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Cannondale C440 manual

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Table of contents for the manual

  • Page 1

    2003 Motorcycle Parts Catalog CONTENTS © 2001 Cannondale Cor p oration - All Ri g hts R eser v ed P/N 5002339-03 Printed : 9/4/02 2003 Motorcyc le Parts Catalog 0902.f m (E440, E440A, E440R, S 440, C440, X440) - 09/02 Legend .........................................2 Front Wheel .................................3 Rear Wheel .......................[...]

  • Page 2

    2 1 2 3 4 5 6 7 8 9 10 11 5002260I ODOMERTER INS TRUCTIONS 51 5002254 SW ITCH, HEAD LIGHT 41 5002248 SENSOR MAGNE T 31 5002257 CABLE, ODOMETER 21 5002260 ODOMETER 11 5002211 ODOMETER MOUNT PLATE XSE E A E R C R A DDITIONA L PARTS TA BLE ODOM ETER PA RTS LIST ITEM NO QTY REQD DEALER PAR T NUMBER DESCRIPTION NO TES MODE L 12 1 - CALL OUT DESIGNA T OR[...]

  • Page 3

    3 Front Wheel 2 3 * 4 * 5 * 6 7 * 9 13 * 11 12 * 8 * 10 1 500254 0 WE I G H T, WH E E L BA LA N C E Str ip of 12, 1/4 oz w eights 051- 50024 98 F R ON T W H E E L A SSE M BLY , M OT A R D 051- 50000 20 F R O N T WH E E L A S S E M BLY * 18 500 25 00A X SP O KE , F R O N T , O U T SI D E , 3.6x 172.0 m m I N C LU D E D I N F R WH E E L A SS Y S 13 1[...]

  • Page 4

    4 Rear W hee l 1 4 * 3 * 2 * 11 * 9 * 6 * 8 5 14 15 12 13 7 10 * 17 * 18 16 *[...]

  • Page 5

    5 500254 0 WE I GH T, W H E E L BA LA N C E St r ip of 12, 1 /4 oz w eights 500033 9 SP R OC KE T , R E A R , 49 T 500034 9 SP R OC KE T , R E A R , 51 T 500035 7 SP R OC KE T , R E A R , 52 T 151-500249 9 R E A R W H E E L A SS E M B LY , M O T A R D 151-5002085 R E A R WH E E L A SS E M BLY , 18" 151-5000069 R E A R WH E E L A SS E M BLY , 1[...]

  • Page 6

    6 Wheel Hubs 5 6 6 5 9 * 8 7 * 10 * 4 6 6 3 * 1 2 6 5 5 * 1 500254 1 X FR O N T WH E E L SP A C E R I N C LU D E D I N R R WH E E L A SSY S 1 0 1 5 0 0 0 0 7 4 X X X X X FRO NT W HE EL S PA CE R INCL UDE D IN FR W HEE L A S S Y S * 1 5 0 0 2 5 3 5 X HUB , F RO NT, B L K INCL UDE D IN FR W HEE L A S S Y S 9 1 5 0 0 0 0 2 2 - 0 7 X X X X X HUB , FRO [...]

  • Page 7

    7 Front Fork 57 1 2 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[...]

  • Page 8

    8 Front Fork Lis t 13 2 50005 48 F OR K O U T E R T U BE B U SH I N G S LE E V E 12 4 50005 47 F OR K O U T E R T U BE B U SH I N G 11 2 50005 61 F OR K O U T E R T U BE B U SH I N G C I R C LI P 10 2 50000 05 F OR K O U T E R T U BE 9 2 5000 559 FO RK OU TE R T UB E D E C A L 8 2 SE E TA BL E F OR K SP R I NG 7 2 5000 553 FO RK SP RI N G WA SH E R[...]

  • Page 9

    9 Ste ering Head 8 * 8 6 * 2 8 * 5 * 8 4 8 1 11 10 9 3 7 13 12 13 2 5000760 H E A D SE T BE A R I N G, U P P E R 12 2 5000722 H E A D SE T SE A L, U P P E R 11 1 5000717 ST E E R E R WA SH E R 10 1 5000170 SLOT TE D LOC KN U T 9 1 50 001 74 ST E E R E R N U T * 4 5 0 0 0 7 2 8 X X FHB , M8 X 5 5 mm FO R US E W / HA NDG UA RD B RCK T 8 12 5000100 X [...]

  • Page 10

    10 Front Brake G uides 5 6 7 4 3 4 2 1 4 2 7 2 5000 822 BR A KE LI N E GU I D E T OP H A T 6 1 5001 270 BR A KE GU I D E C LA M P 5 1 5000 038 BR A KE GU I D E M OU N T A SSY 4 4 5001 013 FLN G H D BLT , M 6 X16, N LK 3 1 5 0 0 2 2 6 1 X X X F R O N T B R A K E G U ID E M O U N T , U P PER F O R U S E W / H EA D L I G H T 2 2 5000 535 FR O N T B R [...]

  • Page 11

    11 Hand le bar & Co n tr ols Li st 18 20 19 23 21 22 3 9 11 13 12 16 44 10 17 2 4 5 6 7 8 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[...]

  • Page 12

    12 47 2 50007 28 X X F H B M 8 X55 m m 46 2 50019 27 F H B M 5X 20 m m 45 A R 500238 5 H Y D R A U L I C C L U T C H O I L, 16 oz . 4 4 1 5 0 0 2 3 7 3 CL UTCH L EV E R PV T HRDW R K IT INCL UDE D I N 5 0 0 2 0 9 5 4 3 1 5 0 0 2 3 7 4 CL UTCH L EV E R S PRI NG INCL UDE D I N 5 0 0 2 0 9 5 4 2 1 5 0 0 2 3 7 5 CL UTCH MA S T ER CY L CA P INCL UDE D I[...]

  • Page 13

    13 Odometer 1 2 3 5 4 500226 0I O D O M E R T E R I N ST R U C T I O N S 5 1 5002 254 SW I T C H , H E A D LI GH T 4 1 5002 248 SE N SOR M A GN E T 3 1 5002 257 C A BLE , OD OM E T E R 2 1 5002 260 O D OM E T E R 1 1 5002 211 O D OM E T E R M OU N T P LA T E XSE E A E R C A DDI T I O NA L P A RT S T A BL E O DO M ET ER PA R T S LIST IT EM NO QTY RE[...]

  • Page 14

    14 Front Br ake Master Cylinder 6 5 9 12 7 8 13 14 2 4 3 1 10 11 15 * * 4 * 15 A R 500026 8 N I SSI N BR A KE GR E A SE , 2 G R A M A S R E Q U I R E D 14 1 500 00 46 F T BR A KE LE V E R R E T U R N SP R I N G N I SS I N - I N C LU D E D I N 500003 2 13 1 500 00 44 F T BR A KE LE V E R N I SS I N - I N C LU D E D I N 500003 2 12 1 500 01 03 F T BR[...]

  • Page 15

    15 Front Brake Cali per 1 2 3 4 5 5 6 7 9 11 10 8 * * * * 13 12 5 * 13 1 5 0025 13 X F R ON T BR A KE C A LI P E R M OU N T 12 2 5 0012 64 X BH C S, M 1 0x 25m m 11 1 50000 55 B R A KE C A LI P E R BLE E D E R KI T 10 1 50000 52 S LI D E P I N BO OT - LA R GE 9 1 5 0 0 0 0 5 4 FRO NT B RA K E P A D PIN K IT 8 1 5 0 0 0 0 4 9 FRO NT B RA K E P A D S[...]

  • Page 16

    16 Rear Brake Pedal 1 3 6 5 4 2 6 6 2 5000 375 SE A L, 15X21X3 I N C L U D E D I N 5 0012 26 5 1 5000 399 BO L T , BR A KE P E D A L 4 1 5000 413 R R BR A KE C O T T E R P I N 3 1 5000 109 BR A KE P E D A L Y O K E P I N I N C L U D E D I N 50012 26 2 1 5000 112 SP R I N G , BR A KE P E D A L 1 1 5001 226 R E A R BR A KE P E D A L XSE E A E R C REA[...]

  • Page 17

    17 Rear B rake Maste r Cylind er 5 7 9 6 8 1 2 12 12 4 2 3 13 13 12 13 13 12 10 11 14 15 16 16 1 500 04 34 N U T , F LA N GE , M 6 15 1 50010 13 F LA N GE H E A D BO LT , M 6 X 16 14 2 50001 26 SH C S, M 8 X 20 13 4 50015 49 C R U SH WA SH E R 12 2 50005 38 BR A K E LI N E B A N JO BO LT 11 1 50012 68 R R BR A KE M ST R C Y L GU A R D 10 1 50005 37[...]

  • Page 18

    18 Rear Brake Caliper 1 2 3 4 5 6 8 9 10 10 1 50000 82 R E A R BR A KE P A D SE T 9 1 5000 052 SLI D E P I N BOO T - LA R GE 8 1 5000 055 BR A KE C A LI P E R BLE E D E R KI T 7 A R 5000268 N I SS I N BR A KE G R E A SE , 2 G R A M A S R E QU I R E D 6 1 5000 050 SLI D E P I N BOO T - SM A L L 5 1 5000 081 R E A R BR A KE C A LI P E R A SSE M BLY 4[...]

  • Page 19

    19 Main fram e 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17 15 16 18 19 * 19 1 5 00 24 09 C L A M P , ON E - E A R E D , STE P LE SSS, 19 . 8 * 1 500233 1 H O SE , BR E A T H E R , F R A M E G R E E N ST I C KE R 18 1 5 0021 98 H OSE , B R E A TH E R , FR A M E 17 1 5 0020 71 OI L LE V E L SI G H T WI N D O W 16 2 5 0020 69 F H C S, M 10 X1.5X16 15 2 5 0004[...]

  • Page 20

    20 Subframe 1 6 2 3 5 7 8 10 * 12 * 11 4 9 13 14 15 4 50001 92 F LA T WA SH E R , M 6 1 4 1 6 0 0 0 3 4 1 NUT , L O CK , M6 G ROUND 13 1 5001013 F H B M 6 X16 m m G R O U N D * 1 500252 0 X X X X X V OLT A G E R E C TI F I E R /R E GU L A T O R 12 1 5002615 X V O LT A G E R E C TI F I E R /R E G U LA T OR 11 2 5000189 T H R E A D E D I N SE R T , M[...]

  • Page 21

    21 Frame Rail & Skid Pl ate 7 2 6 1 5 8 5 4 3 9 10 11 * 11 4 50015 31 X T OP H A T WA SH E R , P LA ST I C F OR U SE W / P LA ST I C SK I D P LA T E 10 4 50010 13 F LA N G E -H E A D BO LT , M 6X 16 * 1 50 0179 2- 04 X X X X SKI D P LA T E , A LU M 9 1 5000156 -02 X SK I D P LA T E , P LA S T I C 8 2 50 0061 2 FLN G H D BLT , M 8 X35, N Y LK 7 [...]

  • Page 22

    22 Footpegs 6 5 3 2 4 7 1 * * 2 50 0013 6 X X X X BH C S, M 10X 30, N Y LKZN C U SE W / KI C K S T A N D 7 2 5001 264 X X BH C S, M 10X25, N Y LKZ N C 6 1 5001 919 FO O T P E G BR A C K E T 5 1 5000 526 FO O T P E G , LE F T 4 1 5000 713 FLA T W A SH E R , M 8 3 1 5000 400 C O T TE R P I N , 2 . 5X20 2 1 5000 985 FO O T P E G SP R I N G , LE F T 1 [...]

  • Page 23

    23 Kickst and 2 3 5 4 1 5 1 5001 891 KI C KST A N D P I V OT BO LT 4 1 5 0 0 1 8 9 2 K ICK S T A ND T E NS ION S PRI NG 3 1 5001 893 N U T , H E X, LOC K, M 10 2 1 50 0188 2- 0 2B KI C KST A N D M O U N T 1 1 500188 2- 0 2A KI C KST A N D LE G XSE E A E R C KI CK STA ND PA RT S L I ST IT EM NO QTY RE Q D D EA L ER PA R T NUMB ER DE S CRIPTION NO TE[...]

  • Page 24

    24 Swingarm 31 * 33 1 50004 21 H E X H E A D S E T SC R E W M 8X 50 m m 32 4 50007 57 SW I N G A R M P I V O T T H R U ST WA S H E R I N C LU D E D I N 5000814 3 1 2 5 0 0 0 7 5 5 SW INGA RM PI V O T B RNG , INR S PCR INCL UDE D IN 5 0 0 0 8 1 4 30 2 50007 56 SW I N G A R M P I V O T N E E D LE B E A R I N G I N C LU D E D I N 5000814 2 9 2 5 0 0 0[...]

  • Page 25

    25 Rear Shock 1 2 3 4 3 2 10 11 10 12 1 13 5 6 7 8 9 14 15 16 15 17 * 500242 6 R R SH OC K S P G - 90 N /m m 500005 9 R R SH OC K S P G - 95 N /m m 500006 0 R R SH OC K S P G - 10 0 N /m m 500006 1 R R SH OC K S P G - 10 5 N /m m 500143 1 R R SH OC K S P G - 11 0 N /m m 500143 2 R R SH OC K S P G - 11 5 N /m m 17 1 5002153 F H B, M 12X 61 m m 16 1 [...]

  • Page 26

    26 Seat & Num ber Plates 14 9 8 4 6 5 3 7 1 2 10 11 12 13 15 16 18 17 * * 19 19 2 5001514 T OP - H A T WA SH E R 18 4 5001612 P H I LI P S H E A D S C R E W, M 6X1 2 m m 17 2 5000095 F H B, M 6X2 0 m m 16 2 5000777 I SO LA T I O N S TR I P , 5 5 X 25.4 m m * 1 500209 1 X SH R OU D , R SLV 1 5 1 5 0 0 2 6 1 3 X X X X X S HRO UD, R, S L V , W IDE[...]

  • Page 27

    27 Frnt Fender & Frn t Number Plte 3 2 4 5 6 7 1 2 8 * 5 9 10 11 12 13 14 15 16 1 18 4 * 18 2 500 15 12 F E N D E R N U T , M 6 17 2 5 0000 95 F LA N G E - H E A D BO L T , M 6X2 0 - N Y L OK 16 1 5002453 B X X B U LB, H E A D LI GH T 15 1 50024 53 X X H E A D LI GH T * 2 5002 392 X BU LB, H E A D LI GH T , 38 D E GR E E BE A M 14 2 500 23 90 X[...]

  • Page 28

    28 Battery Plate 2 1 4 3 24 19 12 15 16 9 23 20 26 27 8 7 13 11 21 17 14 22 6 5 10 18 25 13 28 29 30 30 1 500 13 74 X SP A C E R , 16X 8.4X 3.2 m m 29 1 60003 14 N U T , LO C K, M 6 28 1 50010 13 F H B, M 6X 16 m m 27 1 50023 62 BA T T E R Y BO LT /N U T KI T , M /C 26 1 60005 04 BH C S, M 6 X 20 m m , ZI N C , N Y LOC K 25 1 5002603 M A I N P O WE[...]

  • Page 29

    29 Elec tri cal 6 4 8 9 7 3 1 2 5 9 2 5001 946 FH B M 6X30 m m , Z I N C 8 1 5002 309 X X X LI GH T I N G C A P SE A L 7 1 5 0 0 2 4 5 5 X X X HA RNES S CO NNECTOR, L IGHT ING 6 1 5000 434 N U T , H E X F LA N GE , M 6 5 1 5000 011 ST A R TE R M OT OR 12V 0.65KW 4 1 5002 218 ST A R TE R M OT OR C A BL E 3 1 5002 049 P O S I T I V E BA T T E R Y C A[...]

