Cannondale ATV User manual

1
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 thatan ATV 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.
CHARACTERISTIC PURPOSE REALITY
Example: Sharp knife Useful tool for cutting Risk of cutting yourself
No restraint system, no body, no protective structure Rider must be able to shift weight Motorcycle-like risk, rider can fall or fly off and is
exposed, unprotected
Very high power-to-weight ratio Thrilling acceleration, competition
performance Relatively easy to wheelie, requires focus and skill to stay ahead of machine
Short wheelbase Maneuverable in woods, compact Relatively easy to wheelie, to turn over backwards or
pitch over forward
Narrow track Maneuverable in woods, narrow trails Relatively easy to turn over
High ground clearance, high center of gravity Clearance for obstacles, more suspension
travel Relatively easy to turn over
Soft, high traction tires Traction and flotation on soft, loose
surfaces Grip on hard surface (pavement) makes it easy to turn over
Totally unsuited and illegal for road use Designed exclusively for off road High risk of turn over or collision if you ride on.
POTENTIAL HAZARD
Given the realities of sport ATVs and/or the limits of your own riding abilities, you may lose control. The limits are impossible to be specific about because of
the variation in terrain and rider ability are nearly unlimited. If you chose to ride an ATV, you must understand and respect the reality of the above.
WHAT CAN HAPPEN
You could lose control, have an accident and be severely injured, paralyzed or killed.
HOW TO AVOID THE HAZARD
The hazards of ATV riding cannot be completely avoided. They can be minimized with training, good judgement, experience, use ofhelmet, protective gear and
development of skills in weight shifting, throttle and brake control. Reading and understanding this Owner’s Manual and warninglabels, watching and under-
standing the ATV safety video and completing an ATV training course are essential and can begin your learning process.

2
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 well-
trained and experienced in the operation of high
performance competition vehicles.
• This vehicle is not for beginners or the
inexperienced.
• Before you ride this vehicle, read this Owner’s
Manual thoroughly and understand all of the
instructions, warnings, cautions, and notes
presented.
About this manual
The purpose of this manual is to provide the vehicle
owner with important safety, service, maintenance, and
tuning information. Read and understand this manual
before operating or working on the vehicle. Keep your
Owner's Manual on the vehicle while you ride. If you lose
this manual, contact an authorized Cannondale
motorsports dealer for a replacement.
• This manual contains standard ATV industry
safety information required to be a part ofATV
Owner’s Manuals. It also contains Cannondale
specific model information.
• Read and understand the entire procedure before
performing any work. If you are unfamiliar with or
doubt your own abilities to complete a procedure
as described, have an authorized Cannondale
motorsports dealer service your vehicle.
For detailed service information, obtain the engine
service or chassis manual for your vehicle or contact an
authorized Cannondale motorsports dealer for a list of
available publications.
Addenda to this manual
Before you begin reading the manual, go to the
“Addenda” section at the end of this manual. The addenda
or “supplements” section provides any additional,
replacement, or supplemental information for your product
available at the time of shipment.
Comments?
If you have any comments or suggestions about this
Owner’s manual, we’d appreciate hearing from you. Send
to: Technical Publications
Cannondale Corporation
2 Corporate Drive
Bedford, PA 15522
E-mail:
[e-mail]

3
Noise Regulation
TAMPERING WITH NOISE CONTROL SYSTEM
PROHIBITED
U.S. federal law prohibits the following acts or the
causing thereof;(1) The removal or rendering inoperative
by any person, other than for purposes of maintenance,
repair or replacement, of any device or element of design
incorporated into any new vehicle for the purpose of noise
control prior to its sale or delivery to the ultimate purchaser
or while it is in use; or (2) the use of the vehicle after such
deviceor element of design has been removed or rendered
inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE
TAMPERING ARE THE ACTS LISTED BELOW:
1. Removing, puncturing, or altering of the muffler, the
baffle system, header pipes, or any other component
which conducts exhaust gases.
2. Lack of proper maintenance.
3. Replacing, altering, modifying any moving part of the
vehicle or parts of the exhaust, intake (e.g. air filters)
with parts other than those specified by the
manufacturer.
Limitations
All information in this Owner’s Manual is based upon the
latest product data and specifications available at the time
of printing. Cannondale Corporation reserves the right to
make product changes and improvements which may
affect illustrations, photographs and explanations
contained in this Owner’s Manual.
No part of this publication may be reproduced, stored in
a retrieval system, or transmitted in any form or by any
means, (electronic mechanical photocopying, recording or
otherwise), without the prior written permission of
Cannondale Corporation. No liability can be accepted for
any inaccuracies or omissions in this publication, although
every possible care has been taken to make it as complete
and accurate as possible. All the procedures and
specifications found in this publication are subject to
change without prior notice and without Cannondale
Corporation incurring any obligation. The illustrations in
this publication are intended for reference use only and
may not depict the actual model or component parts. Your
model may differ.
If you have questions about this Owner’s Manual call:
1-800-MOTO-USA.

