Cannondale X440S User Manual

2002 X440s OWNER'S MANUAL

P/N 951-5002032

S a fe ty A le rts

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

• Keep this Owner’s Manual in a safe place.

MESSAGES WITH THE SAFETY ALERT SYMBOL

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

Indicates that severe personal injury or

DANGER

death WILL result if instructions are not followed.

WARNING

CAUTION

Indicates a potential hazard could resul t in vehicle dam age if instructi ons are not follo wed .

NOTE : Provides helpful information

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

P/N 951-05002032

Printed : 8/13/01

Safety Alerts . . . . . . . . . . . . . . . . . 1

Contents . . . . . . . . . . . . . . . . . . . . 2

Important Information . . . . . . . . .3

Pre-Ride Inspection . . . . . . . . . . . 6

Component Locations . . . . . . . . . 7

Controls . . . . . . . . . . . . . . . . . . . . 8

Operating . . . . . . . . . . . . . . . . . . . 11

Fluids. . . . . . . . . . . . . . . . . . . . . . . 14

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . 18

Transmission oil . . . . . . . . . . . . . . . . . . . 23

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Maintenance and Adjustments . .27

Break-in . . . . . . . . . . . . . . . . . . . . . . . . . 27

Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . 46

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Electrical. . . . . . . . . . . . . . . . . . . . . . . . . 56

Steering . . . . . . . . . . . . . . . . . . . . . . . . . 65

Suspension. . . . . . . . . . . . . . . . . . . . . . . 66

Rear shock . . . . . . . . . . . . . . . . . . . . . . . 69

Tires & Wheels. . . . . . . . . . . . . . . . . . . . 73

Frame, Sub-frame, Swingarm. . . . . . . . . 75

Lubrication . . . . . . . . . . . . . . . . . . . . . . . 76

Cleaning and Storage . . . . . . . . . 83

X440s Model Specifications . . . . 85

X440s Service Specifications . . .86

X440s Torques . . . . . . . . . . . . . . . 87

X440s Owner's Manual.fm

Imp or ta nt

In fo r ma tion

available at the time of publication. Cannondale Corporation reserves the right to make changes at any time, without notice. This vehicle has U.S. and Internation al patents pending. Cannondale Motorspo rts Cannondale Corporat ion

We strongly suggest that you do the following before operating the vehicle:

• READ and UNDERSTAND this Owner’s Manual.

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

• Wear appropriate protective gear - approved full faced helmet, gloves, boots, long-sleeve shirt, pants). Consider specially designed protective offroad vehic le riding apparel.

ABOUT THIS MANUAL

The purpose of this manual is to provide the owner with important safety, service, maintenance, and tuning information, and s hou ld be thoroughly read before operating or working on the vehicle. This manual is divided into sections which contain easy-tofollow procedures which are reasonably straight-forward. Anyone with the mechanical ability and the proper tools should be able to perform them. Each procedure is accompanied by illustrations and photos to aid in proper vehicle operation, basic maintenance, tuning, etc.

• Read and understand the entire procedure before performing an y work. If you are unfamiliar with or doubt your o wn abilities to co mplete a pro cedure as described, have an authori zed Cannondale motorsports dealer service y our vehicle.

Please keep your Owner's Manual in a safe and convenient place, and consider it an integral part of your vehicle. For detailed servicing information refer to the Service Manual for your vehicle or contact an authorized Cannondale motorsports dealer for a list of available publications. If this manual is lost or damaged, contact an authorized Cannondale motorsports dealer for a replacement.

LIMITATIONS

EXPERIENCED RIDERS ONLY

• This vehicle is not f or b egin ner s.

All Cannondale motorsports products are designed for use by trained and experienced riders only. All are very high performance, competition sport machines and should only be operated by licensed competition riders in excellent physical condition, who are well-trained and experienced in the operation of high perform an ce competition vehicles.

GOOD JUDGEMENT

There is always a risk involved when riding a vehicle; however, making sure you and the vehicle are in the best condition possible w il l ens ure a gre at riding ex pe rien ce. Use sound judgement wh en ridi ng. Never ride under the influence of alcohol, medication, or drugs. Doing so will greatly reduce your ability to properly operate this vehicle and could lead to an accident, injury, and/or death. If you are taking medications prescribed by your doctor, consult him/her before riding.