  • Page 30

    30 Exhaust 7 6 5 3 8 2 * 1 4 8 4 5001 605 N U T , H E X F LA N GE , M 6- 12P T 7 2 5001 345 E XH A U ST C R U SH WA SH E R 6 1 5000 612 F H B, M 8X35 m m 5 1 5000 095 FH B, M 6X20 m m 4 2 5002 265 GR OM M E T , E XH A U ST 3 1 5002 209 SP R I N G, E XH A U ST * 1 500208 2 X X X X E XH A U ST , SI LE N C E R 2 1 5002 242 X X E XH A U ST , SI LE N C [...]

  • Page 31

    31 Radiator 3 9 2 4 5 6 8 7 1 10 11 11 13 14 15 16 12 11 7 12 17 18 * * 18 1 50004 84 O - R I N G , 2-013 17 2 5000093 F H B M 6 X25 m m 16 1 5000793 H OS E C LA M P , 5.6M M - 16m m 15 1 50021 45- 03 H OS E , C O O LA N T BLE E D 14 1 5002044 R A D I A T O R O V E R FL OW T U BE 13 4 50005 43 H O SE C LA M P , 14-27m m 12 4 5000719 - 03 T P - H T [...]

  • Page 32

    32 Airbox 11 1 2 10 9 4 3 8 12 7 5 6 16 13 14 15 14 17 18 18 1 5000793 H O SE C LA M P , 5.6m m - 16m m 17 1 5002331 H OS E , BR E A T H E R , F R A M E T O A R I BO X 16 1 5001922 V A C U U M H O S E , 5/32" I D 265 m m T O P R E S SU R E R E G U LA T O R 15 1 5001595 V A C U U M H O S E , 5/32" I D 609 m m T O E C U 14 2 5000962 V A C U[...]

  • Page 33

    33 Fuel T ank 4 3 1 2 5 6 11 13 14 7 10 8 9 12 9 * * 1 4 2 5 0 0 0 7 9 9 TOP - HA T W A S HE R, FUE L TA N K TA B 13 2 50007 65 T OP - H A T WA SH E R 12 4 50001 92 F LA T WA SH E R , M 6 11 2 500 08 62 F LN G H D BL T , M 6X 40 m m 10 2 50008 02 G R O M M E T , F U E L T A N K 9 3 5000 137 FH C S, M 6 X16 Z I N C 8 1 5002 398 SE A T C A TC H 7 1 5[...]

  • Page 34

    34 Fuel System 1 10 2 4 5 7 6 8 9 11 13 12 3 14 15 16 27 28 17 19 24 18 20 21 22 23 29 25 26 30 31 31 2 5 0024 10 I N SU L A T I N G BO O T 30 1 5 0011 37 O - R I N G, 008 M A LE FU E L F I T T I N G 29 1 5 0015 44 F U E L R E GU LA TO R H OU SI N G - P LA ST I C 28 2 5 0015 78 G R OM M E T , F U E L R E G U LA T OR 27 2 5 0015 79 T O P -H A T WA S[...]

  • Page 35

    35 Decals 7 2 6 1 * * * 3 5 5 5 4 * * * * * 8 * 9 * * 10 11 11 1 5 0026 26- R X D C L, E 440 A GP , N M BR P LT, R E V LO C 10 1 500 26 27 X D C L, E 44 0A G P , N M BR P LT , BLK , R 9 1 5002 238 D C L, P R E M FU E L * 50 0 2 6 4 6 X X D CL, C LOGO, BL K / Y E L 8 5 0 0 2 6 3 3 X X X DC L , C LOGO, B L K / RE D * 1 50026 25 D C L, G P , N M B R P[...]

  • Page 36

    36 V ehicle W arnings (1) (4) (2) (3) (1) (2) (4) (3) * - Any replac ement warning label can be obtained by vehicle o wner's free of charge b y calling 1-800-MO T O-USA. 4 1 500137 1- 0 1 WR N , F R A M E 3 1 5000 418 D E C A L, U SE 2 1 500126 2- 0 1 D E C A L , D I SC LA I M 1 1 500026 6- 0 1 WR N , M U L T I XSE E A E R C W A RN INGS PA R T[...]