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User manual CANNONDALE 2003 E440, C440, X440, S440 PARTS CATALOG
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Manual abstract: user guide CANNONDALE 2003 E440, C440, X440, S440 PARTS CATALOG
Detailed instructions for use are in the User's Guide. 2003 Motorcycle Parts Catalog
(E440, E440A, E440R, S440, C440, X440) - 09/02
CONTENTS
Legend .........................................2 Front Wheel .................................3 Rear Wheel...................................4 Rear Wheel List ...........................5 Wheel Hubs..................................6 Front Fork ....................................7 Front Fork List .............................8 Steering Head...............................9 Front Brake Guides ....................10 Handlebar & Controls ................11 Handlebar & Controls List.........12 Odometer ...................................13 Front Brake Master Cylinder .....14 Front Brake Caliper....................15 Rear Brake Pedal........................16 Rear Brake Master Cylinder ......17 Rear Brake Caliper.....................18 Mainframe..................................19 Subframe ....................................20 Frame Rail & Skidplate .............21 Footpegs ....................................22 Kickstand ...................................23 Swingarm ...................................24 Rear Shock .................................25 Seat & Plastic.............................26 Fenders & Lights........................27 Battery Plate...............................28 Electrical ....................................29 Exhaust.......................................30 Radiator .....................................31 Airbox ........................................32 Fuel Tank ...................................33 Fuel System................................34 Decals.........................................35 Vehicle Warnings .......................36
P/N 5002339-03
Printed : 9/4/02
2003 Motorcycle Parts Catalog 0902.fm © 2001 Cannondale Corporation - All Rights Reserved
Legend
1 2 3 4 567 89 10 11
5002260I 5002254 5 1 5002248 4 1 5002257 3 1 5002260 2 1 5002211 1 1 ITEM QTY DEALER PART NO REQD NUMBER
X
ODOMERTER INSTRUCTIONS ADDITIONAL PARTS TABLE SWITCH, HEAD LIGHT SENSOR MAGNET CABLE, ODOMETER ODOMETER ODOMETER MOUNT PLATE S E EA ER CR DESCRIPTION MODEL
12
NOTES
ODOMETER PARTS LIST
1 - CALL OUT DESIGNATOR: ASTERICS (*) ARE USED WHEN A SIMILAR PART IS USED ACROSS DIFFERENT MODELS. 2 - QUANTITY REQUIRED FOR THE COMPLETE ASSEMBLY 3 - CANNONDALE PART NUMBER 4 - `03 X440, MOTOCROSS BIKE 5 - `03 S440, SUPER MOTARD BIKE 6 - `03 E440, ENTRY LEVEL ENDURO 7 - `03 E440A, AUTOMATIC ENDURO (REVLOC CLUTCH) 8 - `03 E440R, HIGH END RACING ENDURO 9 - `03 C440R, HIGH END CROSS COUNTRY BIKE 10 - CANNONDALE DESCRIPTION 11 - ADDITIONAL NOTES 12 - CONTAINS AVAILABLE FACTORY BUILT ASSEMBLIES AND ACCESSORY PARTS
NOTE: THE ILLUSTRATIONS CONTAINED IN THIS PARTS CATALOG MAY DIFFER FROM THE DESIRED PART AND SHOULD ONLY BE CONSIDERED AS A VISUAL REPRESENTATION.
