Cannondale E440, C440 User Manual

2002 Motorcycle Parts

Printed :

4/25/02

Catalog (E440, C440) - 05/02

CONTENTS

Front Wheel . . . . . . . . . . . . . . . . . 2

Rear Wheel . . . . . . . . . . . . . . . . . 3

Wheel Hubs . . . . . . . . . . . . . . . . . 4

Front Fork . . . . . . . . . . . . . . . . . . 5

Front Fork List . . . . . . . . . . . . . . 6

Steering Head . . . . . . . . . . . . . . . 7

Front Brake Guides . . . . . . . . . . . 8

Handlebar & Controls List . . . . . . 9

Odometer . . . . . . . . . . . . . . . . . . 11

Front Brake Master Cylinder . . . 12

Front Brake Caliper . . . . . . . . . . 13

Rear Brake Pedal . . . . . . . . . . . 14

Rear Brake Master Cylinder . . . . 15

Rear Brake Caliper . . . . . . . . . . . 16

Mainframe . . . . . . . . . . . . . . . . . . 17

Subframe . . . . . . . . . . . . . . . . . . 18

Frame Rail & Skid Plate . . . . . . . 19

Footpegs . . . . . . . . . . . . . . . . . . . 20

Kickstand . . . . . . . . . . . . . . . . . . 21

Swingarm . . . . . . . . . . . . . . . . . . 22

Rear Shock . . . . . . . . . . . . . . . . . 23

Seat & Number Plates . . . . . . . . 24

Radiator Shroud . . . . . . . . . . . . . 25

Frnt Fender & Frnt Number Plte . 26

Rear Fender & Taillight . . . . . . . 27

Battery Plate . . . . . . . . . . . . . . . 28

Electrical . . . . . . . . . . . . . . . . . . 29

Exhaust . . . . . . . . . . . . . . . . . . . 30

Radiator . . . . . . . . . . . . . . . . . . . 31

Airbox . . . . . . . . . . . . . . . . . . . . 32

Fuel Tank . . . . . . . . . . . . . . . . . . 33

Fuel System . . . . . . . . . . . . . . . . 34

Decals . . . . . . . . . . . . . . . . . . . . 35

Vehicle Warnings . . . . . . . . . . . . 36

2002 Motorcycle Parts Catalog 0302.fm

P/N 5002339

Front Wheel

1

2

11

12

3

13

4

6

5

1

7

9

14 13 18 5000026 FRONT SPOKE - OUTSIDE INCLUDED IN 051-5000020 12 18 5000477 FRONT SPOKE - INSIDE INCLUDED IN 051-5000020 11 36 5001623 NIPPLE, FRONT INCLUDED IN 051-5000020 10 1 5000540 NUT, FLANGE, M16X 1.5

9 6 5000864 FHCS, M6X16,NYLKZIN C

8-1 1 5002246 X FRONT ROTOR

8 1 5000047 X FRONT ROTOR 7 1 5000536 FRONT WHEEL RIM INCLUDED IN 051-5000020 6 1 5002133 FRONT RIM LOCK 5 1 5002134 FRONT RIM STRIP 4 1 5002135 FRONT INNER TUBE 3 1 5002098 FRONT TIRE 2 1 5000021 AXLE, FRONT WHEEL 1 1 SEE FRONT HUB FRONT HUB ASSEMBLY INCLUDED IN 051-5000020

ITEM NOQTY

REQD

051-5000020 FRON T W HEEL ASSEMBLY

DEA LER PA RT

NUMBER

CE

MODEL

DESCRIPTION

NOTES

FRONT WHEEL PARTS LIST

8

8-1

10

2

Rear Wheel

2

15

3

16

4

12

17

11

18

5

14

10

13

9

6

7

8

1

1 183-5000339 REAR SPROCKET , 49 T 1 183-5000349 REAR SPROCKET , 51 T 1 183-5000357 REAR SPROCKET , 52 T

ADDITIONAL PARTS TABLE

19 1 151-5002085 REAR WH EEL ASSEMBLY 18 2 5002199 DUST CAP 17 18 5001873 RR SPOKE - OUTSIDE INCLUDED IN 151-5002085 16 18 5002287 RR SPOKE - INSIDE INCLUDED IN 151-5002085 15 36 5001624 NIPPLE, REAR INCLUDED IN 151-5002085 14 6 5000713 FLAT WASHER, M8 13 6 5000140 LOCKNUT, M8 12 6 5000393 FHCS, M8X28 ZINC 11 1 5000117 R EAR SPRO CKE T, 50 T STOCK 10 1 5001847 MASTER LINK, O-RING