MODIFICATIONS

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

NO PASSENGERS

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

Meticulous engineering and aggressive product designs represent the spirit of innovation - always a driving force at Cannondale. All information, illustrations, and specifications in this manual are based on the latest product information

P/N 951-05002032

Printed : 8/13/01

V EHICLE IDENTIFICATION NUMBER (VIN)

XXXXXXXXXXXX

XXXXXX

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

XXXXXXXXXXXX

Record your vehicle’s ID number here:

LABEL LOCATIONS

ENGINE SERIAL NUMBER

The engine serial numb er i s etche d/s tam pe d into th e eng ine crankcase.

XXXXXXXXXXXX

Record your vehicle’s ID number here:

See illustration on following page for examples of the numbered labels abov e.

X440s Owner's Manual.fm

LABELS

(1)

(2)

(3)

1. General

2. Fuel

3. EPA noise

4. Frame

(4)

P/N 951-05002032

Printed : 8/13/01

Pre-Ride

Inspection

WARNING

POTENTIAL HAZARD

Failure to inspect vehicle before operating.

WHAT CAN HAPPEN

Increases the possibility of equipment failure resulting in a accident where you can be seriously injured or killed.

HOW TO AVOID THE HAZARD

Always inspect before operating. Always follow the inspection and maintenance procedures found in this Owner’s Manual. Have an authorized Cannondale Motorsports Dealer inspect your veh ic le at le ast e very 25 ho urs of ridin g.

SUSPENSION

fork legs . . . . . . . . . . . (wear, damage,settings, oil leaks)

rear shock. . . . . . . . . .(wear, damage, settings, oil leaks)

WHEELS

wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (damage)

spokes . . . . . . . . . . . . . . . . . . (correct tension, damage)

TIRES

physical. . . . (tread conditions, wear, damage, punctures,

tears)

pressure . . . . . . . . . . . . . .(correct, regulate if necessary)

BODY PANELS

seat . . . . . . . . . . . . . . . . . . (damage, installed correctly)

plastics . . . . . . . . . . . . . . . . . . . . . . . . .(secure, damage)

FASTENERS

bolts, fasteners . . . . . . (tightened to the specified torque)

PRE-RIDE CHECKLIST

FLUIDS

brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . (level correct)

coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . (level correct)

engine oil . . . . . . . . . . . . . . . . . . . . . . . . . .(level correct)

transmission oil. . . . . . . . . . . . . . . . . . . . . .(level correct)

Fuel cap tightened securely Inspect vehicle for leaks and repair if necessary.

BRAKES

Front/rear brakes . . . . . . . . . . . . . . . . . .(proper function)

Front/rear pads . . . . . . . . . . . . . . . . . . . . (damage, wear)

Front/rear discs. . . . . . . . . . . . . . . . . . . . (damage, wear)

THROTTLE

lev e r freepl ay. . . . .(as specified in all steering positions ))

proper operation . . . (smooth and returns to idle (clos ed)

position across the entire steering range)

CLUTCH

clutch lever freeplay . . . . . . . . . . . . . . . . . . (as specified)

actuating arm . . . . . . . . . . . . . . . . . . . . (correct position)

DRIVE

sprocket conditions. . . . . . . . . . . . . . . . . (damage, wear)

chain condition . . . . . . . . . . (damage, wear, stretch limit)

chain sag . . . . . . . . . . . . . . . . . . . . . . . . . . (as specified)

clean and lubricate the chain chain rollers . (cracks, excessive wear, or other damage)

chain guide block . . . . .(cracks, excessive wear, or other

damage)

swingarm buffer . . . . . .(cracks, excessive wear, or other

damage)

X440s Owner's Manual.fm

Component

Locations

1. Clutch lever

2. Engine stop button

3. Front brake master cylinder

4. Engine start button

5. Front brake lever

6. Throttle

7. Fuel tank cap

8. Fuel tank

9. Engine oil fill

10. Battery

11. Drive chain adjusters

12. Engine oil drain (frame)

13. Shift lever

14. Transmission oil fill

15. Clutch

16. Engine oil filter

17. Idle adjusting screw

18. Radiator

19. Engine Control Module (ECM)

20. Airbox filter

21. Main air filter

22. Fuel injectors

23. Starter clutch cover

24. Water pump

25. Engine oil crankcase drain

26. Transmission oil drain

27. Brake pedal

28. Rear brake reservoir

P/N 951-05002032

Printed : 8/13/01

Controls

CLUTCH LEVER

The clutch lever is located on the left handlebar. Pull the lever to disengage the clutch. Release the lever to engage the clutch. The lever should be pulled quickly when disengaging and slo wly when engaging.

