Cannondale 440 E C S X 2003 Owner's manual

2003 Motorcycle Owner’s Manual

Models : E440, C440, X440, S440

P/N : 951-5002274-03

Before you operate the vehicle. . . .

• READ and UNDERSTAND this Owner’s Manual. It contains information important to your safety.

• Learn the location and proper operation of all controls.

• Complete the Pre-Ride Inspection checklist.

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

IMPORTANT MANUAL INFORMATION

CAUTION:

NOTE:

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY

OR DEATH.

Information important to your safety is distinguished in this manual by the following notations: \

The safety alert symbol means......

“ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.”

DANGER

WARNING

Indicates that DEATH or severe injury W ILL result

instructions are not followed.

Indicates a pote ntial ha zard tha t coul d result in serio us

injury or death.

A CAUTION indic ates that s pecia l pr eca ution s mu st be

taken to avoid damage to the machine.

A NOTE provides helpful information intended to make

maintenance easier or the instructions presented clearer.

if the

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Post ride checks - - - - - - - - - - - - - - - - - 44

When reading this manual, remember:

WARNING

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

CONTENTS

IMPORTANT MANUAL INFORMATION- - - - - - - - - - - 2 FOREWORD - - - - - - - - - - - - - - - - - - - - - - - - 4

General Safety Precautions - - - - - - - - - - - - 5 Experienced riders only - - - - - - - - - - - - - - 7 Exercise good judgement- - - - - - - - - - - - - - 7 No Modifications - - - - - - - - - - - - - - - - - - 7 No passengers- - - - - - - - - - - - - - - - - - - 7 Inspection of Aluminum chassis components - - - - 8

VEHICLE WARNING AND SPECIFICATION LABELS - - 10 VEHICLE IDENTIFICATION- - - - - - - - - - - - - - - - 12

Vehicle Identification Number (VIN)- - - - - - - - 12 Engine Serial Number - - - - - - - - - - - - - - 12

PARTS AND CONTROLS- - - - - - - - - - - - - - - - - 13

Engine start button - - - - - - - - - - - - - - - - 13 Engine ON/OFF Switch- - - - - - - - - - - - - - 14 Headlight and Taillight (USA) - - - - - - - - - - 14 lighting Option - - - - - - - - - - - - - - - - - - 15 Trip computer - - - - - - - - - - - - - - - - - - 15 Clutch lever - - - - - - - - - - - - - - - - - - - 16 Shift lever - - - - - - - - - - - - - - - - - - - - 16 Throttle Grip - - - - - - - - - - - - - - - - - - 16 Front brake lever- - - - - - - - - - - - - - - - - 18 Footpegs- - - - - - - - - - - - - - - - - - - - - 19 Rear brake pedal- - - - - - - - - - - - - - - - - 20 Side stand (or) kickstand- - - - - - - - - - - - - 21 Handguards - - - - - - - - - - - - - - - - - - - 23 Fuel tank cap - - - - - - - - - - - - - - - - - - 24

BREAK-IN - - - - - - - - - - - - - - - - - - - - - - - - 45 MAINTENANCE & ADJUSTMENT - - - - - - - - - - - - 46

Maintenance schedule - - - - - - - - - - - - - - 47 Seat - - - - - - - - - - - - - - - - - - - - - - - 49 Air filter- - - - - - - - - - - - - - - - - - - - - - 51 Brakes - - - - - - - - - - - - - - - - - - - - - - 53 Clutch - - - - - - - - - - - - - - - - - - - - - - 54 Drive - - - - - - - - - - - - - - - - - - - - - - - 54 Engine Management System - - - - - - - - - - - 61 Electrical - - - - - - - - - - - - - - - - - - - - - 62 Exhaust - - - - - - - - - - - - - - - - - - - - - 68 Fuel - - - - - - - - - - - - - - - - - - - - - - - 70 Steering - - - - - - - - - - - - - - - - - - - - - 73 Suspension- - - - - - - - - - - - - - - - - - - - 75 Adjustment - - - - - - - - - - - - - - - - - - - - 75 Tires - - - - - - - - - - - - - - - - - - - - - - - 87 Wheels- - - - - - - - - - - - - - - - - - - - - - 88

CLEANING - - - - - - - - - - - - - - - - - - - - - - - - 93 STORAGE - - - - - - - - - - - - - - - - - - - - - - - - 94 TIGHTENING TORQUES - - - - - - - - - - - - - - - - - 96 MAINTENANCE RECORD - - - - - - - - - - - - - - - - 97 SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - 98

Service - - - - - - - - - - - - - - - - - - - - - 99 Suspension Settings - - - - - - - - - - - - - - 100

ADDENDA - - - - - - - - - - - - - - - - - - - - - - - -101

FLUIDS- - - - - - - - - - - - - - - - - - - - - - - - - - 24

Brake fluid - - - - - - - - - - - - - - - - - - - - 24 Coolant - - - - - - - - - - - - - - - - - - - - - 26 Engine oil - - - - - - - - - - - - - - - - - - - - 28 Hydraulic clutch fluid - - - - - - - - - - - - - - - 32 Fuel - - - - - - - - - - - - - - - - - - - - - - - 35 Transmission oil - - - - - - - - - - - - - - - - - 38

PRE-RIDE INSPECTION - - - - - - - - - - - - - - - - - 40 OPERATION - - - - - - - - - - - - - - - - - - - - - - - 42

Starting a warm engine- - - - - - - - - - - - - - 42 Jump starting - - - - - - - - - - - - - - - - - - 42 Shifting gears - - - - - - - - - - - - - - - - - - 43 Braking - - - - - - - - - - - - - - - - - - - - - 44

FOREWORD

This Owner’s Manual has been written carefully to provide you with a good basic understanding of all the features, controls, proper operation, and maintenance of your vehicle. It also will provide you with important safety information for you and anyone who operates it.

This manual should be considered a permanent part of the vehicle and it should remain with the vehicle whenever it is resold or possession is transferred to another person. Please take the time necessary to read and understand this entire owner’s manual.

IMPORTANT NOTICE

Some information in this manual may be outdated due to ongoing model improvements made

after the date of publication. The Addenda secti on at the e nd of thi s manual i ncl udes a ny ad ditional, replacement, or supplemental information for your vehi cl e that is availabl e at the tim e of shipment.

You can down load a Ado be PDF copy of this O wner ’s Manual as well as any applicabl e addenda, free of charge from our website. Go to: http://www.cannondale.com/motorsports/tech/

manuals.html,

Anytime you have any question related to the controls, features, or operation and maintenance of your vehicle, please consult your Cannondale dealer. Or, call us at toll free at 1-800-MOTO-USA.

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.

Comments

Send your comments or suggestions about this manual to: T echnical Publications, Cannondale Corporation, 2 Corporate Drive, Bedford, PA, 15522. Or, E-mail us at: technical.publications@cannondale.com.

WARNING

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

Printed : 8/15/02

GENERAL SAFETY PRECAUTIONS

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.

WARNING

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.)

WARNING

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 temperatu res. 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.

POTENTIAL HAZARD Blindness, eye injury

WHAT CAN HAPPEN Anytime you work on the vehicle there is a potential that a n accid ent involvin g a f oreig n 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.

WARNING

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

Printed : 8/15/02

WARNING

EXPERIENCED RIDERS ONLY

POTENTIAL HAZARD 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 otherwise directed in a procedure.

This vehicle is not for beginners. All Cannondale motorsports products are designed

for use by trained and experienced riders only . All are very high performance, competition sport machines and should only be operated by licensed competition riders in excellent physical condition, who are welltrained and experienced in the operation of high performance competiti on ve hic l es.

EXERCISE GOOD JUDGEMENT

There is always risk involved when riding a vehicle; however, making sure you and the vehicle are in the best condition possible will ensure a great riding experience. Use sound judgement when riding.

Never ride under the influence of alcohol, some overthe-counter medi c ati on s ( read th e product label), 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 prescribed medications, consult your doctor before riding.

WARNING

POTENTIAL HAZARD Fluids

WHAT CAN HAPPEN The fluids (engine/transmission oils, brake fluid, coolant) in your vehicle are hazardous substances. Contact with your skin or eyes can result in serious injury or irritation. If they are swallowed, severe in jury or death can result.

HOW TO AVOID THE HAZARD Wear hand and eye protection (rubber glov es and safety glasses or face shield) when working with vehicle fluids. If a fluid gets on your hands or clothing, wash it off immediately with soap and water. If swallowed seek immediate medical attention. KEEP ALL VEHICLE FLUIDS AWAY FROM CHILDREN AND ANIMALS.

