Cannondale 2003 Engine PARTS CATALOG
2003 Engine Parts Catalog
©
CONTENTS
(ATV & Motorcycle) - 09/02
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 . . . . . . . . . . . . . . . . . 11
Piston . . . . . . . . . . . . . . . . . . . . . 12
Crankshaft Cartridge Plate . . . . . 13
Crankcase Cover . . . . . . . . . . . . 14
Starter Clutch . . . . . . . . . . . . . . . 15
Clutch . . . . . . . . . . . . . . . . . . . . . 16
Trans Cart Plate, Rear . . . . . . . . 17
Mainshaft . . . . . . . . . . . . . . . . . . 18
Countershaft . . . . . . . . . . . . . . . . 19
Trans Cart Plate, Front . . . . . . . 20
Countershaft Sprocket . . . . . . . . 21
Generator Stator . . . . . . . . . . . . 22
Water Covers . . . . . . . . . . . . . . . 23
Engine Oil Pickup Assembly . . . 24
Scavenge Pump . . . . . . . . . . . . 25
Engine Oil Pump . . . . . . . . . . . . 26
Oil Supply Tubes . . . . . . . . . . . . 27
Transmission Oil Pump . . . . . . . 28
2003 Engine Parts Catalog.fm
2001 Cannondale Corporation - All Rights Reserved
P/N 5002338-03
Printed : 9/4/02
Throttle Body
*
1
20
16
15
19
14
21
17
13
18
22
23
12
*
2
3
5
7
9
4
8
6
10
11
23 1 5001148 COUPLING, THROTTLE BODY
22 2 5001149 CLAMP, BAND
21 2 5001561 WASHER,M5
20 1 5000513 BTTNHD TORX SCREW, M5X35
19 1 5000512 BTTNHD TORX SCREW, M5X25
18 1 5001973 BYPASS GASKET
17 1 5001972 BYPASS HOUSING
16 2 5001974 SCREW, PHILLIPS, 10X5/8
15 1 5001971 BYPASS ACTUATOR
14 2 5001489 BHCS, M4X12 mm
13 1 5000409 THROTTLE POSITION SENSOR
12 1 5001401 THROTTLE BODY SLEEVE
11 1 5001581 NUT, HEX M8 X 1.0
10 1 5000959 LOCK WASHER, M8
9 1 5002307 THROTTLE CABLE PULLEY
8 1 5000688 THROTTLE SPRING
7 2 5002305 THROTTLE SPRING SLEEVE
6 1 6000502 IDLE ADJUSTMENT SCR EW
5 1 5001346 IDLE ADJUSTMENT THUMBWHEEL
4 1 5000827 SP RING, IDLE ADJUST THUMBWHEEL
3 3 5001473 BHCS, M4X8 mm
* 1 6001121 X THROTTLE CABLE STOP
2 1 5002308 X THROTTLE CABLE STOP
* 1 6000767 X THROTTLE BODY ASSEMBLY
1 1 5002340 X THROTTLE BODY ASSEMBLY
ITEM NOQTY
REQD
DEA LER PA RT
NUMBER
M/C ATV
MODEL
DESCRIPTION NOTES
THROTTLE BODY PARTS LIST
2
Fuel Injectors
*
9
6
1
7
*
8
9
1
5
11
2
3
3
10
4
11 2 5001545 O-RING, FUEL INJECTOR, TOP
10 2 5001546 O-RING, FUEL INJECTOR, BOTTOM
9 1 5002321 HO SE SHEATH, BULK 5’ LENGTH
* 1 6000317 X HOSE, FUEL, 350 mm TO FUEL REGULATOR
8 1 5002204-03 X HOSE, FUEL, REG TO INJECTOR TO FUEL REGULATOR
7 1 5002324 HOSE, FUEL, 6.4 mm ID, 60 mm
* 1 6000318 X HOSE, FUEL, 130 mm TO FUEL PUMP
6 1 5002203-02 X HOSE, FUEL, PUMP TO INJECTOR TO FUEL PUMP
5 2 5000478-06 FUEL INJECTOR BASE
