Engine Systems:
Disassembly, Overhauling, Re-assembly, Lubrication Circuit
Chassis Systems:
Frame, Suspensions, Wheels, Brakes
Electrical Systems:
Complete Electrical System
Fuel System Coverage:
Carburetor tuning, fuel tank, fuel lines
Ignition System Coverage:
Spark plugs, ignition coils, CDI unit (likely)
Cooling System Coverage:
Radiator, hoses, water pump
Exhaust System Coverage:
Exhaust pipes, mufflers
Wheel And Tire Coverage:
Wheel bearing service, tire pressure recommendations
Suspension Coverage:
Front fork service and adjustments, rear shock absorber service
Brake System Coverage:
Front and rear brake caliper service, master cylinder service, brake fluid replacement
Control Cables Coverage:
Throttle cable, clutch cable adjustment and replacement
Transmission Coverage:
Clutch operation, gear shifting mechanisms, transmission oil changes
Frame Coverage:
Frame inspection, bolt tightening, steering head bearing service
Wheel Coverage:
Wheel assembly, spoke tensioning, wheel bearing replacement
Maintenance Procedures:
General Maintenance, Lubrication Circuit Servicing
Troubleshooting Procedures:
Trouble and Remedies
Adjustment Procedures:
General Adjustments
Repair Procedures:
Engine Rebuilds, Brake System Repair, Suspension Overhaul
Specialized Procedures:
Specific Tool Usage
Engine Rebuild Scope:
Piston, rings, connecting rod, crankshaft, valve timing, seal replacement
Troubleshooting Methodology:
Systematic approach to diagnosing engine, electrical, and mechanical faults
Engine Disassembly Detail:
Step-by-step guide for removing and dismantling engine components.
Engine Overhauling Detail:
Instructions for component inspection, repair, and replacement during overhaul.
Engine Reassembly Detail:
Guidance for correctly reassembling the engine with proper timing and settings.
Diagnostic Capabilities:
In-depth troubleshooting guides for common issues
Rebuild Scope:
Comprehensive engine overhaul instructions
Electrical Diagrams:
Includes detailed wiring diagrams for the electrical system
Torque Settings:
Detailed torque wrench settings for critical fasteners
Tolerances:
Specifications for engine component clearances and tolerances
Special Tools Listing:
Identifies specific tools required for specialized tasks
Wiring Diagrams Detail:
Color-coded diagrams for easy identification of components and circuits
Document Purpose:
To facilitate comprehensive understanding and execution of maintenance and repair tasks.
Engine Type 350:
Likely a 4-stroke, single-cylinder, liquid-cooled engine (typical for Cagiva T4 series)
Engine Type 500:
Likely a 4-stroke, single-cylinder, liquid-cooled engine (typical for Cagiva T4 series)
Bore Stroke 350:
Refer to manual for precise specifications
Bore Stroke 500:
Refer to manual for precise specifications
Horsepower 350:
Refer to manual for precise specifications (estimated 25-30 HP)
Horsepower 500:
Refer to manual for precise specifications (estimated 30-35 HP)
Torque 350:
Refer to manual for precise specifications
Torque 500:
Refer to manual for precise specifications
Fuel Delivery 350:
Likely Carburetor (e.g., Dell'Orto PHBH 30 AS for 350)
Fuel Delivery 500:
Likely Carburetor (e.g., Dell'Orto PHBH 34 AS for 500)
Oil Change Interval:
Refer to manual for specific intervals (typically 3,000-5,000 km)
Engine Oil Type:
Refer to manual for specific viscosity and API classification (e.g., SAE 10W-40, API SG or higher)
Coolant Type:
Refer to manual for specific coolant mixture (e.g., Ethylene Glycol based)
Brake Fluid Type:
Refer to manual for specific DOT rating (e.g., DOT 3 or DOT 4)
Fork Oil Type:
Refer to manual for specific viscosity (e.g., SAE 10W)
Common Wear Parts:
Brake pads, chain and sprockets, fork seals, exhaust system components
Electrical Concerns:
Potential for aging wiring harness and regulator/rectifier issues (common in older bikes)
Carburetor Tuning:
Carburetors may require periodic cleaning and adjustment due to fuel variability.
