Cannondale ATV-2002 User Manual

Download

Page 1

Page 2

Page 3

ATV SPORT REALITY

STOP! - If you have the impression that four wheels give you the stability of a car, you are wrong. If you have the impression that an ATV is simple to

drive and similar to those other vehicles, you are wrong. The risks involved are at least equal to those faced when riding a motorcycle.

CHARACTERISTIC PURPOSE REALITY

Example: Sharp kn ife Useful tool for cutting Risk of cutting yo u rs elf

No restraint system, no body, no protective structure Rider must be able to shift weight Motorcycle-like risk, rider can fall or fly off and is

Very high power-to-weight ratio Thrilling acceleration, co m petition

Short wheelb ase Maneuverable in woods, compact Relatively easy to wheel ie, to turn over backwards or

Narrow track Maneuverable in woods, narrow trails Relatively easy to turn over High ground clearance, high center of gravity Clearance for obstacles, more suspension

Soft, high traction tires Traction and flotation on soft , loose

Totally unsuited and illegal for road us e Designed exclusively for off road High risk of turn ove r or collision if you ride on.

performance

travel

surfaces

POTENTIAL HAZARD

Given the realities of spor t ATVs and/or the limit s of your ow n ridin g abilitie s, you may lo se co nt ro l. The limits ar e impos sib le to be sp ecific about becau se o f the variation in terrain and rider abilit y are ne ar ly unlimited. If you chose to r ide an ATV, you must understand and resp ect the reality of the above.

WHAT CAN HAPPEN

You could lose control, have an accident an d be se ver ely injured, paralyzed or killed .

exposed, unprotected Relatively easy to wheelie, requir es focus and ski ll to

stay ahead of machine

pitch over forward

Relatively easy to turn over

Grip on hard surface (pa ve me nt ) mak es it easy to turn over

HOW TO AVOID THE HAZARD

The hazards of ATV riding can not be comple tely avoided. They can be minimized with training, good judgement, experience, use of helmet, protective gear and development of sk ills in weight shifting, throttle an d br ak e con tr ol . Reading and understandin g thi s Owne r’s Manual and warning labels, watching and understanding the ATV safety video and completing an ATV training course are essential and can begin your learning process.

Page 4

FOREWORD

Experienced Riders Only

All Cannondale motorsports products are high performance, sport and/or competition machines and should only be operated by licensed competit ion riders in excellent p hysical condition. Operators should be welltrained and experienced in the operation of high performance com petition vehicles.

• This vehicle is not for beginners or the

inexperienced.

• Before you ride this vehicle, read this Owner’s

Manual thoroughly and understand all of the instructions, warnings, cautions, and notes presented.

• 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 described, have an authorized Cannondale motorsports dealer service your vehicle.

For detailed service information, obtain the engine service or chassis man ual for your vehicle or contact an authorized Cannondale motorsports dealer for a list of available publi cations.

Addenda to this manual

Before you begin reading the manual, go to the “Addenda” section at the end of this manual. The addenda or “supplements” section provides any additional, replacement, or supplemental information for your product available at the time of shipment.

About this manual

The purpose of this manual is to provide the vehicle owner with important safety, service, maintenance, and tuning information. Read and understand this manual before operating or working on the vehicle. Keep your Owner's Manual on the vehic le while you ride. If you lose this manual, contact an authorized Cannondale motorsports dealer for a replacement.

• This manual contains standard ATV industry

safety information required to be a part of ATV Owner’s Manuals. It also contains Cannondale specific model information.

Comments?

If you have any comments or suggestions about this Owner’s manual, we’d appreciate hearing from you. Send to:

Technical Publications

Cannondale Corporation

2 Corporate Drive

Bedford, PA 15522

E-mail:

technical.publications@cannondale.com

Page 5

Noise Regulation

TAMPERING WITH NOISE CONTROL SYSTEM

PROHIBITED

U.S. federal law prohibits the following acts or the causing thereof;(1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any ne w ve hic le for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has been rem oved or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:

1. Removing, puncturing, or altering of the muffler, the

baffle system, header pipes, or any other component which conduct s exhaust gases.

2. Lack of proper m ai ntenance.

3. Replacing, altering, modifying any moving part of the

vehicle or parts of the exhaust, intake (e.g. air filters) with parts other than those specified by the manufacturer.

Limitations

All information in this O wner’s Manual i s based up on the latest product data and specifications available at the time of printing. Cannondale Corp oration reserves the right to make product changes and improvements which may affect illustrations, photographs and explanations contained in this Owner’s M anual.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, (electroni c mec ha nic al photocopying, recordi ng or otherwise), without the prior written permission of Cannondale Corporatio n. No li abi lity can be accepted for any inaccuracies or omiss ion s in this pu bli ca t io n, alth ough every possible care has been taken to make it as complete and accurate as possible. All the procedures and specifications found in this publication are subject to change without prior notice and without Canno nda le Corporation incurring any obligation. The illustrations in this publication are intended for reference use only and may not depict the actual model or component parts. Your model may differ.

If you have questions about this Owner’s Manual call:

1-800-MOTO-USA.

Page 6

SAFETY ALERTS

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

• Keep this Owner’s Manual with your v ehicle at all times.

Messages with the Safet y Alert Symb ol

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

Indicates that severe personal injury or

DANGER

death WILL result if instructions are not followed.

WARNING

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

CAUTION

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

NOTE :

Provides helpful inform atio n.

Page 7

SPECIAL SAFETY MESSAGES

• AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE

• An ATV handles differently from other vehicles including motor cycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.

• Severe injury or Death can result if you do not follow the se instructions:

• Read this manual and all labels carefully and follow the operating procedures described.

• Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 (USA only) to find out about the traini ng courses nea rest you.

• Always follow the age recommendation: A child under 16 years old should never operate an ATV with engine size greater than 90cc.

• Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

• Never carry a passenger on a ATV.

• Never operate an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

• Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

• Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), glove s, boots , long-s lee ved sh irt or jac ket, and long pants.

• Never consume alcohol or drugs before or while operating this ATV.

• Never opera te at e xces sive sp eed s. Al ways go at a speed that is proper for the terrain, visibility, operating conditions, and your experience.

• Never attempt wheelies, j umps or other stunts.

• Always inspect your ATV each time you use it to make sure it is in safe operating condition. Alw ays follow the in spection and maint enance proc edures and schedules described in this manual.

• Always keep both hands on the handlebars and both feet on the footpegs of the ATV during operation.

• Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to

Page 8

changing terrain conditions when operating the ATV.

• Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be espe cia lly cautious on these kinds of terrain.

• Always f ollo w pr oper pro cedures f or turning at lo w speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

• Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

• Always f ollo w pr oper pr ocedu res f or climbin g hills as described in this manual. Check the terrain carefully before you start up any hill. Nev er c l imb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hil l at high speed.

• Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possib le.

• Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual. Avoid hills with excessivel y slip pery or loose surfac es. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on an y hill until you have mastered the turning technique described in this manual on le vel gr ound. Avoid c ro ssing the s ide of a steep hill if possible.

• Always use proper procedures if you stall or roll backwards wh en climbing a hill. To avoid stalling, use the proper gear and maintain a steady speed when climbing a hill. If you stall or r oll backwards, follow the s pecial p roc edure f or braki ng descr ibed in this manual.

• Always c heck for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

• Always be careful when skidding or sliding. Learn to safely contr ol skidding or sliding by pract icing at low speeds and on level, smooth terrain. On extremely s lippery surfaces, s uch as ice, go s lowl y

Page 9

an be very cautious in order to reduce the chance of skidding out of control.

• Never operate an ATV in fast flowing water or in water deeper than that specified in this manual. Remember that wet brakes may have reduced stopping ability. Test you brakes after leaving water. if necessary, apply them several times to let friction dry out the linings.

• Always use the size and type of tires specified in this manual. Always maintain proper tire pressure as described in this manual.

• Never modify an ATV through improper installat ion or use of accessories.

• Never install a twist grip throttle on this ATV.

• Never exceed the sta ted load lim its for an ATV. Cargo should be pro perl y distrib uted and secure ly attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking.

• FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or the ATV Distributors’ Safety Hotline at 1-800-852-5344 (USA only).

Page 10

When reading this manual, remember:

WARNING

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

ATV SPORT REALITY - - - - - - - - - - - - - - 1 FOREWORD- - - - - - - - - - - - - - - - - - - 2 SAFETY ALERTS - - - - - - - - - - - - - - - - 4 SPECIAL SAFETY MESSAGES - - - - - - - - - 5 CONTENTS - - - - - - - - - - - - - - - - - - - 8 WARNING LABELS - - - - - - - - - - - - - - 10 MACHINE IDENTIFICATION - - - - - - - - - - 14

Vehicle Identification Number (VIN) - - - - - - - - 14 Engine Serial Number- - - - - - - - - - - - - - - 15 Key ID Number - - - - - - - - - - - - - - - - - - 15

PARTS AND CONTROL FUNCTIONS - - - - - 16

Owner’s Manual- - - - - - - - - - - - - - - - - - 18 Seat - - - - - - - - - - - - - - - - - - - - - - - 18 Ignition Switch- - - - - - - - - - - - - - - - - - - 21 Tether Switch - - - - - - - - - - - - - - - - - - - 22 Engine Stop/Start Buttons (MC500) - - - - - - - - 23 Engine Stop Switch/ Start Button (MC1000) - - - - 24 Headlights - - - - - - - - - - - - - - - - - - - - 25

Taillight - - - - - - - - - - - - - - - - - - - - - - 25 Front Brake Lever - - - - - - - - - - - - - - - - - 26 Parking Brake - - - - - - - - - - - - - - - - - - - 26 Rear Brake Pedal - - - - - - - - - - - - - - - - - 28 Footpegs & Baskets - - - - - - - - - - - - - - - - 28 Nerf Bars - - - - - - - - - - - - - - - - - - - - - 29 Shift Lever- - - - - - - - - - - - - - - - - - - - - 30 Fuel Tank Cap- - - - - - - - - - - - - - - - - - - 30 Handle Grips - - - - - - - - - - - - - - - - - - - 31 Throttle Lever - - - - - - - - - - - - - - - - - - - 32 Clutch lever (manual) - - - - - - - - - - - - - - - 33 Clutch lever (hydraulic) - - - - - - - - - - - - - - 33 Fuse & Diagnostics Connector - - - - - - - - - - - 34 Safety Flag Mount - - - - - - - - - - - - - - - - - 35

SAFE OPERATION- - - - - - - - - - - - - - - 36

Experienced Riders Only! - - - - - - - - - - - - - 36 Training and Instruction - - - - - - - - - - - - - - 37 Age Recommendation - - - - - - - - - - - - - - - 38 Wear Protective Gear - - - - - - - - - - - - - - - 39 Ride Sensibly - - - - - - - - - - - - - - - - - - - 40 No Passengers: No Exceptions! - - - - - - - - - - 41 Cargo, Loading Limit- - - - - - - - - - - - - - - - 42 Off-road Use Only - - - - - - - - - - - - - - - - - 43 Stay Off Public Roads and Highways- - - - - - - - 44 Turning The ATV - - - - - - - - - - - - - - - - - 45 Don’t Drink and Drive! - - - - - - - - - - - - - - - 46 No Wheelies, Stunts, or Jumps- - - - - - - - - - - 47

Page 11

Keep Your Hands and Feet on the Controls- - - - 48 Watch Out for Terrain Changes- - - - - - - - - - 49 Rough or Slippery Terrain - - - - - - - - - - - - 50 Stay Off Steep Hills- - - - - - - - - - - - - - - - 51 Climbing Hills Improperly - - - - - - - - - - - - - 52 Riding downhill - - - - - - - - - - - - - - - - - - 53 Crossing Slopes or Hills - - - - - - - - - - - - - 54 Turning on Slopes or Hills - - - - - - - - - - - - 55 Obstacles - - - - - - - - - - - - - - - - - - - - 56 Skidding or Sliding - - - - - - - - - - - - - - - - 57 Safety Flag- - - - - - - - - - - - - - - - - - - - 58 Riding Through Shallow Water - - - - - - - - - - 59 Stalling, Rolling Backwards- - - - - - - - - - - - 60 Modifications- - - - - - - - - - - - - - - - - - - 61

PRE-RIDE INSPECTION- - - - - - - - - - - - 62

Pre-Ride Checklist - - - - - - - - - - - - - - - - 63

OPERATION- - - - - - - - - - - - - - - - - - 64 BREAK-IN - - - - - - - - - - - - - - - - - - - 67 MAINTENANCE & ADJUSTMENT - - - - - - - 68

Work safely - - - - - - - - - - - - - - - - - - - 68 Maintenance Schedule - - - - - - - - - - - - - - 72 Panels - - - - - - - - - - - - - - - - - - - - - - 75 Frame, Subframe, Swingarm - - - - - - - - - - - 80 Fuel - - - - - - - - - - - - - - - - - - - - - - - 82 Engine Oil - - - - - - - - - - - - - - - - - - - - 85 Transmission Oil - - - - - - - - - - - - - - - - - 91 Coolant - - - - - - - - - - - - - - - - - - - - - 95

Brakes - - - - - - - - - - - - - - - - - - - - - 100 Clutch - - - - - - - - - - - - - - - - - - - - - 109 Drive - - - - - - - - - - - - - - - - - - - - - - 116 Electrical - - - - - - - - - - - - - - - - - - - - 123 Air - - - - - - - - - - - - - - - - - - - - - - - 136 Exhaust - - - - - - - - - - - - - - - - - - - - 139 Suspension- - - - - - - - - - - - - - - - - - - 140 Wheels- - - - - - - - - - - - - - - - - - - - - 146 Tires - - - - - - - - - - - - - - - - - - - - - - 149

CLEANING- - - - - - - - - - - - - - - - - - -152 STORAGE - - - - - - - - - - - - - - - - - - -153 TRANSPORTING - - - - - - - - - - - - - - -154 TORQUE TABLE- - - - - - - - - - - - - - - -156 TROUBLESHOOTING - - - - - - - - - - - - -157 MAINTENANCE RECORD- - - - - - - - - - -160 2002 MODEL SPECIFICATIONS- - - - - - - -161

Engine - - - - - - - - - - - - - - - - - - - - - 161 Chassis - - - - - - - - - - - - - - - - - - - - 164 Suspension- - - - - - - - - - - - - - - - - - - 166

ATV LIMITED WARRANTY - - - - - - - - - -168 STOLEN UNITS - - - - - - - - - - - - - - - -169 CHANGE OF ADDRESS - - - - - - - - - - - -169 ADDENDA - - - - - - - - - - - - - - - - - - -170

Page 12

WARNING LABELS

Examples of all vehicle w arni ng lab els are found in this section. Read and understand the actual ones on your vehicle. The labels contain information which is im port ant to your safety and that of anyone else who operates the ATV.

• The warning labels should be considered

permanent parts of vehicle. Yes, just like the wheels and engine, they are needed parts for any operator.

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

becomes unreadable, be sure to replace it. Cannondale offers replacemen t labels at no charge. A label’s part number is printe d 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. Examples of the labels are shown on the following pages.

• Always replace labels in the correct position. See

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

(1)

(4)

(7)

(5)

(2)

(6)

(3)

Page 13

315-6000236-01

315-6000237-01

Label 2 P/N 315-6000237-01

Riding as a passenger can cause the ATV to go out of control.

Loss of control can cause a collision or rollover, which can result in severe injury or death.

NEVER ride as a passenger.

315-6000239-01

Label 2 P/N 315-6000236-01

Label 3 P/N 315-6000239-01

Page 14

315-6000238-01

Label 4 P/N 315-6000238-01

315-6000477-01

Label 5 P/N 315-6000477-01

315-6000580-01

Label 6 P/N 315-6000580-01

Page 15

Hangtag

All Cannondale ATVs are shipped w ith a r em ova bl e hangtag attached to the handlebar. Like the vehicle’s warning labels, this hangtag contains important information for your safety. Read and understand it throroughly before removing it.

Page 16

MACHINE IDENTIFICATION

NOTE :

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

Record your vehicle’ s identification numbe rs in the spaces provided. Keep another record of the numbers in a safe place; you may need the m for parts , serv ic e information, or theft recovery.

Your vehicle’ s ID numbe rs ide ntify it from others of the same model type.

(1)

(2)

VEHICLE IDENTIFICATION NUMBER (VIN)

The vehicle identification number (VIN) is etched/ stamped into the frame behind the fron t brush gu ard. The VIN also appears on a temporary factory applied adhesive label in the same area.

1. Etched vehicle identification number

2. Factory VIN label

1. Vehicle identification number (VIN)

2. Engine serial number

Write your number here

Page 17

ENGINE SERIAL NUMBER

The engine serial nu mb er i s etch ed/ stamped into the rear area of the engine crankcase. The number also appears on a metalli c pla te affixed to the crankcase area above the countersha ft sprocket. The number al so appears on a temporary factory applied adhesive label in the same area.

KEY ID NUMBER

Key identification numbers are etched/stamped into key

bodies.

NOTE :

Keep your spare key in a safe place in case you lose the primary key.

1. Engine serial number

Write your number here

(1)

(3)

(2)

XXXXXX

(4)

1. Primary Key (remove housing to view ID number)

2. Spare key

3. Key ID number

4. Housing

Write your number here

Page 18

PARTS AND CONTROL FUNCTIONS

(2)

(5)

NOTE :

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

1. Clutch lever

2. Engine RUN/OFF switch

3. Engine start switch (green)

4. Ignition switch

5. Front brake master cylinder

6. Parking brake lock

7. Front brake lever

8. Throttle

9. Fuel cap

Page 19

(12)

(11)

()

(3)

(4)

(8)

(10)

(14)4)4)

(3)

(18)

(17)

(21)

1. Rectifier/regulator

2. Engine Control Unit (ECU)

3. Diagnostic connector & fuse

4. Fuel pump

5. Starter

6. Engine oil filter (1 of 2)

7. Shift lever

8. Transmission oil level check

9. Left frame spar drain bolt

10. Air filter

11. Fuel cap

12. Owner’s Manual

13. Muffler

14. Taillight

15. Safety flag mount

16. Fuel filter

17. Engine oil, coolant levels check

18. Radiator

19. Battery

20. Coolant bleed bolt

21. Right frame spar drain

22. Rear brake pedal

Page 20

OWNER’S MANUAL

The Owner’s Manual for your vehicle is located under the seat. It contains important safety and maintenance information. Keep it on the vehicle when you ride. To find the manual, remove the seat.

(1)

(3)

SEAT

The seat on your vehicle is for you only. Carrying a passenger can cause you to lose control of the vehicle. The entire length of the seat is required so that you can shift body weight/position while riding to maintain vehicle control and stabilit y. Make sure the seat is in good condition and fasten ed se curely before you ride.

1. To remove the seat, loosen and completely remove the

seat retention bolt.

1. Owner’s manual

2. Low pressure tire gauge

3. Vinyl bag

(2)

1. Seat retention bolt

Page 21

2. Use your fingertips to lift up the rear of the seat slightly. Then, pull the seat back toward the rear of the vehicle and lift it off.

4. Press down gently on the middle of the seat and slide the seat forward onto the clip and subframe guides. If correctly aligned, the rear seat pegs will slip easily through the subframe seat buffers.

(3)

(1)

(5)

3. To install the seat, align the receivers in the seat pan with the fuel tank clip and the subframe guides.

(4)

1. Fuel tank clip

2. Subframe guides (right)

3. Seat pegs

4. Subframe seat buffers (right)

5. Owner’s Manual & Tool Kit

(2)

Page 22

WARNING

POTENTIAL HAZARD

Loose, damaged, or improperly installed seat

WHAT CAN HAPPEN

The seat can shift or come off while you are riding causing you to lose control of the vehicle. You can be severel y injur ed or kil led.

HOW TO AVOID THE HAZARD

Always make sure the seat is locked into position on the mounts and secured properly with the retention bolt. Never ride this ATV with a damaged seat. Have it replaced.

CAUTION

Do not force the seat pegs through the holes in the rear fende r o r sub f ra me buf f er s; y ou c o ul d damage the seat.

Avoid excessive force.

When reading this manual, remember:

WARNING

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

5. Install the seat retenti on bolt and tighten it securely.

Page 23

IGNITION SWITCH

The ignition switch is located between the handlebars. Always remove the key from the switch to help prevent unauthorized vehicle use or theft. See the table for a description of the switch positions.

(2)

(1)

Key Position Function

The engine and lighting

cannot be operated.

