Cannondale X440, E440, E440A, E440R, S440 Parts Catalog

2003 Motorcycle Parts Catalog

CONTENTS

©

2001 Cannondale Corporation - All Rights Reserved

P/N 5002339-03

Printed : 9/4/02

2003 Motorcycle Parts Catalog 0902.fm

(E440, E440A, E440R, S440, C440, X440) - 09/02

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

2

1

2 3

4 5 6

7

8

9

10

11

5002260I

ODOMERTER INSTRUCTIONS

51

5002254

SWITCH, HEAD LIGHT

41

5002248 SENSOR MAGNET

31

5002257 CABLE, ODOMETER

21

5002260 ODOMETER

11

5002211 ODOMETER MOUNT PLATE

XSEEAERCR

ADDITIONAL PARTS TABLE

ODOMETER PARTS LIST

ITEM NOQTY

REQD

DEALER PART

NUMBER

DESCRIPTION NOTES

MODEL

12

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.

Legend

3

Front Wheel

2

3

*

4 *

5 *

6

7

*

9

13

*

11

12

*

8 *

10

1

5002540 WEIGHT, WHEEL BALANCE Strip of 12, 1/4 oz weights
051-5002498 FRONT WHEEL ASSEMBLY, MOTARD
051-5000020 FRONT W HEEL ASSEMBLY

* 18 5002500A X SPOKE, FRONT, OUTSIDE, 3.6x172.0mm INC LUDED IN FR WHEEL ASSYS

13 18 5000026 X X X X X SPOKE, FRONT - OUTSIDE INCLUDED IN FR WHEEL ASSYS

* 18 5002501A X SPOKE, FRONT, INSIDE, 3.6x177.0mm INC LUDED IN FR WHEEL ASSYS
12 18 5000477 X X X X X SPOKE, FRONT, - INSIDE INCLUDED IN FR WHEEL ASSYS
11 36 5001623 NIPPLE, FRONT INCLUDED IN FR WHEEL ASSYS
10 1 5000540 NUT, FLANGE, M16X1.5

9 6 5000864 FHCS, M6X16,NYLKZIN C

* 1 5002511 X ROTOR, FRONT, 320mm

* 1 5002246 X X X X FRONT ROTOR ACCEPTS ODOMETER MAGNET

8 1 5000047 X FRONT ROTOR

* 1 5002504 X RIM, FRONT, 17X3.5", BLK INCLUDED IN FR WHEEL ASSYS

7 1 5000536 X X X X X RIM, FRONT INCLUDED IN FR WHEEL ASSYS
6 1 5000028 RIM LOCK, FRONT

* 1 5002510 X RIM STRIP, 17"

* 1 5002134 X X X X RIM STRIP, FRONT

5 1 5000029 X RIM STRIP, FRONT

* 1 5002508 X TUBE, FRONT, 120/70-17

* 1 5002135 X X X X TUBE, FRONT

4 1 5000030 X TUBE, FRONT

* 1 5002506 X TIRE, FRONT, 120/70-17

* 1 5002098 X X X X TIRE, FRONT

3 1 5000031 X TIRE, FRONT
2 1 5000021 AXLE , FRONT WHEEL
11

SEE FRONT H UB FRONT HUB ASSEMBLY INCLUDED IN FR WHEEL ASSYS

XSEEAERC

ADDITIONAL PARTS TABLE

FRONT WHEEL PARTS LIST

NOTES

DEA LER PA RT

NUMBER

ITEM NOQTY

REQD

DESCRIPTION

MODEL

4

Rear Wheel

1

4

*

3

*

2

*

11

*

9 *

6

*

8

5

14

15

12

13

7

10

*

17

*

18

16

*

5

5002540 WEIGHT, WHEEL BALANCE Strip of 12, 1/4 oz weights

5000339 SPROCKET, REAR, 49 T
5000349 SPROCKET, REAR, 51 T
5000357 SPROCKET, REAR, 52 T

151-5002499 REAR WHEEL ASSEMBLY, MOTARD

151-5002085 REAR WHEEL ASSEMBLY, 18"
151-5000069 REAR WHEEL ASSEMBLY, 19"

18 2 5002199 DUST CAP

* 18 5002502 X SPOKE, REAR, OUTSIDE, 4.0X175.0 mm INCLUDED IN RR WHL ASSYS

* 18 5001873 X X X X SPOKE, REAR, OUTSIDE, 18" WHEEL INCLUDED IN RR WHL ASSYS
17 18 5000075 X SPOKE, REAR, OUTSIDE, 19" WHEEL INCLUDED IN RR WHL ASSYS

* 18 5002503 X SPOKE, REAR, INSIDE, 4.0X181.0 mm INCLUDED IN RR WHL ASSYS

* 18 5002287 X X X X SPOKE, REAR, INSIDE, 18" WHEEL INCLUDED IN RR WHL A SSYS
16 18 5000797 X SPOKE, REAR, INSIDE, 19" WHEEL INCLUDED IN RR WHL ASSYS
15 36 5001624 NI PPLE, REAR INCLUDED IN RR WHL ASSYS
14 6 5000713 FLAT WASHER, M8
13 6 5000140 LOCKNUT, M8
12 6 5000393 FHCS, M8X28 mm, ZI NC

* 1 5002521 X SPROCKET, REAR, 45T
11 1 5000117 X X X X X SPROCKET, REAR, 50 T

* 1 6000315 X X X X MASTER LINK , O -R ING
10 1 5001847 X X MASTER LINK

* 1 5002522 X CHAIN, DRIVE, 112 LINKS

* 1 5001798 X X X X CHAIN, DRIVE, 114 LINKS, O-RING

9 1 5001601 X CHAIN, DRIVE, 114 LINKS
8 4 5000138 FHCS, M8X16, NYLK, ZINC
7 1 5000090 ROTOR, REAR

* 1 5002505 X RIM, REAR, 17X4.50", BLK INCLUDED IN RR WHL A SSY

* 1 5001886 X X X X WHEEL RIM, REAR, 18" INCLUDED IN RR WHL A SSY

6 1 5000076 X WHEEL RIM, REAR, 19" INCLUDED IN RR WHL A SSY
5 1 5000077 RIM LOCK, REAR

* 1 5002510 X RIM STRIP, 17"

* 1 5002130 X X X X RIM STRIP, REAR

4 1 5000078 X RIM STRIP, REAR

* 1 5002508 X TUBE, 120/70-17

* 1 5002131 X X X X TUB E, REAR

3 1 5000079 X TUBE, REAR

* 1 5002507 X TIRE, REAR, 150/60-17

* 1 5002132 X X X X TIRE, REAR, 18"

2 1 5000080 X TIRE, REAR, 19"
1 1 SEE REAR HUB REAR HUB ASSEMBLY INCLUDED IN RR WHL A SSYS

XSEEAERC

ADDITIONAL PARTS TABLE

REAR WHEEL PARTS LIST

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

DESCRIPTION NOTES

MODEL

6

Wheel Hubs

5

6

6

5

9

*

8

7

*

10 *

4

6

6

3

*

1

2

6

5

5

* 1 5002541 X FRONT WHEEL SPACER INCLUDED IN RR WHEEL ASSYS

10 1 5000074 X X X X X FRONT WHEEL SP ACER INCLUDED IN FR WHEEL ASSYS

* 1 5002535 X HUB, FRONT, BLK INCLUDED IN FR WHEEL ASSYS
9 1 5000022-07 X X X X X HUB, FRONT INCLUDED IN FR WHEEL A SSYS
8 1 5000023 FRONT HUB BEARING SPACER INCLUDED IN FR WHEEL ASSYS

* 1 5002542 X FRONT WHEEL SPACER-DISC SIDE INCLUDED IN RR WHEEL ASSYS
7 1 5000024 X X X X X FRONT WHEEL SPACER-DISC SIDE INCLUDED IN FR WHEEL ASSYS
6 5 5000355 SEALED BEARING, 20X42X12 INCLUDED IN WHEEL ASSYS
5 4 5000356 DOUBLE LIP SEAL, 32X42X4 INCLUDED IN WHEEL ASSYS
4 1 5001091 REAR WHEEL SPACER INCLUDED IN RR WHEEL ASSYS

