SB02 008 MC500 Stalling

User Manual: MC500

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SB02-008

Cannondale Motorsports

Service Bulletin

Questions, call : 1-800-MOTO-USA

http://www.cannondale.com/motorsports

Printed : 4/6/02

SB02-008.fm

Information is subject to change without notice.

Page 1 of 8

BULLETIN : SB02-008

MODELS : Consult the following table for affected units.

ISSUED : 4/6/02

SUBJECT : Engine stalling

CONDITION : This is a two part bulletin covering random or intermittent engine stalling.

SOLUTION : Part 1: Operating code installation

A new revision of the MC1000 ECU operating code has been developed to support better ECU

management of sensor data interruption, a cause of engine stalling. The ECU operating code

should not be mistaken for the ECU calibration file or “map.” The operating code revisions defined

in this service bulletin MUST be installed as directed into all affected units. Units previously ser-

viced under service bulletins SBA01-10 (ATV) and SBM01-05 (Motorcycle) are also subject to this

bulletin. The new operating code files are:

All ATVs. - H302V03M.HEX

All Motorcycles - H002V03M.HEX

This bulletin includes installation instructions. See “Operating code installation” on page 2.

Part 2: Inspection points

After the new operating code revision is installed, conduct an inspection of the points listed in this

bulletin. See “Inspection points” on page 4. These points are common causes of engine stalling

related to the conditions of important vehicle systems (battery, connectors, wiring, relays, etc.).

All 2002 Up to VIN

X440s shipped prior to 3/15/02

C440 5B6BC212C32B000101

E440 5B6BC41C62B000167

Cannibal (MC1000 only) 5B6BB31352B001078

Speed 5B6CB31312B000286

Blaze 440 5B6DB313X2B000081

Moto 440 5B6EB31352B000090

All converted MC500 vehicles Kits shipped prior to 3/15/02

SB02-008.fm Page 2 of 8

CAUTION

Installing the operating code “erases” any

calibration file stored in the ECU and the vehicle

variables (Throttle position sensor min./max,

Injector offset and Injector flow rate). When

servicing the vehicle, under this bulletin, be sure

to write down the vehicle variables before

attempting to install the operating code. And use

the appropriate engine calibration files on the

diskette - P/N 5002371.

PARTS : The following parts are required to

perform the instructions of this ser-

vice bulletin:

1. CD - P/N 5002371, includes the

operating code files for ATVs and

Motorcycles and the latest engine

calibration files for each Cannondale

vehicle model.

2. MC1000 CD, Optimum,

P/N 971-5001983

Users with Windows XP, 2000, or NT

systems must call 1-800-DLR-

MOTO to obtain a special diskette to

install the operating code.

3. MC1000 Interface Cable,

P/N 971-5001984.

If you have any questions about

this service bulletin, call toll free

1-800-MOTO-USA.

OPERATING CODE INSTALLATION

NOTE :

Before you start:

So that you are familiar with the process and avoid

frustration or mistakes, read the procedure through

first before performing any of the work described.

Make sure the Cannondale Diagnostic and

Maintenance Tool has been installed onto the shop’s

PC.

Also, we strongly recommend that you read the

Cannondale Diagnostic Tool Manual (P/N 912-

5001985) thoroughly before continuing. This manual

is available on our website. The manual contains

important background information and explanations

that will be helpful to know before you attempt this

simple, but very technical procedure. We also

recommend that the service technician performing

the work have moderate PC skills.

1. Insert the CD labeled P/N 5002371 into the

CD drive of your computer.

2. Copy all but the “Readme.txt” file to the

C:\Program Files\Cal directory on your

computer.

The CD contains the two operating code

versions (ATV and Motorcycle) and all current

engine calibration files for all Cannondale

vehicles as of 4/6/02. Please note that the

exhaust silencer type installed on the vehicle

can determine the engine calibration file to

install. Consult the following table:

3. Click on the Windows START button in the

lower left corner of the PC screen and select

DealerCal.exe from the Cannondale

Diagnostic and Maintenance program group.

The Cannondale Diagnostic Tool main menu

will open. See the tool manual (P/N 912-

5001985) for a description of the main

window.

4. Click the OPEN Calibration file (saved) button

in the Cannondale Diagnostic Tool main menu

and select the correct engine calibration file

from the C:\Program Files\Cal directory.

Consult Be sure to use one of the files listed

below. Older files may be stored in the

directory, be sure you do not use them.

5. Make sure the correct engine calibration file

ID is displayed at Numeric Cal ID field in the

program window. If it is not, repeat the

previous step.

Vehicle

Type Model Engine Calibration

File ID Exhaust Silencer

P/N

Motorcy-

cle E440 03203 5002082

C440 02203 5002082

X440s 00202 5001760

ATV Cannibal 30203 6000215

30204 6000768

Speed 31203 6000215

31204 6000768

Blaze 440 32203 6001055

Moto 440 33203 6001055

Page 3 of 8

Printed : 4/6/02

CAUTION

Make sure the correct engine calibration file

ID number is displayed in the Numeric Cal ID

field of the Cannondale Diagnostic Tool main

menu. Installing the wrong file can result in

severe damage to the vehicle engine.

6. On motorcycles, disconnect the starter

solenoid from the wiring harness.

7. Connect the data cable to the vehicle and

make sure it is attached securely to the PC.

See the Cannondale Diagnostic Tool Manual

for details. Make sure the vehicle battery is

fully charged.

8. On ATVs, turn the ignition key to the ON

position.

For both vehicles types, press the vehicle

engine start button briefly. This will activate

the engine management circuits. The green

LED on the data cable block should be lit.

Look at the block to confirm that it is on. It

must remain on; if the light goes out anytime

during this procedure, just press the engine

start button again to turn it on.

9. Click the RECIEVE Calibration file (from

ECU) button.

When the Choose Receive Option window

opens select “Select to Receive only Throttle

and Injector Calibrations” and click OK. This

option reads only the TPS sensor closed

(volts), TPS open (volts), Throttle Body

Leakage, Injector flow rate, and Injector offset

variables from the current calibration file in

the ECU. These will be needed for the new

calibration file installation later because the

operating code installation “erases” them

from the ECU memory. The current

calibration file in the ECU will not be read.

Because the program is reading this relatively

small set of vehicle variables and not the

complete calibration file, the transfer of data

occurs quickly.

10. Write down the values displayed in the main

menu (see arrows below) for the vehicle. If

handling multiple vehicles make sure you

identify the values with the vehicle.

Written backup is helpful just in case you

encounter PC problems. As long as the

Cannondale Diagnostic and Maintenance

Tool program is open, the values will be held,

if the program is closed or the PC is shut off,

the values would be lost. If that happens, you

can manually input the values using the

software tool. See the manual.

11. From Windows START button (lower left

corner of the computer screen) select the

Cannondale Diagnostic and Maintenance

program group and select “Code Download.”

An MS-DOS program window will open.

12. If you are installing to an ATV type:

D H302V03M

If you are installing to an Motorcycle type:

D 002V03M

.............. but do not press the ENTER key!

13. Have an assistant PRESS AND CONTINUE

TO HOLD the engine start button on the

vehicle.

The arrows in the illustration above shows what values

you need to write down after they have been “read”

from the vehicle. Notice that engine calibration file

“03203” is open in the main menu. This is the engine

calibration file for an E440 motorcycle. Be sure the cor-

rect engine calibration file ID number is displayed at

this field before sending to the ECU after the operating

code installation is done.

SB02-008.fm Page 4 of 8

14. As your assistant holds the engine start

button, press the ENTER key on your

computer - you will see data transfer

information in the MS-DOS window.

15. When the transfer complete message

displays in the lower area of the program

window, tell your assistant to release the

engine start button and type Y and the MS-

DOS window will disappear and the

Cannondale Diagnostic Tool main menu

should be visible again.

16. Check the Numeric Cal ID field in the main

menu. Make sure the correct engine

calibration file ID number is displayed for the

vehicle. If it is not, open the necessary file

from the C:\Program Files\Cal directory.

17. Click the SEND Calibration file (to ECU)

button. The new calibration file together with

the vehicle specific variables read from the

ECU before the operating code installation

will be installed into the ECU. When the send

complete window displays, click OK.

18. On motorcycles, reconnect the starter

solenoid. Make sure the connector is latched

together properly.

19. Disconnect the data cable from the vehicle.

20. Reinstall any removed components.

21. Test engine operation. Be sure to inspect

engine idle and adjust as required.

SERVICE: Engine idle speed

2100 - 2200 r/min

INSPECTION POINTS

Common to ATV & Motorcycle

1. Low Battery Voltage

If the battery is weak the engine can turn over

normally, but a resulting low voltage while

cranking can cause the ECU power relay to

drop voltage supply to the ECU preventing the

engine from starting. Always keep the battery

fully charged and replace a weak battery with a

new one.

2. Loose Battery Terminals

Loose battery terminals can result in

intermittent or broken contact with the battery

and this can cause intermittent engine stalling.

Check the condition of both battery terminals.

Make sure they are free of corrosion and

tighten the terminal bolts to the specified

torque.

On ATVs, tighten the battery terminal bolts to

15.0 lbf•in (inch pounds) or 1.7 N•m.

On motorcycles, use Loctite #262 on the

terminal bolt threads and be sure to use the

star washers between the battery terminals and

harness ends. When using loctite allow a few

hours for the compound to cure. If the

compound is allowed to cure before use, it

results in a better hold. Tighten the motorcycle

battery terminal bolts to 15.0 lbf•in (inch

pounds) or 1.7 N•m.

3. Charging voltage

If the charging system is damaged, the battery

can be depleted and this will result in

intermittent engine stalling. Check the charging

voltage. The charging voltage must be

inspected with the engine running at 3000 rpm

- the voltage must be 13.5 to 14.5 volts.

NOTE :

Allowing the vehicle to idle for extended periods can

deplete the battery voltage.

4. Harness Abrasion or Damage

Check the vehicle wiring harness for signs of

abrasion or damage. Damage to the harness

Page 5 of 8

Printed : 4/6/02

can result in damage to the wires inside -

shorting to the frame or wiring - this will cause

intermittent engine shut down.

5. Loose or Damaged Connectors

Check all harness connectors terminating at a

device (fuel injector, ignition coil, coolant

sensor, air temperature sensor, etc.) for loose,

damaged, or corroded ends.

6. Engine Idle Speed

Check the engine idle speed and adjust to

specified. An incorrectly set engine idle speed

can result in engine stalling when the throttle is

quickly closed and re-opened. The set idle

speed can change as the mechanical stops on

the throttle body wear. Adjust the idle speed to

specification as required. Check the idle speed

more frequently on new vehicles.

SERVICE: Engine idle speed

2100 - 2200 r/min

7. Ignition Coil Connector Zip Tie

Check the ignition coil to make sure it is

connected to the vehicle wiring harness

correctly. A loose connector can result in

intermittent engine shut off.

Apply a zip tie over the harness connector

locking tab. A small tie can prevent the

connector from failing and separating from the

coil.

8. Fuel Filters

We recommend that owner’s replace the fuel

filters on their vehicles every five hours. The

fuel system constantly recirculates fuel and

contaminants inside the tank can clog the filter

quickly. Restricted or stopped fuel flow can

cause engine stalling.

If repeated clogging or restricted fuel flow is

detected, check the inside of the fuel tank for

any contamination.

For both ATVs and Motorcycle’s replace the old

style fuel filter P/N 353-5001674 with the newer

style filter P/N 5000544 (FRAM G4164 or 35

micron equivalent). When installing the filter be

This photo shows the application of the zip tie. This

photo was taken using a motorcycle. The technique is

the same for ATVs.

1. Ignition coil

2. Harness connector

3. Locking tab

4. Zip tie

SB02-008.fm Page 6 of 8

sure to observe the flow indicator. On all

vehicles, fuel flows out of the tank, through this

filter to the fuel pump. See below.

9. EMS Power Relay

Check the terminal ends of the main power

relay inside the EMS relay mounting socket

located under the air filter on ATVs and under

the seat on motorcycles. If the terminals that

receive the blades of the relay are spread or

deformed, or corroded - this will result in

broken or intermittent contact that can cause

an engine shut down.

When reinserting the relay into the harness

socket, apply some dielectric grease to the

relay blades and the socket to help prevent

corrosion. Also position a 5 mm zip tie between

the wires coming out of the back of the harness

socket and over the top of the relay. Secure the

zip tie. Consult Cannondale Technical Bulletin -

TB02-001.

10. Power Latch Accessory Bullet Connector

Check the bullet connector connection.

This connector is only present on X440s

motorcycles; it is located near the relay plate or

outside the harness near the subframe rails

depending on the wiring harness.

This connector is only present on early ATV

MC1000 wiring harnesses. In all cases of all

early ATV wiring harnesses, the connector is

located near the EMS power relay.

If this bullet connector connection is loose or

broken, engine stalling can result.

If electrical tape has been applied over the two

connector ends, removed it and re-apply the

tape. Tape can conceal a broken connection.

1. Old style fuel filter

2. New style fuel filter

a. Flow direction indicator

This photo shows a bullet connector located near the

relay plate mounted on the small frame spar.

1. Relay plate

2. Bullet connector male end

3. Bullet connector female end

This photo shows an ATV bullet connector located near

the EMS power under the air filter.

1. EMS power relay

2. Bullet connector male end

3. Bullet connector female end

Page 7 of 8

Printed : 4/6/02

ATV Specific

1. Frame Grounding

Check the connection of the negative battery

cable to frame and the wiring harness to the

frame terminals ends. Both are attached to the

frame at the fuel regulator mounting tab on the

main frame. If either connection is loose

intermittent contact can result in engine stalling.

2. Engine RUN/OFF Switch

Check the bullet connectors that tie the engine

“kill” switch leads into the wiring harness. A few

cases of random shut down, have been

attributed to loose bullet connectors. These

bullet connectors are located in the top front

area of the radiator. The bundle is probably zip

tied together. If the bullet connectors are

separated completely, the engine would not

start at all, or the connection between two wires

could be enough to start and run the engine

only breaking intermittently when the wires are

moved such as in shock and vibration

encountered while riding. Examine the bullet

connections making sure they are pushed

together completely.

3. Fuel Vapor Lock

Check to make sure the unit fuel line routing

has been re-routed as directed under

Cannondale Service Bulletin SB02-005.

1. Fuel pressure regulator

2. Negative battery cable end

3. Harness to Frame negative ground terminal

This photo take from the left side of the vehicle near the

fuse holder shows the location of the wire bundle of the

Engine RUN/OFF switch leads. The bundle is held in

place by cable ties. Check to make sure the bullet con-

nector ends of the switch leads and the wiring harness

are pushed together completely. Components have

been remove in this photo for clarity.

SB02-008.fm Page 8 of 8

Motorcycle Specific

1. Frame Grounding

Check the check the subframe grounding point

located on the right side of the subframe for

tightness. There are several ground terminals

attached to the bolt on the subframe; vibration

and shock can result in intermittent loss of

contact with the frame.

2. Fuel Tank Pickup Hose

Check the condition of the fuel tank pickup

hose. Make sure the hose has not detached

from the fuel outlet fitting inside the tank. The

bike may run with a full tank of gas but shut off

as fuel level drops.

Check to make sure that the weighted pickup

screen at the end of the hose is not clogged

and attached to the end of the hose. Check to

make sure that the fuel pickup hose inside the

tank is not bent or pinched resulting restricted

fuel flow. The pick up hose is attached to the

tank outlet fitting on the left side of the tank.

If it is necessary to remove the outlet fitting

from the tank and reattach the pickup hose or

pickup screen please keep the following points

in mind:

The total length of the hose 660mm can be

trimmed about 25mm (1 inch) with good result

without sacrificing any fuel in the tank.

Trim the hose ends before re-sliding them onto

the fittings. Be sure to apply a small drop of 3M

CA40H instant CA (cyanoacrylate) adhesive on

both the outlet and pickup screen fitting barbs

before sliding the hose ends to improve the

attachment. Avoid eye and skin contact, avoid

breathing fumes and use adequate ventilation

when working with CA adhesives (super glues).

When reinstalling the pickup assembly back

into the tank, make sure the threads of the

outlet fitting and the tank threads are clean.

Apply a small amount of Loctite# 565 to the

outlet fitting threads and install the fitting into

the tank carefully. Tighten the fitting until it

contacts the tank. Overtightening can damage

the plastic fuel tank threads resulting in fuel

leaks.

Inspect the entire fuel system for leaks or

damage after servicing. Leaking fuel or a

damaged fuel system can cause a fire or

explosion. You can be severely injured or killed.

This photo shows the right side of the subframe.

The right side number panel and fuel tank have

been removed for clarity.

1. Subframe

2. Negative (-) ground points

3. Negative battery terminal

4. Star washer

Loctite #565

(thread sealant)

OUTLET

FITTING

PICKUP SCREEN

"clunk"

PICKUP

HOSE

RETURN

FITTING

FUEL TANK

3M CA40H

SB02 008 MC500 Stalling

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