9 1 5001798 DRIVE CHAIN, O-RING 8 4 5000138 FHCS, M8X16, NYLK, ZINC 7 1 5000090 R EAR ROT OR 6 1 5001886 REAR WHEEL RIM INCLUDED IN 151-5002085 5 1 5002129 R EAR RI M LOCK 4 1 5002130 R EAR RI M STR IP 3 1 5002131 R EAR IN NER TUBE 2 1 5002132 R EAR T IRE 1 1 SEE REAR HUB REAR HUB ASSEMBLY INCLUDED IN 151-5002085

DEA LER PA RT

QTY

ITEM

NO

REQD

NUMBER

CE

MODEL

DESCRIPTION

NOTES

REAR WHEEL PARTS LIST

3

Wheel Hubs

10

5

6

9

8

6

5

7

4

5

6

3

2

6

5

1

10 1 5000074 FRONT WHEEL SPACER

9 1 5000022-07 FRONT HUB 8 1 5000023 FRONT HUB BEARING SPACER 7 1 5000024 FRONT WHEEL SPACER-DISC SIDE 6 5 5000355 SEALED BEARING, 20X42X12 5 4 5000356 DOUBLE LIP SEAL, 32X42X4 4 1 5001091 R EAR WHEEL SPACER 3 1 5000071-08 REAR HU B 2 1 5000072 R EAR HU B B EARING SPACER 1 1 5000073 REAR WHEEL SPACER-DISC SIDE

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE

MODEL

DESCRIPTION NOTES

WHEEL HUBS PARTS LIST

4

Front Fork

58

42

41

49

50

51

52

53

54

57

32

1

2

33

57

3

4

57

5

6

7

8

20

9

57

18

19

21

57

34

35

36

37

38

39

40

41

42

55

57

59

10

11

12

13

12

14

15

16

17

57

28

29

30

22

23

24

25

26

27

31

43

44

57

47

46 46

48

45

56

48

5

Front Fork List

59-115002222

X

FRONT FORK SET, C

5915002247

X

FRONT FORK SET, E

58AR5000572

OHLINS FORK FLUID, 1LITER

57AR5001526

FORK SERVICE KIT

5615000568

FORK INNER TUBE ASSY-RIGHT

5525000608

COMPRESSION ADJUSTER ASSY.

5425000607

COMPRESSION ADJUSTER O-RING

5325000610

COMPRESSION SHIM SET

5225000611

FORK COM PRESSION PISTON

5125000606

FORK COMPRESSION PISTON O-RING

5025000603

COMPRESSION PISTON SHIM

4925000604

COMPRESSION PISTON WAVE WSHR

4845000558

FRONT WHEEL AXLE PINCH BOLT

4715000567

FORK INNER TUBE ASSY-LEFT

4665000556

FORK GUARD BOLT

451SEE TABLE

FORK GUARD SET

4425000518

FORK INNER TUBE BUSHING

4325000565

DAMPING CARTRIDGE TUBE

4245000080

LOCKNUT

4145000601

WASHER

4025000600

MID VALVE SHIM SET

3925000598

FORK REBOUND PISTON RING

3825000597

FORK REBOUND PISTON

3725000594

REBOUND SHIM SET

3625000593

REBOUND ADJUSTER BODY

3525000592

REBOUND ADJNEEDLE SPRING

3425000591

REBOUND ADJ NEEDLE

3325000590

REBOUND ADJ NEEDLE O-RING

3225000587

FORK TOP OUT SPRING

3125000589

FORK DAMPER ROD

3025000586

FORK TOP OUT SPRING WASHER

2925000585

FORK DAMPER ROD BUSHING

2825000584

FORK DAMPER ROD SLEEVE O-RING

2725000583

FORK DAMPER ROD SLEEVE

2625000582

DAMPING CARTRIDGE TUBE CAP

2525000581

DAMPER ROD CIRCLIP

2425000580

HYDRAULIC STOP COLLAR CIRCLIP

2325000579

FORK HYDRAULIC STOP

2225000578

FORK HYDRAULIC STOP COLLAR

2125000577

FORK SPRING GUIDE

2025000575

REBOUND ADJUSTER ASSY.

