Cannondale ATV Owner's Manual
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Cannondale ATV Owner's Manual

Cannondale ATV Owner's Manual

2002
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Summary of Contents for Cannondale ATV

  • Page 3: Atv Sport Reality

    Given the realities of sport ATVs and/or the limits of your own riding abilities, you may lose control. The limits are impossible to be specific about because of the variation in terrain and rider ability are nearly unlimited. If you chose to ride an ATV, you must understand and respect the reality of the above.

  • Page 4: Foreword

    Cannondale 2 Corporate Drive motorsports dealer for a replacement. Bedford, PA 15522 • This manual contains standard ATV industry E-mail: safety information required to be a part of ATV technical.publications@cannondale.com Owner’s Manuals. It also contains Cannondale specific model information.
  • Page 5 U.S. federal law prohibits the following acts or the of printing. Cannondale Corporation reserves the right to causing thereof;(1) The removal or rendering inoperative make product changes and improvements which may...

  • Page 6: Safety Alerts

    SAFETY ALERTS • FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. • Keep this Owner’s Manual with your vehicle at all times. Messages with the Safety Alert Symbol • Pay special attention to all messages preceded by the Safety Alert Symbol. It means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.

  • Page 7: Special Safety Messages

    ATV during without adult supervision, and never allow operation. continued use of an ATV by a child if he or she • Always go slowly and be extra careful when does not have the abilities to operate it safely.
  • Page 8 ATV. Never attempt speeds before attempting to turn at faster speeds. to turn the ATV around on any hill until you have Do not turn at excessive speed. mastered the turning technique described in this manual on level ground.
  • Page 9 • Never operate an ATV in fast flowing water or in water deeper than that specified in this manual. Remember that wet brakes may have reduced stopping ability.

  • Page 10: Table Of Contents

    Tether Switch - - - - - - - - - - - - - - - - - - - 22 Turning The ATV - - - - - - - - - - - - - - - - - 45 Engine Stop/Start Buttons (MC500) - - - - - - - - 23 Don’t Drink and Drive! - - - - - - - - - - - - - - - 46...
  • Page 11 Work safely - - - - - - - - - - - - - - - - - - - 68 ATV LIMITED WARRANTY - - - - - - - - - - 168 Maintenance Schedule - - - - - - - - - - - - - - 72...

  • Page 12: Warning Labels

    If any label is missing, worn, damaged, or becomes unreadable, be sure to replace it. Cannondale offers replacement labels at no charge. A label’s part number is printed in the lower right corner of the label and here in the manual.
  • Page 13 315-6000237-01 Label 2 P/N 315-6000237-01 Riding as a passenger can cause the ATV to go out of control. Loss of control can cause a collision or rollover, which can result in severe injury or death. NEVER ride as a passenger.
  • Page 14 315-6000238-01 Label 4 P/N 315-6000238-01 315-6000580-01 315-6000477-01 Label 6 P/N 315-6000580-01 Label 5 P/N 315-6000477-01...
  • Page 15 Hangtag All Cannondale ATVs are shipped with a removable hangtag attached to the handlebar. Like the vehicle’s warning labels, this hangtag contains important information for your safety. Read and understand it throroughly before removing it.

  • Page 16: Machine Identification

    MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER (VIN) The vehicle identification number (VIN) is etched/ NOTE : stamped into the frame behind the front brush guard. The VIN also appears on a temporary factory applied adhesive Your vehicle may differ from those shown in the label in the same area.

  • Page 17: Engine Serial Number

    ENGINE SERIAL NUMBER KEY ID NUMBER The engine serial number is etched/stamped into the Key identification numbers are etched/stamped into key rear area of the engine crankcase. The number also bodies. appears on a metallic plate affixed to the crankcase area NOTE : above the countershaft sprocket.

  • Page 18: Parts And Control Functions

    PARTS AND CONTROL FUNCTIONS NOTE : Your vehicle may differ slightly from those shown in the illustrations in this manual. 4. Ignition switch 7. Front brake lever 1. Clutch lever 5. Front brake master cylinder 8. Throttle 2. Engine RUN/OFF switch 6.
  • Page 19 (11) (17) (12) (10) (15) (14) 4) 4) (21) (18) 8. Transmission oil level check 16. Fuel filter 1. Rectifier/regulator 9. Left frame spar drain bolt 17. Engine oil, coolant levels check 2. Engine Control Unit (ECU) 10. Air filter 18.

  • Page 20: Owner's Manual

    OWNER’S MANUAL SEAT The Owner’s Manual for your vehicle is located under The seat on your vehicle is for you only. Carrying a the seat. It contains important safety and maintenance passenger can cause you to lose control of the vehicle. information.
  • Page 21 2. Use your fingertips to lift up the rear of the seat slightly. 4. Press down gently on the middle of the seat and slide Then, pull the seat back toward the rear of the vehicle the seat forward onto the clip and subframe guides. If and lift it off.
  • Page 22 Always make sure the seat is locked into position injury or death. on the mounts and secured properly with the retention bolt. Never ride this ATV with a damaged seat. Have it replaced. CAUTION Do not force the seat pegs through the holes in the rear fender or subframe buffers;...

  • Page 23: Ignition Switch

    IGNITION SWITCH Key Position Function The ignition switch is located between the handlebars. Removal Always remove the key from the switch to help prevent The engine and lighting unauthorized vehicle use or theft. See the table for a cannot be operated. description of the switch positions.

  • Page 24: Tether Switch

    If it does not, do not ride the ATV; the switch is damaged and must be replaced. Contact your dealer for a replacement. 1. Tether switch in operate position 2.

  • Page 25: Engine Stop/Start Buttons (Mc500)

    It is also an emergency control. Test the stop button before moving off to ride to confirm that it is operating properly. If the switch does not “kill” the engine, don’t ride the ATV. Turn the ignition switch to the “OFF” position and contact a...

  • Page 26: Engine Stop Switch/ Start Button (Mc1000)

    If the switch does not “kill” a running engine, don’t ride the ATV. Remove the key from the ignition switch to prevent vehicle use and contact an Cannondale motorsports dealer for servicing.

  • Page 27: Headlights

    HEADLIGHTS TAILLIGHT Turn the ignition switch to the “ON w/LIGHTS” position Turn the ignition switch to the “ON with LIGHTS” position to activate the headlights. Test for the proper operation of to activate the taillight. The taillight IS NOT a brake light. the headlights before operating the vehicle.

  • Page 28: Front Brake Lever

    FRONT BRAKE LEVER PARKING BRAKE The front brake lever is located on the right side of the The parking brake is applied with a lock button on the handlebar. Pull it toward the handlebar to apply the front front brake lever. When the parking brake is applied brakes.
  • Page 29 In either case above, severe injury or death can result to the owner or bystanders. HOW TO AVOID THE HAZARD (1) Always block or chock the wheels on your ATV immediately after applying the parking brake. Never apply the parking brake and leave the vehicle unattended.

  • Page 30: Rear Brake Pedal

    REAR BRAKE PEDAL FOOTPEGS & BASKETS The rear brake pedal is located on the right side of the When riding always keep your feet on the footpegs. vehicle. When pressed, braking force is applied to the rear Always check the condition of the footpegs and baskets wheels.

  • Page 31: Nerf Bars

    N RF BAR NERF BARS Always check the condition of the nerf bars, strapping, and footpeg teeth before every ride. Make sure that they are fastened securely to the vehicle and that the footpeg teeth and webbing is in good condition and does not sag excessively when the weight of the rider is applied.

  • Page 32: Shift Lever

    SHIFT LEVER FUEL TANK CAP The shift lever is located on the left side of the engine in Make sure the fuel cap is tightly secured before every front of the left footpeg. The vehicle has five forward gears ride. Turn the fuel cap counterclockwise to remove it and (1-down,”NEUTRAL’”...

  • Page 33: Handle Grips

    Make sure they are firmly attached and do not twist on the handlebar. Inspect the grips for wear, tears, or other damage. Replace the grips with a new set if damage is found. Contact an authorized Cannondale motorsports dealer for a replacement set. 1. Handle grip (right)

  • Page 34: Throttle Lever

    1. Throttle lever “pop” or release the clutch lever quickly. Always a. Freeplay gradually release the clutch lever. If the ATV “wheelies” or the front wheels begin to come off the ground, close the throttle and pull in the clutch lever immediately.

  • Page 35: Clutch Lever (Manual)

    CLUTCH LEVER (MANUAL) CLUTCH LEVER (HYDRAULIC) The clutch lever is located on the left side of the The hydraulic clutch lever is located on the left side of handlebar. Pull in the clutch lever (quickly) to disengage the handlebar. Pull in the clutch lever (quickly) to the clutch, and release the lever (slowly) to engage the disengage the clutch, and release the lever (slowly) to clutch.

  • Page 36: Fuse & Diagnostics Connector

    1. Fuse (in holder) 2. MC1000 Data port NOTE : For information on special tools developed to service your ATV, contact authorized Cannondale motorsports dealer. 1. Fuse (in holder) 2. MC500 Data port...

  • Page 37: Safety Flag Mount

    (e.g. hilly terrain or sand dunes) mount an approved ATV safety flag. Safety flags are required in some riding areas. For more information on approved ATV safety flags, contact an authorized Cannondale motorsports dealer. 1. Safety flag mount...

  • Page 38: Safe Operation

    COULD result in serious accident. injury or death. HOW TO AVOID THE HAZARD If you do not have substantial skill and operating experience, DO NOT OPERATE ANY CANNONDALE ATV. Always remove the ignition key from this vehicle to prevent unauthorized use.

  • Page 39: Training And Instruction

    Owner’s Manual. riders to get training and instruction before operating any For more information about the training course, ATV. Although the message that training and instruction is contact an authorized Cannondale motorsports required for any beginning rider is correct, these riders dealer or call 1-800-887-2887 (USA only).

  • Page 40: Age Recommendation

    Even though a child may be within the age group for which an ATV is recommended, he or she may not have the skills, abilities, or judgement needed to operate the ATV safely and may be involved in a serious accident.

  • Page 41: Wear Protective Gear

    Helmet riding more comfortable. Goggles WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet Protective...

  • Page 42: Ride Sensibly

    Always reduce speed when riding at dusk, dawn, and night. Riding at dusk, dawn, and nighttime, even with the lighting on this ATV, reduces your ability to see obstacles; therefore, you must slow down. When reading this manual, remember:...

  • Page 43: No Passengers: No Exceptions

    HOW TO AVOID THE HAZARD Don’t carry a passenger on any ATV. Passengers will Never carry a passenger. The ATV has a long seat to interfere with your ability to control the vehicle. A special allow the operator to shift position as needed during NO PASSENGERS warning label is affixed on the seat to operation.

  • Page 44: Cargo, Loading Limit

    CARGO, LOADING LIMIT HOW TO AVOID THE HAZARD Do not carry cargo on your ATV. Do not modify your ATV Never exceed the stated load capacity for this ATV. to carry cargo. Cargo should be properly distributed and securely Do not exceed the vehicle’s specified loading limit.

  • Page 45: Off-Road Use Only

    The hard surface makes the handling and stability of all ATVs wildly unpredictable. You can lose control suddenly and without warning. The lighting on this ATV does not imply that it is for public roads or highways. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces.