* 1 5002536 X HUB, REAR, BLK INCLUDED IN RR WHEEL ASSYS
3 1 5000071-08 X X X X X HUB, REAR INCLUDED IN RR WHEEL ASSYS
2 1 5000072 REAR HUB BEARING SPACER INCLUDED IN RR WHEEL ASSYS
1 1 5000073 REAR WHEEL SPACER-DISC SIDE INCLUDED I N RR WHEEL ASSYS

XSEEAERC

WHEEL HUBS PARTS LIST

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

DESCRIPTION NOTES

MODEL

7

Front Fork

57

1

2

3

4

5

6

7

8

9

10

11

12

13

15

16

17

18

19

20

21

22

23
24
25

26

27

28

30

31

32

33

34

35

36

37

38

39

40

41
42

43

44

47

48

50

51

52

53

54

55

57

58

29

59

12

14

57

57

57

57

57

42

41
49

57

57

57

57

57

57

48

56

45

46

46

8

Front Fork List

13 2 5000548 FORK OUTER TUBE BUSHING SLEEVE
12 4 5000547 FORK OUTER TUBE BUSHING
11 2 5000561 FORK OUTER TUBE BUSHING CIRCLIP
10 2 5000005 FORK OUTER TUBE

9 2 5000559 FORK OUTER TUBE DECAL
8 2 SEE TABLE FORK SPRING
7 2 5000553 FORK SPRING WASHER
6 2 5000552 FORK SPRING SPACER
5 2 5000546 FORK OUTER TUBE CAP O-RING
4 2 5000545 FORK OUTER TUBE CAP
3 2 5000551 FORK AIR BLEED SCREW O-RING
2 2 5000550 FORK AIR BLEED SCREW
1 2 5000549 FORK OUTER TUBE CAP NUT

XSEEAERC

FRONT FORK PA RTS LIST

ITEM NOQTY

REQD

DEA L ER PART

NUMBER

DESCRIPTION NOTES

MODEL

5002526 X FORK GUARD SET, MOTARD - SILVER

5002055 X X X X X FORK GUARD SET - SILVER
5000018 FORK GUARD SET - BLACK
5001222 FORK GUARD SET - WHITE
5000013 FORK SPRING - 4.5 N/mm OPTIONAL
5000014 FORK SPRING - 4.7 N/mm STANDARD

5000015 FORK SPRING - 4.9 N/mm OPTIONAL
* 1 5002617 X FRONT FORK SET, CR
* 1 5002619 X FRONT FORK SET, ER
* 1 5002621 X FRONT FORK SET, EA
* 1 5002621 X FRONT FORK SET, E
* 1 5002523 X FRONT FORK SET, S

59 1 5002600 X FRONT FORK SET, X

58 AR 5000572 OHLINS FORK FLUID, 1LITER
57 AR 5001526 FORK SERVICE KIT
56 1 5000568 FORK INNER TUBE ASSY-RIGHT
55 2 5000608 COMPRESSION ADJUSTER ASSY.
54 2 5000607 COMPRESSION ADJUSTER O-RING
53 2 5000610 COMPRESSION SHIM SET
52 2 5000611 FORK COMPRESSION PISTON
51 2 5000606 FORK COMPRESSION PISTON O-RING
50 2 5000603 COMPRESSION PISTON SHIM
49 2 5000604 COMPRESSION PISTON WAVE WSHR
48 4 5000558 FRONT WHEEL AXLE PINCH BOLT
47 1 5000567 FORK INNER TUBE ASSY-LEFT
46 6 5000556 FORK GUARD BOLT
45 1 SEE TABLE FORK GUARD SET
44 2 5000518 FORK INNER TUBE BUSHING
43 2 5000565 DAMPING CARTRIDGE TUBE
42 4 5000080 LOCKNUT
41 4 5000601 WASHER
40 2 5000600 MID VALVE SHIM S ET
39 2 5000598 FORK REBOUND PISTON RING
38 2 5000597 FORK REBOUND PISTON
37 2 5000594 REBOUND SHIM SET
36 2 5000593 REBOUND ADJUSTER BODY
35 2 5000592 REBOUND ADJNEEDLE SPRING
34 2 5000591 REBOUND ADJ NEEDLE
33 2 5000590 REBOUND ADJ NEEDLE O-RING
32 2 5000587 FORK TOP OUT SPRING
31 2 5000589 FORK DAMPER ROD
30 2 5000586 FORK TOP OUT SPRING WASHER
29 2 5000585 FORK DAMPER ROD BUSHING
28 2 5000584 FORK DAMPER ROD SLEEVE O-RING
27 2 5000583 FORK DAMPER ROD SLEEVE
26 2 5000582 DAMPING CARTRIDGE TUBE CAP
25 2 5000581 DAMPER ROD CIRCLIP
24 2 5000580 HYDRAULIC STOP COLLAR CIRCLIP
23 2 5000579 FORK HYDRAULIC STOP
22 2 5000578 FORK HYDRAULIC STOP COLLAR
21 2 5000577 FORK SPRING GUIDE
20 2 5000575 REBOUND ADJUSTER ASSY.
19 2 5000576 REBOUND ADJUSTER O-RING
18 2 5000574 FORK REBOUND ADJUSTER ROD
17 2 5000564 FORK WIPE R
16 2 5000560 FORK SEAL RETAINING CIRCLIP
15 2 5000563 FORK SEAL
14 2 5000562 FORK SEAL RETAINING WASHER

ADDITIONAL PAR TS TABLE

9

Steering Head

8

*

8

6

*

2

8

*

5

*

8

4

8

1

11

10

9

3

7

13

12

13 2 5000760 HEADSET BEARING, UPPER
12 2 5000722 HEADSET SEAL, UPPER
11 1 5000717 STEERER WA SHER
10 1 5000170 SLOTTED LOCKNUT

9 1 5000174 STEERER NUT

* 4 5000728 X X FHB, M8X55 mm FOR USE W/ HANDG UA RD BRCKT
8 12 50001 00 X X X X FHB, M8X45 mm
7 2 5000101 FHB, M12X35 mm, NLK

* 2 5002537 X X X CLAMP, HANDLEBA R, UPPER
6 2 5000534 X X X CLAMP, HA NDLEBAR, UPPER

* 2 5002533 X X X CLAMP, HANDLEBAR, LOWER
5 2 5000533 X X X CLAMP, HA NDLEBAR, LOWER
4 1 012-5002097 LOWER TRIPLE CLAMP ASSY
3 1 5000001B UPPER TRIPLE CLAMP
2 FRNT BRKE GDE, UPPER SEE FRONT BRAKE GUIDE, UPPER
1 FRNT BRKE GDE, LOWER SEE FRONT BRAKE GUIDE, LOWER

XSEEAERC

STEERING HEAD PARTS LIST

ITEM NOQTY

REQD

DEA LER PA R T

NUMBER

DESCRIPTI ON NOTES

MODEL

10

Front Brake Guides

5

6

7

4

3

4

2

1

4

2

7 2 5000822 BRAKE LINE GUIDE TOPHAT
6 1 5001270 BRAKE GUIDE CLAMP
5 1 5000038 BRAKE GUIDE MOUNT ASSY
4 4 5001013 FLNG HD BLT, M6X16, NLK
3 1 5002261 X X X FRONT BRA KE GUIDE MOUNT, UPPER FOR USE W/ HEADLIGHT
2 2 5000535 FRO NT BRAKE GUID E
1 1 5002263 FRONT BRAKE GUIDE MOUNT, LOWER

XSEEAERC

BRAKE GUIDES PA RTS LIST

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

DESCRIPTION NOTES

MODEL

11

Handlebar & Controls Li st

18

20

19

23

21

22

3

9

11

13

12

16

44

10

17

2

4

5

6

7

8

1

*

*

26

*

24

25

43

42

41

40

38

37

36

35

32

33

39

31

15

*

14

*

34

45

29

30

28

27

46

47