Cannondale 2002 Blaze Owner'S Manual Download | Manualshive

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CONTENTS

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

WARNING

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

When reading this manual, remember:

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Summary of Contents for 2002 Blaze

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Page 3: ...s more suspension travel Relatively easy to turn over Soft high traction tires Traction and flotation on soft loose surfaces Grip on hard surface pavement makes it easy to turn over Totally unsuited a...

Page 4: ...nt This manual contains standard ATV industry safety information required to be a part ofATV Owner s Manuals It also contains Cannondale specific model information Read and understand the entire proce...

Page 5: ...the manufacturer Limitations All information in this Owner s Manual is based upon the latest product data and specifications available at the time of printing Cannondale Corporation reserves the right...

Page 6: ...l messages preceded by the Safety Alert Symbol It meansATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED CAUTION Indicates a potential hazard which that could result in vehicle damage if instructions are...

Page 7: ...low 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 dri...

Page 8: ...harply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose s...

Page 9: ...cified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never install a twist grip throttle on th...

Page 10: ...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...

Page 11: ...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 Transmissi...

Page 12: ...for any operator If any label is missing worn damaged or becomes unreadable be sure to replace it Cannondale offers replacement labels at no charge A label s part number is printed in the lower right...

Page 13: ...315 6000237 01 Label 3 P N 315 6000239 01 315 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 inju...

Page 14: ...Label 4 P N 315 6000238 01 Label 5 P N 315 6000477 01 315 6000238 01 315 6000477 01 Label 6 P N 315 6000580 01 315 6000580 01...

Page 15: ...ale ATVs are shipped with a removable hangtag attached to the handlebar Like the vehicle s warning labels this hangtag contains important information for your safety Read and understand it throroughly...

Page 16: ...mation or theft recovery Your vehicle s ID numbers identify it from others of the same model type VEHICLE IDENTIFICATION NUMBER VIN The vehicle identification number VIN is etched stamped into the fra...

Page 17: ...et The number also 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...

Page 18: ...fer slightly from those shown in the illustrations in this manual 8 9 2 5 6 1 Clutch lever 2 Engine RUN OFF switch 3 Engine start switch green 4 Ignition switch 5 Front brake master cylinder 6 Parking...

Page 19: ...r 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...

Page 20: ...ly 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 s...

Page 21: ...the seat pan with the fuel tank clip and the subframe guides 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 s...

Page 22: ...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 severely injured or killed HOW TO AVOID THE HAZARD Always make sure the...

Page 23: ...ning the ignition switch to the OFF position will stop a running engine however we recommend using the engine stop button or switch as the primary means to shut off a running engine follow up by turni...

Page 24: ...ted correctly Start the engine With the engine running pull the strap quickly from the switch body the engine should shut down immediately If it does not do not ride the ATV the switch is damaged and...

Page 25: ...ne don t ride the ATV Turn the ignition switch to the OFF position and contact a Cannondale motorsports dealer to have it replaced NOTE The stop button is a normally closed circuit switch If the switc...

Page 26: ...be maintained nearer the handle grip for this reason During your pre ride inspection and before moving off to ride start the engine and test the switch to confirm that it is operating properly If the...

Page 27: ...headlights Test for the proper operation of the headlights before operating the vehicle TAILLIGHT Turn the ignition switch to the ON with LIGHTS position to activate the taillight The taillight IS NOT...

Page 28: ...d can provide braking force when needed Roll the vehicle forward and back applying the brake to confirm that braking force is applied to the front brake discs PARKING BRAKE The parking brake is applie...

Page 29: ...ARD 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 Brak...

Page 30: ...ied 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...

Page 31: ...s applied Pay particular attention to strapping in the areas where it attaches to the bars See example at dotted circle in photo below 1 Nerf bar right 2 Teeth replacable 3 Strapping 1 NURF BAR 1 2 3...

Page 32: ...he entire range of gears with the engine turned off roll the vehicle forward and back as you shift through all the gears to avoid damaging the transmission FUEL TANK CAP Make sure the fuel cap is tigh...

Page 33: ...ride Make sure they are firmly attached and do not 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 Can...

Page 34: ...Freeplay is the distance the lever moves until the slack in the cable is taken up DANGER POTENTIAL HAZARD Overturning or flipping the ATV onto yourself WHAT CAN HAPPEN Opening the throttle too quickl...

