2002 Engine Parts Catalog (ATV & Motorcycle) CONTENTS Throttle Body . . . . . . . . . . . . . . . . 2 Fuel Injectors . . . . . . . . . . . . . . . . 3 Cam Cover & Spark Plug . . . . . . 4 Cylinder Head . . . . . . . . . . . . . . . 5 Valve Train . . . . . . . . . . . . . . . . . 6 Valve Train Parts LIst . . . . . . . . . 7 Cam Drive . . . . . . . . . . . . . . . . . . 8 Crankcase . . . . . . . . . . . . . . . . . . 9 Crankcase Parts List . . . . . . . . . 10 Crankshaft . . . . . . . . . . . . . . . . . Piston . . . . . . . . . . . . . . . . . . . . . Crankshaft Cartridge Plate . . . . . Crankcase Cover . . . . . . . . . . . . Starter Clutch . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . Trans Cart Plate, Rear . . . . . . . Mainshaft . . . . . . . . . . . . . . . . . . Countershaft . . . . . . . . . . . . . . . . 11 12 13 14 15 16 17 18 19 Trans Cart Plate, Front . . . . . . . Countershaft Sprocket . . . . . . . . Generator Stator . . . . . . . . . . . . Water Covers . . . . . . . . . . . . . . Engine Oil Pickup Assembly . . . Scavenge Pump . . . . . . . . . . . . Engine Oil Pump . . . . . . . . . . . . Oil Supply Tubes . . . . . . . . . . . . Transmission Oil Pump . . . . . . . 20 21 22 23 24 25 26 27 28 2002 Engine Parts Catalog.fm © 2001 Cannondale Corporation - All Rights Reserved P/N 5002338 Printed : 2/5/02 Throttle Body 1 12 16 23 10 3 9 5 28 11 7 22 20 26 25 24 18 21 19 8 2 17 27 13 4 6 15 14 1 1 1 1 2 3 1 1 1 1 1 2 1 1 1 1 1 ITEM QTY NO REQD 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 1 1 1 1 2 2 1 1 1 1 2 1 834-5002039 841-6000578 812-5000513 812-5000512 841-5001561 824-5001974 603-5001971 603-5001972 603-5001973 603-5001148 861-5001149 603-5001346 853-5001564 842-5000959 834-5001581 829-5001743 812-5001489 812-5001473 603-5001401 603-6000352 603-5001142 603-5000827 603-5000825 603-5000704 603-6000351 603-5001890 603-5000688 473-5000409 601-6000683 DEALER PART NUMBER NUT, M4 WASHER, M4, ZINC BTTNHD TORX SCREW, M5X35 BTTNHD TORX SCREW, M5X25 WASHER,M5 SCREW, PHILLIPS, 10X5/8 BYPASS ACTUATOR BYPASS HOUSING BYPASS GASKET COUPLING, THROTTLE BODY CLAMP, BAND IDLE ADJUSTMENT THUMBWHEEL CIRCLIP, 7mm(STAINLESS) LOCK WASHER, M8 NUT, HEX M8 X 1.0 IDLE ADJUSTMENT SCREW BHCS, M4 X 0.7 X 12 BHCS, M4 X 0.7 X 8 THROTTLE BODY SLEEVE THROTTLE CABLE STOP THROTTLE SPRING SLEEVE SPRING, IDLE ADJUST THUMBWHEEL THROTTLE CABLE PULLEY WASHER,THROTTLE ROD THROTTLE CABLE PULLEY STOP PLATE THROTTLE BODY THROTTLE SPRING THROTTLE POSITION SENSOR THROTTLE BODY ASSEMBLY M/C ATV MODEL DESCRIPTION DOES NOT INCLUDE #18 & #19 NOTES THROTTLE BODY PARTS LIST 2 Fuel Injectors 9 6 1 7 8 1 9 5 11 2 3 10 4 3 4 11 1 872-5001545 10 1 872-5001546 9 1 893-5002321 8-1 1 894-6000317 X 8 1 894-5002204-03 X 7 1 891-5002324 6-1 1 894-6000318 X 6 1 894-5002203-02 X 5 2 353-5000478-06 4 2 836-5001458 3 2 353-5000171 2 1 351-5000166 1 4 864-5001607 ITEM QTY DEALER PART M/C ATV MODEL NO REQD NUMBER O-RING, FUEL INJECTOR, TOP O-RING, FUEL INJECTOR, BOTTOM HOSE SHEATH, BULK HOSE, FUEL, 350 mm HOSE, FUEL, REG TO INJECTOR FUEL HOSE, 6.4 mm ID, 60 mm HOSE, FUEL, 130 mm HOSE, FUEL, PUMP TO INJECTOR FUEL INJECTOR BASE NUT, HEX FLANGE, M3 FUEL INJECTOR CLIP FUEL INJECTOR SET OTKR HOSE CLAMP, 12.3mm DESCRIPTION CUT TO LENGTH TO FUEL REGULATOR TO FUEL REGULATOR TO FUEL PUMP TO FUEL PUMP INCLUDES FLOW RATE VALUE NOTES FUEL INJECTORS PARTS LIST 3 Cam Cover & Spark Plug 12 16 13 9 ATV 3-1 3 17 MX 10 18 7 8 1 4 15 2 15 5 14 15 11 18 2 17-1 1 17 1 16 1 15 1 14 1 13 1 12 1 11 1 10 1 9 1 8 4 7 2 6 1 5 1 4 1 3-1 1 3 2 2 1 1-1 1 1 1 ITEM QTY NO REQD 864-5001610 891-6000386-03 X 891-5001352 X 891-5001351 X 513-5000916-01 872-5000915 814-5001925 483-5001781 483-5002029 483-5000853 483-5000852 814-5001927 814-5001945 513-5000914 513-5000913 513-5000912-03 807-6000393-02 X 808-5001043-02 X X 801-5001136 552-6000496-02 X 552-5001126-02 X DEALER PART M/C ATV MODEL NUMBER HOSE CLAMP, DOUBLE WIRE HOSE, OIL, COVER TO SPAR HOSE, OIL, COVER TO STARTER HOSE, OIL, COVER TO FRAME CAM COVER GASKET SET O-RING, 2-023 FHB M5X12 mm, ZINC IGNITION COIL ASSEMBLY SPARK PLUG - CR8EK COIL SEAL- UPPER COIL HOLD DOWN FHB M5X20 mm, ZINC FHB M5X35 mm, ZINC CAM COVER RBR LEFT SIDE CAM COVER RBR INTAKE CAM COVER RBR EXHAUST OIL BREATHER PLUG BREATHER NIPPLE SPLIT DOWEL PIN,5X10 CAM COVER ASSY CAM COVER ASSY DESCRIPTION 6 15 INCLUDES #4, #5, #6, #14 INCLUDED IN CAM COVER ASSY INCLUDED IN CAM COVER ASSY INCLUDED IN CAM COVER ASSY NOTES CAMSHAFT COVER PARTS LIST 4 Cylinder Head 20 19 6 5 21 11 1 10 15 14 4 7 8 12 16 3 2 17 18 21 8 811-5001482 20 4 836-5001182 19 4 841-5000770 18 2 836-5001957 17 2 841-5000713 16 2 816-5000426 15 1 817-5001671 14 1 817-5001454 13 2 593-5001259 12 2 872-5000482 11 1 513-5001861 10 2 872-5000487 9 1 513-5000252-05 8 1 883-5001007 7 2 844-5001724 6 4 816-5001523 5 2 801-5001136 4 2 816-5001457 3 1 872-5001461 2 1 473-5000408 1 1 502-5001446 ITEM QTY DEALER PART M/C ATV MODEL NO REQD NUMBER SHCS, M6X25 mm NUT, HEX FLANGE, M10 FLAT WASHER, M10 STEEL NUT, FLANGE, M8 FLAT WASHER, M8 STUD, M8 FHCS ,M6X1.0X45 FHTS,M5X0.8X25 OIL TRANSFER TUBE O-RING, 2-011 IDLER GEAR BRACKET O-RING, 2-012 CAMSHAFT IDLER GEAR 31T NEEDLE BEARING,12X16X10 THRUST WASHER,12X20X.08 STUD, M6 X 35 SPLIT DOWEL PIN, 5X10 STUD, M3 X 12 O-RING, 2-111 COOLANT TEMPERATURE SENSOR CYLINDER HEAD SUB ASSY DESCRIPTION NOTES 9 13 CYLINDER HEAD PARTS LIST 5 Valve Train 12 30 10 8 13 11 4 7 19 18 9 24 27 25 20 29 26 23 15 21 17 14 14 1 28 16 2 3 5 6 22 6 Valve Train Parts LIst 30 SEE TABLE VALVE ADJUSTMENT SHIM 29 1 871-5000465 OIL SEAL,14X25X5 28 1 801-5000792 SOLID DOWEL PIN 5X24 27 2 883-5000506 NEEDLE BEARING,16X24X13 26 2 881-5000498 BALL BEARING 25 1 871-5001355 OIL SEAL:16X24X5 24 1 871-5001783-02 SEAL, 12X25X5 mm 23 2 871-5000464 OIL SEAL,40X62X6 22 2 811-5001488 SHCS, M12X 1.25X 25 21 4 801-5001676 BEARING, ROLLER, 3X9.8mm 20 2 801-5001406 DOWEL PIN, 2X20 19 1 513-5000253 IDLER GEAR SHAFT 18 1 513-5000251 CMSHFT DRV GR SHAFT 17 2 513-5000249 CAM GEAR 16 1 513-5001982 INTAKE CAMSHAFT 15 1 512-5001756 EXHAUST CAMSHAFT ASSY 14 4 503-5000874 RETAINER,BEARING 13 4 503-5000463 VALVE STEM SEAL 12 4 503-5000239 VALVE BUCKET 11 4 503-5002041 VALVE SPRING KEEPER 10 4 503-5002057 VALVE SPRING RETAINER 9 4 503-5000210-03 INNER VALVE SPRING 8 4 503-5000209-03 OUTER VALVE SPRING 7 4 503-5000208 VALVE SPRING SEAT 6 2 503-5000207 EXHAUST VALVE 5 2 503-5000206 INTAKE VALVE 4 1 503-5000205 VALVE GUIDE 3 2 503-5001965 EXHAUST VALVE SEAT 2 2 503-5001964 INTAKE VALVE SEAT 1 1 502-5001446 CYLINDER HEAD SUB ASSY ITEM QTY DEALER PART DESCRIPTION NO. REQ NO. CALL BEFORE MC1000 INCLUDED IN 502-5001446 INCLUDED IN 502-5001446 INCLUDED IN 502-5001446 NOTES 503-5001715 503-5001714 503-5001713 503-5001665 503-5001666 503-5001667 503-5001668 503-5001669 503-5001670 503-5001186 503-5001187 503-5001188 503-5001189 503-5001190 503-5001191 503-5001192 503-5001193 503-5001194 503-5001195 503-5001196 503-5001197 503-5001198 503-5001199 503-5001200 503-5001201 503-5001202 503-5001203 503-5001204 503-5001205 503-5001206 DEALER PART NO. Valve Shim,2.05 Valve Shim,2.10 Valve Shim,2.15 Valve Shim,2.20 Valve Shim,2.25 Valve Shim,2.30 Valve Shim,2.35 Valve Shim,2.40 Valve Shim,2.45 Valve Shim,2.50 Valve Shim,2.55 Valve Shim,2.60 Valve Shim,2.65 Valve Shim,2.70 Valve Shim,2.75 Valve Shim,2.80 Valve Shim,2.85 Valve Shim,2.90 Valve Shim,2.95 Valve Shim,3.00 Valve Shim,3.05 Valve Shim,3.10 Valve Shim,3.15 Valve Shim,3.20 Valve Shim,3.25 Valve Shim,3.30 Valve Shim,3.35 Valve Shim,3.40 Valve Shim,3.45 Valve Shim,3.50 DESCRIPTION VALVE TRAIN PARTS LIST ADDITIONAL PARTS TABLE 7 Cam Drive 19 12 16 11 11 17 20 19 17 15 13 18 9 14 4 1 2 3 6 10 5 7 20 1 513-5001156 19 2 883-5001007 18 1 513-5000250 17 2 844-5001724 16 1 513-5001862 15 1 811-5001475 14 1 811-5001477 13 2 811-5001480 2 12 811-5001491 11 1 512-5001102 10 1 852-5001028 9 1 513-5000671-04 8 2 811-5001481 7 1 513-5001039-03 6 1 513-5001829 5 1 513-5000999 4 1 812-5000420 3 1 513-5001948 2 1 872-5000482 1 1 513-5000256 ITEM QTY DEALER PART M/C ATV MODEL NO REQD NUMBER 8 SPACER, DRIVE GEAR SPROCKET NEEDLE BEARING, 12X16X10 DRIVE GEAR SPROCKET 27T, 33T WASHER, THRUST, 12X20X.08 CAMSHAFT DRIVE GEAR BRACKET SHCS , M5X0.8X12 mm SHCS , M5X0.8X18 mm SHCS , M5X0.8X50 mm SHCS , M6X1.0X16 mm CAM CHAIN TENSIONER ASSEMBLY EXTRNL RETANING RING, M10 CAM CHAIN TENSIONER SHOE SHCS , M6X1.0X14 mm TIMING CHAIN GUIDE TIMING CHAIN GUIDE SUPPORT CAM CHAIN TENSIONER PVT BOLT TBHCS, M5X0.8X10 mm, SS CAM CHAIN TENSIONER SHOE PIVOT O-RING, 2-011 TIMING CHAIN DESCRIPTION NOTES CAM DRIVE PARTS LIST 8 Crankcase 24 1 23 18 19 17 22 3 2 16 15 14 20 13 5 25 13 4 21 7 6 11 12 10 9 8 7 9 Crankcase Parts List 25 1 879-5002161 24 2 861-5000793 23 1 893-5000773 22 1 891-5001349 21 1 552-5001921 20 1 816-5001731 19 1 872-5001063 18 1 593-5001062 17 1 593-5001117 16 1 593-5000389 15 1 849-5001704 14 1 593-5000920 13 2 885-5000649-02 12 2 885-5000648 11 2 885-5000650-02 10 2 801-5001136 9 1 883-5001675 8 1 871-5000469 7 2 882-5001871 6 1 883-5000820 5 1 881-5000500 4 2 801-5001557 3 1 871-5000470 2 1 851-5001135 1 2 801-5001051 ITEM QTY DEALER PART MO SP MODEL NO REQD NUMBER CYLINDER HEAD SEAL SCREW CLAMP HOSE SHEATH OIL INLET HOSE CRANKCASE CYL HEAD STUD, COLD HEADED O-RING, 2-018 ENGINE OIL INLET FITTING ENGNE OIL INLET SCREEN ASSY TRANSMISSION OIL FILTER WASHER, TRANSMISSION DRAIN TRANSMISSION OIL FILTER PLUG RR ENGINE MOUNTNG BUSHING FT OUTER ENGINE MOUNTING BUSHING FT INNER ENGNE MOUNTING BUSHING SPLIT DOWEL PIN, 5X10 NEEDLE BEARING,15X21X16 OIL SEAL, 20X30X7 HMS4 ROLLER BEARING, 31.5X52X15 NEDLE BEARING, 33.3X38.3X9.5 BALL BEARING, 20X42X12 HOLLOW DOWEL PIN OIL SEAL, 30X40X7 INTRNL CIRCLIP, 40mm SOLID DOWEL PIN, 5X12 DESCRIPTION NOTES CRANKCASE PARTS LIST 10 Crankshaft 11 9 8 4 10 7 5 6 12 2 1 3 12 1 889-5000519 11 1 801-5001146 10 1 802-5001970 9 1 882-5001796 8 1 817-5001608 7 1 881-5000816 6 1 532-5001124 5 1 883-5001793 4 1 849-5001622 3 1 533-5000283-05 2 1 844-5000998 1 1 531-5001961 ITEM QTY DEALER PART M/C ATV MODEL NO REQD NUMBER STARTER CLUTCH FWD DOWEL PIN, .0627X.375 WOODRUFF KEY BEARING, 25X62X17 mm, PLSTC FLTHD SCRW, M6X1.0X12 BALL BEARING:17X40X12-SEALED BALANCE SHAFT ASSY BEARING, NEEDLE, 20X26X16 ONE WAY CLUTCH SPACER STARTER GEAR, 54T BALANCE SHAFT THRUST WASHER CRANKSHAFT ASSEMBLY DESCRIPTION NOTES CRANKSHAFT PARTS LIST 11 Piston 5 3 14 2 1 10 4 8 7 11 6 9 12 13 14 1 13 2 12 1 11 1 10 2 9 1 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 ITEM QTY NO REQD 872-5001787 817-5001935 811-5001477 811-5001475 872-5000482 872-5000921 872-5000915 553-5001866 879-5000627 522-5001981 523-5001424 523-5002314 523-5002315 522-5002316 DEALER PART NUMBER O-RING, 100X2.5 mm FHTS, M5X10 mm SHCS ,M5X18 mm SHCS ,M5X12 mm O-RING, 2-011 O-RING, 2-019 O-RING, 2-023 PISTON PIN ACCESS COVER QUAD-RING, CYLINDER LINER PISTON, 95 mm, .180 CYLINDER LINER, 95 mm PISTON PIN, 18 X 46.48 mm PISTON PIN CIRCLIP SET PISTON RING SET M/C ATV MODEL DESCRIPTION NOTES PISTON PARTS LIST 12 Crankshaft Cartridge Plate 4 1 2 3 24 17 18 19 9 21 20 16 8 5 6 7 23 4 6 7 13 2 14 10 11 12 15 5 8 1 3 9 22 24 1 872-5000304 23 1 872-5001120 22 1 533-5001737-11 21 5 811-5001484 20 4 811-5001485 19 1 879-5001230 18 1 872-5000487 17 1 872-5000482 16 1 593-5001002 15 2 801-5001037 14 1 849-5000452-02 13 1 811-5000428 12 1 801-5000629-06 11 1 593-5000390 10 1 882-5001152 9 1 844-5001244 8 1 852-5001028 7 1 871-5000466 6 1 851-5001109 5-1 1 533-6000227 X 5 1 533-5000630 X 4 1 593-5000367 3 1 513-5000263 2 1 849-5001110 1 1 835-5000216 ITEM QTY DEALER PART M/C ATV MODEL NO REQD NUMBER O-RING, 2-009 O-RING, 2-022 CRANKSHAFT CARTRIDGE PLATE SHCS, M8 X 1.25X 20 SHCS, M8 X 1.25X 25 CRANKSHAFT CARTRIDGE PLATE SEAL O-RING, 2-012 O-RING, 2-011 PRESSURE PUMP SEAL SCAVENGE PUMP LOCATING DOWEL TDC WASHER, 8X13X5.5 mm TDC SCREW IDLR GEAR SHAFT 10X45 SCAVENGE PUMP IDLER GEAR ROLLER BEARING, 10X14X12 THRST WASHER 10.1X20X1 EXTERNAL RETANING RING, M10 OIL SEAL, 33X47X7 INTERNAL RETANING RING, 47mm PRIMARY DRIVE GEAR: 28T PRIMARY DRIVE GEAR: 29T SCAVENGE PUMP DRIVE GEAR: 30T TIMING CHAIN SPROCKET: 22T DISC SPRING,16.3 X 31.5 X 2 JAM NUT, M16X1.5 DESCRIPTION POSITIONS 4...5...6...7...9 POSITIONS 1...2...3...8 NOTES CRANKSHAFT CARTRIDGE PLATE PARTS LIST 13 Crankcase Cover 10 2 1 3 4 5 17 Locations 11 8 11 7 3 Locations 9 6 11 1 593-5002071 10-1 1 891-5001556-03 X 10 1 891-5002313 X 9 3 819-5001944 8 17 819-5001927 7 1 871-5000473 6 1 885-5000517 5 1 872-5000828 4 1 553-5001434 3 1 553-5002269 2 1 808-5001255-03 1 1 553-5000315 ITEM QTY DEALER PART M/C ATV MODEL NO REQD NUMBER OIL LEVEL SIGHT WINDOW BREATHER HOSE BREATHER HOSE THCS, M5X0.8X22 TBHCS, XTRL M5X0.8X20 OIL SEAL: 14X22X4 (2 LIP) BUSHING O-RING, 2-016 TRANSMISSION OIL FILL CAP CRANKCASE COVER HOSE NIPPLE, 6M CRANKCASE COVER GASKET DESCRIPTION INCLUDED IN 553-5 ...