Turning th e igni tion s wi tc h to the “OFF” position, will stop a running engine, however, we recommend using the engine

“OFF”

“ON”

stop button (or switch) as the primary me ans to shut off a running engine - follow-up by turning the switch to the “OFF” position.

With the Engine Stop switch in the “RUN” position and the clutch lever pulled in, the e ngi ne can be started using the Engine Start button.

We recommend starting the engine with the ig nit ion switch in the (I) position then switch to the “ON w/LIGHTS” position

Key

Removal

Yes

1. Ignition switch (key shown inserted)

2. Switch positions

“ON w/

LIGHTS”

Lighting (headligh ts and taillight are activated.

Page 24

TETHER SWITCH

On equipped models, the tether switch is an additional safety device. Test for proper operation of the switc h before riding. The switch mus t be i n the ope rating position to start the vehicle. To test the switch, make sure the switch pin is inserted correctly. Start the engine. With the engine running, pull the strap quic kl y fr om the sw i tc h body the engine should shut down imme diatel y. If it does not, do not ride the ATV; the switch is damaged and must be replaced. Contact your dealer for a replacement.

1. Switch body

2. Tether pin

3. Tether strap

4. Body clip (to be secured to the rider)

(1)

(2)

1. Tether switch in operate position

2. Detached position

NOTE :

Body clip attachment to rider not illustrated.

Page 25

ENGINE STOP/START BUTTONS (MC500)

1. Engine stop button

2. Engine start button

Engine stop button

The engine st op button is located on the left handlebar close to the inside edge of the handle grip and is red in color. Press the stop button to shut off the running engine. It is also an emergency con trol. Test the stop button before moving off to ride to confirm that it is operating properly. If the switch does not “kill” the engine, don’t ride the ATV. Turn the i gn itio n s witc h to t he “OFF” position and contact a Cannondale motorsports dealer to have it replaced.

NOTE :

The stop button is a “normally closed” circuit switch. If the switch is damaged or the wires are frayed or torn, (i.e. circuit open) the engine will not start.

Engine start button

The engine start button is green in c ol or and is mounted closer to the center of the handleb ars. Pressin g it activate s the engine management system ci rcuits and the starter motor. Make sure it operates properly before each ride.

Page 26

ENGINE STOP SWITCH/ START BUTTON (MC1000)

1. Engine OFF/RUN Switch

2. Engine start button a. OFF posi t ion

NOTE :

The switch is show n in the R UN positi on in this photo.

Engine stop switch

The engine stop switch is located on the left handlebar close to the inside ed ge of the han dle grip and is the sli ding type with two positions. Sliding the switch to the “OFF” position will deactivate the Engine Management System and is the recommend ed me thod to stop the engin e while it is running as opposed to using the ignition switch. This switch is also an e m ergency contr ol used t o shut down the engine quickly with your thumb without removing your hands from the handle grip. This switch must be maintained nearer the handle grip for this reason. During your pre-ride inspection an d before movin g of f to ride, start the engine and test the swi tch to confi rm that i t is o peratin g properly. If the switc h does not “kill” a running engine, d on’t ride the ATV. Remove the key from the ignition switch to prevent vehicle use and contact an Cannondale motorsports dealer for servicing.

Engine start button

Page 27

HEADLIGHTS

Turn the ignition switch to the “ON w/LIGHTS” position to activate the headlights. Test for the proper operation of the headlights before op erating the vehicle.

1. Headlights

TAILLIGHT

Turn the ig nition swi tch to the “ON with L IGHT S” positio n to activate the taill igh t. T he tail lig ht I S NOT a brake ligh t. Make sure it works before every ride.

1. Taillight

Page 28

FRONT BRAKE LEVER

The front brake lever is located on the right side of the handlebar. Pull it toward the handlebar to apply the front brakes. Pull the lever harder to increa se brak in g force .

Before each ride, make sure the front brake s are operating properly and can provide braking force when needed. Roll the v ehicle forward and back apply ing the brake to confirm that brak in g force is applied to the front brake discs.

Front brake lever view

PARKING BRAKE

The parking brake is ap plied with a lock button on the front brake lever. When the parking brake is applied (locked), the front brakes temporarily from rolling. Be sure to read the warning about using the parking brake!

prevent the vehicle

1. Front brake lever

Page 29

WARNING

POTENTIAL HAZARD(S)

(1) ATV rolling away (2) Riding with the parking brake applied

WHAT CAN HAPPEN

(1) A potential decline in fluid pressure can decrease the applied braking force allowing the ATV to begin to roll. (2) Brake system will overheat, cause premature wear, and damage to the brake pads. This can result in a loss of brake function. In either case above, severe injury or death can result to the owner or bystanders.

HOW TO AVOID THE HAZARD

(1) Always block or chock the wheels on your ATV immediately after applying the parking brake. Never apply the parking brake and leave the vehicle unattended. Always choose firm level ground on which to park your ATV. (2) Release the parking brake before you ride.

your index finger until it is fully depressed - release the lever and remove your index finger from the button.

2. To disengage the parking br ak e , pres s do wn on the re ar brake pedal with your foot. Then, pull the front brake lever against the handle grip; the locking mechanism will automatically disengage (pop up).

3. Release the front bra ke lev er slowly.

1. To apply, pull the front brake lever against the handle grip and hold it. Press and hold the locking button with

Page 30

REAR BRAKE PEDAL

The rear brake pedal is located on the right side of the vehicle. When pressed, braking forc e is appli ed to the rear wheels. Make sure the rear brake is operating properly before you ride. Roll the vehicle forward and back and press the pedal to confirm that braking force is applied to the rear brake disc.

FOOTPEGS & BASKETS

When riding always keep your feet on the footpegs. Always check the condition of the footpegs and baskets before every ride. Make sure that they are fastened securely to the vehicle. The footpeg teeth should be in good condition (not smooth or wo rn exc es sive ly). The baskets should be free of an y packed soils an d they sh ould not be cracked, broken, or dam aged in any way. If damage is found install new ones.

1. Rear brake pedal

1. Foot peg (left)

2. Basket

Page 31

NERF BARS

NRF BAR

Always check the condition of the nerf bars, strapping, and footpe g teeth before every ride. Make sure that t hey are fastened securely to the vehicle and that the footpeg teeth and webbing is in good condition and does not sag excessively when the weight of the rider is applied. Pay particular attention to strapping in the areas where it attaches to the bars. See example at dotted circle in photo

below.

NURF BAR

1. Nerf bar (right)

2. Teeth (replacable)

3. Strapping

WARNING

POTENTIAL HAZARD(S)

Damaged webbing

WHAT CAN HAPPEN

Foot can go through the bars while riding. You can lose control and have a serious accident.

HOW TO AVOID THE HAZARD

Inspect the webbing before you ride. If its damaged don’t ride the vehicle. Replace it.

Page 32

SHIFT LEVER

The shift lever is located on the left side of the engine in front of the left footpeg. The vehicle has five forward gears (1-down,”NEUTRAL’” 4-up). Place the vehicle on a level surface. Before every ride, make sure the shift lever operates properly and shifts through the entire range of gears with the engine turned off; roll the vehicle forward and back as you shift through al l the gear s to av oi d damaging the transmission.

FUEL TANK CAP

Make sure the fuel cap is tightly secured before every ride. Turn the fuel cap counterclockwise to remove it and clockwise to tighten it. Al ways make sure the breather hose is routed from the cap p roperly (inse rted int o the ha ndleb ar cover hole).

5 4

1. Shift lever

1. Fuel cap

2. Breather hose

3. Hole

Page 33

HANDLE GRIPS

Inspect both (left and ri ght) handl ebar grips before ever y ride. Make sure th ey are firmly attached and do no t twist on the handlebar. Inspect the grips for wear, tears, or other damage. Replace the grips with a new set if damage is found. Contact an authorized Cannondale motorsports dealer for a replacement set.

1. Handle grip (right)

Page 34

THROTTLE LEVER

The throttle lever is located on the right side of the handlebar. When pushed, the engine speed will increase. When released, engine speed will decrease - the lever spring pressure should return the lever to the set idle (engine) speed. Check for proper operation and specified freeplay of the throttle be fore every ride. See “2002 Model Specifications” star ting on page 161.

Lever movement should work smoothly without binding or pinching in all lever and handlebar positions.

DANGER

POTENTIAL HAZARD

Overturning or flipping the ATV onto yourself

NOTE :

Freeplay is the distance the lever moves until the slack in the cable is taken up.

WHAT CAN HAPPEN

Opening the throttle too quickly and/or releasing the clutch lever too quickly can overturn or “flip” the ATV. You can be severely injured or killed.

HOW TO AVOID THE HAZARD

Never open the throttle abruptly. Open the throttle gradually when moving off or accelerating. Never “pop” or release the clutch lever quickly. Always gradually release the clutch lever. If the ATV “wheelies” or the front wheels begin to come off the ground, close the throttle and pull in the clutch lever immediately.

1. Throttle lever a. Freeplay

Page 35

CLUTCH LEVER (MANUAL)

The clutch lever is lo ca ted on t he left side of the handlebar. Pull in the clutch lever (quickly) to disengage the clutch, and release the lever (slowly) to engage the clutch. Check the condition and proper operation of the clutch lever and cabl e be for e every ride. Als o make sure the clutch lever freepla y is adjus ted to spe ci fic ati on. See “Clutch lever (manual)” starting on page 33.

1. Clutch Lever

2. Starting system interlock switch

CLUTCH LEVER (HYDRAULIC)

The hydraulic clutch lever is located on the left side of the handlebar. Pull in the clutch lev er (quickly) to disengage the cl utc h, and release the lever (slowly) to engage the clutch. The lever position can be adjusted for individual hand sizes. See “Clutch lever position (hydraulic)” starting on page 110.

1. Clutch Lever

2. Starting system interlock switch

3. Clutch reservoir

Page 36

FUSE & DIAGNOSTICS CONNECTOR

The main electrical fuse is located in the area under the left front fender. Always replace the fuse with one of the specified rating. See “Fuse” starting on page 130. A special diagnostic tool co nne cto r is al so located in the same area. The connector type is different for MC500 and MC1000 equipped models. Se e the photos. The diagnost ic tools ca n be used to diagnose faults with the engin e management system as well as other function s.

1. Fuse (in holder)

2. MC500 Data port

1. Fuse (in holder)

2. MC1000 Data port

NOTE :

For information on special tools developed to service your ATV, contact an authorized Cannondale motorsports dealer.

Page 37

SAFETY FLAG MOUNT

The safety flag mounting bracket is integrated into the left side of the rear grab rail. When riding in areas where you might not be eas il y seen (e.g. hilly terra in or san d dunes) mount an approved ATV safety flag.

Safety flags are required i n some rid ing area s. For mo re information on ap prov ed ATV safety flags, contact an authorized Cannond ale motorsports deale r.

1. Safety flag mount

Page 38

SAFE OPERATION

When reading this manual, remember:

WARNING

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

EXPERIENCED RIDERS ONLY!

WARNING

POTENTIAL HAZARD

Crashing t he ATV

WHAT CAN HAPPEN

Cannondale ATVs are high-performance sport category machines designed for competition use only by operators who already have substantial skill and operating experience. Operating without substantial skill and operating experience increases the risk that you could lose control of the vehicle becoming severely injured or killed in a resulting accident.

HOW TO AVOID THE HAZARD

If you do not have substantial skill and operating experience, DO NOT OPERATE ANY CANNONDALE ATV. Always remove the ignition key from this vehicle to prevent unauthorized use.

Page 39

TRAINING AND INSTRUCTION

The following warning message is required to be part of this Owner’s Manual as part of an agre eme nt betwe en the ATV Industry and the U.S. Consumer Product Safety Commission (CPSC). The warning was written to communicate the need for beginning and inexperienced riders to get training and in struction before operating any A TV. Although the mess age that train ing a nd i nst ructio n is required for any beginning rider is correct, these riders SHOULD NOT operate Cannondale ATVs. See the warning on the previous page.

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in diff erent si tuations a nd on dif fer ent types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced riders should complete the certified training course. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized Cannondale motorsports dealer or call 1-800-887-2887 (USA only).

Page 40

AGE RECOMMENDATION

WARNING

POTENTIAL HAZARD

Failure to follow the age recommendation for this ATV.

WHAT CAN HAPPEN

Use by children of ATV’s that are not recommended for their age can lead to se ver e inju ry or death of the child. Even though a child may be within the age group for which an ATV is recommended, he or she may not have the skills, abilities, or judgement needed to operate the ATV safely and may be involved in a serious accident.

HOW A CHILD UNDER 16 SHOULD NEVER OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC.

Page 41

WEAR PROTECTIVE GEAR

The proper riding apparel (gear) can help reduce the chance of injury in the ev ent of an accid ent and make

riding more comfortable.

WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.

WHAT CAN HAPPEN

Operating without an approved motorcycle helmet increases your chances of severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of severe eye injury in the event of an accident. Operating without prot ective c lo thing incre ases y o ur chances of severe injury in the event of an accident.

HOW TO AVOID THE HAZARD

Always wear an ap pr o ved motor c yc le he lmet that fits properly. You should also wear: eye protection (goggles or face shield), gloves, boots, long pants and a jacket or long sleeved shirt.

Helmet

Goggles

Protective clothing

Example of a properly dressed rider

Gloves

Boots

Page 42

RIDE SENSIBLY

Riding too fast increases your chances of an accident occurring which could result i n a serio us inj ury or de ath, no matter what your experience level.

Do not ride faster than what is appropriate for your skill level and surrounding conditions.

Always reduce speed when rid ing at dusk, dawn, and night. Riding at dusk, dawn, and nighttime, even with the lighting on this ATV, reduces your ability to see obstacles; therefore, you must slow down.

When reading this manual, remember:

WARNING

POTENTIAL HAZARD

Riding this ATV at excessive speeds.

WHAT CAN HAPPEN

Increases your chances of losing control of the ATV, which can result in an accident.

HOW TO AVOID THE HAZARD

Always go at a speed that is proper for your vehicle, the terrain, visibility and other operating conditions, and your experience.

WARNING

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

Page 43

NO PASSENGERS: NO EXCEPTIONS!

Don’t carry a passenger on any ATV. Passenge rs will interfere with your a bil ity to control the vehicle. A special NO P ASSENGE RS warning label is affixed on the seat to always remind you and those who ask for a ride. If someone asks for a ride, refuse and ask them to read the warning label on the rear of the seat. Then, explain that your ATV has no seating space, footpegs, or grab rails for his/her use. And, that the seemingly large seat is needed for you to shift body position/weight as necessary when riding. Also explain that if they put their feet on the footpegs you will not be able to operate the foot controls (e.g. rear brake, shift lever.

WARNING

POTENTIAL HAZARD

Carrying a passenger on this ATV. WHAT CAN HAPPEN

Greatly reduces your ability to balance and control this ATV. Passengers affect balance and steering increasing the risk of losing control. Carrying a passenger could cause an accident, resulting in injury or death to you and/or your passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The ATV has a long seat to allow the operator to shift position as needed during operation. It is not for carrying passengers.

Page 44

CARGO, LOADING LIMIT

Do not carry cargo on your ATV. Do no t modify y our ATV

to carry cargo.

Do not exceed the veh ic le’s specified loadin g lim it. Loading limit is defined as: the weight of the operator (wearing all protective gear/apparel) - nothing else! Consult the Model Specificati ons section of this Owner’s Manual for your vehicle’s loading lim it. “2002 Model Specif ic atio ns ” on page 161.

Exceeding the vehic le’s specif ied loadi ng limit will cause a lose of stability and erratic handling that can res ul t in the loss of vehicle cont rol. You could be involved in an accident and be seriously injured or killed.

WARNING

POTENTIAL HAZARD

Overloading this ATV or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle handling which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owner’s Manual for carrying cargo or pulling a trailer.

Page 45

OFF-ROAD USE ONLY

Stay off the public streets, highways, or any other paved

surfaces.

First, you risk a collisi on with othe r vehicles. Aside from severely injuring or killing yo urs elf , you’ll probably injure or kill a motorist. Second, no matter what speed you might choose to attempt it, you can’t operate an ATV safely on a public road or highway. The hard surface makes the handling and stability of all ATVs wildly unpred ict able. You can lose control sudden ly and withou t warning. The lig hting on this ATV does not imply that it is for public roads or highways.

WARNING

POTENTIAL HAZARD

Operating this ATV on paved surfaces. WHAT CAN HAPPEN

The ATV and its tires are designed for off-road use only. Paved surfaces may seriously affect handling of the ATV which may cause you to lose control of the vehicle.

HOW TO AVOID THE HAZARD

Never operate this ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. If you must ride on a paved surface, go slowly and do not make sudden turns or stops.

Page 46

STAY OFF PUBLIC ROADS AND HIGHWAYS

WARNING

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN

You can collide with another vehicle.

HOW TO AVOID THE HAZARD

Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATV’s on public streets, roads and highways.

Page 47

TURNING THE ATV

Practice making turns in a large open area at sl o w speeds to build experience before attemptin g more difficult turns at increased speed.

To turn, slide forward on the seat and turn the handlebars in the direction of the turn. Lean yo ur b ody to the inside of the tu rn while maint aining the thro ttle po sitio n. When the turn is compl ete, straig hten the handlebars and return to a normal riding position.

The ability of the rea r inside wheel to slip during a turn also depends on the ty pe of terrain where you are riding. If the terrain is loose the inside wheel will slip more easily and turns can be made in a smaller radius. If the terrain is hard, where the insi de wh ee l is slippi ng less, the t urn ing radius will be larger.

Always slow down before turning and reduce your speed before entering a turn.

WARNING

POTENTIAL HAZARD

Turning improperly. Removing your feet from the footpegs when turning.

WHAT CAN HAPPEN

The ATV can go out of control, causing a collision or overturn. Your foot can come in to contact with the rear wheel resulting in severe personal injury.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds. Keep your feet on the footpegs when operating this ATV. Do not turn at excessive speeds.

If you have experience ridin g a motorcy cle yo u will have to quickly “unlearn” the technique you might have developed of removing your inside foot from the footpeg and positioning it on the ground when making a turn. This motorcycle technique will result in severe personal injury and possibly a loss of control if a ttem pt ed on any ATV. Never remove your feet from the footpegs while riding this ATV.

Page 48

DON’T DRINK AND DRIVE!

ATV’s are no different than ca rs wh en it com es to drinking an d driving. Do it and people wind up dying or hurting themselves and others severely.

Alcohol impairs your judgement and slows yo ur reactions - so stay off any ATV if you’ve been drinking alcohol or taking drugs or medication. And, remember that even prescription and over-the counter drugs can impair your ability to safely operate this ATV. If you are taking a ny type of medication, check with your doctor before riding.

WARNING

POTENTIAL HAZARD

Operating this ATV after consuming alcohol or drugs.

WHAT CAN HAPPEN

Could seriously affect your judgment. Could cause you to react more slowl y. Could affect your balance and perception. Could result in an accident.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while driving this ATV.

When reading this manual, remember:

WARNING

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

Page 49

NO WHEELIES, STUNTS, OR JUMPS

We urge you NOT TO DO STUNTS, ride sensibly. and develop a healthy respect for the vehicle. All Cannondale ATV’s are high-perfor m an ce vehicles. If the throttle is opened abruptly and/or the clutch lever is released too quickly the front w h eel s w ill c om e off the ground. This may result in the vehicle overturning.

You will see people attempting jumps or other stunts with ATVs. You’ll probably see someone do it in one of the magazines or at an ATV event. What you could be seeing is a professional rider or a weekend amateur. In any case, whoever the jumper or stunter is, they are engaging in a extremely high-risk activity which can result in crippling injury or death.

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps, and other stunt s.

WHAT CAN HAPPEN

Increases the chance of an accident, including an overturn.

HOW TO AVOID THE HAZARD

Never attempt stunts, such as wheelies or jumps. Don’t be a show off!

Page 50

KEEP YOUR HANDS AND FEET ON THE CONTROLS

Riding ATV’s safely means being in complete control of

the vehicle at all times.

Always keep your hands on the handle grips and your feet on the footpegs. By removing your hands and feet from the handle grips an d footp egs you risk serious injury and losing control of this ATV.

ATTENTION MOTORCYCLE RIDERS:

You may have a motorcycle riding technique to unlearn! The common practice of removing a foot from your motorcycle footpegs when rounding a turn is VERY DANGEROUS if done on an ATV. If you take your foot off the footpeg while turning the rear tires will run over your foot or leg and cause severe injury - maybe even death.

