2002 X440s OWNER'S MANUAL P/N 951-5002032 S afety A lerts · · 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 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 could result in vehicle damage if instructions are not followed. NOTE : Provides helpful information 1 P/N 951-05002032 Printed : 8/13/01 C ontents Safety Alerts . . . . . . . . . . . . . . . . . 1 Contents . . . . . . . . . . . . . . . . . . . . 2 Important Information . . . . . . . . . 3 Pre-Ride Inspection . . . . . . . . . . . 6 Component Locations . . . . . . . . . 7 Controls . . . . . . . . . . . . . . . . . . . . 8 Operating . . . . . . . . . . . . . . . . . . . 11 Fluids. . . . . . . . . . . . . . . . . . . . . . . 14 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . Engine oil . . . . . . . . . . . . . . . . . . . . . . . . Transmission oil . . . . . . . . . . . . . . . . . . . Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Break-in . . . . . . . . . . . . . . . . . . . . . . . . . Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . . . . . . . . . . . Suspension . . . . . . . . . . . . . . . . . . . . . . . Rear shock . . . . . . . . . . . . . . . . . . . . . . . Tires & Wheels . . . . . . . . . . . . . . . . . . . . Frame, Sub-frame, Swingarm. . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . 14 16 18 23 26 27 30 35 38 43 46 47 49 56 65 66 69 73 75 76 Maintenance and Adjustments . . 27 Cleaning and Storage . . . . . . . . . 83 X440s Model Specifications . . . . 85 X440s Service Specifications . . . 86 X440s Torques . . . . . . . . . . . . . . . 87 X440s Owner's Manual.fm © 2001 Cannondale Corporation - All Rights Reserved 2 Im portant Inform ation 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 vehicle riding apparel. available at the time of publication. Cannondale Corporation reserves the right to make changes at any time, without notice. This vehicle has U.S. and International patents pending. Cannondale Motorsports Cannondale Corporation EXPERIENCED RIDERS ONLY · This vehicle is not for beginners. · All Cannondale motorsports products are designed for use by trained and experienced riders only. All are very high performance, competition sport machines and should only be operated by licensed competition riders in excellent physical condition, who are well-trained and experienced in the operation of high performance competition vehicles. GOOD JUDGEMENT ABOUT THIS MANUAL The purpose of this manual is to provide the owner with important safety, service, maintenance, and tuning information, and should 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 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. There is always a risk involved when riding a vehicle; however, making sure you and the vehicle are in the best condition possible will ensure a great riding experience. Use sound judgement when riding. Never ride under the influence of alcohol, 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. 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. 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. LIMITATIONS 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 3 P/N 951-05002032 Printed : 8/13/01 VEHICLE IDENTIFICATION NUMBER (VIN) The vehicle identification number (VIN) is located on the left side of the steering head. LABEL LOCATIONS 3 2 1 XXX XXX XXX XXX 4 Record your vehicle's ID number here: ENGINE SERIAL NUMBER The engine serial number is etched/stamped into the engine crankcase. See illustration on following page for examples of the numbered labels above. XX XX XX XX XX XX Record your vehicle's ID number here: X440s Owner's Manual.fm © 2001 Cannondale Corporation - All Rights Reserved 4 LABELS (1) (2) (3) (4) 1. 2. 3. 4. General Fuel EPA noise Frame 5 P/N 951-05002032 Printed : 8/13/01 P re-R ide Inspection WARNING POTENTIAL HAZARD Failure to inspect vehicle before operating. 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) 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 vehicle at least every 25 hours of riding. 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 lever freeplay. . . . . (as specified in all steering positions)) proper operation . . . (smooth and returns to idle (closed) 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 © 2001 Cannondale Corporation - All Rights Reserved 6 C om ponent Locations 1 3 5 6 19 2 7 8 4 20 21 22 28 27 26 25 24 23 9 10 18 17 16 15 14 13 12 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Clutch lever Engine stop button Front brake master cylinder Engine start button Front brake lever Throttle Fuel tank cap Fuel tank Engine oil fill Battery Drive chain adjusters Engine oil drain (frame) 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Shift lever Transmission oil fill Clutch Engine oil filter Idle adjusting screw Radiator Engine Control Module (ECM) Airbox filter Main air filter Fuel injectors Starter clutch cover Water pump 25. 26. 27. 28. Engine oil crankcase drain Transmission oil drain Brake pedal Rear brake reservoir 7 P/N 951-05002032 Printed : 8/13/01 C ontrols ENGINE STOP BUTTON 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 switch is damaged or the wires are frayed or torn, (circuit open) the engine may not start. 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 slowly when engaging. NOTE : When starting it is recommended that you shift the transmission into neutral and pull in the clutch lever to increase the starter's efficiency. 1 1 1. Clutch lever SHIFT LEVER The shift lever is located on the left side of the engine. 1. Engine stop button NOTE : The transmission 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 is located on the right handlebar 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 1. Engine start button X440s Owner's Manual.fm © 2001 Cannondale Corporation - All Rights Reserved 8 THROTTLE 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 FRONT BRAKE LEVER The front brake lever is located on the right handlebar. Pull the lever toward you to activate the front brake. 1 a b 1. Front brake lever 1 WARNING POTENTIAL HAZARD (1) Malfunctioning throttle (2) Incorrect freeplay The rear brake pedal is located on the right side of the vehicle. Press it firmly to apply the rear brake. REAR BRAKE PEDAL 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 released. 1. Rear brake pedal 1 (2) Make sure the throttle freeplay is adjusted as specified. See "throttle Freeplay" starting ...