ATV SPORT REALITY STOP! - If you have the impression that four wheels give you the stability of a car, you are wrong. If you have the impression that an A TV is simple to drive and similar to those other vehicles, you are wrong. The risks involved are at least equal to those faced when riding a motorcycle.
FOREWORD Experienced Riders Only All Cannondale motorsports products are high performance, sport and/or competition machines and should only be operated by licensed competition riders in excellent physical condition. Operators should be welltrained and experienced in the operation of high performance competition vehicles. • This vehicle is not for beginners or the inexperienced.
Noise Regulation Limitations TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED U.S.
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. DANGER Indicates that severe personal injury or death WILL result if instructions are not followed.
SPECIAL SAFETY MESSAGES • AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE • An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. • Never carry a passenger on a ATV. • Never operate an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.
changing terrain conditions when operating the ATV. • Never 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. • Always follow proper procedures for turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. • Never operate the ATV on hills too steep for the ATV or for your abilities.
an be very cautious in order to reduce the chance of skidding out of control. • 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. Test you brakes after leaving water. if necessary, apply them several times to let friction dry out the linings. • Always use the size and type of tires specified in this manual. Always maintain proper tire pressure as described in this manual.
When reading this manual, remember: WARNING Indicates a potential hazard that COULD result in serious injury or death.
Keep Your Hands and Feet on the Controls Watch Out for Terrain Changes - - - - - - Rough or Slippery Terrain - - - - - - - - Stay Off Steep Hills- - - - - - - - - - - - Climbing Hills Improperly - - - - - - - - - Riding downhill - - - - - - - - - - - - - - Crossing Slopes or Hills - - - - - - - - - Turning on Slopes or Hills - - - - - - - - Obstacles - - - - - - - - - - - - - - - - Skidding or Sliding - - - - - - - - - - - - Safety Flag- - - - - - - - - - - - - - - - Riding Through Shallow Water - - - - - -
WARNING LABELS Examples of all vehicle warning labels are found in this section. Read and understand the actual ones on your vehicle. The labels contain information which is important to your safety and that of anyone else who operates the ATV. • • The warning labels should be considered permanent parts of vehicle. Yes, just like the wheels and engine, they are needed parts for any operator. If any label is missing, worn, damaged, or becomes unreadable, be sure to replace it.
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.
315-6000238-01 Label 4 P/N 315-6000238-01 315-6000580-01 315-6000477-01 Label 5 12 P/N 315-6000477-01 Label 6 P/N 315-6000580-01
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.
MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER (VIN) NOTE : Your vehicle may differ from those shown in the illustrations in this manual. The vehicle identification number (VIN) is etched/ stamped into the frame behind the front brush guard. The VIN also appears on a temporary factory applied adhesive label in the same area. Record your vehicle’s identification numbers in the spaces provided.
ENGINE SERIAL NUMBER KEY ID NUMBER The engine serial number is etched/stamped into the rear area of the engine crankcase. The number also appears on a metallic plate affixed to the crankcase area above the countershaft sprocket. The number also appears on a temporary factory applied adhesive label in the same area. Key identification numbers are etched/stamped into key bodies. NOTE : Keep your spare key in a safe place in case you lose the primary key. (2) (1) (3) 1 XXXXXX (4) 1. 2. 3. 4.
PARTS AND CONTROL FUNCTIONS NOTE : Your vehicle may differ slightly from those shown in the illustrations in this manual. (5) (2) (6) 8 9 1. Clutch lever 2. Engine RUN/OFF switch 3. Engine start switch (green) 16 4. Ignition switch 5. Front brake master cylinder 6. Parking brake lock 7. Front brake lever 8. Throttle 9.
(11) (17) (12) (10) (15) (14) 4) (4) (3) 1. 2. 3. 4. 5. 6. 7. ( ) (21) (8) Rectifier/regulator Engine Control Unit (ECU) Diagnostic connector & fuse Fuel pump Starter Engine oil filter (1 of 2) Shift lever (3) 8. Transmission oil level check 9. Left frame spar drain bolt 10. Air filter 11. Fuel cap 12. Owner’s Manual 13. Muffler 14. Taillight 15. Safety flag mount (18) 16. Fuel filter 17. Engine oil, coolant levels check 18. Radiator 19. Battery 20. Coolant bleed bolt 21.
OWNER’S MANUAL SEAT The Owner’s Manual for your vehicle is located under the seat. It contains important safety and maintenance information. Keep it on the vehicle when you ride. To find the manual, remove the seat. The seat on your vehicle is for you only. Carrying a passenger can cause you to lose control of the vehicle. The entire length of the seat is required so that you can shift body weight/position while riding to maintain vehicle control and stability.
2. Use your fingertips to lift up the rear of the seat slightly. Then, pull the seat back toward the rear of the vehicle and lift it off. 4. Press down gently on the middle of the seat and slide the seat forward onto the clip and subframe guides. If correctly aligned, the rear seat pegs will slip easily through the subframe seat buffers. (3) (1) (5) (4) 3. To install the seat, align the receivers in the seat pan with the fuel tank clip and the subframe guides. 1. 2. 3. 4. 5.
WARNING POTENTIAL HAZARD Loose, damaged, or improperly installed seat WHAT CAN HAPPEN The seat can shift or come off while you are riding causing you to lose control of the vehicle. You can be severely injured or killed. HOW TO AVOID THE HAZARD Always make sure the seat is locked into position on the mounts and secured properly with the retention bolt. Never ride this ATV with a damaged seat. Have it replaced.
IGNITION SWITCH The ignition switch is located between the handlebars. Always remove the key from the switch to help prevent unauthorized vehicle use or theft. See the table for a description of the switch positions. (2) Key Position “OFF” (1) “ON” 1. Ignition switch (key shown inserted) 2. Switch positions Function The engine and lighting cannot be operated.
TETHER SWITCH On equipped models, the tether switch is an additional safety device. Test for proper operation of the switch before riding. The switch must be in the operating position to start the vehicle. To test the switch, make sure the switch pin is inserted correctly. Start the engine. With the engine running, pull the strap quickly from the switch body the engine should shut down immediately. If it does not, do not ride the ATV; the switch is damaged and must be replaced.
ENGINE STOP/START BUTTONS (MC500) 1 2 NOTE : The stop button is a “normally closed” circuit switch. If the switch is damaged or the wires are frayed or torn, (i.e. circuit open) the engine will not start. Engine start button The engine start button is green in color and is mounted closer to the center of the handlebars. Pressing it activates the engine management system circuits and the starter motor. Make sure it operates properly before each ride. 1. Engine stop button 2.
ENGINE STOP SWITCH/ START BUTTON (MC1000) 1 1 2 2 a Engine stop switch The engine stop switch is located on the left handlebar close to the inside edge of the handle grip and is the sliding type with two positions. Sliding the switch to the “OFF” position will deactivate the Engine Management System and is the recommended method to stop the engine while it is running as opposed to using the ignition switch.
HEADLIGHTS TAILLIGHT Turn the ignition switch to the “ON w/LIGHTS” position to activate the headlights. Test for the proper operation of the headlights before operating the vehicle. Turn the ignition switch to the “ON with LIGHTS” position to activate the taillight. The taillight IS NOT a brake light. Make sure it works before every ride. 1 1 1. Taillight 1.
FRONT BRAKE LEVER PARKING BRAKE The front brake lever is located on the right side of the handlebar. Pull it toward the handlebar to apply the front brakes. Pull the lever harder to increase braking force. Before each ride, make sure the front brakes are operating properly and can provide braking force when needed. Roll the vehicle forward and back applying the brake to confirm that braking force is applied to the front brake discs.
WARNING POTENTIAL HAZARD(S) (1) ATV rolling away (2) Riding with the parking brake applied your index finger until it is fully depressed - release the lever and remove your index finger from the button. 2. To disengage the parking brake, press down on the rear brake pedal with your foot. Then, pull the front brake lever against the handle grip; the locking mechanism will automatically disengage (pop up). 3. Release the front brake lever slowly.
REAR BRAKE PEDAL FOOTPEGS & BASKETS The rear brake pedal is located on the right side of the vehicle. When pressed, braking force is applied to the rear wheels. Make sure the rear brake is operating properly before you ride. Roll the vehicle forward and back and press the pedal to confirm that braking force is applied to the rear brake disc. When riding always keep your feet on the footpegs. Always check the condition of the footpegs and baskets before every ride.
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. Pay particular attention to strapping in the areas where it attaches to the bars. See example at dotted circle in photo below.
SHIFT LEVER FUEL TANK CAP The shift lever is located on the left side of the engine in front of the left footpeg. The vehicle has five forward gears (1-down,”NEUTRAL’” 4-up). Place the vehicle on a level surface. Before every ride, make sure the shift lever operates properly and shifts through the entire range of gears with the engine turned off; roll the vehicle forward and back as you shift through all the gears to avoid damaging the transmission.
HANDLE GRIPS Inspect both (left and right) handlebar grips before every ride. 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 1.
THROTTLE LEVER The throttle lever is located on the right side of the handlebar. When pushed, the engine speed will increase. When released, engine speed will decrease - the lever spring pressure should return the lever to the set idle (engine) speed. Check for proper operation and specified freeplay of the throttle before every ride. See “2002 Model Specifications” starting on page 161. Lever movement should work smoothly without binding or pinching in all lever and handlebar positions.
CLUTCH LEVER (MANUAL) CLUTCH LEVER (HYDRAULIC) The clutch lever is located on the left side of the handlebar. Pull in the clutch lever (quickly) to disengage the clutch, and release the lever (slowly) to engage the clutch. Check the condition and proper operation of the clutch lever and cable before every ride. Also make sure the clutch lever freeplay is adjusted to specification. See “Clutch lever (manual)” starting on page 33. The hydraulic clutch lever is located on the left side of the handlebar.
FUSE & DIAGNOSTICS CONNECTOR The main electrical fuse is located in the area under the left front fender. Always replace the fuse with one of the specified rating. See “Fuse” starting on page 130. A special diagnostic tool connector is also located in the same area. The connector type is different for MC500 and MC1000 equipped models. See the photos. The diagnostic tools can be used to diagnose faults with the engine management system as well as other functions. 2 1 2 1 1. Fuse (in holder) 2.
SAFETY FLAG MOUNT The safety flag mounting bracket is integrated into the left side of the rear grab rail. When riding in areas where you might not be easily seen (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 1.
SAFE OPERATION EXPERIENCED RIDERS ONLY! WARNING POTENTIAL HAZARD Crashing the ATV WHAT CAN HAPPEN When reading this manual, remember: WARNING Indicates a potential hazard that COULD result in serious injury or death. Cannondale ATVs are high-performance sport category machines designed for competition use only by operators who already have substantial skill and operating experience.
TRAINING AND INSTRUCTION The following warning message is required to be part of this Owner’s Manual as part of an agreement between the ATV Industry and the U.S. Consumer Product Safety Commission (CPSC). The warning was written to communicate the need for beginning and inexperienced riders to get training and instruction before operating any ATV. Although the message that training and instruction is required for any beginning rider is correct, these riders SHOULD NOT operate Cannondale ATVs.
AGE RECOMMENDATION WARNING POTENTIAL HAZARD Failure to follow the age recommendation for this ATV. WHAT CAN HAPPEN Use by children of ATV’s that are not recommended for their age can lead to severe injury or death of the child. 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.
WEAR PROTECTIVE GEAR The proper riding apparel (gear) can help reduce the chance of injury in the event of an accident and make riding more comfortable. WARNING Helmet Goggles 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 increases your chances of severe head injury or death in the event of an accident.
RIDE SENSIBLY Riding too fast increases your chances of an accident occurring which could result in a serious injury or death, no matter what your experience level. Do not ride faster than what is appropriate for your skill level and surrounding conditions. 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.
NO PASSENGERS: NO EXCEPTIONS! Don’t carry a passenger on any ATV. Passengers will interfere with your ability to control the vehicle. A special NO PASSENGERS warning label is affixed on the seat to always remind you and those who ask for a ride. If someone asks for a ride, refuse and ask them to read the warning label on the rear of the seat. Then, explain that your ATV has no seating space, footpegs, or grab rails for his/her use.
CARGO, LOADING LIMIT Do not carry cargo on your ATV. Do not modify your ATV to carry cargo. Do not exceed the vehicle’s specified loading limit. Loading limit is defined as: the weight of the operator (wearing all protective gear/apparel) - nothing else! Consult the Model Specifications section of this Owner’s Manual for your vehicle’s loading limit. “2002 Model Specifications” on page 161.
OFF-ROAD USE ONLY Stay off the public streets, highways, or any other paved surfaces. First, you risk a collision with other vehicles. Aside from severely injuring or killing yourself, you’ll probably injure or kill a motorist. Second, no matter what speed you might choose to attempt it, you can’t operate an ATV safely on a public road or highway. The hard surface makes the handling and stability of all ATVs wildly unpredictable. You can lose control suddenly and without warning.
STAY OFF PUBLIC ROADS AND HIGHWAYS WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN 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.
TURNING THE ATV Practice making turns in a large open area at slow speeds to build experience before attempting more difficult turns at increased speed. To turn, slide forward on the seat and turn the handlebars in the direction of the turn. Lean your body to the inside of the turn while maintaining the throttle position. When the turn is complete, straighten the handlebars and return to a normal riding position.
DON’T DRINK AND DRIVE! ATV’s are no different than cars when it comes to drinking and driving. Do it and people wind up dying or hurting themselves and others severely. Alcohol impairs your judgement and slows your reactions - 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.
NO WHEELIES, STUNTS, OR JUMPS We urge you NOT TO DO STUNTS, ride sensibly. and develop a healthy respect for the vehicle. All Cannondale ATV’s are high-performance vehicles. If the throttle is opened abruptly and/or the clutch lever is released too quickly the front wheels will come off the ground. This may result in the vehicle overturning. 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.
KEEP YOUR HANDS AND FEET ON THE CONTROLS Riding ATV’s safely means being in complete control of the vehicle at all times. Always keep your hands on the handle grips and your feet on the footpegs. By removing your hands and feet from the handle grips and footpegs you risk serious injury and losing control of this ATV.
WATCH OUT FOR TERRAIN CHANGES Watch out for terrain changes or hidden hazards that can cause you to lose control of the vehicle or collide with unseen obstacles (e.g., gopher holes, logs, gullies, or ditches). Always use caution in an unfamiliar area. For example, never ride through an area where the view of the ground surface is not clear (e.g., high-standing grass, fallen branches, holes, large obstacles or other hazards); you could collide with a hidden hazard and be seriously injured or even killed.
ROUGH OR SLIPPERY TERRAIN Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn.
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. WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills.
CLIMBING HILLS IMPROPERLY Climbing hills is an advanced technique. Before attempting to climb difficult hills, begin by practicing on flat ground and then smaller hills to build experience. Never attempt a hill or slope beyond your skill level and evaluate all hills and slopes carefully to avoid terrain that might cause the ATV to overturn. Only attempt difficult hills and inclines after you have developed considerable skill and experience through study and practice.
RIDING DOWNHILL When riding downhill, shift your weight back as far as possible with your arms straight. Choose a low gear to allow the engine to do most of the braking for you. Improper braking with either the front or rear brakes could lead to a loss of traction and vehicle control resulting in an accident. Always travel straight down a hill when possible. Avoid sharp turns which could cause the ATV to tip or roll over. Always choose a path down hill that is free of obstacles.
CROSSING SLOPES OR HILLS WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD 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. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.
TURNING ON SLOPES OR HILLS Turning on slopes or hills is an advanced skill so before attempting a turn on a slope or hill, practice turning on level ground. Avoid slopes with unstable or slippery surfaces that will cause the tires to lose traction. When turning on a slope or hill you may need to shift a greater amount of your weight and lean more to successfully make the turn. Practice turning on smaller slopes or hills first and never attempt a turn on steep, slippery, or rough slopes or hills.
OBSTACLES Never attempt to ride or jump over obstacles such as large rocks or fallen trees. WARNING POTENTIAL HAZARD 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. When you go over obstacles, always follow proper procedures as described in this Owner’s Manual.
SKIDDING OR SLIDING Slow down and use caution when riding over loose, slippery, or unstable surfaces such as snow, ice, or mud. 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. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
SAFETY FLAG In hilly terrain, use a safety flag so that others can see you. Use extra care when approaching the tops of hills or blind areas such as around bends or turns. Some states and state-run areas require a safety flag. Make sure your flag meets state and local requirements. WARNING POTENTIAL HAZARD Operating in areas where you might not be easily seen by other ATV’s or off-road vehicles. WHAT CAN HAPPEN You could collide with another vehicle.
RIDING THROUGH SHALLOW WATER The ATV can be used to cross through slow moving shallow water - up to a maximum depth specified for each ATV model. See “2002 Model Specifications” starting on page 161. Never attempt to ride any ATV in deep or fast moving water, such as rivers or streams. The tires will float causing the vehicle to become unstable. You could quickly lose control and become caught in water currents. Never enter water without first checking out the area.
STALLING, ROLLING BACKWARDS WARNING POTENTIAL HAZARD Stalling, rolling backwards dismounting while climbing a hill. or improperly WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock parking brake, after you are stopped. If you begin rolling backwards: Keep weight uphill. Never apply the rear brake abruptly while rolling backward.
4. If you lose control of the ATV, don’t attempt to regain control , for your safety, get away from the vehicle and alert others. If you can’t back the ATV downhill If you stall and the hill is too slippery or you doubt whether you can back the ATV down the hill safely as described above, leave the ATV where it is and go to get help. Apply the parking brake and block the wheels so that the ATV won’t begin to roll backwards on its own.
PRE-RIDE INSPECTION WARNING POTENTIAL HAZARD Failure to inspect vehicle before operating. WHAT CAN HAPPEN Increases the possibility of equipment failure resulting in an accident. HOW TO AVOID THE HAZARD Always inspect this ATV before you operate it. Always follow the inspection and maintenance procedures found in this Owner’s Manual. Have your vehicle serviced by an authorized Cannondale motorsports dealer every 25 hours of operation.
PRE-RIDE CHECKLIST ITEM CHECK PAGE Apparel Condition of (helmet, eye protection, boots, gloves, longsleeved shirt and, long trousers). Start on page39. Brakes Proper operation, fluid levels, front lever freeplay, leaks. Fill with DOT4 brake fluid if necessary. Check the rear brake disc carrier for tightness. Start on page100. Clutch (if applicable) Proper operation, condition, and lever freeplay, actuating arm position Start on page109. Coolant Drive Coolant level.
OPERATION extra fuel needed. If you crank more than 2-3 seconds you’re wasting battery power because the fuel spray has become too small to start the cold engine. WARNING POTENTIAL HAZARD 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 the clutch, the starter working efficiency is reduced; It doesn’t turn the crankshaft as fast and can result in overheating and damage.
MC500 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 and wait 3 seconds as the fuel pump pressurizes the fuel injectors. 3. Shift transmission into NEUTRAL and pull-in and hold in the clutch lever. 4. Carefully take up the throttle lever freeplay, then take up 1mm more. 5. Press and hold the engine start button for no more than 2 to 3 seconds at a time.
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: WARNING 66 Indicates a potential hazard that COULD result in serious injury or death.
BREAK-IN The break-in period is critical to the long term life and reliability of the engine. The break-in period for the engine is 1 hour. When operating during this period be sure to observe the following cautions: • Ride at low to medium engine speeds. • Do not lug or rev the engine during the break-in period. • Avoid full-throttle starts and rapid acceleration. • Do not hold the throttle grip in one position for more than a few seconds.
MAINTENANCE & ADJUSTMENT When reading this manual, remember: WARNING Indicates a potential hazard that COULD result in serious injury or death. Torque specs Many maintenance procedures found in this section require the use of a “torque wrench,” - a special tool enabling a precise tightness to be applied to a fastener. If you do not have a torque wrench or are not familiar with using one; contact your authorized Cannondale dealer for assistance.
Carbon Monoxide Hot Components DANGER WARNING POTENTIAL HAZARD POTENTIAL HAZARD Running the engine indoors. Breathing exhaust gases Hot components (e.g., engine, radiator, hoses, bulbs, exhaust, brakes) WHAT CAN HAPPEN WHAT CAN HAPPEN Running the engine indoors will expose you to dangerous exhaust gases. Breathing carbon monoxide gas leads to poisoning, asphyxiation, and death. This will happen rapidly and without notice.
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 or explosion. Anytime you work on the vehicle there is a potential that an accident involving a foreign object, vehicle component part, fluid, tool, or other maintenance related item can result in severe injury to your eyes.
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 Moving parts can catch your clothing, fingers or hand resulting in severe injury. HOW TO AVOID THE HAZARD Never perform maintenance procedures with the engine running unless directed otherwise in a procedure. WHAT CAN HAPPEN The fluids in your vehicle are hazardous substances.
MAINTENANCE SCHEDULE Perform a Pre-Ride Inspection before every ride and at scheduled maintenance periods. C: Clean, R: Replace, L: Lubricate, I: Inspect, verify, clean, adjust, lubricate, replace if necessary Regular Maintenance Interval (in hours) NOTE(s) 1. 2. Service more if operating in dusty, sandy or snowy areas. Service more frequently if operating in wet or muddy conditions. Replace every 2 years 3.
C: Clean, R: Replace, L: Lubricate, I: Inspect, verify, clean, adjust, lubricate, replace if necessary Regular Maintenance Interval (in hours) NOTE(s) 1. 2. 3. Service more if operating in dusty, sandy or snowy areas. Service more frequently if operating in wet or muddy conditions.
C: Clean, R: Replace, L: Lubricate, I: Inspect, verify, clean, adjust, lubricate, replace if necessary Regular Maintenance Interval (in hours) NOTE(s) 1. 2. Service more if operating in dusty, sandy or snowy areas. Service more frequently if operating in wet or muddy conditions. Replace every 2 years 3.
PANELS Many of the maintenance procedures in this manual require that you remove and reinstall vehicle panels. Consult the following procedures: To install the covers, return the cover to its original position and tighten the bolts snug. Do not over-tighten. Radiator Guards Headlight covers To remove either headlight cover, loosen the bolts but do not try to remove them from the cover holes. When loose, simply lift off the cover. 2 1 2 1 3 2 1. Guard 2. Bolts 3. Clutch cable (manual) NOTE : 1.
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. Lift the outer fender edges of the cowl - spreading them out slightly - and move the cowl forward off the frame making sure that the fender support braces clear the frame and shock structure. 5. Remove the fuel cap and lift off the center piece. Return the fuel cap. 6.
Side Panels Rear Fender 1. To remove, first remove the seat. 2. Remove the panel bolts. 1. Remove the seat and side panels. 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 install the bolts. Rear fender bolts (3 of 4 visible in photo) 3. To install, place the panel in the original position and install the bolts.
Fuel tank removal/installation 3. Remove the bolts and subframe cross braces. 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 1 Inspect and lubricate with clean engine oil - each of the quick connect hose end O-rings before installing them into the tank fittings. Also, press in the tabs on the tank fittings before inserting the hose ends.
5. Press in the tank fitting tab and remove the quick connect from the tank. 3 6. Remove the quick connect at the rear of tank in the same manner. 1 2 1 2 1. Tab 2. Fuel tank return (from pressure regulator) quick connect 3. O-ring 1. Tab 2. Fuel tank outlet quick connect 7. To install the fuel tank, reverse the removal procedure.
FRAME, SUBFRAME, SWINGARM Regular Inspection The aluminum chassis components of your ATV have a finite, limited useful life. The length of that life varies depending on the material used in their manufacture, the amount of use they are subjected to and the care they receive while in service. Regular inspection by a Cannondale motorsports dealer is important. • Frame - a main support structure for the engine, various components, and rider. • Subframe - adds structural support.
(1) (2) (3) (4) (5) 1. Frame 2. Rear shock strut 3. Subframe 4. Swingarm 5. Engine rail/skid plate 6.
FUEL Adding fuel Always use clean high quality unleaded gasoline. See “2002 Model Specifications” starting on page 161.) 1. Make sure the vehicle is completely cold. 2. Remove the ignition switch key. 3. Remove the fuel cap and fill the fuel tank with the specified fuel to the correct level. 4. Reinstall fuel tank cap and tighten it securely. 5. Make sure the fuel cap hose is routed correctly. WARNING POTENTIAL HAZARD Overfilling the fuel tank WHAT CAN HAPPEN Fuel expands due to heat (e.g.
Idle speed adjustment Throttle lever adjustment The idle speed adjustment screw is located on the throttle body. It is accessible from the left side of the vehicle. A special diagnostic tool is necessary to 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). 2.
Fuel filter replacement See “2002 Model Specifications” starting on page 161. Replace the inline fuel filter every 5 hours. 3. Cradle the fuel filter with the hoses attached in a clean dry shop towel to help absorb any residual fuel that will drain as the filter is removed. Loosen the fuel hose clamps and remove the fuel filter. CAUTION Do not operate with the fuel filter removed. You can seriously damage the fuel injection system.
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 & Adjustment” starting on page68. Service more frequently under severe conditions. Checking engine oil CAUTION Run the engine for 1 minute before checking or you will take an inaccurate measurement.
Changing engine oil NOTE : Have a clean shop towel handy to clean up any spilled 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 specified torque. 1. Start the engine and allow to reach normal operating temperature 158°F (70°C). Then, turn the engine off. 2. Connect a clear plastic hose to the left spar drain bolt and loosen it. Allow the spar contents to drain completely into a suitable container.
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) (2) (1) (3) 1 1. Sealing washer 2. Fitting 3. Drain bolt 1.
5. Place a container under engine oil filter cover and remove the bolt, engine oil filter cover and the two cover O-rings. 8. Inspect the seals and filter element for tears, cracks, and other damage. Replace if damaged. (3) 1 (5) (2) (1) (6) 2 (5) (4) 1. Bolt 2. Cover 6. Remove the engine oil filter seal, oil filter and oil filter seal from the housing. Wipe the inside of the filter housing with a clean shop towel to remove any accumulated sediments or other debris. 7.
NOTE : Use some O-ring grease to “stick” the filter seals so that they are centered on the filter. This will help assure that the seals remain in place when you insert the filter into the housing. 11. Now, carefully work the heat shield back to expose the left spar return hose and clamp. Then, remove the clamp and hose from the engine oil inlet fitting. (4) 10. Install the cover and cover bolt. Tighten the bolt to the specified torque. (3) (2) CAUTION (1) Do not over-tighten the cover bolt.
12. Loosen and remove the inlet fitting. Then, remove the inlet filter (screen) from the hole. 17. Install the fitting. Tighten it to the specified torque. (3) (4) (5) (6) (2) (1) 1 1. Inlet filter (screen) 13. Clean the screen using compressed air. 14. Inspect the inlet fitting, 0-ring, and inlet screen for tears, cracks, and other damage. Replace any damaged part with a new one. 15. Reinstall the filter into the crankcase. Inspect the fitting O-ring and replace it with a new one if necessary. 16.
TRANSMISSION OIL The transmission oil in your ATV is just as critical to engine life and performance as the engine oil. Be sure to maintain the correct level of the specified transmission oil. See “2002 Model Specifications” starting on page 161. Change the oil in accordance with the maintenance schedule and more frequently under severe conditions. See “Maintenance & Adjustment” starting on page 68. 2. Remove transmission oil level check bolt and sealing washer.
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. (1) HIGH OK LOW 1. Transmission oil window NOTE : The transmission oil level within the crankcase should be visible in the window. Maintain the oil level between the “LOW” and “HIGH” as indicated in the illustration above.
Changing transmission oil CAUTION 1. Place vehicle on a level surface with a suitable container under the transmission drain bolt and remove 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. This helps assure that the other end of the filter will locate into the back of the transmission oil pump (rear of cartridge plate inside gearbox cavity).
3. If the filter did not come out with the bolt, remove it carefully from the hole. Clean it using compressed air. leak. Install the washer onto the bolt so that the flat side (a) faces the case. Insert the filter into the bolt, and install into the case. (1) (2) (1) (3) (a) 1. Filter 1. Drain bolt 2. Sealing washer 3. Filter (screen) a. Sealing washer flat side 4. Inspect the filter for cracks, holes, tears, and other damage. Replace new if damaged. 5.
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” mark on the bottle when the engine is cold. We recommend a 50/50 mixture of high-quality aluminum compatible anti-freeze/coolant and distilled water.
Checking the coolant level Adding coolant 1. Make sure the engine and radiator are completely cold. 2. Remove the right headlight cover and observe the coolant level in the bottle without opening the cap. The level should be at the ‘LEVEL’ mark. 1. To add coolant, make sure the engine is cold. 2. Place a thick rag over the coolant bottle cap and open it very slowly to allow any residual pressure to escape.
3. Place a clean bucket under the radiator drain bolt and remove it. Allow the radiator contents to drain completely. Then, inspect the drain bolt 0-ring - if damaged, replace. Apply some O-ring lubricant to the O-ring and install the drain bolt. 4. Remove the coolant outlet drain bolt and sealing washer and allow coolant to drain completely. Reinstall the sealing washer and bolt. Tighten snug. 1 3 (2) 1 2 1. Coolant outlet 2. Drain bolt 3. Sealing washer 1. Radiator drain bolt 2. O-ring 5.
Bleeding coolant NOTE : Check to see if your vehicle is equipped with the selfbleeding coolant pump cover and coolant bottle. If it is, bleeding coolant is not required. 4. Loosen the bleed bolt on the water pump cover and allow any trapped air to escape. It is not necessary to remove the bolt. (2) (1) 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.
When reading this manual, remember: WARNING Indicates a potential hazard that COULD result in serious injury or death.
BRAKES Brake fluid System test 1. Squeeze the front brake lever and test for proper braking. The lever should feel firm and proportional force should be applied to the discs preventing theATV from rolling. If the brake lever feels spongy or weak, or the vehicle is not prevented from rolling have the brakes inspected by a Cannondale motorsports dealer. 2. Check for fluid leaks. Inspect the entire length of the hoses paying close attention to the banjo bolts, calipers, and master cylinders. 3.
Front 1. To check the front system, place vehicle on a level surface and level the handlebars. 2. Inspect the fluid level through the inspection window in the master cylinder reservoir. The fluid should be above the ‘LOWER’ mark on reservoir body. Add fluid if necessary. FRONT (2) (1) LOWER 5. Add the recommended brake fluid from a sealed container until the fluid level is above the ‘LOWER’ mark on the reservoir body. 6. Reinstall the diaphragm, cover, and cover screws.
fluid level should be above the ‘LOWER’ mark. Add if necessary. Brake pads and discs, inspection 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. Inspect the brake pads wear limit indicators on each pad before every ride. When the friction material wears to these indicators, have the brake pads replaced. (1) (2) 1. UPPER mark 2. LOWER mark 2.
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. 2 1 2 a 1 a 1. Front brake pads (right) wear limit indicator 2. Banjo bolt a. Disc thickness 3 NOTE : Remove the front wheel to check the front pads. 2. Inspect the brake discs for bending, chips, cracks, deep wear grooves, or other damage.
1 3 2 1. Front disc mounting bolts (1 visible in photo) 2. Caliper mounting bolts 3.
Front brake line routing 1 WARNING POTENTIAL HAZARD 2 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. 1 2 FWD a HOW TO AVOID THE HAZARD The inner line clamp (1) must face back and the outer line clamp (2) must face forward. 1. Inner clamp 2.
Rear brake disc carrier preload nut inspection Inspect for play in the rear brake disc carrier before every ride to ensure proper brake function and to protect the rear axle assembly from damage. WARNING HOW TO AVOID THE HAZARD (1) Always allow the brake discs to cool completely before servicing. Wear a protective leather glove when checking the rear brake disc for play. (2) Never ride this ATV with a malfunctioning brake system. Contact an authorized Cannondale motorsports dealer for servicing.
wheel when attempting to detect play. You should detect no play in the disc. If you detect any play, you must tighten the rear brake disc carrier preload nut. 4. Remove the protective boot covering the rear brake disc carrier preload nut and slide it back. It helps to use a thin-blade screwdriver to carefully pry the boot edge away from the nut. Also, rotate the boot as you remove it. 1 2 This photo shows how to detect play in the rear brake disc. There should be no play found.
photo). Use only moderate force when tightening the preload nut. Using greater force on the preload nut (e.g., cheater bars, pipe wrenches, etc.) will not extend the maintenance interval for the brake disc carrier it will damage the nut and axle assembly. Rear pedal height adjustment The rear brake pedal can be adjusted for comfort as well as proper operation. 1. Loosen the locknut on the master cylinder pushrod. Turn the hex on top of the pushrod until the brake pedal is at the correct height.
3. When lowering the brake pedal, make sure the clearance (a) between the lower end of the pushrod and the brake pedal is within specification. When raising the brake pedal, ensure that at least two pushrod threads are visible inside the pedal joint. 1 1 Pushrod Brake pedal Pushrod thread Pedal joint a. Clearance NOTE : Adjust at the lever first. If the specified freeplay cannot be achieved, adjust at the inline adjuster. Inspect the clutch arm position anytime the lever freeplay is adjusted. 4 4 1.
2. To adjust, loosen the lockring and turn adjuster until the specified freeplay is reached. Tighten the locknut securely and reposition the boot when finished. If the specified freeplay can not be adjusted at the lever, adjust the inline cable adjuster. 3. To adjust the inline cable adjuster, loosen the locknut and turn the adjuster in direction (a) to decrease freeplay, direction (b) to increase available freeplay at the lever. Tighten the locknut securely after adjusting the clutch cable.
the adjusting screw counterclockwise to increase the distance between the clutch lever and handle grip. Checking the oil level of the hydraulic clutch CAUTION 1 Never substitute brake fluid for SAE 10 (mineral hydraulic oil. a 1. To check the level, remove the cover screws, cover and rubber boot. 1 2 b 3 1. Adjusting screw a. Increases distance b. Reduces distance 1. Screws 2. Cover 3.
Bleeding the hydraulic clutch 1. To bleed, remove the master cylinder cover and slave cylinder bleed bolt cap. 2. Attach a clean syringe filled with SAE 10 (mineral hydraulic oil) to the bleeder bolt at the slave cylinder. 3. Loosen the bolts and slowly compress the syringe until only oil, (no air bubbles) is discharged at the bore of the master cylinder. Make sure the oil does not overflow out of the master cylinder. 1 1 2 3 1. Bore CAUTION 1. Syringe 2. Tube 3.
Setting the clutch release collar with a hydraulic clutch system Complete the following procedure anytime the clutch plates or springs are replaced. 1. Remove the shift lever and clutch cover. 2. Loosen the clutch release collar lock nut. 3. Turn the adjuster locknut all the way in (clockwise). Then back the adjuster out (counterclockwise) three full turns. 4. Tighten the adjuster locknut to the specified torque. 5. Check the fluid level in the master cylinder.
1. Place the vehicle on a level surface. 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. Remove the shift lever pinch bolt and shift lever from the shift shaft. 5. Remove the clutch cover bolts and clutch cover. 1 1 1. Clutch cover bolts 1.
7. Have an assistant hold light pressure on the actuating arm toward the cylinder head on the actuating arm. 1 2 FWD 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. Now, you are ready to begin the adjustment. 8.
adjuster locknut. Turn the adjuster until the actuating arm is in the specified position. Tighten the adjuster locknut when completed. (1) DRIVE Drive chain lubrication The drive chain must be cleaned and lubricated before every ride. Significant forces act on the chain during operation. If its not clean and lubricated, it can quickly wear-out and possibly fail or contribute to un-safe operating conditions. (2) CAUTION (3) The O-rings of the drive chain can be damaged by steam or high pressure washers.
Swingarm buffer inspection NOTE : Make sure the chain has dried completely before applying the lubrication. CAUTION Wear may be distributed differently across the buffer length. Inspect the entire length carefully. b 1. Measure the buffer thickness on the upper and lower sides of the swingarm and at several points along its entire length. Out of specification → replace. 1 a 2 a 1. O-ring type chain 2. Conventional (non-O-ring chain) a. O-ring b. Chain plates 1.
Chain rollers inspection Rear brake disc & sprocket guards 1. Rotate the chain rollers. They should rotate smoothly. 2. Measure the outside diameter of the upper and lower rollers. Replace if out of specification. Make sure both guards are mounted securely. Inspect each guard for cracking and/or other signs of excessive damage or wear. On the sprocket guard, pay particular attention to the areas (dotted circles) indicated in the photo.
Chain guide block inspection Chain slack inspection Check the drive chain guide block for excessive wear, cracks, and/or any other damage. Make sure it is fastened securely to the swingarm. If the guide block is damaged or worn, replace it with a new one. NOTE : 2 1 Clean and lubricate the drive chain before measuring the slack. The chain’s condition affects the accuracy of measurement. Also, when measuring, rotate the chain and measure different links at the mid-point between the sprockets. 1.
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. (See hand figure in photo below) 1 1 W LO E B LE O PH EE 2 1. Locking bolts 2.
4. Insert a tool with a round shaft diameter (Philips screwdriver in photo) that closely approximates the hole in the eccentric. Then, slowly rotate the wheels in direction (a) to increase the drive chain slack or direction (b) to decrease drive chain slack. When the specified chain slack is reached, tighten the rear axle locking bolts. Drive chain stretch inspection 1.
Masterlink clip inspection Sprocket inspection The open end of the masterlink clip must face the opposite direction of the chain rotation. Visually inspect the condition of the rear countershaft sprocket(s) before every ride. If damage is found; contact an authorized Cannondale motorsports dealer. (b) 2 2 (a) (1) 1 1. Master link clip a. Open-end b. Direction of chain rotation 122 1. OK 2.
ELECTRICAL Engine Control Units - MC500 & M1000 Troubleshooting On all models, the vehicle ECU is located on the electronics tray under the cowl. Many electrical problems are caused by faulty electrical connectors or couplers. For example, wet terminals/pins, dirty or corroded terminals/pins, or broken or bent cable pins within multi-plug couplers. Engine Management System (EMS) All Cannondale ATV models use an advanced fuel injection system.
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. This information is then used to adjust the amount of injected fuel to match the prevailing conditions.
Throttle position sensor (TPS) 1 a 2 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 throttleplate opening angles are calculated using the fully-closed position as a base. Throttle-plate angle is used by the ECM to determine fueling requirements for all throttle positions.
application and data cable have been developed. Ask an authorized Cannondale Motorsports dealer for special tools developed to service your vehicle. correct position depending on the air and engine temperature. Be sure to follow the cold starting procedure described in this manual to ensure that you allow enough time (5 seconds) for this valve to actuate before turning over the engine. As the engine reaches operating temperature the valves will close. 1 Engine shown removed for clarity. 1 1.
Coolant temperature sensor Air temperature sensor The engine temperature sensor is brown, located on the front of the cylinder head. It is an NTC thermistor. The ECM receives electronic signals from this thermistor and uses them to determine the coolant temperature. This information is used by the ECM to optimize fueling at all engine temperatures and to calculate hot and cold start fueling requirements. The sensor resistance decreases as the temperature increases.
Fuel injectors (left and right) The fuel injectors are mounted in the cylinder head intake tract and are positioned as close as possible to the back of the intake valves. The spray pattern and flow rate of the injectors are fixed, but the length of time they remain open varies. The duration that the injectors stay open is calculated by the ECU using the calibration file and data received by the various sensors.
Fuel Pump Fuel Pressure Regulator The fuel pump is located on the left side of the vehicle (front). When the engine management system is first “powered-up” 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. The fuel pressure regulator is mounted on the right side of the vehicle (front).
Ignition coil The ignition coil is a “pencil-type” coil located on top of the spark plug within the cylinder head. The ECU controls when the coil is switched on or off. The coil is switched on to allow sufficient time for the coil to charge to a level where a spark can be produced at the spark plug. The coil switches off at ignition, which is timed for good engine performance.
2. Remove the fuse holder from the cap. 3. Remove the fuse and replace with the specified fuse. . (1) REPLACE (1) Fuse replace 0000 (2) 1. Link (3) 4. If the fuse immediately blows again, check the electrical circuits. 1. Cap 2. Fuse 3.
Lighting NOTE : Always wipe off a newly installed bulb with alcoholdampened clean cloth or tissue. Oils from your fingers can cause premature bulb failure. 5. Reconnect the harness. 6. Test for proper operation. Taillight bulb replacement Turn the bulb mount counterclockwise and remove it from the housing. 1. Pull the bulb out from mount and install a new bulb. Headlight bulb replacement 1. Remove the headlight cover (left or right). 2. Disconnect the headlight harness connector. 3.
Battery Spark plug All models use a sealed type battery therefore they do not require any maintenance other than routine charging such as during storage and cleaning. Always have the battery serviced by an authorized Cannondale motorsports dealer. CAUTION Never attempt to add water to a maintenance-free battery. Never allow a battery to stand in a discharged condition. WARNING POTENTIAL HAZARD Attempting to open the battery, remove the cap strip or add fluids to this maintenance free battery.
6. Remove the upper shock strut bolt. Loosen the lower frame spar bolt enough so that it can be tilted back. 7. Tilt the shock strut back and disconnect the coil from the wiring harness. 2 2 1 1 3 4 3 1. Spar 2. Upper bolt 3. Lower bolt 134 1. 2. 3. 4. Connector Coil holder Bolt Coil 8. Remove the spark plug coil holder bolt and clip. 9. Clean the area surrounding the coil to prevent dirt from entering the cylinder head when the coil and spark plug are removed.
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. 1 (a) (a) 111794 Z SA 1. Coil 11. Use a spark plug socket and long extension to loosen and remove the spark plug from the cylinder head. NOTE : Spark plugs are good indicators of the engine’s operating condition.
AIR Air filter element cleaning 1. Remove the cowl. 2. Release the filter retaining clip and remove it. 3. Remove the air filter from the air filter base plate. The air filter is located under the cowl. WARNING 3 POTENTIAL HAZARD Fire or explosion, filter damage WHAT CAN HAPPEN 2 Using gasoline or other low flash point solvents to clean the air filter can result in a fire or explosion. HOW TO AVOID THE HAZARD Use a non-flammable (high-flash point) solvent to clean the air filter elements.
4. Carefully separate the foam and cage. (2) (1) (3) 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. 7. Recombine the cage and foam element. Be sure to install the foam onto the cage so that the seam in the foam is aligned with the seam in the cage. 8.
the area indicated in the photo below. If the filter is install carelessly, the result may be creating a path for unfiltered air to bypass the filter. 10. Apply a small dab or waterproof grease to the end of the air filter and reinstall the retaining clip. 2 This photo shows the area where, if the airfilter is installed incorrectly, the foam element can drag away from the cage allowing unfiltered air to bypass the filter. 1. Clip 2. Area to apply waterproof grease 11. Reinstall the removed components.
EXHAUST Spark arrester cleaning The spark arrester must be purged of carbon build up at the intervals specified in the maintanace schedule of this Owner’s Manual. 1 3. Increase the engine speed with the throttle lever repeatedly while momentarily blocking the end of the muffler / spark arrester with a clean shop towel, then quickly remove it. This technique causes brief system back pressure and will force carbon build-up out the purge bolt hole.
SUSPENSION CAUTION The front and rear suspension systems are pre-set at the factory with settings developed for an average rider (weight & skill). Choosing individual settings will depend on your skill level, weight, and riding style (preferences). The adjustability of the suspension system varies with the type of shock installed.
fully seated). This is the hardest damping and should be your starting point. Turn the adjuster counterclockwise and listen for the clicks that identify setting positions “1”, “2”, etc. • Turning the adjusters counterclockwise (more clicks out) will give less damping force. • Normally, the adjusters should not be adjusted more than two clicks at a time and not outside the maximum click range.
Compression adjuster Rebound adjuster 1. To adjust, turn the adjuster clockwise and count the clicks until the adjuster is fully seated (closed). Be sure to write down the number of clicks. This will let you know what you are adjusting from. 2. Turn the adjuster counterclockwise the desired number of clicks. 1. To adjust, turn the adjuster clockwise and count the number clicks until the adjuster is fully seated. Be sure to write down the number of clicks. 2.
Adjusting the front shocks Front spring pre-load Type II Front spring pre-load Type I The spring adjusting sleeve has three positions so that the spring can be adjusted for different riding conditions. Adjust the spring preload using two spanner wrenches turning in opposite directions. The spring adjusting sleeve has five positions so that the spring can be adjusted for different riding conditions. To adjust the preload turn the adjusting sleeve with a spanner wrench.
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. 2 1 3 2 1. Cam 2. Adjusting sleeve 3. Spanner wrenches 1 NOTE : This photo shows how to hold the spanners when reducing the preload. Reverse the orientation shown when increasing the preload. 1. Adjuster 2.
Front compression adjuster Type III Front rebound adjuster Type III D b FW a a b a. More damping (stiffer) b. Less damping (softer) a. More damping (stiffer) b.
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. (2) Damaged rims will allow air pressure to escape resulting in improper tire pressure. NO In either case above, you could be seriously injured or killed in the resulting accident.
other damage in the steering assembly. Contact an authorized Cannondale motorsports dealer and have the conditions corrected. 4. Make sure the wheel axle nut cotter pins on each wheel are in good condition before every ride. Make sure the pin is not broken or damaged. It should have both tabs (or legs) and they should be bent properly. (2) (1) 1. Cotter pin 2.
Wheel removal / installation (1) 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. 2 (2) 1 (2) 1. Cotter pin 2. Tab 3 This is a photo of a front wheel. 1. Wheel lug nut (4) 2. Axle (hub) nut 3. Valve stem 3. Now, place a stable support under the vehicle frame and raise the wheel off the ground.
4. Remove the wheel from the wheel hub. 5. To install the wheels, first make sure the wheel hub stud threads in the wheel hub are clean. 6. Apply a light coat of anti-seize lubricant to the studs. 7. Install the wheel onto the hub so that the valve stem faces out. If the wheel installed includes a directional indicator, install the wheel as indicated. 8. Install the wheel (lug) nuts. Be sure the flat side of the nuts face the wheel rim. Tighten the nuts in a crisscross pattern.
. Tire inspection POTENTIAL HAZARD 1. Take two tire pressure measurements of each tire using the low pressure gauge while the tires are cool. Use the second reading. 2. Adjust pressure in each tire to meet tire pressure specifications for your vehicle. 3. Add air in small amounts and re-check often to help avoid overinflating. Unusual air loss might be attributed to damaged tires or rims.
4. Inspect the tire tread wear. Check the tread wear indicators and condition of the rims and tires of all four wheels. (1) (2) When reading this manual, remember: WARNING Indicates a potential hazard that COULD result in serious injury or death. 1. Tread 2. Wear limit 5. Check the physical condition of each tire. Make sure there is adequate tread. If the tire is ripped, torn, punctured, or damaged have it replaced with a new one.
CLEANING Regular cleaning helps to maintain appearance and contributes to overall performance of the ATV by keeping it free of damaging dirt, soils, and grime. • When cleaning, avoid harsh detergents and chemical solvents. • Use an ordinary garden hose and only enough water pressure to do the job. • Use mild solutions of ordinary dish soaps and clean water. • The advertising claims of “power” cleaning products are no substitute for careful and deliberate attention when cleaning the ATV. cleaning it.
STORAGE When the vehicle will not be operated for an extended 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. 1. Change the engine and transmission oils and clean the filters. 2. Perform all necessary repairs. 3. Either drain the fuel tank completely or fill it with fresh fuel. Add a good quality fuel stabilizer directly to the tank.
TRANSPORTING WARNING POTENTIAL HAZARD Towing WARNING POTENTIAL HAZARD ATV may roll off the truck or trailer WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Ordinary ropes can stretch and break. The parking brake on this vehicle is not designed to prevent a roll-away during transport. A properly applied parking brake can slowly release braking force resulting in this ATV becoming unstable during transport. Never tow anything with this ATV, or tow this ATV with any other vehicle.
(4) (3) (5) (2) 1. Brush guard 2. RIght footpeg (1) 3. Left footpeg 4. Grab rail 5.
TORQUE TABLE Item Item Torque lbf•ft N•m Sprocket/disc guard mounting bolts kgf•m Cowl support bracket bolts (cowl) 5.0 6.8 0.69 Cowl mounting bolts 5.0 6.8 0.69 Side panel mounting bolts 5.0 6.8 0.69 Rear fender mounting bolt 5.0 6.8 0.69 15.0 20.3 2.07 Engine oil bolt (crankcase) 6.0 8.1 0.83 Engine oil filter cover bolt 3.3 4.5 0.47 Transmission oil check bolt 5.0 6.8 0.69 Transmission oil drain bolt 6.0 8.1 0.83 Coolant bleed screw 3.3 4.5 0.
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 Fuel deterioration, water in fuel or no fuel in tank. Fouled spark plug Low compression Battery voltage is low, discharged.
Engine will not turn over. Engine starts hard when hot. Spark plug fouls repeatedly 158 Battery voltage is low or the terminals are loose. Fuse blown. Ignition is in the “OFF” position Engine stop and start switches are faulty. Solenoid faulty. Air filter clogged Fuel not reaching the fuel injection system. Corroded battery terminal Fouled spark plug Clogged air filter. Faulty solenoid. Fuel return line blocked Fuel regulator faulty. Incorrect calibration file. Corroded batter terminals.
Engine lacks power. Overheating Engine stalls. Throttle body air boots are loose or damaged. Faulty or incorrectly gapped spark plug. Faulty ignition coil. Fuel filter clogged. Deteriorated or contaminated fuel. Faulty fuel pump. Fuel pressure is low. Fuel deterioration Brake dragging. Air filter is clogged. Compression release damaged Air pocket in water system Low coolant level. Coolant leak in engine. Water pump impeller malfunction Coolant bottle cap loose. Fuel deterioration. Fouled spark plug.
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.
2002 MODEL SPECIFICATIONS NOTE : Specifications subject to change without notice ENGINE CANNIBAL SPEED BLAZE Engine 4 - stroke single Bore and stroke 95 mm x 61 mm Compression ratio 12.
ENGINE CANNIBAL SPEED BLAZE 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 Clutch plates Engine idle speed Spark plug, standard Spark plug gap Crankshaft position sensor gap Valve clearance Fuel 13T 42T 38T Wet, multi-disc 10 metal, 9- friction 2100 - 2200 r/min NGK (CR10EK) 0.024 - 0.028 in (0.6 - 0.7 mm) 0.00 in (0.5 -1.0 mm) IN .006 -.008, EX.
ENGINE CANNIBAL TEMP (C°) SPEED -20 -15 -10 -5 BLAZE 0 5 10 15 MOTO 440 20 25 30 35 40 20W 50 Engine oil 15W 50 Recommended viscosity: 10W40 10W 40, 10W 50 Synthetic or semi-synthetic 10W 30 Classification: Use only highdetergent, premium quality motor oils with the American Petroleum Institute (API) service classification SF or SG type displayed on the container.
ENGINE CANNIBAL SPEED Engine oil quantity (dry fill) BLAZE MOTO 440 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 Frame Moto440 Aluminum twin spar perimeter Overall length Overall width Blaze 73.5 in (187 cm) 46.4 (118 cm) Overall height 44 in (112 cm) Seat height 32.5 in (83 cm) 50 in (127 cm) 43.5 in (110 cm) 32.75 in (83 cm) 29 in (74 cm) Wheel base 49.
CHASSIS Cannibal Turning radius Speed Blaze 8 ft (2.4 m) Fuse 8.7 ft (2.65 m) 20A Loading limit 245 lbs (111kg) Headlight 12V (2 x 37w) Taillight 12V (168 -automotive type bulb) Battery Ground clearance, unloaded Water crossing maximum depth Throttle lever freeplay Air filter Brake fluid YUASA, , YTX5L-BS 4.5 in (114) 3.
CHASSIS Cannibal Speed Blaze Clutch lever freeplay (manual) 0.08 - 0.16 in (2 4 mm) N/A Clutch arm position (manual) 37.5 mm N/A Clutch oil (hydraulic) Moto440 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) Drive chain roller O.D. (STD / MIN) 1.4 in (35.2 mm) / 1.3 in (32.0 mm) SUSPENSION See “Addenda” starting on page170.
SUSPENSION See “Addenda” starting on page170.
ATV LIMITED WARRANTY WARRANTY CONDITIONS Cannondale warrants new Cannondale ATV’s, that are purchased from and properly assembled, serviced for delivery, and warranty registered by an authorized Cannondale Motorsports Dealer, to be free from defects in materials and factory workmanship subject to the following exclusions, obligations, and limitations. WARRANTY PERIOD The warranty period for Cannondale ATV’s begins on the date of purchase and ends six (6) months from the date of purchase.
STOLEN UNITS CHANGE OF ADDRESS In the event that your vehicle is stolen, notify local authorities first. Then, call our customer service reps at 1-800-MOTO-USA. We will maintain a list of all Vehicle Identification Numbers (VIN) reported stolen on our website (www.cannondale.com). We’ll also provide the list to our dealers. Any warranty claims registered against the listed units will be flagged stolen in our dealer service databases.
ADDENDA This section is reserved for updates, supplements, and revisions.
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When reading this manual, remember: WARNING 176 Indicates a potential hazard that COULD result in serious injury or death.