NO MODIFICATIONS

We recommend that you do n ot substitute par ts, change or modify your vehi c le. Such cha nge s c ou ld 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 th is vehic le or carr y passenger s. Doing so could seriously impair your vehicle’s handling, stability, and braking, making it unsafe to ride which could result in dam age to the vehicle or serious injury or death to the operator and/or passenger.

INSPECTION OF ALUMINUM CHASSIS COMPONENTS

The aluminum chassis com ponents of your vehi cle 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 b y a Ca nnon dale Mo tor spor ts Deal er i s important.

• Frame - a main support structure for the engine, various components, and rider.

• Subframe - adds str uc tural sup port.

• Swin garm - a susp ensi on co mponent

Use in competitive events, hard and aggressive riding, riding on severe terrain, riding in severe climates, and riding fast can dramatically shorten the life of the aluminum (frame) components. Any one and/or a combination of the se con ditions may result in an unpredictable failure.

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

If you have crashe d or roll ed your ve hicle, the re could be damage hidden from your view. DO NOT ride a vehicle with any crack, even a small one. It must be careful ly ins pect ed by an a uthoriz ed Ca nnondale Motorsports Dealer before it is operated 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.

WARNING

POTENTIAL HAZARD(S) (1) Riding on a cracked or damaged frame. (2) Attempting to fix a damaged frame.

WHAT CAN HAPPEN (1) Riding on a cracked or 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 Inspect carefully before riding. Don’t ride on a cracked or damaged frame. Don’t try to repair the frame, su bframe , sw ingarm, or other components. Have your Cannondale dealer inspect the frame at every visit and at the 25 hour maintenance interval. Call 1-800-MOTO-USA with any questions.

WARNING

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

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Inspect the frame ( 1), lower frame rails (2) and sub -

frame (3) for cracks, deep scratches, or other damage. If any damage is found, contact an authorized Cannondale Motorsports Dealer for servicing.

(1)

(3)

(2)

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. If any damage to the swingarm is detected, take corrective action before riding. Contact an authorized Cannondale Motorsports dealer for servicing.

(1)

1. Frame

2. Lower frame rails

3. Subframe

OTE :

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

Inspect the swingarm fo r cr ac ks, dee p s cratc hes , o r other damage.

Inspect the weld ments (ind ividual we lded com ponents comprising the total swingarm) and fastener fixtures for any sign of cracking or damage.

1. Swingarm (shown removed for clarity)

VEHICLE WARNING AND

NOTE :

SPECIFICATION LABELS

You and anyone else who operates your vehicle must read and understand all of the labels. They contain information for safe and proper operation.

• Do not r emov e the la bels for any r easo n.

• If any label is missing, damaged, worn, or becomes difficult to read, you can get free replacements from Cannondale. Contact us toll free at 1-800-MOTO-USA.

• Alwa ys repl ace l abels in the proper location.

Part numbers are printed in the lo wer right corner of every label. The part numbers are also printed in this manual.

Label 1 P/N 315-5000266-01

(4)

(3)

(5,6)

(1)

(2)

Label 2 P/N 315-5001262-01

Label 3

WARNING

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Label 4

Label 5

Label 6 P/N 315-6000477-01

VEHICLE IDENTIFICATION

NOTE :

xxxxxxxxxxxxx

XXXXXX

ENGINE SERIAL NUMBER

The identification numbers found on your vehicle identify it from others of the same model type.

You may need the identification numbers when ordering replacement parts, service information, or to assist in theft investigation and recovery.

Record your vehicle identification numbers in the spaces provided. Keep a copy of the numbers in another location.

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

VEHICLE IDENTIFICATION NUMBER (VIN)

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

The engine serial nu mber is etched/stamped into the rear area of the engine crankcase. The number also appears on a temp orary, factory-appli ed, ad hesi ve label in the same area.

XXXXXXXXXXXX

1. Engine seria l nu mber

1. Vehicle identification number

Record here

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WARNING

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

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PARTS AND CONTROLS

This section con tains in forma t ion a bout the controls and component features of your vehicle.

OTE :

This section may contain information about controls and features not present on your particular model.

The right and left sides of the vehicle are determined by the operator’s left/right orientation while seated on the vehicle facing forward in the operating position.

IMPORTANT NOTICE

Your vehicle may be equipped with optional or special components (e.g., suspension, steering, or handlebar controls) de pendi ng on the model you purchased.

