Cannondale E440 Owner'S Manual Download Page 1

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P/N 951 - 5002274

Before you operate the vehicle. . . .

•

READ and UNDERSTAND this manual. It contains information important to
your safety.

•

Familiarize yourself with all vehicle controls and their proper operation.

•

Perform the Pre-Ride Inspection found in this manual.

•

Wear appropriate protective gear - approved full faced helmet, eye protection,
gloves, boots, long-sleeve shirt, and pants. Consider specially designed
protective off-road vehicle riding apparel.

• Safety
• Operation
• Maintenance

2002
MOTORCYCLE OWNER’S MANUAL
(E440, C440, X440)

Summary of Contents for E440

Page 1: ...vehicle controls and their proper operation Perform the Pre Ride Inspection found in this manual Wear appropriate protective gear approved full faced helmet eye protection gloves boots long sleeve shi...

Page 2: ...eded by the Safety Alert Symbol It means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED CAUTION Indicates a potential hazard that could result in vehicle damage if instructions are not followed NOTE P...

Page 3: ...work to help eliminate the chance of the vehicle rolling away or becoming unstable while you work Make sure you have the skills and tools necessary before performing any procedure Make sure you are w...

Page 4: ...our eyes and cause serious injury or blindness HOW TO AVOID THE HAZARD Always wear safety glasses when working on the vehicle POTENTIAL HAZARD Losing a finger hand or limb or entanglement WHAT CAN HAP...

Page 5: ...ever 19 Footpegs 20 Rear brake pedal 20 Side stand or kickstand 21 Handguards 22 Fuel cap 23 FLUIDS 24 Fuel 24 Brake fluid 25 Front brake 25 Rear brake 26 Engine oil 27 Transmission oil 34 Coolant 37...

Page 6: ...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 publicatio...

Page 7: ...nd 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 a...

Page 8: ...plete frame failure If you have any questions contact your Cannondale dealer or call 1 800 MOTO USA Inspect the frame 1 lower frame rails 2 and subframe 3 for cracks deep scratches or other damage If...

Page 9: ...f any damage to the swinarm is detected take corrective action before riding Contact an authorized Cannondale motorsports dealer for servicing NOTE The swingarm is shown removed from the vehicle for c...

Page 10: ...rmanent parts of the vehicle If any label is missing worn damaged or becomes unreadable replace it Cannondale offers replacement labels at no charge A label s part number is printed in the lower right...

Page 11: ...11 Printed 1 9 02 11 Label 2 P N 315 5001262 01 Label 3 Label 4 Label 5 Label 6 P N 315 6000477 01...

Page 12: ...of the same model type VEHICLE IDENTIFICATION NUMBER VIN The vehicle identification number VIN is located on the left side of the steering head ENGINE SERIAL NUMBE R The engine serial number is etche...

Page 13: ...be sure to read the Operation section of this manual for a detailed explanation of the best starting procedure NOTE When pressing the button to operate the starter motor hold it for no more than 2 3 s...

Page 14: ...ne management system on press the engine START button quickly 1 second without holding to turn over the engine To test the headlight taillight quickly 1 second press the engine START button to activat...

Page 15: ...ake sure it is operating properly before starting out NOTE Remember that the lighting circuits are energized through the engine management system power relay This relay is controlled by the ECU The EC...

Page 16: ...e and engine management system relay This connector is NOT protected by a fuse so do not improvise contact your Cannondale Motorsports dealer to install the optional lighting system 1 Main fuse 2 Ligh...

Page 17: ...CLUTCH LEVER The clutch lever is located on the left side of the handlebar Pull in the clutch lever quickly to disengage the clutch and release the lever slowly to engage the clutch The lever positio...

Page 18: ...te b c 1 a POTENTIAL HAZARD S 1 Stuck or damaged throttle 2 Incorrect freeplay WHAT CAN HAPPEN 1 The throttle must return to the closed position automatically when you release it If it sticks you can...

Page 19: ...djustment of the freeplay is described in the Maintenance and Adjustment section of this manual The position of the brake lever can be adjusted so that control is comfortable when seated and standing...

Page 20: ...ion REAR BRAKE PED AL The rear brake pedal is located on the right side of the vehicle Press it firmly with your foot to apply the rear brake Test to make sure it is operating correctly before you rid...

Page 21: ...e kick stand position the vehicle on firm level ground Fold the kickstand down and rest the weight of the motorcycle on it Turn the handlebars to the left toward the kickstand side of the motorcycle t...

Page 22: ...ols Tighten the mounting harware securely This photo shows the kickstand in the operating position See a close up of the area indicated in the next photo The image on the left shows a kickstand that i...

Page 23: ...ontrols as required 2 The hand guards TYPE 1 and TYPE 2 provide limited protection against trail hazards e g wind deflection small branches roost the dirt and debris thrown backward from a leading veh...

Page 24: ...rting components e g fuel system sensors tank hoses etc 1 Remove the fuel cap and fill the tank with fuel until it reaches the bottom of the filler neck 2 Tighten the fuel cap securely and make sure t...

Page 25: ...luid types or brands 3 Fluid from unsealed containers 4 Low fluid level 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...

Page 26: ...over screws 1 4 lbf ft 1 9 N m REAR B R A K E 1 To check the rear system level the rear brake master cylinder reservoir The fluid level should be above the LOWER mark 2 If the fluid level is below the...

Page 27: ...ow to run for 1 minute at idle speed then turn off the engine 3 Wait 1 minute for the engine oil to settle inside the spar 4 Inspect oil level in the inspection window on the left frame spar 5 If the...

Page 28: ...ely hot and take time to cool after you shut the engine off Work carefully to avoid hot surfaces You can be burned severely NOTE Remove the spar engine oil filler cap left spar when draining When refi...

Page 29: ...ard the oil pan to drain any remaining oil 5 Drain the right spar in the same way 6 For both the left and right spar bolt inspect the spar bolt O ring Replace it with a new one if you find any tears r...

Page 30: ...e specified torque TORQUE Engine oil crankcase drain bolt 6 0 lbf ft 8 1 N m 9 Position your oil pan under the engine oil filter cover and remove the bolt and the filter cover NOTE Be sure to note the...

Page 31: ...eals remain in place when you insert the filter into the housing This step is unnecessary with paper type filters as the seals are glued in place 13 Insert the filter into the housing 14 Apply a light...

Page 32: ...amaged part with a new one 18 Reinstall the filter and fitting Be sure to inspect the fitting O ring and replace it with a new one if necessary Apply some clean engine oil to the O ring before install...

Page 33: ...owing the oil to flow throughout the spar 21 Reinstall cap and run engine for 1 minute at idle speed to circulate the new oil 22 Inspect the oil level through the inspection window Adjust level as req...

Page 34: ...LEVEL 1 With the engine cold position the vehicle upright on a stand and wait a few minutes until the transmission oil settles 2 For vehicles with the check bolt type crankcase covers hold a clean sho...

Page 35: ...efully from the hole Protect your eyes Wear safety glasses when working with compressed air 4 Clean the filter using compressed air Inspect the filter for cracks holes tears and other damage Replace n...

Page 36: ...filter does not locate into the cartridge plate hole unfiltered oil can enter the system damaging the pump 8 Tighten the bolt to the specified torque TORQUE Transmission oil drain bolt 6 0 lbf ft 8 1...

Page 37: ...nt system on your vehicle is the self bleeding type Manually bleeding the system is not required after refilling a drained system If the you ever add more than 150cc of coolant or the top of the radia...

Page 38: ...can be removed 3 The coolant level should be at the bottom of the filler neck 4 Reinstall the radiator cap 5 Check the entire cooling system for leaks 6 If the coolant level drops after adding and no...

