Cannondale E440, C440, X440, 2002 E440, 2002 C440 Owner's Manual

...

P/N 951 - 5002274

Before you operate the vehicle. . . .

• READ and UNDERSTAND this manual. It contains information important to your safety.

• Familiarize yourself with all vehicle controls and their proper operation.

• Perform the Pre-Ride Inspection found in this manual.

• Wear appropriate protective gear - approved full faced helmet, eye protection, gloves, boots, long-sleeve shirt, and pants. Consider specially designed protective off-road vehicle riding apparel.

• Safety

• Operation

• Maintenance

2002 MOTORCYCLE OWNER’S MANUAL (E440, C440, X440)

Safety Alerts.fm

SAFETY ALERTS

• FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

• Keep this manual in a safe place.

WHAT IS THE SAFETY ALERT SYMBOL ?

• Pay special attention to all messages preceded by the Safety Alert Symbol. It means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.

CAUTION

Indicates a potential hazard that could result in vehicle damage if instructions are not followed.

NOTE :

Provides helpful info rmat ion intended to make maintenance easier or the instructions presented clearer.

Indicates that severe personal injury or death WILL result if instructions are not followed.

Indicates a potential hazard that COULD result in serious injury or death.

DANGER

WARNING

Printed : 1/9/02

GENERAL PRECAUTIONS

YOU must always exercise good judgement when assessing your abilities to perform the work described in this manual.

• Make sure you are familiar with basic safety practices before performing any work on the vehicle.

• Always work in a well-ventilated area. Car bon monoxide gas (a by-product of combustion engines) is poisonous; you can be seriously injured or even killed if you breathe it.

• Do not service the vehicle with the engine running unless otherwise stated in a procedure.

• You can be seriously injured by moving parts. Always keep your hands, fingers, and clothing away from moving parts.

• Avoid hot components (e.g., engine, exhaust system, coolant system, brake discs , etc.); they can burn you. Allow all components to cool completely before touching or handling them.

• Always place the vehicle on a level surface or proper stand when performing any work to help eliminate the chance of the vehicle rolling away or becoming unstable while you work.

• Make sure you have the skills and tools necessary before performing any procedure.

• Make sure you are wearing the appropriate protective clothing when servicing the vehicle (e.g., safety gla sses or a face shield, protect ive gloves.

DANGER

POTENTIAL HAZARD

Running the engine indoors. Breathing exhaust gases

WHAT CAN HAPPEN

Running the engine indoors will expose you to dangerous exhaust gases. Breathing carbon monoxide gas leads to poisoning, asphyxiation, and death. This will happen rapidly and without notice.

HOW TO AVOID THE HAZARD

Never operate the vehicle indoors even for brief periods of time.

POTENTIAL HAZARD

Hot components (e.g., engine, radiator, hoses, bulbs, exhaust, brakes)

WHAT CAN HAPPEN

The engine and other vehicle systems operate at extremely high temperatures. Contact can produce severe burns.

HOW TO AVOID THE HAZARD

Wait for the engine and vehicle systems to cool completely before starting any work. If the engine must be running, work carefully and avoid hot surfaces.

Safety Alerts.fm

POTENTIAL HAZARD

Improper care when handling fuel.

WHAT CAN HAPPEN

Fuel is highly flammable, spilling it can cause a fire or explosion.

HOW TO AVOID THE HAZARD

Be sure the fuel cap is closed securely. Work in a well-ventilated area which is free of sources that could ignite any spilled fuel accidentally (e.g. cigarettes, welders, torches, grinders, electric shop tools, etc.)

POTENTIAL HAZARD

Blindness, eye injury

WHAT CAN HAPPEN

Anytime you work on the vehicle there is a potential that an accident involving a foreign object, vehicle component part, fluid, tool, or other maintenance related item can result in severe injury to your eyes. For example, when cleaning the oil filters, objects propelled by compressed air can strike your eyes and cause serious injury or blindness.

HOW TO AVOID THE HAZARD

Always wear safety glasses when working on the vehicle.

POTENTIAL HAZARD

Losing a finger , h and or limb or entanglement

WHAT CAN HAPPEN

Moving parts can catch your clothing, fingers or hand resulting in severe injury.

HOW TO AVOID THE HAZARD

Never perform maintenance procedures with the engine running unless directed otherwise in a procedure.

POTENTIAL HAZARD

Vehicle fluids (e.g., engine oil, transmission oil, brake fluid, coolant)

WHAT CAN HAPPEN

The fluids in your vehic le are hazar dous subs tances . Contact with your skin or eyes you can result in serious injury or irritation. If swallowe d, death can result

HOW TO AVOID THE HAZARD

Wear hand protection and safety glasses when working with vehic le fluid s. If you touch a fluid, wash it off immediately with soap and water. Clean clothes or rags contaminated with engine oil. If swallowed seek immediate medical attention.

KEEP ALL VEHICLE FLUIDS AWAY FROM CHILDREN AND ANIMALS.

