2003 Engine Parts Catalog

(ATV & Motorcycle) - 09/02

CONTENTS
Throttle Body . . . . . . . . . . . . . . . . 2
Fuel Injectors . . . . . . . . . . . . . . . . 3
Cam Cover & Spark Plug . . . . . . 4
Cylinder Head . . . . . . . . . . . . . . . 5
Valve Train . . . . . . . . . . . . . . . . . 6
Valve Train Parts List . . . . . . . . . 6
Cam Drive . . . . . . . . . . . . . . . . . . 8
Crankcase . . . . . . . . . . . . . . . . . . 9
Crankcase Parts List . . . . . . . . . 10

Crankshaft . . . . . . . . . . . . . . . . .
Piston . . . . . . . . . . . . . . . . . . . . .
Crankshaft Cartridge Plate . . . . .
Crankcase Cover . . . . . . . . . . . .
Starter Clutch . . . . . . . . . . . . . . .
Clutch . . . . . . . . . . . . . . . . . . . . .
Trans Cart Plate, Rear . . . . . . . .
Mainshaft . . . . . . . . . . . . . . . . . .
Countershaft . . . . . . . . . . . . . . . .

2003 Engine Parts Catalog.fm

2001 Cannondale Corporation - All Rights Reserved

11
12
13
14
15
16
17
18
19

Trans Cart Plate, Front . . . . . . .

Countershaft Sprocket . . . . . . . .
Generator Stator . . . . . . . . . . . .
Water Covers . . . . . . . . . . . . . . .
Engine Oil Pickup Assembly . . .
Scavenge Pump . . . . . . . . . . . .
Engine Oil Pump . . . . . . . . . . . .
Oil Supply Tubes . . . . . . . . . . . .
Transmission Oil Pump . . . . . . .

20
21
22
23
24
25
26
27
28

P/N 5002338-03
Printed : 9/4/02

Throttle Body

13

14
16

12
15

3
5
7
9
22
18

20
19

21

17

23

4
8
6
10

23
1
22
2
21
2
20
1
19
1
18
1
17
1
16
2
15
1
14
2
13
1
12
1
11
1
10
1
9
1
8
1
7
2
6
1
5
1
4
1
3
3
*
1
2
1
*
1
1
1
ITEM QTY
NO REQD

5001148
5001149
5001561
5000513
5000512
5001973
5001972
5001974
5001971
5001489
5000409
5001401
5001581
5000959
5002307
5000688
5002305
6000502
5001346
5000827
5001473
6001121
5002308
6000767
5002340
DEALER PART
NUMBER

COUPLING, THROTTLE BODY

CLAMP, BAND
WASHER,M5
BTTNHD TORX SCREW, M5X35
BTTNHD TORX SCREW, M5X25
BYPASS GASKET
BYPASS HOUSING
SCREW, PHILLIPS, 10X5/8
BYPASS ACTUATOR
BHCS, M4X12 mm
THROTTLE POSITION SENSOR
THROTTLE BODY SLEEVE
NUT, HEX M8 X 1.0
LOCK WASHER, M8
THROTTLE CABLE PULLEY
THROTTLE SPRING
THROTTLE SPRING SLEEVE
IDLE ADJUSTMENT SCREW
IDLE ADJUSTMENT THUMBWHEEL
SPRING, IDLE ADJUST THUMBWHEEL
BHCS, M4X8 mm
X THROTTLE CABLE STOP
X
THROTTLE CABLE STOP
X THROTTLE BODY ASSEMBLY
X
THROTTLE BODY ASSEMBLY
M/C ATV
DESCRIPTION
MODEL

11

NOTES

THROTTLE BODY PARTS LIST

Fuel Injectors

6 *

8 *

5
11
2

3
10
4

11
2
10
2
9
1
*
1
8
1
7
1
*
1
6
1
5
2
4
2
3
2
2
1
1
4
ITEM QTY
NO REQD

5001545
5001546
5002321
6000317
5002204-03
5002324
6000318
5002203-02
5000478-06
5001458
5000171
351-5000166
5001607
DEALER PART
NUMBER

O-RING, FUEL INJECTOR, TOP

O-RING, FUEL INJECTOR, BOTTOM
HOSE SHEATH, BULK
X HOSE, FUEL, 350 mm
X
HOSE, FUEL, REG TO INJECTOR
HOSE, FUEL, 6.4 mm ID, 60 mm
X HOSE, FUEL, 130 mm
X
HOSE, FUEL, PUMP TO INJECTOR
FUEL INJECTOR BASE
NUT, HEX FLANGE, M3
FUEL INJECTOR CLIP
FUEL INJECTOR SET
OTKR HOSE CLAMP, 12.3mm
M/C ATV
DESCRIPTION
MODEL

5 LENGTH
TO FUEL REGULATOR
TO FUEL REGULATOR
TO FUEL PUMP
TO FUEL PUMP

INCLUDES FLOW RATE VALUE

NOTES

FUEL INJECTORS PARTS LIST

Cam Cover & Spark Plug

13

12
15

9
18
M/C

ATV

* 3
16 *
10
7

17

8
1 *
4

2
5

14

11
18
1
17
2
*
1
16
1
15
1
14
1
13
1
12
1
11
1
10
1
9
1
8
4
7
2
6
1
5
1
4
1
*
1
3
2
2
1
*
1
1
1
ITEM QTY
NO REQD

5000775
5001610
6000386-03
5001352
5001351
5000915
5001925
5001781
5002029
5000853
5000852
5001927
5001945
5000914
5000913-03
5000912-04
6000393-02
5001081-02
5001136
6000496
5001126
DEALER PART
NUMBER

OETIKER CLAMP, 17mm

HOSE CLAMP, DOUBLE WIRE
X HOSE, OIL, COVER TO SPAR
X
HOSE, OIL, COVER TO STARTER
X
HOSE, OIL, COVER TO FRAME
O-RING, 2-023
FHB M5X12 mm, ZINC
IGNITION COIL ASSEMBLY
SPARK PLUG - CR9EK
COIL SEAL- UPPER
COIL HOLD DOWN
FHB M5X20 mm, ZINC
FHB M5X35 mm, ZINC
CAM COVER RBR LEFT SIDE
CAM COVER RBR INTAKE
CAM COVER RBR EXHAUST
X OIL BREATHER PLUG
BREATHER NIPPLE
SPLIT DOWEL PIN,5X10
X CAM COVER ASSY, ATV
X
CAM COVER ASSY, MOTORCYCLE
M/C ATV
DESCRIPTION
MODEL

INCLUDED IN CAM COVER ASSY

INCLUDED IN CAM COVER ASSY
INCLUDED IN CAM COVER ASSY

NOTES

CAMSHAFT COVER PARTS LIST

Cylinder Head

20

19

21

11
1

10
15
14

4
7
8
12
16

9
13

17

3
2

18
1
21
8
20
4
19
4
18
2
17
2
16
2
15
1
14
1
13
2
12
2
11
1
10
2
9
1
8
1
7
2
6
4
5
2
4
2
3
1
2
1
1
1
ITEM QTY
NO REQD

334-5002443

Engine Rebuild Gasket Kit

ADDITIONAL PARTS TABLE
SHCS, M6X25 mm
NUT, HEX FLANGE, M10
FLAT WASHER, M10 STEEL
NUT, FLANGE, M8
FLAT WASHER, M8
STUD, M8
FHCS ,M6X1.0X45
FHTS,M5X0.8X25
OIL TRANSFER TUBE
O-RING, 2-011
IDLER GEAR BRACKET
O-RING, 2-012
CAMSHAFT IDLER GEAR 31T
NEEDLE BEARING,12X16X10
THRUST WASHER,12X20X.08
STUD, M6 X 35
SPLIT DOWEL PIN, 5X10
STUD, M3 X 12
O-RING, 2-111
COOLANT TEMPERATURE SENSOR
SEE VALVE TRAIN

5001482
5001182
5000770
5001957
5000713
5000426
5001671
5001454
5001259
5000482
5001861
5000487
5000252-05
5001007
5001724
5001523
5001136
5001457
5001461
5000408
DEALER PART
NUMBER

M/C ATV
MODEL

DESCRIPTION

CYLINDER HEAD PARTS LIST

NOTES

Valve Train

12

11

30
10

13
8
7

19

18

24
27

14
14

25
20

15

21
17

29
26

23

28
16
2

6
22

Valve Train Parts List

30
29
1
28
1
27
2
26
2
25
1
24
1
23
2
22
2
21
4
20
2
19
1
18
1
17
2
16
1
15
1
14
4
13
4
12
4
11
4
10
4
9
4
8
4
7
4
6
2
5
2
4
4
3
2
2
2
1
1
ITEM QTY
NO. REQ

SEE TABLE
5000465
5000792
5000506
5000498
5001355
5001783-02
5000464
5001488
5001676
5001406
5000253
5000251
5000249-07
5001982
512-5001756
5000874
5000463-01
5002036
5002041
5002057
5000210-03
5000209-03
5000208
5002335
5002334
5000205
5001965
5001964
502-5001446
DEALER PART
NO.

