IM NT RTA PO of the copy log. AFT a DR arts Cata This ATV P 2003 e ult th g cons lo lease arts Cata P VP d. te AT 2002 ere indica wh 2003 ATV PARTS CATALOG Models : Moto440 (MO), Blaze 440 (BZ), Glamis (GL), Speed (SP), Cannibal (CN) Modified : 1/8/03 www.cannondale.com/motorsports CONTENTS Wheels and Hubs. . . . . . . . . . . . . . . . . 4 Standard A-Arms . . . . . . . . . . . . . . . . . 6 Moto 440 A-Arms . . . . . . . . . . . . . . . . . 8 Front Shock . . . . . . . . . . . . . . . . . . . . 10 Steering Column . . . . . . . . . . . . . . . . 12 Steering Damper . . . . . . . . . . . . . . . . 14 Handlebar and Controls . . . . . . . . . . . 16 Ignition . . . . . . . . . . . . . . . . . . . . . . . . 18 Front Brake Master Cylinder . . . . . . . 20 Front Brake Caliper . . . . . . . . . . . . . . 22 Rear Brake . . . . . . . . . . . . . . . . . . . . 24 Mainframe . . . . . . . . . . . . . . . . . . . . . 26 Brush Guard. . . . . . . . . . . . . . . . . . . . Engine Rail. . . . . . . . . . . . . . . . . . . . . Subframe . . . . . . . . . . . . . . . . . . . . . . Swingarm . . . . . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . Rear Shock . . . . . . . . . . . . . . . . . . . . Airbox and Filter . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . Electrical Tray . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness. . . . . . . . . . . . . . . . . . Headlight . . . . . . . . . . . . . . . . . . . . . . Cooling System . . . . . . . . . . . . . . . . . Fuel Tank and Regulator . . . . . . . . . . 28 30 32 34 36 38 40 42 44 46 48 50 52 54 Fuel Pump . . . . . . . . . . . . . . . . . . . . . 56 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Footpegs and Baskets . . . . . . . . . . . . 60 Nerf Bars . . . . . . . . . . . . . . . . . . . . . . 62 Plastic . . . . . . . . . . . . . . . . . . . . . . . . . 64 2003 Cannibal Graphics (Black Plastic) 66 2003 Cannibal Graphics (Silver Plastic) 68 2003 Speed Graphics (Silver Plastic). 70 2003 Glamis Graphics (Silver Plastic) 72 2003 Moto 440 and Blaze Graphics (Silver Plastic) . . . . . . . . . . . . . . . . . . . . . . . . 74 2003 Warning Decals . . . . . . . . . . . . . 76 The illustrations, photographs, and parts information in this Parts Catalog are for reference to replacement parts only. This manual should not be used for service reassembly. Any part of this document is subject to correction without prior notice. The illustrations and part information included in this parts catalog accurate at the time of the publication date. The part numbers listed in this document may change after publication. Newer revisions of the same part number are processed as supercessions at the time of order. Be sure to ask for available supercession information when ordering or check available parts bulletins on our website. http://www.cannondale.com/motorsports/tech/partslist.html Cannondale reserves the right to make product improvement changes at any time without prior notice. No part of this 2003 Parts Manual may be reproduced without written permission. · Never use anything other than authorized Cannondale parts. · Whenever replacing a part replace the gaskets, o-rings, circlips, etc. whenever possible. · Always thoroughly clean all parts thoroughly before assembly. · All screws, nuts, bolts, etc. are in the metric system. · Always use the recommended tools, liquids, lubricants, fuel and oil quantities. 2 Table/Illustration Legend 6000535 6000536 6000537 SHOCK SPRING, FRONT SHOCK SPRING, FRONT SHOCK SPRING, FRONT 180-84/23 180-48 180-46 1 ITEM NO. - Item number shown in illustration 2 ASTERISKS (*) - Appear in the Item no. column when a similarly appearing part with a different part number is used. The asterisk refers to the item no. directly below it. 9 ADDITIONAL PARTS 17 1 16 1 15 1 14 2 13 2 12 1 11 1 10 2 9 2 8 2 7 1 6 1 5 1 4 1 3 1 2 2 * 2 * 2 * 2 * 2 1 2 ITEM QTY NO REQD 6000444 SPACER, FRONT SHOCK 6000615 SHCK SPRNG PRLOAD CA M RING 6000272 FHB M10X50 mm 5000146 LOCKNUT,M10 5000715 FLAT WASHER, M10 5000424 FHB M10x70mm SHOCK BOLT 5001291 SHOCK MOUNT BEARING 5001288 SHOCK MOUNT BEARING CIRCLIP 5001289 SHOCK MOUNT BEARING SEAL 5001290 SHOCK MOUNT BEARING SPACER 6000543 UPPER MOUNT BUSHING 6000538 SHOCK SPRING RETAINER 6000539 SHOCK SPRING PRELOAD CIRCLIP 6000540 SHOCK SPRING PRELOAD A DJ 6000541 SHOCK BODY PROTECTOR 6000542 SHOCK BODY CIRCLIP 6001248 X SHOCK, FRONT 6001200 X SHOCK, FRONT 6001028 X SHOCK, FRONT 6001183 X SHOCK, FRONT, GLAMIS 6000648 X SHOCK, FRONT DEALER PART MO SP GL BZ CN DESCRIPTION MODEL NUMBER 3 OHLINS OHLINS OHLINS OHLINS OHLINS OHLINS OHLINS OHLINS OHLINS OHLINS ARVIN OHLINS OHLINS OHLINS OHLINS NOTES 3 QTY REQD - The quantity of the Item No. required 4 DEALER PART NUMBER - The Cannondale Part Number, use this part number and quantity when ordering. 5 MODEL - The vehicle base model code. Use for special edition vehicles. Model codes for this catalog are: FRONT SHOCK PARTS LIST 1 2 4 5 6 7 8 MO - Moto440 SP - Speed GL - Glamis BZ - Blaze CN - Cannibal 6 TABLE TITLE - The title of the table that compliments it's corresponding ABBREVIATIONS FHB - Flange head bolt SHCS - Socket head cap screw BHCS - Button head cap screw HHCS - Hex head cap screw FHCS - Flat head cap screw FSHCS - Flat socket head cap screw RTNG - Retaining INT - Internal ASSY - Assembly LWR - Lower CYL - Cylinder PVT - Pivot ADJ - Adjustment ID - Inside Diameter FT - Front RR - Rear R - Right L - Left INR - Inner OUT - Outer PR - Pair BLK - Black RED - Red YEL - Yellow ORG - Orange GRY - Gray SLV - Silver Illustration. 7 DESCRIPTION - A text description of the part. 8 NOTES - Additional information about the part. 9 ADDITIONAL PARTS TABLE - Contains information about available factory built assemblies and parts. 2003 ATV Parts Catalog Interim.fm - 1/8/03 © 2002 Cannondale Corporation - All Rights Reserved 3 Wheels and Hubs Wheels and Hubs www.cannondale.com/motorsports 10 4* 9* 3 12 11 7 8 1* 13* 2* 6 5 3 4 * 2 13 2 12 1 11 1 10 1 * 1 9 1 8 1 7 1 6 1 5 4 * 2 4 2 3 1 * 2 * 2 * 2 * 1 * 1 * 1 2 1 * 2 * 2 * 2 * 1 * 1 * 1 1 1 ITEM QTY NO REQD 152-6001030 X 152-6000326 6000009 6000011 6000026 052-6001031 X 052-6000553 6001150 5000355 6000010 5000138 6001034 X 6000633 6000474 6001080 X 6001033 6000305 6001191 6001190 6000834 6000832 6001189 6001032 6000303 6001079R X 6001079L X 6000833 6000831 DEALER PART MO NUMBER X X X X X X X X X X X X X X X SP GL BZ MODEL REAR HUB ASSEMBLY, RED X REAR HUB ASSEMBLY INSERT, 15.2X20X9.8 mm SEAL, HUB, FRONT, OUTER BEARING, HUB, FRONT, OUTER FRONT HUB ASSEMBLY, RED X FRONT HUB ASSEMBLY SPACER, BEARING HUB, 15.2X25.5X19.5 mm SEALED BEARING, 20X42X12 SEAL, HUB, FRONT, INNER FHCS, M8X16 mm, NYLOK/ZINC FRONT ROTOR X FRONT ROTOR LUG NUT, M10 REAR WHEEL ASSEMBLY REAR WHEEL ASSEMBLY REAR WHEEL ASSEMBLY REAR WHEEL ASSEMBLY, PADDLE, RIGHT REAR WHEEL ASSEMBLY, PADDLE, LEFT X REAR WHEEL ASSEMBLY, RIGHT X REAR WHEEL ASSEMBLY, LEFT FRONT WHEEL ASSEMBLY, PADDLE FRONT WHEEL ASSEMBLY FRONT WHEEL ASSEMBLY FRONT WHEEL ASSEMBLY, RIGHT FRONT WHEEL ASSEMBLY, LEFT X FRONT WHEEL ASSEMBLY, RIGHT X FRONT WHEEL ASSEMBLY, LEFT CN DESCRIPTION Holeshot MX Holeshot XCR Glamis Paddle Glamis Paddle Glamis Paddle Holeshot XCR Holeshot MX Holeshot MX NOTES WHEELS AND HUBS PARTS LIST 2003 ATV Parts Catalog Interim.fm - 1/8/03 © 2002 Cannondale Corporation - All Rights Reserved 5 Standard A-Arms Standard A-Arms www.cannondale.com/motorsports See 2002 ATV Parts Catalog 6 See 2002 ATV Parts Catalog 2003 ATV Parts Catalog Interim.fm - 1/8/03 © 2002 Cannondale Corporation - All Rights Reserved 7 Moto 440 A-Arms Moto 440 A-Arms www.cannondale.com/motorsports 29 5 18 25 27 28 9 21 , 22 7 23 7 8 6 10 25 24 26 12 3 ,4 19 17 16 14 13 8 11 1 ,2 8 15 20 29 1 013-6000870 6000702 6000703 6000270 5000146-01 5000715 6000265 013-6000147-03 013-6000156-03 6001110 6001119 6001128 6001127 6001109 6001111 6001112 6001113 6001114 013-6000686-02 6001117 013-6000730-02 6000706 6000488 6000268 014-6000822 013-6001090 013-6001088 013-6001091 013-6001089 DEALER PART NUMBER X TIE ROD END KIT 2 ENDS PER KIT ADDITIONAL PARTS 28 1 27 1 26 4 25 6 24 4 23 1 22 1 21 1 20 4 19 1 18 1 17 2 16 1 15 2 14 2 13 2 12 1 11 1 10 1 9 1 8 2 7 3 6 2 5 1 4 1 3 1 2 1 1 1 ITEM QTY NO REQD NUT, JAM, LEFT, M10 NUT, JAM, RIGHT, M10 FHB, M10X80mm, ZINC, NYLOK LOCKNUT,M10 FLATHEAD WASHER, M10 NUT, CASTLE, M14 UPRIGHT, RIGHT UPRIGHT, LEFT WASHER, PIVOT, A-ARM ZERK FITTING, M6 STRAIGHT SCREW, SET, M5X8 MM, ZINC SPACER, ZERK FITTING BEARING, SPHERICAL, CB-8-B2 SPACER, PIVOT, A-ARM SEAL, HMS45412 CLIP, SPIROLOXUR-87 INSERT, A-ARM ROD END BALL JOINT, ATV A-ARMS NUT, JAM, M16X1.5 ROD END/ BALL JOINT KIT RING, RTNG, INT, 30 mm PIN, COTTER, 2.5X32 mm NUT, CASTLE, M12 STEERING TIE ROD ASSEMBLY UPPER A-ARM ASSEMBLY, RIGHT UPPER A-ARM ASSEMBLY, LEFT LOWER A-ARM ASSEMBLY, RIGHT LOWER A-ARM ASSEMBLY, LEFT DESCRIPTION X X X X X X X X X X X INCLUDED WITH BALL JOINT X X X X X MO SP GL BZ CN MODEL NOTES A-ARMS PARTS LIST, MOTO440 2003 ATV Parts Catalog Interim.fm - 1/8/03 © 2002 Cannondale Corporation - All Rights Reserved 9 Front Shock Front Shock www.cannondale.com/motorsports 13 14 7 17 12 5 4 16 1* 3 2 6 8 - 11 15 10 6000535 6000536 6000537 17 2 16 1 15 1 14 2 13 2 12 1 11 1 10 2 9 2 8 2 7 1 6 1 5 1 4 1 3 1 2 2 * 2 * 2 * 2 * 2 1 2 ITEM QTY NO REQD SHOCK SPRING, FRONT SHOCK SPRING, FRONT SHOCK SPRING, FRONT 180-84/23 180-48 180-46 ADDITIONAL PARTS 6000444 SPACER, FRONT SHOCK 6000615 SHOCK SPRNG PRLOAD CAM RING 6000272 FHB M10X50 mm 5000146 LOCKNUT,M10 5000715 FLAT WASHER, M10 5000424 FHB M10x70mm SHOCK BOLT 5001291 SHOCK MOUNT BEARING 5001288 SHOCK MOUNT BEARING CIRCLIP 5001289 SHOCK MOUNT BEARING SEAL 5001290 SHOCK MOUNT BEARING SPACER 6000543 UPPER MOUNT BUSHING 6000538 SHOCK SPRING RETAINER 6000539 SHOCK SPRING PRELOAD CIRCLIP 6000540 SHOCK SPRING PRELOAD ADJ 6000541 SHOCK BODY PROTECTOR 6000542 SHOCK BODY CIRCLIP 6001248 X SHOCK, FRONT 6001200 X SHOCK, FRONT 6001028 X SHOCK, FRONT 6001183 X SHOCK, FRONT, GLAMIS 6000648 X SHOCK, FRONT DEALER PART MO SP GL BZ CN DESCRIPTION MODEL NUMBER OHLINS OHLINS OHLINS OHLINS OHLINS OHLINS OHLINS OHLINS OHLINS OHLINS ARVIN OHLINS OHLINS OHLINS OHLINS NOTES FRONT SHOCK PARTS LIST 2003 ATV Parts Catalog Interim.fm - 1/8/03 © 2002 Cannondale Corporation - All Rights Reserved 11 Steering Column Steering Column www.cannondale.com/motorsports See 2002 ATV Parts Catalog 12 See 2002 ATV Parts Catalog 2003 ATV Parts Catalog Interim.fm - 1/8/03 © 2002 Cannondale Corporation - All Rights Reserved 13 Steering Damper Steering Damper www.cannondale.com/motorsports 8 7 8 1 4 2 11 12 6 9 4 10 9 3 5 7 14 214-6001041 12 1 11 1 10 2 9 2 8 2 7 6 6 1 5 1 4 2 3 1 2 1 1 1 ITEM QTY NO REQD 6001147 X X 6001146 X X 6001099 X X 6000314 X X 5000095 X X 6001098 X X 6001093 X X 6001094 X X 6001095 X X 6001096 X X 6001097-04 X X 6001041 X X DEALER PART MO SP GL BZ CN MODEL NUMBER STEERING DAMPER KIT ADDITIONAL PARTS NUT, DAMPER LINK ARM DAMPER SHEER PIN NUT, JAM, M6X1 NUT, LOCK, M6 FLNG HD BLT,M6X20,NYLOK SHCS, M6X30 mm STEERING DAMPER MOUNT STEERING DAMPER MOUNT CLAMP ROD END LINK ROD ROTARY DAMPER LINK ARM STEERING DAMPER DESCRIPTION NOTES STEERING DAMPER PARTS LIST 2003 ATV Parts Catalog Interim.fm - 1/8/03 © 2002 Cannondale Corporation - All Rights Reserved 15 Handlebar and Controls Handlebar and Controls www.cannondale.com/motorsports 3* 2* 6 22 21 26 9 15 20 19 10 7 1* 12 29 8 28 23 13 18 14 24 25 11 16 17 4 5 27 16 29 1 28 1 27 2 26 AR 25 1 24 1 23 1 22 1 21 2 20 1 19 1 18 1 17 1 16 1 15 1 14 1 13 1 12 1 11 1 10 1 9 1 8 1 7 1 6 1 5 1 4 1 * 1 * 1 3 1 * 1 2 1 * 1 * 1 * 1 1 1 ITEM QTY NO REQD 6000827 INTERLOCK SWITCH BOOT 6000824 INTERLOCK SWITCH 5001927 FHB M5X20 mm 5002385 HYDRAULIC CLUTCH OIL, 16 oz. 5002593 O-RING, SLAVE CYLINDER 5002373 CLUTCH LEVER PVT HRDWR KIT 5002374 CLUTCH LEVER SPRING 5002375 CLUTCH MASTER CYL CAP 5002376 CLUTCH MASTER CYL CAP SCREW 5002377 CLUTCH LEVER CLAMP 5002378 CLUTCH LEVER CLAMP SCREW 5002379 CLUTCH LEVER BOOT 5002380 CLUTCH LEVER ADJ GRIP, RED 5002381 CLUTCH MSTR CYL PISTON KIT 5002382 CLUTCH MSTR CYL MEMBRANE 5002383 CLUTCH SLAVE VALVE, CAP KIT 6000825 CLUTCH TUBE KIT, 1100 mm 6000826 MASTER CYLINDER, BLK 5002387 SLAVE CYLINDER, COMPLETE 6000823 CLUTCH LEVER, BLACK 6000671 CLUTCH LEVER ASSEMBLY 6001048 HANDGUARD SET 6000168-04 THROTTLE CABLE 6000248 THROTTLE ASSEMBLY 213-5001952 ENGINE START SWITCH 5001953 ENGINE STOP SWITCH 6001040 X X GRIP SET, RED 6000491 X GRIP,PR,CLOGO,BLK/GRY 6000647 X X GRIP,PR,CLOGO,BLK/YEL 6001178 HANDLEBAR PAD, MAGURA, ORG 6001180 HANDLEBAR PAD, MAGURA, RED 5002454 X HANDLEBAR, MAG, MX2 6001017 X HANDLEBAR, TAG X5 6001037 X X HANDLEBAR, TAG T2 6000283 X HANDLEBAR, BLK DEALER PART MO SP GL BZ CN DESCRIPTION MODEL NUMBER HARDWARE INCLUDED HANDLEBAR PAD INCLUD ...