Cannondale S440 manual

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A good user manual

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First and foremost, an user manual of Cannondale S440 should contain:
- informations concerning technical data of Cannondale S440
- name of the manufacturer and a year of construction of the Cannondale S440 item
- rules of operation, control and maintenance of the Cannondale S440 item
- safety signs and mark certificates which confirm compatibility with appropriate standards

Why don't we read the manuals?

Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Cannondale S440 alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Cannondale S440, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Cannondale service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Cannondale S440.

Why one should read the manuals?

It is mostly in the manuals where we will find the details concerning construction and possibility of the Cannondale S440 item, and its use of respective accessory, as well as information concerning all the functions and facilities.

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Table of contents for the manual

  • Page 1

    2003 Motorcycle Parts Catalog CONTENTS © 2001 Cannondale Cor p oration - All Ri g hts R eser v ed P/N 5002339-03 Printed : 9/4/02 2003 Motorcyc le Parts Catalog 0902.f m (E440, E440A, E440R, S 440, C440, X440) - 09/02 Legend .........................................2 Front Wheel .................................3 Rear Wheel .......................[...]

  • Page 2

    2 1 2 3 4 5 6 7 8 9 10 11 5002260I ODOMERTER INS TRUCTIONS 51 5002254 SW ITCH, HEAD LIGHT 41 5002248 SENSOR MAGNE T 31 5002257 CABLE, ODOMETER 21 5002260 ODOMETER 11 5002211 ODOMETER MOUNT PLATE XSE E A E R C R A DDITIONA L PARTS TA BLE ODOM ETER PA RTS LIST ITEM NO QTY REQD DEALER PAR T NUMBER DESCRIPTION NO TES MODE L 12 1 - CALL OUT DESIGNA T OR[...]

  • Page 3

    3 Front Wheel 2 3 * 4 * 5 * 6 7 * 9 13 * 11 12 * 8 * 10 1 500254 0 WE I G H T, WH E E L BA LA N C E Str ip of 12, 1/4 oz w eights 051- 50024 98 F R ON T W H E E L A SSE M BLY , M OT A R D 051- 50000 20 F R O N T WH E E L A S S E M BLY * 18 500 25 00A X SP O KE , F R O N T , O U T SI D E , 3.6x 172.0 m m I N C LU D E D I N F R WH E E L A SS Y S 13 1[...]

  • Page 4

    4 Rear W hee l 1 4 * 3 * 2 * 11 * 9 * 6 * 8 5 14 15 12 13 7 10 * 17 * 18 16 *[...]

  • Page 5

    5 500254 0 WE I GH T, W H E E L BA LA N C E St r ip of 12, 1 /4 oz w eights 500033 9 SP R OC KE T , R E A R , 49 T 500034 9 SP R OC KE T , R E A R , 51 T 500035 7 SP R OC KE T , R E A R , 52 T 151-500249 9 R E A R W H E E L A SS E M B LY , M O T A R D 151-5002085 R E A R WH E E L A SS E M BLY , 18" 151-5000069 R E A R WH E E L A SS E M BLY , 1[...]

  • Page 6

    6 Wheel Hubs 5 6 6 5 9 * 8 7 * 10 * 4 6 6 3 * 1 2 6 5 5 * 1 500254 1 X FR O N T WH E E L SP A C E R I N C LU D E D I N R R WH E E L A SSY S 1 0 1 5 0 0 0 0 7 4 X X X X X FRO NT W HE EL S PA CE R INCL UDE D IN FR W HEE L A S S Y S * 1 5 0 0 2 5 3 5 X HUB , F RO NT, B L K INCL UDE D IN FR W HEE L A S S Y S 9 1 5 0 0 0 0 2 2 - 0 7 X X X X X HUB , FRO [...]

  • Page 7

    7 Front Fork 57 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 47 48 50 51 52 53 54 55 57 58 29 59 12 14 57 57 57 57 57 42 41 49 57 57 57 57 57 57 48 56 45 46 46[...]

  • Page 8

    8 Front Fork Lis t 13 2 50005 48 F OR K O U T E R T U BE B U SH I N G S LE E V E 12 4 50005 47 F OR K O U T E R T U BE B U SH I N G 11 2 50005 61 F OR K O U T E R T U BE B U SH I N G C I R C LI P 10 2 50000 05 F OR K O U T E R T U BE 9 2 5000 559 FO RK OU TE R T UB E D E C A L 8 2 SE E TA BL E F OR K SP R I NG 7 2 5000 553 FO RK SP RI N G WA SH E R[...]

  • Page 9

    9 Ste ering Head 8 * 8 6 * 2 8 * 5 * 8 4 8 1 11 10 9 3 7 13 12 13 2 5000760 H E A D SE T BE A R I N G, U P P E R 12 2 5000722 H E A D SE T SE A L, U P P E R 11 1 5000717 ST E E R E R WA SH E R 10 1 5000170 SLOT TE D LOC KN U T 9 1 50 001 74 ST E E R E R N U T * 4 5 0 0 0 7 2 8 X X FHB , M8 X 5 5 mm FO R US E W / HA NDG UA RD B RCK T 8 12 5000100 X [...]

  • Page 10

    10 Front Brake G uides 5 6 7 4 3 4 2 1 4 2 7 2 5000 822 BR A KE LI N E GU I D E T OP H A T 6 1 5001 270 BR A KE GU I D E C LA M P 5 1 5000 038 BR A KE GU I D E M OU N T A SSY 4 4 5001 013 FLN G H D BLT , M 6 X16, N LK 3 1 5 0 0 2 2 6 1 X X X F R O N T B R A K E G U ID E M O U N T , U P PER F O R U S E W / H EA D L I G H T 2 2 5000 535 FR O N T B R [...]

  • Page 11

    11 Hand le bar & Co n tr ols Li st 18 20 19 23 21 22 3 9 11 13 12 16 44 10 17 2 4 5 6 7 8 1 * * 26 * 24 25 43 42 41 40 38 37 36 35 32 33 39 31 15 * 14 * 34 45 29 30 28 27 46 47[...]

  • Page 12

    12 47 2 50007 28 X X F H B M 8 X55 m m 46 2 50019 27 F H B M 5X 20 m m 45 A R 500238 5 H Y D R A U L I C C L U T C H O I L, 16 oz . 4 4 1 5 0 0 2 3 7 3 CL UTCH L EV E R PV T HRDW R K IT INCL UDE D I N 5 0 0 2 0 9 5 4 3 1 5 0 0 2 3 7 4 CL UTCH L EV E R S PRI NG INCL UDE D I N 5 0 0 2 0 9 5 4 2 1 5 0 0 2 3 7 5 CL UTCH MA S T ER CY L CA P INCL UDE D I[...]

  • Page 13

    13 Odometer 1 2 3 5 4 500226 0I O D O M E R T E R I N ST R U C T I O N S 5 1 5002 254 SW I T C H , H E A D LI GH T 4 1 5002 248 SE N SOR M A GN E T 3 1 5002 257 C A BLE , OD OM E T E R 2 1 5002 260 O D OM E T E R 1 1 5002 211 O D OM E T E R M OU N T P LA T E XSE E A E R C A DDI T I O NA L P A RT S T A BL E O DO M ET ER PA R T S LIST IT EM NO QTY RE[...]

  • Page 14

    14 Front Br ake Master Cylinder 6 5 9 12 7 8 13 14 2 4 3 1 10 11 15 * * 4 * 15 A R 500026 8 N I SSI N BR A KE GR E A SE , 2 G R A M A S R E Q U I R E D 14 1 500 00 46 F T BR A KE LE V E R R E T U R N SP R I N G N I SS I N - I N C LU D E D I N 500003 2 13 1 500 00 44 F T BR A KE LE V E R N I SS I N - I N C LU D E D I N 500003 2 12 1 500 01 03 F T BR[...]

  • Page 15

    15 Front Brake Cali per 1 2 3 4 5 5 6 7 9 11 10 8 * * * * 13 12 5 * 13 1 5 0025 13 X F R ON T BR A KE C A LI P E R M OU N T 12 2 5 0012 64 X BH C S, M 1 0x 25m m 11 1 50000 55 B R A KE C A LI P E R BLE E D E R KI T 10 1 50000 52 S LI D E P I N BO OT - LA R GE 9 1 5 0 0 0 0 5 4 FRO NT B RA K E P A D PIN K IT 8 1 5 0 0 0 0 4 9 FRO NT B RA K E P A D S[...]

  • Page 16

    16 Rear Brake Pedal 1 3 6 5 4 2 6 6 2 5000 375 SE A L, 15X21X3 I N C L U D E D I N 5 0012 26 5 1 5000 399 BO L T , BR A KE P E D A L 4 1 5000 413 R R BR A KE C O T T E R P I N 3 1 5000 109 BR A KE P E D A L Y O K E P I N I N C L U D E D I N 50012 26 2 1 5000 112 SP R I N G , BR A KE P E D A L 1 1 5001 226 R E A R BR A KE P E D A L XSE E A E R C REA[...]

  • Page 17

    17 Rear B rake Maste r Cylind er 5 7 9 6 8 1 2 12 12 4 2 3 13 13 12 13 13 12 10 11 14 15 16 16 1 500 04 34 N U T , F LA N GE , M 6 15 1 50010 13 F LA N GE H E A D BO LT , M 6 X 16 14 2 50001 26 SH C S, M 8 X 20 13 4 50015 49 C R U SH WA SH E R 12 2 50005 38 BR A K E LI N E B A N JO BO LT 11 1 50012 68 R R BR A KE M ST R C Y L GU A R D 10 1 50005 37[...]

  • Page 18

    18 Rear Brake Caliper 1 2 3 4 5 6 8 9 10 10 1 50000 82 R E A R BR A KE P A D SE T 9 1 5000 052 SLI D E P I N BOO T - LA R GE 8 1 5000 055 BR A KE C A LI P E R BLE E D E R KI T 7 A R 5000268 N I SS I N BR A KE G R E A SE , 2 G R A M A S R E QU I R E D 6 1 5000 050 SLI D E P I N BOO T - SM A L L 5 1 5000 081 R E A R BR A KE C A LI P E R A SSE M BLY 4[...]

  • Page 19

    19 Main fram e 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17 15 16 18 19 * 19 1 5 00 24 09 C L A M P , ON E - E A R E D , STE P LE SSS, 19 . 8 * 1 500233 1 H O SE , BR E A T H E R , F R A M E G R E E N ST I C KE R 18 1 5 0021 98 H OSE , B R E A TH E R , FR A M E 17 1 5 0020 71 OI L LE V E L SI G H T WI N D O W 16 2 5 0020 69 F H C S, M 10 X1.5X16 15 2 5 0004[...]

  • Page 20

    20 Subframe 1 6 2 3 5 7 8 10 * 12 * 11 4 9 13 14 15 4 50001 92 F LA T WA SH E R , M 6 1 4 1 6 0 0 0 3 4 1 NUT , L O CK , M6 G ROUND 13 1 5001013 F H B M 6 X16 m m G R O U N D * 1 500252 0 X X X X X V OLT A G E R E C TI F I E R /R E GU L A T O R 12 1 5002615 X V O LT A G E R E C TI F I E R /R E G U LA T OR 11 2 5000189 T H R E A D E D I N SE R T , M[...]

  • Page 21

    21 Frame Rail & Skid Pl ate 7 2 6 1 5 8 5 4 3 9 10 11 * 11 4 50015 31 X T OP H A T WA SH E R , P LA ST I C F OR U SE W / P LA ST I C SK I D P LA T E 10 4 50010 13 F LA N G E -H E A D BO LT , M 6X 16 * 1 50 0179 2- 04 X X X X SKI D P LA T E , A LU M 9 1 5000156 -02 X SK I D P LA T E , P LA S T I C 8 2 50 0061 2 FLN G H D BLT , M 8 X35, N Y LK 7 [...]

  • Page 22

    22 Footpegs 6 5 3 2 4 7 1 * * 2 50 0013 6 X X X X BH C S, M 10X 30, N Y LKZN C U SE W / KI C K S T A N D 7 2 5001 264 X X BH C S, M 10X25, N Y LKZ N C 6 1 5001 919 FO O T P E G BR A C K E T 5 1 5000 526 FO O T P E G , LE F T 4 1 5000 713 FLA T W A SH E R , M 8 3 1 5000 400 C O T TE R P I N , 2 . 5X20 2 1 5000 985 FO O T P E G SP R I N G , LE F T 1 [...]

  • Page 23

    23 Kickst and 2 3 5 4 1 5 1 5001 891 KI C KST A N D P I V OT BO LT 4 1 5 0 0 1 8 9 2 K ICK S T A ND T E NS ION S PRI NG 3 1 5001 893 N U T , H E X, LOC K, M 10 2 1 50 0188 2- 0 2B KI C KST A N D M O U N T 1 1 500188 2- 0 2A KI C KST A N D LE G XSE E A E R C KI CK STA ND PA RT S L I ST IT EM NO QTY RE Q D D EA L ER PA R T NUMB ER DE S CRIPTION NO TE[...]

  • Page 24

    24 Swingarm 31 * 33 1 50004 21 H E X H E A D S E T SC R E W M 8X 50 m m 32 4 50007 57 SW I N G A R M P I V O T T H R U ST WA S H E R I N C LU D E D I N 5000814 3 1 2 5 0 0 0 7 5 5 SW INGA RM PI V O T B RNG , INR S PCR INCL UDE D IN 5 0 0 0 8 1 4 30 2 50007 56 SW I N G A R M P I V O T N E E D LE B E A R I N G I N C LU D E D I N 5000814 2 9 2 5 0 0 0[...]

  • Page 25

    25 Rear Shock 1 2 3 4 3 2 10 11 10 12 1 13 5 6 7 8 9 14 15 16 15 17 * 500242 6 R R SH OC K S P G - 90 N /m m 500005 9 R R SH OC K S P G - 95 N /m m 500006 0 R R SH OC K S P G - 10 0 N /m m 500006 1 R R SH OC K S P G - 10 5 N /m m 500143 1 R R SH OC K S P G - 11 0 N /m m 500143 2 R R SH OC K S P G - 11 5 N /m m 17 1 5002153 F H B, M 12X 61 m m 16 1 [...]

  • Page 26

    26 Seat & Num ber Plates 14 9 8 4 6 5 3 7 1 2 10 11 12 13 15 16 18 17 * * 19 19 2 5001514 T OP - H A T WA SH E R 18 4 5001612 P H I LI P S H E A D S C R E W, M 6X1 2 m m 17 2 5000095 F H B, M 6X2 0 m m 16 2 5000777 I SO LA T I O N S TR I P , 5 5 X 25.4 m m * 1 500209 1 X SH R OU D , R SLV 1 5 1 5 0 0 2 6 1 3 X X X X X S HRO UD, R, S L V , W IDE[...]

  • Page 27

    27 Frnt Fender & Frn t Number Plte 3 2 4 5 6 7 1 2 8 * 5 9 10 11 12 13 14 15 16 1 18 4 * 18 2 500 15 12 F E N D E R N U T , M 6 17 2 5 0000 95 F LA N G E - H E A D BO L T , M 6X2 0 - N Y L OK 16 1 5002453 B X X B U LB, H E A D LI GH T 15 1 50024 53 X X H E A D LI GH T * 2 5002 392 X BU LB, H E A D LI GH T , 38 D E GR E E BE A M 14 2 500 23 90 X[...]

  • Page 28

    28 Battery Plate 2 1 4 3 24 19 12 15 16 9 23 20 26 27 8 7 13 11 21 17 14 22 6 5 10 18 25 13 28 29 30 30 1 500 13 74 X SP A C E R , 16X 8.4X 3.2 m m 29 1 60003 14 N U T , LO C K, M 6 28 1 50010 13 F H B, M 6X 16 m m 27 1 50023 62 BA T T E R Y BO LT /N U T KI T , M /C 26 1 60005 04 BH C S, M 6 X 20 m m , ZI N C , N Y LOC K 25 1 5002603 M A I N P O WE[...]

  • Page 29

    29 Elec tri cal 6 4 8 9 7 3 1 2 5 9 2 5001 946 FH B M 6X30 m m , Z I N C 8 1 5002 309 X X X LI GH T I N G C A P SE A L 7 1 5 0 0 2 4 5 5 X X X HA RNES S CO NNECTOR, L IGHT ING 6 1 5000 434 N U T , H E X F LA N GE , M 6 5 1 5000 011 ST A R TE R M OT OR 12V 0.65KW 4 1 5002 218 ST A R TE R M OT OR C A BL E 3 1 5002 049 P O S I T I V E BA T T E R Y C A[...]

  • Page 30

    30 Exhaust 7 6 5 3 8 2 * 1 4 8 4 5001 605 N U T , H E X F LA N GE , M 6- 12P T 7 2 5001 345 E XH A U ST C R U SH WA SH E R 6 1 5000 612 F H B, M 8X35 m m 5 1 5000 095 FH B, M 6X20 m m 4 2 5002 265 GR OM M E T , E XH A U ST 3 1 5002 209 SP R I N G, E XH A U ST * 1 500208 2 X X X X E XH A U ST , SI LE N C E R 2 1 5002 242 X X E XH A U ST , SI LE N C [...]

  • Page 31

    31 Radiator 3 9 2 4 5 6 8 7 1 10 11 11 13 14 15 16 12 11 7 12 17 18 * * 18 1 50004 84 O - R I N G , 2-013 17 2 5000093 F H B M 6 X25 m m 16 1 5000793 H OS E C LA M P , 5.6M M - 16m m 15 1 50021 45- 03 H OS E , C O O LA N T BLE E D 14 1 5002044 R A D I A T O R O V E R FL OW T U BE 13 4 50005 43 H O SE C LA M P , 14-27m m 12 4 5000719 - 03 T P - H T [...]

  • Page 32

    32 Airbox 11 1 2 10 9 4 3 8 12 7 5 6 16 13 14 15 14 17 18 18 1 5000793 H O SE C LA M P , 5.6m m - 16m m 17 1 5002331 H OS E , BR E A T H E R , F R A M E T O A R I BO X 16 1 5001922 V A C U U M H O S E , 5/32" I D 265 m m T O P R E S SU R E R E G U LA T O R 15 1 5001595 V A C U U M H O S E , 5/32" I D 609 m m T O E C U 14 2 5000962 V A C U[...]

  • Page 33

    33 Fuel T ank 4 3 1 2 5 6 11 13 14 7 10 8 9 12 9 * * 1 4 2 5 0 0 0 7 9 9 TOP - HA T W A S HE R, FUE L TA N K TA B 13 2 50007 65 T OP - H A T WA SH E R 12 4 50001 92 F LA T WA SH E R , M 6 11 2 500 08 62 F LN G H D BL T , M 6X 40 m m 10 2 50008 02 G R O M M E T , F U E L T A N K 9 3 5000 137 FH C S, M 6 X16 Z I N C 8 1 5002 398 SE A T C A TC H 7 1 5[...]

  • Page 34

    34 Fuel System 1 10 2 4 5 7 6 8 9 11 13 12 3 14 15 16 27 28 17 19 24 18 20 21 22 23 29 25 26 30 31 31 2 5 0024 10 I N SU L A T I N G BO O T 30 1 5 0011 37 O - R I N G, 008 M A LE FU E L F I T T I N G 29 1 5 0015 44 F U E L R E GU LA TO R H OU SI N G - P LA ST I C 28 2 5 0015 78 G R OM M E T , F U E L R E G U LA T OR 27 2 5 0015 79 T O P -H A T WA S[...]

  • Page 35

    35 Decals 7 2 6 1 * * * 3 5 5 5 4 * * * * * 8 * 9 * * 10 11 11 1 5 0026 26- R X D C L, E 440 A GP , N M BR P LT, R E V LO C 10 1 500 26 27 X D C L, E 44 0A G P , N M BR P LT , BLK , R 9 1 5002 238 D C L, P R E M FU E L * 50 0 2 6 4 6 X X D CL, C LOGO, BL K / Y E L 8 5 0 0 2 6 3 3 X X X DC L , C LOGO, B L K / RE D * 1 50026 25 D C L, G P , N M B R P[...]

  • Page 36

    36 V ehicle W arnings (1) (4) (2) (3) (1) (2) (4) (3) * - Any replac ement warning label can be obtained by vehicle o wner's free of charge b y calling 1-800-MO T O-USA. 4 1 500137 1- 0 1 WR N , F R A M E 3 1 5000 418 D E C A L, U SE 2 1 500126 2- 0 1 D E C A L , D I SC LA I M 1 1 500026 6- 0 1 WR N , M U L T I XSE E A E R C W A RN INGS PA R T[...]