Printed : 1/9/02

CONTENTS

SAFETY ALERTS . . . . . . . . . . . . . . . . . 2

CONTENTS . . . . . . . . . . . . . . . . . . . . . . 5

IMPORTANT INFORMATION . . . . . . . . 6

About this manual . . . . . . . . . . . . . . . . . . . . . . . 6

How to use this manual. . . . . . . . . . . . . . . . . . . 6

Experienced riders only. . . . . . . . . . . . . . . . . . . 7

Exercise good judgement . . . . . . . . . . . . . . . . . 7

Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

No passengers . . . . . . . . . . . . . . . . . . . . . . . . . 7

Aluminum chassis components. . . . . . . . . . . . . 8

VEHICLE LABELING . . . . . . . . . . . . . 10

MACHINE IDENTIFICATION. . . . . . . . 12

Vehicle Identification Number (VIN) . . . . . . . . 12

Engine Serial Number. . . . . . . . . . . . . . . . . . . 12

PARTS & CONTROLS . . . . . . . . . . . . 13

Engine start button . . . . . . . . . . . . . . . . . . . . . 13

Engine stop button . . . . . . . . . . . . . . . . . . . . . 13

Lighting switch. . . . . . . . . . . . . . . . . . . . . . . . . 14

Headlight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Optional lighting . . . . . . . . . . . . . . . . . . . . . . . 16

Multi-function ride computer . . . . . . . . . . . . . . 17

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Throttle grip. . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Front brake lever . . . . . . . . . . . . . . . . . . . . . . . 19

Footpegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Rear brake pedal. . . . . . . . . . . . . . . . . . . . . . . 20

Side stand or kickstand. . . . . . . . . . . . . . . . . . 21

Handguards. . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Fuel cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . 24

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Front brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Transmission oil . . . . . . . . . . . . . . . . . . . . . . . 34

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Hydraulic clutch oil . . . . . . . . . . . . . . . . . . . . . 39

PRE-RIDE INSPECTION. . . . . . . . . . . 41

Pre-ride checklist. . . . . . . . . . . . . . . . . . . . . . . 41

OPERATION . . . . . . . . . . . . . . . . . . . . 42

Cold starting . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Starting a warm engine . . . . . . . . . . . . . . . . . .42

Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Shifting gears . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Post ride checks. . . . . . . . . . . . . . . . . . . . . . . .43

Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

MAINTENANCE SCHEDULE. . . . . . . 45

Maintenance record. . . . . . . . . . . . . . . . . . . . .47

MAINTENANCE & ADJUSTMENT . . 48

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Engine Management System. . . . . . . . . . . . . .66

Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Making Damping adjustments . . . . . . . . . . . . . 78

Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Wheel bearing inspection . . . . . . . . . . . . . .90

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Torque table. . . . . . . . . . . . . . . . . . . . . . . . . . .98

2002 MODEL SPECIFICATIONS. . . . 99

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Important Information.fm

IMPORTANT INFORMATION

ABOUT THIS MANUAL

The purpose of this manual is to provide the owner with important safety, service, maintenance, and tuning information , and shou ld be thor ou ghl y read before operating or working on the vehicle.

This manual is divided into sections which contain easy-to-follow procedures which are reasonably straight-forward. Anyone with the mechanical ability and the proper tools should be able to perform them. Each procedure is ac c ompanied by illustrations and photos to aid in proper vehicle operation, basic maintenance, tuning, etc.

• Read and understand the entire procedure

before performing any work. If you are unfamiliar with or doubt your own abilities to complete a procedure as des cribed, have an authorized Cannondale Motorsports Dealer service your vehicle.

Please keep your Owner's Manual in a safe and convenient place, and consider it an integral part of your vehicle.

For detailed servici ng info rmati on re fer to the Service Manual for your vehicle or contact an authorized Cannondale Motorsports Dealer for a list of available publications. If this manual is lost or damaged, contact an authorized Cannondale Motorsports Dealer for a replacement.

HOW TO USE THIS MANUAL

• This manual is broken down in headings, numbered steps [which may contain WARNING(S), CAUTION(S), and/or NOTE(S)], and illustrations or line art.

• Headings and numbered steps should be followed in the order in which they are presented. The explanations given in the numbered steps are intended t o be used as a guide for a technician needing additional information.

• Illustrations and line art are used to identify parts of the vehicle included in the procedure to eliminate any possible confusion and to support the numbered steps.

LIMITATIONS

All information, illustrations, and specifications in this manual are based on the latest product information available at the time of publication. Cannondale Corporation reserves the right to make changes at any time, without notice.

This vehicle has U.S. and International patents pending.

Printed : 1/9/02

EXPERIENCED RIDERS ONLY

• This vehicle is not for beginners.

All Cannondale motorspor ts products are designed for use by trained and experienced riders only . A ll are very hi gh perf ormance , compe tition sp ort machines and sh oul d o nly be operated by licens ed competition riders in excellent physical condition, who are well-trained and experienced in the operation of high performance competition vehicles.

EXERCISE GOOD JUDGEMENT

There is always a ri sk i nvolved when riding a vehicle; however, making sure you and the vehicle are in the best condition pos s ible will en sure a great riding experience. Use sound judgement when riding.

Never ride under the influence of alcohol, medication, or drugs. Doing so will greatly reduce your ability to properly operate this vehicle and could lead to an accident, injury, and/or death. If you are taking medications prescribed by your doctor, consult him/her before ridin g.