VALVE ADJUSTMENT SHIM

OIL SEAL,14X25X5
SOLID DOWEL PIN 5X24
NEEDLE BEARING,16X24X13
BALL BEARING
OIL SEAL:16X24X5
SEAL, 12X25X5 mm
OIL SEAL,40X62X6
SHCS, M12X 1.25X 25
BEARING, ROLLER, 3X9.8mm
DOWEL PIN, 2X20
IDLER GEAR SHAFT
CMSHFT DRV GR SHAFT
CAM GEAR
INTAKE CAMSHAFT
EXHAUST CAMSHAFT ASSY
RETAINER,BEARING
VALVE STEM SEAL
VALVE BUCKET
VALVE SPRING KEEPER
VALVE SPRING RETAINER
INNER VALVE SPRING
OUTER VALVE SPRING
VALVE SPRING SEAT
EXHAUST VALVE
INTAKE VALVE
VALVE GUIDE
EXHAUST VALVE SEAT
INTAKE VALVE SEAT
CYLINDER HEAD SUB ASSY

INCLUDED IN 502-5001446
INCLUDED IN 502-5001446
INCLUDED IN 502-5001446

DESCRIPTION

VALVE TRAIN PARTS LIST

NOTES

503-5001665
503-5001666
503-5001667
503-5001668
503-5001669
503-5001670
503-5001186
503-5001187
503-5001188
503-5001189
503-5001190
503-5001191
503-5001192
503-5001193
503-5001194
503-5001195
503-5001196
503-5001197
503-5001198
503-5001199
503-5001200
503-5001201
503-5001202
DEALER PART
NO.

Valve Shim,2.20
Valve Shim,2.25
Valve Shim,2.30
Valve Shim,2.35
Valve Shim,2.40
Valve Shim,2.45
Valve Shim,2.50
Valve Shim,2.55
Valve Shim,2.60
Valve Shim,2.65
Valve Shim,2.70
Valve Shim,2.75
Valve Shim,2.80
Valve Shim,2.85
Valve Shim,2.90
Valve Shim,2.95
Valve Shim,3.00
Valve Shim,3.05
Valve Shim,3.10
Valve Shim,3.15
Valve Shim,3.20
Valve Shim,3.25
Valve Shim,3.30
DESCRIPTION

ADDITIONAL PARTS TABLE

Cam Drive

12

19

16
11

11

15

17
20

13

19
17

18

14

2
3

10
5
7
20
1
19
2
18
1
17
2
16
1
15
1
14
1
13
2
2
12
11
1
10
1
9
1
8
2
7
1
6
1
5
1
4
1
3
1
2
1
1
1
ITEM QTY
NO REQD

5001156
5001007
5000250
5001724
5001862
5001475
5001477
5001480
5001491
5001102
5001028
5000671-04
5001947
5001039-03
5001829-03
5002157-04
5000420
5001948
5000482
5002332
DEALER PART
NUMBER

SPACER, DRIVE GEAR SPROCKET

NEEDLE BEARING, 12X16X10
DRIVE GEAR SPROCKET 27T, 33T
WASHER, THRUST, 12X20X.08
CAMSHAFT DRIVE GEAR BRACKET
SHCS , M5X0.8X12 mm
SHCS , M5X0.8X18 mm
SHCS , M5X0.8X50 mm
SHCS , M6X1.0X16 mm
CAM CHAIN TENSIONER ASSEMBLY
EXTRNL RETANING RING, M10
CAM CHAIN TENSIONER SHOE
SHCS , M6X1.0X14 mm
TIMING CHAIN GUIDE
TIMING CHAIN GUIDE SUPPORT
CAM CHAIN TENSIONER PVT BOLT
TBHCS, M5X0.8X10 mm, SS
CAM CHAIN TENSIONER SHOE PIVOT
O-RING, 2-011
TIMING CHAIN
M/C ATV
MODEL

DESCRIPTION

NOTES

CAM DRIVE PARTS LIST

Crankcase

24
1

18

23

19
17
22

3
2
16
13

15
14
20

5
25

13
4

21
7
6

11
9

12
10

8
7

Crankcase Parts List

25
1
24
2
23
1
22
1
21
1
20
1
19
1
18
1
17
1
16
1
15
1
14
1
13
2
12
2
11
2
10
2
9
1
8
1
7
2
6
1
5
1
4
2
3
1
2
1
1
2
ITEM QTY
NO REQD

5002161
5000793
5000773
5001349
552-5001921
5001731
5001063
5001062
5001117
5000389
5002405
5002404
5000649-02
5000648
5000650-02
5001136
5001675
5000469
5001871
5000820
5000500
5001557-03
5000470
5001135
5001051
DEALER PART
NUMBER

CYLINDER HEAD SEAL

SCREW CLAMP
HOSE SHEATH
OIL INLET HOSE
CRANKCASE
CYL HEAD STUD, COLD HEADED
O-RING, 2-018
ENGINE OIL INLET FITTING
ENGNE OIL INLET SCREEN ASSY
TRANSMISSION OIL FILTER
WASHER, TRANSMISSION DRAIN
TRANSMISSION OIL FILTER PLUG
RR ENGINE MOUNTNG BUSHING
FT OUTER ENGINE MOUNTING BUSHING
FT INNER ENGNE MOUNTING BUSHING
SPLIT DOWEL PIN, 5X10
NEEDLE BEARING,15X21X16
OIL SEAL, 20X30X7 HMS4
ROLLER BEARING, 31.5X52X15
NEDLE BEARING, 33.3X38.3X9.5
BALL BEARING, 20X42X12
HOLLOW DOWEL PIN
OIL SEAL, 30X40X7
INTRNL CIRCLIP, 40mm
SOLID DOWEL PIN, 5X12
MO SP
MODEL

