standard for this model/era, check manual for specific caliper/drum size)

Passive Features

Lighting:

Headlight, tail light, brake light, turn signals.

💡 Technology Features

Infotainment

Infotainment Features:

Not applicable for this era of motorcycle. Focus is on mechanical and electrical function.

Driver Assistance

Assistance Features:

Not applicable. Basic instrumentation includes speedometer, odometer, and indicator lights.

Connectivity

Connectivity Options:

Not applicable.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km (1,800-3,000 miles) or annually. Specific interval in manual.

Valve Adjustment Interval:

Typically every 6,000-10,000 km (3,700-6,200 miles). Specific interval in manual.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 or 20W-50 motorcycle specific oil, API SF or SG rated (refer to manual for precise specification).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for precise specification).

Fork Oil Type:

Suspension fork oil with specific viscosity (e.g., SAE 10W or 15W), quantity specified in manual.

Known Issues

Common Wear Items:

Clutch plates, valve guide seals, fork seals, brake pad wear, and electrical connections due to vibration and age.

Reliability Points:

As with any vintage motorcycle, proper maintenance and attention to detail are key. Carburetor cleaning and ignition system checks are important.

📚 Vehicle History

Brand Heritage

Cagiva History:

Cagiva was an Italian motorcycle manufacturer founded in 1978. Known for producing a range of motorcycles from off-road to sportbikes, often utilizing Italian and sometimes Japanese engines.

Model Evolution

T4 Series Evolution:

The T4 series represented Cagiva's entry into the dual-sport market, with the T4-500 RE being a prominent model for adventure touring and off-road capability.

Production

Production Years:

The T4 series, including the T4-500 RE, was produced through the late 1980s and early 1990s.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

No specific widely publicized awards are readily available for the 1988 Cagiva T4-500 RE, but it was recognized for its adventurous capabilities within its segment.