ENGINE STOP BUTT ON

The engine stop button is located on the left handlebar. The button is (RED) in color. Push it to stop the engine. Make sure this button functions properly before you begin riding.

NOTE : The stop button is normally a closed circuit switch. If the stop switc h is damag ed or the wires a r e fray ed or torn, (circuit open) the engine may not sta r t.

1. Engine stop button

NOTE : When starting it is recommended that you shift the transmission into neutral and pull in the clutch lever to increase the starte r’s efficiency.

1. Clutch lever

SHIFT LEVER

The shift lever is located on the left side of the engine.

NOTE : The tra n smission is commonly referred to as a “one down, four up” transmission. Neutral is located between first and second gears.

ENGINE START BUTTON

The engine start button i s locat ed on the rig ht handl ebar and is (GREEN) in color. Pressing it activates the starter motor.

NOTE : When using the button, hold it for no more than 2-3 seconds at a time.

1. Engine start button

X440s Owner's Manual.fm

THROTTLE

FRONT BRAKE LEVER

The throttle lever is located on the right handlebaand controls acceleration and deceleration of the engine. To accelerate, turn the grip toward you. To decelerate, turn the

grip away from you.T

WARNING

POTENTIAL HAZARD

(1) Malfunctioning throttle

(2) Incorrect freeplay

The front brake lever is located on the right handlebar. Pull the lever toward you to activate the front brake.

1. Front brake lever

REAR BRAKE PEDAL

The rear brake pedal is located on the right side of the vehicle. Press it firmly to apply the rear brake.

WHAT CAN HAPPEN

(1) The throttle must return to to the closed position when you release it. If it sticks you can lose the ability to accelerate and decelerate the engine which could result in an accident where you could be seriously injured or killed.

(2) The throttle freeplay must be maintained as specified, otherwise the engine speed could increase when the handlebars are turned or when the throttle is slightly grasped. Either situation could result in an unexpected acceleration of the engine where you could be seriously injured or killed.

HOW TO AVOID THE HAZARD

(1) Test the operation of the throttle before each ride. Make sure it operates smoothly (with no sticking or binding) in all steering positions. It should return automatically to the closed position when relea se d.

(2) Make sure the throttle freeplay is adjusted as specified. See “throttle Freeplay” starting on page 38.

(1 & 2) If the throttle malfunctions or you can not adjust the throttle to the specified freeplay, do not ride the vehicle. Contact an authorized Cannondale motorsports for servicing.

1. Rear brake pedal

P/N 951-05002032

Printed : 8/13/01

AIR FILTER CLEANING PLUGS

SIDE STAND

The air filt er cleaning plugs ar e provided with yo ur vehicle and must be installed when washing/cleaning the motorcycle. These plugs will help guard against water and other contaminants entering the engine. Make sure the sealing foam on the plug is in good condition. See the cleaning section of this manual for how to install the plugs properly.

The side stand is used to support the vehicle when not in use. It is only designed to support the weight of the vehicle; do not apply extra weight when using it (e.g., leaning on the bike) Be sure to remove it before starting out.

1. Steering head plug

2. Fuel tank bolt hole plug

3. Airbox plug

X440s Owner's Manual.fm

Operating

This section explains basic operating and riding methods (i.e., starting, stopping, and shifting). If after reading this manual or at anytime you hav e any q uestio ns rega rding ho w to operate the vehicle, contact an authorized Cannondale

motorsports dealer for assistance.

WARNING

POTENTIAL HAZARD

Failure to inspect vehicle before operating.

WHAT CAN HAPPEN

Increases the possibility of equipment failure resulting in a accident where you can be seriously injured or killed.

STARTING

DANGER

POTENTIAL HAZARD

Running the engine indoors. Breathing exhaust gases

WHAT CAN HAPPEN

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

HOW TO AVOID THE HAZARD

Never operate the vehicle indoors even for brief periods.

BATTERY (FULLY CHARGED)

HOW TO AVOID THE HAZARD

Always ins pec t before operating. Always follow the inspection and maintenance procedures found in this Owner’s Manual. Have an authorized Cannondale Motorsports Dealer inspect your vehicle at least after every 25 hours of use.

CAUTION

Allow the engine to reach operating temperature before riding.

This vehicle does not have a cooling fan. Airflow across the radiator is maintained during riding. If the vehicle runs without airflow, the engine can overheat and be severely damaged. The time it would take to overheat will depend on the weather conditions. Do not allow your vehicle to idle for more than 3 minutes without airflow across the radiator.

• Make sure the battery is at full charge. Why? If the battery voltage dr ops wh ile you are using the starter motor, the v olta ge could drop and the power relay of the ECU will shut the ECU off. When this happens, the engine will turn over but not start.

COLD STARTING - (MC1000 )

NOTE : MC1000 equipped unit utilize an idle air control valve which automatically adjust throttle air bypass for cold starts. Do not open the throttle when cold starting.

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

2. Press and hold the engine start button for no more than 2 to 3 seconds at a time.

When the engine fires release the button and slowly release the clutch lever.

P/N 951-05002032

Printed : 8/13/01

STARTING A WARM ENGINE

BRAKING

When starting an engine after it has reached operating temperature, do not open th e th rottl e. This wi ll m ak e s tart ing very difficult a nd pos si bly foul the spark plug.

SHIFTING GEARS

WARNING

POTENTIAL HAZARD

Shifting to a lower gear at high speeds.

WHAT CAN HAPPEN

Tires can lose traction and cause an accident.

HOW TO AVOID THE HAZARD

Do not down shift at high speeds.

CAUTION

When shifting gears, press the shift lever firmly to make sure the gears engagement is complete.

Careless shifting can result in incomplete gear engagement and can cause the transmission to jump out of gear. This can severely damage the engine.

1. To engage first gear from NEUTRAL, pull in the clutch lever and push down on the shift lever.

2. Release the shift lever.

3. Open the throttle a little and slowly let out the clutch lever.

WARNING

POTENTIAL HAZARD(S)

(1) Using the brakes improperly.

(2) Wet brake system (e.g. discs, pads)

WHAT CAN HAPPEN

(1) If you apply the brakes too quickly or suddenly the wheels may slide or skid possibly causing you to lose control resulting in an accident where you could be seriously injured or killed.

(2)Wet brakes do not provide the stopping power needed and therefore are extremely dangerous.

HOW TO AVOID THE HAZARD

(1) Apply the front and rear brakes evenly and gradually. Always consider the surface of the terrain you are riding on and how it will affect your braking ability. Concentrate on applyin g both brakes as har d as possible without skidding. Shift down or fully disengage the clutch as necessary to keep the engine from stalling.

(2) In wet conditions test the brake operation frequently. When riding in wet conditions, ride the vehicle at sl ow spe eds an d ap ply th e b rake s seve ral times until they are dry and at full power. Before riding the vehicle m ake su re the b rakes an d controls (e.g., brake lever, brake pedal, clutch lever, engine stop switch, and throttle) operate properly.

To brake, close the throttle completely with the clutch engaged (except when shifting gears) so the engine will help slow down the vehicle. Apply the front and rear brakes evenly.

4. To shift into a higher gear, pull in the clutch lever, push the shift lever up to the next gear, release the shift lever, then release the clutch lever.

5. To shift into a lower gear, pull in the clutch lever, push down on the shift lever and release - then release the clutch lever.

X440s Owner's Manual.fm

1. Front brake lever

1. Rear brake pedal

STOPPING

When stopping the vehicle, pull in the clutch lever while completely closing the throttle, shift the transmission into neutral, and press the en gin e stop switch with your thumb.

AFTER YOU RIDE

1. After riding the vehicle, clean it thoroughly and allow it to dry , and th en inspect th e entire veh icle for da mage or loose fasteners.

2. Repair or tighten any damaged or loose comp onents and lubricate the vehicle .

3. 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.

P/N 951-05002032

Printed : 8/13/01

Fluids

BRAKE

SERVICE : Brake, fluid type, DOT #4

CAUTION

Avoid spilling brake fluid on painted, plastic or rubber parts; damage can result. Place a shop towel or rag over these parts when servicing the brake system. Any wipe up spills immediat ely.