  • Page 46: Stay Off Public Roads And Highways

    You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATV’s on public streets, roads and highways.

  • Page 47: Turning The Atv

    ATV. Always slow down before turning and reduce your Never remove your feet from the footpegs while riding this speed before entering a turn.

  • Page 48: Don't Drink And Drive

    - so stay off any ATV if you’ve been drinking alcohol or taking drugs or medication. And, remember that even prescription and over-the counter drugs can impair your ability to safely operate this ATV. If you are taking any type of medication, check with your doctor before riding. WARNING...

  • Page 49: No Wheelies, Stunts, Or Jumps

    You will see people attempting jumps or other stunts with ATVs. You’ll probably see someone do it in one of the magazines or at an ATV event. What you could be seeing is a professional rider or a weekend amateur. In any case,...

  • Page 50: Keep Your Hands And Feet On The Controls

    The common practice of removing a foot from your motorcycle footpegs when rounding a turn is VERY DANGEROUS if done on an ATV. If you take your foot off the footpeg while turning the rear tires will run over your foot or leg and cause severe injury - maybe even death.

  • Page 51: Watch Out For Terrain Changes

    WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes without enough time to react.

  • Page 52: Rough Or Slippery Terrain

    HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

  • Page 53: Stay Off Steep Hills

    STAY OFF STEEP HILLS Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. Keep the front wheels on the ground so that you maintain steering control and prevent the possibility of overturning the ATV.

  • Page 54: Climbing Hills Improperly

    Sudden acceleration can cause the front gear changes. The ATV could flip over backward. wheels to come off the ground - you could flip the ATV onto Never go over the top of any hill at high speed. An yourself.

  • Page 55: Riding Downhill

    Always travel straight down a hill when possible. Avoid Shift your weight backward. sharp turns which could cause the ATV to tip or roll over. Never go down a hill at high speed. Always choose a path down hill that is free of obstacles.

  • Page 56: Crossing Slopes Or Hills

    Avoid slopes with unstable or slippery surfaces that will HOW TO AVOID THE HAZARD cause the tires to lose traction. Always travel at a reduced Never attempt to turn the ATV around on any hill speed. until you have mastered the turning technique as described in this Owner’s Manual on level ground.

  • Page 57: Turning On Slopes Or Hills

    HOW TO AVOID THE HAZARD Always reduce speed when turning. Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in this Owner’s Manual on level ground.

  • Page 58: Obstacles

    Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees.

  • Page 59: Skidding Or Sliding

    Slides are more likely on slippery or loose surfaces when turning. If you skid or slide you may lose all steering control of the ATV and an accident will result. If you skid sideways when turning on a loose or slippery surface, steer in the direction of the skid.

  • Page 60: Safety Flag

    ATV’s or off-road vehicles. WHAT CAN HAPPEN You could collide with another vehicle. HOW TO AVOID THE HAZARD Always mount an ATV safety flag to the vehicle to make you more visible. Always use caution around other vehicles.

  • Page 61: Riding Through Shallow Water

    Manual. page 161. Remember that wet brakes may have reduced Never attempt to ride any ATV in deep or fast moving stopping ability. Test your brakes after leaving the water, such as rivers or streams. The tires will float causing water.

  • Page 62: Stalling, Rolling Backwards

    Keep weight uphill. Backing the ATV downhill Never apply the rear brake abruptly while rolling If you stall, you may be able to get off and walk the ATV backward. Apply the front brake. back down the hill if it is not too slippery and you have good When fully stopped, apply rear brake as well, and footing.

  • Page 63: Modifications

    4. If you lose control of the ATV, don’t attempt to regain MODIFICATIONS control , for your safety, get away from the vehicle and alert others. WARNING If you can’t back the ATV downhill POTENTIAL HAZARD If you stall and the hill is too slippery or you doubt Operating this ATV with improper modifications.

  • Page 64: Pre-Ride Inspection

    Increases the possibility of equipment failure resulting in an accident. HOW TO AVOID THE HAZARD Always inspect this ATV before you operate it. When reading this manual, remember: Always follow the inspection and maintenance procedures found in this Owner’s Manual.

  • Page 65: Pre-Ride Checklist

    PRE-RIDE CHECKLIST ITEM CHECK PAGE Condition of (helmet, eye protection, boots, gloves, long- Apparel Start on page39. sleeved shirt and, long trousers). Proper operation, fluid levels, front lever freeplay, leaks. Brakes Fill with DOT4 brake fluid if necessary. Check the rear brake Start on page100.

  • Page 66: Operation

    WARNING engine. POTENTIAL HAZARD NEUTRAL WITH PULLED-IN CLUTCH Operating the ATV without being familiar with all the • controls. Shift the transmission into NEUTRAL and pull-in the clutch lever before starting. Without pulling in...
  • Page 67 4. Carefully take up the throttle lever freeplay, then take up temperature (70°C) before riding. 1mm more. ATV MC1000 Cold Starting 1. Make sure the vehicle is on level ground and the transmission is in NEUTRAL. 2. Turn the ignition switch to the “ON” position.
  • Page 68 Starting a warm engine - (MC500 or MC1000) When starting an engine after it has reached operating temperature, do NOT open the throttle while operating the starter motor. This will make starting very difficult and possibly foul the spark plug. When reading this manual, remember: Indicates a potential hazard WARNING...

  • Page 69: Break-In

    Avoid riding up steep hills and in sand because this produces greater engine loads, possibly damaging engine components. 1. Ride the ATV normally for two 10-minute segments using no more than 1/2 throttle. Wait for the engine to cool completely between segments.

