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Cannondale X440S - User Manual

Cannondale X440S
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2002 X440s OWNER'S MANUAL
P/N 951-5002032
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Summary

Safety Alerts

Safety Alert Symbol Meanings

Explains DANGER, WARNING, and CAUTION symbols and their meanings.

Caution Definition

Indicates a potential hazard could result in vehicle damage if instructions are not followed.

Important Information

Experienced Riders Only

States the vehicle is for trained and experienced riders only, not beginners.

Good Judgement and Precautions

Emphasizes sound decisions, avoiding alcohol/drugs, and prohibiting modifications.

No Passengers Warning

States not to overload the vehicle or carry passengers due to safety risks.

Vehicle Identification

VIN and Label Locations

Shows VIN location and numbered labels on the motorcycle for identification.

Engine Serial Number Location

Identifies the location of the engine serial number.

Labels

General Warning Labels

Lists critical safety advice including helmet use, no passengers, and public road prohibition.

Fuel Type Caution

Specifies using premium unleaded gasoline only.

EPA Noise Compliance

States the motorcycle is for closed course use and does not conform to EPA noise standards.

Frame Integrity Warning

Warns about frame modifications and riding with a cracked frame.

Pre-Ride Inspection

Potential Hazard of Skipping Inspection

Failure to inspect increases the possibility of equipment failure leading to injury or death.

Inspection Procedure

Always inspect before operating and follow manual procedures.

Pre-Ride Checklist

Lists items to check for Fluids, Brakes, Throttle, Clutch, Drive, Suspension, Wheels, Tires, Body Panels, and Fasteners.

Component Locations

Controls and Levers Identification

Identifies clutch, brake levers, throttle, and stop/start buttons.

Fluid Fill and Drain Points

Identifies engine oil, transmission oil fill/drain, and radiator.

Key Electrical Components

Identifies the battery and Engine Control Module (ECM).

Chassis and Drive Components

Identifies brake pedal, rear brake reservoir, and drive chain adjusters.

Controls

Engine Stop Button Operation

Explains how to use the red engine stop button to turn off the engine.

Clutch Lever Operation

Describes how to use the clutch lever to disengage and engage the clutch.

Engine Start Button Operation

Explains how to use the green engine start button to start the engine.

Shift Lever Operation

Describes the location and operation of the shift lever for gear changes.

Throttle Operation and Hazards

Explains throttle use and potential hazards of malfunction or improper freeplay.

Brake Lever and Pedal Operation

Describes how to operate the front brake lever and rear brake pedal.

Vehicle Features

Air Filter Cleaning Plugs

Explains the purpose and use of air filter cleaning plugs during washing.

Side Stand Operation

Describes the use and limitations of the side stand.

Operating

Starting Procedure

Details starting the engine, including hazards of indoor operation and battery charge importance.

Cold Starting (MC1000)

Provides step-by-step instructions for cold starting the MC1000 model.

Starting a Warm Engine

Advises against opening the throttle when starting a warm engine to prevent fouling.

Shifting Gears

Explains proper shifting technique and warns against downshifting at high speeds.

Braking Procedure

Details proper braking technique, including hazards of improper use and wet conditions.

Stopping the Vehicle

Describes the procedure for stopping the vehicle.

After Ride Checks

Outlines post-ride cleaning, inspection, and repair steps.

Fluids

Brake Fluid

Covers brake fluid type, hazards, and checking/adding procedures for front and rear brakes.

Front Brake Fluid Level

Details how to check and add brake fluid to the front master cylinder.

Rear Brake Fluid Level

Details how to check and add brake fluid to the rear master cylinder.

Coolant Level Check

Explains how to check and add coolant, including safety precautions.

Bleeding the Coolant System

Provides steps for bleeding air from the cooling system.

Engine Oil Check

Details how to check the engine oil level, including safety warnings.

Engine Oil Level Check

Step-by-step guide to checking the engine oil level with illustrations.

Engine Oil Level Adjustment

Describes adding oil to reach the correct level.

Changing the Engine Oil

Outlines the procedure and hazards for changing engine oil.

Engine Oil Drain Process

Covers draining oil from the left spar and crankcase, including filter removal.

Engine Oil Filter Reassembly

Details reinstalling the filter cover, O-rings, and inlet fitting.

Transmission Oil Level Check

Explains how to check the transmission oil level and add oil if necessary.

Changing Transmission Oil

Details draining old transmission oil and replacing the filter.

Transmission Oil Filter Replacement

Covers removing and reinstalling the transmission oil filter and drain bolt.

Fueling the Vehicle

Provides instructions for adding fuel, including safety warnings and capacity.

Maintenance and Adjustments

Break-In Procedure

Outlines the recommended break-in period and riding instructions.

Break-In Schedule

Details maintenance tasks required during break-in and regular intervals.

Maintenance Schedule

Fuel System Maintenance

Lists checks for fuel level, filter, and idling.

Transmission Maintenance

Lists checks for oil level, oil change, and filter.

Engine Maintenance

Lists checks for oil level, oil change, filters, and valve clearance.

Brake System Maintenance

Lists checks for fluid level, pad wear, discs, lever freeplay, and pedal height.

Coolant System Maintenance

Lists checks for coolant level and cooling system inspection.

Electrical System Checks

Lists inspection of spark plug, fluid leaks, and cables/wiring.

Fastener and Clutch Checks

Lists visual inspection of fasteners and clutch lever/arm checks.

Air Filter Maintenance

Lists cleaning of air filters.

Drive Chain Maintenance

Lists checks for wear, freeplay, lubrication, and sprockets.

Exhaust System Inspection

Lists inspection for cracks, holes, leaks, or damage.

Frame and Swingarm Inspection

Lists inspection for damage and necessary repairs.

Steering System Checks

Lists checks for head bearings, rotation, and idle speed with steering.

Suspension System Inspection

Lists inspection for fork leg and rear shock oil leaks.

Tires & Wheels Inspection

Lists inspection for tire damage, pressure, and wheel damage.

Panels

Side Number Panels

Describes removal and installation of side number panels.

Seat Removal and Installation

Details how to remove and install the vehicle seat.

Seat Installation Warning

Warns about the hazard of the seat coming off during riding if installed incorrectly.

Fork Leg Guards

Describes removal and installation of fork leg guards.

Front Fender and Number Plate

Describes removal and installation of the front fender and number plate.

Front Fender Removal

Details removing the front number plate and fender.

Radiator Shrouds

Describes removal and installation of radiator shrouds.

Radiator Guard

Describes removal and installation of the radiator guard.

Mudflap Removal and Installation

Details removing and installing the mudflap, including battery terminal safety.

Rear Fender Removal and Installation

Describes removing and installing the rear fender.

Glide Plate Removal and Installation

Describes removing and installing the glide plate.

AIR

Airbox Filter Cleaning

Provides detailed instructions for cleaning and oiling the airbox filter.

Steering Head Filter Cleaning

Details cleaning the steering head filter, including proper orientation and lubrication.

FUEL

Throttle Freeplay Adjustment

Explains how to adjust throttle freeplay at the handlebars.

Throttle Freeplay Adjustment at Throttle Body

Details adjusting throttle cable freeplay at the engine throttle body.

Idle Speed Adjustment

Explains how to adjust the engine idle speed for optimal performance.

Fuel Tank Removal and Installation

Describes disconnecting and removing the fuel tank, with safety precautions.

Replacing the Fuel Filter

Explains how to replace the fuel filter, including flow indicators.

BRAKES

Front Brake Freeplay Adjustment

Explains how to measure and adjust front brake lever freeplay.

Front Brake Lever Position Adjustment

Details how to adjust the front brake lever position for rider comfort.

Front Brake Pad Inspection

Describes how to inspect front brake pads for wear and replace them.

Rear Brake Pedal Height Adjustment

Explains how to adjust the rear brake pedal height for comfort and operation.

Rear Brake Pedal Adjustment Clearance

Details checking and adjusting clearance for the rear brake pedal pushrod.

Rear Brake Pad Inspection

Describes how to inspect rear brake pads for wear and replace them.

EXHAUST

Inspecting the Exhaust System

Explains how to inspect the exhaust pipe and silencer for damage.

CLUTCH

Clutch Lever Position Adjustment

Details adjusting the clutch lever position for comfort.

Clutch Lever Freeplay

Defines clutch lever freeplay and its adjustment.

Inline Cable Adjuster

Explains how to adjust clutch cable freeplay using the inline adjuster.

Clutch Actuating Arm Adjustment

Details adjusting the clutch actuating arm, mentioning special tools.

Clutch Actuating Arm Adjustment (cont.)

Continues the procedure for adjusting the clutch actuating arm.

DRIVE

Drive Chain Slack Adjustment

Explains how to check and adjust drive chain slack, including wheel alignment.

Drive Chain Slack Adjustment (cont.)

Continues the procedure for adjusting drive chain slack and wheel alignment.

Drive Chain Stretch Limit

Explains how to measure and check for drive chain stretch.

Swingarm Buffer Inspection;Replacement

Details inspecting and replacing the swingarm buffer.

Drive Chain Guide and Block

Covers inspection and replacement of the chain guide and block.

Drive Chain Rollers Inspection

Explains how to inspect drive chain rollers for wear and damage.

Checking the Rear End (Swingarm Bearings)

Details checking swingarm bearings for wear or looseness.

Countershaft Sprocket Guard

Describes removing and reinstalling the countershaft sprocket guard.

Countershaft Sprocket Replacement

Details replacing the countershaft sprocket, lock washer, and nut.

Countershaft Sprocket Nut Tightening

Details tightening the countershaft sprocket nut.

Sprocket Inspection

Explains how to inspect sprockets for damage and wear.

ELECTRICAL

System Servicing

Discusses common electrical problems caused by connectors and wiring.

Connector and Coupler Handling

Provides tips for disconnecting and connecting electrical connectors safely.

Cleaning Connectors

Details cleaning electrical connectors with lint-free rags and compressed air.

Engine Management System (EMS)

Explains the EMS, ECM, sensors, and actuators controlling ignition and fuel delivery.

Ignition Timing

Explains ignition timing is controlled by the ECM and not user adjustable.

MC1000 Diagnostics

Mentions diagnostic software and cables for the MC1000 model.

Crankshaft Position Sensor

Explains the function and location of the crankshaft position sensor.

Throttle Position Sensor (TPS)

Describes the TPS and its role in engine management.

Idle Air Control Valve (MC1000)

Explains the function of the IAC valve in MC1000 models.

Coolant Temperature Sensor

Details the coolant temperature sensor and its function in engine management.

Air Temperature Sensor

Explains the air temperature sensor's role in fuel adjustment.

Barometric Pressure Sensor

Explains the barometric pressure sensor integrated into the ECM.

Fuel Injectors (Left and Right)

Describes the location and function of the fuel injectors.

Fuel Pump Operation

Explains the operation of the fuel pump and its pressurizing cycle.

Fuel Pressure Regulator

Describes the fuel pressure regulator's function.

Spark Plug Cap;Coil

Explains the spark plug cap/coil and its ECM control.

Battery Maintenance

Discusses battery type, importance of charge, and warnings.

Battery Removal (MC1000)

Details the procedure for removing the battery from MC1000 models.

Charging the Battery

Provides instructions and warnings for charging the motorcycle battery.

Fuse Location and Function

Explains the fuse location and what a blown fuse might indicate.

Fuse Replacement

Details how to replace a fuse, including warnings about using the correct rating.

Removing the Spark Plug

Step-by-step instructions for removing the spark plug.

Inspecting the Spark Plug

Advises consulting a dealer for inspection and how to measure spark plug gap.

Installing the Spark Plug

Provides instructions and cautions for installing a new spark plug.

STEERING

Adjusting the Handlebar Position

Details how to adjust handlebar position by rotating clamps.

Handlebar Clamp Torque Specs

Provides torque specifications for handlebar clamp bolts.

SUSPENSION

Fork Leg Maintenance

Covers pre-ride and post-ride maintenance for fork legs.

Fork Leg Maintenance (Every 25 Hours)

Details fork leg disassembly and oil change every 25 hours.

Bleeding Air from Front Forks

Explains how to bleed air from the front forks after each ride.

Adjusting Suspension Clickers (Front;Rear)

Describes adjusting front/rear suspension clickers and contacting Pro-Action.

Fork Compression Adjuster

Details adjusting fork compression damping.

Fork Rebound Adjuster

Details adjusting fork rebound damping.

Rear Shock Adjusters

Explains adjusting rear shock compression and rebound damping.

Rear Spring Preload Adjustment

Details adjusting rear shock spring preload.

Ride Height Adjustment

Explains how to set front and rear ride height.

Setting Front Ride Height

Details measuring and setting the front ride height.

Setting Rear Ride Height

Details measuring and setting the rear ride height.

Static Sag Measurement

Explains how to measure front and rear static sag.

TIRES & WHEELS

Checking Tire Pressure

Explains the importance of tire pressure and how to check it.

Inspecting the Tires

Details inspecting tires for wear, damage, and valve stem condition.

Rear Wheel Alignment

Describes rear wheel alignment procedures, noting the need for a special tool.

FRAME, SUB-FRAME, SWINGARM

Inspections

Covers inspection of frame, subframe, and swingarm for cracks or damage.

LUBRICATION

Lubrication Points Overview

Lists various lubrication points on the vehicle.

Throttle Lubrication

Details lubricating the throttle cable and housing.

Cable(s) Lubrication

Describes using aerosol lubricant for cables.

Chain Lubrication

Provides instructions for cleaning and lubricating the drive chain.

Front Brake Lever Lubrication

Details lubricating the front brake lever pivot.

Shift Lever Lubrication

Details lubricating the shift lever and shaft.

Footpeg Pivot Lubrication

Details lubricating the footpeg pivot.

Rear Brake Pedal Lubrication

Details lubricating the rear brake pedal.

Clutch Lubrication

Details lubricating the clutch lever and cable.

Cable(s) Lubrication (cont.)

Describes lubricating clutch and throttle cables.

Cleaning and Storage

Cleaning Precautions

Provides cautions for cleaning the vehicle, avoiding high pressure and detergents on brakes.

Seat Cleaning Warning

Warns against using unrecommended cleaners on the seat.

Pre-Wash Preparation

Details preparing the vehicle by installing plugs before washing.

Storing the Vehicle

Provides instructions for preparing the vehicle for storage.

Storing the Vehicle (cont.)

Continues instructions for storing the vehicle, including tire pressure and location.

Removing from Storage

Outlines steps for preparing the vehicle after storage.

X440 s Model Specifications

General Specifications

Lists overall dimensions, weight, engine type, and capacities.

Engine and Drivetrain Specs

Details engine bore/stroke, compression, oil, transmission, and gears.

Chassis and Wheel Specs

Lists frame type, suspension, tires, wheels, and brakes.

Fuel and Electrical Specs

Lists fuel capacity, type, ignition system, and battery specs.

Drive Chain and Sprocket Specs

Lists drive chain type, slack, length, and sprocket details.

X440 s Service Specifications

Fluid and Fuel Specifications

Lists specifications for brake fluid, coolant, engine oil, transmission oil, and fuel.

Brake and Clutch Specifications

Lists specifications for brake freeplay, pad thickness, and clutch freeplay.

Drive System Specifications

Lists specifications for chain slack, length, buffer, guide block, and rollers.

Suspension and Tire Specifications

Lists specifications for suspension adjustments and tire sizes/pressures.

Electrical and Engine Specifications

Lists specifications for spark plugs, fuses, and engine settings.

X440 s Torques

Frame and Brake Component Torques

Lists torque values for frame, brake master cylinder, and pedal mounting bolts.

Engine and Fuel System Torques

Lists torque values for engine oil, fuel tank, and throttle housing bolts.

Suspension and Drive Torques

Lists torque values for suspension components and drive chain parts.

Electrical and Other Torques

Lists torque values for spark plug, handlebar, and wheel nuts.

Summary

Safety Alerts

Safety Alert Symbol Meanings

Explains DANGER, WARNING, and CAUTION symbols and their meanings.

Caution Definition

Indicates a potential hazard could result in vehicle damage if instructions are not followed.

Important Information

Experienced Riders Only

States the vehicle is for trained and experienced riders only, not beginners.

Good Judgement and Precautions

Emphasizes sound decisions, avoiding alcohol/drugs, and prohibiting modifications.

No Passengers Warning

States not to overload the vehicle or carry passengers due to safety risks.

Vehicle Identification

VIN and Label Locations

Shows VIN location and numbered labels on the motorcycle for identification.

Engine Serial Number Location

Identifies the location of the engine serial number.

Labels

General Warning Labels

Lists critical safety advice including helmet use, no passengers, and public road prohibition.

Fuel Type Caution

Specifies using premium unleaded gasoline only.

EPA Noise Compliance

States the motorcycle is for closed course use and does not conform to EPA noise standards.

Frame Integrity Warning

Warns about frame modifications and riding with a cracked frame.

Pre-Ride Inspection

Potential Hazard of Skipping Inspection

Failure to inspect increases the possibility of equipment failure leading to injury or death.

Inspection Procedure

Always inspect before operating and follow manual procedures.

Pre-Ride Checklist

Lists items to check for Fluids, Brakes, Throttle, Clutch, Drive, Suspension, Wheels, Tires, Body Panels, and Fasteners.

Component Locations

Controls and Levers Identification

Identifies clutch, brake levers, throttle, and stop/start buttons.

Fluid Fill and Drain Points

Identifies engine oil, transmission oil fill/drain, and radiator.

Key Electrical Components

Identifies the battery and Engine Control Module (ECM).

Chassis and Drive Components

Identifies brake pedal, rear brake reservoir, and drive chain adjusters.

Controls

Engine Stop Button Operation

Explains how to use the red engine stop button to turn off the engine.

Clutch Lever Operation

Describes how to use the clutch lever to disengage and engage the clutch.

Engine Start Button Operation

Explains how to use the green engine start button to start the engine.

Shift Lever Operation

Describes the location and operation of the shift lever for gear changes.

Throttle Operation and Hazards

Explains throttle use and potential hazards of malfunction or improper freeplay.

Brake Lever and Pedal Operation

Describes how to operate the front brake lever and rear brake pedal.

Vehicle Features

Air Filter Cleaning Plugs

Explains the purpose and use of air filter cleaning plugs during washing.

Side Stand Operation

Describes the use and limitations of the side stand.

Operating

Starting Procedure

Details starting the engine, including hazards of indoor operation and battery charge importance.

Cold Starting (MC1000)

Provides step-by-step instructions for cold starting the MC1000 model.

Starting a Warm Engine

Advises against opening the throttle when starting a warm engine to prevent fouling.

Shifting Gears

Explains proper shifting technique and warns against downshifting at high speeds.

Braking Procedure

Details proper braking technique, including hazards of improper use and wet conditions.

Stopping the Vehicle

Describes the procedure for stopping the vehicle.

After Ride Checks

Outlines post-ride cleaning, inspection, and repair steps.

Fluids

Brake Fluid

Covers brake fluid type, hazards, and checking/adding procedures for front and rear brakes.

Front Brake Fluid Level

Details how to check and add brake fluid to the front master cylinder.

Rear Brake Fluid Level

Details how to check and add brake fluid to the rear master cylinder.

Coolant Level Check

Explains how to check and add coolant, including safety precautions.

Bleeding the Coolant System

Provides steps for bleeding air from the cooling system.

Engine Oil Check

Details how to check the engine oil level, including safety warnings.

Engine Oil Level Check

Step-by-step guide to checking the engine oil level with illustrations.

Engine Oil Level Adjustment

Describes adding oil to reach the correct level.

Changing the Engine Oil

Outlines the procedure and hazards for changing engine oil.

Engine Oil Drain Process

Covers draining oil from the left spar and crankcase, including filter removal.

Engine Oil Filter Reassembly

Details reinstalling the filter cover, O-rings, and inlet fitting.

Transmission Oil Level Check

Explains how to check the transmission oil level and add oil if necessary.

Changing Transmission Oil

Details draining old transmission oil and replacing the filter.

Transmission Oil Filter Replacement

Covers removing and reinstalling the transmission oil filter and drain bolt.

Fueling the Vehicle

Provides instructions for adding fuel, including safety warnings and capacity.

Maintenance and Adjustments

Break-In Procedure

Outlines the recommended break-in period and riding instructions.

Break-In Schedule

Details maintenance tasks required during break-in and regular intervals.

Maintenance Schedule

Fuel System Maintenance

Lists checks for fuel level, filter, and idling.

Transmission Maintenance

Lists checks for oil level, oil change, and filter.

Engine Maintenance

Lists checks for oil level, oil change, filters, and valve clearance.

Brake System Maintenance

Lists checks for fluid level, pad wear, discs, lever freeplay, and pedal height.

Coolant System Maintenance

Lists checks for coolant level and cooling system inspection.

Electrical System Checks

Lists inspection of spark plug, fluid leaks, and cables/wiring.

Fastener and Clutch Checks

Lists visual inspection of fasteners and clutch lever/arm checks.

Air Filter Maintenance

Lists cleaning of air filters.

Drive Chain Maintenance

Lists checks for wear, freeplay, lubrication, and sprockets.

Exhaust System Inspection

Lists inspection for cracks, holes, leaks, or damage.

Frame and Swingarm Inspection

Lists inspection for damage and necessary repairs.

Steering System Checks

Lists checks for head bearings, rotation, and idle speed with steering.

Suspension System Inspection

Lists inspection for fork leg and rear shock oil leaks.

Tires & Wheels Inspection

Lists inspection for tire damage, pressure, and wheel damage.

Panels

Side Number Panels

Describes removal and installation of side number panels.

Seat Removal and Installation

Details how to remove and install the vehicle seat.

Seat Installation Warning

Warns about the hazard of the seat coming off during riding if installed incorrectly.

Fork Leg Guards

Describes removal and installation of fork leg guards.

Front Fender and Number Plate

Describes removal and installation of the front fender and number plate.

Front Fender Removal

Details removing the front number plate and fender.

Radiator Shrouds

Describes removal and installation of radiator shrouds.

Radiator Guard

Describes removal and installation of the radiator guard.

Mudflap Removal and Installation

Details removing and installing the mudflap, including battery terminal safety.

Rear Fender Removal and Installation

Describes removing and installing the rear fender.

Glide Plate Removal and Installation

Describes removing and installing the glide plate.

AIR

Airbox Filter Cleaning

Provides detailed instructions for cleaning and oiling the airbox filter.

Steering Head Filter Cleaning

Details cleaning the steering head filter, including proper orientation and lubrication.

FUEL

Throttle Freeplay Adjustment

Explains how to adjust throttle freeplay at the handlebars.

Throttle Freeplay Adjustment at Throttle Body

Details adjusting throttle cable freeplay at the engine throttle body.

Idle Speed Adjustment

Explains how to adjust the engine idle speed for optimal performance.

Fuel Tank Removal and Installation

Describes disconnecting and removing the fuel tank, with safety precautions.

Replacing the Fuel Filter

Explains how to replace the fuel filter, including flow indicators.

BRAKES

Front Brake Freeplay Adjustment

Explains how to measure and adjust front brake lever freeplay.

Front Brake Lever Position Adjustment

Details how to adjust the front brake lever position for rider comfort.

Front Brake Pad Inspection

Describes how to inspect front brake pads for wear and replace them.

Rear Brake Pedal Height Adjustment

Explains how to adjust the rear brake pedal height for comfort and operation.

Rear Brake Pedal Adjustment Clearance

Details checking and adjusting clearance for the rear brake pedal pushrod.

Rear Brake Pad Inspection

Describes how to inspect rear brake pads for wear and replace them.

EXHAUST

Inspecting the Exhaust System

Explains how to inspect the exhaust pipe and silencer for damage.

CLUTCH

Clutch Lever Position Adjustment

Details adjusting the clutch lever position for comfort.

Clutch Lever Freeplay

Defines clutch lever freeplay and its adjustment.

Inline Cable Adjuster

Explains how to adjust clutch cable freeplay using the inline adjuster.

Clutch Actuating Arm Adjustment

Details adjusting the clutch actuating arm, mentioning special tools.

Clutch Actuating Arm Adjustment (cont.)

Continues the procedure for adjusting the clutch actuating arm.

DRIVE

Drive Chain Slack Adjustment

Explains how to check and adjust drive chain slack, including wheel alignment.

Drive Chain Slack Adjustment (cont.)

Continues the procedure for adjusting drive chain slack and wheel alignment.

Drive Chain Stretch Limit

Explains how to measure and check for drive chain stretch.

Swingarm Buffer Inspection;Replacement

Details inspecting and replacing the swingarm buffer.

Drive Chain Guide and Block

Covers inspection and replacement of the chain guide and block.

Drive Chain Rollers Inspection

Explains how to inspect drive chain rollers for wear and damage.

Checking the Rear End (Swingarm Bearings)

Details checking swingarm bearings for wear or looseness.

Countershaft Sprocket Guard

Describes removing and reinstalling the countershaft sprocket guard.

Countershaft Sprocket Replacement

Details replacing the countershaft sprocket, lock washer, and nut.

Countershaft Sprocket Nut Tightening

Details tightening the countershaft sprocket nut.

Sprocket Inspection

Explains how to inspect sprockets for damage and wear.

ELECTRICAL

System Servicing

Discusses common electrical problems caused by connectors and wiring.

Connector and Coupler Handling

Provides tips for disconnecting and connecting electrical connectors safely.

Cleaning Connectors

Details cleaning electrical connectors with lint-free rags and compressed air.

Engine Management System (EMS)

Explains the EMS, ECM, sensors, and actuators controlling ignition and fuel delivery.

Ignition Timing

Explains ignition timing is controlled by the ECM and not user adjustable.

MC1000 Diagnostics

Mentions diagnostic software and cables for the MC1000 model.

Crankshaft Position Sensor

Explains the function and location of the crankshaft position sensor.

Throttle Position Sensor (TPS)

Describes the TPS and its role in engine management.

Idle Air Control Valve (MC1000)

Explains the function of the IAC valve in MC1000 models.

Coolant Temperature Sensor

Details the coolant temperature sensor and its function in engine management.

Air Temperature Sensor

Explains the air temperature sensor's role in fuel adjustment.

Barometric Pressure Sensor

Explains the barometric pressure sensor integrated into the ECM.

Fuel Injectors (Left and Right)

Describes the location and function of the fuel injectors.

Fuel Pump Operation

Explains the operation of the fuel pump and its pressurizing cycle.

Fuel Pressure Regulator

Describes the fuel pressure regulator's function.

Spark Plug Cap;Coil

Explains the spark plug cap/coil and its ECM control.

Battery Maintenance

Discusses battery type, importance of charge, and warnings.

Battery Removal (MC1000)

Details the procedure for removing the battery from MC1000 models.

Charging the Battery

Provides instructions and warnings for charging the motorcycle battery.

Fuse Location and Function

Explains the fuse location and what a blown fuse might indicate.

Fuse Replacement

Details how to replace a fuse, including warnings about using the correct rating.

Removing the Spark Plug

Step-by-step instructions for removing the spark plug.

Inspecting the Spark Plug

Advises consulting a dealer for inspection and how to measure spark plug gap.

Installing the Spark Plug

Provides instructions and cautions for installing a new spark plug.

STEERING

Adjusting the Handlebar Position

Details how to adjust handlebar position by rotating clamps.

Handlebar Clamp Torque Specs

Provides torque specifications for handlebar clamp bolts.

SUSPENSION

Fork Leg Maintenance

Covers pre-ride and post-ride maintenance for fork legs.

Fork Leg Maintenance (Every 25 Hours)

Details fork leg disassembly and oil change every 25 hours.

Bleeding Air from Front Forks

Explains how to bleed air from the front forks after each ride.

Adjusting Suspension Clickers (Front;Rear)

Describes adjusting front/rear suspension clickers and contacting Pro-Action.

Fork Compression Adjuster

Details adjusting fork compression damping.

Fork Rebound Adjuster

Details adjusting fork rebound damping.

Rear Shock Adjusters

Explains adjusting rear shock compression and rebound damping.

Rear Spring Preload Adjustment

Details adjusting rear shock spring preload.

Ride Height Adjustment

Explains how to set front and rear ride height.

Setting Front Ride Height

Details measuring and setting the front ride height.

Setting Rear Ride Height

Details measuring and setting the rear ride height.

Static Sag Measurement

Explains how to measure front and rear static sag.

TIRES & WHEELS

Checking Tire Pressure

Explains the importance of tire pressure and how to check it.

Inspecting the Tires

Details inspecting tires for wear, damage, and valve stem condition.

Rear Wheel Alignment

Describes rear wheel alignment procedures, noting the need for a special tool.

FRAME, SUB-FRAME, SWINGARM

Inspections

Covers inspection of frame, subframe, and swingarm for cracks or damage.

LUBRICATION

Lubrication Points Overview

Lists various lubrication points on the vehicle.

Throttle Lubrication

Details lubricating the throttle cable and housing.

Cable(s) Lubrication

Describes using aerosol lubricant for cables.

Chain Lubrication

Provides instructions for cleaning and lubricating the drive chain.

Front Brake Lever Lubrication

Details lubricating the front brake lever pivot.

Shift Lever Lubrication

Details lubricating the shift lever and shaft.

Footpeg Pivot Lubrication

Details lubricating the footpeg pivot.

Rear Brake Pedal Lubrication

Details lubricating the rear brake pedal.

Clutch Lubrication

Details lubricating the clutch lever and cable.

Cable(s) Lubrication (cont.)

Describes lubricating clutch and throttle cables.

Cleaning and Storage

Cleaning Precautions

Provides cautions for cleaning the vehicle, avoiding high pressure and detergents on brakes.

Seat Cleaning Warning

Warns against using unrecommended cleaners on the seat.

Pre-Wash Preparation

Details preparing the vehicle by installing plugs before washing.

Storing the Vehicle

Provides instructions for preparing the vehicle for storage.

Storing the Vehicle (cont.)

Continues instructions for storing the vehicle, including tire pressure and location.

Removing from Storage

Outlines steps for preparing the vehicle after storage.

X440 s Model Specifications

General Specifications

Lists overall dimensions, weight, engine type, and capacities.

Engine and Drivetrain Specs

Details engine bore/stroke, compression, oil, transmission, and gears.

Chassis and Wheel Specs

Lists frame type, suspension, tires, wheels, and brakes.

Fuel and Electrical Specs

Lists fuel capacity, type, ignition system, and battery specs.

Drive Chain and Sprocket Specs

Lists drive chain type, slack, length, and sprocket details.

X440 s Service Specifications

Fluid and Fuel Specifications

Lists specifications for brake fluid, coolant, engine oil, transmission oil, and fuel.

Brake and Clutch Specifications

Lists specifications for brake freeplay, pad thickness, and clutch freeplay.

Drive System Specifications

Lists specifications for chain slack, length, buffer, guide block, and rollers.

Suspension and Tire Specifications

Lists specifications for suspension adjustments and tire sizes/pressures.

Electrical and Engine Specifications

Lists specifications for spark plugs, fuses, and engine settings.

X440 s Torques

Frame and Brake Component Torques

Lists torque values for frame, brake master cylinder, and pedal mounting bolts.

Engine and Fuel System Torques

Lists torque values for engine oil, fuel tank, and throttle housing bolts.

Suspension and Drive Torques

Lists torque values for suspension components and drive chain parts.

Electrical and Other Torques

Lists torque values for spark plug, handlebar, and wheel nuts.

Cannondale X440S Specifications

General IconGeneral
Transmission5-speed
Final DriveChain
IgnitionCDI
Front BrakeHydraulic disc
Rear BrakeHydraulic disc

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