4 2 5001458 NUT, HEX FLANGE, M3
3 2 5000171 FUEL I NJECTOR CLIP
2 1 351-5000166 FUEL INJECTOR SET INCLUDES FLOW RATE VALUE
1 4 5001607 OTKR HOSE CLAMP, 12.3mm
ITEM NOQTY
REQD
DEA LER PA RT
NUMBER
M/C ATV
MODEL
DESCRIPTION NOTES
4
FUEL INJ ECTORS PARTS LIST
3
Cam Cover & Spark Plug
16
12
15
13
9
18
AT V
*
3
M/C
*
10
17
*
1
7
8
4
2
14
6
5
11
18 1 5000775 OETIKER CLAMP, 17mm
17 2 5001610 HOSE CLAM P, DOUBLE WIRE
* 1 6000386-03 X HOSE, OIL, COVER TO SPAR
16 1 5001352 X HOSE, OIL, COVER TO STARTER
15 1 5001351 X HOSE, OIL, COVER TO FRAME
14 1 5000915 O-RING, 2-023
13 1 5001925 FHB M5X12 mm, ZINC
12 1 5001781 IGNITION COIL ASSEMBLY
11 1 5002029 SPARK PLUG - CR9EK
10 1 5000853 COIL SEAL- UPPER
9 1 5000852 COIL HOLD DOWN
8 4 5001927 FHB M5X20 mm, ZINC
7 2 5001945 FHB M5X35 mm, ZINC
6 1 5000914 CAM COVER RBR LEFT SIDE
5 1 5000913-03 CAM COVER RBR INTAKE
4 1 5000912-04 CAM COVER RBR EXHAUST
* 1 6000393-02 X OIL BREATHER PLUG INCLUDED IN CAM COVER ASSY
3 2 5001081-02 BREATHER NIPPLE INCLUDED I N CAM COVER ASSY
2 1 5001136 SPLIT DOWEL PIN,5X10 INCLUDED IN CAM COVER ASSY
* 1 6000496 X CAM COVER ASSY, ATV
1 1 5001126 X CAM COVER ASSY, MOTORCYCLE
ITEM NOQTY
REQD
DEA LER PA RT
NUMBER
M/C ATV
MODEL
DESCRIPTION
NOTES
CAMSHAFT COVER PARTS LIST
4
Cylinder Head
20
19
5
21
6
11
1
10
15
14
4
7
8
12
16
9
M/C ATV
MODEL
17
18
ADDITIONAL PARTS TABLE
DESCRIPTION NOTES
3
2
1 334-5002443 Engine Rebuild Gasket Kit
21 8 5001482 SHCS, M6X25 mm
20 4 5001182 NU T, HEX FLANGE, M10
19 4 5000770 FL AT W ASHER, M10 STEEL
18 2 5001957 NU T, FLANGE, M8
17 2 5000713 FL AT W ASHER, M8
16 2 5000426 STU D, M8
15 1 5001671 FHCS ,M6X1.0X45
14 1 5001454 FHTS,M5X0.8X25
13 2 5001259 OIL TRANSFER TUBE
12 2 5000482 O-RING, 2-011
11 1 5001861 IDLER GEAR BRACKET
10 2 5000487 O-RING, 2-012
9 1 5000252-05 CAMSHAFT IDLER GEAR 31T
8 1 5001007 NEEDLE BEARING,12X16X10
7 2 5001724 THRUST WASHER,12X20X.08
6 4 5001523 S TUD, M6 X 35
5 2 5001136 SPLIT DOWEL PIN, 5X10
4 2 5001457 S TUD, M3 X 12
3 1 5001461 O-RING, 2-111
2 1 5000408 COOLANT TEMPERATURE SENSOR
1 1 SEE VALV E TRA IN
ITEM NOQTY
REQD
DEA LER PA RT
NUMBER
CYLI NDE R HEAD PARTS LIST
13
5
Valve Train
12
30
24
20
29
10
9
11
13
4
8
7
19
18
27
25
15
14
14
21
17
26
23
1
Valve Train Parts List
28
16
2
5
3
6
22
6
30 SEE TABLE VALVE ADJUSTMENT SHIM
29 1 5000465 OIL SEAL,14X25X5
28 1 5000792 SOLID DOWEL PIN 5X24
27 2 5000506 NEEDLE BEARING,16X24X13
26 2 5000498 BALL BEARING
25 1 5001355 OIL SEAL:16X24X5
24 1 5001783-02 SEAL, 12X25X5 mm
23 2 5000464 OIL SEAL,40X62X6 503-5001665 Valve Shim,2.20
22 2 5001488 SHCS, M12X 1.25X 25 503-5001666 Valve Shim,2.25
21 4 5001676 BEARING, ROLLER, 3X9.8mm 503-5001667 Valve Shim,2.30
20 2 5001406 DO W EL PIN, 2X20 503-5001668 Valve Shim ,2.35
19 1 5000253 IDLER G EAR SH AFT 503-5001669 Valve Shim,2.40
18 1 5000251 CMSHFT DRV GR SHAFT 503-5001670 Valve Shim,2.45
17 2 5000249-07 CAM GEAR 503-5001186 Valve Shim,2.50
16 1 5001982 INTAKE CAMSHAFT 503-5001187 Valve Shim,2.55
15 1 512-5001756 EXHAUS T CAMSHAFT ASSY 503-5001188 Valve Shim,2.60
14 4 5000874 RETAINER,BEARING 503-5001189 Valve Shim,2.65
13 4 5000463-01 VALVE STEM SEAL 503-5001190 Valve Shim,2.70
12 4 5002036 VALVE BUCKET 503-5001191 Valve Shim,2.75
11 4 5002041 VALVE SPRING KEEPER 503-5001192 Valve Shim,2.80
10 4 5002057 VALVE SPRING RETAINER 503-5001193 Valve Shim,2.85
9 4 5000210 -03 INNER VALVE SPRING 503-5001194 Valve Shim,2.90
8 4 5000209 -03 OUTER VALVE SPRING 503-5001195 Valve Shim,2.95
7 4 5000208 VALVE SPRING SEAT 503-5001196 Valve Shim,3.00
6 2 5002335 EXHAUST VALVE 503-5001197 Valve Shim,3.05
5 2 5002334 INTAKE VALVE 503-5001198 Valve Shim,3.10
4 4 5000205 VALVE GUIDE INCLUDED IN 502-5001446 503-5001199 Valve Shim,3.15
3 2 5001965 EXHAUST VALVE SEAT INCLUDED IN 502-5001446 503-5001200 Valve Shim,3.20
2 2 5001964 INTAKE VALVE SEAT INCLUDED IN 502-5001446 503-5001201 Valve Shim,3.25
1 1 502-5001446 C YLINDER HEAD SUB ASSY 503-5001202 Valve Shim ,3.30
ITEM
QTY
NO.
REQ
DEALER PA RT
NO.
V ALV E TRAIN PARTS LIST
DESCRIPTION
DEALER PA RT
NO.
DESCRIPTIONNOTES
ADDI T IO NAL PART S TAB L E
7
Cam Drive
2
17
19
19
11111116
11
12
15
20
13
18
2
17
14
9
4
1
6
3
5
7
20 1 5001156 SPACER, DR IVE GEAR S PROCK ET
19 2 5001007 NEEDLE BEARING, 12X16X10
18 1 5000250 DRIVE GEAR SPROCKET 27T, 33T
17 2 5001724 WASHER, THRUST, 12X20X.08
16 1 5001862 CAMSHAFT DRIVE GEAR BRACKET
15 1 5001475 SHCS , M5X0.8X12 mm
14 1 5001477 SHCS , M5X0.8X18 mm
13 2 5001480 SHCS , M5X0.8X50 mm
12
11 1 5001102 CAM CHAIN TENSIONER ASSEMBLY
10 1 5001028 EXTRNL RETANING RING, M10
9 1 5000671-04 CAM CHAIN TENSIONER SHOE
8 2 5001947 SHCS , M6X1.0X14 mm
7 1 5001039-03 TIMING CHAIN GUI DE
6 1 5001829-03 TIMING CHAIN GUIDE SUPPORT
5 1 5002157-04 CAM CHAIN TENSIONER PVT BOLT
4 1 5000420 TBHC S, M5X0.8X10 mm , SS
3 1 5001948 CAM CHAIN TENSIONER SHOE PIVOT
2 1 5000482 O-RING, 2-011
1 1 5002332 TIMING CHAIN
ITEM NOQTY
REQD
5001491 SHCS , M6X1.0X16 mm
DEA LER PA RT
NUMBER
M/C ATV
MODEL
DESCRIPTION NOTES
CAM DRIVE PARTS LIST
10
8
8
Crankcase
3
3
6
5
9
8
24
23
22
1
1
2
1
1
1
20
21
25
11
12
10
5
13
4
7
6
89
7
9
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