My first c dale...

[ZRider400]

How's it going guys??

I've had multiples of every brand 450.... But finally got my hands on this dale. Appears to be a moto. Has the wider axle, long travel arms and previous owner installed elkas front and back.

I started tearing the motor down to do a full rebuild / check over. Have heard stories on here so I want to make sure this is good to go.

Very excited to work on / learn about these..... I know they have issues but what doesn't??

This isn't my only machine as I mainly ride mx bikes now.... So the down time won't bother me. I plan on riding mx with it and some ice racing over winter.

[ZRider400]

Removed plastic

[ZRider400]

.....

Found a few missing bolts and alot loose!!

Last clutch friction plate was badly warped too.

Other than that motor is in great shape.

[yfzttracer76]

Nice man, I dont know alot about these but it looks like a moto and I always thought they were cool as hell and wanted one lol. Good luck with it

[ZRider400]

Same here that's y I'm rebuilding it.


Too bad they snagged the steering stabilizer and put huge tires on it ...


They took front number plate off too. Luckily that came with it

[witech]

Do you have any history on if its a virgin engine or been updated? If you found loose cartridge plate bolts then I would guess its never been updated and also think its very low hour as that would have been fixed by anyone doing work. ( a couple of drops of locktite is all that was needed for that fix)

If thats also the case then the crank might also be salvagable . Metallic sludge in the crankcase sump and debris laying in the bottom of the oil filter housing is a good indicator of a worn out rod journal.

[ZRider400]

Update.


Crank was in great shape... Looking to update it to z400 bearing.

Cam guide bolt/post was broken off also. Def is a low use motor, just going to go through and do the updates including alum valve cover


Are there any other I should look for?

Thanks witech, I appreciate the help

[witech]

The crank condition can only be determined by pressing them apart which many of us old timers have press plates. They may feel great but rod journals only wear down in certain areas so crank play is perfect right up until the last few hours before the center of the journal breaks up. I made a thread on this about ten years ago when we figured out the issue. A simple change of the cage design pretty much make the crank last forever at any power level.

[ZRider400]

Good to know.


Any idea what is up with cannondale riders?? I can't get it to admin validate my acct

[ZRider400]

Update. Chassis cleaned up, some pcs powdercoated , and motor going together soon

[sand_blaster]

Cool build my man keep up on the updates. If I ever got a cannondale again it would have to be a Moto.

[ZRider400]

Update. Satin blk a arms


Keeping this quad simple colors..... Want a clean Oem look when finished

[ZRider400]

No more plastic looking clutch cover. Couldn't stand the stock color..... More blk

[ZRider400]

crank pressed apart... z400 bearing on order.

also going to fix balancing hole that was from the factory...



tons of parts ordered from black widow ATV.. cant wait to get this back together.

[sand_blaster]

Making good progress. Are you going to put on some stock moto graphics?

[ZRider400]

i was thinking about it, but might end up doing a full kit from go for it graphics

[witech]

I cant tell from the pic but the rod wear doesnt seem like there is a step on the journal yet. If you can catch your fingernail on it its worn to far. As far as welding the hole in the counterweight I wouldnt do it unless the engine felt out of balance before. Welding that hole was a half arse solution ATK did and most ended up destroying engines because the weld was sticking up and hitting the piston. Newer cranks that were not fully machined like the older ones had a tendency to be out of balance slightly . The better fix is to send it ti Timbomoose and have him finish machine it or have it rebalanced . Do you have live centers to true a crank? Its pretty cheap from a couple shops to update a good crank.

[ZRider400]

There isn't anything deep enough to catch a nail only slight polishing. The pin is very clean and inside of rod also very clean. I was totally surprised.


What is turn around time like? My guy has done hundreds of cranks for my shop... You think he might have hard time with it?

I was going to machine a piece to stick in balancing hole then slightly fill weld it and grind smooth

[witech]

If he has experience with single cylinder cranks Dale cranks are no different. Just make sure the crank width is right when done. Do not weld the pin or risk cracks. Specs are in the manual. In order to make the pin part of the crank the whole crank itself is super hard . Welding on them can lead to cracks forming.
My local shop does mine in a day usually . He is a perfectionist and they have always been dead true. Its usually only $125 including parts. The crank pin should have the plug removed and the inside of the pin cleaned out. They are a centrifical filter of sorts and build up metallic sludge which can affect balance.

[ZRider400]

Are there replacement caps/ plugs avail ??


Thanks for the info I sure do appreciate it!

[witech]

Plugs are just your basic block plug from a local real auto parts store like carquest. Just drill a screw into it and pry the screw out .it should come with it . If that doesnt work then a big drill bit get the job done. The new plug is just tapped back in with a little sealant.

[ZRider400]

Thank you!

[polyesterpig]

The moto also had wave brake rotors. if it were me, I would send the crank to get balanced and install the z400 bearing. As for welding on the plug, I wouldn't do it. I only have the cannondale motorcycles, but they share the same engine. In a motorcycle you really notice an out of balance crank. When we tried the weld in balance plug fix, the piston stayed still and the bike went up and down! At idle the bike would vibrate soo much that it would fall off its kick stand. Ended up yanking the motor again and sending the crank out to Crankworks in Nevada. Do it right the first time, do it once.

[ZRider400]

I will take your advice and do that. I have the z bearing on order. Should be in any day then shipping it out :-)

Def want this motor to last...im not easy on them but i def take care of my stuff better than most. (Full time mechanic)

Ive always had hondas, suzukis and yamaha... Just hoping after i do all the updates this one will last like they did

[ZRider400]

Box of goodies showed up from black widow today !!!

Front end now installed

All new bearings, joints, rod ends. And lonestar / frapp ball joint upgrade on uppers

[ZRider400]

Box of goodies showed up from black widow today !!!

Front end now installed

All new bearings, joints, rod ends. And lonestar / frapp ball joint upgrade on uppers

[ZRider400]

Update pic

[89trx250r]

Any updates on this project?

[ZRider400]

Ive been updating thread on cannondaleriders

Hardly any interest on here! Lol

[sand_blaster]

Post up the updates here ;)

[ZRider400]

Update back together

[ZRider400]

This thing rips

[ZRider400]

Another pic

[yfzttracer76]

looks awesome

[sand_blaster]

Looks really good no issues at all huh? You seemed tO be breezing right through this build with ease.

[ZRider400]

Overall it wasnt a bad build

I do this for a job lol so fixing something that was neglected is normal routine for me

Here are more pics after the new graphics

[ZRider400]

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[TOfunk2drunk]

Nice Moto! I remember seeing this on Craigslist in Plattsburgh for sale over a year ago. Glad someone bought it who will maintain it and keep it nice.

[ZRider400]

Yup that would be it. Quad was clean but chee wee pounded lol. Rear carrier was broke in half and motor had handfull of bolts loose inside. Overall i rescued it