WARNING

POTENTIAL HAZARD

Removing hands from handlebars or feet from footpegs during operation.

WHAT CAN HAPPEN Removing even one hand or foot can reduce your

ability to control the ATV or could cause you to lose you balance and fall off the ATV. If you remove a foot from the footpeg, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars and both feet on the footpegs of your ATV during operation.

Page 51

WATCH OUT FOR TERRAIN CHANGES

Watch out for terrain changes or hidden hazards that can cause you to lose control of the vehicle or collide with unseen obstacles (e.g., gopher holes, logs, gullies, or ditches). Always use caution in an unfamiliar area.

For example, never ride through an area where the view of the ground surface is not clear (e.g., high-standing grass, fallen branches, holes, large obstacles or other hazards); you could co lli de with a hidden hazard an d be

seriously injured or ev en killed.

WARNING

POTENTIAL HAZARD

Failure to use extra care when operating this ATV on unfamiliar terrain.

WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes

without enough time to react. Could result in the ATV overturning or going out of control.

HOW TO AVOID THE HAZARD

Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

Page 52

ROUGH OR SLIPPERY TERRAIN

Never operate on excessively rough, slippery or loo se terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.

WARNING

POTENTIAL HAZARD

Failure to use extra care when operating on excessively rough, slippery or loose terrain.

WHAT CAN HAPPEN Could cause loss of traction or vehicle control,

which could result in an accident, including an overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

Page 53

STAY OFF STEEP HILLS

Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills be fore attemp ting larger hills.

Keep the front wheels on the gro und s o that you maintain steering control and prevent the possibility of overturning the ATV.

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills. WHAT CAN HAPPEN

The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills.

HOW TO AVOID THE HAZARD

Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

Page 54

CLIMBING HILLS IMPROPERLY

Climbing hills is an advanced technique. Before attempting to climb difficult hills, begin by practicing on flat ground and then smalle r hills to build experience. Nev er attempt a hill or slope beyond your skill level and evaluate all hills and slopes carefully to avoid ter r ain that might cause the ATV to overturn. Only attempt difficult hills and inclines after you have developed considerable skill and experience through study and practice.

When climbing hill s and slopes, shift your weight forward toward the front wheels to help keep them from lifting off the ground. Shift your weight in greater degrees (depending on the hill and cond itions) by sl iding forward on the seat.

As you move forward, lean your body forward and maintain a steady spe ed. Always avoid hills and climbs with loose or slippery surfaces, or where obstacles might cause you to lose control or force a sudden change in direction. This can result in a seri ous ac ci dent resulting in serious injury or death. Maintain steady and controlled throttle openings. Sudd en a cc el erat ion ca n cause the front wheels to come of f the ground - you coul d flip the ATV onto yourself. It’s heavy and you can sever ely in jure or kill yourself.

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backward. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

Page 55

RIDING DOWNHILL

When riding downhi ll, sh ift you r wei ght back as far as possible with your arms straight. Choose a low gear to allow the engine to do mo st of the brak in g for yo u. Improper braking with either the front or rear brakes could lead to a loss of tracti on and ve hic le control resulting in an accident.

Always travel straight down a hill when possible. Avoi d sharp turns which could ca use th e ATV to tip or roll over.

Always choose a path down hill that is free of obstacles.

Never ride faster than your ability to react safely and maneuver the ATV. If you don’t give yourself enough time to avoid obstacles and terrain hazards, you can be seriously injured or ev en killed.

WARNING

POTENTIAL HAZARD

Going downhill improperly. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Always fo llow proper procedures for going down hills as described in this Owner’s Manual. Note: a special technique is re quired whe n braking a s you go down a hill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.

Page 56

CROSSING SLOPES OR HILLS

WARNING

POTENTIAL HAZARD

Improperly crossing hills or turning on hills. WHAT CAN HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in this Owner’s Manual on level ground. Be very careful when turning on any hill. Av oid crossing the side of a steep hill if possib l e. When crossing the side of a hill: Always follow proper procedures as described in this Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

Crossing slopes or h ill s on this ATV requires you to properly position y our we ight to maintain stability and control. Crossi ng slo pe s is an advanc ed sk il l, so learn basic riding skills on flat lev el gro und before attempting to traverse a slope.

In every case, stay off slopes with slippery , loose, or rough surfaces. These surfa ce s can ca us e a loss of traction and control or up se t your bal anc e. Whe n cros si ng a slope keep your body w ei ght toward the top of the slope or hill and avoid making sudden or sharp turns in either up or down hill direction. Sh ifting weight help s to maintain y our balance and stability. It may be necessary to adjust steering up the slope s lightl y so tha t your di rectio n of tr avel is straight across the slope. If the vehicle begins to tip over, correct by reducing speed and gra dually steering in the downhill direct ion .

Avoid slopes with unstable or slippery surfaces that will cause the tires to lose tractio n. Always trav el at a red uc ed speed.

Page 57

TURNING ON SLOPES OR HILLS

Turning on slop es or h il ls is an advanced skill so before attempting a turn on a slop e or hill, practice turning on level ground.

Avoid slopes with unstable or slippery surfaces that will cause the tires to los e trac tio n. When tu rnin g on a s lo pe or hill you may need to shift a greater amount of your weight and lean more to successfully make the turn. Pr actice turning on smaller slopes or hills first and never attempt a turn on steep, slippery, or rough s lopes or hills.

Always reduce speed when turning.

WARNING

POTENTIAL HAZARD

Improperly cr ossing hills or turning on hills. WHAT CAN HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in this Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as described in this Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

Page 58

OBSTACLES

Never attempt to ride or jump over obstacles such as

large rocks or fallen trees.

WARNING

POTENTIAL HAZARD

Improperly ope rating over obstacles.

WHAT CAN HAPPEN

Could cause loss of control or a collision. Could cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles. Never attem pt to ride over large obstacles , such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as descri bed in this Ow ne r’s Manual.

When reading this manual, remember:

WARNING

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

Page 59

SKIDDING OR SLIDING

Slow down and use caution when rid ing ov er l oos e, slippery, or unstable su rfac es such as snow, ice, or mud.

Slides are more likely on sl ippery or loose surfaces when turning. If you skid or slide you may lose all steering control of the ATV and an accident will resul t.

If you skid si dew a ys w hen turning on a loose or slippery surface, steer in the direction of the skid .

WARNING

POTENTIAL HAZARD

Skidding or sliding improperly. WHAT CAN HAPPEN

You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn.

HOW TO AVOID THE HAZARD Learn to safely control skidding by practicing at

slow speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

Page 60

SAFETY FLAG

In hilly terrain, use a safe ty flag so that others can see you. Use extra care when approaching the tops of hills or blind areas such as around bends or turns.

Some states and stat e-run areas require a safety flag. Make sure your flag meets state and local requirements.

WARNING

POTENTIAL HAZARD

Operating in areas where you might not be easily seen by other ATV’s or off-roa d vehicles.

WHAT CAN HAPPEN

You could collide with another vehic le.

HOW TO AVOID THE HAZARD

Always mount an ATV safety flag to the vehicle to make you more visible. Always use caution around other ve hicles.

Page 61

RIDING THROUGH SHALLOW WATER

The A T V can be us ed to cross through slow moving shallow water - up to a maximum depth specified for each ATV model. See “2002 Model Specifications” starting on page 161.

Never attempt to ride any ATV in deep or fast moving water , such as riv ers or stre ams. The tire s will floa t causing the vehicle to become unstable. You could quic kl y lose control and become ca ugh t in w ate r cu rren ts.

Never enter water without first checking out the area. Look for areas to enter and exit the water where surfaces are stable and not slipp ery or loo se .

Check for any hidden obs tructi ons and hole s whic h may trap, disable, or result in the vehicle becoming submerged.

Travel at reduced speed.

WARNING

POTENTIAL HAZARD

Operating this ATV through deep or fast flowing water.

WHAT CAN HAPPEN

Tires may float, causing loss of traction and loss of control, which could lead to an accident.

HOW TO AVOID THE HAZARD

Never operate this ATV in fast flowing water or in water deeper than that specified in this Owner’s Manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving the water. If necessar y, apply them seve ral times to let friction dry out the pads.

Page 62

STALLING, ROLLING BACKWARDS

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards or improperly dismounting while climbing a hill.

WHAT CAN HAPPEN

Could result in ATV overturning.

HOW TO AVOID THE HAZARD

Use proper gear and maintain steady speed when climbing a hill.

If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock parking brake, after you are stopped.

If you begin rolling backwards: Keep weight uphill. Never apply the rear brake abruptly while rolling backward. Apply the front brake. When fully stopped, apply rear brake as well, and then lock parking brake. Dismount on uphill side if the vehicle is not pointed straight uphill. Back the vehicle down the hill, following the instructions in this Owner's Manua l.

Backing the ATV downhill

If you stall, you may be able to get off and walk the ATV back down the hi ll if it is not too slip pery and you hav e good footing.

1. Make sure the path back down the hill is clear.

2. Stand with your body facing downhill at the side of the

vehicle with your hand on the front brake lever.

3. Make sure your legs are clear of the wheels and back

the ATV down the hill. Use the brake lever to control speed.

Page 63

4. If you lose control of the ATV, don’t attempt to regain control , for your safety, get away from the vehicle and alert others.

MODIFICATIONS

WARNING

If you can’t back the ATV downhill

If you stall and the hill is too slippery or you doubt whether you can back the A TV down the hill safely as described above, leave the ATV where it is and go to get help. Apply the parking brake and block the wheels so that the ATV won’t begin to roll backwards on its own.

POTENTIAL HAZARD

Operating this ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modifications of this vehicle may cause changes in handling which could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Cannondale or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Cannondale motorsports dealer.

Page 64

PRE-RIDE INSPECTION

WARNING

POTENTIAL HAZARD

Failure to inspect vehicle before operating.

WHAT CAN HAPPEN

Increases the possibility of equipment failure resulting in an accident.

HOW TO AVOID THE HAZARD

Always inspect this ATV before you operate it. Always follow the inspection and maintenance procedures found in this Owner’s Manual. Have your vehicle serviced by an authorized Cannondale motorsports dealer every 25 hours of operation.

When reading this manual, remember:

WARNING

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

Page 65

PRE-RIDE CHECKLIST

ITEM CHECK PAGE Apparel

Brakes

Clutch (if applicable) Coolant Coolant level. Fill with coolant if necessary. Start on page95. Drive Engine Oil level. Fill with engine oil if necessary Start on page85.

Fuel Fuel level. Fill with fuel if necessary Start on page82. Transmission Oil level. Fill with transmission oil if necessary Start on page91.

Wheels/Tires

Steering

Chassis (frame) Panels, Bolts/Fasteners Secure, tightness Start on page75.

Lights Proper operation (headlights and taillight) Start on page25.

Condition of (helmet, eye protection, boots, gloves, long-

sleeved shirt and, long trousers).

Proper operation, fluid levels, front lever freeplay, leaks. Fill with DOT4 brake fluid if necessary. Check the rear brake disc carrier for tightness.

Proper operation, condition, and lever freeplay, actuating arm position

Clean and lubricate the drive chain. Check drive chain slack, sprockets, swingarm buffer, rollers, and guide block.

Wheels (for damage), tire pressures (all four) and condition. Replace if damaged. Add air if required.

Handlebars turn freely ; no bi ndi ng of the cab les /ho se s throughout the full steering range.

Inspect the frame, subframe, and swingarm for bending, cracks, or other damage. Don’t ride if damage is found.

Start on page39.

Start on page100.

Start on page109.

Start on pag e116.

Start on page149.

Start on page80.

Page 66

OPERATION

WARNING

POTENTIAL HAZARD

Operating the ATV without being familiar with all the controls.

WHAT CAN HAPPEN

Losing control which can cause an accident where you can be severely injured or killed.

HOW TO AVOID THE HAZARD

Read the Owner’s Manual carefully and be sure you understand everything in it before operating the vehicle. If you don’t understand something, ask a Cannondale motorsports dealer.

General Starting Tips

CAUTION

Only hold the start button for 2-3 seconds at a time.

Why? The injectors spray a “starting pulse” of fuel then spray less as cran king conti nues . Since a c old engine requires more fuel, repeated and shorter cranking attempts should be used to deliver the

extra fuel needed. If you crank more than 2-3 seconds you’re wasting battery power because the fuel spray has become too small to start the cold engine.

•

NEUTRAL WITH PULLED-IN CLUTCH

Shift the transmission into NEUTRAL and pull-in the clutch lever before starting. Witho ut pul ling in the clutch, the starter working efficiency is reduced; It doesn’t turn the crankshaft as fast and can result in overheating and damage.

FULLY CHARGED BATTERY

• Make sure the battery is at full charg e b efore you attempt to start the engine. If the battery is not at full charge, the battery voltage can drop enough

while the starter is turning over the engine to disengage the ECU’s power latch relay. When this happens, the engine will turn over but not start.

MC1000 DO NOT OPEN THE

•

THROTTLE

The MC1000 engine management system utilizes an Idle Air Control Valve located on the throttle body to automatically control the idle air mixture during a cold start attempt. Be sure to read the cold start procedure.

Page 67

MC500 Cold starting

1. Make sure the vehicle is on level ground and the transmission is in NEUTRAL.

2. Turn the ignition switch to the “ON” position and wait 3 seconds as the fuel pum p pressuriz e s the fuel injec tors .

3. Shift transmission into NEUTRAL and pull-in and hold in the clutch lever.

4. Carefully tak e up the thrott le le ver freeplay, then take up 1mm more.

1 mm throttle lever freeplay

5. Press and hold the engine start button for no more than 2 to 3 seconds at a time. If the engine “pops” or seems to backfire you’re holding the throttle open too much. 1mm is a very fine l ever movement. Back the lever off, wait briefly, and re-try.

6. When the engine fires, hold the throttle at a fast idle for 10 seconds or until a smo oth idle is obtained.

7. Always wait for the engine to reach operating temperature (70°C) before riding.

A TV MC1000 Cold Starting

1. Make sure the vehicle is on level ground and the transmission is in NEUTRAL.

2. Turn the ignition switch to the “ON” position.

3. Switch the engine stop switc h t o “RUN.”

4. Pull in the clutch lever.

5. Quickly, press the engine start button and release it.

6. WAIT 5 SECONDS. This 5 second wa it is required t o activate the engine management circuits. During this time the fuel pump turns on for three seconds to pressurize the injectors. And, the Idle Air Control Valve (IACV) moves into position opening the idle bypass port. If you don’t wait 5 seconds, insufficient fuel pressure and incorrect idle air bypass positioning will prevent the engine from starting.

7. After wait ing 5 s econds , press a nd hold the engi ne start button for no more than 2 to 3 seconds at a time.

8. When the engine starts, slowly release the clutch lever.

9. Allow the engine to idle until it reaches operating temperature (70°C) before you begin riding.

Page 68

Starting a warm engine - (MC500 or MC1000)

When starting an engine after it has reached operating temperature, do NOT open the throttle while operating the starter motor. This will make starting very difficult and possibly foul the spark plug.

When reading this manual, remember:

WARNING

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

Page 69

BREAK-IN

The break-in period is critical to the long term life and reliability of the engine. The break-in period for the engine is 1 hour. When operating du ring th is period be sure to observe the following cautions:

• Ride at low to medium engine speeds.

• Do not lug or rev the engine during the break-in

period.

• Avoid full-throttle starts and rapid acceleration.

• Do not hold the throttle grip in one position for

more than a few seconds. It is better to roll the throttle on and off and ride on flat terrain.

• Avoid riding up steep hills and in sand because

this produces greater engine loads, possibly damaging engine components.

1. Ride the ATV normally for two 10-minute segments

using no more than 1/2 throttle. Wait for the engine to cool completely betw een segments.

2. Next, ride three 15-minute segments using no more

than 3/4 throttle, again allowing the engine to cool between rides.

NOTE :

During all rides, it is important to shift gears often so that high rpms are avoided and the engine is not lugged.

3. After riding the vehicle, clean it thoroughly and allow it to dry. Then inspect the entire vehicle for damage or loose fasteners.

4. Repair or tighten any damaged or loose components

and lubricate the vehicle .

5. If the vehicle is damaged, it is recommended that

you put tape over the start button to remind you to not start the vehicle. Also, attach a piece of paper to the handlebar with the problem written on it.

6. Complete the break-in period maintenance

schedule. See “Maintenance & Adjustment” starting on page 68.

Page 70

MAINTENANCE & ADJUSTMENT

When reading this manual, remember:

WARNING

Regular Maintenance

Periodic inspection, adjustment and lubrication of your vehicle helps keep it safe and reliable to operate. The maintenance schedule provided in this section is intended as a general gu ide only. Where you ride (geographic location), the weather conditions, terrain (e.g. sand, dirt, dusty, wet, etc.), and your riding style all influence how often a maintenance item should be performed. For example, if you ride in sandy conditions the time (interval) between servicing will be shortened because sand is very abrasive and will act to wear vehicle components more quickly.

Your Ability

If you do not feel comfortable or in any way doubt your own abilities to perform a procedure described in this manual, don’t attempt it; have an authorized Cannondale motorsports dealer perform the servicing.

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

Torque specs

Many maintenance proc ed ures found in this section require the use of a “torque wrench, ” - a special tool enabling a precise tightness to be applied to a fastener. If you do not have a torque wrench or are not familiar with using one; contact your authorized Cannondale dealer for assistance.

WORK SAFELY

Make sure you read and understand the warnings at the beginning of this sect ion.

Page 71

Carbon Monoxide Hot Components

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 n otic e.

HOW TO AVOID THE HAZARD

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

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 temperatures. Contact can produce severe b urns.

HOW TO AVOID THE HAZARD Wait for the engine and vehicle systems to cool completely before starting any work.

engine must be running, work carefully and avoid hot surfaces.

If the

Page 72

Gasoline Protect Your Eyes

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

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.

Page 73

Moving parts Fluids

WARNING

POTENTIAL HAZARD

Losing a finger, hand 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.

WARNING

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.

Page 74

MAINTENANCE SCHEDULE

Perform a Pre-Ride Inspection before every ride and at

scheduled mainten anc e periods.

C: Clean, R: Replace, L: Lubricate, I: Inspect, verify, clean, adjust, lubricate, replace if necessary NOTE(s)

1. Se rv ice mo re if ope ra tin g in du sty, sandy or snow y areas.

2. Service more frequently if operating in wet or muddy conditions.

3. Re pla ce every 2 years

NOTE

BREAK-IN

Regular Maintenance Interv al (in hou rs)

(after 1 hr)

5 10 25 50 100 200

ITEMS

WARNING LABELS (condition, readable) EVERY RIDE

•• FRAME (mainframe, subframe, swingarm) I I I

• FUEL SYSTEM (hoses, tank) I I

FUEL FILTER R

• THROTTLE OPERATION I I AIR FILTER 1 C AIRBOX DRAIN TUBE 2 I, C SPARK PLUG I R

• IDLE SPEED II

• VALVE CLEARANCE I I

• EXHAUST (spark arrester) C

• Cannondale dea l er se r vice suggested. S er vicing owners should have the proper tools, service data, and be mechanica lly qualified.

•• Operational safety involved, The service should be performed by a Cannondale dealer.

••• Lithium soap base grease

Page 75

C: Clean, R: Replace, L: Lubricate, I: Inspect, verify, clean, adjust, lubricate, replace if necessary NOTE(s)

1. Service more if operating in dusty, sandy or snowy areas.

2. Service more frequently if operating in wet or muddy conditions.

3. Re pla ce every 2 years

SWITCHES (engine, stop, start, tether,

NOTE

BREAK-IN

1, 2 I I

Regular Maintenance Interv al (in hou rs)

(after 1 hr)

5 10 25 50 100 200

ignition)

LIGHTING (headlight, tail light) I I I ENGINE OIL R R ENGINE OIL FILTER(s) C C

• TRANSMISSION OIL R R TRANSMISSION OIL FILTER C C DRIVE CHAIN (sag, stretch, buffer, guide

1,2 I I I

block, sprockets (condition/tightness), guards)

• BRAKE FLUID 3 I R

•• BRAKE SYSTEM (cables, discs, pads, hoses,

1,2 I I I

etc.)