Page 35: ...s adjusted to specification See Clutch lever manual starting on page 33 CLUTCH LEVER HYDRAULIC The hydraulic clutch lever is located on the left side of the handlebar Pull in the clutch lever quickly...

Page 36: ...s also located in the same area The connector type is different for MC500 and MC1000 equipped models See the photos The diagnostic tools can be used to diagnose faults with the engine management syste...

Page 37: ...b rail When riding in areas where you might not be easily seen e g hilly terrain or sand dunes mount an approved ATV safety flag Safety flags are required in some riding areas For more information on...

Page 38: ...ed 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...

Page 39: ...te CannondaleATVs 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 operat...

Page 40: ...ed for their age can lead to severe injury 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 judgemen...

Page 41: ...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 withou...

Page 42: ...ghttime even with the lighting on thisATV reduces your ability to see obstacles therefore you must slow down WARNING POTENTIAL HAZARD Riding this ATV at excessive speeds WHAT CAN HAPPEN Increases your...

Page 43: ...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 POT...

Page 44: ...e of stability and erratic handling that can result in the loss of vehicle control You could be involved in an accident and be seriously injured or killed WARNING POTENTIAL HAZARD Overloading this ATV...

Page 45: ...wildly unpredictable You can lose control suddenly and without warning The lighting on this ATV does not imply that it is for public roads or highways WARNING POTENTIAL HAZARD Operating this ATV on p...

Page 46: ...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 m...

Page 47: ...d reduce your speed before entering a turn If you have experience riding a motorcycle you will have to quickly unlearn the technique you might have developed of removing your inside foot from the foot...

Page 48: ...an impair your ability to safely operate this ATV If you are taking any type of medication check with your doctor before riding WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or d...

Page 49: ...pting 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 who...

Page 50: ...n 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 HAZAR...

Page 51: ...ass fallen branches holes large obstacles or other hazards you could collide with a hidden hazard and be seriously injured or even killed WARNING POTENTIAL HAZARD Failure to use extra care when operat...

Page 52: ...a 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 AVOI...

Page 53: ...ain 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...

Page 54: ...lippery surfaces or where obstacles might cause you to lose control or force a sudden change in direction This can result in a serious accident resulting in serious injury or death Maintain steady and...

Page 55: ...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 even killed WARNING POTENTIAL HAZARD Going downhill improperl...

Page 56: ...your direction of travel is straight across the slope If the vehicle begins to tip over correct by reducing speed and gradually steering in the downhill direction Avoid slopes with unstable or slippe...

Page 57: ...y or rough slopes or hills Always reduce speed when turning WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn...

Page 58: ...lision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When yo...

Page 59: ...urning 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 thisATV You may also regain tra...

Page 60: ...un 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 road vehicles...

Page 61: ...it the water where surfaces are stable and not slippery or loose Check for any hidden obstructions and holes which may trap disable or result in the vehicle becoming submerged Travel at reduced speed...

Page 62: ...D 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 clim...

Page 63: ...ards on its own MODIFICATIONS WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modifications of this vehicle may cause ch...

Page 64: ...nt HOW TO AVOID THE HAZARD Always inspect thisATV before you operate it Always follow the inspection and maintenance procedures found in this Owner s Manual Have your vehicle serviced by an authorized...

Page 65: ...sprockets swingarm buffer rollers and guide block Start on pag e116 Engine Oil level Fill with engine oil if necessary Start on page85 Fuel Fuel level Fill with fuel if necessary Start on page82 Tran...

Page 66: ...sure the battery is at full charge before 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 disen...

Page 67: ...before riding ATV 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 switch to R...

Page 68: ...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 WARNING Indicates a potential hazard th...

Page 69: ...10 minute segments using no more than 1 2 throttle Wait for the engine to cool completely between segments 2 Next ride three 15 minute segments using no more than 3 4 throttle again allowing the engi...

Page 70: ...ear 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 authoriz...

Page 71: ...without notice 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...

Page 72: ...garettes 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...

Page 73: ...uids e g engine oil transmission oil brake fluid coolant WHAT CAN HAPPEN The fluids in your vehicle are hazardous substances Contact with your skin or eyes you can result in serious injury or irritati...

Page 74: ...intenance Interval in hours BREAK IN 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 T...

Page 75: ...tion 3 I I I R CLUTCH HYD OIL I R 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...

