Cannondale E440 2003 Page 60 Owner'S Manual Download

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2003 Motorcycle OM.fm

WARNING

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

lower rollers. Replace if out of specification.

Sprocket inspection

NOTE :

Replace both the sprockets and drive chain as a
set

Inspect the sprockets for cracks, chipped or

broken teeth, excessive wear, and/or any other
damage. Check the countershaft sprocket nut and
tighten if necessary.

Upper drive chain roller

a. Outside diameter

Lower drive chain roller

a. Outside diameter

(a)

(1)

(a)

(1)

Normal teeth

Worn teeth

Damaged teeth

(1)

(3)

(2)

Summary of Contents for E440 2003

Page 1: ...It contains information important to your safety Learn the location and proper operation of all controls Complete the Pre Ride Inspection checklist Wear appropriate protective gear approved full face...

Page 2: ...wing notations The safety alert symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Indicates that DEATH or severe injury WILL result if the instructions are not followed Indicates a potential...

Page 3: ...rake pedal 20 Side stand or kickstand 21 Handguards 23 Fuel tank cap 24 FLUIDS 24 Brake fluid 24 Coolant 26 Engine oil 28 Hydraulic clutch fluid 32 Fuel 35 Transmission oil 38 PRE RIDE INSPECTION 40 O...

Page 4: ...publication Cannondale Corporation reserves the right to make changes at any time without notice This vehicle has U S and International patents pending Comments Send your comments or suggestions abou...

Page 5: ...ppen rapidly and without notice HOW TO AVOID THE HAZARD Never operate the vehicle indoors even for brief periods of time WARNING POTENTIAL HAZARD Improper care when handling fuel WHAT CAN HAPPEN Fuel...

Page 6: ...d vehicle systems to cool completely before starting any work If the engine must be running work carefully and avoid hot surfaces WARNING POTENTIAL HAZARD Blindness eye injury WHAT CAN HAPPEN Anytime...

Page 7: ...iously 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 Doi...

Page 8: ...ents for cracking bending deep scratches and or other damage before every ride If you have crashed or rolled your vehicle there could be damage hidden from your view DO NOT ride a vehicle with any cra...

Page 9: ...ratches or other damage Inspect the weldments individual welded compo nents comprising the total swingarm and fastener fixtures for any sign of cracking or damage Place the vehicle on a stand with the...

Page 10: ...They contain information for safe and proper operation Do not remove the labels for any reason If any label is missing damaged worn or becomes difficult to read you can get free replacements from Can...

Page 11: ...11 Printed 8 15 02 11 Label 4 Label 5 Label 6 P N 315 6000477 01...

Page 12: ...ehicle identification numbers in the spaces provided Keep a copy of the numbers in another location NOTE Your vehicle may differ from those shown in the illustrations in this manual VEHICLE IDENTIFICA...

Page 13: ...n section of this manual for a detailed explanation of the best starting pro cedure NOTE When cranking the engine hold the button for no more than 2 3 seconds at a time IMPORTANT NOTICE Your vehicle m...

Page 14: ...tle cable is stuck Test the switch before operating Start the engine and press OFF if the engine does not shut down immediately do not ride the motorcycle contact an Cannondale motorsports dealer and...

Page 15: ...ngine management system relay Do not improvise contact your Cannondale Motor sports dealer to install the optional lighting system TRIP COMPUTER A trip computer is located in the center of the han dle...

Page 16: ...The shift lever is located on the left side of the engine just in front of the left footpeg The transmission has five gears one down four up Neutral is located between first and second gears THROTTLE...

Page 17: ...tion consult an authorized Cannondale Motorsports Dealer WARNING POTENTIAL HAZARD S 1 Stuck or damaged throttle 2 Incorrect freeplay WHAT CAN HAPPEN 1 The throttle must return to the closed position a...

Page 18: ...red so that the lever can move as the rider shifts hand position without resulting in pressure as detected in resistance in the lever causing the brake pads to press against the brake discs prematurel...

Page 19: ...ity waterproof grease onto the pivot bolt NOTE Only apply a light coat of grease so it does not attract a lot of dirt and debris 6 Install the pivot bolt and tighten the nut securely 7 Install the rub...

