Cannondale C440 Instruction Manual

2003 Motorcycle Parts Catalog
CONTENTS
©
2001 Cannondale Cor
p
oration - All Ri
g
hts Reserved P/N 5002339-03
Printed : 9/4/02
2003 Motorcycle Parts Catalog 0902.fm
(E440, E440A, E440R, S440, C440, X440) - 09/02
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
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

2
12 3 4 5 6 78910 11
5002260I ODOMERTER INSTRUCTIONS
51 5002254 SWITCH, HEAD LIGHT
41 5002248 SENSOR MAGNET
31 5002257 CABLE, ODOMETER
21 5002260 ODOMETER
11 5002211 ODOMETER MOUNT PLATE
XSEEAERCR
ADDITIONAL PARTS TABLE
ODOMETER PARTS LIST
ITEM
NO
QTY
REQD
DEALER PART
NUMBER DESCRIPTION NOTES
MODEL
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.
Legend

3
Front Wheel
2
3*
4*
5*
6
7*
9
13 *
11
12 *
8*10
1
5002540 WEIGHT, WHEEL BALANCE Strip of 12, 1/4 oz weights
051-5002498 FRONT WHEEL ASSEMBLY, MOTARD
051-5000020 FRONT WHEEL ASSEMBLY
* 18 5002500A X SPOKE, FRONT, OUTSIDE, 3.6x172.0mm INCLUDEDIN FRWHEEL 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 INCLUDEDINFR 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,NYLKZINC
* 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 RIMLOCK, FRONT
* 1 5002510 X RIMSTRIP, 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
SEEFRONT HUB FRONT HUB ASSEMBLY INCLUDED IN FR WHEEL ASSYS
XSEEAERC
ADDITIONAL PARTS TABLE
FRONT WHEEL PARTS LIST
NOTES
DEALER PART
NUMBER
ITEM
NO QTY REQD DESCRIPTION MODEL

4
Rear Wheel
1
4 *
3 *
2 *
11 *
9 *
6 *
8
5
14
15
12
13
7
10 *
17 *18
16 *

5
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 REARWHEEL ASSEMBLY, MOTARD
151-5002085 REARWHEEL ASSEMBLY, 18"
151-5000069 REARWHEEL ASSEMBLY, 19"
18 2 5002199 DUST CAP
* 18 5002502 X SPOKE, REAR, OUTSIDE, 4.0X175.0 mm INCLUDEDINRRWHL ASSYS
* 18 5001873 X X X X SPOKE, REAR, OUTSIDE, 18" WHEEL INCLUDEDINRR WHL ASSYS
17 18 5000075 X SPOKE, REAR, OUTSIDE, 19" WHEEL INCLUDED INRR WHL ASSYS
* 18 5002503 X SPOKE, REAR, INSIDE, 4.0X181.0 mm INCLUDEDINRR WHL ASSYS
* 18 5002287 X X X X SPOKE, REAR, INSIDE, 18" WHEEL INCLUDED IN RR WHL ASSYS
16 18 5000797 X SPOKE, REAR, INSIDE, 19" WHEEL INCLUDED INRR WHL ASSYS
15 36 5001624 NIPPLE, REAR INCLUDED IN RR WHL ASSYS
14 6 5000713 FLATWASHER, M8
13 6 5000140 LOCKNUT, M8
12 6 5000393 FHCS, M8X28 mm, ZINC
* 1 5002521 X SPROCKET, REAR, 45T
11 1 5000117 X X X X X SPROCKET, REAR, 50 T
* 1 6000315 X X X X MASTERLINK, O-RING
10 1 5001847 X X MASTERLINK
* 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 ASSY
* 1 5001886 X X X X WHEEL RIM, REAR, 18" INCLUDED IN RR WHL ASSY
6 1 5000076 X WHEEL RIM, REAR, 19" INCLUDED IN RR WHL ASSY
5 1 5000077 RIMLOCK, REAR
* 1 5002510 X RIMSTRIP, 17"
* 1 5002130 X X X X RIMSTRIP, REAR
4 1 5000078 X RIM STRIP, REAR
* 1 5002508 X TUBE, 120/70-17
* 1 5002131 X X X X TUBE, 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 SEEREAR HUB REAR HUB ASSEMBLY INCLUDED IN RR WHL ASSYS
XSEEAERC
ADDITIONAL PARTS TABLE
REAR WHEEL PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