DESCRIPTION

INCLUDED IN 552-5001921

INCLUDED IN 552-5001921
INCLUDED IN 552-5001921
INCLUDED IN 552-5001921
INCLUDED IN 552-5001921
INCLUDED IN 552-5001921
INCLUDED IN 552-5001921
INCLUDED IN 552-5001921

NOTES

CRANKCASE PARTS LIST

10

Crankshaft

11

10

12
2

12
1
11
1
10
1
9
1
8
1
7
1
6
1
5
1
4
1
3
1
2
1
1
1
ITEM QTY
NO REQD

5000519
5001146
5001970
5001796
5001608
5000816
5001124
5001793
5001622
5000283-05
5000998
531-5001961
DEALER PART
NUMBER

STARTER CLUTCH FWD

DOWEL PIN, .0627X.375
WOODRUFF KEY
BEARING, 25X62X17 mm, PLSTC
FLTHD SCRW, M6X1.0X12
BALL BEARING:17X40X12-SEALED
BALANCE SHAFT ASSY
BEARING, NEEDLE, 20X26X16
ONE WAY CLUTCH SPACER
STARTER GEAR, 54T
BALANCE SHAFT THRUST WASHER
CRANKSHAFT ASSEMBLY
M/C ATV
MODEL

DESCRIPTION

INCLUDED IN CRANK PLATE 5002419

INCLUDED IN CRANK PLATE 5002419

NOTES

CRANKSHAFT PARTS LIST

11

Piston

NOTE: See lower, RH side of cylinder head for OEM stamp designating piston color

"R"- Red
"VG"- Green

4
6

3 *

5
15

11
9

2 *

12

7
10

13
14

15
1
14
2
13
1
12
1
11
2
10
1
9
1
8
1
7
1
6
2
5
1
4
1
*
1
3
1
*
1
2
1
1
1
ITEM QTY
NO REQD

5001787
5001935
5001477
5001475
5000482
5000921
5000915
5001866-03
5000627
5002315
5002314
522-5002316
5002396G
5002396R
5002397G
5002397R
522-5002395
DEALER PART
NUMBER

O-RING, 100X2.5 mm
FHTS, M5X14 mm
SHCS ,M5X18 mm
SHCS ,M5X12 mm
O-RING, 2-011
O-RING, 2-019
O-RING, 2-023
PISTON PIN ACCESS COVER
QUAD-RING, CYLINDER LINER
PISTON PIN CIRCLIP
PISTON PIN, 18 X 46.48 mm
PISTON RING SET
PISTON, 95 mm, GREEN
PISTON, 95 mm, RED
LINER, 95 mm, GREEN
LINER, 95 mm, RED
PISTON/LINER KIT
M/C ATV
MODEL

DESCRIPTION

PISTON PARTS LIST

INCLUDED IN 522-5002395
INCLUDED IN 522-5002395
INCLUDED IN 522-5002395
Match w / Liner INCLUDED IN 522-5002395
Match w / Liner INCLUDED IN 522-5002395
Match w / Piston INCLUDED IN 522-5002395
Match w / Piston INCLUDED IN 522-5002395
NOTES

12

Crankshaft Cartridge Plate

1
2
3

22

18

20
15

19

17

16

TDC

23

9
21

20

6
4
13

2
14
7

11

12
1

10
3

23
22
1
21
1
20
5
19
4
18
1
17
1
16
1
15
1
14
2
13
1
12
1
11
1
10
1
9
1
8
1
*
1
7
1
6
1
5
1
4
1
3
1
2
1
1
1
ITEM QTY
NO REQD

5000428
5000304
5001120
5001484
5001485
5001903
5000487
5000482
5002329
5001037
5001374
5002015
5001244
5001028
5000466
5001109
6000227
5000630
5000367-04
5000263
5001110
5000216
5000629-07
5002419
DEALER PART
NUMBER

TDC SCREW
O-RING, 2-009
O-RING, 2-022
SHCS, M8 X 1.25X 20
SHCS, M8 X 1.25X 25
CRANKSHAFT CARTRIDGE PLATE SEAL
O-RING, 2-012
O-RING, 2-011
PRESSURE PUMP SEAL
SCAVENGE PUMP LOCATING DOWEL
SPACER, 16x8.4x3.2, mm
SCAVENGE PUMP IDLER GEAR
THRST WASHER 10.1X20X1
EXTERNAL RETANING RING, M10
OIL SEAL, 33X47X7
INTERNAL RETANING RING, 47mm
X PRIMARY DRIVE GEAR: 28T
X
PRIMARY DRIVE GEAR: 29T
SCAVENGE PUMP DRIVE GEAR: 30T
TIMING CHAIN SPROCKET: 22T
DISC SPRING,16.3 X 31.5 X 2
JAM NUT, M16X1.5
IDLR GEAR SHAFT 10X45
CRANKSHAFT CARTRIDGE PLATE
M/C ATV
DESCRIPTION
MODEL

TDC SPECIAL TOOL

POSITIONS 45679
POSITIONS 1238
INCLUDED IN 5002419

INCLUDED IN 5002419
NOTES

CRANKSHAFT CARTRIDGE PLATE PARTS LIST

13

Crankcase Cover

11

*
3

6
17 Locations

10

8
3 Locations

*
1
11
1
10
3
9
17
8
1
7
1
6
1
5
1
4
1
3
1
2
1
1
1
ITEM QTY
NO REQD

5001556-03
5000962
5001944
5001927
5000473
5000517
5000828
5001434-03
5002071
5001255-03
5000315-05
553-5002269
DEALER PART
NUMBER

10

X BREATHER HOSE
BREATHER HOSE
FHB M5X25 mm
FHB M5X20 mm
OIL SEAL: 14X22X4 (2 LIP)
BUSHING
O-RING, 2-016
TRANSMISSION OIL FILL CAP
OIL LEVEL SIGHT WINDOW
HOSE NIPPLE, 6M
CRANKCASE COVER GASKET
CRANKCASE COVER
M/C ATV
DESCRIPTION
MODEL

INCLUDED IN 553-5002269
INCLUDED IN 553-5002269

NOTES

CRANKCASE COVER PARTS LIST

14

Starter Clutch

10

11

7
8
9

13
12

13
3
12
1
11
1
10
1
9
1
8
1
7
1
6
4
5
4
4
1
3
4
2
1
1
1
ITEM QTY
NO REQD

5001926
5001863-05
5001275
5001902
5001598
5002160
5001496-04
5001497-02
5001495
5001465-04
5001797
5001814-04
5001466-06
DEALER PART
NUMBER

FHB M5X16 mm, Zinc

STARTER CLUTCH COVER
O-RING, 2-147
BUSHING, FLANGE, 15X17X9 mm
EXTERNAL RETANING RING: 15
STARTER CLUTCH BUSHING
STARTER CLUTCH PRESSURE PLATE
STARTER CLUTCH METALLIC DISC
STARTER CLUTCH FRICTION DISC
STARTER CLUTCH BASKET
DISC SPRING, 50X1.25
STARTER CLUTCH BUSHING B
STARTER CLUTCH SHAFT
M/C ATV
MODEL

DESCRIPTION

NOTES

STARTER CLUTCH PARTS LIST

15

Clutch

20
8

6
9
10

12

16

11
7
2

13

4
3
15

19

14
18
17
20
2
19
8
18
1
17
1
16
1
15
1
14
6
13
6
12
1
11
1
10
10
9
1
8
1
7
6
6
9
*
1
5
1
4
1
3
1
2
1
1
1
ITEM QTY
NO REQD

5002050
5001927
5001694
5002046
5001280
5001119
5000455-02
5001482
5001627
5002025
5001976
5001069
5002163-02
5001924
5000333
562-6000331
562-5001129
5001928
5002272
5002158
5002026
DEALER PART
NUMBER

BEARING, CLUTCH BASKET

FHB M5X20 mm, ZINC
CLUTCH COVER
CLUTCH COVER SEAL
BALL BEARING, 8mm
EXTRNL RETANING RING: 24
SEAT, SPRING, CLUTCH
SHCS ,M6X25 mm
HUB, CLUTCH
PRESSURE PLATE, CLUTCH
CLUTCH PLATE, STEEL, 1.0mm
WASHER, SPLINED
CLUTCH PUSHROD
SPRING, CLUTCH
CLUTCH PLATE, FRICTION, 2.32mm
X CLUTCH BASKET ASSEMBLY
X
CLUTCH BASKET ASSEMBLY
NUT, HEX, M5
SCREW, SET M5X25
CLUTCH RELEASE COLLAR
BEARING, BALL, 16004
M/C ATV
DESCRIPTION
MODEL

CLUTCH PARTS LIST

INCLUDED W/ BASKET

NOTES

16

Trans Cart Plate, Rear

25

26

28

2
4

14
15
24
27

11

16
17

20
7

21

18
8

22
3
19

10

23

6
11

12
9
13

28
1
27
1
26
1
25
1
24
2
23
1
22
1
21
1
20
1
19
1
18
1
17
1
16
1
15
1
14
1
13
1
12
1
11
6
10
1
9
1
8
1
7
1
6
3
5
1
4
1
3
4
2
1
1
1
ITEM QTY
NO REQD