  • Page 70: Maintenance & Adjustment

    If When reading this manual, remember: you do not have a torque wrench or are not familiar with Indicates a potential hazard using one; contact your authorized Cannondale dealer for WARNING that COULD result in serious assistance.
  • Page 71 Carbon Monoxide Hot Components DANGER WARNING POTENTIAL HAZARD POTENTIAL HAZARD Running the engine indoors. Hot components (e.g., engine, radiator, hoses, Breathing exhaust gases bulbs, exhaust, brakes) WHAT CAN HAPPEN WHAT CAN HAPPEN Running the engine indoors will expose you to The engine and other vehicle systems operate at dangerous exhaust...
  • Page 72 Gasoline Protect Your Eyes WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Improper care when handling fuel. Blindness, eye injury WHAT CAN HAPPEN WHAT CAN HAPPEN Fuel is highly flammable, spilling it can cause a fire Anytime you work on the vehicle there is a or explosion.
  • Page 73 Moving parts Fluids WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Losing a finger, hand or limb or entanglement Vehicle fluids (e.g., engine oil, transmission oil, brake fluid, coolant) WHAT CAN HAPPEN WHAT CAN HAPPEN Moving parts can catch your clothing, fingers or hand resulting in severe injury.

  • Page 74: Maintenance Schedule

    • EXHAUST (spark arrester) • 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 75 CLUTCH (lever, cable and arm position) CLUTCH HYD OIL • 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.
  • Page 76 ••• 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 77: Panels

    PANELS To install the covers, return the cover to its original Many of the maintenance procedures in this manual position and tighten the bolts snug. Do not over-tighten. require that you remove and reinstall vehicle panels. Consult the following procedures: Radiator Guards Headlight covers To remove either headlight cover, loosen the bolts but do...
  • Page 78 Cowl 3. Loosen and remove the cowl mounting bolts. NOTE : The Engine Control Unit (ECU) and air filter are located under the cowl. 1. To remove the cowl and the seat 2. Remove the fender support bracket bolts at the frame. 4.
  • Page 79 Side Panels Rear Fender 1. To remove, first remove the seat. 1. Remove the seat and side panels. 2. Remove the panel bolts. 2. Remove the bolts and lift the rear fender off the subframe. Panel bolts 3. To install, place the panel in the original position and Rear fender bolts (3 of 4 visible in photo) install the bolts.
  • Page 80 The following procedure requires moderate mechanical skill. If you doubt your skills or abilities to remove the fuel tank safely, have the fuel tank serviced by an authorized Cannondale motorsports dealer. CAUTION Inspect and lubricate with clean engine oil - each of the quick connect hose end O-rings before installing them into the tank fittings.
  • Page 81 5. Press in the tank fitting tab and remove the quick 6. Remove the quick connect at the rear of tank in the connect from the tank. same manner. 1. Tab 1. Tab 2. Fuel tank outlet quick connect 2. Fuel tank return (from pressure regulator) quick connect 3.

  • Page 82: Frame, Subframe, Swingarm

    If you have crashed or rolled your ATV, there could be subframe, or swingarm is damaged; never try to damage hidden from your view. DO NOT ride an ATV with repair the frame, subframe, swingarm, or other any crack, even a small one.
  • Page 83 3. Subframe 5. Engine rail/skid plate 1. Frame 4. Swingarm 6. Brush guard 2. Rear shock strut...

  • Page 84: Fuel

    FUEL Adding fuel Always use clean high quality unleaded gasoline. See 1. Make sure the vehicle is completely cold. “2002 Model Specifications” starting on page 161.) 2. Remove the ignition switch key. 3. Remove the fuel cap and fill the fuel tank with the WARNING specified fuel to the correct level.
  • Page 85 Tighten the locknut. communicate with the vehicle ECU and accurately read (display) the engine rpm. For this reason, idle adjust should be left to a Cannondale service technician. 1. To adjust the idle, allow the engine to reach operating temperature 158°F (70°C).
  • Page 86 Fuel filter replacement 3. Cradle the fuel filter with the hoses attached in a clean dry shop towel to help absorb any residual fuel that will See “2002 Model Specifications” starting on page 161. drain as the filter is removed. Loosen the fuel hose Replace the inline fuel filter every 5 hours.

  • Page 87: Engine Oil

    ENGINE OIL 3. Remove the dipstick. Engine oil is a significant factor in the service life and performance of the engine. See “2002 Model Specifications” starting on page 161. Change the engine oil and clean the filters in accordance with the maintenance schedule. See “Maintenance &...
  • Page 88 Changing engine oil 3. Move to the right frame spar and drain the engine oil from it the same way. Tighten the spar drain bolt to the NOTE : specified torque. Have a clean shop towel handy to clean up any spilled oil.
  • Page 89 4. Now, drain the crankcase by removing the crankcase drain bolt. Be sure to note and return the two crush (sealing) washers of the drain bolt. They can be reused but replace them with new washers if they are damaged. 1.
  • Page 90 5. Place a container under engine oil filter cover and Inspect the seals and filter element for tears, cracks, remove the bolt, engine oil filter cover and the two cover and other damage. Replace if damaged. O-rings. 1. Bolt 1. Bolt 2.
  • Page 91 11. Now, carefully work the heat shield back to expose the NOTE : left spar return hose and clamp. Then, remove the Use some O-ring grease to “stick” the filter seals so that clamp and hose from the engine oil inlet fitting. they are centered on the filter.
  • Page 92 12. Loosen and remove the inlet fitting. Then, remove 17. Install the fitting. Tighten it to the specified torque. the inlet filter (screen) from the hole. 1. Screen 2. O-ring 3. Inlet fitting 4. Clamp 5. Spar return hose 6. Heat shield 1.

