2002 Motorcycle Parts Catalog (E440, C440) - 05/02 CONTENTS Front Wheel . . . . . . . . . . . . . . . . . 2 Rear Wheel . . . . . . . . . . . . . . . . . 3 Wheel Hubs . . . . . . . . . . . . . . . . . 4 Front Fork . . . . . . . . . . . . . . . . . . 5 Front Fork List . . . . . . . . . . . . . . 6 Steering Head . . . . . . . . . . . . . . . 7 Front Brake Guides . . . . . . . . . . . 8 Handlebar & Controls List . . . . . . 9 Odometer . . . . . . . . . . . . . . . . . . 11 Front Brake Master Cylinder . . . 12 Front Brake Caliper . . . . . . . . . . 13 Rear Brake Pedal . . . . . . . . . . . 14 Rear Brake Master Cylinder . . . . Rear Brake Caliper . . . . . . . . . . . Mainframe . . . . . . . . . . . . . . . . . . Subframe . . . . . . . . . . . . . . . . . . Frame Rail & Skid Plate . . . . . . . Footpegs . . . . . . . . . . . . . . . . . . . Kickstand . . . . . . . . . . . . . . . . . . Swingarm . . . . . . . . . . . . . . . . . . Rear Shock . . . . . . . . . . . . . . . . . Seat & Number Plates . . . . . . . . Radiator Shroud . . . . . . . . . . . . . Frnt Fender & Frnt Number Plte . 15 16 17 18 19 20 21 22 23 24 25 26 Rear Fender & Taillight . . . . . . . Battery Plate . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . Airbox . . . . . . . . . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . Decals . . . . . . . . . . . . . . . . . . . . Vehicle Warnings . . . . . . . . . . . . 27 28 29 30 31 32 33 34 35 36 2002 Motorcycle Parts Catalog 0302.fm © 2001 Cannondale Corporation - All Rights Reserved P/N 5002339 Printed : 4/25/02 Front Wheel 2 12 11 3 13 4 6 5 1 8 7 8-1 9 10 1 14 051-5000020 13 18 5000026 12 18 5000477 11 36 5001623 10 1 5000540 9 6 5000864 8-1 1 5002246 X 8 1 5000047 X 7 1 5000536 6 1 5002133 5 1 5002134 4 1 5002135 3 1 5002098 2 1 5000021 1 1 SEE FRONT HUB ITEM QTY DEALER PART C E NO REQD NUMBER MODEL FRONT WHEEL ASSEMBLY FRONT SPOKE - OUTSIDE FRONT SPOKE - INSIDE NIPPLE, FRONT NUT, FLANGE, M16X1.5 FHCS, M6X16,NYLKZINC FRONT ROTOR FRONT ROTOR FRONT WHEEL RIM FRONT RIM LOCK FRONT RIM STRIP FRONT INNER TUBE FRONT TIRE AXLE, FRONT WHEEL FRONT HUB ASSEMBLY DESCRIPTION INCLUDED IN 051-5000020 INCLUDED IN 051-5000020 INCLUDED IN 051-5000020 INCLUDED IN 051-5000020 INCLUDED IN 051-5000020 NOTES FRONT WHEEL PARTS LIST 2 Rear Wheel 2 15 3 16 4 17 18 12 11 14 5 10 13 9 6 1 7 8 1 1 1 183-5000339 183-5000349 183-5000357 19 1 151-5002085 18 2 5002199 17 18 5001873 16 18 5002287 15 36 5001624 14 6 5000713 13 6 5000140 12 6 5000393 11 1 5000117 10 1 5001847 9 1 5001798 8 4 5000138 7 1 5000090 6 1 5001886 5 1 5002129 4 1 5002130 3 1 5002131 2 1 5002132 1 1 SEE REAR HUB ITEM QTY DEALER PART NO REQD NUMBER REAR SPROCKET, 49 T REAR SPROCKET, 51 T REAR SPROCKET, 52 T ADDITIONAL PARTS TABLE REAR WHEEL ASSEMBLY DUST CAP RR SPOKE - OUTSIDE RR SPOKE - INSIDE NIPPLE, REAR FLAT WASHER, M8 LOCKNUT, M8 FHCS, M8X28 ZINC REAR SPROCKET, 50 T MASTER LINK, O-RING DRIVE CHAIN, O-RING FHCS, M8X16, NYLK, ZINC REAR ROTOR REAR WHEEL RIM REAR RIM LOCK REAR RIM STRIP REAR INNER TUBE REAR TIRE REAR HUB ASSEMBLY CE MODEL DESCRIPTION INCLUDED IN 151-5002085 INCLUDED IN 151-5002085 INCLUDED IN 151-5002085 STOCK INCLUDED IN 151-5002085 INCLUDED IN 151-5002085 NOTES REAR WHEEL PARTS LIST 3 Wheel Hubs 10 5 6 9 8 6 5 7 4 5 6 6 3 2 6 5 1 10 1 9 1 8 1 7 1 6 5 5 4 4 1 3 1 2 1 1 1 ITEM QTY NO REQD 5000074 5000022-07 5000023 5000024 5000355 5000356 5001091 5000071-08 5000072 5000073 DEALER PART NUMBER FRONT WHEEL SPACER FRONT HUB FRONT HUB BEARING SPACER FRONT WHEEL SPACER-DISC SIDE SEALED BEARING, 20X42X12 DOUBLE LIP SEAL, 32X42X4 REAR WHEEL SPACER REAR HUB REAR HUB BEARING SPACER REAR WHEEL SPACER-DISC SIDE CE MODEL DESCRIPTION NOTES WHEEL HUBS PARTS LIST 4 Front Fork 32 1 2 33 3 4 5 6 19 57 7 8 38 39 40 41 42 9 57 57 55 37 57 20 36 57 18 34 35 42 41 49 50 51 52 53 57 54 57 21 58 57 59 22 10 23 11 12 57 26 13 24 25 45 43 44 27 12 14 15 16 17 57 57 31 48 48 57 28 29 30 47 56 57 46 46 5 Front Fork List \ 59-1 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ITEM NO. 1 5002222 X 1 5002247 X AR 5000572 AR 5001526 1 5000568 2 5000608 2 5000607 2 5000610 2 5000611 2 5000606 2 5000603 2 5000604 4 5000558 1 5000567 6 5000556 1 SEE TABLE 2 5000518 2 5000565 4 5000080 4 5000601 2 5000600 2 5000598 2 5000597 2 5000594 2 5000593 2 5000592 2 5000591 2 5000590 2 5000587 2 5000589 2 5000586 2 5000585 2 5000584 2 5000583 2 5000582 2 5000581 2 5000580 2 5000579 2 5000578 2 5000577 2 5000575 2 5000576 2 5000574 2 5000564 2 5000560 2 5000563 2 5000562 2 5000548 4 5000547 2 5000561 2 5000005 2 5000559 2 SEE TABLE 2 5000553 2 5000552 2 5000546 2 5000545 2 5000551 2 5000550 2 5000549 QTY DEALER XCE REQ PART NO. MODEL FRONT FORK SET, C FRONT FORK SET, E OHLINS FORK FLUID, 1LITER FORK SERVICE KIT FORK INNER TUBE ASSY-RIGHT COMPRESSION ADJUSTER ASSY. COMPRESSION ADJUSTER O-RING COMPRESSION SHIM SET FORK COMPRESSION PISTON FORK COMPRESSION PISTON O-RING COMPRESSION PISTON SHIM COMPRESSION PISTON WAVE WSHR FRONT WHEEL AXLE PINCH BOLT FORK INNER TUBE ASSY-LEFT FORK GUARD BOLT FORK GUARD SET FORK INNER TUBE BUSHING DAMPING CARTRIDGE TUBE LOCKNUT WASHER MID VALVE SHIM SET FORK REBOUND PISTON RING FORK REBOUND PISTON REBOUND SHIM SET REBOUND ADJUSTER BODY REBOUND ADJNEEDLE SPRING REBOUND ADJ NEEDLE REBOUND ADJ NEEDLE O-RING FORK TOP OUT SPRING FORK DAMPER ROD FORK TOP OUT SPRING WASHER FORK DAMPER ROD BUSHING FORK DAMPER ROD SLEEVE O-RING FORK DAMPER ROD SLEEVE DAMPING CARTRIDGE TUBE CAP DAMPER ROD CIRCLIP HYDRAULIC STOP COLLAR CIRCLIP FORK HYDRAULIC STOP FORK HYDRAULIC STOP COLLAR FORK SPRING GUIDE REBOUND ADJUSTER ASSY. REBOUND ADJUSTER O-RING FORK REBOUND ADJUSTER ROD FORK WIPER FORK SEAL RETAINING CIRCLIP FORK SEAL FORK SEAL RETAINING WASHER FORK OUTER TUBE BUSHING SLEEVE FORK OUTER TUBE BUSHING FORK OUTER TUBE BUSHING CIRCLIP FORK OUTER TUBE FORK OUTER TUBE DECAL FORK SPRING FORK SPRING WASHER FORK SPRING SPACER FORK OUTER TUBE CAP O-RING FORK OUTER TUBE CAP FORK AIR BLEED SCREW O-RING FORK AIR BLEED SCREW FORK OUTER TUBE CAP NUT DESCRIPTION 5002055 5000018 5001222 5000013 5000014 5000015 DEALER PART NO. FORK GUARD SET - SILVER FORK GUARD SET - BLACK FORK GUARD SET - WHITE FORK SPRING - 4.5 N/mm OPTIONAL FORK SPRING - 4.7 N/mm STANDARD FORK SPRING - 4.9 N/mm OPTIONAL DESCRIPTION NOTES FRONT FORK PARTS LIST ADDITIONAL PARTS TABLE 6 Steering Head 8 6 8 11 5 9 10 2 3 12 7 8 13 8 8 1 4 13 2 5000760 12 2 5000722 11 1 5000717 10 1 5000170 9 1 5000174 8 12 5000100 7 2 5000101 6 2 5000534 5 2 5000533 4 1 012-5002097 3 1 5000001B 2 1 ITEM QTY DEALER PART C E NUMBER MODEL NO REQD HEADSET BEARING, UPPER Before E VIN#164 & C VIN # 98 Use (1) 5002059 (Low er) HEADSET SEAL, UPPER Before E VIN#164 & C VIN # 98 Use (1) 5002060 (Low er) STEERER WASHER SLOTTED LOCKNUT STEERER NUT FHB, M8X45 mm FHB, M12X35 mm, NLK UPPER HANDLEBAR CLAMP LOWER HANDLEBAR CLAMP LOWER TRIPLE CLAMP ASSY Before E VIN# 164 & C VIN # 98 Use 012-5002289 UPPER TRIPLE CLAMP FRNT BRKE GDE, UPPER SEE FRONT BRAKE GUIDE, UPPER FRNT BRKE GDE, LOWER SEE FRONT BRAKE GUIDE, LOWER NOTES DESCRIPTION STEERING HEAD PARTS LIST 7 Front Brake Guides 5 4 6 7 4 2 3 2 1 4 7 2 6 1 5 1 4 4 3 1 2 2 1 1 ITEM QTY NO REQD 5000822 5001270 5000038 5001013 5002261 5000535 5002263 DEALER PART NUMBER BRAKE LINE GUIDE TOPHAT BRAKE GUIDE CLAMP BRAKE GUIDE MOUNT ASSY FLNG HD BLT, M6X16, NLK X FRONT BRAKE GUIDE MOUNT, UPPER FRONT BRAKE GUIDE FRONT BRAKE GUIDE MOUNT, LOWER CE DESCRIPTION MODEL NOTES BRAKE GUIDES PARTS LIST 8 Handlebar & Controls List 20 21 18 2 1-1 1 5 3 4 6 7 8 22 19 9 11 10 12 17 17-1 13 2 16 16-1 14 15 23 24 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 24 1 23 4 22 1 21 1 20 1 19 1 18 1 17-1 1 17 1 16-1 1 16 15 1 14 1 13 1 12 2 11 1 10 1 9 1 8 2 7 1 6 1 5 1 4 1 3 1 2 1 1-1 1 1 1 ITEM QTY NO REQD 5002373 5002374 5002375 5002376 5002377 5002378 5002379 5002380 5002381 5002382 5002383 5002384 5002385 5002386 5002387 5002215 5001808 5000379 5000505 5000131 5000437 5001274 5002262 5000317 5002279 5000120 5002372 5002095 5000125 5000786 5000123 5001590 5001369 5001368 5001367 5001366 5001365 5000488 5000124 5000121 5002252 5000474 DEALER PART NUMBER X X X X X X X X CE MODEL CLUTCH LEVER PVT HRDWR KIT CLUTCH LEVER SPRING CLUTCH MASTER CYL CAP CLUTCH MASTER CYL CAP SCRW CLUTCH LEVER CLAMP CLUTCH LEVER CLAMP SCRW CLUTCH LEVER BOOT CLUTCH LEVER ADJ GRIP, RED CLUTCH MSTR CYL PISTON KIT CLUTCH MSTR CYL MEMBRANE CLUTCH SLAVE VALVE, CAP KIT CLUTCH TUBE KIT, 1045 mm HYDRAULIC CLUTCH OIL, 16 oz. MASTER CYLINDER, SLV, M/C SLAVE CYLINDER, COMPLETE ADDITIONAL PARTS TABLE HANDGUARD SET, LOOP, SILVER HANDGUARD SET, BLACK SHCS,M4X12 ZINC ENGINE STOP SWITCH ENGINE START SWITCH SWITCH CAP SWITCH CLAMP CROSSBAR PAD - SILVER CROSSBAR PAD - BLACK HANDLEBAR, E HANDLEBAR CLUTCH LEVER HYDRAULIC CLUTCH LEVER ASSY THROTTLE CABLE FLANGE HEAD BOLT, M6X20 mm THROTTLE HOUSING BOOT THROTTLE CABLE ADJ BOOT THROTTLE CABLE ADJUSTER THROTTLE PULLEY COVER SCRW THROTTLE PULLEY COVER THROTTLE PULLEY BUSHING THROTTLE PULLEY THROTTLE HOUSING SET THROTTLE TUBE HANDLEBAR GRIP SET THROTTLE ASSEMBLY, E THROTTLE ASSEMBLY, C DESCRIPTION INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5002095 INCLUDED IN 5000474 INCLUDED IN 5000474 INCLUDED IN 5000474 INCLUDED IN 5000474 INCLUDED IN 5000474 INCLUDED IN 5000474 INCLUDED IN 5000474 INCLUDED IN 5000474 INCLUDED IN 5000474 INCLUDED IN 5000474 NOTES HANDLEBAR & CONTROLS PARTS LIST 10 Odometer 1 2 4 5 3 5 1 4 1 3 1 2 1 1 1 ITEM QTY NO REQD 5002254 5002248 5002257 5002260 5002211 DEALER PART NUMBER SWITCH, HEAD LIGHT SENSOR MAGNET CABLE, ODOMETER ODOMETER ODOMETER MOUNT PLATE CE MODEL DESCRIPTION NOTES ODOMETER PARTS LIST 11 Front Brake Master Cylinder 11 10 12 9 5 6 7 8 1 4 3 13 14 2-1 2 15 15 AR 14 1 13 1 12 1 11 1 10 1 9 1 8 1 7 1 6 1 5 1 4 2 3 4 2-1 1 2 1 1 1 ITEM QTY NO REQD 5000268 5000046 5000044 5000103 5000043 5000099 5000033 5000045 5000041 5000042 5000040 5000538 5001549 5002311 5002264 5000032 DEALER PART NUMBER NISSIN BRAKE GREASE, 2 GRAM FT BRAKE LEVER RETURN SPRING FT BRAKE LEVER FT BRAKE LEVER RUBBER COVER FT BRAKE MSTR CYL BOOT FT BRAKE MSTR CYL CIRCLIP FT BRAKE MSTR CYL KIT FT BRAKE LEVER ADJ BOLT KIT FT BRAKE LEVER PIVOT BOLT KIT FT BRAKE MSTR CYL CLAMP KIT FT BRAKE MASTER CYL CAP KIT BRAKE LINE BANJO BOLT CRUSH WASHER X FT BRAKE LINE, E X FT BRAKE LINE, C FT BRAKE MASTER CYL ASSY CE DESCRIPTION MODEL AS REQUIRED INCLUDED IN 5000032 INCLUDED IN 5000032 INCLUDED IN 5000032 INCLUDED IN 5000032/072-5000033 INCLUDED IN 5000032/072-5000033 INCLUDED IN 5000032 INCLUDED IN 5000032 INCLUDED IN 5000032 INCLUDED IN 5000032 INCLUDED IN 5000032 NOTES FRONT BRAKE MASTER CYLINDER PARTS LIST 12 Front Brake Caliper 5 6 2 3 11 1-1 1 5 10 7 8 4 9 11 1 10 1 9 1 8 1 7 AR 6 1 5 2 4 1 3 1 2 1 1-1 1 1 1 ITEM QTY NO REQD 5000055 5000052 5000054 5000049 5000268 5000050 5000863 5000035 5000036 5000048 5002256 5000034 DEALER PART NUMBER BRAKE CALIPER BLEEDER KIT SLIDE PIN BOOT - LARGE FRONT BRAKE PAD PIN KIT FRONT BRAKE PAD SPRING NISSIN BRAKE GREASE, 2 GRAM SLIDE PIN BOOT - SMALL FLANGE HEAD BOLT, M8X40 mm FRONT BRAKE CALIPER PAD KIT FRONT BRAKE CALIPER PISTON KIT FRONT BRAKE CALIPER BRACKET X FRONT BRAKE CALIPER ASSEMBLY, E X FRONT BRAKE CALIPER ASSEMBLY CE DESCRIPTION MODEL AS REQURIED NOTES FRONT BRAKE CALIPER PARTS LIST 13 Rear Brake Pedal 4 3 6 6 1 5 2 6 2 5 1 4 1 3 1 2 1 1 1 ITEM QTY NO REQD 5000375 5000399 5000413 5000109 5000112 5001226 DEALER PART NUMBER SEAL, 15X21X3 BOLT, BRAKE PEDAL RR BRAKE COTTER PIN BRAKE PEDAL YOKE PIN SPRING, BRAKE PEDAL REAR BRAKE PEDAL CE MODEL DESCRIPTION INCLUDED IN 5001226 INCLUDED IN 5001226 NOTES REAR BRAKE PEDAL PARTS LIST 14 Rear Brake Master Cylinder 12 8 13 13 10 16 7 12 1 6 15 13 9 13 2 5 1 3 1 4 2 11 2 14 2 16 1 15 1 14 2 13 4 12 2 11 1 10 1 9 1 8 AR 7 1 6 1 5 1 4 1 3 1 2 1 1 1 ITEM QTY NO REQD 5000434 NUT, FLANGE, M6 5001013 FLANGE HEAD BOLT, M6 X 16 5000126 SHCS, M8 X 20 5001549 CRUSH WASHER 5000538 BRAKE LINE BANJO BOLT 5001268 RR BRAKE MSTR CYL GUARD 5000537 REAR BRAKE LINE 5002285 RR BRAKE MSTR CYL ASSY 5000268 NISSIN BRAKE GREASE, 2 GRAM 5000085 RR BRAKE RESERVOIR ASSY 5000104 RR BRAKE RESERVOIR HOSE KIT 5000105 RR BRAKE MSTR CYL ELBOW KIT 5000107 RR BRAKE MSTR CYL BOOT 5000267 RR BRAKE MSTR CYL PISTON CIRCLIP 5000106 RR BRAKE MSTR CYL PUSHROD KIT 5000086 RR BRAKE MASTER CYL KIT DEALER PART C E DESCRIPTION NUMBER MODEL AS REQUIRED NOTES ...