Cannondale Moto440-MO, Blaze 440-BZ, Glamis-GL, Speed-SP, Cannibal-CN User Manual

This a DRAFT copy of the

2003 ATV Parts Catalog.

2002 ATV Parts Catalog

where indicated.

2003 ATV PARTS CATALOG

Models : Moto440 (MO), Blaze 440 (BZ), Glamis (GL), Speed (SP), Cannibal (CN)

Modified : 1/8/03

www.cannondale.com/motorsports

CONTENTS

Wheels and Hubs. . . . . . . . . . . . . . . . . 4

Standard A-Arms . . . . . . . . . . . . . . . . . 6

Moto 440 A-Arms. . . . . . . . . . . . . . . . . 8

Front Shock . . . . . . . . . . . . . . . . . . . . 10

Steering Column . . . . . . . . . . . . . . . . 12

Steering Damper . . . . . . . . . . . . . . . . 14

Handlebar and Controls. . . . . . . . . . . 16

Ignition . . . . . . . . . . . . . . . . . . . . . . . . 18

Front Brake Master Cylinder . . . . . . . 20

Front Brake Caliper . . . . . . . . . . . . . . 22

Rear Brake . . . . . . . . . . . . . . . . . . . . 24

Mainframe . . . . . . . . . . . . . . . . . . . . . 26

The illustrations, photographs, and parts information in this Parts Catalog are for reference to replacement parts only.

This manual should not be used for service reassembly. Any part of this document is subject to correction without prior notice.

The illustrations and part information included in this parts catalog accurate at the time of the publication date.

Newer revisions of the same part number are processed as supercessions at the time of order.

Be sure to ask for available supercession information when ordering or check available parts bulletins on our website.

Cannondale reserves the right to make product improvement changes at any time without prior notice.

Brush Guard. . . . . . . . . . . . . . . . . . . . 28

Engine Rail. . . . . . . . . . . . . . . . . . . . . 30

Subframe . . . . . . . . . . . . . . . . . . . . . . 32

Swingarm. . . . . . . . . . . . . . . . . . . . . . 34

Rear Axle . . . . . . . . . . . . . . . . . . . . . . 36

Rear Shock . . . . . . . . . . . . . . . . . . . . 38

Airbox and Filter. . . . . . . . . . . . . . . . . 40

Exhaust . . . . . . . . . . . . . . . . . . . . . . . 42

Electrical Tray . . . . . . . . . . . . . . . . . . 44

Battery . . . . . . . . . . . . . . . . . . . . . . . . 46

Wiring Harness. . . . . . . . . . . . . . . . . . 48

Headlight . . . . . . . . . . . . . . . . . . . . . . 50

Fuel Pump . . . . . . . . . . . . . . . . . . . . . 56

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Footpegs and Baskets . . . . . . . . . . . . 60

Nerf Bars . . . . . . . . . . . . . . . . . . . . . . 62

Plastic. . . . . . . . . . . . . . . . . . . . . . . . . 64

2003 Cannibal Graphics (Black Plastic) 66 2003 Cannibal Graphics (Silver Plastic) 68 2003 Speed Graphics (Silver Plastic). 70 2003 Glamis Graphics (Silver Plastic) 72 2003 Moto 440 and Blaze Graphics (Silver

Plastic) . . . . . . . . . . . . . . . . . . . . . . . . 74

2003 Warning Decals. . . . . . . . . . . . . 76

Cooling System . . . . . . . . . . . . . . . . . 52

Fuel Tank and Regulator . . . . . . . . . . 54

The part numbers listed in this document may change after publication.

http://www.cannondale.com/motorsports/tech/partslist.html

No part of this 2003 Parts Manual may be reproduced without written permission.

• Never use anything other than authorized Cannondale parts.

• Whenever replacing a part replace the gaskets, o-rings, circlips, etc. whenever possible.