FRONT BRAKE

1. T o ch ec k the front system, start by leveling the top of the master cylinder (mounted on the right handlebar).

WARNING

POTENTIAL HAZARD(S)

(1) Eye and skin injury, death if swallowed.

(2) Not using the specified, mixing different types (or brands) of, and using unsealed containers of brake fluid.

(3) Inadequate brake fluid levels.

WHAT CAN HAPPEN

(1) Brake fluid is a hazar dous substance. It can cause injury to your ey es or skin if you touch it. If swallo we d it can cause death.

(2) Using unspecified brake fluid can damage the brake system leaving you without brakes. A container of brake fluid once unsealed can begin to absorb moisture from the atmosphere - if used in the brake system, the moisture will reduce braking force. You could lose your brakes an d hav e an accide nt resulting in injury or death.

(3) Low brake fluid can allow air to enter the system and this will reduce braking power. Again, you could have an accident and be serio usly injured or killed.

HOW TO AVOID THE HAZARD

(1) Always wear eye and hand protection when working with brake fluid. Keep brake fluid out of the reach of children and animals. If ingested contact contact a doctor immediately.

CLEAN BEFORE OPENING!

1. Master cylinder

2. Site window

3. ‘LWR’ mark

2. Inspect the fluid level through the site glass. If the fluid level is below the ‘LWR’ mark, add the specified brake fluid until the fluid is at the top of the window.

3. To add fluid, remove the screws, cover and diaphragm from the master cylinder. Pour DOT#4 brake fluid from a sealed container into the resevoir. Pour only until the fluid level rises to the top of the site window and no higher. If you fill above the window

(2) Always use DOT 4 brake fluid from a sealed container. Don’t mix fluids or use opened fluids. Have the system drained and refilled by an authorized Cannonadale Motorsports dealer if you suspect fluids have been mixed acciden tally .

(3) Check for proper brake operation and fluid level before riding the vehicle.

X440s Owner's Manual.fm

fluid will spill when you re-install the diaphram and

cover.

POUR TO TOP OF WINDOW

DOT

2. If the fluid level is below the ‘UPPER’ mark, add specified brake fluid until it reaches the ‘UPPER’ mark.

1. Front brake master cylinder cover screws

2. Front brake master cylinder cover

3. Diaphragm

4. Reinstall the front brake master cylinder diaphragm and cover. Tighten front master cyli nd er cove r scre ws to the specified torque.

TORQUE : Brake, master cylinder, front, cover screws

1.9 N•m (1.4 lbf•ft)

REAR BRAKE

1. To check the rear system, level the rear brake master cylinder reservoir. The fluid level should be above the ‘LOWER’ mark.

1. ‘LOWER’ mark

2. ‘UPPER’ mark

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

DOT 4

1. Reservoir cap

2. Diaphragm plate

3. Diaphragm

3. Install reservoir diaphrag m, diaphragm plate and cap.

P/N 951-05002032

Printed : 8/13/01

COOLANT LEVEL

COOLANT

SERVICE : Coolant, type

Anti-freeze Ethylene glyc ol with corrosion inhibitors fo r alumin um en gines

SERVICE : Coolant, mixture ratio

1:1 (coolant/distilled water)

WARNING

POTENTIAL HAZARD(S)

(1) Scalding coolant sprayed onto YOU

(2) Serious eye or skin injury

WHAT CAN HAPPEN

(1) You can be severely burned by coolant sprayed out from under high pressure if the bottle is opened while the system is hot.

(2) Coolant is poisonous. If it gets in your eyes or contacts your skin the fluid can cause irritation or severe injury.

1. To check the level, make sure the engine and radiator are cold.

2. Place a thick towel over the radiator cap.

3. Slowly turn the cap in direction (a) until you feel the cap reach the detent; this will allow any residual pressure to escape. Allow all pressure to escape before continuing. Press down on the cap and keep turning it until it can be removed.

HOW TO AVOID THE HAZARD

(1) Wait for engine to cool before removing the cap or servicing the coolant system. Be sure to wear eye protection, a long-sleeve shirt, and hand protection (e.g. rubber gloves) when working with coolant.

(2) Always wear eye protection and protective clothing when working with any components of the cooling system. Keep coolant away from children and pets. Call a doctor immediately if coolant is swallowed and induce vomiting. Flush eyes and skin with water if coolant gets in eyes or comes into contact with skin.

CAUTION

Operating the vehicle with a leaky or faulty cooling system can result in severe engine damage. Always use the specified coolant. If the coolant level drops significantly, bleed the system after adding.

NOTE : We recommend that you bleed the coolant system each time you add fluid.

1. Radiator cap

a. Loosening direction

4. Coolant level should be at the bottom of the filler neck. Add if necessary.

1. Filler neck

X440s Owner's Manual.fm

5. To add, add the specified coolant at the radiator filler hole using a clean funnel. Wipe up any spill ed cool ant with a clean shop towel.

6. Reinstall the radiator cap.

7. Check the entire cooli ng system for le aks.

8. If the coolant level drops after adding and no leaks are found, contact an authorized Cannondale Motorsports dealer for servicing.

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.

BLEEDING THE COOLANT SYSTEM

DANGER

POTENTIAL HAZARD

Running the engine indoors. Breathing exhaust gases

WHAT CAN HAPPEN

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

HOW TO AVOID THE HAZARD

Never operate the vehicle indoors even for brief periods.

CAUTION

Do not over-tighten the bleed bolt and check the condition of the sealing washer. If it leaks, replace it.

1. Sealing washer

2. Bleed bolt

5. When no more air is coming out of the bolt hole; only coolant, tighten the bleed bolt. Add coolant at the radiator to bring to proper level if necessary.

6. Reinstall the radiator cap.

1. Make sure the engine and coolant system are cold.

2. Place vehicle on a stand.

3. Remove radiator cap.

7. Start engine and allow to idle for three minutes and briefly touch the radiator. If the radiator is warm, the cooling system was ble d properly . If the radiator is still cool, stop the engine. Repeat the bleed procedure and check again.

P/N 951-05002032

Printed : 8/13/01

ENGINE OIL

SERVICE : Engine, oil recommended

Synthetic or semi-synthetic, 10W-40.

SERVICE : Engine, oil, total quantity,

1.3 US qt. (1.2 L)

SERVICE : Engine, oil, change, quantity (* see note

below) 1 US quart (0.9 L)

NOTE : * When adding engine oil following a change (i.e. drain of the spars, crankcase, filters removal and cleaning), small volumes of oil can remain within the spar reservoirs. Keep this fact in mind and be careful not to over fill the system. The change quantity specified here provides sufficient oil to operate engine safely so that level may be checked in the spar. Be careful not to overfill the engine oil. Pour small amounts rechecking the le ve l b etw e en pours. Place vehicle on a level surface.

CHECKING T H E EN GI NE OI L

DANGER

POTENTIAL HAZARD

Running the engine indoors. Breathing exhaust gase s

WHAT CAN HAPPEN

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

HOW TO AVOID THE HAZARD

Never operate the vehicle indoors even for brief periods.

1. T o check, place the vehicle on a stan d so it is le ve l.

WARNING

POTENTIAL HAZARD(S)

Serious injury or irritation to the skin or eyes. Death if swallowed.

WHAT CAN HAPPEN

Engine oil is a hazardous substance. If it comes into contact with your skin or eyes you can suffer serious injury or irritation. If it is swallowed it can cause death.

HOW TO AVOID THE HAZARD

Wear hand protection and safety glasses when working with engine oil. If you touch engine oil, wash it off immediately with soap and water. Clean clothes or rags contaminated with engine oil. If swallowed seek immediate medical attention. KEEP ENGINE OIL AWAY FROM CHILDREN AND ANIMALS.

CAUTION

The correct oil level can only be checked after the engine has run for a 1 minute.

2. Shift the transmission into NEUTRAL and start the vehicle. Allow to run for 1 minute at idle speed, then turn the engine off.

3. Remove the engine oil level check bolt.

1. Engine oil level check bolt (left frame spar)

X440s Owner's Manual.fm

4. The engine oil level should be even with the bo ttom of the check hole. Add if necessary.

LEFT FRAME SPAR

CORRECT

CHECK BOLT HOLE

OIL LEVEL AFTER 1 MINUTE

CHANGING THE ENGINE OIL

DANGER

POTENTIAL HAZARD

Running the engine indoors. Breathing exhaust gases

WHAT CAN HAPPEN

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

HOW TO AVOID THE HAZARD

Never operate the vehicle indoors even for brief periods.

WARNING

5. To add, remove the filler ca p on the left frame spar and pour the specified engine oil until the level reaches the bottom of the check hole. Pour slowly to allow the oil to flow throughout the spar.