• BRAKE, REAR, DISC CARRIER I I I

• CLUTCH (lever, ca ble and arm position) 3 I I I R

CLUTCH HYD OIL I R

• Cannondale dea l er s er vice suggested. S er vicing owners should have the pr op er to ols, service data, and be mechanically qualified.

•• Operational safety involved, The service should be performed by a Cannondale dealer.

••• Lithium soap base grease

Page 76

C: Clean, R: Replace, L: Lubricate, I: Inspect, verify, clean, adjust, lubricate, replace if necessary NOTE(s)

1. Se rv ice mo re if ope ra tin g in du sty, sandy or snow y areas.

2. Service more frequently if operating in wet or muddy conditions.

3. Re pla ce every 2 years

COOLANT (radiator, cap, hoses, level,

NOTE

BREAK-IN

3I I R

Regular Maintenance Interv al (in hou rs)

(after 1 hr)

5 10 25 50 100 200

strength)

• SUSPENSION (front/rear shocks, condition,

IIII I

setting)

• NUTS, BOLTS AND FASTENERS I I I SEAT (condition, wear, damage) I

•• WHEELS/TIRES (pressure, condition, wear) I I I I SWINGARM (bearings) 1,2 I I STEERING ASSEMBLY (fasteners, operation) I

••• A-ARM BUSHINGS I

••• TIE ROD ENDS 1,2 I I I I I

• Cannondale dea l er se r vice suggested. S er vicing owners should have the proper tools, service data, and be mechanica lly qualified.

•• Operational safety involved, The service should be performed by a Cannondale dealer.

••• Lithium soap base grease

Page 77

PANELS

Many of the maintenance procedures in this manual require that you remove and rei nstall vehicle panel s. Consult the following procedures:

Headligh t covers

T o re move either h eadlight cov er , loosen the bolts but do not try to remove them from the cover holes. When loo se , simply lift off the cover.

1. Right panel

2. Bolts

To install the covers, return the cover to its original

position and tighten the bolts snug. Do not over-tighten.

Radiator Guards

1. Guard

2. Bolts

3. Clutch cable (manual)

NOTE :

Remove the clutch cable at the actuating arm then withdraw the cable from the right guard.

Page 78

Cowl

NOTE :

The Engine Control Unit (ECU) and air filter are located under the cowl.

1. To remove the cowl and the seat

2. Remove the fender support bracket bolts at the frame.

3. Loosen and remove the cowl mounting bolts.

4. Lift the outer fender edges of the cowl - spreading them out slightly - and move the cowl forward off the frame making sure that the fender support braces clear the frame and shock structure.

5. Remove the fuel cap and lift o ff the c enter p iece . Return the fuel cap.

6. To install, place the panel in the original position and install the bolts and tighten to the specified torque.

Page 79

Side Panels

1. To remove, first remove the seat.

2. Remove the panel bolts.

Panel bolts

Rear Fender

1. Remove the seat and side panels.

2. Remove the bolts and lift the rear fender off the subframe.

3. To install, place the panel in the original position and install the bolts.

Rear fender bolts (3 of 4 visible in photo)

3. To install, place the panel in the original position and install the bolts.

Page 80

Fuel tank removal/installation

The following procedure requires moderate mechanical skill. If you doubt your skills or abilities to remove the fuel tank safely, have the fuel tank serviced by an authorized Cannondale motorsport s deal er.

CAUTION

Inspect and lubricate with clean engine oil - each of the quick connect hose end O-rings before installing them into the tank fittings. Also, press in the tabs on the tank fittings before inserting the hose ends.

Follow the torque recommendation for the tank to frame mounting bolts, over-tightening the tank bolts will result in damage to the embedded threaded inserts.

1. Make sure the fuel cap is tightened securely.

2. Remove the fuse, seat, rear fender, and cowl.

3. Remove the bolts and subf rame cross braces .

1. Bolt

2. Cross brace

4. Remove two (front sides of tank) tank mounting bolts and gently lift up on the front of the fuel tank.

Page 81

5. Press in the tank fitting tab and remove the quick connect from the tank.

6. Remove the quick connect at the rear of tank in the same manner.

1. Tab

2. Fuel tank return (from pressure regulator) quick connect

3. O-ring

1. Tab

2. Fuel tank outlet quick connect

7. To install the fuel tank, reverse the removal procedure.

Page 82

FRAME, SUBFRAME, SWINGARM Regular Inspection

The aluminum chassi s com po nents of your A TV have a finite, limited useful life. The length of that life varies depending on the material used in their manuf act ure, the amount of use they are subjected to and the care they receive while in service. Regu lar inspe cti on by a Cannondale motorsports dealer is important.

• Frame - a main support structure for the engine,

various components, and rider.

• Subframe - adds structural support.

• Swingarm - a suspension component

• Brush guard - mounted on the front of the ATV

Use in competitive events, hard and aggressive riding, riding on severe terrain , riding i n severe c limates and riding fast can dramatically shorten the life of the aluminum (frame) components. Any one and/or a combination of these conditions may res ult in an unpredictable fail ure.

We recommend that you carefully inspect your ATV’s chassis compone nts fo r crac king, bendin g, dee p scr atches and/or other damage before every ride.

If you have crashed or rol led your ATV, there could be damage hidden from your view. DO NOT ride an ATV with any crack, even a small one. It must be carefully inspec ted by an authorized Cannond ale m otorsports dealer before it is used again.

Riding a cracked frame could lead to complete frame failure. If you ha ve an y ques tions c ont act your Cann ondale dealer or call 1-800-MOTO-USA.

WARNING

POTENTIAL HAZARD(S)

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

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.

Page 83

(1)

)

(5)

1. Frame

2. Rear shock strut

3. Subframe

4. Swingarm

5. Engine rail/skid plate

6. Brush guard

Page 84

FUEL

Always use clean hi gh quality unleaded gasoli ne. See

“2002 Model Specifications” starting on page 161.)

WARNING

POTENTIAL HAZARD

Overfilling the fuel tank

WHAT CAN HAPPEN

Fuel expands due to heat (e.g., engine, sun) and may overflow if the tank is overfilled, resulting in a fire.

HOW TO AVOID THE HAZARD

Stop adding fuel when the correct level is reached.

CAUTION

If engine “knocking” or pinging occurs, use a different brand of gasoline or a higher octane rating. Never experiment. Other fuels or additives can severely damage the engine and its supporting components (e.g. fuel system, sensors, tank, hoses, etc.)

Adding fuel

1. Make sure the vehicle is completely cold.

2. Remove the ignition switch key.

3. Remove the fuel cap and fill the fuel tank with the

specified fuel to the correct level.

4. Reinstall fuel tank cap and tighten it securely.

5. Make sure the fuel cap hose is routed correctly.

3 3/8"

FUEL

1. Correct fuel level

Page 85

Idle speed adjustment

The idle speed adjustment screw is located on the throttle body. It is accessible from the left side of the vehicle. A special diagn ostic tool is necessary to communicate with the vehicle ECU and accurately read (display) the engine rpm . For this reason, idle a djust should be left to a Cannondale service technician.

1. To adjust the id le, allow the en gine to reac h operating

temperature 158°F (70°C).

2. Set the idle speed by turning the adjuster (1) in

direction (a) to increase idle speed, or direction (b) to decrease idle speed.

Throttle lever adjustment

See “2002 Model Spe ci fic ations” starting on page 161. Loosen locknut and then turn the adjuster until the

specified freepla y is reache d. Tighten the locknut.

1. Adjuster a. Increase (clockwise)

b. Decrease (counterclockwise)

1. Rubber boot

2. Locknut

3. Adjuster

NOTE :

If the proper adjustment cannot be obtained or the throttle lever does not operate properly, the cable end at the throttle body can be adjusted, however, access to it is difficult and should be left to a qualified service technician. See your Cannondale motorsports dealer for servicing.

Page 86

Fuel filter replacement

See “2002 Model Speci fic ati ons ” starting on page 161. Replace the inline fuel filter every 5 hours.

CAUTION

Do not operate with the fuel filter removed. You can seriously damage the fuel injection system. The result may be hard starts, stalling, performance loss, or severe damage to the system. Always use a high quality filter of the specified type. “Cheap” or inexpensive filters not meeting the specified efficiency can result in damage to the fuel system (e.g., clogged fue l injectors , inadequa te fuel supply, blockage, and reduced flow).

3. Cradle the fuel filter with the hoses attached in a clean dry shop t owel to hel p abso rb any res idual fuel that will drain as the filter is removed. Loosen the fuel hose clamps and remove the fuel filter.

FLOW

NOTE :

We recommend that you keep a few fuel filters which are inexpensive and easily obtained - handy for convenient replacement.

1. Make sure the engine and exhaust system are completely cool bef ore starting this procedure.

2. Remove the fuse, seat, and right side panel.

1. Inline fuel fi lt er

2. Fuel hose clamps

4. Install the specified fuel filter and tighten the hose clamps securely.

5. Reinstall removed components.

6. Follow-up with a visual inspection of the fuel system. If any leaks or damage is found, take the necessary corrective action.

Page 87

ENGINE OIL

Engine oil is a significant factor in the service life and performance of the engine. See “2002 Model Specifications” star ting on page 161.

Change the engine oil and clean the filters in accordance with the maintenance schedule. See “Maintenance & Adjustment” starting on page68. Service more frequently under severe conditions.

Checking engine oil

CAUTION

Run the engine for 1 minute b efore checking or you will take an inaccurate measurement. Add in small amounts and recheck the level between pours.

1. To check the level, start the engine and allow to run for

1 minute at idle speed, then turn off the engine.

2. Remove the right headlight cover.

3. Remove the dipstick .

1. Engine oil dipstick

2. Markings

4. Wipe the dipstick with a clean rag and screw back in completely. Then remove and inspect the level on the stick. The oil level should be between the markings on the dipstick. If lo w, add a sufficient amount of oil to raise it to the correct level.

Page 88

Changing engine oil

NOTE :

Have a clean shop towel handy to clean up any spilled oil.

1. Star t the engine and allow to reach normal operating temperature 158°F (70°C). Then, turn the engine off.

2. Connect a clear plastic hose to the left spar drain bolt and loosen it. Allow the spar contents to drain completely into a suitable container. Tighten the bolt to the specified torque.

(1)

(2)

3. Move to the right frame spar and drain the en gine oil from it the sa me way. Tighten th e spar drain bol t to t he specified torque.

