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© 2001 Cannondale Corporation - All Rights Reserved

44

X440s Owner's Manual.fm

FRONT BRAKE PADS INSPECTION

Worn brake pads can damage the brake disc, adversely
affecting brake performance and possibly causing an
accident. Never ride the motorcycle with worn or damaged
brake pads.

Each brake pad has wear indicator marks (1) and grooves
(2). If either brake pad is worn to the minimum thickness
indicator (3) or beyond the minimum thickness (a), the brake
pads need to be replaced with a new set.
Contact an authorized Cannondale Motorsports delaer for
replacement.

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 the locknut on the master cylinder
pushrod.

2. Turn the hex on top of the pushrod until the brake

pedal is at the correct height.

3. Turning the hex in direction (a) will lower the brake

pedal and turning the hex in direction (b) will raise the
pedal.

4. Tighten the locknut to the specified torque.

TORQUE : Brake, rear brake master cylinder pushrod,

locknut
13.0 lbf•ft (17.6 N•m)

1.

Wear indicator marks

2.

Minimum thickness indicator

3.

Wear indicator grooves

a. Minimum

thickness

1

a

a

3

2

1.

Locknut

2.

Hex

a.

Lowers the brake pedal

a.

Raises the brake pedal

a

b

1

2

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Содержание X440S

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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