  • Page 93: Transmission Oil

    TRANSMISSION OIL 2. Remove transmission oil level check bolt and sealing The transmission oil in your ATV is just as critical to washer. The oil level should be even with the bottom of engine life and performance as the engine oil. Be sure to the check hole.
  • Page 94 3. To add, reinstall the check bolt and pour the specified transmission oil slowly and in small amounts using a clean funnel. Recheck the level. HIGH 1. Transmission oil window NOTE : The transmission oil level within the crankcase should be visible in the window.
  • Page 95 Changing transmission oil 1. Place vehicle on a level surface with a suitable container under the transmission drain bolt and remove CAUTION the bolt and sealing washer. When re-installing the transmission oil filter, sealing washer, and bolt, insert the filter into the bolt, then insert the pair into the crankcase hole together.
  • Page 96 3. If the filter did not come out with the bolt, remove it leak. Install the washer onto the bolt so that the flat side carefully from the hole. Clean it using compressed air. (a) faces the case. Insert the filter into the bolt, and install into the case.

  • Page 97: Coolant

    COOLANT The engine coolant bottle is located on the right side of the vehicle under the headlight cover. Check the coolant level in the bottle when the engine is cold. The fluid level in the bottle will vary during operation. Maintain coolant at the “LEVEL”...
  • Page 98 Checking the coolant level Adding coolant 1. Make sure the engine and radiator are completely cold. 1. To add coolant, make sure the engine is cold. 2. Remove the right headlight cover and observe the 2. Place a thick rag over the coolant bottle cap and open it coolant level in the bottle without opening the cap.
  • Page 99 3. Place a clean bucket under the radiator drain bolt and 4. Remove the coolant outlet drain bolt and sealing remove it. Allow the radiator contents to drain washer and allow coolant to drain completely. Reinstall completely. Then, inspect the drain bolt 0-ring - if the sealing washer and bolt.
  • Page 100 The coolant bleed bolt is located in the top right corner of the coolant pump cover (right side of engine). Access to it is difficult. If you are unfamiliar with coolant bleeding, have an authorized Cannondale dealer bleed the coolant. 1. Make sure the coolant system is completely cold and...
  • Page 101 When reading this manual, remember: Indicates a potential hazard WARNING that COULD result in serious injury or death.

  • Page 102: Brakes

    1. Squeeze the front brake lever and test for proper braking. The lever should feel firm and proportional POTENTIAL HAZARD force should be applied to the discs preventing the ATV Using contaminated brake fluid, using brake fluid from rolling. If the brake lever feels spongy or weak, or other than DOT4, mixing brake fluid types.
  • Page 103 Front 5. Add the recommended brake fluid from a sealed container until the fluid level is above the ‘LOWER’ 1. To check the front system, place vehicle on a level mark on the reservoir body. surface and level the handlebars. 6.
  • Page 104 fluid level should be above the ‘LOWER’ mark. Add if Brake pads and discs, inspection necessary. NOTE : Consult the Model Specifications section in this Owner’s Manual for brake pad and disc wear specifications. Consult the Torque Table, for torque values. REAR 1.
  • Page 105 necessitate replacing the brake disc. However, if the brake disc is worn beyond the specified thickness it must be replaced. 3. Make sure the front and rear brake disc mounting bolts are tightened to the specified torque. 1. Front brake pads (right) wear limit indicator 2.
  • Page 106 1. Front disc mounting bolts (1 visible in photo) 2. Caliper mounting bolts 3. Banjo bolt...
  • Page 107 Front brake line routing WARNING POTENTIAL HAZARD Incorrect brake line routing WHAT CAN HAPPEN If the brake line clamps are positioned incorrectly, the line can be damaged or break resulting in a loss of braking control resulting in a serious accident. You can be severely injured or killed.
  • Page 108 Wear a protective leather glove the rear axle assembly from damage. when checking the rear brake disc for play. (2) Never ride this ATV with a malfunctioning brake WARNING system. Contact...
  • Page 109 wheel when attempting to detect play. You should 4. Remove the protective boot covering the rear brake detect no play in the disc. If you detect any play, you disc carrier preload nut and slide it back. It helps to use must tighten the rear brake disc carrier preload nut.
  • Page 110 7. Reinstall the protective boot and recheck the rear brake disc carrier for play. If play is still present, do not ride the 2. Tighten the locknut to the specified torque. vehicle; contact an authorized Cannondale motorsports dealer for servicing...

  • Page 111: Clutch

    3. When lowering the brake pedal, make sure the CLUTCH clearance (a) between the lower end of the pushrod and the brake pedal is within specification. When Clutch lever (manual) freeplay raising the brake pedal, ensure that at least two NOTE : pushrod threads are visible inside the pedal joint.
  • Page 112 2. To adjust, loosen the lockring and turn adjuster until the Clutch lever position (hydraulic) specified freeplay is reached. Tighten the locknut The lever position of vehicles equipped with a hydraulic securely and reposition the boot when finished. If the clutch can be adjusted to suit individual hand sizes.
  • Page 113 the adjusting screw counterclockwise to increase the Checking the oil level of the hydraulic clutch distance between the clutch lever and handle grip. CAUTION Never substitute brake fluid for SAE 10 (mineral hydraulic oil. 1. To check the level, remove the cover screws, cover and rubber boot.
  • Page 114 Bleeding the hydraulic clutch 3. Loosen the bolts and slowly compress the syringe until only oil, (no air bubbles) is discharged at the bore of the 1. To bleed, remove the master cylinder cover and slave master cylinder. Make sure the oil does not overflow out cylinder bleed bolt cap.
  • Page 115 NOTE : A special “clutch release collar” holding tool has been developed for the following procedure, but right angle circlip plier of the correct size can be used successfully. Contact authorized Cannondale dealer information on special tools for your vehicle.
  • Page 116 1. Place the vehicle on a level surface. 5. Remove the clutch cover bolts and clutch cover. 2. Clean the area surrounding the clutch cover area to prevent contamination of the transmission oil when the clutch cover is removed. 3. Disconnect the clutch cable end from the clutch arm. 4.
  • Page 117 7. Have an assistant hold light pressure on the actuating arm toward the cylinder head on the actuating arm. 1. Seal 2. Clutch release collar 6. The clutch cover seal is reusable, however, inspect it carefully for damage. When reusing the seal, we recommend, cleaning the mating surfaces and applying a thin film of silicone sealant to the seal when reinstalling the cover.

  • Page 118: Drive

    adjuster locknut. Turn the adjuster until the actuating DRIVE arm is in the specified position. Tighten the adjuster locknut when completed. Drive chain lubrication The drive chain must be cleaned and lubricated before every ride. Significant forces act on the chain during operation.
  • Page 119 Swingarm buffer inspection NOTE : Make sure the chain has dried completely before CAUTION applying the lubrication. Wear may be distributed differently across the buffer length. Inspect the entire length carefully. 1. Measure the buffer thickness on the upper and lower sides of the swingarm and at several points along its entire length.
  • Page 120 Chain rollers inspection Rear brake disc & sprocket guards 1. Rotate the chain rollers. They should rotate smoothly. Make sure both guards are mounted securely. Inspect 2. Measure the outside diameter of the upper and lower each guard for cracking and/or other signs of excessive rollers.
  • Page 121 Chain guide block inspection Chain slack inspection Check the drive chain guide block for excessive wear, NOTE : cracks, and/or any other damage. Make sure it is fastened Clean and lubricate the drive chain before measuring securely to the swingarm. If the guide block is damaged or the slack.
  • Page 122 3. To adjust, loosen rear axle locking bolts. CAUTION When adjusting drive chain slack, keep the hole in the eccentric below the rear axle midline. If the hole is adjusted above the midline, the chain will wear into the sprocket guard causing damage to the guard and the chain.
  • Page 123 4. Insert a tool with a round shaft diameter (Philips Drive chain stretch inspection screwdriver in photo) that closely approximates the hole 1. With the upper or lower section of the drive chain tight in the eccentric. Then, slowly rotate the wheels in between the sprockets, measure the distance between direction (a) to increase the drive chain slack or the span of 13 pins from pin center to pin center.
  • Page 124 The open end of the masterlink clip must face the Visually inspect the condition of the rear countershaft opposite direction of the chain rotation. sprocket(s) before every ride. If damage is found; contact an authorized Cannondale motorsports dealer. 1. Master link clip 1. OK a. Open-end 2.

  • Page 125: Electrical

    Engine Management System (EMS) All Cannondale ATV models use an advanced fuel injection system. Engine operation is supported by an Engine Control Unit (ECU) controlling both ignition and fuel delivery.
  • Page 126 Barometric pressure sensor The intake air pressure (barometric) sensor is built into the ECU and is connected to the airbox plenum by a narrow hose. The sensor measures the air pressure in the airbox. Using this information the ECU determines the air density, and when other inputs are added to the ECU, the engine load is calculated.
  • Page 127 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. The TPS is a potentiometer that gives a reading in the fully-closed position and all other throttle- plate opening angles are calculated using the fully-closed position as a base.
  • Page 128 Ask an correct position depending on the air and engine authorized Cannondale Motorsports dealer for special tools temperature. Be sure to follow the cold starting procedure developed to service your vehicle. described in this manual to ensure that you allow enough time (5 seconds) for this valve to actuate before turning over the engine.
  • Page 129 Coolant temperature sensor Air temperature sensor The engine temperature sensor is brown, located on the The intake air temperature sensor is green. It is front of the cylinder head. It is an NTC thermistor. The ECM mounted on the front area of the airbox (base). It is a NTC receives electronic signals from this thermistor and uses thermistor.
  • Page 130 Fuel injectors (left and right) The fuel injectors are mounted in the cylinder head CONNECT intake tract and are positioned as close as possible to the back of the intake valves. The spray pattern and flow rate (FUEL ENTRY) of the injectors are fixed, but the length of time they remain open varies.
  • Page 131 Fuel Pump Fuel Pressure Regulator The fuel pump is located on the left side of the vehicle The fuel pressure regulator is mounted on the right side (front). When the engine management system is first of the vehicle (front). This device maintains the correct fuel “powered-up”...
  • Page 132 WARNING POTENTIAL HAZARD NOTE : Electrical fire or damage to the ATV electrical system Turning the ignition switch OFF will isolate some areas of the electrical system. It is an added step in circuit protection. See your vehicle’s wiring diagram.
  • Page 133 2. Remove the fuse holder from the cap. 3. Remove the fuse and replace with the specified fuse. . REPLACE Fuse replace 0000 1. Link 4. If the fuse immediately blows again, check the electrical circuits. 1. Cap 2. Fuse 3.
  • Page 134 Lighting 5. Reconnect the harness. 6. Test for proper operation. NOTE : Always wipe off a newly installed bulb with alcohol- Taillight bulb replacement dampened clean cloth or tissue. Oils from your fingers Turn the bulb mount counterclockwise and remove it can cause premature bulb failure.
  • Page 135 CAUTION such as during storage and cleaning. Always have the battery serviced by an authorized Cannondale motorsports Place a clean shop towel over the cylinder head to dealer. help guard against dirt or other object falling into...
  • Page 136 6. Remove the upper shock strut bolt. Loosen the lower 7. Tilt the shock strut back and disconnect the coil from frame spar bolt enough so that it can be tilted back. the wiring harness. 1. Connector 2. Coil holder 3.
  • Page 137 10. Lift out the spark plug coil. 12. Before reinstalling the spark plug measure each gap (a) with a wire gauge or feeler gauge. If either gap is out of specification, adjust it. 111794 1. Coil a. gap 11. Use a spark plug socket and long extension to loosen and remove the spark plug from the cylinder head.