MODIFICATIONS

We recommend that you do not substitute parts, change or modify your vehicle. Such changes could seriously impair your vehicle’s handling, stability , and braking, making it unsafe to ride and causing serious injury and/or vehicle damage.

NO PASSENGERS

Do not overload this vehicle or carry passengers. Doing so could seriously impair your vehicle’s handling, stability, and braking, making it unsafe to ride which could result in damage to the vehicle or serious injury or death to the operator and/or passenger.

Important Information.fm

ALUMINUM CHASSIS COMPONENTS

The aluminum chassis components of your vehicle have a finite, limited useful life. The length of that life varies depending on the material used in their manufacture, the amount of use they are subjected to and the care they receive while in service. Regular inspection by a Cannondale Motorsp or ts Deal er i s important.

• Frame - a main support structure for the

engine, various components, and rider.

• Subframe - adds structural support.

• Swingarm - a suspension component

Use in competitive events, hard and aggressive riding, riding on severe terrain, ridi ng in sev er e climates and riding fast can dramatically shorten the life of the aluminum (frame) components. Any one and/or a combination of th ese conditions may result in an unpredictable failure.

We recommend that you carefully inspect your vehicle’s chassis components for crac king, bending, deep scratches and/or other damage before e very ride.

If you have crashed or rolled your vehicle, there could be damage hidden from your view. DO NOT ride a vehicle with any crack, even a small one. It must be carefully inspected by an authorized Cannondale Motorsports Dealer before it is used again.

Riding a cracked frame could lead to complete frame failure. If you have any questions contact your Cannondale dealer or call 1-800-MOTO-USA.

Inspect the frame (1), lower frame rails (2) and subframe (3) for cracks, deep scratches, or other damage. If any damage is found, contact an authorized Cannondal e Motor s por ts Dea le r for servicing.

NOTE :

The frame and subframe ar e shown removed from the vehicle for clarity.

Inspect the swi ngarm for cracks, deep scratches, or other damage.

Inspect the weldments (individual welded components comprising the total swingarm) and fastener fixtures for any sign of cracking or damage.

Place the vehicle on a stand with the rear wheel suspended. The swingarm should move freely up and down with no play side to side.

POTENTIAL HAZARD(S)

(1) Operating with a bent, corroded/rusted, cracked, dented, or damaged fra me, subframe, swingarm or other aluminum component. (2) Attempting to repair the frame, subframe, or swingarm on this vehicle.

WHAT CAN HAPPEN

(1) Riding on a damaged frame can lead to a complete frame failure. (2) Aluminum frame (and components) are heat treated. Welding, drilling, or modifying the frame, subframe, or swingarm may weaken the component and result in complete failure leading to a serious accident with subsequent injury or death.

HOW TO AVOID THE HAZARD

(1 & 2) Contact an authorized Cannondale motorsports dealer for servicing if either the frame, subframe, or swingarm is damaged; never try to repair the frame, subframe, swingarm, or other components.

1. Frame

2. Lower frame rails

3. Subframe

(2)

(1)

(3)

Printed : 1/9/02

If any damage to the sw ina rm is de tec ted , take corrective action before riding. Contact an authorized Cannondale motorsports dealer for servicing.

NOTE :

The swingarm is shown removed from the vehicle for clarity.

1. Swingarm

(1)

Motorcycle Vehicle Labeling.fm

VEHICLE LABELING

Read and understand the labels on your vehicle. Examples of the labels can be found in this section. Warning labels contain information which is important to your safety and that of anyone else who operates the vehicle. Other lab el s provide important information.

• The labels should be considered permanent

parts of the vehicle.

• If any label is missing, worn, damaged, or

becomes unreadable, replace it. Cannondale offers replacement labels at no charge. A label’s part number is printed in the lower right corner of the label and here in the manual. Contact an authorized Cannondale Motorsports Dealer for replacements.

• Label locations are shown in the following

illustration. Always replace labels in the correct position.

• Examples of the labels are shown on the

following pages. See the illustration for the correct location of the warning labels on your vehicle.

Label 1 P/N 315-5000266-01

(1)

(5,6)

(2)

(3)

(4)

Printed : 1/9/02

Label 2 P/N 315-5001262-01

Label 3

Label 4

Label 5

Label 6 P/N 315-6000477-01

Motorcycle Machine Identification.fm

MACHINE IDENTIFICATION

NOTE :

Your vehicle may differ from those shown in the illustrations in this manual.

Record your vehicle’s identification numbers in the spaces pro vided. Keep another record of the numbers in a safe place; you may n eed them for parts, service information, or theft recovery.

Your vehicle’s ID numbers identify it from others of the same model type.

VEHICLE IDENTIFICATION NUMBER (VIN)

The vehicle identification number (VIN) is locate d on the left side of the steering head.

ENGINE SERIAL NUMBE R

The engine serial number is etc hed /st amped into the rear area of the engine cran kcas e. Th e numb er also appears on a metallic pla te affixed to the crankcase area above the countershaft sprocket. The number also appears on a te mpo ra r y fact ory applied adhesive label in the same area.

1. Etched vehicle i dentification numbe r

Write your number here

XXXXXXXXXXXX

1. Engine se rial number

Write your number here

XXXXXXXXXXXX

XXXXXX

Printed : 1/9/02

PARTS & CONTROLS

This section des c ri bes the parts and control functions found on your vehicle. Not all the items found in this section may be installed on your vehicle.

If you have any questions about the parts, control functions, or components installed on your vehicle, consult your Cannondale Motorsports Dealer.

ENGINE START BUTTON

The engine start button is l oc ated on the ri ght handlebar and is ( GREEN) in color.

Before attempting to start the engine, press it for 1 second to activate the eng ine ma nage men t system circuits. Then, press and hold it to activate the starter motor. But, be sure to read the Operation section of this manual for a detailed explanation of the best starting procedure.

NOTE :

When pressing the button to operate the starter, motor hold it for no more than 2-3 seconds at a time.

ENGINE STOP BUTTON

The engine stop button is located on the left

handlebar. The button is (RED) in color.

Pressing it will shut of f a running e ngine. Or, press it to deactivate the engine manage men t system circuits.

Make sure this button operates properly be for e starting out.

To test it, start the engine then press and hold the button. When pressed the engine should stop running.

NOTE :

The stop button is normally a closed circuit switch. If the stop switch is damaged o r the wires are frayed or torn, (circuit open) the engine may not start.

1. Engine start button

(1)

1. Engine stop button

(1)

Motorcycle Parts and Controls.fm

LIGHTING SWITCH

The lighting switch is used to activate the headlight and taillight together. It is located on the ride computer mounting bracket in front of the handlebar.

The taillight should turn on with the headlight in either the HI or LO switch position. Be sure the lighting operates pr op er ly before starting out.

NOTE :

The lights on your motorcycle are powered throug h the engine management system relay. This relay supplies voltage as long as the ECU tells it to. The ECU itself has a 2 minute timer which will shut o ff itself and the relay. If those two things are o ff, so is the lighting, even if the switch is in either the HI or LO position.

To turn the engine management system on, press the engine START button quickly (1 second) without holding to turn over the engine).

To test the headlight/taillight, quickly (1 second) press the engine START button to activate the engine management system. Toggle the switch positions and observe that the headlight/taillight are functioning properly. The HI and LOW intensity lamps of the headlight should operate and the taillight should remain lighted in both posi tions. If the headlight or taillight does not work properly, check the fuse and bulb. If the fuse or bulb is blown, correct the problem before riding .

Select HI or LO intensity before moving off to ride. Do not remove your hands from the handlebar to toggle the switch while the vehicle is moving. You could lose control and have an accident.

NOTE :

Switch the lights off before attempting to star t the engine.

Return the switch to the center position when the lighting is not requ ir ed .

1. Headlight/ Taillight switch

Printed : 1/9/02

HEADLIGHT

The headlight is located at the front of the vehicle and is activated with the headlight/ taillight switch. The highlight can be switch to HI or LO intensity with the headlight switch. Be sure the headlight is fastened securely with the mounting straps and operating properly (HI and LO inten sit y) befo re starting out.

Details on bulb replacement can be found in the Maintenance and Adjustment section of this manual.

TAILLIGHT

The taillight with the headlight/tai llight switch. It should light in both the HI or LO switch position. It is NOT a braking ligh t!

Make sure it is operating properly before starting out.

NOTE :

Remember that the lighting circuits are energized through the engine management system power relay. This relay is controlled by the ECU. The ECU will shut down the system automatically after 2 minutes if the engine is not started or the START button has not been pressed. In short, the lights can be turned on as long as the engine management system is activated.

The taillight should be activated in both switch positions (HI and LO). If it does not light, check to see if a fuse or bulb replacement is needed. Correct the problem before riding.

Details on bulb replacement can be found in the Maintenance and Adjustment section of this manual.

1. Headlight

2. Mounting straps (left fork)

3. Headlight/Taillight switch

1. Taillight

Motorcycle Parts and Controls.fm

FUSES

The fuses for your vehicle are located inside fuse

holders under the seat.

Unless directed otherwise in a procedure, you should always remove the fuses before working on the vehicle.

Fuse replacement is described in the Maintenance and Adjustment section of this manual.

SERVICE: Main fuse rating

10 A

SERVICE: Lighting fuse rating

10 A

When a fuse blows repeatedl y, it usually indicates a short circuit or current overload in the electrical system. The problem could be inte r mit tent or constant. In either case, don’t ride the vehi cl e because an electrical fire could lead to a serious accident. If you experience frequent fuse “blows,” have the vehicle inspected by an authorized Cannondale dealer.

OPTIONAL LIGHTIN G

If you have an C440 or X440 model, you may choose to install the available lighting systems. The connection for optional lighting is located under the seat near the main fuse and engine management system relay. This connector is NOT protected by a fuse, so do not improvise; contact your Cannondale Motorsports dealer to in stall the optional li ghting system.

1. Main fuse

2. Lighting fuse

3. EMS power relay

POTENTIAL HAZARD

Using an unspecified fuse or shorting the fuse holder.

WHAT CAN HAPPEN

Using a fuse with a rating other than specified or using other materials in place of the fuse will cause damage to the system. A malfunctioning electrical system increases the risk that you may be seriously injured or killed while operating the vehicle. For example, an electrical fire can develop from a system overload or you could lose vehic le light ing.

HOW TO AVOID THE HAZARD

Always use a replacement fuse of the specified rating. Never use other materials in place of the fuse. If a fuse blows immediately after replacement have the electrical circuits checked by an authorized Cannondale Motorsports Dealer. Check the condition of the wiring harness and connectors before replacing a blown fuse. Make sure the lighting is switched off when replacing a fuse.

1. Optional lighting tap (non-fused)

2. Main fuse

3. Engine Management System power relay

Printed : 1/9/02

MULTI-FUNCTION RIDE COMPUTER

The multi-function ride computer is located

between the handlebars.

Consult the manufacture r’s instruction manual included with this manual for th e unit fea ture s and operating instructions .

Never remove your hands from the handlebar when riding the vehicle; you can lose control and have a serious accident. Always stop the vehicle on level ground before operating (programming/setting) the computer.

CLUTCH LEVER

The clutch lever is located on the left side of the

handlebar.

Pull in the clutch lever (quickly) to disengage the clutch, and release the lever (slowly) to engage the clutch.

The lever position can be adjusted for individual hand sizes. To adjust it, see the Maintenance and Adjustment section of this manual.

SHIFT LEVE R

The shift lever is located on the left side of the engine just in front of the left footpeg.

The transmission has five gears, “one down, four up.” Neutral is located between first and sec ond gears.

1. Multi-function ride computer

1. Manual

1. Clutch lever

2. Clutch reservoir

3. Lever position adjuster

1. Shift lever

(1)

Motorcycle Parts and Controls.fm

THROTTLE GRIP

SERVICE: Throttle lever freeplay

1/8 - 5/16 in (3 - 8 mm)

The throttle lever is located on the right han dle bar and controls acceleration and deceleration of the engine.

Before every ride make sure the specified freeplay is available at the grip. Fre epl ay is the distance the grip rotates before al l cab le slac k is tak en up. See the illustration bel ow. Adjustment of the freepl ay is described in the Maintenance and Adju stment section of this m anual.

To accelerate, turn the lever towards you. To decelerate, turn the grip away from yo u.

Make sure the throttle lever oper ate s properl y before you ride. It should operate freely (e.g., without binding, dragging, or sticking) and return to the closed position automatically in all steering positions.

1. Throttle grip a. Freeplay b. Open throttle (accelerate) c. Close throttle (decelerate)

(b)

(c)

(1)

(a)

POTENTIAL HAZARD(S)

(1) Stuck or damaged throttle (2) Incorrect freeplay

WHAT CAN HAPPEN

(1) The throttle must return to the closed position automatically when you release it. If it sticks you can lose the ability to accelerate and decelerate the engine which could result in an accident where you could be seriously injured or ki lled . (2) The throttle freeplay must be maintained as specified, otherwise the engine speed could increase when the handlebars are turned or when the throttle is slightly grasped. Either situa tion c oul d result in an unexpected acceleration of the engine where you could be seriously injured or killed.

HOW TO AVOID THE HAZARD

(1) T es t th e o p e ration of the throttle before e ach ride. Make sure it operates smoothly (with no sticking or binding) in all steering positions. It should return automatically to the closed position when released. (2) Make sure the throttle freeplay is adjusted as specified. (1 & 2) If the throttle malfunctions or you can not adjust the throttle to the specified freeplay, do not ride the vehicle. Contact an authorized Cannondale Motorsports Dealer for servicing.

Printed : 1/9/02

FRONT BRAKE LEVER

The front brake lever is l oc ated on the ri ght

handlebar.

Pull the lever against the handle grip to activate

the front brake.

Always make sure the brakes (front and rear) on

your vehicle operate properly before riding.

Make sure the lever has the specified freeplay. Measure the freeplay at the tip of the lever. See the illustration. Adjustment of the freeplay is described in the Maintenance and Adjustment section of this manual.

The position of the brake lever can be adjusted so that control is comfortable when seated and standing. Adjustment of the lever position is described in the Maintenance and Adjustment section of this manual.

SERVICE: Brake, lever, front, freeplay,

maximum

0.8 inches (20 mm)

1. To measure the freeplay, gently pull in the brake lever until the play is taken up, then measure distance (a) at the end of the brake

lever. Adjust if out of specification.

1. Front brake lever

2. Freeplay

(a)

(1)

Motorcycle Parts and Controls.fm

FOOTPEGS

The right and left footpegs on your vehicle should be fastened securely and free of any collected mud or dirt. The footpegs should move freely (up and down on the pivot) and not bind - springing back when released.

After cleaning the vehicle, always lubricate the footpeg pivot points with some clean engine oil. Move the pegs up and down to work the lubricate in. Don’t use grease; grease will catch and col lect di rt and small particles which will damage the pivot point. Make sure the teeth are in good condition.

REAR BRAKE PED AL

The rear brake pedal is located on the right side of

the vehicle.

Press it firmly with your foot to apply th e rear brake. Test to make sure it is operating correctly before you ride. When pressed, braking force should be applied to the rear brake disc . Braki ng force wil l increase the mor e yo u press down on the pedal.

The rear brake pedal height can be ad ju st ed fo r comfort. To adjust it, see the Maintenance and Adjustment section of this manual.

After cleaning the vehicle, be sure to lubricate the pedal pivot point with clean engine oil. It is not necessary to remove the bolt, simply apply a few drops of oil to the bolt and work the pedal up and down.

1. Left footpeg

2. Pivot

3. Spring

4. Teeth

1. Right footpeg

footpegs

1. Rear brake pedal

2. Pivot a. Pedal height

Printed : 1/9/02

SIDE STAND OR KICKSTA N D

The side stand or kickstand (on equipped vehicles) can be used to support the ve hic le on firm level ground when not in use (wi th engine off). It is only designed to support the weight of the vehicle; so do not apply extra weight when using it (e.g., leaning on the bike or sitting on it with the stand or kickstand in place).

The kickstand is mounted on the left side of the motorcycle.

CAUTION

Turn the handlebars to the left side of the vehicle when using the kickstand. Stability of the motorcycle is greater with the wheel pointing to the left; risk of toppling is increase with the handlebars turned to the right.

To use the side stand (triangle shaped and removable from the vehicle), position the vehicle on firm level ground. Hold the vehicle upri ght and ins ert the side stand completely into the hole in the rear axle shaft on the right side of the vehicle. Tilt the vehicle toward the stand allowing the weight of the

vehicle to rest on the stand. Make sure there is no danger of the vehicle falling over before leaving the vehicle unattended.

The kickstand is located on th e l eft side of the vehicle behind the le ft fo otpe g. It is de si gned to support only the weight of the vehicle when it is not in use (with the engine off).

To use the ki c k stand, pos ition the veh ic le on firm level ground. Fold the kickstand down and rest the weight of the motorcycle on it. Turn the handlebars, to the left (toward the k ickstand) side of the motorcycle; this shifts more of the weight toward the stand reducing the potential of the vehicle to tip on its right side if bumped. However, the kickstand

Make sure the kickstand is folded up as far as possible and is firmly attached (not wobbling) on the mount before every ride.

After cleaning the vehicle, apply some cle an engine oil to the pivot point and work the stand up and down to work in the oil.

POTENTIAL HAZARD(S)

(1) Sitting or leaning on the vehicle (2) Riding with the side stand attached, the kick stand down, or not fully upright. (3) Working on the vehicle with the side stand or kickstand.

WHAT CAN HAPPEN

(1) The side stand and kickstand are designed to support only the weight of the vehicle. If you sit or lean on the vehicle, the additional weight could cause the vehicle to fall over. (2) The stand can cause you to lose control of the vehicle. (3) The motorcycle can fall onto you.

In any of the cases above, you can be serious injured or killed.

HOW TO AVOID THE HAZARD

(1) Never sit or lean on a vehicle. (2) Remove th e side stand ; lift the kick stand before riding. (3) Always place th e vehicle on a work stand when performing maintenace. Ask your Cannondale Motorsports Dealer about motorc y cle work stands.

1. Side stand

1. Kickstand (shown supporting weight of the vehicle )

Kick stand down

Motorcycle Parts and Controls.fm

HANDGUARDS

The handguards are located on the ri ght and lef t sides of the handlebar directly in front of the handle grips.

These guards are designed to only offer limited hand protection. Make sure you read the warning following a description of the guards.

Make sure the han dgu ar ds ar e in good co ndi tio n and fastened securely before riding. The handguards should not interfere with operation of the vehicle

controls. Tighten the mounting harware securely.

This photo shows the ki ck s tand in the operatin g position. See a close-up of the area indicated in the next photo.

The image on the left shows a kickstand that is in the correct operating position. Notice that there is no gap (1) present between the kickstand leg and the plate. The image on the right shows a kickstand in the up position but “hanging.” Notice that gap between the leg and the plate. The kickstand may be dam age d (e.g., bad spring, bent leg or plate). This condition must be corrected before riding th e vehicle.

YES

1. Type 1 handguard (left side)

2. Type 1 handguard (right side)

1. Type 2 handguard (left side)

2. Type 2 handguard (right side)

Printed : 1/9/02

FUEL CAP

Remove the fuel cap to fuel the motorcycle. You should fill the vehicle wi th the specif ied gasoline before each ride. See the Fluids section of this manual.

To open: Turn the cap counter-clockwise.

To close: Reinstall the fuel cap and turn it clockwise until it is secured.

POTENTIAL HAZARD(S)

(1) Interference with the vehicle controls (2) Crushed, mangled, or injured hands

WHAT CAN HAPPEN

(1) If a handguard is loose or damaged, it can interfere with the controls possibly preventing your hands from operating the controls as required. (2) The hand guards (TYPE 1 and TYPE 2) provide limited protection against trail hazards [e.g., wind deflection, small branches, “roost” (the dirt and debris thrown backward from a leading vehicle)]. The guards WILL NOT protect you (your hands) from injury in a crash. In either case above (1,2) you can be severely injured or killed.

HOW TO AVOID THE HAZARD

(1 & 2) The handguards should be inspected before every ride to ensure that they are mounted securely and will not interfere with the vehicle controls. If they are damaged or loose, take corrective action. If you have any questions about the conditions or intended use of the handguards, contact your Cannondale Motorsports Dealer for assistance.

1. Fuel cap

2. Breather (vent) hose

Motorcycle Fluids.fm

FLUIDS

FUEL

Use only clean, fresh unleaded gasoline with a

minimum Anti-Kno ck Inde x of 92 or highe r.

Fill the tank with the specified fuel before every

ride.

We recommend that the inline fuel filter is replaced every 5 hours of operation for the best performance. See the Maintenance and Adjustment section of this manual.

CAUTION

If engine “knocking” or pinging occurs, use a different brand of gasoline or a higher octane rating.

Never experiment by using fuels other than the recommended type in this vehicle. Other fuels or additives that are not designed specifically for this vehicle can severely damage the engine and its supporting components (e.g. fuel system, sensors, tank, hoses, etc.)

1. Remove the fuel cap and fill the tank wi th fuel until it reaches the bottom of the filler neck.

2. Tighten the fuel cap securely and make sure the breather hose is undamaged and routed correctly.

POTENTIAL HAZARD

Improper care when handling fuel.

WHAT CAN HAPPEN

Fuel is highly flammable, spilling it can cause a fire or explosion.

HOW TO AVOID THE HAZARD

Work in a well-ventilated area which is free of sources that could ignite any spilled fuel accidentally (e.g. cigarettes, welders, torches, grinders, electric shop tools, etc.)

1. Fuel level

2. Filler neck

POTENTIAL HAZARD

Overfilling the fuel tank

WHAT CAN HAPPEN

Fuel expands due to heat (e.g., engine, sun) a nd ma y overflow if the tank is ov erfilled, resulting in a fire.

HOW TO AVOID THE HAZARD

Stop adding fuel when the correct le vel is re a ched.

1. Cap

2. Breather (vent) hose

3. Steering stem hole

(1)

(2)

Printed : 1/9/02

BRAKE FLUID

Check the brake fluid in both the front and rear

systems before every ride.

Use only clean DOT #4 brake fluid from a sealed

container. Do not mix brake fluid types or brands.

Have the brake fluid in both systems replaced

every year.

CAUTION

Avoid spilling brake fluid on painted, plastic or rubber parts; damage will result. Place a shop towel or rag over these parts when servicin g the brake system. Wipe up any spills immediately.

FRONT BRAKE

1. To check the front syst em, start by leveling the top of the master cylinder (mounted on the right handlebar).

2. Inspect the fluid level through the site glass. If the fluid level i s below t he ‘LWR’ mark, add the specified brake flu id until the fluid is at the top of the window.

3. To add fluid, make sure the area around the master cylinder is clean to prevent contamination which can lead to a loss of braking force. Remove the screws, cover and diaphragm from the master cy linder.

POTENTIAL HAZARD

(1) Eye and skin injury, death if swallowed (2) Mixing fluid types or brands (3) Fluid from unsealed containers (4) Low fluid level

WHAT CAN HAPPEN

(1) Brake fluid is a hazardous substance. It can cause injury to your eyes or skin if you touch it. If swallowed it can cause death. (2) Mixing types and brands can damage the brake system leaving you without brake s. (3) A container of brake fluid once unsealed can begin to absorb moisture from the atmosphere - if used in the brake system, the moisture will reduce braking force. You could lose your brakes and have an accident resulting in injury or death. (4) Low brake fluid can allow air to enter the system and this will reduce braking power. Again, you could have an accide nt and be s er iously inju r ed or killed.

HOW TO AVOID THE HAZARD

(1) Always wear eye and hand protection when working with brake fluid. Keep brake fluid out of the reach of children and animals. If ingested contact a doctor immediately. (2,3) Always use DOT 4 brake fluid from a sealed container. Don’t mix fluids or use opened fluids. Have the system drained and refilled by an authorized Cannonadale Motorsports dealer if you suspect fluids have been mixed accidentally. (4) Check the fluid level before riding the ve hicle.

1. Master cylinder

2. Site window

3. ‘LWR’ mark

(2)

(3)

(1)

Motorcycle Fluids.fm

4. Pour DOT#4 brake fluid from a sealed container until the flui d level rises to the top of the site window and no higher. If you fill above the window the fluid will overflow when the diaphragm and cover are re-installed.

5. Reinstall the front brake master cylinder diaphragm and cover. Tighten front master cylinder cover sc rews to the specified torque.

TORQU E : Front brake master cylin der

cover screws

1.4 lbf• ft (1.9 N •m)

REAR BRAKE

1. To chec k the re ar sy st em , leve l the rea r brake master cylinder reservoir. The fluid level should be above the ‘LOWER’ mark.

2. If the fluid level is below the ‘UPPER’ mark, remove the cap and add the specified brake fluid until it reach es the ‘UPPER’ mark.

NOTE :

Do not fill the brake master cylinder above the ‘UPPER’ mark or the fluid will overflow when the diaphragm is installed.

3. Install reservoir diaphragm, diaphragm plate and cap.

1. Front brake master cylinder cover screws

2. Front brake master cylinder cover

3. Diaphragm

(1)

(2)

(3)

DOT 4

1. ‘LOWER’ mark

2. ‘UPPER’ mark

1. Reservoir cap

2. Diaphragm plate

3. Diaphragm

(2)

(1)

DOT 4

(1)

(2)

(3)

Printed : 1/9/02

ENGINE OIL

See the Model Specification section in this manual for the recommended engine oil type and capacity.