ENGINE START BUTTON

(1)

1. Engine start button

The engine start button is located on the right handlebar and is (GREEN) in color.

Press and release it without cranking over the engine to activate the engine management system circuits.

Consult the sup ple mental ma nufa ctur er ’s information about those components provided to you at the time of sale before operating or servicing the component or the related system.

You can obtain Adobe PDF copies of all owner’s manuals at our website. Go to:

http://www.cannondale.com/motorsports/ tech/manuals.html,

Anytime you have any question related to the available manual supplements, controls, features, or operation and maintenance of your vehicle, please consult your Cannondale dealer . Or, call us at toll free at 1-800-MOTO-USA.

Press and hold it to activate the starter motor. Be sure to read the Operation section of this manual

for a detailed explanation of the best starting procedure.

OTE :

When cranking the engine, hold the button for no more than 2-3 seconds at a time.

ENGINE ON/OFF SWITCH

HEADLIGHT AND TAILLIGHT (USA)

1. ON/OFF switch

The engine ON/OFF siwtch is located on the left handlebar. It is a two position (ON and OFF) toggle switch.

Press “ON” to enable the engine management circuits.

Press “OFF” t o d isab l e th e eng in e management circuits to shut down a running engine normally (finished riding). Press ‘OFF’ to stop a running engine in the event of an emergency such as when the motorcycle overturns or throttle cable is stuck.

Test the switch before operating. Start the engine and press OF F; if the en gine d oes not shut down immediately, do not ride the motorcycle; contact an Cannondale motorsports dealer and have the switch fixed.

1. Headlight

2. Mounting straps (left fork)

3. Headlight/Taillight switch

1. Taillight

The headlight and tail li gh t on eq ui ppe d v eh icle s a r e activated by the three position toggle switch mounted on the center of the handlebar. The taillight should turn on with the headlight when the switch is in either the HI or LO headlight switch position. When the switch is in the center position both lights should be off.

WARNING

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Make sure the headlight and taillight operate properly before starting out

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

Printed : 8/15/02

If either headligh t or tail li ght doe s not li ght , c hec k to

see if a fuse or bulb replacement is needed. .

LIGHTING OPTION

1. Lighting switch

WARNING

POTENTIAL HAZARD Removing your hands from the handlebar when operating

WHAT CAN HAPPEN You can lose control of the vehicle and have a serious accident.

HOW TO AVOID THE HAZARD 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.

OTE :

Switch the lights off before attempting to start the engine.

1. Optional lighting tap (non-fused)

2. Main fuse

3. Engine Management System power relay

Your vehicle may have optional lighting power takeoff connector. This connector can be used to install approved lighting systems. The connection for optional lighting is located under the seat near the main fuse and engine mana gement sys tem relay. Do not improvise; contact y our Cannond ale Mo torsports dealer to install the optional lighting system.

TRIP COMPUTER

Be sure to return the switch to the center position when the lighting is not required.

1. Trip computer

A trip computer is located in the center of the handlebar.

Consult the Manufacturer’s Instruction Manual for the

WARNING

unit features and operating instructions.

POTENTIAL HAZARD Removing your hands from the handlebar when operating

WHAT CAN HAPPEN You can lose control of the vehicle and have a serious accident.

HOW TO AVOID THE HAZARD Make adjustments and settings before moving off to ride. Always stop the vehicle on level ground before operating (programming/setting) the computer.

CLUTCH LEVER

SHIFT LEVER

(1)

1. Shift lever

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 second gears.

1. Clutch lever

2. Clutch reservoir

3. Lever position adjuster

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 so that the lever is closer or further from the grip to suit for individual hand sizes. To adjust the lever position, see the Maintenance and Adjustment section of this manual.

THROTTLE GRIP

Throttle freeplay: 1/8 - 5/16 in (3 - 8 mm)

(a)

(1)

(b)

1. Throttle grip a. Freeplay

b. Open throttle (accelerate) c. Close throttle (decelerate)

The throttle lever is located on the right handlebar and controls acceleration and deceleration of the engine.

(c)

WARNING

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Printed : 8/15/02

T o accelerate the engine, rotate the grip towards you.

Adjusting the throttle freeplay

To decelerate the engine, turn the grip away from you. When released the grip should spring back to the idle position automatically.

Do the following before every ride: Check the freeplay. Make sure the specified freeplay

is available in all handlebar positions. Adjust the freeplay if necessary.

