Cannondale E440, C440 User Manual

2002 Motorcycle Parts

© 2001 Cannondale Corporation - All Rights Reserved

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

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

57

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

57

57

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

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

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

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

Front Brake Master Cylinder

3
3

12

8

11

10

9

5

6

7

1

4

3

13

14

2

2-1

15

15 AR 5000268 NISSIN BRAKE GREASE, 2 GRAM AS REQUIRED
14 1 5000046 FT BRAKE LEVER RETURN SPRING INCLUDED IN 5000032
13 1 5000044 FT BRAKE LEVE R INCLUDED IN 5000032
12 1 5000103 FT BRAKE LEVER RUBBER COVER INCLUDED IN 5000032
11 1 5000043 FT BRAKE MSTR CYL BOOT INCLUDED IN 5000032/072-500003
10 1 5000099 FT BRAKE MSTR CYL CIRCLIP INCLUDED IN 5000032/072-500003

9 1 5000033 FT BRAKE MSTR CYL KIT INCLUDED IN 5000032
8 1 5000045 FT BRAKE LEVER ADJ BOLT KIT INCLUDED IN 5000032
7 1 5000041 FT BRAKE LEVER PIVOT BOLT KIT INCLUDED IN 5000032
6 1 5000042 FT BRAKE MSTR CYL CLAM P KIT INCLUDED IN 5000032
5 1 5000040 FT BRAKE MASTER CYL CA P KIT INCLUDED IN 5000032
4 2 5000538 BRAKE LINE BANJO BOLT
3 4 5001549 CRUSH WASHER

2-1 1 5002311 X FT BRAKE LINE, E

2 1 5002264 X FT BRAKE LINE, C
1 1 5000032 FT BRAKE M ASTER CYL ASSY

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

FRONT BRAKE MASTER CYLINDER PARTS LIST

12

Front Brake Caliper

5

6

1-1

2

1

5

7

3

11

10

9

8

4

11 1 5000055 BRAKE CALIPER BLEEDER KIT
10 1 5000052 SLIDE PIN BOOT - LARGE

9 1 5000054 FRONT BRAKE PAD PIN KIT
8 1 5000049 FRONT BRAKE PAD SPRING
7 AR 5000268 NISSIN BRAKE GREASE, 2 GRAM AS REQURIED
6 1 5000050 SLIDE PIN BOOT - SMALL
5 2 5000863 FLANGE HEAD BOLT, M8X40 mm
4 1 5000035 FRONT BRAKE CALIPER PAD KIT
3 1 5000036 FRONT BRAKE CALIPER PISTON KIT
2 1 5000048 FRONT BRAKE CALIPER BRACKET

1-1 1 5002256 X FRONT BRAKE CALIPER ASSEMBLY, E

1 1 5000034 X FRONT BRAKE CALIPER ASSEMBLY

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

FRONT BRAKE CA L IPER PARTS LIST

13

Rear Brake Pedal

4

3

6

6

1

5

2

6 2 5000375 SEAL, 15X21X3 INCLUDED IN 5001226
5 1 5000399 BOLT, BRAKE PEDAL
4 1 5000413 RR BRAKE COTTER PIN
3 1 5000109 BRAKE PEDAL Y OKE PIN INCLUDED IN 5001226
2 1 5000112 SPRING, BR AKE PED AL
1 1 5001226 REAR BRAKE PEDAL

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

REAR BRAKE PEDAL P ARTS LIST

14

Rear Brake Master Cylinder

12

8

13

13

10

12

1

9

2

12

3

12

4

6

13

13

16

7

15

5

11

14

2

16 1 5000434 NUT, FLANGE, M6
15 1 5001013 FLANGE HEAD BOLT, M6 X 16
14 2 5000126 SHCS, M8 X 20
13 4 5001549 CRUSH WASHER
12 2 5000538 BRAKE LINE BANJO BOLT
11 1 5001268 RR BRAKE MSTR CYL GUARD
10 1 5000537 R EAR BRAKE LI NE

9 1 5002285 RR BRAKE MSTR CYL ASSY
8 AR 5000268 NISSIN BRAKE GREASE, 2 GRAM AS REQUIRED
7 1 5000085 RR BRAKE RESERVOIR ASSY
6 1 5000104 RR BRAKE RESERVOIR HOSE KIT
5 1 5000105 RR BRAKE MSTR CYL ELBOW KIT
4 1 5000107 RR BRAKE MSTR CYL BOOT
3 1 5000267 RR BRAKE MSTR CYL PISTON CIRCLIP
2 1 5000106 RR BRAKE MSTR CYL PUSHROD KIT
1 1 5000086 RR BRAKE MASTER CYL KIT

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

REAR BRAKE MASTER CYLINDE R PARTS LIST

15

Rear Brake Caliper

3

1

8

5

2

4

6

7

9

10

10 1 5000082 REAR BRAKE PAD SET

9 1 5000052 SLIDE PIN BOOT - LARGE
8 1 5000055 BRAKE CALIPER B LEEDER KI T
7 AR 5000268 NISSIN B RAKE GREASE, 2 GRAM AS REQUIRED
6 1 5000050 SLIDE PIN BOOT - SMALL
5 1 5000081 REAR BRAKE CALIPER ASSE MBLY
4 1 5000096 REAR BRAKE CALIPER BRACKET
3 1 5000098 REAR BRAKE PAD PIN KIT
2 1 5000091 REAR BRAKE PAD SPRING
1 1 5000083 REAR BRAKE CALIPER PISTON KIT

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

REAR BRAKE CALIPER PARTS LIS T

16

Mainframe

18

2

19

1

7

13

5

11

14

4

3

9

10

8

17

15

16

19 1 5002323 OETIKER HOSE CLAMP, 19.8 mm
18 1 5002198 HOSE, BREATHER, FRAME
17 1 5002071 OIL LEVEL SIGHT WINDOW
16 2 5002069 FHCS, M10X1.5X16
15 2 5000482 O-RING, 2-011
14 1 5000487 O-RING, 2-012
13 1 5000828 O-RING, 2-016
12 1 5000140 LOCKNUT, M8
11 1 5001184 FLNG HD BLT, M6X12,NLK
10 1 5000863 FLNG HD BLT, M8X40,NYLK

9 1 5002068 FHB, M8X60 mm
8 1 5001374 CHAIN ROLLER SPACER
7 1 5001434-03 OIL FILL CAP
6 2 5000524 DRIVE CHAIN ROLLER
5 1 5000233-E ENGINE OI L FITTING
4 4 5000190 THREADED INSERT, M8 I NCLUDED IN 5002100
3 1 5001593 INSERT, M8 INCLUDED IN 5002100
2 5 5000888 RIVNUT, M6 INCLUDED IN 5002100
1 1 201-5002100 MAIN FRAME SUB ASSY

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

MAINFRAME PARTS LIST

6

12

17

Subframe

5

13

1

12

9

11

10

14

3

4

8

7

2

5

6

14 1 6000341 NUT, LOC K , M6 GROUND
13 1 5001013 FHB M6X16 mm GROUND
12 1 5001822 VOLTAGE RECTIFIER/REGULATOR
11 2 5000189 THREADED INSERT, M6 INC L UDED IN 201-5002103
10 2 5000093 FLANGE-HEAD BO LT, M 6X 25

9 1 5002297 HARNESS CNNCTR, VLTG REG
8 1 5002228 SEAT LATCH WEAR PLATE INCLUDED IN 201-5002103
7 2 5002234 BHCS, M3X5 mm INCLUDED IN 201-5002103
6 2 5002326 ISOLATION B LOCK, LEFT Before C VIN# 160 & E VIN #245 USE (1) 500232
5 2 6000116 BOLT, SHOULDER, M8X15 mm
4 2 5000139 SHLDR SS,M10X12,NLKZC
3 1 5001593 THREADED INSERT, M8 INCLUDED IN 201-5002103
2 7 5000888 RIVNUT, M6 INCLUDED IN 201-5002103
1 1 201-5002103 SUBF RAME WELDMENT

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

SUBFRAME PARTS LIST

18

Frame Rail & Skid Plate

2
2
2

1

5

8

2

3

5

7

6

4

9

10

10 4 5001013 FLANGE-HEAD BOLT, M6X16 - NYLOK

9 1 5001792-04 SKID PLATE , ALUM
8 2 5000612 FLNG HD BLT, M8X35, NYLK
7 4 5000134 SHCS DGPT. M8X20, ZNCNLK
6 2 5000527 FLNG HD BLT, M10X90, NLK
5 6 5000190 THREADED INSERT, M8 INCLUDED IN 201-5002101/500210
4 4 5001967 INSERT,M6 INCLUDED IN 201-5002101/500210
3 2 5000888 RIVNUT, M6 INCLUDED IN 201-5000521/500052
2 1 201-5002102 FR AME RAIL, LEFT
1 1 201-5002101 FR AME RAIL, RIGHT

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

FRAME RAIL PARTS LIST

19

Footpegs

NOTES

ITEM NOQTY

DEA LER PA RT

1

6

5

7

2

4

7 2 5000136 BHC S, M10X30, NYLKZNC US E W/ KICKSTAND
6 1 5001919 FOOT PEG BR ACK ET
5 1 5000526 FOOTPEG, LEFT
4 1 5000713 FLAT WASHER, M8
3 1 5000400 C OTTER P IN, 2.5X20
2 1 5000985 FOOT PE G SPRI NG, LEF T
1 1 5000986 FOOT PEG PIVOT PI N

CE NOTESITEM NOQTY

MODEL

DESCRIPTION

REQD

DEA LER PA RT

NUMBER

3

LEFT FOOTPEG PARTS LIST

1

6

5

3

7 2 5001264 BHCS, M10X25, NYLKZNC
6 1 5001919 FOOT PEG BR ACK ET
5 1 5002286 FOOTP EG, RIGHT
4 1 5000713 FLAT WASHER, M8
3 1 5000400 C OTTER P IN, 2.5X20
2 1 5000984 FOOTP EG SPRING, RIGHT
1 1 5000986 FOOT PEG PIVOT PI N

REQD

NUMBER

CE

MODEL

RIGH T FOOTPEG PARTS LIST

DESCRIPTION

7

2

4

20

Kickstand

3

2

4

5

1

5 1 5001891 KICKSTAND PIVOT BOLT
4 1 5001892 KICKSTAND TENS ION SPRING
3 1 5001893 NUT, HEX, LOCK, M10
2 1 5001882-02B KICKSTAND MOUNT
1 1 5001882-02A KICKSTAND LEG

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

KICKSTAND PARTS LIST

DESCRIPTION

21

Swingarm

31

33 1 5000421 HEX HEAD SET SCREW M8X50 mm
32 4 5000757 SWINGARM PIVOT THRUST WASHER INCLUDED IN 5000814
31 2 5000755 SWINGARM PIVOT BRNG, INR SPCR INCLUDED IN 5000814
30 2 5000756 SWINGARM PIVOT NEEDLE BEARING INCLUDED IN 5000814
29 2 5000758 BEARING, THRUST INCLUDED IN 5000814
28 2 5000759 SWINGARM PIVOT OUTER SEAL INCLUDED IN 5000814
27 2 5000754 SWINGARM PIVOT INNER SEAL INCLUDED IN 5000814
26 4 5001470 TOP-HAT WASHER, BUFFER, M6
25 1 5000115 DRIVE CHAIN G UIDE BLOCK
24 1 5000716 WASHER , REAR AXLE
23 1 5000541 NU T, REAR AXLE
22 1 5002298 BRAKE LINE GUIDE - FRONT
21 1 5000088 BRAKE LINE GUIDE - REAR
20 1 5000231 R EAR AXLE BL OCK
19 1 5000070 AXLE, REAR WHEEL
18 1 252-5002104 SWINGARM WELD MENT
17 1 5000114 DRIVE CHAIN G UIDE SHELL
16 1 5001939 SWINGARM BUFFER
15 2 5000144 SWINGARM PIVOT OUTER SPACER
14 2 5000145-04 SWINGARM PIVOT INNER SPACER
13 1 5000143 REAR AXLE ADJUSTER BLOCK
12 1 5000142-13 SWINGARM PIVOT BOLT
11 1 5001008 C OTTER PIN, 4X36
10 1 5000439 FLAT WASHER, M14