542-5001132
5000482
5001630
5000930
5000917
5000345
5001619
5001618
5000346
5001628
5000880
5000364
5000358
5002336
5001548
572-5001131
5001509
5001935
5000656-02
5000996
5000348
5000660-04
5000997
5001617
5001076
5000655
5000654
5001519
DEALER PART
NUMBER

SPRAYBAR ASSEMBLY
O-RING, 2-011
DOWEL PIN, 3 X 11.8
O-RING, 2-010
BEARING RETAINER PLATE
MAINSHAFT SHIFT FORK SHAFT
COUNTERSHAFT SHIFT FORK 2ND
COUNTERSHAFT SHIFT FORK 1 & 3
COUNTERSHAFT SHIFT FORK SHAFT
BHCS, M6 X 1.0 X 30
WSHR .251X.560X.062
DETENT LEVER SPRING
DETENT LEVER BOLT
DETENT LEVER ASSEMBLY
WASHER, TRA-411
SHIFT DRUM ASSEMBLY
SOLID DOWEL PIN, 4 X 8
FLTHD TXSCW,M5X0.8X14
SHIFT DRUM BEARING RETAINER
SHIFT FORK CENTERING SPRING
SHIFT CAPSTAN
SCREW, SHIFT PIN
SHIFT FORK ROLLER BUSHING
MAINSHAFT SHIFT FORK 1 & 3
BALL BEARING, 20X42X12
BALL BEARING, 25X42X9
BALL BEARING, 25X52X15
TRANSMISSION CARTRIDGE PLATE
M/C ATV
MODEL

INCLUDED IN 542-5001132
INCLUDED IN 542-5001132
INCLUDED IN 542-5001132

DESCRIPTION

INCLUDED IN 5001519

INCLUDED IN 5001519
INCLUDED IN 5001519
INCLUDED IN 5001519
NOTES

TRANSMISSION CARTRIDGE PLATE, REAR

17

Mainshaft

9
7
5

8
7

9
2

3
9

6
9

9
2
8
1
7
2
*
1
6
1
5
1
4
1
3
1
2
1
1
1
ITEM QTY
NO REQD

5001425
5000461
5000454
5002415
6000554
5000292
5000291-04
5000290-06
6000555
5000288-08
DEALER PART
NUMBER

CONSTANT SECTION RTNG RING

EXTERNAL RETANING RING: 25
SPLINED WASHER: 25
MAINSHAFT 5TH GEAR
MAINSHAFT 5TH GEAR
MAINSHAFT SPLINED BUSHING
MAINSHAFT 4TH GEAR
MAINSHAFT 3RD GEAR
MAINSHAFT 2ND GEAR
MAINSHAFT
M/C ATV
MODEL

DESCRIPTION

MOTARD

NOTES

MAINSHAFT PARTS LIST

18

Countershaft

1
4

10

12

14
2

13
7

9
15

11
3
16

16
1
15
1
14
1
13
1
1
12
11
1
10
1
9
1
*
1
8
1
7
1
6
1
5
1
4
1
3
1
2
1
1
1
ITEM QTY
NO REQD

5001606
5000461
5000454
5000908
5000657
5000446
5000445
5000441
5002414
6000558
5000300
6000557
5000298
6000556
5000296
5000295-05
5000294-06
DEALER PART
NUMBER

EXTERNAL RETAINING RING, 20

EXTERNAL RETANING RING, 25
SPLINED WASHER: 25
THRUST WASHER, 35X25.2X1
THRST WASHER, 25.1X36X1.5
THRUST WASHER,19
THRUST WASHER:25.2X30
THRST WASHER, MAINSHAFT
COUNTERSHAFT 5TH GEAR
COUNTERSHAFT 5TH GEAR
COUNTERSHAFT 4TH GEAR
COUNTRSHAFT 3RD GEAR
COUNTRSHAFT 2ND GEAR BUSHING
COUNTERSHAFT 2ND GEAR
COUNTRSHAFT 1ST GEAR BUSHING
COUNTERSHAFT 1ST GEAR
COUNTERSHAFT
M/C ATV
MODEL

DESCRIPTION

MOTARD

NOTES

COUNTERSHAFT PARTS LIST

19

Trans Cart Plate, Front

22
7

8
10

12

25
11

20
2
6

21
15

24

3
23

13

5
16
4
17
25
1
5000928
24
1
5000095
*
1
6000211
23
1
5000341
22
1
5000366
21
2
5001947
20
2
5001935
19
1
5000658
18
1
5000360-06
17
2
5000354
16
1
5000351-02
15
1
5000352-02
14
2
5000353
13
1
5000660-04
12
1
5000662
11
1
5000968
10
1
5001028
9
1
5000462
8
1
5000365
7
1
5000340
6
1
5000359-05
5
1
5001557-03
4
1
5001487
3
1
5001486
2
2
5001485
1
3
5001484
ITEM QTY DEALER PART
NO REQD
NUMBER

14

18

19

SHIFT SHAFT SPACER

FHB, M6X20 mm, NYLK
X GEARSHIFT LEVER, ATV
X
GEARSHIFT LEVER
SHIFT COLLAR
BHTS M5X14 mm
FLTHD TXSCW, M5X0.8X14 mm
SHIFT DRUM RATCHET
SHIFT DRUM RATCHET PLATE
SHIFT PAWL PLUNGER
SHIFT PAWL B
SHIFT PAWL A
SHIFT PAWL SPRING
SCREW, SHIFT PIN
MAINSHAFT END CAP
O-RING, 2-025
EXTRNL RTNING RING, M10
EXTRNL RTNNG RNG:14mm
SHIFT SHAFT SPRING
SHIFT SHAFT WELDMENT
SHIFT STOP PIN
HOLLOW DOWEL PIN
SHCS, M8 X1.25X35
SHCS, M8 X1.25X30
SHCS, M8 X1.25X25
SHCS, M8 X1.25X20
M/C ATV
DESCRIPTION
MODEL

TRANSMISSION CARTRIDGE PLATE , FRONT

NOTES

20

Countershaft Sprocket

1
13
2
13
3
13
413

5
13
6
13
7
13
8
13

9
13

9
1
8
1
7
1
6
1
5
1
*
1
*
1
4
1
3
1
2
1
1
1
ITEM QTY
NO REQD

5002195
5000862
5000468-02
5000321
5000991
5000278
5000276
5000118
5000990
5000693-05
5000494
DEALER PART
NUMBER

M/C ATV
MODEL

FHB, M6X65 mm
FHB, M6X40 mm
COUNTERSHAFT SPROCKET COVER
DRIVE CHAIN GUIDE PLATE
RETANING NUT
COUNTERSHAFT SPROCKET:15T
COUNTERSHAFT SPROCKET:14T
COUNTERSHAFT SPROCKET:13T
SPLINED LOCK WASHER
COUNTERSHAFT SPROCKET SPACER
O-RING, 2-021
DESCRIPTION

MOTO440, MOTARD

NOTES

COUNTERSHAFT SPROCKET PARTS LIST

21

Generator Stator

14

12
8

13

6
5

2
10
9
11

14
1
13
1
12
1
*
3
*
3
11
3
*
1
10
1
*
1
*
1
9
1
8
1
7
1
6
1
5
1
4
1
3
1
2
4
1
1
ITEM QTY
NO REQD

5001925
5000687
5001271
6000490
5001478
5001476
5002614
5001979
6000322
5002532
5002616
5001258
5001473
5001857
5001580
5001044
5000924-04
5001592
5000316
DEALER PART
NUMBER

FHB M5X12 mm, Zinc

CRANKSHAFT POSITION SENSOR
FLAT WSHR, M4
X SHCS, M5X0.8X22 mm
X
SHCS, M5X0.8X20 mm
X
SHCS, M5X0.8X16 mm
X
GENERATOR ALIGNMENT COLLAR
GENERATOR ALIGNMENT COLLAR
X GENERATOR STATOR
X
GENERATOR STATOR
X
GENERATOR STATOR
ALUM CLAMP
BHCS, M4X0.7X8 mm
FLYWHEEL
LOCK WASHER, M12
FLANGE NUT, M12X1.25
GENERATOR COVER GASKET
PHILIPS HD SCREW, M5X20
COVER, GENERATOR
M/C ATV
DESCRIPTION
MODEL

X440
X440

S440, C440R, E440R

X440

NOTES

GENERATOR STATOR PARTS LIST

22

Water Covers

6
2

4
7

1
5

9
2
8
1
7
1
6
1
5
1
4
1
3
1
2
1
1
4
ITEM QTY
NO REQD

5001925
5001879
5000915
5001933
5001442-05
5000180-06
5001895
5001860-01
5001927
DEALER PART
NUMBER

FHB M5X12 mm, ZINC

OUTLET, WATER
O-RING, 2-023
WSHR, .320X.547X.040 IN
WATER PUMP IMPELLER
WATER PUMP GASKET
WASHER, BRASS, 5X9X.9 mm
WATER PUMP HOUSING
FHB M5X20 mm, ZINC
M/C ATV
MODEL

DESCRIPTION

NOTES

WATER COVERS PARTS LIST

23

Engine Oil Pickup Assembly

3
1

10

11

8
8

4
9

7
*
1
10
1
9
4
8
2
7
1
6
1
5
1
4
1
3
1
2
1
1
1
ITEM QTY
NO REQD

6000384-02
5002233
5001926
5000484
5000897
5001705
5001279
5000309
5000308-06
5001865-03
5001864-02
DEALER PART
NUMBER

X HOSE, OIL,RETURN
HOSE, OIL,RETURN
FHB M5X16 mm, ZINC
O-RING, 2-013
INTRNL RETAINING RING, 35
WASHER, ENGINE DRAIN
ENGINE OIL DRAIN PLUG
ENGINE OIL PICKUP SCREEN
GASKET, ENGINE OIL PICK-UP
ENGINE OIL PICKUP COVER
ENGINE OIL PICKUP
M/C ATV
DESCRIPTION
MODEL
X

NOTES

ENGINE OIL PICKUP ASSY PARTS LIST

24

Scavenge Pump

5
4
3
11

6
6
13
8

14

12

10
1

7
9

14
1
13
1
12
2
11
1
10
1
9
1
8
1
7
1
6
2
5
1
4
1
3
1
2
1
1
1
ITEM QTY
NO REQD

5000930
5000489
5001478
5001485
5001134
5001248
5000448
5002337
5001036
5001159
5001158
593-5001880
5002016
5002155
DEALER PART
NUMBER

O-RING, 2-010
O-RING, 2-031
SHCS, M5X20 mm
SHCS, M8X25 mm
OIL SEAL:12X22X6
E-CLIP, 8 mm
THRUST WASHER .687X.511X.040
DOWEL PIN, 3.8 X 22.2 mm
SCAVENGE PUMP DRIVE PIN
GEROTOR ASSY,THICK, 4065 X .165
GEROTOR ASSY,THIN, 4065 X .1875
SCAVENGE PUMP COVER
GEAR, SCAVENGE PUMP
SHAFT, SCAVENGE PUMP
M/C ATV
MODEL

DESCRIPTION

NOTES

SCAVENGE PUMP PARTS LIST

25

Engine Oil Pump

11
12

5
8

4
6
9
1
10
2
7

12
1
5000647
11
1
5000016
10
1
5001926
3
9
5002283
8
1
5001207
7
1
5001878-02
6
1
5000638
5
1
593-5001858-04
4
1
593-5001859
3
1
5000482
2
1
5000634
1
1
5001740
ITEM QTY DEALER PART M/C ATV
MODEL
NO REQD
NUMBER

O-RING, 2-138
THRST WASHER, 8X12X.762
FHB, M5X12 mm, ZINC
SHCS ,M5X40 mm
GEROTOR ASSY, 6022 X .226
COVER, OIL FILTER
SEAL, 3 RING, PRESSURE PUMP
HOUSING, PRESSURE PUMP
OIL FILTER HOUSING
O-RING, 2-011
O-RING, 2-033
FILTER, ENGINE OIL ASSEMBLY
DESCRIPTION

NOTES

ENGINE OIL PUMP PARTS LIST

26

Oil Supply Tubes

11
5

10

12

13

8
9

13
2
12
1
11
1
10
1
9
1
8
1
7
1
6
1
5
1
4
2
3
1
2
1
1
1
ITEM QTY
NO REQD

5001478
5000484
5001028
5000930
532-5001122
5000689
5000487
5001066
5001065
5001061
5000930
5001059-05
5000895
DEALER PART
NUMBER

SHCS, M5X20 mm
O-RING, 2-013
EXTERNAL RETANING RING, M10
O-RING, 2-010
CRANKSHAFT OIL SUPPLY BRIDGE ASSY
OIL SEAL: 8X14X4
O-RING, 2-012
OIL RETURN PIPE
OIL RETURN FITTING
O-RING, 2-008
O-RING, 2-010
TRANSMISSION OIL LINE LEFT ADAPTOR
TIMING CHAIN OIL PIPE
M/C ATV
MODEL

DESCRIPTION

NOTES

OIL SUPPLY TUBES PARTS LIST

27

Transmission Oil Pump

3
9

13

11
2
4

12

10

7
13
1
12
1
11
1
10
1
9
1
8
1
7
1
6
1
5
1
4
1
3
2
2
1
1
1
ITEM QTY
NO REQD

5001852
5001564
5000016
5001474
5001630
5001183
5000993
5000992
5002014
5001867
5000386-05
5000385-02
5000384
DEALER PART
NUMBER

BHCS, M5X16 mm
CIRCLIP,7mm (STAINLESS)
THRUST WASHER, 8X12X.762
BHCS, M6 X 1.0 X 8 mm
DOWEL PIN, 3 X 11.8
DOWEL PIN, 3 X 9.8
PRESSURE RELIEF SPRING
PRESSURE RELIEF BALL
TRANS OIL PUMP DRIVE GEAR
TRANSMISSION OIL PUMP COVER
OIL PUMP DRIVEN GEAR
OIL PUMP IDLER SHAFT
TRANS OIL PUMP DRIVE SHAFT
M/C ATV
MODEL

DESCRIPTION

NOTES

TRANSMISSION OIL PUMP PARTS LIST

28