1. Right spar engine oil drain bolt

1. Left spar drain bolt

2. Hose

Page 89

4. Now, drain the crankcase by removing the crankcase drain bolt. Be sure to note and return the two crush (sealing) washers of the drain bolt. They can be reused but replace them with new washers if they are damaged.

1. Crankcase engine oil drain bolt

1. Sealing washer

2. Fitting

3. Drain bolt

(1)

(2)

(1)

(3)

Page 90

5. Place a container under engine oil filter cover and remove the bolt, engin e oil filter cover and the two cover O-rings.

8. Inspect the seals and filter element for tears, cracks, and other damage. Replace if damaged.

(3)

(2)

1. Bolt

2. Cover

6. Remove the engine oil filter seal, oil filter and oil filter seal from the housing. Wipe the inside of the filter housing with a clean shop towel to remove any accumulated sediments or other debris.

7. If your filter is the screen type, clean the filter using compressed air. If your filter is the paper element type, discard it and replac e it wi th a new one.

(5)

(1)

(6)

(5)

(4)

1. Bolt

2. Cover

3. O-ring

4. O-ring

5. Filter seal

6. Filter (screen)

9. Apply a light coat of O-ring grease to the large and small cover O-rings and insert them back into the cover.

Page 91

NOTE :

Use some O-ring grease to “sti ck” the filter s eals so th at they are centered on the filter. Thi s will help assure that the seals remain in place when you insert the filter into the housing.

11.Now, carefully work the heat shield back to expose the left spar return hose and clamp. Then, remove the clamp and hose from the engine oil inlet fitting.

(4)

10. Install the cover and cover bolt. Tighten the bolt to the specified torque.

CAUTION

Do not over-tighten the cover bolt. You will damage the threads of the filter housing. If the cover leaks, you may need to replace the cover O-rings or inspect the cover and housing mating surfaces for damage.

(3)

(2)

(1)

1. Heat shield

2. Spar return hose

3. Clamp

4. Inlet fitting

Page 92

12. Loosen and remove the inlet fitting. Then, remove the inlet filter (screen) from the hole.

17.Install the fitting. Tighten it to the s pec ifi ed torq ue.

1. Inlet filter (screen)

13.Clean the screen using compress ed air.

14. Inspect the inlet fitting, 0-ring, and inlet screen for tears,

cracks, and other damage. Replace any damaged part with a new one.

15.Reinstall the filter into the crankcase. Inspect the fitting

O-ring and replace it w ith a new one if necessary.

16.Apply light coat of clean engine oil to the fitting O-ring.

(3)

(4)

(5)

(6)

(2)

(1)

1. Screen

2. O-ring

3. Inlet fitting

4. Clamp

5. Spar return hose

6. Heat shield

18.Reinstall the engine oil inlet hose and clamp onto the fitting.

19.Re-position the heat shield up to the clamp .

20. Add 1US quart of the specified engine oil in the dipstick hole at the right frame spar usin g a clean fun nel .

21. Reinstall dipstick and run engine for 1 minute at idle speed to circulate the new oil.

22. Remove the dipstick and recheck the level. The oil level should be between the dipstick markings. Add as required.

Page 93

TRANSMISSION OIL

The transmission oil in your ATV is just as critical to engine life and performance as the engine oil. Be sure to maintain the correct level of the specified transmission oil. See “2002 Model Speci fic ati ons ” starting on page 161.

Change the oil in accordance with the maintenance schedule and more frequently under severe condi tio ns . See “Maintenance & Adjustment” starting on page 68.

Checking transmission oil

CAUTION

A low transmission oil level may result in severe engine damage. Always use the specified transmission oil and check the level before every ride.

NOTE :

The sealing washer of the chec k bolt is reusab le but n ot indefinitely. We recommend that you replace it if it is damaged or you observe signs of oil leakage at the bolt. Have a clean shop towel handy to clean up any spilled oil.

2. Remove transmission oil level check bolt and sealing washer. The oil level should be even with the bottom of the check hole. If your model is equipped with a window, see the illustr ati on for how to read the level.

1. T o che ck the level, first make sure the engine is cold.

1. Transmission oil check bolt

2. Sealing washer

Page 94

(1)

HIGH OK

LOW

1. Transmission oil window

NOTE :

The transmi ssi on oil leve l wit hin the c ran kcas e shou ld be visible in the w in dow. Maintain the oil level between the “LOW” and “HIGH” as indicated in the illustration above.

3. To add, reinstall the check bolt and pour the specified transmission oil slowly and in small amounts using a clean funnel. Recheck the level.

Transmission oil filler hole

Page 95

Changing transmission oil

CAUTION

When re-installing the transmission oil filter, sealing washer, and bolt, insert the filter into the bolt, then insert the pair into the crankcase hole together . This he lps ass ure that th e other en d of the filter will locate into the back of the tr ansmis sion oil pump (rear of cartridge plate inside gearbox cavity). If the filter does not locate into the plate hole, unfiltered oil can enter and damage the pump.

NOTE :

The transmission drain bolt is located on the right side of the engin e. The filter (s creen) may not come out with the drain bolt. After the oil drains, use needle nose pliers to gently remove it from w it hin the drain hole.

1. Place vehicle on a level surface with a suitable container under the transmission drain bolt and remove the bolt and sealing was her.

2. Allow the transmission oil to drain from the hole completely.

Page 96

3. If the filter did not come out with the bolt, remove it carefully from the hole. Clean it using compressed ai r.

(1)

1. Filter

4. Inspect the filter for cracks, holes, tears, and other damage. Replace new if damaged.

5. Make sure the threads of the bolt and crankcase are clean.

6. Apply anti-seize compound to the threads of the transmission drain bolt (1). The sealing washer is reusable, however, inspect its condition before reinstalling. A damaged washer may result in a fluid

leak. Install the washer onto the bolt so that the flat side (a) faces the case. Insert the filter into the bolt, and install into the case.

(2)

(1)

(3)

(a)

1. Drain bolt

2. Sealing washer

3. Filter (screen) a. Sealing washer flat side

7. Tighten the bolt to the specified torque.

8. Add the specified transmission oil at the filler cap until the oil level reaches t he bott om of the che ck bolt hole. Pour slowly and allow time for the oil to flow throughout the case cavity.

9. Then, run the engine briefly (1-2 minutes) to circulate newly added oi l and rechec k the le v el. Add if nece ssary.

Page 97

COOLANT

The engine coolant bottle is located on the right side of the vehicle under the headlight cover. Check the coolant level in the bottle when the engine is c old . The fluid level in the bottle will vary during operati on. Maintai n coolant at the “LEVEL” mark on the bottle when the engine is cold. We recommend a 50/50 mixture of high-quality alum inu m compatible anti-freeze/coolant and distilled water.

WARNING

POTENTIAL HAZARD

Severe burns

WHAT CAN HAPPEN

Coolant can spray ed out un der hi gh pressu re if the bottle is opened while the system is hot.

HOW TO AVOID THE HAZARD

Wait for the engine to cool completely before removing the cap.

CAUTION

Anytime the coolant level falls significantly (not visible in the bottle), the non-self bleeding systems will require bleeding after refilling the system. See page 98.

1. Coolant bottle

2. Bleed hose

3. Coolant pump cover

NOTE :

Components have been removed in the above photo for clarity. If the coolant system on your vehicle is the self bleed type (bottle & pump cover), the hose should visible with just the headlight cover removed.

Page 98

Checking the coolant level

1. Make sure the engine and radiator are compl etel y col d.

2. Remove the right headlight cover and observe the coolant level in the bottle without opening the cap. The level should be at the ‘LEVEL’ mark.

Adding coolant

1. To add coolant, make sure the engine is cold.

2. Place a thick rag ov er th e co ola nt bottl e c ap a nd open it very slowly to allow any residual pressure to escape. Then, remove the cap and slowly add the specified coolant using a clean fun nel until it reaches the ‘LEVEL’ mark.

3. Reinstall the cap and check coolant system for leaks.

Changing the coolant

1. “LEVEL’ mark

2. Cap

CAUTION

Bleed the coolant system after refilling.

1. Make sure the coolant system is completely cold and you are wearing safety glasses and protective rubber gloves. Have a few clean rags handy to wipe up any spills.

2. Place a thick towel over the coolant bottle cap and remov e the cap sl ow ly to releas e an y residu al press ure .

Page 99

3. Place a clean bucket under the radiator drain bolt and remove it. Allow the radiator contents to drain completely. Then, inspect the drain bolt 0-ring - if damaged, replace. Apply some O-ring lubricant to the O-ring and install the drain bolt.

(2)

4. Remove the coolant outlet drain bolt and sealing washer and allow coolant to drain completely. Reinstall the sealing washer and bolt. Tighten snug.

1. Coolant outlet

2. Drain bolt

3. Sealing washer

1. Radiator drain bolt

2. O-ring

5. Add the specified coolant at the bottle until it reaches the LEVEL mark on the bottle.

6. Bleed the coolant system.

Page 100

Bleeding coolant

NOTE :

Check to see if your vehicle is equipped with the selfbleeding coolant pump cover and coolant bottle. If it is, bleeding coolant is not required.

The coolant bleed bolt is located in the top right corner of the coolant pump cove r (right s ide o f engin e). Acc ess to it is difficult. If you are unfamiliar with coolant bleeding, have an authorized Cannondale dealer bleed the coolant.

1. Make sure the cool ant system is complete ly cold and you are wearing safety glasses and protective rubber gloves. Have a few clean rags handy to wipe up any spills.

2. Place a thick towel over the coolant bottle cap and slowly remove the cap to release an y res idual pressure .

3. Fill the coolant bottle to the LEVEL mark with the specified cool ant.

4. Loosen the bleed bolt on the water pump cover and allow any trapped air to escape. It is not necessary to remove the bolt.

(2)

(1)

1. Bleed bolt

2. Sealing washer

5. Continue bleeding the system until only coolant flows out (no air). Then, tighten the bleed bolt.

6. Refill the coolant bottle to the LEVEL mark when completed.

7. Reinstall the coolant bottle cap.

8. Start the engine and allow to idle for 3 minutes. Quickly, touch the radiator. If it is warm the system was bled properly. If it is cool to the touch, the system was not bled properly. The procedure must be repeated.

9. Shut off the engine and wait for the system to cool completely and repeat this procedure.