User manual CANNONDALE 2002, 2001 ENGINE SERVICE MANUAL

[. . . ] 1 P/N 941 5002037 Printed : 8/27/01 AB O U T T HE M A N U A L This is an "engine" service manual. It has been developed to address major mechanical service issues (example: component and systems removal, inspection, disassembly, assembly, and reinstallation. ) This manual can be used for 2001 and 2002 Cannondale vehicles (motorcycles & ATVs). You must possess significant mechanical knowledge, skills, and tools to perform most of the procedures found in this document. Any supplemental information developed or written after printing may be available on our web site as a "manual supplement. " Service bulletins and technical notes are also published as required. [. . . ] The engine may be damaged. a x y Install top and second ring with the manufacturer's mark up. a. Piston wrist pin bore I. D. NOTE : The piston has an arrow mark on the exhaust side. 9. Install the oil ring expander into the piston oil ring groove with the butted tips facing the intake side of the piston. Install the upper (above the expander) and lower (below the expander) oil rings onto the piston. Position each of the three rings. a a. Piston wrist pin 0. D. c 10. 0. 7089 - 0. 7090 in (18. 005 ~ 18. 010 m m ) Piston-to pin-clearance standard - 0. 0002755 ~ 0. 00059 in (0. 007 ~ 0. 015 m m ) ESM Body. fm © 2001 Cannondale Corporation - All Rights Reserved a INTAKE SIDE VIEW a. c. Oil ring (butted end) Lower oil ring gap Upper oil ring gap 86 2. Install the 2nd ring onto piston with the manufacturer's mark facing up. Install the first ring onto the piston with the manufacturer's mark facing up. 4. Position all illustration. ring gaps according to the EXHAUST Oil Ring (lower) 2nd Ring UP 1st 1st Ring WRIST PIN BORE Oil Ring (upper) UP 2nd Oil Ring Expander INTAKE MARK 1st Ring 2nd Ring Oil Ring SIDE VIEW PISTON, INSTALL 1. Refer to "Sleeve (and piston), install" starting on page 88. 87 P/N 941 5002037 Printed : 8/27/01 SLEEVE (AND PISTON), INSTALL 3. Install a new right side wrist pin circlip with the flat side of the clip facing out of the pin bore. Position the open end of the circlip downward. CAUTION Do not reuse piston pin circlips when re-installing the piston pin. Using old circlips or installing them improperly will increase the risk of the clip and wrist pin becoming dislodged during engine operation; this will result in EXTREME engine damage. Also, make sure that the flat side of the clip faces out of the wrist pin bore. Make sure piston ring gaps are positioned properly before installation into the sleeve. If they are positioned incorrectly, the engine may smoke excessively, performance may be significantly reduced or damage can result. Refer to "Piston, assemble" starting on page 86. 2 1 NEW 3 1. Align the arrow on mark (1) on the piston with dot marking (2) on the sleeve. 4. Lubricate the piston, rings, and inner sleeve walls with clean engine oil or assembly lube. Then, using a ring compressor install the piston into the bottom end of the sleeve. 2 1 E NEW EXHAUST SIDE VIEW 1. Piston mark (exhaust side) Sleeve "dot" TOOL : CM-503876 Piston ring compressor ESM Body. fm © 2001 Cannondale Corporation - All Rights Reserved 88 6. Position the piston in the sleeve so that the wrist pin relief (2) is parallel to the bottom edge of the sleeve rim. [. . . ] To install the starter motor, apply a light coat of clean engine oil to the O-ring and carefully slide the starter motor into the crankcase. Tighten the bolts to the specified torque. Starter m ounting bolts 7. 4 lbf·ft (10. 0 N ·m ) Starter term inal nut 4. 4 lbf·ft (6. 0 N ·m ) 1. 4. Bolt Coil hold down bracket Coil Coil seal ESM Body. fm © 2001 Cannondale Corporation - All Rights Reserved 176 IGNITION COIL, INSTALL GENERATOR COVER, REMOVE INSTALL 1. Apply clean dielectric grease to the inner part of the rubber tip, and insert the coil into the cylinder head. [. . . ]