Cannondale S440 User Manual

2003 Motorcycle Owner’s ManualModels : E440, C440, X440, S440P/N : 951-5002274-03Before you operate the vehicle. . . . • READ and UNDERSTAND this Owne

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101 Printed : 8/15/02101ADDENDAThis section is reserved for updates, supplements,and revisions. Pages are left blank intentionally.

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103 Printed : 8/15/02103

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11IMPORTANT MANUAL INFORMATION- - - - - - - - - - - 2FOREWORD - - - - - - - - - - - - - - - - - - - - - - - - 4Genera

11 Printed : 8/15/0211Label 4 Label 5

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13 Printed : 8/15/0213PARTS AND CONTROLSThis section contains information about the controlsand component features of your vehicle. NOTE :This sectio

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15 Printed : 8/15/0215If either headlight or taillight does not light, check tosee if a fuse or bulb replacement is needed. .NOTE :Switch the lights

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17 Printed : 8/15/0217To accelerate the engine, rotate the grip towards you. To decelerate the engine, turn the grip away fromyou. When released the

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19 Printed : 8/15/0219Adjusting the front brake lever positionTo adjust the front brake lever position on the han-dlebar, loosen the clamp bolts and

© 2002 Cannondale Corporation - All Rights Reserved2003 Motorcycle OM Cover.fmIMPORTANT MANUAL INFORMATIONFAILURE TO FOLLOW THE WARNINGS CONTAINED IN

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21 Printed : 8/15/0221SIDE STAND (OR) KICKSTANDThe side stand or kickstand (on equipped vehicles)can be used to support the vehicle on firm levelgro

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23 Printed : 8/15/0223HANDGUARDSThe handguards are located on the right and leftsides of the handlebar directly in front of the handlegrips. These gu

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25 Printed : 8/15/0225system before riding. Test with the engine off byrolling the vehicle forward and back while applythe brakes. Then, also test th

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27 Printed : 8/15/0227removed.3. The coolant level should be at the bottom of thefiller neck.4. Reinstall the radiator cap.5. Check the entire coolin

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29 Printed : 8/15/0229is visible through the window.CAUTION:Use a clean funnel.Changing engine oil and cleaning the filtersNOTE :Your vehicle has t

3 Printed : 8/15/023CONTENTSIMPORTANT MANUAL INFORMATION- - - - - - - - - - - 2FOREWORD - - - - - - - - - - - - - - - - -

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31 Printed : 8/15/023110. Remove the filter from the housing and discard it.11. Clean the filter housing and cover with a cleanshop towel to remove a

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33 Printed : 8/15/0233upper edge. Bleeding air from the hydraulic clutch1. To bleed, level the handlebars and remove themaster cylinder cover and sla

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35 Printed : 8/15/0235FUEL CAUTION:If engine “knocking” or pinging occurs, use adifferent brand of gasoline or one with a higheroctane rating. Neve

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37 Printed : 8/15/0237the filter hose clamps allowing fuel in the hose tobe absorbed by the towel.5. Remove the old filter.6. Reinstall a new, replac

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39 Printed : 8/15/0239Be sure to remove it from within the drain hole. 4. Clean the filter and inspect for damage (cracksholes, splitting, tears)

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41 Printed : 8/15/0241Pre-Ride Inspection ChecklistITEM CHECKApparelCondition of (helmet, eye protection, boots, gloves, long-sleeved shirt and longp

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43 Printed : 8/15/0243re-charge the battery before shutting the vehicle off.It not, remove the battery and place it on a batterycharger.SHIFTING GEAR

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45 Printed : 8/15/0245BREAK-INThe break-in period is critical to the long term life andreliability of the engine. CAUTION:Avoid high engine rpm and

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47 Printed : 8/15/0247MAINTENANCE SCHEDULEThe following maintenance schedule is intended as a general guide only. Where and how you ride will affect

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49 Printed : 8/15/0249SEATSeat removal1. Position the vehicle upright on a work stand sothere is no danger of it falling over while youwork.2. Press

5 Printed : 8/15/025GENERAL SAFETY PRECAUTIONS DANGERPOTENTIAL HAZARDRunning the engine indoorsBreathing exhaust gasesWHAT CAN HAPPENRunning the engi

