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2002 cannondale X440S motorcycle project
http://www.pilotodyssey.com/PO/viewtopic.php?f=61&t=12551		 Page 2 of 3
Author:  shoubadaba [ Fri Sep 06, 2013 8:27 pm ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
I see what your doing this weekend now ;)
Author:  B S [ Fri Sep 06, 2013 10:39 pm ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
shoubadaba wrote:
I see what your doing this weekend now ;)

I wish
But got work tomarrow :shock:

I have to get a race off the old crank if not i got to buy another bearing just for the race witch sucks



Plus I got to read the manual over once or twice before I start any thing as this thing is unlike any thing I have ever done
Lots of moving parts in this one compared to other 4 strokes I have worked on
Author:  B S [ Wed Sep 11, 2013 2:33 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
Well got almost all the Engine parts In

I kinda bit my self in the ass on one part

Forgot to order one bearing race and now it pushed me back another week


But I got the Engine flushed out,gaskets removed and all the other parts cleaned and ready to go

Now every thing is sitting in my office ready to be put togher
If you wonder why my office because I won't leave an open Engine in our shop as there's lots of grinding and welding going on lately


Will probally Tackel the head and valves tomarrow
And the race I need is the only thing holding me back on the Engine anyways
Once that comes in ill be tackling the Engine to get it done

Just got to do a little to the rest of the bike
Mostly the forks need a rebuild,fuel tank needs cleaned and the frame needs a flush that's about it for now .

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Author:  B S [ Wed Sep 18, 2013 10:13 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
Well got some work done to the Engine last night
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Got the crank plate and crank installed
Just have to lock tight the plate bolts

Then I got to start on the head Lapp the valves new oil seals ect

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Author:  Kuma [ Wed Sep 18, 2013 10:50 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
Hey, one thing you should do before installing the Engine is flush the frame out as that is the oil tank, you don't want to ruin a fresh build with contaminated oil.
Author:  B S [ Wed Sep 18, 2013 11:54 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
Kuma wrote:
Hey, one thing you should do before installing the Engine is flush the frame out as that is the oil tank, you don't want to ruin a fresh build with contaminated oil.

I was going to flush it for sure
Any thing with in frame oil tank I always flush out

I'm going to flush the frame

The tank is going to be the pain as its partially green looks like someone put in stabilizer

the bike is gonna have fresh fluids
Author:  shoubadaba [ Wed Sep 18, 2013 12:31 pm ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
When do you think you will have her up and running?
Author:  B S [ Thu Sep 19, 2013 2:11 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
shoubadaba wrote:
When do you think you will have her up and running?

not really sure
our Season is going to start in a couple of days :shock:

might not have this done for at least a month or two or three and so on? :shock:


still got tons to do
Author:  B S [ Thu Sep 19, 2013 2:47 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
Well got the crank plate torqued to spect. And the piston and cylinder installed tonight

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Author:  B S [ Thu Sep 19, 2013 2:51 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
Kinda started on the head also tonight


The cams are in good shape thank god

Tomorrow I will be removing the tappet cups, valve springs and lapping the valves. Then installing new valve guid seals


The head should take most of my free time tomorrow :shock:

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Author:  shoubadaba [ Thu Sep 19, 2013 3:09 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
I cant believe how much stuff is inside that Engine.
Author:  B S [ Thu Sep 19, 2013 6:53 pm ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
shoubadaba wrote:
I cant believe how much stuff is inside that Engine.

Yup its a cluster
Lots to go Wrong in this one
Author:  B S [ Fri Sep 20, 2013 1:36 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
We'll got quite a bit done today :-)
Got the head rebuilt new seals and lapped valves
Installed new seals on the cams


Then got the head installed and torqued to spec

Got the cams timed

Still got to do a bit till it's done

Got to torque the crank adjust the valves (have to wait till Friday or sat as my shim kit is coming in the mail)

Install the oil lines ,flywheel ,valve cover ,starter clutch,starter ,water pump and cover,and crank position sensor.
As well as the injectors
So I got a little bit more to do :-)

The forks are going to be tricky for me as I have only done one set before on my ttr90 but that oil was already measured out

So I got some more reading to do :shock:

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Author:  shoubadaba [ Fri Sep 20, 2013 2:13 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
man that looks like a watch inside. Was it hard to put it together by yourself?
Author:  B S [ Fri Sep 20, 2013 10:09 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
shoubadaba wrote:
man that looks like a watch inside. Was it hard to put it together by yourself?

Na

Just learning it is different every Engine is different
Author:  DMoneyAllstar [ Fri Sep 20, 2013 1:08 pm ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
I'd love to take on a 4-stroke project just to get more familiar with it all. There's so much more to it than a 2-poke. :shock:
Author:  Kuma [ Fri Sep 20, 2013 4:04 pm ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
too many moving parts, any of them fail and your out some $$$$ and time. that Engine will turn 11,500 rpm, more if you like :-)
Too bad, those were way ahead of their time, aluminum frame, dry sump, fuel injected, reverse head and American made!
Author:  B S [ Fri Sep 20, 2013 5:58 pm ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
DMoneyAllstar wrote:
I'd love to take on a 4-stroke project just to get more familiar with it all. There's so much more to it than a 2-poke. :shock:


get a little honda 50 or 70 to work on first there easyer than this one


i can redo a top end of one of those in 1-2hr :-)

Kuma wrote:
too many moving parts, any of them fail and your out some $$$$ and time. that Engine will turn 11,500 rpm, more if you like :-)
Too bad, those were way ahead of their time, aluminum frame, dry sump, fuel injected, reverse head and American made!


and too bad they had a bad crak desin and not enough funding
i think it they diddnt have that problem they might still be here
Author:  Kuma [ Fri Sep 20, 2013 6:26 pm ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
what are you using for cartridge bolts? those have an issue with backing out, there is a stage 8 kit or you should be able to get by with red Loctite, you have to clean out the threads and degrease or you won't get the full effect. do you have the aluminum valve cover or Mag? the Mag tends to corrode and leak into the Engine. there is a check valve that in on the oil pump that doesn't work real good on many engines, that will allow the oil from the frame tank to make it's way into the crank case and can hydrolock. if a daily driver you would probable not even notice but for a machine that is taken out for a weekend once a month, I had to drain the Engine and refill the frame before starting the first time.
Oh it brings back memories :shock:
Author:  B S [ Fri Sep 20, 2013 6:45 pm ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
I have the aluminum valve cover
cleaned out the crank plate cartage holes and used red lock tight they were the Allen bolts
Read the updates on the torque settings

Replaced all the seals and orings except for the clutch acuator shaft as it didnt come in the kit

all
Author:  B S [ Sun Sep 22, 2013 1:01 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
We'll got the forks rebuilt today

What a pain in the arse

Took around 4-5 hrs made a good mess all over

First time I have done a set of inverted forks


Got the gas tank soaking so most Of the crap will come out easy

Also got my shim kit for my drz400 and it works with this bike :-)

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Author:  shoubadaba [ Sun Sep 22, 2013 1:33 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
your going all out on this bike. It will be rolling new when your done. Great job thanks for sharing
Author:  B S [ Sun Sep 22, 2013 2:09 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
shoubadaba wrote:
your going all out on this bike. It will be rolling new when your done. Great job thanks for sharing

the plastic looks like crap at the moment
Should be able to fix that real easy

i want to get it done broke in oil changed and sold off
but first i want one of my buddies to ride it before it goes
Author:  B S [ Sat Oct 05, 2013 3:29 pm ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
Well haven't done any thing to the bike lately only installed the fitting in the radatior
Plus I have been working on something else :-)

Just started our season I got the awesome schedule :-) Tuesday to Friday days and nights on sat and sun off Monday thank god :-)

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Author:  shoubadaba [ Sun Oct 06, 2013 4:48 am ]
Post subject:  Re: 2002 cannondale X440S motorcycle project
Whats that for?
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