With the engine off, rotate the throt tl e from sma ller to larger openings and release the throttle. It should close automatically to the idle position when release at all positions and handlebar positions. It should operat freely (e.g., without binding, dragging, or sticking) and return to the closed position automatically in all steering positions.

WARNING

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 accel erate and decelerate the engine which could result in an accident where you could be seriously injured or killed. (2) The throttle freeplay must be ma intained as specified, otherwise the engine speed could increase when the handlebars are turned or when the throttle is slightly grasped. Either situation could result in an unexpected accelerat ion o f t he engine where you could be seriously injured or killed.

1. To adjust the freeplay, slide boot back to expose lock ring and adjuster.

2. Loosen the lock r ing, and turn the ad juster until the specified freeplay is reached.

3. Tighten the lock ring securely , when finished, and return the boot.

(3)

(1)

(2)

(a)

(b)

1. Long rubber boot

2. Cable adjuster

3. Lock ring a. Decrease freeplay

b. Increase freeplay

OTE :

If the throttle can not be adjusted further and the freeplay is still out of specification, consult an authorized Cannondale Motorsports Dealer.

HOW TO AVOID THE HAZARD (1) Test the operation of the throttle before each 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.

FRONT BRAKE LEVER

(a)

(1)

Front brake lever freeplay:

0.12 - 0.8 in (3 - 20 mm)

1. Front brake lever

2. Freeplay

Adjusting the front brake lever freeplay

Freeplay is the free travel distance required before hydraulic pressure forces the brake pads to press against the brake discs. The minimum freeplay is required so that the lever can move as the rider shifts hand position without resulting in pressure (as detected in resistance in the lever) causing the brake pads to press against the brake discs prematurely.

To measure the freeplay, roll the vehicle back and forthwhile squeezing the lever lightly to detect the fluid pressure point. The pressure point is indicated when the brake pads start to press against the brake disc applying br aking f orce . Meas ure the distanc e the lever moved at the end of the lever.

CAUTION:

Make sure the minimum freeplay of .12 in (3 mm) is available. Incorrect fre eplay can result in unintended pressure application in brake system. The brake system can over overheat damaging the pads or discs.

The front brake lever is located on the right handlebar. Pull it against the grip to apply the front brakes.

Always make sur e the brak es (fron t and rear ) on your vehicle operate properly before riding.

Measure the fre eplay bef ore yo u ride. A djust the freeplay if it is out of specification.

The position of the brake lever on the handlebar can be adjusted so that control is comfortably positioned to the operator’s preference.

(1)

0.12-0.8in (3-20mm)

(2)

(3)

(b)

1. Locknut

2. Adjuster a. Decrease freeplay

b. Increase freeplay

(a)

1. To adjust, loosen the the locknut.

2. Turning the adjustment screw.

3. Tighten the locknut to 4.3 lbf•ft (5.8 N•m).

WARNING

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

Printed : 8/15/02

Adjusting the front brake lever position

To adjust the front brak e leve r positi on on the handlebar, loosen the clamp bolts and rotate the brake lever to the desired position. Tighten the bolts to 5.0 lbf•ft (6.8 N•m) when finished. Tighten the upper bolt to the specified torque, then tighten the lower bolt.

(1)

(2)

1. Upper bolt

2. Lower bolt

OTE :

Only apply a light coat of grease so it does not attract a lot of dirt and debris.

6. Install the pivot bolt and tighten the nut securely.

7. Install the rubber boot over the brake lever.

FOOTPEGS

Front brake lever lubrication

1. Place the vehicle on a stand.

2. Remove the rubber cover from the brake lever.

3. Remove the nut (1), pivot bolt (2), and brake lever (3).

1. Nut

2. Pivot bolt

3. Brake lever

4. Spray all the parts with a water-displacement chemical, wipe them off, and dry them thoroughly.

5. Install the brake lev er, and apply a light co at of high quality waterproof grease onto the pivot bolt.

1. Footpeg (left)

2. Pivot

3. Spring

4. Teeth

The right and left footpegs on your vehicle should be fastened securely and free of any collected mud or dirt. The footpeg s sh ou ld mo ve fr ee ly (up and down on the pivot) and not bind - springing back when released.