4
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 meansATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED.
CAUTION
Indicates a potential hazard which that could result in vehicle damage if instructions are not followed.
NOTE :
Provides helpful information.
Indicates that severe personal injury or
death WILL result if instructions are not
followed.
Indicates a potential hazard that COULD
result in serious injury or death.
DANGER
WARNING

5
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, ifyou fail to take proper
precautions.
• Severe injury or Death can result if you do not
follow these instructions:
• Read this manual and all labels carefully and
follow the operating procedures described.
• Never operate an ATV without proper instruction.
Take a training course. Beginners should receive
training from a certified instructor. Contact an
authorized ATV dealer or call 1-800-887-2887 (USA
only) tofind out about the training courses nearest
you.
• Always follow the age recommendation: A child
under 16 years old should never operate an ATV
with engine size greater than 90cc.
• Never allow a child under age 16 to operate an ATV
without adult supervision, and never allow
continued use of an ATV by a child if he or she
does not have the abilities to operate it safely.
• Never carry a passenger on a ATV.
• Never operate an ATV on any paved surfaces,
including sidewalks, driveways, parking lots and
streets.
• Never operate an ATV on any public street, road or
highway, even a dirt or gravel one.
• Never operate an ATV without wearing an
approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face
shield), gloves, boots, long-sleeved shirt or jacket,
and long pants.
• Never consume alcohol or drugs before or while
operating this ATV.
• Never operate at excessive speeds. Always go at a
speed that is proper for the terrain, visibility,
operating conditions, and your experience.
• Never attempt wheelies, jumps or other stunts.
• Always inspect your ATV each time you use it to
make sure it is in safe operating condition. Always
follow the inspection and maintenance procedures
and schedules described in this manual.
• Always keep both hands on the handlebars and
both feet on the footpegs of the ATV during
operation.
• Always go slowly and be extra careful when
operating on unfamiliar terrain. Always be alert to

6
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 theATV 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. Practice on smaller hills
before attempting larger hills.
• Always follow proper procedures for climbing hills
as described in this manual. Check the terrain
carefully before you start up any hill. Never climb
hills with excessively slippery or loose surfaces.
Shift your weight forward. Never open the throttle
suddenly or make sudden gear changes. Never go
over the top of any hill at high speed.
• Always follow proper procedures for going down
hills and for braking on hills as described in this
manual. Check the terrain carefully before you
start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going
down a hill at an angle that would cause the
vehicle to lean sharply to one side. Go straight
down the hill where possible.
• Always follow proper procedures for crossing the
side of a hill as described in this manual. Avoid
hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the ATV.
Never attempt to turn theATV around on any hill
until you have mastered the turning technique
described in this manual. Avoid hills with
excessively slippery or loose surfaces. Shift your
weight to the uphill side of the ATV. Never attempt
to turn the ATV around on any hill until you have
mastered the turning technique described in this
manual on level ground. Avoid crossing the side of
a steep hill if possible.
• Always use proper procedures if you stall or roll
backwards when climbing a hill. To avoid stalling,
use the proper gear and maintain a steady speed
when climbing a hill. If you stall or roll backwards,
follow the special procedure for braking described
in this manual.
• Always check for obstacles before operating in a
new area. Never attempt to operate over large
obstacles, such as large rocks or fallen trees.
Always follow proper procedures when operating
over obstacles as described in this manual.
• Always be careful when skidding or sliding. Learn
to safely control skidding or sliding by practicing
at low speeds and on level, smooth terrain. On
extremely slippery surfaces, such as ice, go slowly

7
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.
• Never modify an ATV through improper installation
or use of accessories.
• Never install a twist grip throttle on this ATV.
• Never exceed the stated load limits for an ATV.
Cargo should be properly distributed and securely
attached. Reduce speed and follow instructions in
this manual for carrying cargo. Allow greater
distance for braking.
• FOR MORE INFORMATION ABOUT ATV SAFETY,
call the Consumer Product Safety Commission at
1-800-638-2772, or the
ATV Distributors’ Safety Hotline
at 1-800-852-5344 (USA only).

8
CONTENTS
ATV SPORT REALITY - - - - - - - - - - - - - - 1
FOREWORD- - - - - - - - - - - - - - - - - - - 2
SAFETY ALERTS - - - - - - - - - - - - - - - - 4
SPECIAL SAFETY MESSAGES - - - - - - - - - 5
CONTENTS - - - - - - - - - - - - - - - - - - - 8
WARNING LABELS - - - - - - - - - - - - - - 10
MACHINE IDENTIFICATION - - - - - - - - - - 14
Vehicle Identification Number (VIN) - - - - - - - - 14
Engine Serial Number - - - - - - - - - - - - - - - 15
Key ID Number - - - - - - - - - - - - - - - - - - 15
PARTS AND CONTROL FUNCTIONS - - - - - 16
Owner’s Manual- - - - - - - - - - - - - - - - - - 18
Seat - - - - - - - - - - - - - - - - - - - - - - - 18
Ignition Switch- - - - - - - - - - - - - - - - - - - 21
Tether Switch - - - - - - - - - - - - - - - - - - - 22
Engine Stop/Start Buttons (MC500) - - - - - - - - 23
Engine Stop Switch/ Start Button (MC1000) - - - - 24
Headlights - - - - - - - - - - - - - - - - - - - - 25
Taillight - - - - - - - - - - - - - - - - - - - - - - 25
Front Brake Lever - - - - - - - - - - - - - - - - - 26
Parking Brake - - - - - - - - - - - - - - - - - - - 26
Rear Brake Pedal - - - - - - - - - - - - - - - - - 28
Footpegs & Baskets - - - - - - - - - - - - - - - - 28
Nerf Bars - - - - - - - - - - - - - - - - - - - - - 29
Shift Lever- - - - - - - - - - - - - - - - - - - - - 30
Fuel Tank Cap- - - - - - - - - - - - - - - - - - - 30
Handle Grips - - - - - - - - - - - - - - - - - - - 31
Throttle Lever - - - - - - - - - - - - - - - - - - - 32
Clutch lever (manual) - - - - - - - - - - - - - - - 33
Clutch lever (hydraulic) - - - - - - - - - - - - - - 33
Fuse & Diagnostics Connector - - - - - - - - - - - 34
Safety Flag Mount - - - - - - - - - - - - - - - - - 35
SAFE OPERATION- - - - - - - - - - - - - - - 36
Experienced Riders Only! - - - - - - - - - - - - - 36
Training and Instruction - - - - - - - - - - - - - - 37
Age Recommendation - - - - - - - - - - - - - - - 38
Wear Protective Gear - - - - - - - - - - - - - - - 39
Ride Sensibly - - - - - - - - - - - - - - - - - - - 40
No Passengers: No Exceptions! - - - - - - - - - - 41
Cargo, Loading Limit- - - - - - - - - - - - - - - - 42
Off-road Use Only - - - - - - - - - - - - - - - - - 43
Stay Off Public Roads and Highways- - - - - - - - 44
Turning The ATV - - - - - - - - - - - - - - - - - 45
Don’t Drink and Drive! - - - - - - - - - - - - - - - 46
No Wheelies, Stunts, or Jumps- - - - - - - - - - - 47
WARNING Indicates a potential hazard
that COULD result in serious
injury or death.
When reading this manual, remember:

9
Keep Your Hands and Feet on the Controls- - - - 48
Watch Out for Terrain Changes- - - - - - - - - - 49
Rough or Slippery Terrain - - - - - - - - - - - - 50
Stay Off Steep Hills- - - - - - - - - - - - - - - - 51
Climbing Hills Improperly - - - - - - - - - - - - - 52
Riding downhill - - - - - - - - - - - - - - - - - - 53
Crossing Slopes or Hills - - - - - - - - - - - - - 54
Turning on Slopes or Hills - - - - - - - - - - - - 55
Obstacles - - - - - - - - - - - - - - - - - - - - 56
Skidding or Sliding - - - - - - - - - - - - - - - - 57
Safety Flag- - - - - - - - - - - - - - - - - - - - 58
Riding Through Shallow Water - - - - - - - - - - 59
Stalling, Rolling Backwards- - - - - - - - - - - - 60
Modifications- - - - - - - - - - - - - - - - - - - 61
PRE-RIDE INSPECTION- - - - - - - - - - - - 62
Pre-Ride Checklist - - - - - - - - - - - - - - - - 63
OPERATION- - - - - - - - - - - - - - - - - - 64
BREAK-IN - - - - - - - - - - - - - - - - - - - 67
MAINTENANCE & ADJUSTMENT - - - - - - - 68
Work safely - - - - - - - - - - - - - - - - - - - 68
Maintenance Schedule - - - - - - - - - - - - - - 72
Panels - - - - - - - - - - - - - - - - - - - - - - 75
Frame, Subframe, Swingarm - - - - - - - - - - - 80
Fuel - - - - - - - - - - - - - - - - - - - - - - - 82
Engine Oil - - - - - - - - - - - - - - - - - - - - 85
Transmission Oil - - - - - - - - - - - - - - - - - 91
Coolant - - - - - - - - - - - - - - - - - - - - - 95
Brakes - - - - - - - - - - - - - - - - - - - - - 100
Clutch - - - - - - - - - - - - - - - - - - - - - 109
Drive - - - - - - - - - - - - - - - - - - - - - - 116
Electrical - - - - - - - - - - - - - - - - - - - - 123
Air - - - - - - - - - - - - - - - - - - - - - - - 136
Exhaust - - - - - - - - - - - - - - - - - - - - 139
Suspension- - - - - - - - - - - - - - - - - - - 140
Wheels- - - - - - - - - - - - - - - - - - - - - 146
Tires - - - - - - - - - - - - - - - - - - - - - - 149
CLEANING- - - - - - - - - - - - - - - - - - -152
STORAGE - - - - - - - - - - - - - - - - - - -153
TRANSPORTING - - - - - - - - - - - - - - -154
TORQUE TABLE- - - - - - - - - - - - - - - -156
TROUBLESHOOTING - - - - - - - - - - - - -157
MAINTENANCE RECORD- - - - - - - - - - -160
2002 MODEL SPECIFICATIONS - - - - - - - -161
Engine - - - - - - - - - - - - - - - - - - - - - 161
Chassis - - - - - - - - - - - - - - - - - - - - 164
Suspension- - - - - - - - - - - - - - - - - - - 166
ATV LIMITED WARRANTY - - - - - - - - - -168
STOLEN UNITS - - - - - - - - - - - - - - - -169
CHANGE OF ADDRESS - - - - - - - - - - - -169
ADDENDA - - - - - - - - - - - - - - - - - - -170

10
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.
Cannondale offers replacement labels at no
charge. A label’s part number is printed in the
lower right corner of the label and here in the
manual. Contact an authorized Cannondale
motorsports dealer for replacements.
• Label locations are shown in the following
illustration. Examples of the labels are shown on
the following pages.
• Always replace labels in the correct position. See
the illustration for the correct location of the
warning labels on your vehicle.
(1) (2)
(3)
(4)
(5) (6)
(7)

11
Label 2 P/N 315-6000236-01
315-6000236-01
Label 2 P/N 315-6000237-01
Label 3 P/N 315-6000239-01
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.
315-6000239-01

12
Label 4 P/N 315-6000238-01
Label 5 P/N 315-6000477-01
315-6000238-01
315-6000477-01
Label 6 P/N 315-6000580-01
315-6000580-01

13
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.

14
MACHINE IDENTIFICATION
NOTE :
Your vehicle may differ from those shown in the
illustrations in this manual.
Record your vehicle’s identification numbers in the
spaces provided. Keep another record of the numbers in a
safe place; you may need them for parts, service
information, or theft recovery.
Your vehicle’s ID numbers identify it from others of the
same model type.
VEHICLE IDENTIFICATION NUMBER (VIN)
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.
1. Vehicle identification number (VIN)
2. Engine serial number
(1)
(2)
1. Etched vehicle identification number
2. Factory VIN label
Write your number here
1
2

15
ENGINE SERIAL 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 alsoappears
on a temporary factory applied adhesive label in the same
area.
KEY ID NUMBER
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.
1. Engine serial number
Write your number here
1
1. Primary Key (remove housing to view ID number)
2. Spare key
3. Key ID number
4. Housing
Write your number here
XXXXXX
(1) (2)
(3)
(4)

16
PARTS AND CONTROL FUNCTIONS
NOTE :
Your vehicle may differ slightly from those shown in the illustrations in this manual.
8
9
(
2
)
(
5
)
(6)
1. Clutch lever
2. Engine RUN/OFF switch
3. Engine start switch (green)
4. Ignition switch
5. Front brake master cylinder
6. Parking brake lock
7. Front brake lever
8. Throttle
9. Fuel cap

17
(
12
)
(11)
()
(
3
)
(4)
(
8
)
(
10
)
(14)
4)
4)
(15)
(
3
)
(
18
)
(
17
)
(21)
1. Rectifier/regulator
2. Engine Control Unit (ECU)
3. Diagnostic connector & fuse
4. Fuel pump
5. Starter
6. Engine oil filter (1 of 2)
7. Shift lever
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
16. Fuel filter
17. Engine oil, coolant levels check
18. Radiator
19. Battery
20. Coolant bleed bolt
21. Right frame spar drain
22. Rear brake pedal

18
OWNER’S MANUAL
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.
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. Make sure the seat is in good
condition and fastened securely before you ride.
1. To remove the seat, loosen and completely remove the
seat retention bolt.
1. Owner’s manual
2. Low pressure tire gauge
3. Vinyl bag
(2)
(1)
(3)
1. Seat retention bolt
b
a
1