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Thread: Street Legal 2002 Cannondale E440 Stars & Stripes

  1. #1
    Join Date
    Oct 2006
    Location
    Boise, ID
    Posts
    840

    Street Legal 2002 Cannondale E440 Stars & Stripes

    Engine
    432CC
    Unicorn Engine Case (Hydro Clutch)
    Dynamically Balanced Timbo-built Z400 bearing crankshaft
    Crankshaft side-side clearance set with shims before engine installation
    Canniboomer€™s Blue Bolts & Red Loctite used inside engine
    Stock sized ASSO piston (with 90psi compression after rebuild)
    Piston Ring gap set prior to installation
    ASSO sleeve dimple facing intake side of engine
    Timbo-Ported Cylinder Head w/ Dimpled Intake Valves (by Timbo)
    Cam Timing set by me €“ 106Intake/106Exhaust (for low end/midrange power)
    12 Hole Megacycle Intake camshaft
    12 Hole Italian Exhaust camshaft (hardness tested by Timbo, within spec)
    Decompression mechanism inspected by Timbo (bolt style)
    DLC coated valve buckets (QTY 4)
    Valve clearances set before engine installation
    Timbo-Ported Throttle Body
    Cyclone Velocity Stack w/ custom 90 degree intake tube (for dirtbike)
    Custom Machined Throttle Plate/Shaft
    No-Toil TRX250R Air Filter
    Metal Scavenge Pump Gears
    New Main Bearings & Seals Installed
    Self Bleeding Water Pump Cover w/ Oversized outlet
    Powdercoated Side Cover w/ tranny fluid sight glass (Bengal Black €“ Tiger Drylac)
    Polished Billet Aluminum Clutch Cover (RIS Designs)
    Polished/Powdercoated Starter Clutch Cover
    Red Anodized Billet Aluminum Oil Filter Cover
    Aluminum Cam Cover
    Billet Aluminum Water Pump Impeller (with spacer washer installed behind it)
    Stainless Steel Hex Key Screws used on outside of engine
    NGK CR8EIX Iridium Spark Plug

    Drivetrain
    Gold Series WPS chain (~10k lb tensile strength)
    45T Talon self cleaning rear sprocket
    16T KTM front sprocket
    Dunlop K606 Street Legal knobby tires
    Dynamically (machine) balanced front & rear hand laced Cannondale wheels

    Suspension
    2003 E440 Ohlins front forks (new seals, 5wt Red Line synthetic fluid) €“ Set for street
    2002 E440 Ohlins rear shock

    Lubrication
    Red Line 5W30 Fresh Synthetic Oil
    Red Line Lightweight Shock Proof Gear Oil (Transmission)
    Evans NPG+ Coolant
    91 Octane Pump Gas (Full Tank)

    Extras
    Conical Scavenge Pump Filter installed in cylinder head downtube
    Engine Sump Pickup Magnet Installed
    Engine Rear Oil Inlet Magnet Installed
    Magnetic Sump Drainplug Installed
    Magnetic Transmission Drainplug Installed
    Canniboomer€™s fuel line update installed (hi-flow disconnects/petcocks/fuel pump inlet)
    Spare rear Cannondale wheel with Super Scoop paddle tire installed (w/ rotor/sprocket)
    Spare 50T Talon rear sprockets (QTY 2)
    Spare 13T front sprocket
    Spare 14T front sprocket
    Cateye Enduro2 Speedometer Installed
    Cannondale European Keyplate
    Cannondale ATV Keyswitch
    Canniboomer€™s Status Light LED Kit installed
    Cannondale European Wiring Harness
    Cannondale European Off/Run/Start Switch
    Cannondale European brake light pressure switches (front & rear)
    New Cannondale Silver plastic set with stars & stripes graphics by TSS Graphics
    Acerbis Silver Hand Guards
    Acerbis LEDTaillight
    Cannondale S440 front fender with matching stars & stripes graphics
    Matching stars & stripes barpad installed
    Matching stars & stripes swingarm graphics (new in package)
    Stainless Steel bolts used throughout dirtbike
    Original E440 plastics with OEM graphics
    New Cannondale front brake pads
    New Domino (Italy) Grips installed
    Fresh Galfer Dot4 Brake Fluid (front & rear)
    Fresh Magura Red Blood Clutch Fluid (Mineral Oil)
    New radiator hoses
    New Oil Lines
    New Fuel Lines
    New Vent Lines
    Custom Quick Release License Plate Mount
    Custom Oversized Battery Box
    Odyssey PC310 Battery €“ 100CCA (Cold Cranking Amps)
    ATV (Hi-Output) Stator
    ATV (Hi-Output) Voltage Regulator
    Transmission Shift Shaft O-ring installed to prevent shifter slop
    Frame sight glass installed
    Fuel tank burp mod installed
    Working aftermarket heavy-duty kickstand installed
    Battery Tender Jr. Included (with tether attached to battery for quick-connect)
    Extra starter included
    Extra throttle slide included
    Extra chain slide included
    Extra small parts included

    STREET LEGAL €“ TITLE IN HAND (May need to add signals/mirrors for your state)

    Dyno Tuned map €“ setup for slow throttle response off idle (for street use).
    48 peak hp on a Dynojet dynamometer with a spark arrestor installed.
    Wheelies in 1st and 2nd while entering the freeway.
    Current top speed is well over 80mph.
    45mpg consistently (90 miles per tank).

    Please refer to my €œFinally Finished€ thread on www.Cannondaler.com for a detailed writeup of the build. Lots of trial and error, but an amazing result with loads of reliability. 900+ miles of time on this build so far. Very reliable. Most fun ride to work you will ever own!

    -$4000- including everything listed above, and whatever else I can think of to throw in. STREET LEGAL with title in hand. Plated in Montana since 2005, as of July 2008 it is plated in Idaho with an Idaho title.

    Bike will be delivered in spotless condition, with a full tank of premium and fresh oil/filters. Local delivery can be arranged. California delivery is possible around Thanksgiving. Delivery fees will need to be arranged/talked about. For East Coast deliveries please contact a motorcycle shipper or www.uship.com.

    Selling due to a lay-off at work, that is the only reason. Would love to keep it€

    All pictures of the build can be seen here:
    http://forums.cannondaler.com/viewtopic.php?t=12730

    James Deaton
    Attached Images Attached Images

  2. #2
    Join Date
    Oct 2006
    Location
    Boise, ID
    Posts
    840
    Still available.... Now $3500. Selling due to job loss 8 weeks ago.

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