OTE :

After cleaning, lubricate the footpeg pivot points with clean engine oil. Move the pegs up and down to work the lubricant in. Don’t use grease; grease will catch and collect dirt and small particles which will damage the pivot point. Make sure the teeth are in good con dition

REAR BRAKE PEDAL

NOTE :

(a)

(b)

(1)

(2)

brake pedal and turnin g the hex in direction (b) will raise the pedal.

1. Rear brake pedal

2. Pivot a. Pedal height

The rear brake pedal is located on the right side of the vehicle.

Press it firmly with your fo ot to appl y the rea r br ake . Test to make sure it is operating correctly before you ride. When pressed, braking force should be applied to the rear brake disc. Braking force will increase the more you press down on the pedal.

The rear brake pedal height can be adjusted for comfort. To adjust it, see the Maintenance and Adjustment section of this manua l.

After cleaning, 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. Locknut

2. Hex a. Lowers the brake pedal

b. Raises the brake pedal

2. Tighten the locknut to 13.0 lbf•ft (17.6 N•m)

CAUTION:

When adjusting the brake pedal, make sure that clearance (a) between the lower end of the pushrod (1) and the brake pedal (2) is within specification.

When raising the brake pedal, do not allow the lower end of the pushrod thread to enter into the brake pedal joint.

(1)

Adjusting the rear brake pedal height

1. Loosen the locknut on the mast er cylinder pushrod. Turn the hex on top of the pushrod until the brake pedal is at the correct height.

Turning the hex in direction (a) will lower the

WARNING

2003 Motorcycle OM.fm

(a)

(2)

1. Pushrod

2. Brake pedal a. Clearance 0.04 in (1mm)

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

Printed : 8/15/02

SIDE STAND (OR) KICKSTAND

The side stand or kickstand (on equipped vehicles) can be used to support the vehicle on firm level ground when not in use (with the engine off). Both are designed to only support the we ight of the

vehicle..

weight of the vehicle to rest on the stand.

WARNING

POTENTIAL HAZARD(S) Sitting or leaning on the vehicle with the kickstand or side stand.

WHAT CAN HAPPEN The side stand and kickstand are designed to support only the weight of the vehicle. If you sit or lean on the vehicle, the add itional weight could cause the vehicle to fall over. You can be severely injured.

HOW TO AVOID THE HAZARD Never sit or lean on a vehicle with the kickstand or side stand in use; it could fall over unexpectedly. Place the vehicle on a wo rk stand when performing maintenance.

OTE :

After cleaning the vehicle, apply some clean engine oil to the kickstand pivot point, and fold the stand up and down to work in the oil.

1. Side stand

SIde stand

1. To use the side stand, position the vehicle on firm level ground.

2. Hold the vehicle upright and insert the side stand completely into the hole in the rear axle shaft on the right side of the vehicle.

3. Tilt the vehicle toward the stand allowing the

Kick stand

WARNING

Kick stand down

YES

1. Kick stand

1. To use the kick stand, position the vehicle on firm level ground.

2. Fold the kickstand down until i t is fully ex tended, and rest the weight of the motorcycle on it.

CAUTION:

Turn the handlebar so that FRONT WHEEL is pointing to the LEFT when the KICK STAND is folded down; this shifts more of the weight toward the stand reducing the potential of the vehicle to tip on its right side if bumped.

Folding the kickstand up

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

This photo shows the kickstand in the operating position. See a close-up of the area indicated in the next photo.

POTENTIAL HAZARD(S) Riding with the side stand attached or the kickstand down.

WHAT CAN HAPPEN Can lose control of the vehicle unexpectedly. You can be severly injured or killed in an accident.

HOW TO AVOID THE HAZARD Remove the side stand; lift the kickstand t o operating position before riding.

WARNING

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

YES

The “YES” photo shows a kickstand that is folded up completely (the correct operating position). Notice that there is no g ap (1 ) p rese nt be twee n th e kic kstand leg and the plate. The “NO” photo shows a folded kickstand “hanging.” Notice that gap betw een the le g a nd t he plate. The kickstand may be damaged (e.g., bad spring, bent leg or plate). This co ndition must be corr ected before riding the vehicle.

2003 Motorcycle OM.fm

Printed : 8/15/02

HANDGUARDS

Make sure the handguards are in good condition and fastened securely before riding. The handguards should not interfere with operation of the vehicle controls. Tighten the mounting harware securely.