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51 Printed : 8/15/0251AIR FILTERCleaning the air filter and re-oiling the air filterCAUTION:Clean the area surrounding the air filter beforeremovin

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53 Printed : 8/15/0253BRAKESTesting the brakesFor safe vehicle operation, it is critical to have thebrake system performing at its best. Regularinspe

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55 Printed : 8/15/0255solution. Do not forcefully scrub the chain. Wipethe chain dry with a clean shop towel. CAUTION:Never use steam, a high pres

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57 Printed : 8/15/02573. Increase or decrease slack by turning theadjusted equally on both sides of the swingarm.CAUTION:The alignment marks on the

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59 Printed : 8/15/0259Inspecting the swingarm chain bufferMeasure the buffer thickness (a) at many points ofthe upper and lower sides of the buffer.

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61 Printed : 8/15/0261ENGINE MANAGEMENT SYSTEMEngine operation is supported by an EngineManagement System (EMS) which controls bothignition and fuel

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63 Printed : 8/15/0263replacement fuse. BatteryYour vehicle has a sealed type battery. Perform onlyroutine charging maintenance when it becomes dis-c

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65 Printed : 8/15/02657. Lift out the coil.8. Use a 5/8” spark plug socket and an extension toloosen and remove the spark plug. In the photobelow, we

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67 Printed : 8/15/0267NOTE :Note the fit and form of the housing as you removeit. Later, install the housing as removed or a gapbetween it and the he

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69 Printed : 8/15/0269The spark arrestor should be removed after every 50 hours of operation to be cleaned and inspected for damage.Replace the scree

7 Printed : 8/15/027EXPERIENCED RIDERS ONLYThis vehicle is not for beginners. All Cannondale motorsports products are designedfor use by trained and

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71 Printed : 8/15/0271(below bottom) radiator shrouds.7. Press in the tabs on the fuel tank fittings, andremove the inlet and outlet hoses from the t

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73 Printed : 8/15/0273ting tabs in first. Then inspect the O-rings for anydamage (e.g., swelling, distortion, tears, rips,etc.) and replace if necess

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75 Printed : 8/15/0275Steering headbearing inspection1. Place the vehicle on a stand so that the frontwheel is off the ground.2. Hold the bottom of t

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77 Printed : 8/15/0277Front suspension (6)(2)(5)(7)(1)(3)(4)1. Fork2. Protector3. Rebound damping adjuster4. Air bleed screw5. Wear ring6. Seal (wipe

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79 Printed : 8/15/0279CAUTION:Observe the torque specification found in theTorque Table in this manual. The forks can beseverely damaged if you ove

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81 Printed : 8/15/0281Fork Rebound damping adjustmentCAUTION:Adjust both forks to the same setting.Rebound damping affects how quickly the fork“reb

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83 Printed : 8/15/0283Rear suspension NOTE :Component shown removed for clarity(1)(2)(3)(4)(8)(7)(6)(5)(10)(9)1. Body2. Reservoir3. Nitrogen gas haza

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85 Printed : 8/15/0285Adjusting the rear spring preloadThe following rear shock spring servicespecifications can be found in the ModelSpecifications

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87 Printed : 8/15/0287TIRESThe following tire service specifications for yourvehicle can be found in the Model Specificationssection in this manual:

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89 Printed : 8/15/0289loosen the right pinch bolts. 4. Hold the top of the front wheel firmly to supportits weight. Pull out the axle from the right

9 Printed : 8/15/029Inspect the frame (1), lower frame rails (2) and sub-frame (3) for cracks, deep scratches, or otherdamage. If any damage is found

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91 Printed : 8/15/0291condition.Make sure both adjuster blocks are in the sameposition on each side of the swingarm.1. Place motorcycle on a workstan

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93 Printed : 8/15/0293CLEANINGRegular cleaning helps to maintain theappearance and contributes to the overallperformance of the vehicle by keeping it

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95 Printed : 8/15/0295Removing from storage1. Uncover the vehicle. Clean and dry it.2. Install the fully-charged battery.3. Remove the rag and plasti

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97 Printed : 8/15/0297MAINTENANCE RECORDIt is important to keep accurate records of maintenance service. This data is vital for referencing previous

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99 Printed : 8/15/0299SERVICE Model X440 C440 E440 S440Engine oilRecommended viscosity: 10W40Classification: Use only high-detergent, premium quality