Cagiva T4-350 R-E T4-500 E 1987 All Service Repair Manual
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The 1987 T4, available in 350 R-E and 500 E sub-models, represents a robust dual-sport motorcycle designed for adventure and versatility. Building on an Italian heritage of performance-oriented bikes, the T4 series offered a balance of off-road durability and on-road comfort, competing effectively within its segment against established Japanese and European counterparts. These models likely featured reliable Rotax engines, with the 350cc variant offering agility and the 500cc providing increased power, both aiming for a blend of torque for trail use and manageable performance for touring. The T4's design emphasized a strong construction suitable for varied terrains, embodying the spirit of exploration for riders in the late 1980s. This comprehensive service and repair manual is tailored for the T4-350 R-E and T4-500 E models. It serves as an essential resource for owners, mechanics, and technicians, covering a wide array of critical systems. Within its pages, you will find detailed procedures for general maintenance, engine service and repair for both 350cc and 500cc Rotax engines, transmission overhauls, brake system servicing, and electrical system diagnostics, including wiring diagrams. The manual also addresses suspension, cooling, fuel systems, steering, and chassis components, providing systematic troubleshooting guidance, repair instructions, and refurbishment advice to ensure optimal performance and longevity of your T4. 🏷️ Basic Information Identification Make: Cagiva Model: T4 Year: 1987 Sub Model: 350 R-E / 500 E Codes Engine Code 350: Likely a Rotax 350cc unit (specific code not provided in product info, but common for the era) Engine Code 500: Likely a Rotax 500cc unit (specific code not provided in product info, but common for the era) 👋 Introduction Market Position Positioning: 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. Competitive Analysis Competitors: Key competitors included the Yamaha XT600, Honda XL600, Suzuki DR600/DR650, and potentially some BMW GS models for riders seeking larger displacement dual-sports. Key Features Design Philosophy: 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. Performance Focus: 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. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for Cagiva T4-350 R-E and T4-500 E models Specific Systems Listed: 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 Page Count Estimated Page Count: Estimated 300-500 pages (typical for comprehensive service manuals of this era, specific count not provided) Manual Type Type: Service Repair Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed service, repair, troubleshooting, and overhaul procedures for both 350cc and 500cc Rotax engines (expected), including disassembly, assembly, tuning, and component testing. Transmission: Service and repair information for the gearbox, clutch operation, and related components. Expected to cover inspection, adjustment, and replacement procedures. Electrical System: Comprehensive coverage including detailed wiring diagrams for all circuits, troubleshooting electrical faults, component testing, and repair of ignition, lighting, charging, and starting systems. Fuel System: 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. Cooling System: Maintenance and repair of the cooling system, likely liquid-cooled, including radiator, water pump, thermostat, hoses, and coolant specifications. Suspension: Detailed procedures for front forks (likely telescopic), rear shock absorbers, swingarm inspection, and adjustment of suspension settings. Includes seal replacement and fluid changes. Brakes: 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. Steering: Information on the steering mechanism, including handlebar and linkage components. Covers inspection, lubrication, and potential adjustments or replacements. Chassis Body: Maintenance and repair of the frame, body panels, fairings, seat, and other chassis components. Includes procedures for removing and installing bodywork. Procedures Included Maintenance: Scheduled maintenance tasks, routine inspections, lubrication points, and replacement of wear items like filters and spark plugs. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common mechanical and electrical problems. Repair Rebuild: Step-by-step instructions for the complete disassembly, repair, and reassembly of all major vehicle components and systems. Refurbishment: Guidance on restoring worn or damaged components to their original operating condition. Technical Depth Depth: Comprehensive, suitable for both experienced mechanics and technically inclined DIY enthusiasts. Covers everything from basic adjustments to complete engine and transmission overhauls. 📊 Manual Specifications File Format Format: PDF Compatibility: Compatible with all Windows and Mac operating systems....
The 1987 T4, available in 350 R-E and 500 E sub-models, represents a robust dual-sport motorcycle designed for adventure and versatility. Building on an Italian heritage of performance-oriented bikes, the T4 series offered a balance of off-road durability and on-road comfort, competing effectively within its segment against established Japanese and European counterparts. These models likely featured reliable Rotax engines, with the 350cc variant offering agility and the 500cc providing increased power, both aiming for a blend of torque for trail use and manageable performance for touring. The T4's design emphasized a strong construction suitable for varied terrains, embodying the spirit of exploration for riders in the late 1980s.
This comprehensive service and repair manual is tailored for the T4-350 R-E and T4-500 E models. It serves as an essential resource for owners, mechanics, and technicians, covering a wide array of critical systems. Within its pages, you will find detailed procedures for general maintenance, engine service and repair for both 350cc and 500cc Rotax engines, transmission overhauls, brake system servicing, and electrical system diagnostics, including wiring diagrams. The manual also addresses suspension, cooling, fuel systems, steering, and chassis components, providing systematic troubleshooting guidance, repair instructions, and refurbishment advice to ensure optimal performance and longevity of your T4.
🏷️ Basic Information
Identification
Make:
Cagiva
Model:
T4
Year:
1987
Sub Model:
350 R-E / 500 E
Codes
Engine Code 350:
Likely a Rotax 350cc unit (specific code not provided in product info, but common for the era)
Engine Code 500:
Likely a Rotax 500cc unit (specific code not provided in product info, but common for the era)
👋 Introduction
Market Position
Positioning:
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.