1. Engine oil filler cap (left frame spar)

2. Vent hose

6. Reinstall the check bolt.

TORQUE : Frame, engine oil spar check bolt

15.0 lbf•ft (20.3 N•m.

POTENTIAL HAZARD

Blindness, eye injury,

WHAT CAN HAPPEN

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

Wear safety glasses when working with compressed air.

1. Place the vehicle on a stand.

2. Start engine and allow to reach normal operating temperature 158°F (70°C).

3. Turn the engine off.

4. Place an oil pan under the left frame spar drain bo lt.

5. Connect a clear plastic hose to the engine oil drain bolt and loosen it

6. Allow the contents of the spar to drain completely into an oil pan.

P/N 951-05002032

Printed : 8/13/01

NOTE : Remove the spar oil filler cap to facilitate draining.

that the flat side faces the crankcase and install. Tighten to the spe ci fie d torqu e.

TORQUE : Engine, engine oil drain bolt (crankcase)

6.0 lbf•ft (8.1 N•m)

10. Now, place a container under engine oil filter cover and remove bolt and engine oil filter cover.

NOTE : Be sure to note the two cover O-rings as you remove the cove r.

1. Engine oil drain plug (left spar)

2. Clear hose

7. Tighten the bolt.

TORQUE : Engine, engine oil drain bolt (left spar)

15.0 lbf•ft (20.3 N•m)

8. Place a container under engine oil crankcase drain bolt located on the right side of the engine and remove it and the sealing washer. Allow the oil to drain completely.

1. Filter cover bolt

2. Filter cover

11. Remove the seal, filter (screen) and seal from the filter housing.

12. Clean the filter using compressed air and clean the the filter housing cavity with a clean shop towel.

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

FLAT SIDE

SEALING

BOLT

WASHER

1. Bolt

2. Sealing washer

9. Apply anti-seize compo und to t he threa ds of th e drain bolt. Then install the sealing washer onto the bolt so

X440s Owner's Manual.fm

1. Bolt

2. Cover

3. O-ring (2-011)

4. O-ring (2-033)

5. Filter seal

6. Filter (screen)

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

15. Use some O-ring grease to “stick” the filter seals s o that they are centered on the filter. This will help assure that the seals remain in place when you insert the filter into the housing.

16. Install the cover and cover bolt.

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.

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

1. Inlet filter (screen)

19. Clean the screen using compressed air.

TORQUE : Engine, engine oil, filter cover bolt

3.3 lbf•ft (4.5 N•m)

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

1. Heat shield

2. Spar return hose

3. Clamp

4. Inlet fitting

20. Inspect the inlet fitting, 0-ring, and inlet screen for tears, cracks, and other damage. Replace any damaged part with a new one.

21. Reinstall the filter into the crankcase. Inspect the fitting O-ring and replace it with a new one if necessary.

22. Apply light coat of clean engine oil to the fitting O-ring install the fitting. Tighten it to the specified torque.

1. Screen

2. O-ring

3. Inlet fitting

4. Clamp

5. Spar return hose

6. Heat shield

TORQUE : Engine, engine oil inlet fitting

18.0 lbf•ft (25.0 N•m)

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

24. Re-position the heat shield up to the cl amp.

P/N 951-05002032

Printed : 8/13/01

25. Now, remove the left spar oil filler cap and add the specified “engine oil change quantity” using a clean funnel. Pour slowly allowing the oil to flow throughout the spar.

1. Engine oil filler hole (left frame spar)

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

27. Recheck the level as described in the engine oil checking procedure. Add oil as required to bring level to the bottom of the c hec k bol t hole.

X440s Owner's Manual.fm

TRANSMISSION OIL

SERVICE : Transmission, oil, recommended type

80W or 85W

SERVICE : Transmission, oil, total quantity (dry fill)

0.74 US quart (0.7 L)

WARNING

POTENTIAL HAZARD(S)

Serious injury or irritation to the skin or eyes. Death if swallowed.

and add small amounts slowly at the filler hole and recheck the level.

WHAT CAN HAPPEN

Transmission oil is a hazardous substance. If it comes into contact with your skin or eyes you can suffer serious injury or irritation. If swallowed it can cause death.

