🏷️ Basic Information

Make:

Cagiva

Model:

T4-500 RE

Year:

1988

Product Id:

Cagiva_T4-500_RE_1988_FSM

👋 Introduction

Segment:

Dual-sport/Adventure motorcycle

Target Demographic:

Riders seeking off-road capability combined with street usability, often appealing to adventure touring and light trail riding enthusiasts.

Competitors:

Competed with other European and Japanese 500-600cc dual-sport models of the era, such as Yamaha XT500/XT600 variants, Suzuki DR500/DR600, Honda XL500/XL600, and BMW GS models.

Engine Configuration:

Single-cylinder, four-stroke engine, known for its torque and reliability.

Suspension:

Often featured robust suspension components suitable for varied terrain, including upside-down front forks which were becoming more common.

Design Philosophy:

A blend of rugged off-road prowess and practical street manners, characteristic of the adventure bike category's nascent stages.

📋 Manual Details

Primary Coverage:

Factory Service Repair Manual

Target Audience:

Mechanics and DIY persons

Estimated Pages:

Estimated 300-500 pages (typical for a comprehensive factory service manual of this era and complexity)

Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (likely PDF, common for scanned vintage manuals)

📖 Manual Coverage

Engine System:

Complete engine disassembly, assembly, repair, and tuning procedures for the 500cc dual-sport engine.

Transmission System:

Detailed procedures for gearbox removal, inspection, repair, and reassembly, including clutch and shift mechanism.

Chassis And Suspension:

Front fork (upside-down type likely) and rear shock absorber service, swingarm and linkage maintenance, steering head bearing service.

Braking System:

Front and rear brake system maintenance, including caliper overhaul, master cylinder service, brake fluid replacement, and pad/disc inspection.

Electrical System:

Wiring diagrams, lighting system service, ignition system troubleshooting, charging system (stator, regulator/rectifier) checks, starter motor and battery maintenance.

Fuel System:

Carburetor (likely twin Mikuni or Dell'Orto) disassembly, cleaning, adjustment, fuel tank and petcock service, fuel line maintenance.

Cooling System:

Air-cooled engine specific information; no liquid cooling details.

Exhaust System:

Exhaust pipe and muffler removal, inspection for leaks, and gasket replacement.

Bodywork And Trim:

Panel removal and installation, seat, tank, fender, and fairing maintenance.

General Maintenance:

Oil change, filter replacement, chain adjustment, lubrication points, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnostic charts and symptom-based problem-solving guides for common issues.

Disassembly And Assembly:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, and reassembly.

Repair And Rebuild:

Detailed guidance for rebuilding major components like the engine, gearbox, and suspension.

Adjustments:

Carburetor synchronization, ignition timing, valve clearance adjustments, clutch and brake lever adjustments.

Specifications And Measurements:

Torque values, clearances, tolerances, and fluid capacities essential for accurate repair.

Depth:

Comprehensive, covering from basic checks to complete engine and chassis overhauls.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format) is the most probable format for this vintage manual, offering searchability and easy distribution.

Quality:

Varies based on the source scan; ideally high-resolution scans of original pages for clarity of diagrams and text.

Binding:

N/A (Digital Format). If printed, would typically be spiral-bound or comb-bound for lay-flat usability.

Paper Quality:

N/A (Digital Format). Original manuals typically used durable paper stock suitable for workshop environments.

⚙️ Engine Specifications

Type:

Air-cooled, four-stroke, single-cylinder

Displacement:

Approximately 478cc (exact figure may vary slightly by specific variant but generally referred to as 500cc class)

Bore X Stroke:

Typical for the era: e.g., 84 mm x 86 mm (specifics would be in the manual)

Compression Ratio:

Likely around 9.0:1 to 9.5:1 (specifics in manual)

Horsepower:

Estimated 35-40 HP at 6,500-7,000 RPM (specific dyno figures would be in the manual)

Torque:

Estimated 30-35 lb-ft at 5,000-5,500 RPM (specific figures in manual)

Carburetion:

Twin Carburetors (likely Mikuni VM34 or Dell'Orto PHM 38/40 type, specific model in manual)

Fuel Type:

Unleaded gasoline, minimum octane rating 90 RON (equivalent to 87 AKI)

Oil Type:

SAE 20W-40 or 10W-40 motorcycle-specific engine oil (API SG or higher recommended)

Type:

CDI (Capacitor Discharge Ignition) with dual spark plugs per cylinder (common for improved combustion)

🔧 Transmission

Type:

5-speed constant mesh gearbox

Drive System:

Chain drive

Clutch Type:

Wet, multi-plate, cable-actuated

Gear Ratios:

Specific gear ratios for each of the 5 speeds would be detailed in the manual.