6
Wheel Hubs
5
6
6
5
9 *8
7 *
10 *
4
6
6
3 *
1
2
65
5
* 1 5002541 X FRONT WHEEL SPACER INCLUDED IN RR WHEEL ASSYS
10 1 5000074 X X X X X FRONT WHEEL SPACER 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 ASSYS
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 LIPSEAL, 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 IN RR WHEEL ASSYS
XSEEAERC
WHEEL HUBS PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

7
Front Fork
57
12
3
4
5
6
7
8
9
10
11
12
13
15
16
17
18
19
20
21
22
23
24
25
26
27
28
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
47
48
50
51
52
53
54
55
57
58
29
59
12
14
57
57
57
57
57
42
41
49
57
57
57
57
57
57
48
56
45
46 46

8
Front Fork List
13 2 5000548 FORK OUTER TUBEBUSHING SLEEVE
12 4 5000547 FORK OUTER TUBEBUSHING
11 2 5000561 FORK OUTER TUBEBUSHING CIRCLIP
10 2 5000005 FORK OUTERTUBE
9 2 5000559 FORK OUTER TUBEDECAL
8 2 SEETABLE FORK SPRING
7 2 5000553 FORK SPRING WASHER
6 2 5000552 FORK SPRING SPACER
5 2 5000546 FORK OUTER TUBECAPO-RING
4 2 5000545 FORK OUTER TUBECAP
3 2 5000551 FORK AIR BLEED SCREW O-RING
2 2 5000550 FORK AIR BLEED SCREW
1 2 5000549 FORK OUTER TUBECAPNUT
XSEEAERC
FRONT FORK PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL
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
5000015 FORK SPRING - 4.9 N/mm OPTIONAL
* 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 SERVICEKIT
56 1 5000568 FORK INNER TUBE ASSY-RIGHT
55 2 5000608 COMPRESSIONADJUSTERASSY.
54 2 5000607 COMPRESSION ADJUSTER O-RING
53 2 5000610 COMPRESSIONSHIMSET
52 2 5000611 FORK COMPRESSIONPISTON
51 2 5000606 FORK COMPRESSION PISTONO-RING
50 2 5000603 COMPRESSIONPISTONSHIM
49 2 5000604 COMPRESSIONPISTONWAVEWSHR
48 4 5000558 FRONT WHEEL AXLEPINCH BOLT
47 1 5000567 FORK INNER TUBEASSY-LEFT
46 6 5000556 FORK GUARDBOLT
45 1 SEE TABLE FORK GUARD SET
44 2 5000518 FORK INNER TUBEBUSHING
43 2 5000565 DAMPING CARTRIDGE TUBE
42 4 5000080 LOCKNUT
41 4 5000601 WASHER
40 2 5000600 MIDVALVESHIMSET
39 2 5000598 FORK REBOUND PISTON RING
38 2 5000597 FORK REBOUND PISTON
37 2 5000594 REBOUNDSHIMSET
36 2 5000593 REBOUNDADJUSTERBODY
35 2 5000592 REBOUND ADJNEEDLE SPRING
34 2 5000591 REBOUND ADJ NEEDLE
33 2 5000590 REBOUND ADJ NEEDLEO-RING
32 2 5000587 FORK TOPOUT SPRING
31 2 5000589 FORK DAMPERROD
30 2 5000586 FORK TOPOUT SPRING WASHER
29 2 5000585 FORK DAMPERRODBUSHING
28 2 5000584 FORK DAMPER ROD SLEEVE O-RING
27 2 5000583 FORK DAMPERRODSLEEVE
26 2 5000582 DAMPING CARTRIDGE TUBE CAP
25 2 5000581 DAMPERRODCIRCLIP
24 2 5000580 HYDRAULIC STOP COLLAR CIRCLIP
23 2 5000579 FORK HYDRAULIC STOP
22 2 5000578 FORK HYDRAULIC STOPCOLLAR
21 2 5000577 FORK SPRING GUIDE
20 2 5000575 REBOUNDADJUSTERASSY.
19 2 5000576 REBOUND ADJUSTER O-RING
18 2 5000574 FORK REBOUND ADJUSTER ROD
17 2 5000564 FORK WIPER
16 2 5000560 FORK SEAL RETAINING CIRCLIP
15 2 5000563 FORK SEAL
14 2 5000562 FORK SEAL RETAINING WASHER
ADDITIONAL PARTS TABLE

9
Steering Head
8*
8
6*
2
8*
5*
8
4
8
1
11
10
9
3
7
13
12
13 2 5000760 HEADSET BEARING, UPPER
12 2 5000722 HEADSET SEAL, UPPER
11 1 5000717 STEERER WASHER
10 1 5000170 SLOTTED LOCKNUT
9 1 5000174 STEERER NUT
* 4 5000728 X X FHB, M8X55 mm FOR USE W/ HANDGUARD BRCKT
8 12 5000100 X X X X FHB, M8X45 mm
7 2 5000101 FHB, M12X35 mm, NLK
* 2 5002537 X X X CLAMP, HANDLEBAR, UPPER
6 2 5000534 X X X CLAMP, HANDLEBAR, UPPER
* 2 5002533 X X X CLAMP, HANDLEBAR, LOWER
5 2 5000533 X X X CLAMP, HANDLEBAR, LOWER
4 1 012-5002097 LOWER TRIPLECLAMP ASSY
3 1 5000001B UPPER TRIPLE CLAMP
2 FRNT BRKE GDE, UPPER SEE FRONT BRA KE GUIDE, UPPER
1 FRNT BRKE GDE, LOWER SEEFRONT BRAKEGUIDE, LOWER
XSEEAERC
STEERING HEAD PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

10
Front Brake Guides
5
67
4
3
4
2
1
4
2
7 2 5000822 BRAKELINEGUIDETOPHAT
6 1 5001270 BRAKEGUIDECLAMP
5 1 5000038 BRAKEGUIDEMOUNT 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 FRONT BRAKEGUIDE
1 1 5002263 FRONT BRAKEGUIDEMOUNT, LOWER
XSEEAERC
BRAKE GUIDES PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

11
Handlebar & Controls List
18
20
19
23
21
22
3
911
13
12
16
44
10
17
2
4
56
78
1
*
*
26 *
24 25
43
42 41
40
38
37
36
35
32
33
39
31
15
*
14
*
34
45
29
30
28
27
46
47

12
47 2 5000728 X X FHB M8X55 mm
46 2 5001927 FHB M5X20 mm
45 AR 5002385 HYDRAULIC CLUTCH OIL, 16 oz.
44 1 5002373 CLUTCH LEVER PVT HRDWR KIT INCLUDED IN 5002095
43 1 5002374 CLUTCH LEVER SPRING INCLUDED IN 5002095
42 1 5002375 CLUTCH MASTER CYL CAP INCLUDED IN 5002095
41 2 5002376 CLUTCH MASTER CYL CAPSCRW INCLUDED IN 5002095
40 1 5002377 CLUTCH LEVER CLAMP INCLUDED IN 5002095
39 1 5002378 CLUTCH LEVER CLAMP SCRW INCLUDED IN 5002095
38 1 5002379 CLUTCH LEVER BOOT INCLUDED IN 5002095
37 1 5002380 CLUTCH LEVER ADJ GRIP, RED INCLUDED IN 5002095
36 1 5002381 CLUTCHMSTRCYL PISTONKIT INCLUDEDIN5002095
35 1 5002382 CLUTCH MSTR CYL MEMBRANE INCLUDED IN 5002095
34 1 5002383 CLUTCH SLAVE VALVE, CAP KIT INCLUDED IN 5002095
33 1 5002384 CLUTCHTUBEKIT, 1045 mm INCLUDEDIN5002095
32 1 5002386 MASTER CYLINDER, SLV, M/C INCLUDED IN 5002095
31 1 5002387 SLAVE CYLINDER, COMPLETE INCLUDED IN 5002095
30 2 5002538 X X BRACKET, HANDGUARD, UPPER
29 2 5002539 X X BRACKET, HANDGUARD, LOWER
28 2 6000252 X X FHB M8X25 mm HANDGUARD MNTNG HRDWR
27 2 6000277 X X FHB M8X20 mm HANDGUARD MNTNG HRDWR
* 1 5002519 X HANDGUARD SET, LOOP, SILVER
26 1 5002215 X HANDGUARDSET, LOOP, SILVER
25 1 5001808L X HANDGUARD HARDWARE KIT
24 1 5001808 X HANDGUARDSET, BLACK
23 4 5000379 SHCS,M4X12 ZINC
22 1 5002364 ENGINEON/OFF SWITCH
21 1 5000131-01 ENGINESTART SWITCH
20 1 5002363 SWITCH CAP USEW/ ON/OFF SWITCH5002364
19 1 5000437 SWITCHCAP
18 1 5001274-04 SWITCH CLAMP
* 1 6001180 X X X HANDLEBAR PAD, RED, MAGURA
* 1 5002262 X CROSSBAR PAD - SILVER
17 1 5000317 X X CROSSBARPAD- BLACK/YELLOW
* 1 5002518 X HANDLEBAR, MAGURA, SX
* 1 5002454 X X HANDLEBAR, MAGURA, MX2
16 1 5000120 X X X HANDLEBAR
* 1 5002372S CLUTCHLEVER, SILVER, SHORT
15 1 5002372 CLUTCHLEVER, SILVER
14 1 5002095 HYDRAULIC CLUTCH LEVER ASSY
13 1 5000125 THROTTLECABLE
12 2 5000786 FLANGE HEAD BOLT, M6X20 mm INCLUDED IN THROTTLE ASSY
11 1 5000123 THROTTLE HOUSING BOOT INCLUDED IN THROTTLE ASSY
10 1 5001590 THROTTLE CABLE ADJ BOOT INCLUDED IN THROTTLE ASSY
9 1 5001369 THROTTLE CABLE ADJUSTER INCLUDED IN THROTTLE ASSY
8 2 5001368 THROTTLE PULLEY COVER SCRW INCLUDED IN THROTTLE ASSY
7 1 5001367 THROTTLE PULLEY COVER INCLUDED IN THROTTLE ASSY
6 1 5001366 THROTTLE PULLEY BUSHING INCLUDED IN THROTTLE ASSY
5 1 5001365 THROTTLE PULLEY INCLUDED IN THROTTLE ASSY
4 1 5000488 THROTTLE HOUSING SET INCLUDED IN THROTTLE ASSY
3 1 5000124 THROTTLE TUBE INCLUDED IN THROTTLE ASSY
2 1 5000121 HANDLEBAR GRIPSET
* 1 5002252 X THROTTLEASSEMBLY, E440R FORUSEW/ HANDGUARDS
1 1 5000474 X X X X X THROTTLEASSEMBLY
XSEEAERCITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

13
Odometer
1
2
3
5
4
5002260I ODOMERTERINSTRUCTIONS
5 1 5002254 SWITCH, HEADLIGHT
4 1 5002248 SENSORMAGNET
3 1 5002257 CABLE, ODOMETER
2 1 5002260 ODOMETER
1 1 5002211 ODOMETER MOUNT PLATE
XSEEAERC
ADDITIONAL PARTS TABLE
ODOMETER PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

14
Front Brake Master Cylinder
6
5
9
12
7
8
13 14
2
4
3
1
10
11
15
*
*
4
*
15 AR 5000268 NISSIN BRAKEGREASE, 2 GRAM AS REQUIRED
14 1 5000046 FT BRAKELEVERRETURN SPRING NISSIN - INCLUDEDIN5000032
13 1 5000044 FT BRAKELEVER NISSIN - INCLUDEDIN5000032
12 1 5000103 FT BRAKELEVERRUBBERCOVER NISSIN - INCLUDEDIN5000032
11 1 5000043 FT BRAKEMSTRCYL BOOT INCLUDEDIN5000032 / 5000033
10 1 5000099 FT BRAKEMSTRCYL CIRCLIP INCLUDEDIN 5000032 / 5000033
9 1 5000033 FT BRAKEMSTR CYL KIT NISSIN - INCLUDED IN 5000032
8 1 5000045 FT BRAKELEVER ADJ BOLT KIT NISSIN - INCLUDED IN 5000032
7 1 5000041 FT BRAKELEVERPIVOT BOLT KIT NISSIN - INCLUDED IN5000032
6 1 5000042 FT BRAKEMSTR CYL CLAMP KIT NISSIN - INCLUDED IN 5000032
5 1 5000040 FT BRAKEMASTERCYL CAPKIT NISSIN - INCLUDEDIN5000032
* 1 5002515 X BANJO BOLT, M10X1.0X10 mm TO CALIPER
4 2 5000538 X X X X X BRAKELINEBANJO BOLT
3 4 5001549 CRUSH WASHER
* 1 5002311 X X X FT BRAKELINE, E
* 1 5002514 X FT BRAKELINE, S
2 1 5002264 X X FT BRAKELINE
* 1 5002516 X FTBRAKEMSTR CYL ASSY, MOTARD
1 1 5000032 X X X X X FT BRAKEMSTRCYL ASSY
XSEEAERC
FRONT BRAKE MASTER CYLINDER PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

15
Front Brake Caliper
1
23
4
5
5
6
7
9
11
10
8
*
*
*
*
13
12
5
*
13 1 5002513 X FRONT BRAKECALIPER MOUNT
12 2 5001264 X BHCS, M10x25mm
11 1 5000055 BRAKECALIPERBLEEDERKIT
10 1 5000052 SLIDEPINBOOT- LARGE
9 1 5000054 FRONT BRAKE PAD PIN KIT
8 1 5000049 FRONT BRAKE PAD SPRING
7 AR 5000268 NISSINBRAKEGREASE, 2 GRAM AS REQURIED
6 1 5000050 SLIDE PIN BOOT - SMALL
* 2 5000612 X FLANGEHEADBOLT, M8X35 mm
5 2 5000863 X X X X X FLANGEHEADBOLT, M8X40 mm
* 1 5002517 X FRONT BRAKE CALIPER PAD SET SUPER MOTARD
4 1 5000035 X X X X X FRONT BRAKECALIPER PAD KIT
3 1 5000036 FRONT BRAKECALIPERPISTONKIT
2 1 5000048 FRONT BRAKECALIPERBRACKET
* 1 5002256 X X X FRONTBRAKECALIPERASSEMBLY, E FORUSEW/ ODOMETER
* 1 5002512 X FRONT BRAKE CALIPER ASSY, MOTARD S MOTARD. PAD SET NOT INCLD
1 1 5000034 X X FRONTBRAKECALIPERASSEMBLY
XSEEAERC
FRONT BRAKE CALIPER PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

16
Rear Brake Pedal
1
3
6
5
4
2
6
6 2 5000375 SEAL, 15X21X3 INCLUDED IN5001226
5 1 5000399 BOLT, BRAKEPEDAL
4 1 5000413 RR BRAKECOTTER PIN
3 1 5000109 BRAKEPEDAL YOKEPIN INCLUDED IN5001226
2 1 5000112 SPRING, BRAKEPEDAL
1 1 5001226 REAR BRAKEPEDAL
XSEEAERC
REAR BRAKE PEDAL PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

17
Rear Brake Master Cylinder
5
7
9
6
8
1
2
12
12
4
2
3
13
13
12
13
13
12
10
11
14
15
16
16 1 5000434 NUT, FLANGE, M6
15 1 5001013 FLANGEHEADBOLT, M6 X 16
14 2 5000126 SHCS, M8 X 20
13 4 5001549 CRUSHWASHER
12 2 5000538 BRAKELINEBANJO BOLT
11 1 5001268 RRBRAKEMSTR CYL GUARD
10 1 5000537 REAR BRAKELINE
9 1 5002285 RR BRAKEMSTR CYL ASSY
8 AR 5000268 NISSINBRAKEGREASE, 2 GRAM AS REQUIRED
7 1 5000085 RR BRAKE RESERVOIR ASSY
6 1 5000104 RR BRAKE RESERVOIR HOSE KIT
5 1 5000105 RR BRAKEMSTR CYL ELBOW KIT
4 1 5000107 RR BRAKEMSTR CYL BOOT
3 1 5000267 RR BRAKEMSTR CYL PISTONCIRCLIP
2 1 5000106 RR BRAKE MSTR CYL PUSHROD KIT
1 1 5000086 RR BRAKEMASTERCYL KIT
XSEEAERC
REAR BRAKE MASTER CYLINDER PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

18
Rear Brake Caliper
1
2
3
4
5
6
8
9
10
10 1 5000082 REARBRAKEPADSET
9 1 5000052 SLIDE PIN BOOT - LARGE
8 1 5000055 BRAKECALIPERBLEEDERKIT
7 AR 5000268 NISSINBRAKEGREASE, 2 GRAM AS REQUIRED
6 1 5000050 SLIDE PIN BOOT - SMALL
5 1 5000081 REAR BRAKECALIPER ASSEMBLY
4 1 5000096 REAR BRAKECALIPER BRACKET
3 1 5000098 REARBRAKEPAD PINKIT
2 1 5000091 REAR BRAKE PAD SPRING
1 1 5000083 REARBRAKECALIPERPISTONKIT
XSEEAERC
REAR BRAKE CALIPER PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

19
Mainframe
1
2
3
4
5
6
7
8
9
10
11
12
13
14
17
15
16
18 19
*
19 1 5002409 CLAMP, ONE-EARED, STEPLESSS, 19.8
* 1 5002331 HOSE, BREATHER, FRAME GREEN STICKER
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 HDBLT, M6X12,NLK
10 1 5000863 FLNG HDBLT, 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 ENGINEOIL FITTING
4 4 5000190 THREADED INSERT, M8 INCLUDED IN 5002100
3 1 5001593 INSERT, M8 INCLUDED IN5002100
2 5 5000888 RIVNUT, M6 INCLUDED IN5002100
1 1 201-5002100 MAINFRAMESUB ASSY
XSEEAERC
MAINFRAME PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL

20
Subframe
1
6
2
3
5
7
8
10 *12 *
11
4
9
13
14
15 4 5000192 FLAT WASHER, M6
14 1 6000341 NUT, LOCK, M6 GROUND
13 1 5001013 FHB M6X16 mm GROUND
* 1 5002520 X X X X X VOLTAGERECTIFIER/REGULATOR
12 1 5002615 X VOLTAGERECTIFIER/REGULATOR
11 2 5000189 THREADEDINSERT, M6 INCLUDEDIN201-5002103
* 2 5000093 X X X X X FLANGE-HEAD BOLT, M6X25
10 2 5000423 X FLANGE-HEADBOLT, M6X50
9 1 6000378 X SPACER, REAR BRAKERESERVOIR
8 1 5002228 SEAT LATCH WEAR PLATE INCLUDED IN 201-5002103
7 2 5002234 BHCS, M3X5 mm INCLUDED IN201-5002103
6 2 5002326 ISOLATIONBLOCK
5 2 6000116 BOLT, SHOULDER, M8X15 mm
4 2 5000139 SHLDR SS,M10X12,NLKZC
3 1 5001593 THREADED INSERT, M8 INCLUDED IN201-5002103
2 7 5000888 RIVNUT, M6 INCLUDED IN201-5002103
1 1 201-5002103 SUBFRAMEWELDMENT
XSEEAERC
SUBFRAME PARTS LIST
ITEM
NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL