Cannondale E440 2003 Owner's Manual
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Cannondale E440 2003 Owner's Manual

Cannondale E440 2003 Owner's Manual

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2003 Motorcycle Owner's Manual
Models : E440, C440, X440, S440
Before you operate the vehicle. . . .
•
READ and UNDERSTAND this Owner's Manual.
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 faced helmet, eye
protection, gloves, boots, long-sleeve shirt, and pants.
Consider purchasing specially designed protective off-road vehicle
riding apparel.
P/N : 951-5002274-03

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  • Page 1 2003 Motorcycle Owner’s Manual Models : E440, C440, X440, S440 P/N : 951-5002274-03 Before you operate the vehicle..• READ and UNDERSTAND this Owner’s Manual. It contains information important to your safety. • Learn the location and proper operation of all controls. •...

  • Page 2: Warning

    A CAUTION indicates that special precautions must be CAUTION :  taken to avoid damage to the machine. A NOTE provides helpful information intended to make NOTE: maintenance easier or the instructions presented clearer. 2003 Motorcycle OM Cover.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 3: Table Of Contents

    Post ride checks - - - - - - - - - - - - - - - - - 44 BREAK-IN - - - - - - - - - - - - - - - - - - - - - - - - 45 When reading this manual, remember: MAINTENANCE &...

  • Page 4: Foreword

    All information, illustrations, and specifications in this manual are based on the latest product information available at the time of publication. Cannondale Corporation reserves the right to make changes at any time, without notice. This vehicle has U.S. and International patents pending.

  • Page 5: General Safety Precautions

    GENERAL SAFETY PRECAUTIONS WARNING DANGER POTENTIAL HAZARD POTENTIAL HAZARD Improper care when handling fuel Running the engine indoors Breathing exhaust gases WHAT CAN HAPPEN Fuel is highly flammable; spilling it can WHAT CAN HAPPEN cause a fire or explosion. Running the engine indoors will expose you to dangerous exhaust gases.
  • Page 6 HOW TO AVOID THE HAZARD Always wear safety glasses when working on the vehicle. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 7: Experienced Riders Only

    WARNING This vehicle is not for beginners. POTENTIAL HAZARD Entanglement All Cannondale motorsports products are designed WHAT CAN HAPPEN for use by trained and experienced riders only. All are Moving parts can catch your clothing, fin- very high performance, competition sport machines gers or hand resulting in severe injury.

  • Page 8: Inspection Of Aluminum Chassis Components

    Can- nondale Motorsports Dealer before it is operated again. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 9 If any damage is found, contact an autho- down with no play side to side. If any damage to the rized Cannondale Motorsports Dealer for servicing. swingarm is detected, take corrective action before riding. Contact an authorized Cannondale Motor- sports dealer for servicing.

  • Page 10: Vehicle Warning And Specification Labels

    The part numbers are also printed Label 1 P/N 315-5000266-01 in this manual. Label 2 P/N 315-5001262-01 (5,6) Label 3 WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 11 Label 4 Label 5 Label 6 P/N 315-6000477-01 Printed : 8/15/02...

  • Page 12: Vehicle Identification

    Engine serial number the left side of the steering head. Record here Vehicle identification number Record here WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 13: Parts And Controls

    2-3 seconds at a time. Anytime you have any question related to the available manual supplements, controls, features, or operation and maintenance of your vehicle, please consult your Cannondale dealer. Or, call us at toll free at 1-800-MOTO-USA. Printed : 8/15/02...

  • Page 14: Engine On/Off Switch

    Make sure the headlight and taillight operate properly before starting out WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 15: Lighting Option

    Do not improvise; contact your Cannondale Motor- WHAT CAN HAPPEN sports dealer to install the optional lighting system. You can lose control of the vehicle and have a serious accident.

  • Page 16: Clutch Lever

    To adjust the lever position, see the engine. Maintenance and Adjustment section of this manual. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 17 Cannondale Motorsports Dealer. (2) The throttle freeplay must be maintained as specified, otherwise the engine speed could increase when the handlebars are turned or when the throttle is slightly grasped.

  • Page 18: Front Brake Lever

    1. To adjust, loosen the the locknut. 2. Turning the adjustment screw. 3. Tighten the locknut to 4.3 lbf•ft (5.8 N•m). WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 19: Footpegs

    Adjusting the front brake lever position NOTE : To adjust the front brake lever position on the han- Only apply a light coat of grease so it does not dlebar, loosen the clamp bolts and rotate the brake attract a lot of dirt and debris. lever to the desired position.

  • Page 20: Rear Brake Pedal

    Turning the hex in direction (a) will lower the Pushrod Brake pedal a. Clearance 0.04 in (1mm) WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 21: Side Stand (Or) Kickstand

    SIDE STAND (OR) KICKSTAND weight of the vehicle to rest on the stand. The side stand or kickstand (on equipped vehicles) can be used to support the vehicle on firm level ground when not in use (with the engine off). Both are designed to only support the weight of the vehicle..
  • Page 22 HOW TO AVOID THE HAZARD Remove the side stand; lift the kickstand to operating position before riding. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 23: Handguards

    If they are damaged or loose, take corrective action. If you have any questions about the condi- tions or intended use of the handguards, contact your Cannondale Motorsports Dealer Type 2 handguards for assistance. The handguards are located on the right and left sides of the handlebar directly in front of the handle grips.

  • Page 24: Fuel Tank Cap

    After filling fluid, check the entire system for leaks, and test for the proper operation of the braking WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 25 system before riding. Test with the engine off by cover are re-installed.. rolling the vehicle forward and back while apply the brakes. Then, also test the brakes at slow riding speeds. Checking the front brake fluid level Front brake master cylinder cover screws Front brake master cylinder cover Diaphragm 5.

  • Page 26: Coolant

    2. When all pressure has escaped, press down on the cap and keep turning it until it can be WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 27 Cannondale Motor- sports Dealer for servicing. Radiator cap a. Loosening direction 3. The coolant level should be at the bottom of the filler neck. Coolant level Filler neck 4.

  • Page 28: Engine Oil

    3. Inspect oil level in the inspection window on the left frame spar. The oil level should be visible in WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 29 is visible through the window. contents into an oil pan. Engine oil filler hole Left spar drain bolt O-ring NOTE : Position a clean shop towel behind a folded piece CAUTION :  of thin cardboard to channel or direct the flow of oil from the spar drain bolts into your oil pan.
  • Page 30 NOTE : Be sure to note the two O-rings in the cover when you remove it. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 31 10. Remove the filter from the housing and discard it. CAUTION :  If engine oil seeps or a leak develop 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;...

  • Page 32: Hydraulic Clutch Fluid

    23. Add 1 US quart of the specified engine oil at the spar filler hole using a clean funnel. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 33 upper edge. cylinder. Bore CAUTION :  Correct oil level After bleeding, make sure the fluid level in the master cylinder is correct. Oil level should be 4 Bleeding air from the hydraulic clutch mm below the upper edge. 1. To bleed, level the handlebars and remove the master cylinder cover and slave cylinder bleed 4.
  • Page 34 2.5 mm allen to turn the adjuster locknut (clockwise) until it lightly bottoms. Then, back the adjuster out (counterclockwise) three full turns. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 35: Fuel

    FUEL until it reaches the bottom of the filler neck. Recommended Fuel: Premium 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. Fuel level WHAT CAN HAPPEN Filler neck...
  • Page 36 4. Hold the filter in a clean shop towel and loosen WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 37 the filter hose clamps allowing fuel in the hose to be absorbed by the towel. 5. Remove the old filter. 6. Reinstall a new, replacement filter making sure to observe the flow indicator on the filter body. CAUTION :  Replace the filter with the specified type. Do not operate with the fuel filter removed.

  • Page 38: Transmission Oil

    Clean around cap before removing it. Use a clean funnel. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 39 Be sure to remove it from within the drain hole. CAUTION :  The drain bolt should turn easily with your finger tips until the washer seats against the crankcase. If forced, damage to the filter can result . Transmission oil filter 4.

  • Page 40: Pre-Ride Inspection

    Have your vehicle serviced by an authorized Cannondale Motorsports Dealer after every 25 hours of operation. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 41 Pre-Ride Inspection Checklist ITEM CHECK Condition of (helmet, eye protection, boots, gloves, long-sleeved shirt and long Apparel pants). Check proper operation, fluid levels, front lever and rear pedal freeplay, leaks. Fill Brakes with DOT4 brake fluid if necessary. Check front and rear pads and discs. Inspect the frame, subframe, and swingarm for bending, cracks, or other Chassis (frame) damage.

  • Page 42: Operation

    6. Allow the engine to idle until it reaches operating temperature 158 F° (70°C) before you begin riding. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 43: Shifting Gears

    re-charge the battery before shutting the vehicle off. SHIFTING GEARS It not, remove the battery and place it on a battery charger. WARNING WARNING POTENTIAL HAZARD Down shifting to a lower gear at high speeds. POTENTIAL HAZARD Electrical short-circuit or electrical fire WHAT CAN HAPPEN Tires can lose traction resulting in a loss of WHAT CAN HAPPEN...

  • Page 44: Braking

    2. Apply the front and rear brakes evenly. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 45: Break-In

    BREAK-IN The break-in period is critical to the long term life and reliability of the engine. CAUTION :  Avoid high engine rpm and/or lugging the engine during the break-in period. Shift gears as required to best match travelling speeds and loads. Avoid full-throttle starts and rapid acceleration.

  • Page 46: Maintenance & Adjustment

    If you doubt your skills and ability to com- plete a procedure as described, have the service per formed by y our Cannondale Dealer. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 47: Maintenance Schedule

    ••• Check wear, lubricate the tie rod ends • Cannondale dealer service suggested. Servicing owners should have the proper tools, service data, and be mechanically qualified. •• Operational safety involved, The service should be performed by a Cannondale dealer. ••• Lithium soap base grease...
  • Page 48 •• Check the tires (cold pressure, wear) • Cannondale dealer service suggested. Servicing owners should have the proper tools, service data, and be mechanically qualified. •• Operational safety involved, The service should be performed by a Cannondale dealer. ••• Lithium soap base grease WARNING Indicates a potential hazard that could result in serious injury or death.

  • Page 49: Seat

    SEAT tank. Seat removal 1. Position the vehicle upright on a work stand so there is no danger of it falling over while you work. 2. Press down slightly on the rear of the seat with one hand while pulling up on the quick release lever with a finger of the other hand.
  • Page 50 5. Test similarly at the front of the seat. situation before riding. Contact your Cannondale Dealer for a replacement seat if damaged. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 51: Air Filter

    Do not operate with the air filter removed. Use only high-quality foam air filter specific oils. Consult your authorized Cannondale Motorsports Dealer for available oil brands. The air filter must be completely dry before 4. Place a clean shop towel over the airbox open- applying the air filter oil.
  • Page 52 ECU senses the correct air pressure within the airbox. Faulty readings will WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 53: Brakes

    Have worn pads replaced with by a Cannondale Motorsports Dealer. new ones by a Cannondale Motorsports 2. Check for fluid leaks. Inspect the entire length of Dealer. the hoses paying close attention to the banjo bolts, calipers, and master cylinders.

  • Page 54: Clutch

    O-rings can be damaged. Use a mild dish washing detergent and water WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 55 solution. Do not forcefully scrub the chain. Wipe NOTE : Make sure the chain has dried completely before the chain dry with a clean shop towel. applying the lubricant. CAUTION :  Place a piece of cardboard (2) between the drive chain (1) and vehicle to catch any over-spray. Never use steam, a high pressure washer, or wire brushes to clean the drive chain.
  • Page 56 Adjust the chain slack if it is out of Cotter pin Rear axle nut Locknut Adjuster bolt WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 57 3. Increase or decrease slack by turning the tabs around the axle nut. adjusted equally on both sides of the swingarm. Cotter pin tabs Adjuster locknut Adjuster Alignment marks Swingarm marks WARNING a. Increase slack b. Decrease slack POTENTIAL HAZARD Reusing a cotter pin.
  • Page 58 Open end b. Direction of chain rotation 17 pins Countershaft sprocket Rear sprocket a. 17 pins WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 59 4. Install the new buffer and tighten screws to 7.0 Inspecting the swingarm chain buffer lbf•in (2.0 N•m). Standard thickness: 9/32 in (7.0 mm) Inspecting the drive chain guide block Minimum thickness: 1/8 in (3.0 mm) Standard thickness: 0.5 inches (12 mm) Measure the buffer thickness (a) at many points of Minimum thickness: 0.1 inches (3 mm) the upper and lower sides of the buffer.
  • Page 60 Outside diameter Sprocket inspection NOTE : Replace both the sprockets and drive chain as a WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 61: Engine Management System

    The diagnostic connector is located under the seat. Engine Management System diagnostics can be performed using the Cannondale Diagnostic Tool. The tool is a combination of a specially developed Windows- based software program and a data cable used to connect your PC or pocket PC computer to Components have been removed for this photo.

  • Page 62: Electrical

    Do not pull on the wires. 4. Remove the fuse, and install the specified Main fuse Lighting fuse EMS power relay WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 63 Your vehicle has a sealed type battery. Perform only Recharge the battery before reinstallation and during routine charging maintenance when it becomes dis- vehicle storage. Consult your Cannondale Motor- charged from over utilization or when removed for sports dealer for more information.
  • Page 64 Space is tight here so avoid remov- ing the bolt. Latch Connector Bolt Clip WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 65 7. Lift out the coil. head hole with a clean rag. Coil Spark plug Hole 8. Use a 5/8” spark plug socket and an extension to 10. Inspect the spark plug gap. loosen and remove the spark plug. In the photo 11.
  • Page 66 The headlight has two lamps; the process is identical for both. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 67 NOTE : NOTE : Note the fit and form of the housing as you remove You may elect to examine the overall headlight it. Later, install the housing as removed or a gap mounting at this point. The entire headlight can be between it and the headlight body may result.

  • Page 68: Exhaust

    Outlet restriction causes excessive heat to buildup in the muffler which will cause the system to overheat. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 69 The spark arrestor should be removed after every 50 hours 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. Silencer Exhaust header Grommets...

  • Page 70: Fuel

    3. Make sure the fuel cap is tightened securely. 6. Remove remove the left (below top) and right 4. Remove the seat. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 71 (below bottom) radiator shrouds. Return tank fitting (right side of 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. 8. Remove the fuel tank mounting bolts. Screws Bolt 7.
  • Page 72 When reinstalling the quick connect fittings, be sure to press the fit- WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 73: Steering

    (display) the engine rpm. For this properly. reason, we strongly recommend that this procedure be left to a Cannondale Service Technician. LUBRICATE Attempting to adjust the idle “by ear” is not recom- O-RING mended.
  • Page 74 Tighten the upper handlebar clamp bolts to 17.0 lbf•ft (23.0 N•m). Tighten the lower handlebar clamps to 60.0 lbf•ft (81.0 N•m) WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 75: Suspension

    Please consult the supplements or damage by an authorized Cannondale Motor- before attempting to adjust or service any sus- sports Dealer.
  • Page 76 Only a qualified service technician with consider- able experience should perform any suspen- sion service. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 77 Front suspension Air bleed screw Compression damping adjuster Fork Wear ring Protector Seal (wipers) Rebound damping adjuster Printed : 8/15/02...
  • Page 78 Wear ring pinch bolts are tightened to the specified torque. Seal Seal spring Inner tube Protector WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 79 CAUTION :  Observe the torque specification found in the Torque Table in this manual. The forks can be severely damaged if you over tighten them in the clamps. Upper triple clamp bolts Lower triple clamp bolts 6. Inspect bolts and nuts for tightness. 7.
  • Page 80 Optional springs are available 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 front wheel is off the ground and the forks are fully extended. Measure the unloaded measurement (F1).
  • Page 81 Fork Rebound damping adjustment heard when turning the adjustment screw. There are 8 clicks in each full revolution of the adjustment screw. CAUTION :  Adjust both forks to the same setting. 1. To set rebound damping to the standard setting, turn the adjustment screw clockwise until it will Rebound damping affects how quickly the fork no longer turn.
  • Page 82 4. Reinstall the bleed screw. Do not over tighten the screw. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 83 Rear suspension NOTE : Component shown removed for clarity Compression damping adjuster Adjuster nut Body Spring Lock ring Reservoir Spring ID (Type, rate) Rebound damping adjuster Nitrogen gas hazard warning Bump stop Printed : 8/15/02...
  • Page 84 Optional springs are available 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 rear wheel is off the ground and the swingarm is fully extended. Mea- sure the unloaded measurement (R1).
  • Page 85 Adjusting the rear spring preload Rear shock rebound damping adjustment T h e f o l l o w i n g r e a r s h o c k s p r i n g s e r v i c e Rebound damping affects how quickly the shock s p e c i f i c a t i o n s c a n b e f o u n d i n t h e M o d e l “rebounds”...
  • Page 86 Compression adjuster a. More damping (stiffer) b. Less damping (softer) High speed adjuster Low speed adjuster WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 87: Tires

    TIRES Insufficient tire pressure will result in: • Poor handling and may cause the vehicle to The following tire service specifications for your “wander.” vehicle can be found in the Model Specifications section in this manual: (front tire size, rear tire size, •...

  • Page 88: Wheels

    1. Check each spoke with a spoke nipple wrench. 2. Tighten so that all spokes have the same ten- WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 89 loosen the right pinch bolts. Installing the front wheel CAUTION : Follow installation steps provided. Incorrect wheel installation can result in severe damage (e.g., binding during fork travel) to the fork legs. NOTE : The right and left sides of the motorcycle are determined when the rider is sitting on the motorcycle, facing forward (e.g., the brake pedal is on the right side of the motorcycle).
  • Page 90 Make sure the axle dust caps are in good WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 91 condition. Install the adjuster block, washer, and finger-tighten the rear wheel axle nut (3). Make sure both adjuster blocks are in the same position on each side of the swingarm. 1. Place motorcycle on a workstand. 2. Clean the wheel axle and the inside of the axle cutouts in the swingarm with contact cleaner.
  • Page 92 WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 93: Cleaning

    Use an ordinary garden doesn’t don’t ride the vehicle; contact an hose and only enough water pressure to do the authorized Cannondale motorsports dealer. job. Be sure to thoroughly dry your vehicle after Before you start cleaning the vehicle take the washing it.

  • Page 94: Storage

    Select a cool, dry place away from heat, humidity, dust and dirt to store the vehicle. 13. Cover the vehicle. WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 95 Removing from storage 1. Uncover the vehicle. Clean and dry it. 2. Install 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.

  • Page 96: Tightening Torques

    (to radiator) Radiator shroud mounting screws (to tank) Fuel tank mounting bolts Side number panels mounting bolts WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 97: Maintenance Record

    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 conditions. DATE SERVICE REMARKS Printed : 8/15/02...

  • Page 98: Specifications

    FRAM G4164 or equivalent (35 micron rating) Fuel system Electronic fuel injection Valve train DOHC, four-valve WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 99: Service

    SERVICE Model X440 C440 E440 S440 -20 -15 -10 -5 TEMP (C°) Engine oil 20W 50 Recommended viscosity: 10W40 Classification: Use only high- 15W 50 detergent, premium quality synthetic motor oils with the 10W 40, 10W 50 American Petroleum Institute (API) service classification SF or 10W 30 SG type displayed on the...

  • Page 100: Suspension Settings

    3.7 - 4.0 in (95 - 100 mm) Static sag 1.0 - 1.2 in (25 - 30 mm) WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...

  • Page 101: Addenda

    ADDENDA This section is reserved for updates, supplements, and revisions. Pages are left blank intentionally. Printed : 8/15/02...
  • Page 102 WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 103 Printed : 8/15/02...
  • Page 104 WARNING Indicates a potential hazard that could result in serious injury or death. 2003 Motorcycle OM.fm © 2002 Cannondale Corporation - All Rights Reserved...
  • Page 105 Suspension- - - - - - - - - - - - - - - - - - - - 75 IMPORTANT MANUAL INFORMATION- - - - - - - - - - - 2 Adjustment - - - - - - - - - - - - - - - - - - - - 75 FOREWORD - - - - - - - - - - - - - - - - - - - - - - - - 4 Tires - - - - - - - - - - - - - - - - - - - - - - - 87 General Safety Precautions - - - - - - - - - - - - 5...

This manual is also suitable for:

C440 2003X440 2003S440 2003

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