HOW TO AVOID THE HAZARD

Wear hand protection and safety glasses when working with engine oil. If you touch tran smissio n oil, wash it off imm ediatel y with soap and water . Clean clothes or rags contaminated with engine oil. If swallowed seek immediate medical attention. KEEP TRANSMISSION OIL AWAY FROM CHILDREN AND ANIMALS.

CAUTION

A low transmission oil level may result in severe engine damage. Check level before eve ry ride.

Always use the specified transmission oil.

Always use a clean funnel when adding transmission oil

1. Check bolt

4. Install t he transmission oil level check bolt.

TORQUE : Transmission, oil level check bolt

5.0 lbf•ft (6.8 N•m)

1. Transmission oil filler hole

1. To check, make sure the engine is cold.

2. Place the vehicle on a stand so it is level and wait a few minutes until the tran sm ission oil settles.

3. Place a few rags under the transmission oil level check bolt and remove it. The transmission oil level should be even with the bottom of the check hole. If the transmission oil level is low, install the check bolt,

P/N 951-05002032

Printed : 8/13/01

CHANGING THE TRANSMISSION OIL

WARNING

POTENTIAL HAZARD

Blindness, eye injury,

WHAT CAN HAPPEN

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

Wear safety glasses when working with compressed air.

CAUTION

When re-installing the transmission oil filter, be sure to insert it into the drain bolt, then insert the pair into the crankcase hole together. This helps assure that the other end of the filter will locate into the back of the transmission 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.

4. Lean the vehicle slightly to the right to ensure all oil is drained.

5. If the fil ter did not com e out with the bo lt, remove it carefully from the hole. Clean it using compressed air.

NOTE : The transmission drain bolt is located on the right side of the engine. The filter (screen) may not come out with the drain bolt. After the oil drains, use needle nose pliers to gently remove it from within the drain hole.

Take notice of the sealing washer on the bolt when you remove it.

1. Place vehicle on a level surface.

2. Place a suitable container under transmission drain bolt and remove the bolt.

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

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

8. Apply anti-seize compound to the threads of the transmission drain bolt (1). Then install the sealing washer (2) onto the bolt with the flat side (a) facing

3. Allow the transmission oil to drain completely.

X440s Owner's Manual.fm

the case. Insert the filter into the bolt, and install into the case.

1. Drain bolt

2. Sealing washer

3. Filter (screen)

a. Sealing washer flat side

9. Tighten the bolt to the specified torque.

TORQUE : Transmission, oil, drain bolt

6.0 lbf•ft (8.1 N•m)

10. Add the specified transmission oil at the filler cap until oil level reaches the bottom of the check bolt hole. Pour slowly and allow time for the oil to flow throughout the case cavity.

11. Then, run the engine briefly (1-2 minutes) to circulate newly added oil and recheck the level. Add if necessary.

NOTE : The transmission oil level should always be at the bottom of the check bolt hole.

P/N 951-05002032

Printed : 8/13/01

3. After fueling, turn the fuel tank cap clockwise to tighten.

FUEL

SERVICE : Fuel, recommended fuel

Premium unleaded gasoline

SERVICE : Fuel, fuel tank ca pac ity

2.1 US gal (8.0 L)

WARNING

POTENTIAL HAZARD(S)

(1) Fire or explosion

(2) Overfilling the fuel tank.

WHAT CAN HAPPEN

(1) Gasoline is extremely flammable. Handling it inappropriately or near cigarettes, flame, sparks, welders, or other sources of ignition can result in a fire or explosion where you can be seriously injured or killed.

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

1. Fuel tank cap

2. Fuel tank

3. Fuel level

4. Filler neck

4. Make sure the fuel cap breather hose is routed correctly.

HOW TO AVOID THE HAZARD

(1) Only handle gasoline outdoors and away from cigarettes, flame, sparks, welders, or other sources of ignition.

(2) Stop adding fuel when the fuel level reaches the bottom of the filler neck

CAUTION

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

Never experiment by using fuels other than the recommended type in this vehicle. Other fuels or additives not designed specifically for this vehicle can severely damage the eng ine a nd its sup porting com ponents (e.g. fuel system, sensor s, tank, hoses, etc. )

1. To add fuel, remove the fuel tank cap by turni ng it counterclockwise.

2. Carefully fill the fuel tank with the recommended fuel until the fuel level reaches the bottom of the filler neck.

X440s Owner's Manual.fm

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