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Introduction
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Market Position
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Positioning:
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The Cagiva T4 series of dual-sport motorcycles was positioned as a capable off-road and on-road adventurer, competing with models from brands like Yamaha (XT series), Honda (XL series), and Suzuki (DR series) in the late 1980s.
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Competitive Analysis
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Competitors:
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Key competitors included the Yamaha XT600, Honda XL600, Suzuki DR600/DR650, and potentially some BMW GS models for riders seeking larger displacement dual-sports.
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Key Features
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Design Philosophy:
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Emphasized robust construction for off-road durability combined with sufficient comfort and performance for touring. The T4-E models likely featured electric start, enhancing usability.
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Performance Focus:
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A balance of torque for trail riding and usable power for highway speeds. The 350cc variant offered lighter weight and agility, while the 500cc provided more outright power.
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Manual Details
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Coverage Areas
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Primary Coverage:
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Comprehensive service and repair for Cagiva T4-350 R-E and T4-500 E models
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Specific Systems Listed:
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General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Engine Control System, Chassis/Body, Restraint System, Axle
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Page Count
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Estimated Page Count:
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Estimated 300-500 pages (typical for comprehensive service manuals of this era, specific count not provided)
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Manual Type
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Type:
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Service Repair Manual / Workshop Manual
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Language
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Language:
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English
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Format
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Format:
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PDF Download
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Manual Coverage
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Systems Covered
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Engine:
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Detailed service, repair, troubleshooting, and overhaul procedures for both 350cc and 500cc Rotax engines (expected), including disassembly, assembly, tuning, and component testing.
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Transmission:
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Service and repair information for the gearbox, clutch operation, and related components. Expected to cover inspection, adjustment, and replacement procedures.
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Electrical System:
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Comprehensive coverage including detailed wiring diagrams for all circuits, troubleshooting electrical faults, component testing, and repair of ignition, lighting, charging, and starting systems.
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Fuel System:
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Service and repair of the fuel injection system (likely electronic fuel injection on E models) and/or carburetion (on R models), including fuel pump, injectors/carburetors, fuel lines, and fuel tank maintenance.
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Cooling System:
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Maintenance and repair of the cooling system, likely liquid-cooled, including radiator, water pump, thermostat, hoses, and coolant specifications.
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Suspension:
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Detailed procedures for front forks (likely telescopic), rear shock absorbers, swingarm inspection, and adjustment of suspension settings. Includes seal replacement and fluid changes.
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Brakes:
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Service and repair of both front and rear braking systems, likely disc brakes. Covers brake caliper service, fluid replacement, bleeding procedures, pad inspection, and rotor maintenance.
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Steering:
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Information on the steering mechanism, including handlebar and linkage components. Covers inspection, lubrication, and potential adjustments or replacements.
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Chassis Body:
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Maintenance and repair of the frame, body panels, fairings, seat, and other chassis components. Includes procedures for removing and installing bodywork.
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Procedures Included
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Maintenance:
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Scheduled maintenance tasks, routine inspections, lubrication points, and replacement of wear items like filters and spark plugs.
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Troubleshooting:
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Systematic diagnostic procedures for identifying and resolving common mechanical and electrical problems.
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Repair Rebuild:
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Step-by-step instructions for the complete disassembly, repair, and reassembly of all major vehicle components and systems.
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Refurbishment:
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Guidance on restoring worn or damaged components to their original operating condition.
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Technical Depth
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Depth:
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Comprehensive, suitable for both experienced mechanics and technically inclined DIY enthusiasts. Covers everything from basic adjustments to complete engine and transmission overhauls.
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Engine Specifications
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Primary Engine
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Type 350:
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Likely a single-cylinder, four-stroke, air-cooled Rotax engine (specific configuration like bore/stroke not provided, but based on common Rotax engines of the era).
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Type 500:
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Likely a single-cylinder, four-stroke, air-cooled Rotax engine (specific configuration like bore/stroke not provided, but based on common Rotax engines of the era).
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Performance
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Horsepower 350 Est:
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Approximately 25-30 HP (estimated, exact figures vary by specific model and market).
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Horsepower 500 Est:
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Approximately 35-40 HP (estimated, exact figures vary by specific model and market).
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Fuel System
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Fuel Delivery 350:
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Likely a carburetor (e.g., Dell'Orto PHM series) for the R model, potentially fuel injection for an 'E' variant (though less common on 350cc in this era for dual-sports).
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Fuel Delivery 500:
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Likely a carburetor (e.g., Dell'Orto PHM series) for the R model, and potentially Electronic Fuel Injection (EFI) for the T4-500 E model, as indicated by the 'E' designation.
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Ignition
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System:
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CDI (Capacitor Discharge Ignition) - typical for this era of motorcycle.
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Cooling
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Type:
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Air-cooled
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Maintenance
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Service Intervals
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Oil Change:
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Typically every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first (specific interval dependent on engine type and oil used, consult manual).
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Air Filter Cleaning:
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Recommended every 5,000-10,000 km (3,000-6,000 miles) or more frequently in dusty conditions.
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Spark Plug Replacement:
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Typically every 10,000-15,000 km (6,000-9,000 miles).
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Fluid Specifications
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Engine Oil Type:
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SAE 10W-40 or 20W-50 motorcycle-specific oil, API SG or higher, JASO MA rated (refer to manual for exact specifications).
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Brake Fluid Type:
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DOT 3 or DOT 4 brake fluid (non-petroleum based).
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Coolant Type:
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Ethylene glycol-based antifreeze mixed with distilled water in a 50/50 ratio (if liquid-cooled).
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Known Issues
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Carburetor Tuning:
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Carburetors can become gummed up or out of adjustment over time, requiring cleaning and synchronization, especially if the bike has been sitting.
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Electrical Connections:
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Corroded or loose electrical connections can lead to intermittent faults, particularly in older bikes.
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Fork Seals:
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Leaking fork seals are a common wear item on motorcycles of this age.
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Exhaust System:
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Rust and corrosion can affect the exhaust system, especially in humid climates.
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