Page 76: ...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 condi tio...

Page 77: ...sen the bolts but do not try to remove them from the cover holes When loose simply lift off the cover To install the covers return the cover to its original position and tighten the bolts snug Do not...

Page 78: ...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 s...

Page 79: ...e panel in the original position and install the 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 or...

Page 80: ...e 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 tightenin...

Page 81: ...t from the tank 6 Remove the quick connect at the rear of tank in the same manner 7 To install the fuel tank reverse the removal procedure 1 Tab 2 Fuel tank return from pressure regulator quick connec...

Page 82: ...amage before every ride If you have crashed or rolled yourATV there could be damage hidden from your view DO NOT ride an ATV with any crack even a small one It must be carefully inspected by an author...

Page 83: ...1 3 4 5 2 1 Frame 2 Rear shock strut 3 Subframe 4 Swingarm 5 Engine rail skid plate 6 Brush guard...

Page 84: ...ding 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 ca...

Page 85: ...er 1 in direction a to increase idle speed or direction b to decrease idle speed Throttle lever adjustment See 2002 Model Specifications starting on page 161 Loosen locknut and then turn the adjuster...

Page 86: ...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 before star...

Page 87: ...for 1 minute before 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...

Page 88: ...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 3 Move to the r...

Page 89: ...case 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...

Page 90: ...lated 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 replace it with a new one 8 Inspect th...

Page 91: ...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 hou...

Page 92: ...he fitting O ring 17 Install the fitting Tighten it to the specified torque 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...

Page 93: ...esult in severe engine damage Always use the specified transmission oil and check the level before every ride NOTE The sealing washer of the check bolt is reusable but not indefinitely We recommend th...

Page 94: ...ll amounts using a clean funnel Recheck the level 1 Transmission oil window NOTE The transmission oil level within the crankcase should be visible in the window Maintain the oil level between the LOW...

Page 95: ...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 engine The filter scr...

Page 96: ...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 7 Tighten the bolt to the...

Page 97: ...falls significantly not visible in the bottle the non self bleeding systems will require bleeding after refilling the system See page 98 WARNING POTENTIAL HAZARD Severe burns WHAT CAN HAPPEN Coolant...

Page 98: ...w any residual pressure to escape Then remove the cap and slowly add the specified coolant using a clean funnel until it reaches the LEVEL mark 3 Reinstall the cap and check coolant system for leaks C...

Page 99: ...nt to the O ring and install the drain bolt 4 Remove the coolant outlet drain bolt and sealing washer and allow coolant to drain completely Reinstall the sealing washer and bolt Tighten snug 5 Add the...

Page 100: ...ant bottle cap and slowly remove the cap to release any residual pressure 3 Fill the coolant bottle to the LEVEL mark with the specified coolant 4 Loosen the bleed bolt on the water pump cover and all...

Page 101: ...WARNING Indicates a potential hazard that COULD result in serious injury or death When reading this manual remember...

Page 102: ...for wear 5 Test both brake systems at slow speed Make sure that both systems function properly and that there is proper braking force available always 6 When riding in wet conditions or after exiting...

Page 103: ...mmended brake fluid from a sealed container until the fluid level is above the LOWER mark on the reservoir body 6 Reinstall the diaphragm cover and cover screws NOTE The rear brake master cylinder res...

Page 104: ...n before riding the vehicle Brake pads and discs inspection NOTE Consult the Model Specifications section in this Owner s Manual for brake pad and disc wear specifications Consult the Torque Table for...

Page 105: ...isc is worn beyond the specified thickness it must be replaced 3 Make sure the front and rear brake disc mounting bolts are tightened to the specified torque 1 Front brake pads right wear limit indica...

Page 106: ...1 Front disc mounting bolts 1 visible in photo 2 Caliper mounting bolts 3 Banjo bolt 3 2 1...

Page 107: ...are positioned incorrectly the line can be damaged or break resulting in a loss of braking control resulting in a serious accident You can be severely injured or killed HOW TO AVOID THE HAZARD The in...

Page 108: ...the WARNING POTENTIAL HAZARDS 1 Injury to your hands burns cuts 2 Crashing the ATV losing control WHAT CAN HAPPEN 1 Brake discs operate at very high temperatures and remain hot for a period of time af...