Competitive Analysis
Competitors:
Key competitors included the Yamaha XT600, Honda XL600, Suzuki DR600/DR650, and potentially some BMW GS models for riders seeking larger displacement dual-sports.
Key Features
Design Philosophy:
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.
Performance Focus:
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.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair for Cagiva T4-350 R-E and T4-500 E models
Estimated 300-500 pages (typical for comprehensive service manuals of this era, specific count not provided)
Manual Type
Type:
Service Repair Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed service, repair, troubleshooting, and overhaul procedures for both 350cc and 500cc Rotax engines (expected), including disassembly, assembly, tuning, and component testing.
Transmission:
Service and repair information for the gearbox, clutch operation, and related components. Expected to cover inspection, adjustment, and replacement procedures.
Electrical System:
Comprehensive coverage including detailed wiring diagrams for all circuits, troubleshooting electrical faults, component testing, and repair of ignition, lighting, charging, and starting systems.
Fuel System:
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.
Cooling System:
Maintenance and repair of the cooling system, likely liquid-cooled, including radiator, water pump, thermostat, hoses, and coolant specifications.
Suspension:
Detailed procedures for front forks (likely telescopic), rear shock absorbers, swingarm inspection, and adjustment of suspension settings. Includes seal replacement and fluid changes.
Brakes:
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.
Steering:
Information on the steering mechanism, including handlebar and linkage components. Covers inspection, lubrication, and potential adjustments or replacements.
Chassis Body:
Maintenance and repair of the frame, body panels, fairings, seat, and other chassis components. Includes procedures for removing and installing bodywork.
Procedures Included
Maintenance:
Scheduled maintenance tasks, routine inspections, lubrication points, and replacement of wear items like filters and spark plugs.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common mechanical and electrical problems.
Repair Rebuild:
Step-by-step instructions for the complete disassembly, repair, and reassembly of all major vehicle components and systems.
Refurbishment:
Guidance on restoring worn or damaged components to their original operating condition.
Technical Depth
Depth:
Comprehensive, suitable for both experienced mechanics and technically inclined DIY enthusiasts. Covers everything from basic adjustments to complete engine and transmission overhauls.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
Compatible with all Windows and Mac operating systems.
Software Requirements:
Requires Adobe PDF Reader and WinZip (or similar extraction utility).
Print Quality
Quality:
Printable (quality depends on user's printer)
Binding Type
Type:
Digital Download (PDF format)
Paper Type
Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Type 350:
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).
Type 500:
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).
Performance
Horsepower 350 Est:
Approximately 25-30 HP (estimated, exact figures vary by specific model and market).
Horsepower 500 Est:
Approximately 35-40 HP (estimated, exact figures vary by specific model and market).
Fuel System
Fuel Delivery 350:
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).
Fuel Delivery 500:
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.
Ignition
System:
CDI (Capacitor Discharge Ignition) - typical for this era of motorcycle.
Cooling
Type:
Air-cooled
🔧 Transmission
Standard
Type:
5-speed constant mesh manual transmission
Optional
Type:
N/A
Features
Clutch:
Wet multi-plate clutch
📐 Dimensions
Exterior
Wheelbase:
Approx. 1450 mm (57.1 inches) - typical for this class of motorcycle.
Weights
Dry Weight 350 Est:
Approx. 145 kg (320 lbs) - estimated.
Dry Weight 500 Est:
Approx. 155 kg (342 lbs) - estimated.
🛡️ Safety Features
Ratings
Certification:
CE, EPA, CARB (depending on market of sale, not explicitly stated in product info but typical for homologation).
Active Features
Brakes:
Front and rear disc brakes, offering good stopping power for the era.
Passive Features
Lighting:
Integrated headlight, taillight, turn signals, and brake light for road legality.
💡 Technology Features
Infotainment
Features:
N/A (This is a 1987 motorcycle; technology focused on basic functionality and reliability).
Driver Assistance
Features:
N/A
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change:
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).
Air Filter Cleaning:
Recommended every 5,000-10,000 km (3,000-6,000 miles) or more frequently in dusty conditions.
Spark Plug Replacement:
Typically every 10,000-15,000 km (6,000-9,000 miles).
Fluid Specifications
Engine Oil Type:
SAE 10W-40 or 20W-50 motorcycle-specific oil, API SG or higher, JASO MA rated (refer to manual for exact specifications).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (non-petroleum based).
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water in a 50/50 ratio (if liquid-cooled).
Known Issues
Carburetor Tuning:
Carburetors can become gummed up or out of adjustment over time, requiring cleaning and synchronization, especially if the bike has been sitting.
Electrical Connections:
Corroded or loose electrical connections can lead to intermittent faults, particularly in older bikes.
Fork Seals:
Leaking fork seals are a common wear item on motorcycles of this age.
Exhaust System:
Rust and corrosion can affect the exhaust system, especially in humid climates.
📚 Vehicle History
Brand Heritage
Heritage:
Cagiva is an Italian motorcycle manufacturer known for its sporty and performance-oriented bikes, often utilizing innovative designs and engines sourced from other manufacturers like Rotax.
Model Evolution
T4 Lineage:
The T4 model line represented Cagiva's entry into the popular dual-sport segment, aiming to provide a versatile machine capable of both off-road adventure and everyday commuting.
Production
Production Period:
The T4 models, including the 1987 variants, were produced in the mid-to-late 1980s.
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Awards:
No specific awards are readily documented for the 1987 Cagiva T4 models, but they were generally well-regarded for their ruggedness and off-road capability in their segment.