Cannondale S440, C440, E440, X440, E440R User Manual
...
2003 Motorcycle Parts Catalog
©
(E440, E440A, E440R, S440, C440, X440) - 09/02
CONTENTS
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
2003 Motorcycle Parts Catalog 0902.fm
2001 Cannondale Corporation - All Rights Reserved
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
P/N 5002339-03
Printed : 9/4/02
Legend
2 3
1
51
41
31
21
11
ITEM NOQTY
REQD
4 5 6
5002260I
5002254
5002248 SENSOR MAGNET
5002257 CABLE, ODOMETER
5002260 ODOMETER
5002211 ODOMETER MOUNT PLATE
DEALER PART
NUMBER
XSEEAERCR
MODEL
9
7
8
ODOMERTER INSTRUCTIONS
ADDITIONAL PARTS TABLE
SWITCH, HEAD LIGHT
DESCRIPTION NOTES
ODOMETER PARTS LIST
10
11
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.
2
Front Wheel
3
*
12
*
11
4 *
2
5 *
13
*
6
*
7
1
9
8 *
* 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
ITEM NOQTY
REQD
5002540 WEIGHT, WHEEL BALANCE Strip of 12, 1/4 oz weights
051-5002498 FRONT WHEEL ASSEMBLY, MOTARD
051-5000020 FRONT W HEEL ASSEMBLY
ADDITIONAL PARTS TABLE
SEE FRONT H UB FRONT HUB ASSEMBLY INCLUDED IN FR WHEEL ASSYS
DEA LER PA RT
NUMBER
XSEEAERC
MODEL
DESCRIPTION
10
NOTES
FRONT WHEEL PARTS LIST
3
Rear Wheel
2
*
3
*
*
4
17
*
16
18
15
*
10
12
11
*
14
5
*
13
9 *
6
*
1
7
8
4
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"
ADDITIONAL PARTS TABLE
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
ITEM NOQTY
REQD
DEA LER PA RT
NUMBER
XSEEAERC
MODEL
DESCRIPTION NOTES
REAR WHEEL PARTS LIST
5
Wheel Hubs
10 *
5
6
9
*
8
6
5
*
7
4
5
6
6
3
*
2
6
5
1
* 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
ITEM NOQTY
REQD
DEA LER PA RT
NUMBER
XSEEAERC
MODEL
DESCRIPTION NOTES
WHEEL HUBS PARTS LIST
6
Front Fork
58
41
49
50
51
52
53
54
42
57
57
57
32
1
2
33
57
3
4
57
5
20
6
7
8
9
57
19
18
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
22
23
24
25
26
27
28
29
30
31
43
44
57
47
48
46
45
46
56
48
7
Front Fork List
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
* 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
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
ITEM NOQTY
REQD
5000015 FORK SPRING - 4.9 N/mm OPTIONAL
ADDITIONAL PAR TS TABLE
DEA L ER PART
NUMBER
XSEEAERC
MODEL
DESCRIPTION NOTES
FRONT FORK PA RTS LIST
8
Steering Head
8
8
6
*
*
5
*
9
11
8
8
12
10
7
4
13
2
3
8
*
1
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
ITEM NOQTY
REQD
DEA LER PA R T
NUMBER
XSEEAERC
MODEL
STEERING HEAD PARTS LIST
DESCRIPTI ON NOTES
9
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 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
ITEM NOQTY
REQD
DEA LER PA RT
NUMBER
XSEEAERC
MODEL
BRAKE GUIDES PA RTS LIST
DESCRIPTION NOTES
10
Handlebar & Controls Li st
2
3
23
18
*
1
5
8
7
6
19
20
4
9
11
22
21
24
12
13
16
*
25
32
10
17
33
45
*
42
41
14
35
40
39
*
15
36
37
43
38
44
27
29
26
34
*
31
28
46
30
47
11
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