WARNING

1. Type 1 handguards

2. Type 2 handguards

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 contro ls 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 wil l not interfere with the vehicle controls. If they are damag ed 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.

The handguards are located on the right and left sides of the handlebar directly in front of the handle grips. These guards are designed to only offer limited hand protection.

FUEL TANK CAP

FLUIDS

Remove the fuel cap to fuel the motorcycle. You should fill the vehicle with the specified gasoline before each ride. See the Fluids section of this manual.

To open: Turn the cap counter-clockwise. To close: Reinstall the fuel c ap and tur n it cl oc kwis e

until it is secured.

1. Fuel cap

2. Breather (vent) hose

BRAKE FLUID

Brake fluid: Use only DOT 4 brake fluid.

WARNING

POTENTIAL HAZARD Mixing brake fluid

WHAT CAN HAPPEN Mixing fluid types and brands can damage the brake system. Once unsealed, a container of brake fluid can begin to absorb moisture from the atmosphere. If used in the brake system, the moisture will reduce braking force. A Low brake fluid can allow air to enter the system and this will reduce braking power. YOU CAN BE SEVERELY INJURED OR KILLED IN AN ACCIDENT IF YOU LOSE YOUR BRAKES.

HOW TO AVOID THE HAZARD Don’t mix brake fluids. Don’t use fluid from opened containers. Have the system drained and refilled by an authorized Cannondale Motorsports dealer if you suspect fluids have been mixed accidentally. Check the fluid level before riding the vehicle.

WARNING

2003 Motorcycle OM.fm

CAUTION:

To help prevent fluid contamination, clean the area surrounding the both brake system reservoirs before removing the covers. Avoid spilling brake fluid on painted, plastic, or rubber parts; damage will result. Place a shop towel or rag over these parts when servicing the brake system. Wipe up any spills immediately.

OTE :

Position the vehicle on a level surface and level the handlebars. After filling fluid, check the entire system for leaks, and test for the proper operation of the braking

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

Printed : 8/15/02

system before riding. Test with the engine off by rolling the vehicle forward and back while apply the brakes. Then, also test the brakes at slow riding speeds.

cover are re-installed..

(1)

(2)

Checking the front brake fluid level

(2)

(1)

(3)

1. Front brake master cyli nd er

2. Site window

3. ‘LWR’ mark

1. To check the front system, level the top of the master cylinder (mounted on the right handlebar).

2. Inspect the fluid level through the site glass. If the fluid level is below the ‘LWR’ mar k, add the specified brake fluid until the flu id 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 dia phragm from the master cylinder.

4. Pour DOT#4 brake fluid, from a sealed container, until the fluid level ri ses to the to p of t he s ite win dow and no higher. If you fill above the window, the fluid will overflow when the diaphragm and

(3)

DOT 4

1. Front brake master cylinder cover screws

2. Front brake ma ster cylinder cover

3. Diaphragm

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

1.4 lbf•ft (1.9 N•m)

6. Pour DOT 4 brake fluid from a sealed container until it reaches the ‘UPPER’ mark.

7. Reinstall the diaphr agm, i nsert, an d cap. Tighten the cap securely.

Checking the rear brake fluid level

1. To check the rear system, level the rear brake master cylind er reservoir. The flui d level should be above the ‘LOWER’ mark.

(2)

(1)

1. ‘LOWER’ mark

2. ‘UPPER’ mark

2. If the fluid level is below the ‘UPPER’ mark, clean the cap and surround ing area thoroughly before opening.

3. Remove the cap and pour DOT 4 brake fluid until

it reaches the ‘UPPER’ mark.

NOTE :

DOT 4

(1)

(2)

(3)

COOLANT

Coolant: Use distilled water and [ethylene glycol

(containing corrosion inhibitors for aluminum engines and radiators)]

Mixture ratio: 1:1 (Consult coolant manufacturer’s labeling to ach ieve c oolant pe rform ance fo r y our operating climate.

WARNING

POTENTIAL HAZARD Removing the radiator cap while the engine is hot

1. Reservoir cap

2. Diaphragm plate

3. Diaphragm

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

4. Install reservoir diaphragm, diaphragm plate, and cap.

WHAT CAN HAPPEN Can be burned severely by hot coolant sprayed out at high pressure

HOW TO AVOID THE HAZARD Wait for the en gine to cool com p l e tely before removing the bottle cap. Place a thick towel over the cap; turn slowly to relieve residual pressure.

Checking the coolant level

1. With the engine cold, place a thick towel over the radiator cap. Slowly turn the cap in direction (a) to the first detent and allow any residual pressure to escape.

2. When all pressure has es caped, press down on the cap and keep turning it until it can be

WARNING

2003 Motorcycle OM.fm

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

Printed : 8/15/02

removed.

(a)

(1)

1. Radiator cap a. Loosening direction

3. The coolant level s hould be at the bo ttom of the filler neck.

coolant level drops after adding and no leaks are found, contact an autho rized Cannon dale Motorsports Dealer for servicing.

(2)

(1)

1. Coolant level

2. Filler neck

4. Reinstall the radiator cap.

5. Check the entire cooling system for leaks. If the

ENGINE OIL

NOTE :

TEMP (F°)

-20 -15 -10 -5 0 5 10 15 20 25 30 35 40

-4 5 14 23 32 41 50 59 68 78 86 95 104

TEMP (C°)

20W 50

15W 50

10W 40, 10W 50

10W 30

0W 40

Recommended viscosit y: SAE 10W-40 (synthetic or semi synthetic)

Classification: Use only high-detergent, premium quality motor oils with the American Petroleum Institute (API) service classification SF or SG type displayed on the container.

Capacity (dry fill): 1500cc (1.6 US qt.)

Other viscosities can be used when the average temperature range is within the indicated range.

the window.

1. Inspecti on win dow (lef t f ra me spar)

CAUTION:

A low oil level can result in severe engine damage. Be sure to change the oil and clean/replace the filter(s) in accordance with the maintenance schedule and more frequently when operating under extreme conditions.

Checking the engine oil level

1. Position the vehicle upr ight on a work stand outdoors - NOT INDOORS. Refer to "General Safety Precautions" starting on page 5.

2. Start the engine, and warm it up to normal operating temperature 158°F (70°C). Allow the engine to idle for several seconds after operating temperature is reached and sh ut the engine off. Wait a few minutes for the oil to settle.

3. Inspect oil level i n the inspection window on the left frame spar. The oil level shoul d be visible in

WARNING

2003 Motorcycle OM.fm

This photo is a close up of the inspection window showing the oil inside the spar. The oil level is OK when you can see the level.

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 funnel.

If you see that the level is too high, drain some out using the lef t spar drain bolt until the oi l lev el

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

Printed : 8/15/02

is visible through the window.

contents into an oil pan.

1. Engine oil filler hole

2. Cap

3. O-ring

CAUTION:

Use a clean funnel.

Changing engine oil and cleaning the filters

OTE :

Your vehicle has two engine oil filters. One filter i s located within the engine oil pressure pump housing on the left (fr ont) side of the engine. The other filter is located at the left rear of the crankcase inside the crankcase inlet fitting. We highly recommend cleaning (or replacing) both as directed.

Replace the paper engine oil filter every time you change the oil. Clean the inlet fitting as directe d.

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 sy stem .

1. Position the vehicle upright on a work stand outdoors - NOT INDOORS. Refer to "General Safety Precautions" starting on page 5.

2. Start engine and all ow to run brie fly to warm the engine oil. Then, turn the engine off.

3. Remove the left spar drain bolt and drain the

1. Left spar drain bolt

OTE :

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.

1. Shop towel

2. Folded cardboar d

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.

oil pan.

(3)

(a)

1. Right spar drain

6. For both the left and right spa r bolt, inspect the spar bolt O-ring.

(2)

1. Bolt

2. Sealing washer

3. Crankcase drain hole a. Sealing washer (flat side)

(1)

8. Apply some anti-se ize compound to the thre ads of the drain bolt. Install the sea ling washer onto the bolt so that the flat side faces the crankcase and install the bolt and washer into the crankcase. Tighten the bolt to 6.0 lbf•ft (8.1 N•m).

9. Position your oil pan under the engine oil filter cover and remove the bolt and the filter cover.

1. Spar drain bolt

2. O-ring

Replace th e O-r ing wit h a new one if y ou fi nd an y tears, rips, or if it is distorted in shape. Make sure the bolt threads are clean. Apply some clean engine oil to the threads and O-ring and reinstall. Tighten the spar drain bolt(s) to 15.0 lb f•ft (20.3 N•m).

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

WARNING

2003 Motorcycle OM.fm

1. Bolt

2. Cover

OTE :

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

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

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