1 P/N 941 5002037 Printed : 8/27/01 AB O U T T HE M A N U A L This is an "engine" service manual. It has been developed to address major mechanical service issues (example: component and systems removal, inspection, disassembly, assembly, and reinstallation.) This manual can be used for 2001 and 2002 Cannondale vehicles (motorcycles & ATVs). You must possess significant mechanical knowledge, skills, and tools to perform most of the procedures found in this document. This manual was accurate at the time of publication. Any supplemental information developed or written after printing may be available on our web site as a "manual supplement." Service bulletins and technical notes are also published as required. These are also posted on the website. You may find that this service manual uses technical terms and part names slightly different from published parts catalogs or microfiche. Most sections of this manual begin with illustrations (line art or photograph) of the assemblies considered in the section. All the procedures in this manual are organized in a numbered (step-by-step) easy to read format with accompanying photographs, line art, torque values and specifications. The numbered steps of a few procedures are likely to be separate procedures themselves. When this is the case, the numbered step will include a page reference number. U PD AT E S Supplements to this manual are published on an ongoing basis. A list of supplements to this manual are maintained at www.cannondale.com COMMENTS? We invite your comments and suggestions on this or any other publication offered by Cannondale Motorsports. When giving us your comments, please include the publication title and date. Send your comments to: Cannondale Corporation Technical Publications 2 Corporate Drive Bedford, PA 15522 e-mail: technical.publications@cannondale.com O T H ER T Y PES O F M A NU A L S A V A IL A B L E Vehicles using the same engine also have a "chassis" manual which includes the specific periodic maintenance, engine removal, engine installation, operating, and/or tuning procedures relevant to the installed engine. This type of manual is also designed to be used by qualified service technicians. An "Owner's" manuals for all vehicles include basic vehicle maintenance and service information. This manual is designed for the vehicle owner. Cover.fm © 2001 Cannondale Corporation - All Rights Reserved 2 Safety Alerts · FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. 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 death WILL result if instructions are not followed. DANGER WARNING Indicates a potential hazard that COULD result in serious injury or death. CAUTION Indicates a potential hazard that could result in vehicle damage if instructions are not followed. NOTE : Provides helpful information This manual is written for Cannondale motorsports dealers and qualified service technicians. This is not a comprehensive shop safety manual and should not be used by anyone who is not familiar with standard safety practices and service techniques. This manual does include warnings and cautions (see descriptions above) that if ignored, could result in SEVERE PERSONAL INJURY to the service technician or significant damage to the vehicle rendering it unsafe to operate. Anyone operating an "unsafe" vehicle can be seriously injured or KILLED. We have done our best to identify situations where warnings or cautions are needed and will continue to do so in future publications. But, YOU must always exercise good judgement, and follow safe shop practices when performing service procedures as described in this manual. 3 P/N 941 5002037 Printed : 8/27/01 Death by Carbon Monoxide Protect your eyes DANGER POTENTIAL HAZARD Running the engine indoors. Breathing exhaust fumes The golden rule here is "Always wear safety glasses." You can never predict and certainly can't avoid all instances when a part, snapring, clip, dirt, debris, or fluid will injure your unprotected eyes. 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. WARNING POTENTIAL HAZARD Blindness, eye injury HOW TO AVOID THE HAZARD Never operate the vehicle indoors even for brief periods. WHAT CAN HAPPEN There are thousands of scenarios in the work shop where working with a tool, a fluid, or a part can result in a serious injury to your eyes. Here are just a few: You can have fluids sprayed into your eyes when you least expect it (pressurized fuel or coolant) Respect the environment When cleaning the oil filters, objects being propelled by compressed air can strike your eyes and cause serious eye injury or blindness. You can poke your eye out with a tool by using it incorrectly or by using a tool that is not designed or suitable for the job. Small parts such as a snap ring or circlip can "fling" off and strike your eye while you are working. Its illegal and clearly environmentally irresponsible to dispose of used engine and transmission oils, coolant and other discarded parts improperly. Cannondale strongly suggests that you help protect and preserve the enviroment. Take the extra step necessary and find out the proper way to dispose of these potentially toxic substances in your area. For information on "recycling" and "hazardous material disposal" in