  • Page 138: Air

    1. Remove the cowl. 2. Release the filter retaining clip and remove it. Air filter element cleaning 3. Remove the air filter from the air filter base plate. The air filter is located under the cowl. WARNING POTENTIAL HAZARD Fire or explosion, filter damage WHAT CAN HAPPEN Using gasoline or other low flash point solvents to clean the air filter can result in a fire or explosion.
  • Page 139 4. Carefully separate the foam and cage. 6. Coat the outer surface of the foam with a high-quality foam air filter oil. Even if you use a spray or pour type oil, be sure to massage the foam to ensure a good application throughout.
  • Page 140 the area indicated in the photo below. If the filter is 10. Apply a small dab or waterproof grease to the end of install carelessly, the result may be creating a path for the air filter and reinstall the retaining clip. unfiltered air to bypass the filter.

  • Page 141: Exhaust

    EXHAUST 3. Increase the engine speed with the throttle lever repeatedly while momentarily blocking the end of the Spark arrester cleaning muffler / spark arrester with a clean shop towel, then quickly remove it. This technique causes brief system The spark arrester must be purged of carbon build up at back pressure and will force carbon build-up out the the intervals specified in the maintanace schedule of this purge bolt hole.

  • Page 142: Suspension

    Uneven adjustment will result in poor handling and/ Adjustment Tips or loss of vehicle stability. You can lose control of the ATV and suffer severe injury or death in a • When making adjustments, make them one at a resulting accident.
  • Page 143 fully seated). This is the hardest damping and Rear shock spring pre-load should be your starting point. Turn the adjuster To adjust, loosen the lockring and turn the adjuster ring counterclockwise and listen for the clicks that clockwise to increase the preload or counterclockwise to identify setting positions “1”, “2”, etc.
  • Page 144 Compression adjuster Rebound adjuster 1. To adjust, turn the adjuster clockwise and count the 1. To adjust, turn the adjuster clockwise and count the clicks until the adjuster is fully seated (closed). Be sure number clicks until the adjuster is fully seated. Be sure to write down the number of clicks.
  • Page 145 Adjusting the front shocks Front spring pre-load Type II The spring adjusting sleeve has three positions so that the spring can be adjusted for different riding conditions. Front spring pre-load Type I Adjust the spring preload using two spanner wrenches The spring adjusting sleeve has five positions so that the turning in opposite directions.
  • Page 146 Front spring preload Type III To adjust the preload, loosen the lockring and turn the adjuster ring clockwise to increase the preload or counterclockwise to reduce the preload. 1. Cam 2. Adjusting sleeve 3. Spanner wrenches NOTE : This photo shows how to hold the spanners when reducing the preload.
  • Page 147 Front compression adjuster Type III Front rebound adjuster Type III a. More damping (stiffer) b. Less damping (softer) a. More damping (stiffer) b. Less damping (softer)

  • Page 148: Wheels

    WHEELS Wheel inspection 1. Check the wheel rims for damage. WARNING POTENTIAL HAZARD(S) (1) Damaged cotter pins (or re-using cotter pins) (2) Riding on damaged wheel rims WHAT CAN HAPPEN (1) A damaged cotter pin can become dislodged allowing the hub nut and wheel to come off suddenly causing you to lose control.
  • Page 149 Contact an 4. Make sure the wheel axle nut cotter pins on each wheel authorized Cannondale motorsports dealer and have are in good condition before every ride. Make sure the the conditions corrected. pin is not broken or damaged. It should have both tabs (or legs) and they should be bent properly.
  • Page 150 Wheel removal / installation 1. Place the vehicle on a level surface and block the wheels not being removed to prevent the vehicle from rolling away unexpectedly. 2. Loosen the wheel lug nuts. 1. Cotter pin 2. Tab This is a photo of a front wheel. 1.

  • Page 151: Tires

    All Cannondale ATVs are equipped with low pressure threads in the wheel hub are clean. tires. The air pressure within the tires affects the ATV’s 6. Apply a light coat of anti-seize lubricant to the studs. handling and stability. Check the air pressure and maintain 7.
  • Page 152 WHAT CAN HAPPEN (1 & 2) Tire characteristics influence the handling and stability of this ATV. Use of tire types/sizes other than specified (front/rear) in this Owner’s Manual or improper tire pressures can adversely affect the handling and stability (operation) of this ATV increasing your risk of an accident.
  • Page 153 4. Inspect the tire tread wear. Check the tread wear indicators and condition of the rims and tires of all four wheels. When reading this manual, remember: Indicates a potential hazard WARNING that COULD result in serious injury or death. 1.

  • Page 154: Cleaning

    • Thoroughly dry the vehicle after washing it. Regular cleaning helps to maintain appearance and contributes to overall performance of the ATV by keeping it • Cover the rear muffler opening, brake lever and free of damaging dirt, soils, and grime.

  • Page 155: Storage

    STORAGE 11. Position the vehicle on a level surface and block the wheels to prevent the wheels from moving. When the vehicle will not be operated for an extended 12. Remove the ignition key. period of time (e.g., winter months, 45 days or more), it is necessary to perform certain procedures to guard against deterioration and to make sure it is in perfect running condition when the riding season begins.