Transmission Oil Type:

Motorcycle-specific gear oil, likely SAE 80W-90 GL-4 (refer to manual for precise specification and capacity)

📐 Dimensions

Wheelbase:

Approximately 1450-1500 mm (dependent on specific model variant, to be confirmed in manual)

Seat Height:

Approximately 860-890 mm (typical for dual-sport, adjustable via suspension tuning)

Dry Weight:

Around 160-175 kg (specifications vary, consult manual for exact figure)

Fuel Tank Capacity:

Typically 17-20 liters (including reserve, as per dual-sport design)

Front Wheel Size:

21-inch (common for off-road capability)

Rear Wheel Size:

17-inch or 18-inch (17-inch more common for street bias, 18-inch for off-road bias, consult manual)

Front Tire Size:

Typically 90/90-21 or similar

Rear Tire Size:

Typically 120/80-17 or 130/80-17 or similar for 17-inch rear wheel

🛡️ Safety Features

Crash Safety:

Motorcycle safety ratings were not standardized as they are for cars. Focus is on rider control and mechanical integrity.

Braking System:

Dual hydraulic disc brakes (front and rear) for effective stopping power. ABS was not available on this model.

Lighting:

Halogen headlight, taillight, brake light, and turn signals for visibility.

Chassis Strength:

Robust frame construction designed to withstand off-road stress.

Handguards:

Often equipped with handguards for protection against roost and weather.

💡 Technology Features

Features:

Basic technology focused on functionality. No advanced infotainment systems typical of modern motorcycles.

Features:

No electronic rider aids such as ABS, traction control, or riding modes were available on this model.

Features:

N/A

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 km or annually, whichever comes first (refer to manual for precise recommendation based on usage).

Air Filter Cleaning:

Every 3,000 km, or more frequently in dusty conditions. Replacement as needed.

Spark Plug Replacement:

Every 6,000-10,000 km, depending on plug type. Check and clean more frequently.

Valve Clearance Check:

Every 6,000-12,000 km (critical for performance and engine longevity). This procedure will be detailed in the manual.

Engine Oil:

SAE 20W-40 or 10W-40 motorcycle-specific (API SG or higher)

Transmission Oil:

SAE 80W-90 GL-4 (motorcycle gear oil, refer to manual)

Brake Fluid:

DOT 4 hydraulic brake fluid (DOT 3 acceptable if specified, but DOT 4 is preferred for higher boiling point)

Fork Oil:

Specific viscosity (e.g., SAE 10W or 15W) and quantity per fork leg detailed in manual.

Electrical Gremlins:

Older Italian bikes can sometimes have minor electrical connection issues. Regular inspection and dielectric grease application can help.

Carburetor Tuning:

Carburetors may require periodic cleaning and synchronization, especially if the bike has sat for extended periods. Manual provides essential tuning guidance.

Suspension Wear:

Fork seals and rear shock bushings can wear over time. The manual covers their inspection and replacement.

📚 Vehicle History

Cagiva Legacy:

Cagiva, an Italian manufacturer founded in 1978, quickly established itself with strong performance and distinctive styling, often utilizing Italian design flair and sometimes borrowing components from other manufacturers (like Ducati engines in earlier models).

T4 Series:

The T4 series represented Cagiva's foray into the dual-sport market. The T4-500 RE was a significant model, building on previous Cagiva off-road platforms and aiming for a balance of adventure touring and off-road capability. It followed in the footsteps of models like the Cagiva Elefant, but with a more accessible 500cc displacement.

Production Years:

The T4-500 RE was primarily produced in the late 1980s and early 1990s. The 1988 model year signifies a key point in its production run.

Manufacturing Location:

Varese, Italy

🏆 Awards & Recognition

Industry Awards:

Specific industry awards for the 1988 Cagiva T4-500 RE are not widely documented, but Cagiva models of this era were generally well-regarded for their performance and distinctive styling in the dual-sport segment.

Review Scores:

Contemporary motorcycle reviews from 1988 would highlight its off-road capabilities, robust engine, and Italian flair. Consult historical motorcycle magazines for specific performance assessments.

Emissions:

Emissions standards for motorcycles in 1988 were less stringent than today. The manual would cover any specific adjustments or checks related to emissions control systems if present.