1925000576

REBOUND ADJUSTER O-RING

1825000574

FORK REBOUND ADJUSTER ROD

1725000564

FORK WIPER

1625000560

FORK SEAL RETAINING CIRCLIP

1525000563

FORK SEAL

1425000562

FORK SEAL RETAINING WASHER

1325000548

FORK OUTER TUBE BU SHING SLEEVE

1245000547

FORK OUTER TUBE BU SHING

1125000561

FORK OUTER TUBE BU SHING CIRCLIP

1025000005

FORK OUTER TUBE

925000559

FORK OUTER TUBE DECAL

82SEE TABLE

FORK SPRING

725000553

FORK SPRING WA SHER

625000552

FORK SPRING SPACER

5002055

FORK GUARD SET - SILVER

525000546

FORK OUTER TUBE CAP O-RING

5000018

FORK GUARD SET - BLACK

425000545

FORK OUTER TUBE CA P

5001222

FORK GUARD SET - WHITE

325000551

FORK AIR BLEED SCREW O-RING

5000013

FORK SPRING - 4.5 N/mm

OPT ION AL

225000550

FORK AIR BLEED SCREW

5000014

FORK SPRING - 4.7 N/mm

STA NDARD

125000549

FORK OUTER TUBE CAP NUT

5000015

FORK SPRING - 4.9 N/mm

OPT ION AL

MODEL

ITEM

QTY

DEALER

\

NO.

REQ

PART NO.

FRONT FORK PARTS LIST ADDITIONAL PARTS TABLE

XCE

DESCRIPTION

PART NO.

DESCRIPTION

NOTES

6

Steering Head

) )

DEALER PA RT

8

6

8

5

9

11

10

3

2

8

12

7

13

8

4

1

13 2 5000760 HEADSET BEARING, UPPER Before E VIN#164 & C VIN # 98 Use (1) 5002059 (Low er 12 2 5000722 HEADSET SEAL, UPPER Before E VIN#164 & C VIN # 98 Use (1) 5002060 (Low er 11 1 5000717 STEERER WASHER 10 1 5000170 SLOTTED LOCKNUT

9 1 5000174 STE ERER NUT 8 12 5000100 FHB, M8X45 mm 7 2 5000101 FHB, M12X35 mm, NLK 6 2 5000534 UPPER HANDLEBAR CLAMP 5 2 5000533 LOWER HANDLEBAR CLAMP 4 1 012-5002097 LOWER TRIPLE CLAMP ASSY Before E VIN# 164 & C VIN # 98 Use 012-5002289 3 1 5000001B UPPER TRIPLE CLAMP 2 FRNT BRKE GDE, UPPER SEE FRONT BRA KE GUIDE, UPPER 1 FRNT BRKE GDE, LOWER SEE FR ONT BRAKE GUIDE, LOWER

ITEM NOQTY

REQD

NUMBER

CE NOTES

MODEL

DESCRIPTION

STEERING HEAD PARTS LIST

7

Front Brake Guides

5

4

6

7

4

3

2

1

4

7 2 5000822 BRAKE LINE GUIDE TOPHAT 6 1 5001270 BRAKE GUIDE CLAMP 5 1 5000038 BRAKE GUIDE MOUN T ASSY 4 4 5001013 FLNG HD BLT, M6X16, NLK 3 1 5002261 X FRONT BRAKE GUIDE MOUNT, UPPER 2 2 5000535 FRONT BRAKE GUIDE 1 1 5002263 FRONT BRAKE GUIDE MOU NT, LOWER

CE NOTESITEM NOQTY

MODEL

BRAKE GUIDES PARTS LIST

DESCRIPTION

REQD

DEA LER PA RT

NUMBER

8

Handlebar & Controls List

2

20

21

18

1

-1

1

6

5

3

8

7

22

19

12

13

4

9

10

17-1

17

16

16-1

11

2

14

15

23

24

9

1 5002373 C LUTCH LEVER PVT HR DWR K IT I NCLUDED IN 500 20 95

2415002215

X

HANDGUA RD SET, LOOP, SILVER

23

1

5001808

X

HANDGUA RD SET, BLACK

22

4

5000379

SHCS,M4X12 ZINC

2115000505

ENGINE STOP SWITCH

2015000131

ENGINE START SWITCH

1915000437

SWITCH CAP

1815001274

SWITCH CLAMP

17-115002262

XXCROSSBAR PAD - SILVER

1715000317

CROSSBAR PAD - BLACK

16-115002279

X

HANDLEBAR, E

1615000120

X

HANDLEBAR

1515002372

CLUTCH LEVER

1415002095

HYDRAULIC CLUTCH LEVER ASSY

1315000125

THROTTLE CABLE

1225000786

FLA NGE HEAD BOLT, M6X20 mm

I NCLUDED IN 500 04 74

1115000123

THROTTLE HOUSING BOOT

I NCLUDED IN 500 04 74

1015001590

THROTTLE CABLE ADJ BOOT

I NCLUDED IN 500 04 74

915001369

THROTTLE CABLE ADJUSTER

I NCLUDED IN 500 04 74

825001368

THROTTLE PULLEY COV ER SCRW

I NCLUDED IN 500 04 74

715001367

THROTTLE PULLEY COVER

I NCLUDED IN 500 04 74

615001366

THROTTLE PULLE Y BUSHIN G

I NCLUDED IN 500 04 74

515001365

THROTTLE PULLE Y

I NCLUDED IN 500 04 74

415000488

THROTTLE HOUSING SET

I NCLUDED IN 500 04 74

315000124

THROTTLE TUBE

I NCLUDED IN 500 04 74

215000121

HANDLEBAR GRIP SET

1-1

1

5002252

X

THROTTLE ASSEMBLY, E

115000474

X

THROTTLE ASSEMBLY, C

MODEL

ITEM NOQTY

DEA LER PA RT

1 5002374 C LUTCH LEVER SPRING IN CLUDED IN 500 20 95 1 5002375 C LUTCH MASTER CYL CAP INCLU DED IN 5002095 1 5002376 CLUTCH MASTER CYL CAP SCRW INCLUDED IN 5002095 1 5002377 C LUTCH LEVER CLAMP IN CLUDED IN 500 20 95 1 5002378 C LUTCH LEVER CLAMP SCRW I NCLUDED IN 500 20 95 1 5002379 C LUTCH LEVER BOOT I NCLUDED IN 500 20 95 1 5002380 C LUTCH LEVER ADJ GR IP , RED I NCLUDED I N 5002095 1 5002381 CLUTCH MSTR CYL PISTON KIT INCLUDED IN 5002095 1 5002382 CLUTCH MSTR CYL MEMBRANE INCLUDED IN 5002095 1 5002383 C LUTCH SLAVE VALVE , CAP KI T IN CLUDED IN 500 20 95 1 5002384 CLU TCH TUBE KIT, 1045 mm INCLUDED IN 5002095 1 5002385 HYDRAULIC CLUTCH OIL, 16 oz. 1 5002386 MASTER CYLINDER, SLV, M/C INCLUDED IN 5002095 1 5002387 SLAVE CYLINDER, COMPLETE INCLUDED IN 5002095

ADDITIONAL PARTS TABLE

REQD

NUMBER

CE NOTES

DESCRIPTION

HANDLEBAR & CONTROLS PARTS LIS T

10

Odometer

1

2

4

5

3

5 1 5002254 SWITCH, HEAD LIGHT 4 1 5002248 SENSOR MAGNET 3 1 5002257 CABLE, O DOMETER 2 1 5002260 ODOMETER 1 1 5002211 ODOMETER MOUNT PLATE

ITEM NOQTY

REQD

DEALER PART

NUMBER

CE NOTES

MODEL

DESCRIPTION

ODOMETER PARTS LIST

11