Cannondale 2002 X440S Owner'S Manual Download Page 1

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2002 X440s OWNER'S MANUAL

P/N 951-5002032

Summary of Contents for 2002 X440S

Page 1: ...2002 X440s OWNER S MANUAL P N 951 5002032...

Page 2: ...attention to all messages preceded by the Safety Alert Symbol It means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED CAUTION Indicates a potential hazard could result in vehicle damage if instruction...

Page 3: ...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 St...

Page 4: ...ns 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 available at the...

Page 5: ...ft side of the steering head ENGINE SERIAL NUMBER The engine serial number is etched stamped into the engine crankcase LABEL LOCATIONS Record your vehicle s ID number here Record your vehicle s ID num...

Page 6: ...Printed 8 13 01 5 P N 951 05002032 LABELS 1 General 2 Fuel 3 EPA noise 4 Frame 1 2 3 4...

Page 7: ...llers cracks excessive wear or other damage chain guide block cracks excessive wear or other damage swingarm buffer cracks excessive wear or other damage SUSPENSION fork legs wear damage settings oil...

Page 8: ...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 adju...

Page 9: ...ing it activates the starter motor NOTE When using the button hold it for no more than 2 3 seconds at a time CLUTCH LEVER The clutch lever is located on the left handlebar Pull the lever to disengage...

Page 10: ...ch 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...

Page 11: ...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 SIDE STAND The side stand is...

Page 12: ...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...

Page 13: ...vehicle Apply the front and rear brakes evenly 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...

Page 14: ...1 After riding the vehicle clean it thoroughly and allow it to dry and then inspect the entire vehicle for damage or loose fasteners 2 Repair or tighten any damaged or loose components and lubricate t...

Page 15: ...3 Inadequate brake fluid levels WHAT CAN HAPPEN 1 Brake fluid is a hazardous substance It can cause injury to your eyes or skin if you touch it If swallowed it can cause death 2 Using unspecified bra...

Page 16: ...ter cylinder reservoir The fluid level should be above the LOWER mark 2 If the fluid level is below the UPPER mark add specified brake fluid until it reaches the UPPER mark NOTE Do not fill the brake...

Page 17: ...turning it until it can be removed 4 Coolant level should be at the bottom of the filler neck Add if necessary WARNING POTENTIAL HAZARD S 1 Scalding coolant sprayed onto YOU 2 Serious eye or skin inj...

Page 18: ...w any trapped air to escape It is not necessary to remove the 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...

Page 19: ...ransmission 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 WARNING POTENTIAL HAZARD S Serious injury or ir...

Page 20: ...the engine oil drain bolt and loosen it 6 Allow the contents of the spar to drain completely into an oil pan 1 Engine oil filler cap left frame spar 2 Vent hose CORRECT OIL LEVEL AFTER 1 MINUTE CHECK...

Page 21: ...to the specified torque 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 sur...

Page 22: ...e and clamp Then remove the clamp and the hose from the engine oil inlet fitting 18 Loosen and remove the inlet fitting Then remove the inlet filter screen from the crankcase hole 19 Clean the screen...

Page 23: ...quantity using a clean funnel Pour slowly allowing the oil to flow throughout the spar 26 Reinstall cap and run engine for 1 minute at idle speed to circulate the new oil 27 Recheck the level as desc...

Page 24: ...he transmission oil level is low install the check bolt and add small amounts slowly at the filler hole and recheck the level 4 Install the transmission oil level check bolt TORQUE Transmission oil le...

Page 25: ...ling 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 3 Allow the transmission oil to drain compl...

Page 26: ...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...

Page 27: ...ed fuel until the fuel level reaches the bottom of the filler neck 3 After fueling turn the fuel tank cap clockwise to tighten 4 Make sure the fuel cap breather hose is routed correctly WARNING POTENT...

Page 28: ...more than 3 4 throttle again allowing the engine to cool between rides NOTE During all rides it is also important to shift gears often so that high rpms are avoided and the engine is not lugged SUSPEN...

Page 29: ...level x Pad wear replace pads as a set x Check brake lever freeplay x Check brake discs x x x x Check brake pedal height x x Change brake fluid x Check brake system routing x Coolant Check level x x I...