Page 20: ...oil It is not necessary to remove the bolt simply apply a few drops of oil to the bolt and work the pedal up and down Adjusting the rear brake pedal height 1 Loosen the locknut on the master cylinder...

Page 21: ...side stand completely into the hole in the rear axle shaft on the right side of the vehicle 3 Tilt the vehicle toward the stand allowing the weight of the vehicle to rest on the stand WARNING POTENTIA...

Page 22: ...b bling on the mount before every ride 1 Kick stand This photo shows the kickstand in the operating position See a close up of the area indicated in the next photo WARNING POTENTIAL HAZARD S Riding wi...

Page 23: ...r damaged it can interfere with the controls possibly prevent ing your hands from operating the controls as required 2 The hand guards TYPE 1 and TYPE 2 provide limited protection against trail haz ar...

Page 24: ...iately NOTE Position the vehicle on a level surface and level the handlebars After filling fluid check the entire system for leaks and test for the proper operation of the braking 1 Fuel cap 2 Breathe...

Page 25: ...the top of the site win dow and no higher If you fill above the window the fluid will overflow when the diaphragm and cover are re installed 5 Reinstall the front brake master cylinder dia phragm and...

Page 26: ...sidual pressure to escape 2 When all pressure has escaped press down on the cap and keep turning it until it can be 1 Reservoir cap 2 Diaphragm plate 3 Diaphragm DOT 4 1 2 3 Coolant Use distilled wate...

Page 27: ...er neck 4 Reinstall the radiator cap 5 Check the entire cooling system for leaks If the coolant level drops after adding and no leaks are found contact an authorized Cannondale Motor sports Dealer for...

Page 28: ...d shut the engine off Wait a few minutes for the oil to settle 3 Inspect oil level in the inspection window on the left frame spar The oil level should be visible in the window If the level is low can...

Page 29: ...When refilling engine oil add slowly and recheck level frequently so as not to over fill the system 1 Position the vehicle upright on a work stand out doors NOT INDOORS Refer to General Safety Precaut...

Page 30: ...o 15 0 lbf ft 20 3 N m 7 Remove the engine oil crankcase drain bolt and sealing washer and allow the oil to drain into your oil pan 8 Apply some anti seize compound to the threads of the drain bolt In...

Page 31: ...elop at the cover you may need to replace the cover O rings or inspect the cover and housing mating surfaces for damage Trying to stop a leak by over tightening the cover bolt will result in thread da...

Page 32: ...inutes for the added engine oil to flow through out the frame spars You will need to reinstall the filler cap start the engine and run it briefly Turn the engine off wait for the oil to settle and che...

Page 33: ...t remove the syringe and replace the cap Setting the clutch release collar The clutch release collar only requires adjustment if replacement clutch plates or springs are installed NOTE A special clutc...

Page 34: ...e a 2 5 mm allen to turn the adjuster locknut clockwise until it lightly bottoms Then back the adjuster out counterclockwise three full turns 10 Tighten the adjuster locknut to 3 3lbf ft 4 5 N m 11 In...

Page 35: ...m unleaded gasoline Anti Knock Index 93 or higher Replacement fuel filter FRAM G4164 or equiv alent Filter rating 35 micron WARNING POTENTIAL HAZARD Improper care when handling fuel WHAT CAN HAPPEN Fu...

Page 36: ...at frequent replacement is hassle free 1 Make sure the engine and exhaust system are completely cool 2 Remove the seat and remove the left radiator shroud 3 Press in the quick connect locking tab and...

Page 37: ...removed 7 Tighten the hose clamps securely 8 Inspect the external quick connect fitting O rings Replace them with new ones if you find any swelling tears rips or other damage Coat O rings with O ring...

Page 38: ...H as indicated CAUTION To add remove the cap and pour the specified transmission oil at the filler hole to raise it to the correct level in the window Clean around cap before removing it Use a clean f...

Page 39: ...ilter screen should locate in the hole in the transmis sion cartridge plate easily If the drain bolt is diffi cult to turn back it off and turn slowly until the filter end finally locates CAUTION The...

Page 40: ...ride WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operat ing WHAT CAN HAPPEN Increases the possibility of equipment failure resulting in an accident HOW TO AVOID THE HAZARD Always i...

Page 41: ...or damage to the fuel system Throttle Check the throttle freeplay make sure it operates properly in all handlebar posi tions Closes completely when released Transmission Check oil level Fill with tran...

Page 42: ...will be higher and slowly reduce as the valve reacts to the increasing engine temperature STARTING A WARM ENGINE When starting an engine after it has reached operating temperature DO NOT open the thro...

Page 43: ...D Electrical short circuit or electrical fire WHAT CAN HAPPEN You can short the battery to ground with a tool and the vehicle frame This can cause an electrical fire You can be burned severely or be i...

Page 44: ...G POTENTIAL HAZARD S 1 Sudden or uneven brake application 2 Wet brake system e g discs pads WHAT CAN HAPPEN 1 If you apply the brakes too quickly or sud denly the wheels may slide or skid causing you...

Page 45: ...low it to warm up to oper ating temperature 158 F 70 C 4 Check the idle speed proper operation of all vehicle controls 5 Operate the vehicle as follows Ride normally for 10 minutes using no more than...

Page 46: ...he instructions as described This manual DOES NOT include every DANGER WARNING CAUTION that can affect your safety Before you attempt to perform any procedure described in this section make sure you r...

Page 47: ...make sure seat is fastened securely Inspect for damage O O AIR Clean and re oil the air filter 1 O O O BRAKES Check the brake fluid levels Check the system hoses caliper fittings for leaks 3 O O D Che...

Page 48: ...n the filter O O O WHEELS TIRES Check the wheels rims bearings cotter pins O O D Check the tires cold pressure wear O O D NOTE 1 Service more frequently if operating in dusty sandy or snowy areas 2 Se...

Page 49: ...of the seat should rise slightly 3 Slide the seat towards the rear of the vehicle and off the retaining tab and receivers on the gas tank 4 Examine the receivers slots on the bottom of the seat pan Ma...

Page 50: ...rectly not latched bolted or secured or if the seat is damaged it can shift or come off while you are riding causing you to lose control You could be seriously injured or killed in an accident HOW TO...

Page 51: ...re it contacts the airbox to help guard against unfiltered air entering the system 1 To clean the filter remove the seat 2 Release the retaining clip and remove the filter from the airbox Use your thu...

Page 52: ...o be sure to note the small brass air pressure port fitting A hose is attached to this fitting on the other side of the air box The hose and this fitting should be unob structed so that the ECU senses...

Page 53: ...systems at slow speed Make sure that both systems function properly and that there is proper braking force always available 6 When riding in wet conditions or after exiting a water crossing apply the...

Page 54: ...and handle grip DRIVE Cleaning and lubricating the drive chain Clean and lubricate the drive chain before every ride after washing the vehicle after operating in wet or dusty conditions and before me...

Page 55: ...2 Thoroughly lubricate the drive chain with the specified lubricant Saturate each chain joint so that the lubricant penetrates the joint chain plates and rollers NOTE Make sure the chain has dried co...

Page 56: ...slack NOTE If the chain slack can not be adjusted within specification the chain or sprockets may be damaged Have them replaced by a Cannondale Motorsports Dealer 1 To adjust the chain slack remove t...

Page 57: ...perly bend the tabs around the axle nut 6 Tighten the drive chain adjuster locknuts securely 7 Measure the drive chain slack again Correct if necessary 8 Take the vehicle off the stand roll it forward...

Page 58: ...eplace the chain Master link clip inspection The open end of the masterlink clip must face the opposite direction of the chain rotation Chain length service limit 10 20 259 0 mm 1 Countershaft sprocke...

Page 59: ...screws to 7 0 lbf in 2 0 N m Inspecting the drive chain guide block 1 Measure the guide block thickness a Replace with a new block if wear exceed service limits 2 Inspect the drive chain guide and gu...

Page 60: ...fication Sprocket inspection NOTE Replace both the sprockets and drive chain as a set Inspect the sprockets for cracks chipped or broken teeth excessive wear and or any other damage Check the counters...

Page 61: ...system This brain calculates fuel delivery and ignition timing based on information gathered from vehicle sensors and the calibration file loaded at the factory Engine calibration file Your vehicle wa...

Page 62: ...ehicle CAUTION Do not pull on the wires 4 Remove the fuse and install the specified 1 Diagnostic connector 2 ECU power relay 3 Main fuse Main fuse rating 10A Lighting fuse rating 10A 1 Main fuse 2 Lig...

Page 63: ...dition Battery maintenance If your vehicle will be in storage for more than a month remove the battery and place it in a cool dark dry location that is free from sources of ignition Cover the terminal...

Page 64: ...in the spark plug hole 1 Remove the seat 2 Carefully clean the area surrounding the coil with compressed air 3 Remove the air filter and the fuel tank 4 Use a 3 8 drive socket with a 2 deep 6mm socke...

Page 65: ...specification adjust it If the spark plug utilizes multiple ground electrodes measure each gap 12 Lightly coat the plug threads with a suitable anti seize compound this will allow for easier spark pl...

Page 66: ...connect the coil harness connector Slide it onto the coil making sure it latches Install a zip tie over the latch See photo below 21 Reinstall removed components Headlight bulb replacement Consult the...

Page 67: ...mine the overall headlight mounting at this point The entire headlight can be positioned slightly higher or slightly lower on the two fork legs The position of the straps on the fork legs will change...

Page 68: ...louder Do not allow water to enter the silencer and saturate the media Only replace the stainless wool media if it is damaged Failure to maintain the fiberglass media will cause the vehicle to lose po...

Page 69: ...urs of operation to be cleaned and inspected for damage Replace the screen if punctures or splits are observed In the photo above the side panel is shown removed for clarity 1 2 3 4 5 6 1 Exhaust head...

Page 70: ...fuel from it However gasoline is extremely flammable and can explode under certain conditions A tank with fuel in it can be heavy to handle If you drop it or fuel spills from the tank the risk of fire...

Page 71: ...talling the tank remember to inspect and coat the O rings with clean engine oil Be sure to press in the tabs before reinserting 8 Remove the fuel tank mounting bolts 9 Lift the tank out from the frame...

Page 72: ...cle 2 Make sure the tank rests in the frame without interference The edge of the tank should meet the main frame in the area indicated in the photo with minimal force applied In the following photo th...

Page 73: ...ired to accurately read display the engine rpm For this reason we strongly recommend that this procedure be left to a Cannondale Service Technician Attempting to adjust the idle by ear is not recom me...

Page 74: ...81 0 N m NOTE Tighten the front bolts to the specified torque first Then tighten the rear bolts to the final torque This creates a pinching action instead of a squeezing action that is produced if th...

Page 75: ...rofessionals External adjustments Both the front forks and rear shock can be adjusted externally by selecting a range of positions in the compression damping and rebound damping adjusters But before y...

Page 76: ...about 1 hour of use Therefore do not change the initial suspension settings until after the vehicle has been ridden for 1 hour Suspension servicing WARNING POTENTIAL HAZARD Worn or damaged suspension...

Page 77: ...77 Printed 8 15 02 77 Front suspension 6 2 5 7 1 3 4 1 Fork 2 Protector 3 Rebound damping adjuster 4 Air bleed screw 5 Wear ring 6 Seal wipers 7 Compression damping adjuster...

Page 78: ...mponents on your vehicle 3 Inspect the wear rings Replace the ring if it is damaged or flat with the outer tube surface Position the gap in the wear ring rearward If the wear rings are worn beyond spe...

Page 79: ...uts for tightness 7 Apply a thin film of the specified lubricant to the inner tube Take the vehicle off the stand apply the front brake and push down on the handlebar several times This will spread th...

Page 80: ...will have to be installed in the forks Optional springs are available for your vehicle but you should not attempt to install them yourself Consult your Cannondale Motorsports Dealer for spring and in...

Page 81: ...ositions Each position can be identified by an audible click heard when turning the adjustment screw There are 8 clicks in each full revolution of the adjustment screw 1 To set rebound damping to the...

Page 82: ...on a stand with the front wheel off the ground and forks fully extended CAUTION Clean the area surrounding the screw to prevent oil contamination The smallest amount of dirt can severely damage the f...

Page 83: ...OTE Component shown removed for clarity 1 2 3 4 8 7 6 5 10 9 1 Body 2 Reservoir 3 Nitrogen gas hazard warning 4 Compression damping adjuster 5 Spring 6 Spring ID Type rate 7 Adjuster nut 8 Lock ring 9...

Page 84: ...sag measurement R3 is directly influenced by changes in the ride height If either the ride height or static sag is out of specification a spring with a different spring rate will have to be installed...

Page 85: ...at the bottom of the shock The adjuster has 42 positions Each position can be identified by an audible click heard when turning the adjuster There are 20 clicks in each full revolution of the adjuste...

Page 86: ...ION Do not force the adjuster past the stop point 2 Turn the adjuster counter clockwise counting each click until the specified standard setting for your vehicle is achieved Consult the Model Specific...

Page 87: ...or your vehicle 3 Add air in small amounts and re check often to help avoid over inflating Unusual air loss might be attributed to damaged tires or rims 4 Check the physical condition of each tire Mak...

Page 88: ...peration 1 Check each spoke with a spoke nipple wrench 2 Tighten so that all spokes have the same ten sion Tighten to 3 3 lbf ft 4 5 N m Removing the front wheel NOTE Avoid sqeezing the front brake le...

Page 89: ...dust seal lips 4 Make sure both spacers are clean and install the wheel spacers into the wheel The left wheel spacer is the larger one and should be installed on the brake disc side with the FRONT DI...

Page 90: ...efore removing the rear wheel to ease remounting later 1 Place the motorcycle on a stand so the rear wheel is off the ground 2 Straighten the cotter pin and remove it using pli ers 3 Remove the rear w...

Page 91: ...rocket fits between the drive chain guide 7 Push the rear wheel forward and install the drive chain onto the rear sprocket 8 Install the rear wheel axle from the right side of the swingarm 9 Install t...

Page 92: ...against the brake pads Then take the motorcycle off the stand roll it forward and backward a few times apply the rear brake and make sure it operates properly Checking the rear end for excessive play...

Page 93: ...ads Do not wax or lubricate the brake discs Braking power will be reduced which may result in an accident Before you start cleaning the vehicle take the following precautions Make sure the vehicle is...

Page 94: ...orage period 4 Carefully inspect the vehicle and perform all nec essary repairs 5 Either drain the fuel tank completely or fill it with fresh fuel If you drain the fuel tank drain it into an approved...

Page 95: ...the fully charged battery 3 Remove the rag and plastic bag from the silencer 4 Drain the gasoline into an approved fuel con tainer and recycle or dispose of the fuel at an EPA approved center 5 Lubri...

Page 96: ...ke pedal adjusting locknut 13 0 17 6 1 8 Radiator shroud mounting bolt to radiator 5 0 6 8 0 7 Radiator shroud mounting screws to tank Fuel tank mounting bolts 5 0 6 8 0 7 Side number panels mounting...

Page 97: ...MAINTENANCE 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 condition...

Page 98: ...rive 520 non o ring chain 520 O ring chain Primary reduction ratio 3 071 86 28 1st 2 000 30 15 2nd 1 588 27 17 3rd 1 316 25 19 4th 1 095 23 21 5th 0 833 20 24 Frame Aluminum twin spar perimeter Wheelb...

Page 99: ...hibitors for aluminum engines and radiators Front tire 80 100 21 120 70 17 Rear tire 110 100 19 120 100 18 160 60 17 Recommended cold tire pressure front rear 14 psi Main fuse 10 A Lighting fuse 10A H...

Page 100: ...16 Oil level Adjustment range 90 130mm 90 mm 80 mm Spring free length 467 mm service limit 460 mm Spring rate standard 4 7 N m optional 4 3 N m 4 5 N m 4 9 N m Recommended oil SAE 5W hlins High Perfo...

Page 101: ...101 Printed 8 15 02 101 ADDENDA This section is reserved for updates supplements and revisions Pages are left blank intentionally...

Page 103: ...103 Printed 8 15 02 103...

Page 105: ...rip 16 Front brake lever 18 Footpegs 19 Rear brake pedal 20 Side stand or kickstand 21 Handguards 23 Fuel tank cap 24 FLUIDS 24 Brake fluid 24 Coolant 26 Engine oil 28 Hydraulic clutch fluid 32 Fuel 3...

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Cannondale E440 2003, Owner'S Manual

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Summary of Contents for E440 2003

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