9 2 5000423 FLANGE-HEAD BOLT, M6X50 - NYLOK
8 1 5001184 FLANGE-HEAD BOLT, M6X12
7 2 5001957 NUT, HEX FLANG E, M8
6 2 5000434 NUT, HEX FLANG E, M6
5 4 5001468 PHILLIPS HD SCREW, M6X16,NYLOK
4 4 5000726 PHILLIPS HD SCREW, M5X8,NYLOK
3 1 5000189 THREADED INSERT, M6 INCLUDED IN 252-5002104
2 1 5000152 LOCKNUT, M14 X 1.5
1 1 5000814 SWINGARM BEARING & SEAL KIT INCLUDED IN 252-5002104

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

SWINGARM PARTS LIST

22

Rear Shock

17

1

14-115002284

X

REAR SHOCK ABSORBER, E

14

1

X

REAR SHOCK ABSORBER, C

L

STANDARD

L
L
L

ITEM NOQTY

1

2

3

4

3

2

1

7

8

15

15

16

17

9

10

11

5

6

14-1

14

10

12

13

5002153 FHB, M12X61 mm
16 1 5002 154 FHB, M12X73 mm
15 2 5002 191 FLANGED LOCKNUT, M12

5002221
13 1 5000 065 SHOCK SPRING RETAINER
12 1 SEE TABLE REAR SHOCK SPRING
11 1 5001 299 SHOCK SPRING SLEEVE
10 2 5001 298 SHOCK SPRING SLEEVE CIRCLIP

9 1 5001 296 SHOCK SPRING SEAT WA SHER
8 1 5000 064 SHOCK SPRING SEAT
7 1 5001 295 SHOCK SPG PRELOAD LK RG
6 1 5001 330 RESERVOIR BODY OHLINS DCL
5 1 5001 331 RESERVOIR BODY WRNG DCL 5000059 RR SHOCK SPG - 95 N/mm OPTIONA
4 2 5001 291 SHOCK MOUNT BEARING 5000060 RR SHOCK SPG - 100 N/mm
3 2 5001 288 SHOCK MOUNT BEARING CIRCLIP 5000061 RR SHOCK SPG - 105 N/mm OPTIONA
2 4 5001 289 SHOCK MOUNT BEARING SEAL 500 1431 RR SHOCK SPG - 110 N/mm OPTIONA
1 4 5002220 SHOCK EYELET BU SHING, 12mm 5001432 RR SHOCK SPG - 115 N/mm OPTIONA

DEALER

PART NO.

DESCRIPTION NOTES

REQ

DEALER

PART

CE

MODEL

DESCRIPTI ON

REAR SHOCK PARTS LIST ADDITIONAL PARTS TABLE

23

Seat & Number Plates

1-1

1

8

10

4

12 4 5001013 FHB, M6X16 mm
11 4 5001531 TOP-HAT WASHER
10 1 5002251 HEAT SHIELD

9 1 5002089 LEFT NUMBER PANEL - WHITE
8 1 5002088 RIGH T NUMBER PANEL - WHITE
7 1 5002229 PUSH NUT, ZINC
6 4 5000141 BHCS, M6X12 m m
5 1 5002223 SEAT LATCH MOUNT
4 1 5002225 SEAT LATCH HOOK
3 1 5002226 SEAT LATCH SPRING
2 1 5002227 SEAT LATCH PIN

1-1 1 5002094C SEAT COVER, BLK/SLV

1 1 5002094 SEAT ASSEMBLY, BLK/SLV

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

7

6

CE NOTES

MODEL

5

2

3

DESCRIPTION

SEAT & PLATES PARTS LIST

9

11

12

24

Radiator Shroud

6

1

4

5

3

2

6 4 5001612 PHILIPS HEAD SCREW, M6X12 mm
5 2 5000095 FHB, M6X20 mm
4 2 5001531 TOP-HAT WASHER
3 2 5000777 ISOLATION STRIP, 55 X 25.4 mm
2 1 5002091 RIGHT RADIATOR SHROUD - SILVER
1 1 5002090 LEFT R ADIATOR S HROUD - SI LVE R

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

RADIATOR SHROUDS PARTS LIST

25

Frnt Fender & Frnt Number Plte

8

2

2

7

7-1

4

4

3-1

3

5

6

8 1 5002212 H EADLI G HT

7-1 1 5002392 X BU LB , HEADLIGHT, 38 DEGREE BE AM

7 2 5002390 X BULB, H EADLIGHT, 10 DEGREE B EAM
6 4 5001013 FHB, M6X16 mm
5 4 5000192 FLAT WASH ER, M6
4 4 5001514 TOP-HAT WASHER

3-1 1 5002259 X FRONT FENDER , SILVER, E

3 1 5002093 X FRONT FEND ER, SILVER
2 1 5001184 FHB, M6X12 mm
1 1 5002092 FRONT N UMBER PLATE - WHITE

CE NOTESITEM NOQTY

MODEL

DESCRIPTION

REQD

DEA LER PA RT

NUMBER

26

Rear Fender & Taillight

1

3

6

4

8

2

9

7

10

5

10 1 5002391 X BULB, TAILLIGHT

9 1 5002393 X LENS, TAILLIGHT
8 2 5001512 FENDER NUT, M6
7 2 5001184 FLANGE-HEAD BOLT, M6X12 - NYLOK
6 2 5000095 FLANGE-HEAD BOLT, M6X20 - NYLOK
5 1 5002213 X TAILLIGHT ASSEMBLY
4 2 5001013 FLANGE-HEAD BOLT, M6X16 - NYLOK
3 2 5002292 SP ACER, REAR F ENDER
2 2 5000192 FLAT WASHER, M6
1 1 5002087 REAR FENDER, SILVER

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

REAR FENDE R P ARTS LIST

27

Battery Plate

10

18

3

16

15

7

8

27

23

20

26

4

24

9

25

22

17

14

13

11

19

12

1

2

21

5

6

13

27 1 5002362 BATTERY BOLT/NUT KIT, M/C
26 1 6000504 BHCS, M6X20 mm, ZINC, NY LOCK
25 1 5002273 MAIN POWER RELAY
24 2 5002148 BOLT, M6X12 BRASS
23 1 5001962-01 STARTER SOLENOID
22 2 5001184 FHB, M6X12 mm
21 1 5000434 NUT, HEX FLANGE, M6
20 4 5001512 FENDER NUT, M6, SQUARE
19 2 5001514 TOP HAT WASH ER
18 1 5001241 RIVET WASHER
17 4 5001584 WASHER , M5
16 2 5001561 WASHER , M5
15 2 5001562 LOCKNUT, M5
14 2 5001944 FHB M5X 2 5 mm , ZINC
13 2 5000192 FLAT WASHER,M6
12 2 5000095 FHB, M6X20 mm
11 2 5002268 BHCS, M6X10 mm, ZINC
10 2 5001240 FUSE HOLDER RIVET

9 1 472-5001951 ELECTRONIC CONTROL MODULE
8 1 5002280 BATTERY
7 2 5001794 WASHER, LOC K , 10
6 1 5001435 FUSE HOLDER
5 1 5000887 FUSE, 10 AMP
4 1 5002255 BUS BAR
3 1 5002217 BATTERY STRAP
2 1 5002267 MUD FLAP
1 1 5002190 BATTERY PLATE

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

BATTERY PLATE PARTS LIST

28

Electrical

5

3

2

6

10

4

1

9

8

7

10 2 5001946 FHB M6X30 mm, ZINC

9 1 5002299 X LIGHTING CAP
8 1 5002309 X LIGHTING CAP SEAL
7 1 5002266 X HARNESS CONNECTOR, LIGHTING, E
6 1 5000434 NUT, HEX FLANGE, M6
5 1 5000011 STARTER MOTOR 12V 0.65KW
4 1 5002218 STARTER MOTOR CABLE
3 1 5002049 POSITIVE BATTERY CABLE
2 1 5002216 NEGATIVE BATTERY CABLE
1 1 5002086 MAIN WIRE HARNESS

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

ELECTRICAL PARTS LIST

3

29

Exhaust

10

1

8

2

4

6

9

5

7

3

10 4 5001524 LOCK WASHER, M6, ZINC

9 4 5001605 NUT, HEX F LANGE, M6-12PT
8 2 5001345 EXHAUST CR USH WASHER
7 1 5000612 FHB, M8X35 mm
6 1 5000095 FHB, M6X20 mm
5 2 5002265 GROMMET, EXHAUST
4 2 5002209 SPRING, E X HAUS T IN CLUDED IN 50 02 08 1
3 1 5002082 EXHAUS T, SILENCER I NCLUDED I N 5002081
2 1 5002083 EXHAUST, HEADER PIPE INCLUDED IN 5002081
1 1 5002081 EXH AUST ASSE MBLY

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

EXHAUST PARTS LIST

30

Radiator

17

1

11

7

3

12

16

4

11

15

9

14

10

5

13

11

2

17 2 5000093 FHB M6X 2 5 mm
16 1 5000793 HOSE CLAMP, 5.6MM - 16mm
15 1 5002145 HOSE, COOLANT BLEED
14 1 5002044 RADIATOR OVERFLOW TUBE
13 4 5000543 H OSE CLAMP, 14-27mm
12 4 5000719-03 TP-HT WASHER
11 6 5000192 FLAT WASHER, M6
10 2 5000323 TINNERMAN CLIP

9 2 5001184 FLANGE-HEAD BOLT, M 6X12 - NYLOK
8 2 5000350 FHB, M6X25 mm
7 4 5000178 GROMMET, 3/8 ID
6 1 5001511 RADIATOR DRAIN PLUG
5 1 5002147 COOLANT HOSE, RAD TO WATER PUMP
4 1 5002146 COOLANT HOSE, RAD TO OUTLET CVR
3 1 5000542 RADIATOR CAP
2 1 5002079 RADIATOR GUARD
1 1 401-5002080 RADIATO R

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

6

CE NOTES

MODEL

8

DESCRIPTION

RADIATOR PARTS LIS T

12

7

31

Airbox

5

1

6

8

3

4

10

9

2

12

7

11

12

1
11 1 5000403 AIR TEMPERATURE SENSOR
10

1

9 2 5002293 TOPHAT, AIRBOX
8 2 5000178 GROMMET, 3/8 ID
7 2 5000350 FHB, M6X30, mm
6 1 5002152 AIR FILTER CLIP
5 1 5002150 AIR FILTER
4 6 5001238 RIVET AB4-6CLD INCLUDED IN 603-5002149
3 2 5001239 INTAKE END RETAINING RING INCLUDED IN 603-5002149
2 1 5002138 AIR FUNNEL INCLUDED IN 603-5002149
1 1 603-5002149 AIRBOX

ITEM NOQTY

REQD

5000487 O-RING, 2-012

5001149 CLAMP, BAND

DEA LER PA RT

NUMBER

CE NOTES

MODEL

AIRBOX PARTS LIST

DESCRIPTION

32

Fuel Tank

7

9

8

14

5

9

1

6

4

3

11

13

2

12

14 2 5000799 TOP -HAT WASHER, FUEL TANK TAB
13 2 5000765 TOP-HAT WASHER
12 4 5000192 FLAT WASHER, M6
11 2 5000862 FLNG HD BLT, M6X40 mm
10 2 5000802 GROMMET, FUEL TANK

9 3 5000137 FHCS, M6X16 ZINC
8 1 5002231 SEAT CATCH
7 1 5000175 FUEL TANK BREATHER HOSE
6 1 5000873 FUEL TANK CAP GASKET
5 1 5000169 FUEL TANK CAP
4 1 5001778 FUEL PICKUP FILTER INCLUDED IN 351-5002074
3 1 5002270 FUEL PICKUP TUBE INCLUDED IN 351-5002074
2 2 5002140-02 FUEL TANK FEMALE QUICK CONNECT INCLUDED IN 351-5002074
1 1 351-5002074 FUEL TANK

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

FUEL TANK PARTS LIST

10

33

Fuel System

1

12

21

24

8

5

9

15

3

13

2

11

27

28

4

14

10

22

23

7

6

18

19

29

26

25

1

30

17

16

20

30 1 5001137 O-RING, 008 MALE FU EL FITTING
29 1 5001544 FUEL REGULATOR HOUSING - PLASTIC
28 2 5001578 GROMMET,FUEL REGULATOR
27 2 5001579 TOP-HAT WASHER
26 1 5000395 FUEL PRESSURE REGUL ATOR
25 1 5000836 INTERNAL RETAINING RING, 36mm
24 6 5001607 OETIKE R HOSE CLAMP, 12.3mm
23 1 5002205-03 HOSE, FUEL, REGULATOR TO TANK
22 1 5002204-03 HOSE, FUEL, INJECTOR TO REGULATOR
21 1 5002203-03 HOSE, FUEL, PUMP TO INJECTOR
20 1 5002202-03 HOSE, FUEL, FILTER TO PUMP
19 1 5002201-02 HOSE, FUEL, TANK TO FILTER
18 2 5002141-02 FUEL TANK MALE BARBED INLET
17
16 2 5000793 HOSE CLAMP, 5.6-16 mm
15 2 5001789 H OSE CLAMP, 37-51 mm
14 3 5000434 NUT, HEX FLANGE, M6
13 1 5001184 FLANGE-HEAD BOLT, M6X12 - NYLOK
12 2 5000093 FLANGE-HEAD BOLT, M6X25 - NYLOK
11 1 5002327 ISO LATION STRIP, 6.4X30 mm
10 1 5002328 ISO LATION STRIP, 3.2X30 mm

9 4 5001549 WASHER, CRUSH, ALUMINUM
8 2 5001502 BANJO BOLT
7 2 5001641 NUT, HEX, 6-32
6 2 5001642 WASHER, SERRATED, NO. 6 ZINC
5 2 5001501 BANJO FITTING
4 1 5002290 FUEL PUMP PIGTAIL
3 1 5002124 FUEL PUMP GUARD
2 1 5002075 FUEL PUMP MOUNT
1 1 5000168 FUEL PUMP

ITEM NOQTY

REQD

5000544 FUEL FI LTER

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

FUEL SYSTEM PARTS LIST

34

Decals

DECALS PARTS LIST

12

11

6

7

8

9

2

13

3

4

5

1

14 1 5002238 DCL, PREM FUEL
13 1 50021 89 DCL, C LOGO, BLK
12 1 5002182 DCL, GP CONTROL, L
11 1 5002183 DCL, GP CONTROL, R
10 2 5002181 DCL, CDALE, FK GRD, BLK, SET

9 1 5002175 DCL, SHROUD FADE, L
8 1 5002176 DCL, SHROUD FADE, R
7 1 5002177 DCL, CDALE/C, BLK, L, SET
6 1 5002178 DCL, CDA L E/C, B LK, R, SET
5 2 5001990 DCL, SWINGA RM
4 1 5002186 DCL, X440, RR FDR, BLK
3 2 5002187 DCL, C440 , RR FDR, BLK
2 2 5002188 DCL, E44 0, RR FDR, BLK
1 1 5002173 DCL, GRAPHIC, RR FDR

ITEM NOQTY

REQD

DEA LER PA R T

NUMBER

CE NOTES

MODEL

DESCRIPTION

14

10

35

Vehicle Warnings

WARNINGS PARTS LIST

(1)

(2)

(3)

(3)

(4)

(1)

(2)

(4)

* - Any replacement warning label can be obtained by vehicle owner's
free of charge by calling 1-800-MOTO-USA.

4 1 5001371-01 WRN, FRAME
3 1 500418 DECAL, USE
2 1 5001262-01 DECAL, DISCLAIM
1 1 5000266-01 WRN, MULTI

ITEM NOQTY

REQD

DEA LER PA RT

NUMBER

CE NOTES

MODEL

DESCRIPTION

36