Page 30: ...otation from left to right steering stops and no interference from cables hoses and wiring and adjust if necessary Also make sure the idle speed does not increase when turning the steering head x x Su...

Page 31: ...ber bolts 5 0 lbf ft 6 8 N m SEAT 1 To remove first remove the side number panels 2 Lift up the rear of the seat slightly pulling it back and away from the fuel tank 3 To install the seat align retain...

Page 32: ...place the panel in the original position and install the bolts TORQUE Fork leg guard bolts 5 0 lbf ft 6 8N m TORQUE Brake fork leg brake line clamp bolts 5 0 lbf ft 6 8N m To remove remove the upper...

Page 33: ...tall place the panel in the original position and install the bolts TORQUE Panel front fender mounting bolts 5 0 lbf ft 6 8 N m RADIATOR SHROUDS Place the vehicle on a stand and remove radiator shroud...

Page 34: ...TORQUE Panel mudflap mounting bolts 5 0 lbf ft 6 8 N m 1 Side bolts 2 Upper bolts 3 Radiator guard 1 2 1 3 WARNING POTENTIAL HAZARD Electrical short circuit or electrical fire WHAT CAN HAPPEN You can...

Page 35: ...8 N m GLIDE PLATE 1 Secure the vehicle in a wheel vice 2 Remove the bolts nuts and glide plate 1 NOTE To prevent the nuts from spinning hold them with a thin blade screwdriver while removing the bolts...

Page 36: ...aintenance Adjustment section of this manual for how to properly remove the fuel tank 2 Remove the airbox filter bolt and the filter elements 3 Spray the inside and outside of the filter elements comp...

Page 37: ...TER CAUTION When re installing the filter make sure the inner light blue foam is not exposed This will allow unfiltered air to enter the system resulting in severe engine damage Also apply a layer of...

Page 38: ...g or twist the air filter 7 Inspect steering head filter foam element and cage for any damage Replace new if damaged 8 Apply a light even coat of high quality foam air filter oil over both sides of th...

Page 39: ...or at the engine side of the throttle cable ADJUSTING THROTTLE FREEPLAY AT THE HANDLEBARS 1 Pull the long rubber boot 1 down the throttle cable so the lockring 2 and throttle cable adjuster 3 are vis...

Page 40: ...he locknut Turn the throttle cable adjuster in direction a to increase freeplay or direction b to reduce freeplay WARNING POTENTIAL HAZARD Crash resulting from a stuck throttle WHAT CAN HAPPEN If the...

Page 41: ...olt is supporting the radiator along with the coolant hoses so do not swing the radiator out too far IDLE SPEED ADJUSTMENT It is necessary to periodically adjust the idle speed for optimum fuel effici...

Page 42: ...ct outlet 1 located on the left side of the fuel tank by pressing on connector tabs and carefully withdrawing the hose fitting 4 Disconnect the fuel return quick connect located on the right side of t...

Page 43: ...turn the quick connects and install them into the fuel tank valves REPLACING THE FUEL FILTER NOTE Accumulation of dirt in the fuel filter will restrict fuel flow Proper fuel flow and pressure is criti...

Page 44: ...brake lever adjuster 2 in direction a decrease freeplay in direction b to increase freeplay 4 Tighten the locknut to the specified torque TORQUE Brake lever adjuster front locknut 4 3 lbf ft 5 8 N m F...

Page 45: ...SERVICE Brake pad thickness front minimum 0 04 inches 1 0 mm REAR BRAKE PEDAL HEIGHT ADJUSTMENT The rear brake pedal height can be adjusted for comfort as well as proper operation 1 To adjust loosen...

Page 46: ...enter into the brake pedal joint 4 SERVICE Brake rear master cylinder pushrod clearance 0 04 in 1mm REAR BRAKE PADS INSPECTION Each brake pad has wear indicator grooves 1 If either brake pad is worn...

Page 47: ...acceptable level and to route the exhaust gases away from the rider INSPECTING THE EXHAUST SYSTEM Inspect the exhaust pipe and silencer for cracks dents rust or other damage If any damage is found con...

Page 48: ...E Clutch lever clamp bolts 5 0 lbf ft 6 8 N m CLUTCH LEVER FREEPLAY SERVICE Clutch lever freeplay 0 08 0 16 inches 2 4 mm CAUTION Check the clutch actuating arm position following any adjustment to th...

Page 49: ...ere is no need to drain transmission fluid to perform the following procedure But be sure to avoid contaminating the transmission oil when the clutch cover is removed Also make sure the cover seal is...

Page 50: ...on affects the accuracy of your measurement Also when measuring rotate the chain and measure different links over the same spot 1 Place the vehicle on a stand so the rear wheel is off the ground 2 Ins...

Page 51: ...en the rear wheel axle nut TORQUE Wheels rear axle nut 72 0 lbf ft 98 0 N m 8 Install a new cotter pin and properly bend the tabs around the axle nut 9 Tighten the drive chain adjuster locknuts secure...

Page 52: ...e drive chain with a new one INSPECTING THE MASTER LINK CLIP I a Measurement a WARNING POTENTIAL HAZARD Breaking the drive chain WHAT CAN HAPPEN If the master link clip is installed incorrectly it can...

Page 53: ...old buffer Make sure you clean the buffer mounting screws with contact cleaner and apply Loctite 242 agent before installing the new buffer 4 Install the new buffer and tighten screws to specified to...

Page 54: ...r worn or loose swingarm bearings Place the vehicle on a stand so the rear wheel is off the ground Hold each side of the swingarm and try to move it from side to side If any freeplay is felt contact a...

Page 55: ...ube to the countershaft sprocket spacer and to the lips of the seal Install the spacer so that the internal o ring faces inward 2 Install the countershaft sprocket the splined lock washer and counters...

Page 56: ...et nut 29 5 lbf ft 40 0 N m 4 Bend the splined lock washer over the nut SPROCKET INSPECTION NOTE Replace both the sprockets and drive chain as a set Inspect the sprockets for cracks chipped or broken...

Page 57: ...e corrosion rust stains or other foreign material using contact cleaner on terminals and a water displacement chemical on connector seals Apply a light coat of dielectric grease onto the terminals pin...

Page 58: ...not TDC Engine Control Module ECM M1000 The ECM is located on the ECM mounting plate within the subframe ECM diagnostics are performed by using specially developed Windows based software and a data ca...

Page 59: ...d ignition of the air fuel mixture occurs THROTTLE POSITION SENSOR TPS The TPS is a small black plastic sensor attached to the throttle plate shaft and located on the right side of the throttle body T...

Page 60: ...rature affects the density of the inducted air and therefore the amount of oxygen available to ignite the fuel altering the effective engine load and thus the fuel required for proper combustion The E...

Page 61: ...motor this pump activates for 3 seconds to pressure the fuel system then turns off again until the engine starts When the engine starts it resumes pumping providing pressurized fuel to the injectors T...

Page 62: ...and in a discharged condi tion The battery capacity is sized for maximum perfor mance and minimal weight Repeated starting with out running the engine long enough to replenish the battery will result...

Page 63: ...the leads when separating the bottom from the top of the fuse holder 1 Remove the seat 2 Pull the catch up with your finger or a thin blade screwdriver 3 Pull the bottom of the fuse holder towards th...

Page 64: ...e the bolts 1 and move the main relay mounting plate assembly 2 along with the wire harness away from the rear shock strut 3 Remove the bolts washers and the rear shock strut NOTE Keep your hand under...

Page 65: ...rodes measure each gap INSTALLING THE SPARK PLUG CAUTION Only install the spark plug into a cool engine Always use the specified spark plug with the proper gap Using an incorrect spark plug may cause...

Page 66: ...bolts to the specified torque TORQUE Steering handlebar clamp upper bolts 17 0 lbf ft 23 0 N m TORQUE Steering handlebar clamp lower bolts 60 0 lbf ft 81 0 N m After installing the handlebar sit on t...

Page 67: ...lower triple clamp pinch bolts are tightened to the specified torque 4 After inspecting the fork legs apply a small amount of the specified lubricant onto the fork tubes Daily care 5 Take the vehicle...

Page 68: ...AR Your 2002 Cannondale motorcycle suspension valving settings are provided by Pro Action Suspension The production settings and adjustments are design for a wide range of riders and terrain However t...

Page 69: ...tions 1 2 etc 6 Turning the adjusters counterclockwise more clicks out will give less damping force 7 Normally the adjusters should not be adjusted more than two clicks at a time and not outside the m...

Page 70: ...RVICE Suspension rear shock compression adjuster clicks out from fully seated maximum 32 REAR SHOCK REBOUND ADJUSTER SERVICE Suspension rear shock rebound adjuster clicks out from fully seated standar...

Page 71: ...uninstalled length 230mm SERVICE Suspension rear shock spring minimum installed length a 228mm SERVICE Suspension rear shock spring maximum installed length b 220mm On the rear shock absorber the prel...

Page 72: ...der 3 Calculate a b ride height SETTING THE REAR RIDE HEIGHT Ride height is the amount the suspension sags with the rider on the bike in full riding gear NOTE Adjust if out of the specified range To d...

Page 73: ...must be changed Changing the spring preload should be left to an authorized Can nondale motorsports dealer NOTE Measure from the axle to the same point on the upper triple clamp each time SETTING THE...

Page 74: ...alve stem for cracks or other damage If damage is found replace with a new inner tube A tilted tire valve stem indicates that the tire has slipped out of position and must be remounted properly Make s...

Page 75: ...it on the left side of the vehicle If the spindle does not fit snug and flush into the rear axle and the pivot shaft on the left side of the vehicle the wheel is out of alignment and needs to be adju...

Page 76: ...is found contact an authorized Cannondale motorsports dealer for servicing NOTE The swingarm is shown removed from the vehicle for clarity WARNING POTENTIAL HAZARD Driving a vehicle with a cracked or...

Page 77: ...operly the cable may have been installed incorrectly Remove the throttle cable and make sure it is installed properly 1 Place the vehicle on a stand 2 Remove the engine start switch 1 screws and separ...

Page 78: ...roof grease to the collar NOTE Only apply a light coat of grease so it does not attract a lot of dirt and debris 14 Install the collar and throttle housing wheel Install the throttle housing plate and...

Page 79: ...the ground Carefully clean the chain with a mild detergent and water solution Rinse with clean water while gently scrubbing the chain with a light nylon brush Repeat as needed Wipe dry with a clean sh...

Page 80: ...e rubber boot over the brake lever SHIFT LEVER LUBRICATION 1 Remove the pinch bolt 1 and carefully slide the shift lever 2 off the shift shaft 3 CAUTION Do not bend the shift shaft or damage the splin...

Page 81: ...ly a light coat of a high quality waterproof grease onto the mounting bolt and rubber seals NOTE Only apply a light coat of grease so it does not attract a lot of dirt and debris 5 Install the pivot b...

Page 82: ...housing NOTE Apply a light coat of high quality grease to the clutch lever pivot bolt Only apply a light coat of grease so it does not attract a lot of dirt and debris 7 Install the clutch lever pivot...

Page 83: ...AUTION After lubricating the cable be sure to check the clutch and throttle operate properly Use aerosol cable lubricant and lubricating tool on all cables Clutch cable inner Throttle cable inner Appl...

Page 84: ...installed prior to washing the vehicle and according to exploded illustrations Failure to follow this caution will result in water getting into the engine and causing severe engine damage Do not inst...

Page 85: ...6 Insert a clean rag into the silencer opening and tie a plastic bag over the end of the silencer to prevent moisture from entering 7 Coat all unexposed metal surfaces with a water displacement chemi...

Page 86: ...utch number of plates metallic 10 friction 9 Transmission type Constant mesh five speed cassette Transmission Gearshift pattern One down four up 1st gear ratio 30 15 2 000 2nd gear 27 17 1 588 3rd gea...

Page 87: ...52 Drive chain guide block thickness minimum 0 1 inches 3 mm page 52 Drive chain rollers diameter standard 1 4 inches 35 2 mm page 53 Drive chain rollers diameter minimum 1 3 inches 32 mm page 53 Ele...

Page 88: ...ft frame rail center bolt 35 0 lbf ft 47 5 N m 40 Frame left frame rail lower bolt 20 lbf ft 27 0 N m 40 Coolant upper radiator mounting bolt 5 0 lbf ft 6 8 N m 40 Fuel fuel tank mounting bolt 5 0 lbf...

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Cannondale 2002 X440S, Owner'S Manual

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