2
Front Wheel
3
*
4
12
*
11
*
2 5
*
13
*
6 7
*
1
9
8
5002540 051-5002498 051-5000020 * 18 5002500A 13 18 5000026 * 18 5002501A 12 18 5000477 11 36 5001623 10 1 5000540 9 6 5000864 * 1 5002511 * 1 5002246 8 1 5000047 * 1 5002504 7 1 5000536 6 1 5000028 * 1 5002510 * 1 5002134 5 1 5000029 * 1 5002508 * 1 5002135 4 1 5000030 * 1 5002506 * 1 5002098 3 1 5000031 2 1 5000021 1 1 S E E F R ONT HUB ITEM QTY DEALER PART NO REQD NUMBER X X X X X XX X XX WEIGHT, WHEEL BALANCE FRONT WHEEL ASSEMBLY, MOTARD FRONT WHEEL ASSEMBLY ADDITIONAL PARTS TABLE SPOKE, FRONT, OUTSIDE, 3.6x172.0mm X SPOKE, FRONT - OUTSIDE SPOKE, FRONT, INSIDE, 3.6x177.0mm X SPOKE, FRONT, - INSIDE NIPPLE, FRONT NUT, FLANGE, M16X1.5 FHCS, M6X16,NYLKZINC ROTOR, FRONT, 320mm X FRONT ROTOR FRONT ROTOR RIM, FRONT, 17X3.5", BLK X RIM, FRONT RIM LOCK, FRONT RIM STRIP, 17" X RIM STRIP, FRONT RIM STRIP, FRONT TUBE, FRONT, 120/70-17 X TUBE, FRONT TUBE, FRONT TIRE, FRONT, 120/70-17 X TIRE, FRONT TIRE, FRONT AXLE, FRONT WHEEL FRONT HUB ASSEMBLY C DESCRIPTION
*
10
Strip of 12, 1/4 oz w eights
INCLUDED IN FR WHEEL ASSYS INCLUDED IN FR WHEEL ASSYS INCLUDED IN FR WHEEL ASSYS INCLUDED IN FR WHEEL ASSYS INCLUDED IN FR WHEEL ASSYS
X X X X X X X X X X X X X X XX XX XX X XX XX
ACCEPTS ODOMETER MAGNET INCLUDED IN FR WHEEL ASSYS INCLUDED IN FR WHEEL ASSYS
INCLUDED IN FR WHEEL ASSYS NOTES
X S E EA ER MODEL
FRONT WHEEL PARTS LIST
3
Rear Wheel
2
*
3
15
*
4
16
*
*
17
*
18
12 11
*
5 14
10
*
13
9
*
6 1
*
7
8
4
5002540 5000339 5000349 5000357 151-5002499 151-5002085 151-5000069 18 2 5002199 * 18 5002502 * 18 5001873 17 18 5000075 * 18 5002503 * 18 5002287 16 18 5000797 15 36 5001624 14 6 5000713 13 6 5000140 12 6 5000393 * 1 5002521 11 1 5000117 * 1 6000315 10 1 5001847 * 1 5002522 * 1 5001798 9 1 5001601 8 4 5000138 7 1 5000090 * 1 5002505 * 1 5001886 6 1 5000076 5 1 5000077 * 1 5002510 * 1 5002130 4 1 5000078 * 1 5002508 * 1 5002131 3 1 5000079 * 1 5002507 * 1 5002132 2 1 5000080 1 1 SEE REAR HUB ITEM QTY DEALER PART NO REQD NUMBER
X XX X X XX X X X
X X XX X XX X X XXX XXX
X XX X X XX X X XX X X XX X X S E EA ER MODEL X X X X
WEIGHT, WHEEL BALANCE SPROCKET, REAR, 49 T SPROCKET, REAR, 51 T SPROCKET, REAR, 52 T REAR WHEEL ASSEMBLY, MOTARD REAR WHEEL ASSEMBLY, 18" REAR WHEEL ASSEMBLY, 19" ADDITIONAL PARTS TABLE DUST CAP SPOKE, REAR, OUTSIDE, 4.0X175.0 mm X SPOKE, REAR, OUTSIDE, 18" WHEEL SPOKE, REAR, OUTSIDE, 19" WHEEL SPOKE, REAR, INSIDE, 4.0X181.0 mm X SPOKE, REAR, INSIDE, 18" WHEEL SPOKE, REAR, INSIDE, 19" WHEEL NIPPLE, REAR FLAT WASHER, M8 LOCKNUT, M8 FHCS, M8X28 mm, ZINC SPROCKET, REAR, 45T X SPROCKET, REAR, 50 T X MASTER LINK, O-RING MASTER LINK CHAIN, DRIVE, 112 LINKS X CHAIN, DRIVE, 114 LINKS, O-RING CHAIN, DRIVE, 114 LINKS FHCS, M8X16, NYLK, ZINC ROTOR, REAR RIM, REAR, 17X4.50", BLK X WHEEL RIM, REAR, 18" WHEEL RIM, REAR, 19" RIM LOCK, REAR RIM STRIP, 17" X RIM STRIP, REAR RIM STRIP, REAR TUBE, 120/70-17 X TUBE, REAR TUBE, REAR TIRE, REAR, 150/60-17 X TIRE, REAR, 18" TIRE, REAR, 19" REAR HUB ASSEMBLY C DESCRIPTION
Strip of 12, 1/4 oz w eights
INCLUDED IN RR WHL ASSYS INCLUDED IN RR WHL ASSYS INCLUDED IN RR WHL ASSYS INCLUDED IN RR WHL ASSYS INCLUDED IN RR WHL ASSYS INCLUDED IN RR WHL ASSYS INCLUDED IN RR WHL ASSYS
INCLUDED IN RR WHL ASSY INCLUDED IN RR WHL ASSY INCLUDED IN RR WHL ASSY
INCLUDED IN RR WHL ASSYS NOTES
REAR WHEEL PARTS LIST
5
Wheel Hubs
10
*
5
6
9
*
8
6 5 7
*
4
5
6
6
3
*
2 6 5 1
* 1 5002541 10 1 5000074 * 1 5002535 9 1 5000022-07 8 1 5000023 * 1 5002542 7 1 5000024 6 5 5000355 5 4 5000356 4 1 5001091 * 1 5002536 3 1 5000071-08 2 1 5000072 1 1 5000073 ITEM QTY DEALER PART NO REQD NUMBER
X X X X X X XX XX XX
X X XX
X S E EA MODEL
FRONT WHEEL SPACER X X FRONT WHEEL SPACER HUB, FRONT, BLK X X HUB, FRONT FRONT HUB BEARING SPACER FRONT WHEEL SPACER-DISC SIDE X X FRONT WHEEL SPACER-DISC SIDE SEALED BEARING, 20X42X12 DOUBLE LIP SEAL, 32X42X4 REAR WHEEL SPACER HUB, REAR, BLK X X HUB, REAR REAR HUB BEARING SPACER REAR WHEEL SPACER-DISC SIDE ER C DESCRIPTION
INCLUDED IN RR WHEEL ASSYS INCLUDED IN FR WHEEL ASSYS INCLUDED IN FR WHEEL ASSYS INCLUDED IN FR WHEEL ASSYS INCLUDED IN FR WHEEL ASSYS INCLUDED IN RR WHEEL ASSYS INCLUDED IN FR WHEEL ASSYS INCLUDED IN WHEEL ASSYS INCLUDED IN WHEEL ASSYS INCLUDED IN RR WHEEL ASSYS INCLUDED IN RR WHEEL ASSYS INCLUDED IN RR WHEEL ASSYS INCLUDED IN RR WHEEL ASSYS INCLUDED IN RR WHEEL ASSYS NOTES
WHEEL HUBS PARTS LIST
6
Front Fork
32 12 33 3 4 5 6 19 57 7 8 38 39 21 40 41 42 9 57 57 55 37 57 18 34 35 57 20 36
42 41 49 50 51 57 52 53
54 57
58 59 22 10 11 12 57 26 13 23 24 25 43
57
45
44 12 57 14 15 57 16 17 57 31 27 28 29 30 48 48 57 47 46 46 56
7
Front Fork List
* * * * * 59
1 1 1 1 1 1
5002526 5002055 5000018 5001222 5000013 5000014 5000015 5002617 5002619 5002621 5002621 5002523 5002600
58 AR 5000572 57 AR 5001526 56 1 5000568 55 2 5000608 54 2 5000607 53 2 5000610 52 2 5000611 51 2 5000606 50 2 5000603 49 2 5000604 48 4 5000558 47 1 5000567 46 6 5000556 45 1 SEE TABLE 44 2 5000518 43 2 5000565 42 4 5000080 41 4 5000601 40 2 5000600 39 2 5000598 38 2 5000597 37 2 5000594 36 2 5000593 35 2 5000592 34 2 5000591 33 2 5000590 32 2 5000587 31 2 5000589 30 2 5000586 29 2 5000585 28 2 5000584 27 2 5000583 26 2 5000582 25 2 5000581 24 2 5000580 23 2 5000579 22 2 5000578 21 2 5000577 20 2 5000575 19 2 5000576 18 2 5000574 17 2 5000564 16 2 5000560 15 2 5000563 14 2 5000562 13 2 5000548 12 4 5000547 11 2 5000561 10 2 5000005 9 2 5000559 8 2 SEE TABLE 7 2 5000553 6 2 5000552 5 2 5000546 4 2 5000545 3 2 5000551 2 2 5000550 1 2 5000549 ITEM QTY DEALER PART NO REQD NUMBER
FORK GUARD SET, MOTARD - SILVER X X X FORK GUARD SET - SILVER FORK GUARD SET - BLACK FORK GUARD SET - WHITE FORK SPRING - 4.5 N/mm FORK SPRING - 4.7 N/mm FORK SPRING - 4.9 N/mm X FRONT FORK SET, CR X FRONT FORK SET, ER X FRONT FORK SET, EA X FRONT FORK SET, E X FRONT FORK SET, S X FRONT FORK SET, X ADDITIONAL PARTS TABLE 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 X S E EA ER C DESCRIPTION MODEL X X
X
OPTIONAL STANDARD OPTIONAL
NOTES
FRONT FORK PARTS LIST
8
Steering Head
8 6* 8* 11 10 2 3 7
13
5* 9
12
8*
8 4 8 1
13 2 5000760 12 2 5000722 11 1 5000717 10 1 5000170 9 1 5000174 * 4 5000728 8 12 5000100 7 2 5000101 * 2 5002537 6 2 5000534 * 2 5002533 5 2 5000533 4 1 012-5002097 3 1 5000001B 2 1 ITEM QTY DEALER PART NO REQD NUMBER HEA DSET BEA RING, UPPER HEA DSET SEA L, UPPER STEERER WASHER SLOTTED LOCKNUT STEERER NUT X FHB, M8X55 mm X FHB, M8X45 mm FHB, M12X35 mm, NLK X X CLA MP, HA NDLEBA R, UPPER CLA MP, HA NDLEBA R, UPPER X X CLA MP, HA NDLEBA R, LOWER CLA MP, HA NDLEBA R, LOWER LOWER TRIPLE CLA MP A SSY UPPER TRIPLE CLA MP FRNT BRKE GDE, UPPER FRNT BRKE GDE, LOWER ER C DESCRIPTION
X X X X X X X X X X X X
FOR USE W/ HANDGUARD BRCKT
SEE FRONT BRA KE GUIDE, UPPER SEE FRONT BRA KE GUIDE, LOWER NOTES
X
S
E EA MODEL
STEERING HEAD PARTS LIST
9
Front Brake Guides
5 4 6 7
4 2
3
2 1 4
7 2 5000822 6 1 5001270 5 1 5000038 4 4 5001013 3 1 5002261 2 2 5000535 1 1 5002263 ITEM QTY DEALER PART NO REQD NUMBER BRAKE LINE GUIDE TOPHAT BRAKE GUIDE CLAMP BRAKE GUIDE MOUNT ASSY FLNG HD BLT, M6X16, NLK FRONT BRAKE GUIDE MOUNT, UPPER FRONT BRAKE GUIDE FRONT BRAKE GUIDE MOUNT, LOWER DESCRIPTION
XX
X
FOR USE W/ HEADLIGHT
X S E EA ER C MODEL
NOTES
BRAKE GUIDES PARTS LIST
10
Handlebar & Controls List
23 2 18 1* 56 3 4 7 8 19 20 9 10 12 13 16 * 24 32 11 22 45 41 35 40 39 15 * 36 37 14 21
17 * 42
25 43 33 38 34 26 * 31 44
28
27 46 29 30
47
11
47 2 5000728 46 2 5001927 45 AR 5002385 44 1 5002373 43 1 5002374 42 1 5002375 41 2 5002376 40 1 5002377 39 1 5002378 38 1 5002379 37 1 5002380 36 1 5002381 35 1 5002382 34 1 5002383 33 1 5002384 32 1 5002386 31 1 5002387 30 2 5002538 29 2 5002539 28 2 6000252 27 2 6000277 * 1 5002519 26 1 5002215 25 1 5001808L 24 1 5001808 23 4 5000379 22 1 5002364 21 1 5000131-01 20 1 5002363 19 1 5000437 18 1 5001274-04 * 1 6001180 * 1 5002262 17 1 5000317 * 1 5002518 * 1 5002454 16 1 5000120 * 1 5002372S 15 1 5002372 14 1 5002095 13 1 5000125 12 2 5000786 11 1 5000123 10 1 5001590 9 1 5001369 8 2 5001368 7 1 5001367 6 1 5001366 5 1 5001365 4 1 5000488 3 1 5000124 2 1 5000121 * 1 5002252 1 1 5000474 ITEM QTY DEALER PART NO REQD NUMBER
X
X
X X X X X
X X X X X X X
X X X X X
XX
XX X XX
X XXXX X X S E EA ER C MODEL
FHB M8X55 mm FHB M5X20 mm HYDRAULIC CLUTCH OIL, 16 oz. 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 MASTER CYLINDER, SLV, M/C SLAVE CYLINDER, COMPLETE BRACKET, HANDGUARD, UPPER BRACKET, HANDGUARD, LOWER FHB M8X25 mm FHB M8X20 mm HANDGUARD SET, LOOP, SILVER HANDGUARD SET, LOOP, SILVER HANDGUARD HARDWARE KIT HANDGUARD SET, BLACK SHCS,M4X12 ZINC ENGINE ON/OFF SWITCH ENGINE START ...
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