Check the engine oil level before every ride.

Clean the engine oil filters (screen type) or replace with new ones (paper el ement type) in accordanc e with Maintenance Schedule in this manual.

Service more frequently when operating in/under extreme conditions.

CHECKING ENGINE OIL

You have to start and run the engine for 1 minute, shut the engine off, wait another minute befor e checking the oil level.

The engine and exhaust system are extremely hot and take time to cool after you shut the engine off. Work carefully to avoid hot surfaces. You can be burned severely.

1. Position the vehicl e upr ight on a stan d.

2. Start the engine and allow to run for 1 minute at idle speed, then turn off the engine.

3. Wait 1 minute for the eng ine oil to settle in side the spar.

4. Inspect oil level in the inspection window on the left frame spar.

5. If the level is low (cannot see oil in the window), add a sufficient amount of oil to raise it to the correct level. Add at the filler hole using a clean

DANGER

POTENTIAL HAZARD

Running the engine indoors. Breathing exhaust ga se s

WHAT CAN HAPPEN

Running the engine indoors will expose you to dangerous exhaust gases. Breathing carbon monoxide gas leads to poisoning, asphyxiation, and death. This will happen rapidly and without notice.

HOW TO AVOID THE HAZARD

Never operate the vehicle indoors even for brief periods of time.

1. Inspection window (left frame spar)

This is a close-up photo of the inspection window showing the oil inside the spar an d its ‘level’ observed wit h th e ve hi cl e he l d up ri gh t . Th is oil level is OK. The “level” of the oil should be visible in the window.

Motorcycle Fluids.fm

funnel. If you see that the level is too high, drain some out using the left spar drain bolt until the oil level is visible through the window.

CHANGING ENGINE OIL AND CLEANING THE FILTERS

Your vehicle has two engine oi l filt ers. One filte r is located within the engine oil pressure pump housing. The other filter is located in si de the cr an kc ase inl et fitting. We highly recommend cleani ng (o r repla ci ng) both as directed.

Clean (the screen type) or replace (the paper element type) engine oil filters every time you change the oil.

The engine and exhaust system are extremely hot and take time to cool after you shut the engine off. Work carefully to avoid hot surfaces. You can be burned severely.

NOTE :

Remove the spar engine oil filler cap (left spar) when draining.

When refilling engine oil, add slowly and recheck level frequently so as not to over fill the system.

1. Position the vehicle upright on a stand.

2. Start engine and allow to run briefly to warm the engine oil. Then, turn the engine off.

1. Engine oil filler hole

2. Cap

3. O-ring

DANGER

POTENTIAL HAZARD

Running the engine indoors. Breathing exhaust gases

WHAT CAN HAPPEN

Running the engine indoors will expose you to dangerous exhaust gases. Breathing carbon monoxide gas leads to poisoning, asphyxiation, and death. This will happen rapidl y and without notice.

HOW TO AVOID THE HAZARD

Never operate the vehicle indoors even for brief periods of time.

Printed : 1/9/02

3. Remove the left spar drain bolt and drain the contents into an oil pan.

NOTE :

Position a clean shop towel behind a folded piece of thin cardboard to channel or direct the flow of oil from the spar drain bolts into your oil pan.

4. When the spar flow is reduced, have an assistant hold the handlebars and slightly tilt the vehicle toward the oil pan to drain any remaining oil.

5. Drain the right spar in the same way.

6. For both the left and right s par bolt, inspe ct the spar bolt O-ring. Replace it with a new one if you find any tears, rips, or if it is distorted in shape. Make sure the bolt threads are clean. Apply some clean en gine oil to the thr ead s a n d O-ring and reinstall. Tighten the bolt(s) to the specified torque.

TORQUE : Spar engine oil drain bolts

15.0 lbf•ft (20.3 N•m)

1. Left spar drain bolt

1. Shop towel

2. Folded cardboard

1. Right spar drain

1. Spar drain bolt

2. O-ring

Motorcycle Fluids.fm

7. Remove the engine oil crankcase drain bolt and sealing washer and allow the oil to drain

into your oil pan.

8. Apply some anti-seize compound to the threads of the drain bolt. Install the sealing washer onto the bolt so t hat the flat side faces the crankcase a nd install the bolt and washer into the crankcase. Tighten the bolt to the specified torque.

TORQU E : Engine oil crankcase drain b olt

6.0 lbf• ft (8.1 N •m)

9. Position your oil p an under the engine oil filter cover and remove the bolt and the fi lter cov er.

NOTE :

Be sure to note the two O-rings in the cover when you remove it.

If the installed filter is the scr een type, remove the seal, oil filter (screen) and oil seal from the filter housing.

1. Bolt

2. Sealing washer

3. Crankcase drain hole

a. Sealing washer (flat side)

1. Bolt

2. Cover

(3)

(a)

(1)

(2)

1. Bolt

2. Cover

3. O-ring

4. O-ring

5. Filter seal

6. Filter (screen)

1. Screen type filter (with seals)

2. Paper type filter (glued seals)

(1)

(2)

(3)

(4)

(6)

(5)

+ 72 hidden pages

Cannondale E440, C440, X440, 2002 E440, 2002 C440 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual