2003 Engine Parts Catalog (ATV & Motorcycle) - 09/02 CONTENTS Throttle Body . . . . . . . . . . . . . . . . 2 Fuel Injectors . . . . . . . . . . . . . . . . 3 Cam Cover & Spark Plug . . . . . . 4 Cylinder Head . . . . . . . . . . . . . . . 5 Valve Train . . . . . . . . . . . . . . . . . 6 Valve Train Parts List . . . . . . . . . 6 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 2003 Engine Parts Catalog.fm © 2001 Cannondale Corporation - All Rights Reserved P/N 5002338-03 Printed : 9/4/02 Throttle Body 1 14 16 15 13 * 12 2 * 3 5 7 9 22 20 19 21 17 18 23 4 8 6 10 11 23 1 22 2 21 2 20 1 19 1 18 1 17 1 16 2 15 1 14 2 13 1 12 1 11 1 10 1 9 1 8 1 7 2 6 1 5 1 4 1 3 3 * 1 2 1 * 1 1 1 ITEM QTY NO REQD 5001148 5001149 5001561 5000513 5000512 5001973 5001972 5001974 5001971 5001489 5000409 5001401 5001581 5000959 5002307 5000688 5002305 6000502 5001346 5000827 5001473 6001121 5002308 6000767 5002340 DEALER PART NUMBER COUPLING, THROTTLE BODY CLAMP, BAND WASHER,M5 BTTNHD TORX SCREW, M5X35 BTTNHD TORX SCREW, M5X25 BYPASS GASKET BYPASS HOUSING SCREW, PHILLIPS, 10X5/8 BYPASS ACTUATOR BHCS, M4X12 mm THROTTLE POSITION SENSOR THROTTLE BODY SLEEVE NUT, HEX M8 X 1.0 LOCK WASHER, M8 THROTTLE CABLE PULLEY THROTTLE SPRING THROTTLE SPRING SLEEVE IDLE ADJUSTMENT SCREW IDLE ADJUSTMENT THUMBWHEEL SPRING, IDLE ADJUST THUMBWHEEL BHCS, M4X8 mm X THROTTLE CABLE STOP X THROTTLE CABLE STOP X THROTTLE BODY ASSEMBLY X THROTTLE BODY ASSEMBLY M/C ATV DESCRIPTION MODEL NOTES THROTTLE BODY PARTS LIST 2 Fuel Injectors 9 6* 1 7 1 8* 9 5 11 2 3 10 4 3 4 11 2 10 2 9 1 * 1 8 1 7 1 * 1 6 1 5 2 4 2 3 2 2 1 1 4 ITEM QTY NO REQD 5001545 5001546 5002321 6000317 5002204-03 5002324 6000318 5002203-02 5000478-06 5001458 5000171 351-5000166 5001607 DEALER PART NUMBER O-RING, FUEL INJECTOR, TOP O-RING, FUEL INJECTOR, BOTTOM HOSE SHEATH, BULK X HOSE, FUEL, 350 mm X HOSE, FUEL, REG TO INJECTOR HOSE, FUEL, 6.4 mm ID, 60 mm X HOSE, FUEL, 130 mm X HOSE, FUEL, PUMP TO INJECTOR FUEL INJECTOR BASE NUT, HEX FLANGE, M3 FUEL INJECTOR CLIP FUEL INJECTOR SET OTKR HOSE CLAMP, 12.3mm M/C ATV DESCRIPTION MODEL 5' 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 15 13 9 18 ATV M/C *3 16 * 10 17 7 8 1* 4 2 5 14 11 18 1 17 2 * 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 * 1 3 2 2 1 * 1 1 1 ITEM QTY NO REQD 5000775 5001610 6000386-03 5001352 5001351 5000915 5001925 5001781 5002029 5000853 5000852 5001927 5001945 5000914 5000913-03 5000912-04 6000393-02 5001081-02 5001136 6000496 5001126 DEALER PART NUMBER OETIKER CLAMP, 17mm HOSE CLAMP, DOUBLE WIRE X HOSE, OIL, COVER TO SPAR X HOSE, OIL, COVER TO STARTER X HOSE, OIL, COVER TO FRAME O-RING, 2-023 FHB M5X12 mm, ZINC IGNITION COIL ASSEMBLY SPARK PLUG - CR9EK 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 X OIL BREATHER PLUG BREATHER NIPPLE SPLIT DOWEL PIN,5X10 X CAM COVER ASSY, ATV X CAM COVER ASSY, MOTORCYCLE M/C ATV DESCRIPTION MODEL 6 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 1 21 8 20 4 19 4 18 2 17 2 16 2 15 1 14 1 13 2 12 2 11 1 10 2 9 1 8 1 7 2 6 4 5 2 4 2 3 1 2 1 1 1 ITEM QTY NO REQD 334-5002443 5001482 5001182 5000770 5001957 5000713 5000426 5001671 5001454 5001259 5000482 5001861 5000487 5000252-05 5001007 5001724 5001523 5001136 5001457 5001461 5000408 DEALER PART NUMBER M/C ATV MODEL 9 17 18 Engine Rebuild Gasket Kit ADDITIONAL PARTS TABLE 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 SEE VALVE TRAIN DESCRIPTION NOTES 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 Valve Train Parts List 6 30 29 1 28 1 27 2 26 2 25 1 24 1 23 2 22 2 21 4 20 2 19 1 18 1 17 2 16 1 15 1 14 4 13 4 12 4 11 4 10 4 9 4 8 4 7 4 6 2 5 2 4 4 3 2 2 2 1 1 ITEM QTY NO. REQ SEE TABLE 5000465 5000792 5000506 5000498 5001355 5001783-02 5000464 5001488 5001676 5001406 5000253 5000251 5000249-07 5001982 512-5001756 5000874 5000463-01 5002036 5002041 5002057 5000210-03 5000209-03 5000208 5002335 5002334 5000205 5001965 5001964 502-5001446 DEALER PART NO. VALVE ADJUSTMENT SHIM OIL SEAL,14X25X5 SOLID DOWEL PIN 5X24 NEEDLE BEARING,16X24X13 BALL BEARING OIL SEAL:16X24X5 SEAL, 12X25X5 mm OIL SEAL,40X62X6 SHCS, M12X 1.25X 25 BEARING, ROLLER, 3X9.8mm DOWEL PIN, 2X20 IDLER GEAR SHAFT CMSHFT DRV GR SHAFT CAM GEAR INTAKE CAMSHAFT EXHAUST CAMSHAFT ASSY RETAINER,BEARING VALVE STEM SEAL VALVE BUCKET VALVE SPRING KEEPER VALVE SPRING RETAINER INNER VALVE SPRING OUTER VALVE SPRING VALVE SPRING SEAT EXHAUST VALVE INTAKE VALVE VALVE GUIDE EXHAUST VALVE SEAT INTAKE VALVE SEAT CYLINDER HEAD SUB ASSY DESCRIPTION INCLUDED IN 502-5001446 INCLUDED IN 502-5001446 INCLUDED IN 502-5001446 NOTES 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 DEALER PART NO. 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 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 19 2 18 1 17 2 16 1 15 1 14 1 13 2 2 12 11 1 10 1 9 1 8 2 7 1 6 1 5 1 4 1 3 1 2 1 1 1 ITEM QTY NO REQD 5001156 5001007 5000250 5001724 5001862 5001475 5001477 5001480 5001491 5001102 5001028 5000671-04 5001947 5001039-03 5001829-03 5002157-04 5000420 5001948 5000482 5002332 DEALER PART 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 M/C ATV MODEL 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 24 2 23 1 22 1 21 1 20 1 19 1 18 1 17 1 16 1 15 1 14 1 13 2 12 2 11 2 10 2 9 1 8 1 7 2 6 1 5 1 4 2 3 1 2 1 1 2 ITEM QTY NO REQD 5002161 5000793 5000773 5001349 552-5001921 5001731 5001063 5001062 5001117 5000389 5002405 5002404 5000649-02 5000648 5000650-02 5001136 5001675 5000469 5001871 5000820 5000500 5001557-03 5000470 5001135 5001051 DEALER PART 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 MO SP MODEL DESCRIPTION INCLUDED IN 552-5001921 INCLUDED IN 552-5001921 INCLUDED IN 552-5001921 INCLUDED IN 552-5001921 INCLUDED IN 552-5001921 INCLUDED IN 552-5001921 INCLUDED IN 552-5001921 INCLUDED IN 552-5001921 NOTES CRANKCASE PARTS LIST 10 Crankshaft 11 9 8 4 10 7 5 6 12 2 1 3 12 1 11 1 10 1 9 1 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 ITEM QTY NO REQD 5000519 5001146 5001970 5001796 5001608 5000816 5001124 5001793 5001622 5000283-05 5000998 531-5001961 DEALER PART 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 M/C ATV MODEL DESCRIPTION INCLUDED IN CRANK PLATE 5002419 INCLUDED IN CRANK PLATE 5002419 NOTES CRANKSHAFT PARTS LIST 11 Piston "R"- Red "VG"- Green NOTE: See lower, RH side of cylinder head for OEM stamp designating piston color 4 3* 15 6 5 11 2* 9 8 12 7 10 13 14 15 1 14 2 13 1 12 1 11 2 10 1 9 1 8 1 7 1 6 2 5 1 4 1 * 1 3 1 * 1 2 1 1 1 ITEM QTY NO REQD 5001787 5001935 5001477 5001475 5000482 5000921 5000915 5001866-03 5000627 5002315 5002314 522-5002316 5002396G 5002396R 5002397G 5002397R 522-5002395 DEALER PART NUMBER O-RING, 100X2.5 mm FHTS, M5X14 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 PIN CIRCLIP PISTON PIN, 18 X 46.48 mm PISTON RING SET PISTON, 95 mm, GREEN PISTON, 95 mm, RED LINER, 95 mm, GREEN LINER, 95 mm, RED PISTON/LINER KIT M/C ATV MODEL DESCRIPTION INCLUDED IN 522-5002395 INCLUDED IN 522-5002395 INCLUDED IN 522-5002395 Match w / Liner INCLUDED IN 522-5002395 Match w / Liner INCLUDED IN 522-5002395 Match w / Piston INCLUDED IN 522-5002395 Match w / Piston INCLUDED IN 522-5002395 NOTES PISTON PARTS LIST 12 Crankshaft Cartridge Plate 4 1 2 3 22 16 17 18 9 20 19 15 5 TDC 6 7 21 6 8 23 9 8 20 4 13 2 14 7 3 5 * 10 11 12 1 23 22 1 21 1 20 5 19 4 18 1 17 1 16 1 15 1 14 2 13 1 12 1 11 1 10 1 9 1 8 1 * 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 ITEM QTY NO REQD 5000428 5000304 5001120 5001484 5001485 5001903 5000487 5000482 5002329 5001037 5001374 5002015 5001244 5001028 5000466 5001109 6000227 5000630 5000367-04 5000263 5001110 5000216 5000629-07 5002419 DEALER PART NUMBER TDC SCREW O-RING, 2-009 O-RING, 2-022 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 SPACER, 16x8.4x3.2, mm SCAVENGE PUMP IDLER GEAR THRST WASHER 10.1X20X1 EXTERNAL RETANING RING, M10 OIL SEAL, 33X47X7 INTERNAL RETANING RING, 47mm X PRIMARY DRIVE GEAR: 28T X 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 IDLR GEAR SHAFT 10X45 CRANKSHAFT CARTRIDGE PLATE M/C ATV DESCRIPTION MODEL TDC SPECIAL TOOL POSITIONS 4...5...6...7...9 POSITIONS 1...2...3...8 INCLUDED IN 5002419 INCLUDED IN 5002419 NOTES CRANKSHAFT CARTRIDGE PLATE PARTS LIST 13 Crankcase Cover 11 * 3 2 1 5 6 17 Locations 10 9 4 8 3 Locations 10 7 * 1 11 1 10 3 9 17 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 ITEM QTY NO REQD 5001556-03 5000962 5001944 5001927 5000473 5000517 5000828 5001434-03 5002071 5001255-03 5000315-05 553-5002269 DEALER PART NUMBER X BREATHER HOSE BREATHER HOSE FHB M5X25 mm FHB M5X20 mm OIL SEAL: 14X22X4 (2 LIP) BUSHING O-RING, 2-016 TRANSMISSION OIL FILL CAP OIL LEVEL SIGHT WINDOW HOSE NIPPLE, 6M CRANKCASE COVER GASKET CRANKCASE COVER M/C ATV DESCRIPTION MODEL X INCLUDED IN 553-5002269 INCLUDED IN 553-5002269 NOTES CRANKCASE COVER PARTS LIST 14 Starter Clutch 4 2 6 1 3 10 3 5 11 7 8 9 13 12 13 3 12 1 11 1 10 1 9 1 8 1 7 1 6 4 5 4 4 1 3 4 2 1 1 1 ITEM QTY NO REQD 5001926 5001863-05 5001275 5001902 5001598 5002160 5001496-04 5001497-02 5001495 5001465-04 5001797 5001814-04 5001466-06 DEALER PART NUMBER FHB M5X16 mm, Zinc STARTER CLUTCH COVER O-RING, 2-147 BUSHING, FLANGE, 15X17X9 mm EXTERNAL RETANING RING: 15 STARTER CLUTCH BUSHING START ...