Page 39: ...master cylinder is clean before removing the cover 1 Position the handlebar so that the top of the master cylinder is level 2 Remove the cover screws cover and rubber boot The oil level should be 4mm...

Page 40: ...ts Reserved 40 Motorcycle Fluids fm 4 Loosen the bolt 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 not overflow...

Page 41: ...if necessary Drive Clean and lubricate the drive chain Check drive chain slack and condition sprockets swingarm buffer rollers and guide block Engine Check oil level Fill with engine oil if necessary...

Page 42: ...nd you are no longer able to start the engine with it Jump starting enables you to start the engine quickly and then use the vehicles charging circuits to charge the battery to its full capacity If yo...

Page 43: ...towards preventing of the vehicle until it is serviced properly POTENTIAL HAZARD Down shifting to a lower gear at high speeds WHAT CAN HAPPEN Tires can lose traction resulting in a loss of vehicle co...

Page 44: ...damaging engine components 1 Ride the vehicle normally for two 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 s...

Page 45: ...ILTER 1 C SPARK PLUG I IDLE SPEED I I VALVE CLEARANCE I I EXHAUST silencer C SWITCHES engine stop start 1 2 I I LIGHTING headlight tail light I I I ENGINE OIL R R ENGINE OIL FILTER s C C R TRANSMISSIO...

Page 46: ...te 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 tions 3 Replace every 1 years 4 Replace every 2 ye...

Page 47: ...AINTENANCE 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...

Page 48: ...orm a procedure described in this manual don t attempt it Have an authorized Cannondale Motorsports Dealer perform the servicing Many maintenance procedures found in this section require the use of a...

Page 49: ...atched properly by lifting the rear of the seat up with your fingers 5 Test similarly at the front of the seat POTENTIAL HAZARD Unlatched or damaged seat WHAT CAN HAPPEN If you install the seat incorr...

Page 50: ...3 Lock ring a Decrease freeplay b Increase freeplay 1 a b 2 3 POTENTIAL HAZARD Fuel fire or explosion WHAT CAN HAPPEN The fuel tank on your vehicle has been designed to be removed without having to d...

Page 51: ...e inlet and outlet hoses from the tank CAUTION Later when re installing the tank remember to inspect and coat the O rings with clean engine oil Be sure to press in the tabs before reinserting 1 Right...

Page 52: ...d an ordinary 2x4 for the photo below 1 To install the tank start by making sure that the tank subframe buffers are in place Then position the tank into the vehicle 2 Make sure the tank rests in the f...

Page 53: ...ulation of dirt in the fuel filter will restrict fuel flow Proper fuel flow and pressure is critical to the reliability of the fuel injection system and level of vehicle performance Therefore the fuel...

Page 54: ...ar the O rings IDLE SPEED ADJUSTMENT SERVICE Engine idle speed 2100 2200 r min The idle speed adjustment screw is located on the throttle body and is accessible from the left side of the vehicle A spe...

Page 55: ...ith the front brakes force applied to the pedal should apply force to the rear disc preventing the vehicle from rolling If the rear brake operates improperly have a Cannondale Motorsports Dealer inspe...

Page 56: ...urn the hex on top of the pushrod until the brake pedal is at the correct height Turning the hex in direction a will lower the brake pedal and turning the hex in direction b will raise the pedal 2 Tig...

Page 57: ...the vehicle on a stand 2 Remove the rubber cover from the brake lever 3 Remove the nut 1 pivot bolt 2 and brake lever 3 4 Spray all the parts with a water displacement chemical wipe them off and dry...

Page 58: ...to be replaced with a new set Contact an authorized Cannondale Motorsports dealer for replacement SERVICE Brake pad thickness front minimum 0 04 inches 1 0 mm REAR BRAKE PADS INSPECTION Each brake pad...

Page 59: ...clutch lever and handle grip SETTING THE CLUTCH RELEASE HYDRAULIC CLUTCH SYSTEM Complete the following procedure anytime the clutch plates or springs are replaced 1 Remove the shift lever and clutch c...

Page 60: ...s over the same spot LUBRICATING THE DRIVE CHAIN CAUTION Never use steam or high pressure washers to clean the chain You can force dirt into the chain and wash out the sealed lubricants Never clean th...

Page 61: ...MENT SERVICE Drive chain slack 2 2 2 4 inches 55 60 mm 1 Place the vehicle on a stand so the rear wheel is off the ground 2 Inspect the drive chain slack at a middle point between the two sprockets If...

Page 62: ...on the swingarm must be adjusted so they are in the same position on each side of the swingarm Make sure the drive chain is straight and in line with the sprockets 6 Place a rag between the drive cha...

Page 63: ...CH INSPECTION SERVICE Drive chain length stretch maximum see specification for exact pin count 6 0 inches 151 mm 1 With the upper or lower section of the drive chain tight between the sprockets measur...

Page 64: ...r thickness standard 0 4 inches 10 mm SERVICE Drive swingarm buffer thickness minimum 0 1 inches 3 mm POTENTIAL HAZARD Chain coming off unexpectedly WHAT CAN HAPPEN If the master link clip is installe...

Page 65: ...ation SERVICE Drive chain guide block thickness standard 0 5 inches 12 mm SERVICE Drive chain guide block thickness minimum 0 1 inches 3 mm Check the drive chain guide bolts and tighten to the specifi...

Page 66: ...fuel delivery The system consists of three types of electrical components an Engine Control Module ECM sensors and actuators The engine control unit ECU or ECM precisely calculates ignition timing an...

Page 67: ...when they are developed however always consult with your dealer before attempting to install any calibration file All authorized engine calibration files are maintained on our website www cannondale...

Page 68: ...e with a rating other than specified or using other materials in place of the fuse will cause damage to system A malfunctioning electrical system increases the risk that you may be seriously injured o...

Page 69: ...ug 20 0 lbf ft 27 1 N m CAUTION Clean the top of the engine and surrounding area with compressed air before removing the coil and spark plug as a step toward preventing dirt and other contaminants fro...

Page 70: ...with compressed air 3 Remove the air filter and the fuel tank 4 Use a 3 8 drive socket with a 2 deep 6mm socket to loosen the coil retaining clip bolt just enough so that the clip can be lifted and t...

Page 71: ...nnondale Motorsports Dealer The simple answer is to replace an old spark plug with a new one anytime you remove it but since the spark plug is a valuable indicator of engine operating characteristics...

Page 72: ...N m 14 Inspect the coil for any signs of damage 15 Remove any old silicone sealant from the coil seal 16 Slide the seal onto the coil Before the seal reaches the top apply a thin bead of silicone seal...

Page 73: ...t bracketing 3 Tilt the headlight out slightly and remove the housing screws and remove the bulb housing from the headlight body The headlight has two lamps the process is identical for both NOTE Note...

Page 74: ...ly on both fork legs will produce good results with regard to tilting of the beam The bracket is also slotted to allow for up down movement TAILLIGHT BULB REPLACEMENT Consult the Model Specifications...

Page 75: ...ality water proof grease on the filter where 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 remo...

Page 76: ...y covers the screen so that the mating surface of the airbox meets the foam and no part of the screen element 9 Carefully wipe the interior of airbox with a lint free clean shop towel Avoid the tip of...

Page 77: ...damage the engine if the conditions remain uncorrected Under normal conditions the silencer should be re packed every year to ensure that the exhaust system functions as designed However individual r...

Page 78: ...www pro action com MAKING DAMPING 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...

Page 79: ...le with worn or damaged suspension components HOW TO AVOID THE HAZARD Inspect and maintain the suspension systems front rear on your vehicle as described in this Owner s Manual before every ride If yo...

Page 80: ...ration All Rights Reserved 80 Motorcycle Maintenance and Adjustment fm 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 Compre...

Page 81: ...is damaged or flat with the outer tube surface Position the gap in the wear ring rearward If the wear rings are worn beyond specification incorrectly positioned or damaged the outer tube of the fork...

Page 82: ...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 allow the grease to spread evenly ov...

Page 83: ...vailable for your vehicle but you should not attempt to install them yourself Consult your Cannondale Motorsports dealer for spring and installation service 1 Place the vehicle on a stand so that the...

Page 84: ...ng each click until the specified standard setting for your vehicle is achieved Consult the Model Specification section in this owner s manual FORK COMPRESSION DAMPING ADJUSTMENT CAUTION Adjust both f...

Page 85: ...e forks during a moto or through changes in elevation atmospheric pressure during a ride Release the air pressure in the fork legs This pressure will affect the fork action making them stiffer or soft...

Page 86: ...and Adjustment fm REAR SUSPENSION NOTE 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 Ty...

Page 87: ...t If either the ride height or static sag is out of specification a spring with a different spring rate will have to be installed onto the rear shock Optional springs are available for your vehicle bu...

Page 88: ...de height and static sag after adjustment Make sure you re tighten the lock ring securely when finished 4 Loosen the lock ring 5 Make a reference mark on the adjuster nut and spring NOTE Turning the a...

Page 89: ...odel Specification section in this owner s manual REAR SHOCK COMPRESSION DAMPING ADJUSTMENT Compression damping affects how quickly the shock compresses The compression adjuster is located at the top...

Page 90: ...eel with your hand and try to detect any play in the wheel bearings by trying to move the top and bottom on the wheel REAR WHEEL CHECKING THE REAR END FOR EXCESSIVE PLAY Before every ride check the re...

Page 91: ...r vehicle 3 Add air in small amounts and re check often to help avoid overinflating Unusual air loss might be attributed to damaged tires or rims 4 Check the physical condition of each tire Make sure...

Page 92: ...ed 92 Motorcycle Maintenance and Adjustment fm TORQUE Rimlock nut 9 0 lbf ft 12 2 N m NOTE If the tire or inner tube needs to be replaced or remounted contact an authorized Cannondale dealer for servi...

Page 93: ...bolts to the specified torque 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 th...

Page 94: ...the handlebar from lock to lock to check for looseness or binding STEERING HEAD INSPECTION 1 Place the vehicle on a stand so that the front wheel is off the ground 2 Hold the bottom of the forks with...

Page 95: ...glaze and ruin the brake pads Do not wax or lubricate the brake discs Braking power will be reduced and may result in an accident Before you start cleaning the vehicle take the following precautions M...

Page 96: ...debris with a clean rag Use contact cleaner to displace any hidden water residue 3 Reinstall the generator cover making sure that the cover gasket is properly installed onto the cover and tighten the...

Page 97: ...be purchased at most automotive parts or large department stores Make sure you follow the directions on the product label 6 Remove the air filter and thoroughly clean the area surrounding the airbox...

Page 98: ...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 bolts 5 0 6 8 0 7 Clutch release c...

Page 99: ...is within the indicated range CAUTION Be sure to change the engine oil and clean replace the filters in accordance with the vehicle maintenance schedule Service more frequently when operating under se...

Page 100: ...0 15 0 20 mm EX 013 015 in 0 33 0 38 Fuel Premium unleaded Anti Knock Index 93 or higher Fuel filter 35 micron rating Fuel system Electronic fuel injection Valve train DOHC four valve CHASSIS X440 C4...

Page 101: ...t Fork Type Ohlins 46mm USD external compresson and rebound damping adjustment 12 0 inch travel 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...

Page 102: ...ration All Rights Reserved 102 2002 Motorcycle Model Specifications fm Compression damping STD 18 18 23 Rebound damping STD 14 15 15 Ride height 3 7 4 0 in 95 100 mm Static sag 1 0 1 2 in 25 30 mm SUS...

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