  • Page 156: Transporting

    ATV becoming unstable during HOW TO AVOID THE HAZARD transport. Never tow anything with this ATV, or tow this ATV HOW TO AVOID THE HAZARD with any other vehicle. Only use “tie-downs” designed for cargo securing application.
  • Page 157 3. Left footpeg 5. Rear axle 1. Brush guard 4. Grab rail 2. RIght footpeg...

  • Page 158: Torque Table

    TORQUE TABLE Torque Item lbf•ft N•m kgf•m Torque Sprocket/disc guard mounting bolts 0.69 Item lbf•ft N•m kgf•m Chain guide block mounting bolts 0.69 Cowl support bracket bolts (cowl) 0.69 Wheel lug nuts (front/rear) 35.0 47.5 4.83 Cowl mounting bolts 0.69 Front axle nut 35.0 47.5...

  • Page 159: Troubleshooting

    TROUBLESHOOTING NOTE : The troubleshooting items listed here are provided as a rough guide to assist in some of the more common difficulties. For more complete systems troubleshooting, consult the vehicle chassis manual. PROBLEM POSSIBLE CAUSE SOLUTION Fuel deterioration, water in fuel or Drain fuel and replace with fresh fuel.
  • Page 160 Battery voltage is low or the Charge the battery or secure the terminals are loose. terminals. Fuse blown. Replace the blown fuse. Engine will not turn over. Ignition is in the “OFF” position Turn the ignition to the “ON” position. Engine stop and start switches Check.
  • Page 161 Throttle body air boots are loose Tighten. or damaged. Faulty or incorrectly gapped Replace. spark plug. Faulty ignition coil. Replace. Fuel filter clogged. Clean or replace. Deteriorated or contaminated Replace. Engine lacks power. fuel. Faulty fuel pump. Repair or replace. Fuel pressure is low.

  • Page 162: 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...

  • Page 163: 2002 Model Specifications

    2002 MODEL SPECIFICATIONS NOTE : Specifications subject to change without notice ENGINE CANNIBAL SPEED BLAZE MOTO 440 Engine 4 - stroke single Bore and stroke 95 mm x 61 mm Compression ratio 12.5: 1 Displacement 432 cc Engine Management System MC500,MC 1000 MC1000 Coolant system...
  • Page 164 ENGINE CANNIBAL SPEED BLAZE MOTO 440 1st gear ratio 2,000 (30/15) 2nd gear ratio 1.588 (27/17) 3rd gear ratio 1.316 (25/19) 4th gear ratio 1.095 (23/21) 5th gear ratio 0.833 (20/24) Countershaft sprocket Rear sprocket Clutch type Wet, multi-disc Clutch plates 10 metal, 9- friction Engine idle speed 2100 - 2200 r/min...
  • Page 165 ENGINE CANNIBAL SPEED BLAZE MOTO 440 -20 -15 -10 -5 TEMP (C°) 20W 50 Engine oil 15W 50 Recommended viscosity: 10W40 10W 40, 10W 50 Synthetic or semi-synthetic 10W 30 Classification: only high- 0W 40 detergent, premium quality motor oils with the American Petroleum Institute TEMP (API) service classification SF or SG...

  • Page 166: Chassis

    ENGINE CANNIBAL SPEED BLAZE MOTO 440 Engine oil quantity (dry fill) 1600cc (1.7 US qt.) Transmission oil 80W or 85W (Do not use hypoid gear oils) Transmission oil quantity (dry fill) 600cc (0.85 US qt.) CHASSIS Cannibal Speed Blaze Moto440 Frame Aluminum twin spar perimeter Overall length...
  • Page 167 CHASSIS Cannibal Speed Blaze Moto440 Turning radius 8 ft (2.4 m) 8.7 ft (2.65 m) Fuse Loading limit 245 lbs (111kg) Headlight 12V (2 x 37w) Taillight 12V (168 -automotive type bulb) YUASA, , Battery YUASA, YTX9-VS YTX5L-BS Ground clearance, unloaded 4.5 in (114) 3.5 in (89mm) Water crossing maximum depth...

  • Page 168: Suspension

    CHASSIS Cannibal Speed Blaze Moto440 0.08 - 0.16 in (2 - Clutch lever freeplay (manual) 4 mm) Clutch arm position (manual) 37.5 mm Clutch oil (hydraulic) SAE 10 mineral hydraulic oil Drive chain type DID 520V (O-ring type) Drive chain slack 1.37 - 1.60 in (35 - 40mm) Swingarm buffer thickness (STD / MIN) 0.275 in (7 mm) / 0.118 in (3 mm)
  • Page 169 SUSPENSION See “Addenda” starting on page170. CANNIBAL SPEED BLAZE MOTO 440 REAR SHOCK Type Compression adjuster (MIN/STD/MAX) 0/18/40 Rebound adjuster 0/15/32...

  • Page 170: Atv Limited Warranty

    Owner's Manual. to the following exclusions, obligations, and limitations. • Keep records and receipts of the date of purchase of the Cannondale ATV and all WARRANTY PERIOD scheduled maintenance performed at the intervals specified in the Owner's Man- The warranty period for Cannondale ATV’s begins on the date of purchase and ends six...

  • Page 171: Stolen Units

    Identification Numbers (VIN) reported stolen on our compiled from the completed vehicle registration forms website (www.cannondale.com). We’ll also provide the list filled out at the time of sale. The information is used to to our dealers. Any warranty claims registered against the...

  • Page 172: Addenda

    ADDENDA This section is reserved for updates, supplements, and revisions.
  • Page 178 When reading this manual, remember: Indicates a potential hazard WARNING that COULD result in serious injury or death.

This manual is also suitable for:

2002 cannibal2002 speed2002 blaze2002 moto440

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