Page 109: ...lps to use a thin blade screwdriver to carefully pry the boot edge away from the nut Also rotate the boot as you remove it 5 Loosen and back out the allen bolts It is not necessary to remove them Usin...

Page 110: ...lay If play is still present do not ride the vehicle contact an authorized Cannondale motorsports dealer for servicing Rear pedal height adjustment The rear brake pedal can be adjusted for comfort as...

Page 111: ...t at the lever first If the specified freeplay cannot be achieved adjust at the inline adjuster Inspect the clutch arm position anytime the lever freeplay is adjusted 1 To measure the freeplay slide b...

Page 112: ...ease available freeplay at the lever Tighten the locknut securely after adjusting the clutch cable Re adjust freeplay at the lever when finished Clutch lever position hydraulic The lever position of v...

Page 113: ...handle grip Checking the oil level of the hydraulic clutch CAUTION Never substitute brake fluid for SAE 10 mineral hydraulic oil 1 To check the level remove the cover screws cover and rubber boot 1 A...

Page 114: ...oil to the bleeder bolt at the slave cylinder 3 Loosen the bolts and slowly compress the syringe until only oil no air bubbles is discharged at the bore of the master cylinder Make sure the oil does...

Page 115: ...4 Tighten the adjuster locknut to the specified torque 5 Check the fluid level in the master cylinder Clutch arm adjustment manual Normal clutch plate wear and cable stretch influences the clutch arm...

Page 116: ...t contamination of the transmission oil when the clutch cover is removed 3 Disconnect the clutch cable end from the clutch arm 4 Remove the shift lever pinch bolt and shift lever from the shift shaft...

Page 117: ...o the seal when reinstalling the cover Now you are ready to begin the adjustment 7 Have an assistant hold light pressure on the actuating arm toward the cylinder head on the actuating arm 8 As your as...

Page 118: ...The drive chain must be cleaned and lubricated before every ride Significant forces act on the chain during operation If its not clean and lubricated it can quickly wear out and possibly fail or contr...

Page 119: ...lubricant to the entire length of the chain 3 Next inspect the chain slack and adjust it if necessary page 119 Swingarm buffer inspection CAUTION Wear may be distributed differently across the buffer...

Page 120: ...h guards are mounted securely Inspect each guard for cracking and or other signs of excessive damage or wear On the sprocket guard pay particular attention to the areas dotted circles indicated in the...

Page 121: ...e the drive chain before measuring the slack The chain s condition affects the accuracy of measurement Also when measuring rotate the chain and measure different links at the mid point between the spr...

Page 122: ...e hole in the eccentric below the rear axle midline If the hole is adjusted above the midline the chain will wear into the sprocket guard causing damage to the guard and the chain See hand figure in p...

Page 123: ...e rear axle locking bolts Drive chain stretch inspection 1 With the upper or lower section of the drive chain tight between the sprockets measure the distance between the span of 13 pins from pin cent...

Page 124: ...n of the chain rotation Sprocket inspection Visually inspect the condition of the rear countershaft sprocket s before every ride If damage is found contact an authorized Cannondale motorsports dealer...

Page 125: ...nit ECU or ECM precisely calculates ignition timing and fuel delivery for all engine speeds and loads based on the currently installed calibration file and its mapping The ECU is an extremely reliable...

Page 126: ...movement of a toothed wheel that is molded into the flywheel and attached to the right side of the crankshaft The wheel has a 36 tooth pattern The teeth are evenly spaced with the exception of one tr...

Page 127: ...ot only the position of the throttle plate but the speed with which it is being opened or closed The engine load is determined from the TPS and engine speed rpm The voltage output from the TPS increas...

Page 128: ...cher fuel mixture needed when the engine is cold When the start button is pressed this valve begins to move to the correct position depending on the air and engine temperature Be sure to follow the co...

Page 129: ...alculate hot and cold start fueling requirements The sensor resistance decreases as the temperature increases Air temperature sensor The intake air temperature sensor is green It is mounted on the fro...

Page 130: ...d but the length of time they remain open varies The duration that the injectors stay open is calculated by the ECU using the calibration file and data received by the various sensors Engine shown rem...

Page 131: ...the injectors Fuel Pressure Regulator The fuel pressure regulator is mounted on the right side of the vehicle front This device maintains the correct fuel pressure in the fuel rail hoses and injector...

Page 132: ...h OFF will isolate some areas of the electrical system It is an added step in circuit protection See your vehicle s wiring diagram 1 Turn the ignition switch OFF WARNING POTENTIAL HAZARD Electrical fi...

Page 133: ...e fuse holder from the cap 3 Remove the fuse and replace with the specified fuse 4 If the fuse immediately blows again check the electrical circuits 1 Cap 2 Fuse 3 Holder Fuse replace 0000 3 2 1 1 Lin...

Page 134: ...ight harness connector 3 Turn the bulb unit counterclockwise to remove it from the headlight housing 4 Install a new bulb unit into the housing 5 Reconnect the harness 6 Test for proper operation Tail...

Page 135: ...guard against dirt or other object falling into the combustion chamber when the spark plug is removed NOTE Accessing the spark plug requires a moderate degree of mechanical skill and the appropriate...

Page 136: ...strut back and disconnect the coil from the wiring harness 8 Remove the spark plug coil holder bolt and clip 9 Clean the area surrounding the coil to prevent dirt from entering the cylinder head when...

Page 137: ...ine conditions normal and abnormal should be left to a qualified service technician 12 Before reinstalling the spark plug measure each gap a with a wire gauge or feeler gauge If either gap is out of s...

Page 138: ...ntaminating the airbox with foreign objects water dirt or other debris 1 Remove the cowl 2 Release the filter retaining clip and remove it 3 Remove the air filter from the air filter base plate WARNIN...

Page 139: ...il be sure to massage the foam to ensure a good application throughout 7 Recombine the cage and foam element Be sure to install the foam onto the cage so that the seam in the foam is aligned with the...

Page 140: ...10 Apply a small dab or waterproof grease to the end of the air filter and reinstall the retaining clip 11 Reinstall the removed components This photo shows the area where if the airfilter is installe...

Page 141: ...r repeatedly while momentarily blocking the end of the muffler spark arrester with a clean shop towel then quickly remove it This technique causes brief system back pressure and will force carbon buil...

Page 142: ...ces Adjustment Tips When making adjustments make them one at a time and in small steps The external adjusters have a normal right hand thread As you turn the external adjusters you will hear them clic...

Page 143: ...pay attention to changes in conditions e g tires air temperature In general compression damping changes should be used to influence the vehicle s stability and response while rebound damping changes...

Page 144: ...2 Turn the adjuster counterclockwise the desired number of clicks Rebound adjuster 1 To adjust turn the adjuster clockwise and count the number clicks until the adjuster is fully seated Be sure to wri...

Page 145: ...a spanner wrench The photo below shows a shock with settings 1 5 Front spring pre load Type II The spring adjusting sleeve has three positions so that the spring can be adjusted for different riding c...

Page 146: ...ring clockwise to increase the preload or counterclockwise to reduce the preload 1 Cam 2 Adjusting sleeve 3 Spanner wrenches NOTE This photo shows how to hold the spanners when reducing the preload R...

Page 147: ...Front compression adjuster Type III Front rebound adjuster Type III a More damping stiffer b Less damping softer a b a More damping stiffer b Less damping softer a b FW D...

Page 148: ...er pins or re using cotter pins 2 Riding on damaged wheel rims WHAT CAN HAPPEN 1 A damaged cotter pin can become dislodged allowing the hub nut and wheel to come off suddenly causing you to lose contr...

Page 149: ...rts dealer and have the conditions corrected 4 Make sure the wheel axle nut cotter pins on each wheel are in good condition before every ride Make sure the pin is not broken or damaged It should have...

Page 150: ...eing removed to prevent the vehicle from rolling away unexpectedly 2 Loosen the wheel lug nuts 3 Now place a stable support under the vehicle frame and raise the wheel off the ground 1 Cotter pin 2 Ta...

Page 151: ...flat side of the nuts face the wheel rim Tighten the nuts in a criss cross pattern TIRES See 2002 Model Specifications starting on page 161 All Cannondale ATVs are equipped with low pressure tires Th...

Page 152: ...damaged tires or rims WARNING POTENTIAL HAZARD 1 Uneven or improper tire pressure 2 Improper tires WHAT CAN HAPPEN 1 2 Tire characteristics influence the handling and stability of this ATV Use of tir...

Page 153: ...r wheels 5 Check the physical condition of each tire Make sure there is adequate tread If the tire is ripped torn punctured or damaged have it replaced with a new one 1 Tread 2 Wear limit 1 2 WARNING...

Page 154: ...connectors and devices bearings engine seals wheel bearings seals promoting rust and corrosion Severe damage can result Before you start cleaning the ATV take the following precautions Make sure the v...

Page 155: ...ollow the directions on the product label 4 Remove the air filter and thoroughly clean the area surrounding the airbox 5 Start the engine With the engine idling spray for 10 20 seconds a high quality...

Page 156: ...r being towed HOW TO AVOID THE HAZARD Never tow anything with this ATV or tow this ATV with any other vehicle WARNING POTENTIAL HAZARD ATV may roll off the truck or trailer WHAT CAN HAPPEN Ordinary ro...

Page 157: ...1 4 5 3 2 1 Brush guard 2 RIght footpeg 3 Left footpeg 4 Grab rail 5 Rear axle...

Page 158: ...nut 3 3 4 5 0 47 Clutch cover bolts 3 3 4 5 0 47 Transmission shift lever pinch bolt 5 0 6 8 0 69 Rear sprocket mounting bolts 35 0 47 5 4 83 Sprocket disc guard mounting bolts 5 0 6 8 0 69 Chain guid...

Page 159: ...ng is worn or stuck Cylinder is worn Battery voltage is low discharged The terminals are loose or corroded Charge and or clean the battery Fuel pump injectors or pressure regulator is leaking or fault...

Page 160: ...s are faulty Check Solenoid faulty Replace Engine starts hard when hot Air filter clogged Clean or replace Fuel not reaching the fuel injection system Change fuel filter Corroded battery terminal Clea...

Page 161: ...uel deterioration Replace fuel Brake dragging Adjust the brake system Air filter is clogged Clean or replace Compression release damaged Replace Overheating Air pocket in water system Bleed coolant ad...

Page 162: ...RECORD It is important to keep accurate records of maintenance service This data is vital for referencing previous work or knowing what type of tuning was performed under certain conditions DATE SERV...

Page 163: ...ement 432 cc Engine Management System MC500 MC 1000 MC1000 Coolant system Liquid cooled Coolant 1 1 water anti freeze ethylene glycol containing corrosion inhibitors for aluminum engines and radiators...

Page 164: ...sc Clutch plates 10 metal 9 friction Engine idle speed 2100 2200 r min Spark plug standard NGK CR10EK Spark plug gap 0 024 0 028 in 0 6 0 7 mm Crankshaft position sensor gap 0 00 in 0 5 1 0 mm Valve c...

Page 165: ...ther viscosities can be used when the average temperature range is within the indicated range CAUTION Be sure to change the engine oil and clean replace the filters in accordance with the vehicle main...

Page 166: ...perimeter Overall length 73 5 in 187 cm Overall width 46 4 118 cm 50 in 127 cm Overall height 44 in 112 cm 43 5 in 110 cm Seat height 32 5 in 83 cm 32 75 in 83 cm 29 in 74 cm Wheel base 49 5 in 126 c...

Page 167: ...3 5 in 89mm Water crossing maximum depth 8 in 203mm Front suspension travel 9 in 229mm 11in 279mm Rear suspension travel 10 in 254mm Dry weight appx 375 lbs 168kg 370 lbs 170kg Fuel tank capacity 3 2...

Page 168: ...0V O ring type Drive chain slack 1 37 1 60 in 35 40mm Swingarm buffer thickness STD MIN 0 275 in 7 mm 0 118 in 3 mm Drive chain roller O D STD MIN 1 4 in 35 2 mm 1 3 in 32 0 mm SUSPENSION See Addenda...

Page 169: ...REAR SHOCK Type I Compression adjuster MIN STD MAX 0 18 40 Rebound adjuster 0 15 32 SUSPENSION See Addenda starting on page170 CANNIBAL SPEED BLAZE MOTO 440...

Page 170: ...ton rings cylinder liner valve guides valve seats valves transmission gear engagement surfaces seals and bearings Parts and labor required as a result of piston or cylinder seizures Parts and labor re...

Page 171: ...OF ADDRESS Manufacturers of motor vehicles are required by the federal government to maintain a complete and up to date list of all original purchasers This information is first compiled from the com...

Page 172: ...ADDENDA This section is reserved for updates supplements and revisions...

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Page 178: ...WARNING Indicates a potential hazard that COULD result in serious injury or death When reading this manual remember...

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