• Always use the recommended tools, liquids, lubricants, fuel and oil quantities.

• Always thoroughly clean all parts thoroughly before assembly.

• All screws, nuts, bolts, etc. are in the metric system.

2

6000535 SHOCK SPRING, FRONT 180-84/23 6000536 SHOCK SPRING, FRONT 180-48 6000537 SHOCK SPRING, FRONT 180-46

9

3

17 1 6000444 SPACER, FRONT SHOCK 16 1 6000615 SHCK SPRNG PRLOAD CA M RING 15 1 6000272 FHB M10X50 mm 14 2 5000146 LOCKNUT,M10 13 2 5000715 FLAT WASHER, M10 12 1 5000424 FHB M10x70mm SHOCK BOLT 11 1 5001291 SHOCK MOUNT BEARING OHLINS 10 2 5001288 SHOCK MOUNT BEARING CIRCLIP OHLINS

9 2 5001289 SHOCK MOUNT BEARING SE AL OHLINS 8 2 5001290 SHOCK MOUNT BEARING SP ACER OHLINS 7 1 6000543 UPPER M OUNT BUSHING OHLINS 6 1 6000538 SHOCK SPRING RETAINER OHLINS 5 1 6000539 SHOCK SPRING PRELOA D CIRCLIP OHLINS 4 1 6000540 SHOCK SPRING PRELOA D A DJ OHLINS 3 1 6000541 SHOCK BODY PROTECTO R OHLINS 2 2 6000542 SHOCK BODY CIRCLIP OHLINS * 2 6001248 X SHOCK, FRONT ARVIN * 2 6001200 X SHOCK, FRO NT OHLINS * 2 6001028 X SHOCK, FRONT OHLINS * 2 6001183 X SHOCK, FRONT, GLAMIS OHLINS 1 2 6000648 X SHOCK, FRONT OHLINS

ITEM NOQTY

1

REQD

2

DEALER PART

NUMBER

4

ABBREVIATIONS

FHB - Flange head bolt SHCS - Socket head cap screw BHCS - Button head cap screw HHCS - Hex head cap screw FHCS - Flat head cap screw FSHCS - Flat socket head cap screw

MO SP GL BZ CN

MODEL

FRONT SHOCK PARTS LIST

5

RTNG - Retaining INT - Internal ASSY - Assembly LWR - Lower CYL - Cylinder PVT - Pivot ADJ - Adjustment ID - Inside Diameter

ADDITIONAL PARTS

DESCRIPTION

6

FT - Front RR - Rear R - Right L - Left INR - Inner OUT - Outer PR - Pair

NOTES

7

8

BLK - Black RED - Red YEL - Yellow ORG - Orange GRY - Gray SLV - Silver

Table/Illustration Legend

1 ITEM NO. - Item number shown in illustration

2 ASTERISKS (*) - Appear in the Item no. column when a similarly appearing

part with a different part number is used. The asterisk refers to the item no. directly below it.

3 QTY REQD - The quantity of the Item No. required

4 DEALER PART NUMBER - The Cannondale Part Number, use this part number

and quantity when ordering.

5 MODEL - The vehicle base model code. Use for special edition vehicles.

Model codes for this catalog are:

MO - Moto440 SP - Speed GL - Glamis BZ - Blaze CN - Cannibal

6

TABLE TITLE - The title of the table that compliments it's corresponding

Illustration.

7 DESCRIPTION - A text description of the part.

8 NOTES - Additional information about the part.

9 ADDITIONAL PARTS TABLE - Contains information about available factory

built assemblies and parts.

3

Wheels and Hubs

10

www.cannondale.com/motorsports

4*

9*

12

3

13*

11

2*

8

7

6

1*

5

3

4

* 2 152-6001030 X X REAR HUB ASSEMBLY, RED

MODEL

13 2 152-6000326 X X REAR HUB ASSEMBLY 12 1 6000009 INSERT, 15.2X20X9.8 mm 11 1 6000011 SEAL, HUB, FRONT, O UTER 10 1 6000026 BEARING, HUB, FRONT, OUTER

* 1 052-6001031 X X FRONT HUB ASSEMBLY, RED 9 1 052-6000553 X X X FRONT HUB ASSEMBLY 8 1 6001150 SPACER, BEARING HUB, 15.2X25.5X19.5 mm 7 1 5000355 SEALED BEARING, 20X42X12 6 1 6000010 SEAL, HUB, FRO NT, IN NER 5 4 5000138 FHCS, M8X16 mm, NYLOK/ZINC

* 2 6001034 X X FRON T ROTOR 4 2 6000633 X X X FRONT ROTOR 3 1 6000474 LUG NUT, M10

* 2 6001080 X REAR WHEEL ASSEMBLY Holeshot MX

* 2 6001033 X REAR WHEEL ASSEMBLY Holeshot XCR

* 2 6000305 X REAR WHEEL ASSEMBLY

* 1 6001191 X REAR WHEEL ASSEMBLY, PADDLE, RIGHT Glamis Paddle

* 1 6001190 X REAR WHEEL ASSEMBLY, PADDLE, LEFT Glamis Paddle

* 1 6000834 X REAR WHEEL ASSEMBLY, RIGHT 2 1 6000832 X REAR W HEEL ASSEMBLY, LEF T

* 2 6001189 X FRONT WHEEL ASSEMBLY, PADDLE Glamis Paddle

* 2 6001032 X FRONT WHEEL ASSEMBLY Holeshot XCR

* 2 6000303 X FRONT WHEEL ASSEMBLY

* 1 6001079R X FRONT WHEEL ASSEMBLY, RIGHT Holeshot MX

* 1 6001079L X FRO NT WHEEL ASSEMBLY, LEFT Holeshot MX

* 1 6000833 X FRONT WHEEL ASSEMBLY, RIGHT 1 1 6000831 X FRONT WHEEL ASSEMBLY, LEFT

ITEM NOQTY

REQD

DEALER PART

NUMBER

MO SP GL BZ CN

DESCRIPTION

NOTES

WHEELS A ND HUBS PARTS LIST

5

Standard A-Arms

See 2002 ATV Parts Catalog

www.cannondale.com/motorsports

6

See 2002 ATV Parts Catalog

7

Moto 440 A-Arms

www.cannondale.com/motorsports

5

25

27

23

28

21 , 22

7

29

9

8

18

6

10

7

25

12

24

19

17

26

3 , 4

16

14

13

20

8

15

11

1 , 2

8

29 1 013-6000870 X TIE ROD END KIT 2 ENDS PER KIT

MOSPGLBZCN

ADDITIONAL PARTS

MODEL

ITEM NOQTY

DEA LER PART

28 1 6000702 NUT, JAM, LEFT, M10 27 1 6000703 NU T, JAM , RIG HT, M10 26 4 6000270 FHB, M10X80mm, ZINC, NYLOK 25 6 5000146-01 LOCKNUT,M10 24 4 5000715 FLATHEAD WASHER, M10 23 1 6000265 NUT, CASTLE, M14 22 1 013-6000147-03 UPRI GHT , RIG HT 21 1 013-6000156-03 UPRI GHT , LEFT 20 4 6001110 X WASHER, PIVOT, A-ARM 19 1 6001119 X ZERK FITTING, M6 STRAIGHT 18 1 6001128 X SCR EW, SET, M5X8 MM, ZINC 17 2 6001127 X SPACER, ZERK FITTING 16 1 6001109 X BEARING, SPHERICAL, CB-8-B2 15 2 6001111 X SPACER, PIVOT, A-ARM 14 2 6001112 X SEAL, HM S 45412 13 2 6001113 X CLIP, SPIROLOXUR-87 12 1 6001114 X IN SERT, A-ARM ROD END 11 1 013-6000686-02 BALL JOINT, ATV A-ARMS 10 1 6001117 X NUT, JAM, M16X1.5

9 1 013-6000730-02 X RO D END/ BALL JOINT KIT 8 2 6000706 RING, RTNG, INT, 30 mm INCLUDED WITH BALL JOINT 7 3 6000488 PIN, COTTER, 2.5X32 mm 6 2 6000268 NUT, CAST LE, M12 5 1 014-6000822 X STEERING TIE ROD ASSEMBLY 4 1 013-6001090 X UPPER A-ARM ASSEMBLY, RIGHT 3 1 013-6001088 X UPPER A-ARM ASSEMBLY, LEFT 2 1 013-6001091 X LOWER A-ARM ASSEMBLY, RIGHT 1 1 013-6001089 X LOWER A-ARM ASSEMBLY, LEFT

REQD

NUMBER

DESCRIPTION

NOTES

A-A RMS PARTS LIST, MOTO440

9

Front Shock

1

13

12

Front Shock

www.cannondale.com/motorsports

17

14

7

5

4

16

*

3

2

6

15

8 - 11

10

6000535 SHOCK SPRING, FRONT 180-84/23

ADDITIONAL PARTS

MODEL

6000536 SHOCK SPRING, FRONT 180-48 6000537 SHOCK SPRING, FRONT 180-46

17 2 6000444 SPACER, FRON T SHOCK 16 1 6000615 SHOCK SPRNG PRLOAD CAM RING 15 1 6000272 FHB M10X50 mm 14 2 5000146 LOCKNUT,M10 13 2 5000715 FLAT WASHER, M10 12 1 5000424 FHB M10x70mm SHOCK BO LT 11 1 5001291 SHOCK MOUNT BEARING OHLINS 10 2 5001288 SHOCK MOUNT BEARING CIRCLIP OHLINS

9 2 5001289 SHOCK MOUN T BEARING SEAL OHLINS 8 2 5001290 SHOCK MOUN T BEARING SPACER OHLINS 7 1 6000543 UPPER MOUNT BUSHING OHLINS 6 1 6000538 SHOCK SPRING RETAINER OHLINS 5 1 6000539 SHOCK SPRING PRELOAD CIRCLIP OHLINS 4 1 6000540 SHOCK SPRING PRELOAD ADJ OHLINS 3 1 6000541 SHOCK BODY PROTECTOR OHLINS 2 2 6000542 SHOCK BODY CIRCLIP OHLINS

* 2 6001248 X SHOCK, FRONT ARVIN

* 2 6001200 X SHOCK, FRONT OHLINS

* 2 6001028 X SHOCK, FRONT OHLINS

* 2 6001183 X SHOCK, FRONT, GLAMIS OHLIN S 1 2 6000648 X SHOCK, FRONT OHLINS

ITEM NOQTY

REQD

DEA LER PART

NUMBER

MO SP GL BZ CN

DESCRIPTION

NOTES

FRONT SHOCK PARTS LIST

11

Steering Column

See 2002 ATV Parts Catalog

www.cannondale.com/motorsports

12

See 2002 ATV Parts Catalog

13

Steering Damper

4

Steering Damper

7

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8

1

11

6

2

12

5

9

8

3

9

10

4

14

7

214-6001041 STEE RING DAM PE R KIT

MODEL

ADDITIONAL P ARTS

12 1 6001147 X X NUT, DAMPER LINK ARM 11 1 6001146 X X DAMPER SHEER PIN 10 2 6001099 X X NUT, JAM, M6X1

9 2 6000314 X X NUT, LOCK, M6 8 2 5000095 X X FLNG HD BLT,M6X20,NYLOK 7 6 6001098 X X SHCS, M6X30 mm 6 1 6001093 X X STEE RING DAMPER MOUNT 5 1 6001094 X X STEE RING DAMPER MOUNT CLAMP 4 2 6001095 X X ROD END 3 1 6001096 X X LINK ROD 2 1 6001097-04 X X ROTARY DAMPER LINK ARM 1 1 6001041 X X STEE RING DAMPER

ITEM NOQTY

REQD

DEA LER PART

NUMBER

MO SP GL BZ CN

DESCRIPTION

STEERING DAMPER PARTS LIST

NOTES

15

Handlebar and Controls

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3*

26

2*

6

22

21

9

4

15

20

19

10

*

7

1

12

16

5

17

29

28

8

23

13

16

14

27

18

24

25

11

29 1 6000827 I NTERLOCK S WITCH BO OT

MOSPGLBZCN

MODEL

ITEM NOQTY

DEA LER PART

28 1 6000824 I NTERLOCK S WITCH 27 2 5001927 FHB M5X20 mm 26 AR 5002385 HYDRAULIC CLUTCH OIL, 16 oz. 25 1 5002593 O-RING, SL AVE CYLINDER 24 1 5002373 CLUTCH LEVER PVT HRDWR KIT 23 1 5002374 CLUTCH LEVER SPRING 22 1 5002375 CLUTCH MASTER CYL CAP 21 2 5002376 CLUTCH MASTER CYL CAP SCREW 20 1 5002377 CLUTCH LEVER CLAMP 19 1 5002378 CLUTCH LEVER CLAMP SCREW 18 1 5002379 CLUTCH LEVER BOOT 17 1 5002380 CLUTCH LEVER ADJ GRIP, RED 16 1 5002381 CLUTCH MSTR CYL PISTON KIT 15 1 5002382 CLUTCH MSTR CYL MEMBRANE 14 1 5002383 CLUTCH SLAVE VALVE, CAP KIT 13 1 6000825 CL UTCH TUBE KIT, 1100 mm 12 1 6000826 MASTER CYLINDER, BLK 11 1 5002387 SLAVE CYLINDER, COMPLETE 10 1 6000823 CLUTCH LEVER, BLACK

9 1 6000671 CLUTCH LEVER ASSEMBLY 8 1 6001048 HANDGUARD SET HARDWA RE INCLUDED 7 1 6000168-04 THROTTLE CABLE 6 1 6000248 THROTTLE ASSEMBLY 5 1 213-5001952 ENGINE START SWITCH 4 1 5001953 ENGINE STOP SWITCH

* 1 6001040 X X GRIP SET, RED

* 1 6000491 X GRIP,PR,CLOGO,BLK/GRY 3 1 6000647 X X GRIP ,PR ,CLOGO,BLK/YEL

* 1 6001178 HANDLEBAR PAD, MAGURA, ORG 2 1 6001180 HANDLEBAR PAD, MAGURA, RED

* 1 5002454 X HANDLEBAR, MAG, MX2

* 1 6001017 X HA NDLEBAR, TAG X5 HANDLEBAR PAD INCLUDED

* 1 6001037 X X HANDLEBAR, TAG T2 HA NDLEBAR PAD INCLUDED 1 1 6000283 X HANDLEBAR, BLK

REQD

NUMBER

DESCRIPTION

NOTES

HANDLEBAR & CONTROLS PARTS LI ST

17

Ignition

5

2*

9

6

4

www.cannondale.com/motorsports

18

8

7

3

1

9 1 6000738 X X PLUG, 5/8", PLASTIC

MODEL

8 1 6001039 XXXX PLATE, IGNITON SWITCH 7 1 6001038 X X SWITCH , TETHE R KILL 6 2 5000378 FHB, M5X12 mm 5 1 6000521 IGNITION KEY COVER INCLUDED IN 6000247 4 1 6000520 IGNITION SWITCH RING INCLUDED IN 6000247 3 1 6000592 IGNIT ION COVER

* 1 6000287A IGNITION KEY, BLANK USE WITH "A" SERIAL # INCLUDED IN 6000247 2 1 6000287B IGNITION KEY, BLANK USE WITH "B" SERIAL # INCLUDED I N 6000247 1 1 6000247 IGNIT ION S WITCH ASSEMBLY

ITEM NOQTY

REQD

DEA LER PART

NUMBER

MO SP GL BZ CN

DESCRIPTION

NOTES

IGNITION PARTS LIST

19

Front Brake Master Cylinder

13

15

17

14

Front Brake Master Cylinder

10

9

8

5

7

www.cannondale.com/motorsports

6

1

16

11

4

3

2*

12

20

17

1

MODEL

16 15 14 13 12 AR 5000268 NISSIN BRAKE GREASE, 2 GRAM 11 1 6000021 FRONT BRAKE LEVER 10 1 6000025 FT BRAKE MSTR CYL BOOT

9 1 5000099 FT BRAKE MSTR CYL CIRCLIP 8 1 6000019 FT BRAKE MSTR CYL PISTON KIT 7 1 6000022 FRONT BRAKE LEVER BOLT KIT 6 1 6000024 FT BRAKE MSTR CYL CLAMP KIT 5 1 6000020 FT BRAKE MASTER CYL CAP KIT 4 3 6000242 BOLT, BANJO, M10X22 mm 3 6 5001549 WASHER, CRUSH, ALUMINUM

* 1 6001042 X BRAKE LINE, FRONT 2 1 6000162 X X X X BRAKE LIN E, FRONT 1 1 6000000 FRONT BRAKE MASTER CYL ASSY

ITEM NOQTY

REQD

6000596 BHCS, M10X16 mm 6000285 CIRCLIP, 4 m m 6000286 SPRING, BUTT ON 6000169 PARKING BRAKE LATCH 6000170 PARKING BRAKE BUTTON

DEA LER PART

NUMBER

MO SP GL BZ CN

DESCRIPTION

FRONT BRAKE MASTER CYLINDE R ASSY PARTS LIST

NOTES

21

Front Brake Caliper

14

12

Front Brake Caliper

www.cannondale.com/motorsports

15

5

11

13

7*

10

6*

8*

9

1*

4

22

2

3

15

AR

1

MODEL

14 13 12 11 10

9

*

8 1 072-6000015 BRAKE PAD SET, L

*

7 1 073-6000016 BRAKE CALIPER BRACKET, L

* 1 6000003 FRONT BR AKE CALIPER, RIGHT

6 1 6000002 FRONT BRAKE CALIPER, LEFT 5 4 6000277 FHB M8X16 mm 2 PER BR ACKET 4 4 5001700 PHILLIPS BOLT 3 2 5001013 FHB, M6X16 mm, NYLOK 2 6 6000279 BRAKE LINE CLAMP

* 1 6001042 X BRAKE LINE, FRONT

1 1 6000162 X X X BRAKE LINE , FRONT

ITEM NOQTY

REQD

073-5000268 NISSIN BRAKE GREASE, 2 GRAM 073-6000014 BRAKE CALIPER PISTON KIT 173-5000091 REAR BRAKE PAD SPRING 172-5000098 REAR BRAKE PAD RETAINING PINS 072-5000055 BRAKE CALIPER BLEEDER AND CAP 073-5000050 BRAKE CALIPER BRACKET SLIDE PIN BOOT 073-5000052 BRAKE CALIPER SLIDE PIN BOOT 072-6000017 BRAKE PAD SET, R

073-6000018 BRAKE CALIPER BRACKET, R

DEA LER PART

NUMBER

MO SP GL BZ CN

DESCRIPTION

NOTES

FRONT BRAKE CALIPER PARTS LIS T

23

Rear Brake

1

3

Rear Brake

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2

17

18

24

19

22

25

15

20

23

21

16

13

1

8

7

14

8

6*

2

24

10

23

11

9

5

4