your area consult your local phone book. HOW TO AVOID THE HAZARD Always wear safety glasses. When working with compressed air - use short bursts and direct the tip of the air nozzle away from yourself. Use tools appropriately. There's always "the right tool for the right job." If you do not have the tools necessary to complete a procedure - get them before attempting it. Safety Alerts.fm © 2001 Cannondale Corporation - All Rights Reserved 4 Coolant is hazardous Engine oil is hazardous WARNING POTENTIAL HAZARD(S) (1) Scalding coolant sprayed onto YOU (2) Serious eye or skin injury, ingestion (3) (drinking or swallowing) coolant WARNING POTENTIAL HAZARD(S) (1) Serious injury or irritation to the skin or eyes (2) Death if swallowed. WHAT CAN HAPPEN (1) Engine oil is a hazardous substance. If it comes into contact with your skin or eyes you can suffer serious injury or irritation. Prolonged contact with skin may cause skin cancer. (2) If it is swallowed it can cause death. WHAT CAN HAPPEN (1) Hot coolant being sprayed from under high pressure when the bottle is opened. (2) Coolant is poisonous. If it gets in your eyes or contacts your skin the fluid can cause irritation or severe injury. (3) Coolant is sweet tasting and is very attractive to small children and pets. It is very poisonous and its ingestion will cause serious injury or death. HOW TO AVOID THE HAZARD (1) 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. (2) If swallowed seek immediate medical attention. KEEP ENGINE OIL AWAY FROM CHILDREN AND ANIMALS. 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. Place a thick rag or towel over the radiator cap and slowly turn the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. Wait for the hissing to stop then press down on the cap while turning it counterclockwise and remove it. (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. (3) If coolant is swallowed induce vomiting, rinse the mouth and throat with water, and seek immediate medical attention. Transmission oil is hazardous WARNING POTENTIAL HAZARD(S) Serious injury or irritation to the skin or eyes. Death if swallowed. 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 transmission oil, wash it off immediately 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. 5 P/N 941 5002037 Printed : 8/27/01 Gasoline is VERY hazardous Heated components can give you SEVERE burns WARNING POTENTIAL HAZARD(S) (1) Fire or explosion WARNING POTENTIAL HAZARD(S) Severe burns 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. WHAT CAN HAPPEN Some procedures require that components be heated (a normal assembly/disassembly technique). Anytime you work with heated components you risk burning yourself severely. HOW TO AVOID THE HAZARD (1) Only handle gasoline outdoors and away from cigarettes, flame, sparks, welders, or other sources of ignition. HOW TO AVOID THE HAZARD Generally, but not always, working with heated components in a procedure means that the procedure is not a simple one (ie., not something for the home mechanic or hobbyist). Leave any procedure where heating components are a part to the specialists (e.g., machine and specialty mechanic shops). Wear thermally protective gloves and arm coverings when working with heated components. Breathing dust and fiber is hazardous WARNING POTENTIAL HAZARD(S) Respiratory disease and cancer WHAT CAN HAPPEN Certain components (e.g., brake pads, gaskets, clutch linings) produce dust and fibers that when inhaled may cause respiratory disease and cancer. You could become very sick and die! HOW TO AVOID THE HAZARD Always wear an OSHA-approved mask or ventilator when working on these components. Safety Alerts.fm © 2001 Cannondale Corporation - All Rights Reserved 6 CONTENTS SAFETY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 COVERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 CYLINDER HEAD/CAMSHAFTS/VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SLEEVE (AND PISTON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 CRANKSHAFT CARTRIDGE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 TRANSMISSION CARTRIDGE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 VALVE CLEARANCE SHIM TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 NEW 5 1 11 1 2 2 1 6 3 N A 7 P/N 941 5002037 Printed : 8/27/01 Engine Service Manual _PN 941 5002037TOC.fm © 2001 Cannondale Corporation - All Rights Reserved 8 G eneral Inform ation VE HIC L E ID EN TIFI CA TIO N N UM BE RS ( VIN ) Motorcycle vehicle identification numbers (VIN) are located on the left side of the steering head. ENGINE IDENTIFICATION XXX XXX XXX XXX ATV vehicle identification numbers (VIN) are etched/ stamped into the frame in the area behind the front brush guard. A temporary factory applied adhesive label with the VIN is also mounted in the same area. The engine serial number is etched/stamped into the engine crankcase. XX XX XX XX XX XX 1 2 1. 2. Etched VIN Factory VIN label 9 P/N 941 5002037 Printed : 8/27/01 SPECIAL TOOL S The following is a list of special tools available to service the engine. Special tools are developed on an ongoing basis. For an up-to-date listing of special tools developed to service Cannondale vehicles, contact Cannondale dealer service. Valve spring compressor ...