User manual CANNONDALE X440S-2002

[. . . ] 2002 X440s OWNER'S MANUAL P/N 951-5002032 S afety A lerts · · FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Keep this Owner's Manual in a safe place. MESSAGES WITH THE SAFETY ALERT SYMBOL · Pay special attention to all messages preceded by the Safety Alert Symbol. Indicates that severe personal injury or death WILL result if instructions are not followed. DANGER WARNING Indicates a potential hazard that COULD result in serious injury or death. CAUTION Indicates a potential hazard could result in vehicle damage if instructions are not followed. NOTE : Provides helpful information 1 P/N 951-05002032 Printed : 8/13/01 C ontents Safety Alerts . 14 16 18 23 26 27 30 35 38 43 46 47 49 56 65 66 69 73 75 76 Maintenance and Adjustments . [. . . ] Each brake pad has wear indicator marks (1) and grooves (2). If either brake pad is worn to the minimum thickness indicator (3) or beyond the minimum thickness (a), the brake pads need to be replaced with a new set. Contact an authorized Cannondale Motorsports delaer for replacement. 3. Turning the hex in direction (a) will lower the brake pedal and turning the hex in direction (b) will raise the pedal. 1 2 b a a 1 a 2 3 1. Locknut Hex Lowers the brake pedal Raises the brake pedal 1. a. Wear indicator marks Minimum thickness indicator Wear indicator grooves Minimum thickness 4. Tighten the locknut to the specified torque. TORQUE : Brake, rear brake master cylinder pushrod, locknut 13. 0 lbf·ft (17. 6 N·m) SERVICE : Brake, pad thickness, front, minimum 0. 04 inches (1. 0 mm) REAR BRAKE PEDAL HEIGHT ADJUSTMENT The rear brake pedal height can be adjusted for comfort as well as proper operation. To adjust, 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. 2. X440s Owner's Manual. fm © 2001 Cannondale Corporation - All Rights Reserved 44 When adjusting the brake pedal, make sure that clearance (a) between the lower end of the pushrod (1) and the brake pedal is within specification. When raising the brake pedal (2), do not allow the lower end of the pushrod thread (3) to enter into the brake pedal joint (4). Check brake operation before riding the motorcycle. Failure to follow this warning can lead to a serious accident with subsequen t serious injury or death. 1 a 4 2 1. Pushrod lower end Brake pedal Pushrod thread Brake pedal joint Clearance SERVICE : Brake, rear, master cylinder pushrod, clearance 0. 04 in (1mm) REAR BRAKE PADS INSPECTION Each brake pad has wear indicator grooves (1). If either brake pad is worn to the minimum thickness indicator (2) (or beyond the minimum thickness (a)), the brake pads need to be replaced with new ones as a set. Contact an authorized Cannondale Motorsports dealer for replacement. 1 a CHECK BOTH PADS! 1. a. Wear limit indicators Minimum thickness SERVICE : Brake, pad thickness, rear, minimum 0. 04 inches (1. 0 mm) P/N 951-05002032 Printed : 8/13/01 45 EXHAUST The primary functions of the exhaust system are to deliver the burned combustion gases to the atmosphere, reduce exhaust noise to an acceptable level, and to route the exhaust gases away from the rider. INSPECTING THE EXHAUST SYSTEM Inspect the exhaust pipe and silencer for cracks, dents, rust or other damage. If any damage is found, contact an authorized Cannondale dealer for servicing. NOTE : The exhaust system is shown removed from the vehicle for clarity. TORQUE : Exhaust pipe bolt 5. 0 lbf-ft (6. 8 N·m) TORQUE : Silencer mounting bolt 15. 0 lbf-ft (20. 3 N·m) X440s Owner's Manual. fm © 2001 Cannondale Corporation - All Rights Reserved 46 CLUTCH LEVER FREEPLAY CLUTCH SERVICE : Clutch, lever, freeplay 0. 08 - 0. 16 inches (2 - 4 mm) CLUTCH LEVER POSITION The clutch lever position can be adjusted so it can be used comfortably while sitting or standing. Loosen the clutch lever clamp bolts (1). 1 a TAKE UP SLACK IN CABLE a. Clutch lever freeplay CAUTION 1 1. Clutch lever clamp bolts Check the clutch actuating arm position following any adjustment to the lever. 2. Rotate the clutch lever to the desired position and tighten the clamp bolts to the specified torque. Tighten the upper clamp bolt first, then the lower clamp bolt. 3. NOTE : Adjust clutch lever freeplay at the lever first. If the specified freeplay cannot be achieved, adjust for more available freeplay at the inline adjuster. TORQUE : Clutch, lever clamp, bolts 5. 0 lbf·ft (6. 8 N·m) LEVER 1. To adjust the lever, the quick adjuster until the specified freeplay is reached. a 1 1. Quick adjuster Increases freeplay 47 P/N 951-05002032 Printed : 8/13/01 THE INLINE CABLE ADJUSTER To increase available freeplay at the lever, loosen locknut and turn the adjuster clockwise. [. . . ] Electronic fuel injection, two injectors Drive chain type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-ring type Drive chain slack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 2 - 2. 4 in (55 - 60 mm) Drive chain max length (9-link section) . . . . . . . . . . . . . . . . . 6. 0 in (151 mm) Countershaft sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ]