Engine case

I did end up getting the engine case welded.  It looks good and I am pretty sure nothing got warped. 

I also cleaned the case very thoroughly.  It's ready for when I get the crank back.  I discovered this was what was referred to as a "unicorn" case.  This is because it was converted to a hydraulic clutch case at the factory.  So the flywheel side seal is a 5mm instead of a 7mm.  All the bearings look great.  They are highend German bearings.  

Suspension

Just got the Ohlin's suspension back from getting rebuilt. The rear shock went up to Washington to David at Bent Lever motorsports.  While Brandon at The Moto Shop took care of the front forks.

Starting to assemble frame parts

I'm getting started on rewiring the frame and doing small fixes.  I have the wires laid out and starting to connect the connectors.  It's pretty easy because everything is labeled!  I also have a schematic of all the wiring!  The forks and shock should be ready soon.   I got a super light weight battery from WPS.  

Fits perfect. 

Fresh rubber

Picked up my wheels from the Moto Shop today.  I had DOT specific Kenda off road tires mounted.  I also installed new axle bearings.  I mounted the disc's and chain ring.  Ready to go! 

Powder coated parts

Just got the side case, water pump cover and clutch cover back from the powdercoater.  The parts look great!  Went for a custom look on the side case cover and water pump.  Also found and new chain guide on eBay along with rear brake pads. 

Now the problems

I found this while cleaning the case.  It looks as though the head was over-torqued at the factory.  I have been told to just "run it" but I am looking into possible getting it welded.  

Cannondale corporation went bankrupt in January of 2004 because they were not making a profit on the moto's they were selling.  They were doing a lot of warrantee's on engines that would blow up.  I have done a lot of research on the engine problems.  Most engines were blowing up due to the type of connecting rod bearing being used in the crank.  It would develop up and down play due to the bearing not having enough needle bearings supporting the contact area's.  When the bearing would finally fall a part it would get cycled throughout the engine.  The other major problem was the lack of locktite on the case plates.  The engine vibration would loosen these bolts and they also would cause major engine damage.  Their was a tech note on the bolts but not on the connecting rod bearing.  I think my crank is ok and I got to it before the bearing caused damage.  I sent the crank down to Crankworks in AZ to get the new Z400 bearing installed and to get balanced.

Luckily for a lot of C-Dale Moto owners there are still lots of parts still available from 3 different businesses.  After the bankruptcy ATK bought the rights, machinery and SOME left over stock of the C-Dale's.  ATK is one of the only American motorsports companies left still making product here in the USA.  Surprisingly they only fixed the few engine problems that plagued the engine.  Besides that the ATK's look the exact same as the Cannondale's did in 2004.  

I want to restore this Moto back to its original glory and of coarse do the key updates to keep the engine together.  I have ordered all the parts I need and am now in a waiting pattern until they arrive and the crank is ready to go.  I am also going to dual sport this bike to make it street legal.  One model was made street legal and sold in Europe.. 

Engine tear down

I neglected to take photo's during the beginning of the disassembly.  Cannondale engineers decided to go a different direction with a lot of their engine technology.  Besides the reverse cylinder head the engine has a piston and sleeve cylinder that presses into the engine case.  And a cassette style transmission.  As you can see in the last picture the previous owner (PO) didn't install the tranny filter correctly.  I'm lucky it didn't get chewed up and cycled throughout the engine.  

Pulling the engine

This moto was really greasy and dirty.  It took a lot more time cleaning everything then turning any bolts.  The lower engine cradles unbolt from the main frame for ease of engine removal.  If you notice from the above pictures Cannondale engineers decided to reverse the cylinder head.  The belief was to allow natural air flow from front to back.  The intake is in front of the engine and the exhaust is at the back.  Yamaha decided to do the same type of setup with their newer YZR's almost 10 years after Cannondale.  

Frame tear down

Striped down to the frame, engine, suspension and wheels.

First step, build a work space.

First I had to build a proper work bench.   My 6 foot table wasn't going to help with this bigger project. 

Now I can keep things organized with space to spare.  This bench is 11 feet long and 24 inches wide.  I made it wider at one end without legs so I had a place to sit and either true a wheel or do delicate engine work.   

Stock spec's

The start of the project

Here it is, a 2003 Cannondale E440R

At this point it doesn't run.  All the oil hoses and vacuum lines are rotten and leaking.  It is also missing the side plates.  

Cannondale was ten years ahead of the whole motor sports industry with their first entry into the industry.   The quads and motorcycles had full aluminum frames, large bore 4-stroke fuel injected engines complete with electric start.