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 ....................
Legend 1 2 3 4 5 6 7 8 9 5002260I 5002254 5 1 5002248 4 1 5002257 3 1 5002260 2 1 5002211 1 1 ITEM QTY DEALER PART NO REQD NUMBER X 10 ODOMERTER INSTRUCTIONS ADDITIONAL PARTS TABLE SWITCH, HEAD LIGHT SENSOR MAGNET CABLE, ODOMETER ODOMETER ODOMETER MOUNT PLATE S E EA ER CR DESCRIPTION MODEL 11 12 NOTES ODOMETER PARTS LIST 1 - CALL OUT DESIGNATOR: ASTERICS (*) ARE USED WHEN A SIMILAR PART IS USED ACROSS DIFFERENT MODELS.
Front Wheel 3 * 12 4 * 5 * * 11 13 * 7 * 2 6 9 1 8 5002540 051-5002498 051-5000020 * 18 5002500A 13 18 5000026 * 18 5002501A 12 18 5000477 11 36 5001623 10 1 5000540 9 6 5000864 * 1 5002511 * 1 5002246 8 1 5000047 * 1 5002504 7 1 5000536 6 1 5000028 * 1 5002510 * 1 5002134 5 1 5000029 * 1 5002508 * 1 5002135 4 1 5000030 * 1 5002506 * 1 5002098 3 1 5000031 2 1 5000021 1 1 S E E F R ONT HUB ITEM QTY DEALER PART NO REQD NUMBER X X X X X X X X X X X X X X X X X X X X X X X X X
Rear Wheel 2 * 15 3 * 16 4 * 17 * 12 11 10 * 18 * 5 14 * 13 9 * * 6 1 7 8 4
002540 5000339 5000349 5000357 151-5002499 151-5002085 151-5000069 18 2 5002199 * 18 5002502 * 18 5001873 17 18 5000075 * 18 5002503 * 18 5002287 16 18 5000797 15 36 5001624 14 6 5000713 13 6 5000140 12 6 5000393 * 1 5002521 11 1 5000117 * 1 6000315 10 1 5001847 * 1 5002522 * 1 5001798 9 1 5001601 8 4 5000138 7 1 5000090 * 1 5002505 * 1 5001886 6 1 5000076 5 1 5000077 * 1 5002510 * 1 5002130 4 1 5000078 * 1 5002508 * 1 5002131 3 1 5000079 * 1 5002507 * 1 5002132 2 1 5000080 1 1 SEE REAR HUB ITEM QTY DEALER
Wheel Hubs * 10 5 6 9 * 8 6 5 4 7 * 5 6 6 3 * 1 5002541 10 1 5000074 * 1 5002535 9 1 5000022-07 8 1 5000023 * 1 5002542 7 1 5000024 6 5 5000355 5 4 5000356 4 1 5001091 * 1 5002536 3 1 5000071-08 2 1 5000072 1 1 5000073 ITEM QTY DEALER PART NO REQD NUMBER * 2 6 X X X X X X X X X X X X X X X X X S E EA MODEL FRONT WHEEL SPACER X X FRONT WHEEL SPACER HUB, FRONT, BLK X X HUB, FRONT FRONT HUB BEARING SPACER FRONT WHEEL SPACER-DISC SIDE X X FRONT WHEEL SPACER-DISC SIDE SEALED BEARING, 2
Front Fork 42 32 34 41 49 50 51 57 35 52 36 53 1 2 33 3 4 57 5 57 18 20 6 54 57 19 57 7 37 8 38 39 21 55 57 40 41 42 9 57 58 57 59 22 10 11 43 23 24 25 45 12 57 26 13 44 12 57 14 27 28 57 29 47 46 56 30 15 57 16 46 31 48 48 17 57 7
Front Fork List * * * * * 59 1 1 1 1 1 1 5002526 5002055 5000018 5001222 5000013 5000014 5000015 5002617 5002619 5002621 5002621 5002523 5002600 58 AR 5000572 57 AR 5001526 56 1 5000568 55 2 5000608 54 2 5000607 53 2 5000610 52 2 5000611 51 2 5000606 50 2 5000603 49 2 5000604 48 4 5000558 47 1 5000567 46 6 5000556 45 1 SEE TABLE 44 2 5000518 43 2 5000565 42 4 5000080 41 4 5000601 40 2 5000600 39 2 5000598 38 2 5000597 37 2 5000594 36 2 5000593 35 2 5000592 34 2 5000591 33 2 5000590 32 2 5000587 31 2 500
Steering Head 8 6 * 8 * 5 * 9 11 3 10 2 8 * 7 12 13 8 4 8 1 13 2 5000760 12 2 5000722 11 1 5000717 10 1 5000170 9 1 5000174 * 4 5000728 8 12 5000100 7 2 5000101 * 2 5002537 6 2 5000534 * 2 5002533 5 2 5000533 4 1 012-5002097 3 1 5000001B 2 1 ITEM QTY DEALER PART NO REQD NUMBER X X X X X X X X X X X X X S E EA MODEL HEA DSET BEA RING, UPPER HEA DSET SEA L, UPPER STEERER WASHER SLOTTED LOCKNUT STEERER NUT X FHB, M8X55 mm X FHB, M8X45 mm FHB, M12X35 mm, NLK X X CLA MP, HA NDLEBA R, UPPER CL
Front Brake Guides 5 4 6 7 4 3 2 2 1 4 7 2 5000822 6 1 5001270 5 1 5000038 4 4 5001013 3 1 5002261 2 2 5000535 1 1 5002263 ITEM QTY DEALER PART NO REQD NUMBER X X X X S E EA ER C MODEL BRAKE LINE GUIDE TOPHAT BRAKE GUIDE CLAMP BRAKE GUIDE MOUNT ASSY FLNG HD BLT, M6X16, NLK FRONT BRAKE GUIDE MOUNT, UPPER FRONT BRAKE GUIDE FRONT BRAKE GUIDE MOUNT, LOWER DESCRIPTION BRAKE GUIDES PARTS LIST FOR USE W/ HEADLIGHT NOTES 10
Handlebar & Controls List 23 18 2 1* 5 6 3 7 8 19 20 4 11 9 10 22 17 * 42 12 21 45 41 14 35 40 13 39 16 * 24 15 * 32 36 37 25 43 33 38 44 34 26 * 31 28 27 46 29 30 47 11
47 2 5000728 46 2 5001927 45 AR 5002385 44 1 5002373 43 1 5002374 42 1 5002375 41 2 5002376 40 1 5002377 39 1 5002378 38 1 5002379 37 1 5002380 36 1 5002381 35 1 5002382 34 1 5002383 33 1 5002384 32 1 5002386 31 1 5002387 30 2 5002538 29 2 5002539 28 2 6000252 27 2 6000277 * 1 5002519 26 1 5002215 25 1 5001808L 24 1 5001808 23 4 5000379 22 1 5002364 21 1 5000131-01 20 1 5002363 19 1 5000437 18 1 5001274-04 * 1 6001180 * 1 5002262 17 1 5000317 * 1 5002518 * 1 5002454 16 1 5000120 * 1 5002372S 15 1 5002372 14
Odometer 1 2 4 5 3 5002260I 5 1 5002254 4 1 5002248 3 1 5002257 2 1 5002260 1 1 5002211 ITEM QTY DEALER PART NO REQD NUMBER ODOMERTER INSTRUCTIONS ADDITIONAL PARTS TABLE SWITCH, HEAD LIGHT SENSOR MAGNET CABLE, ODOMETER ODOMETER ODOMETER MOUNT PLATE X S E EA ER C DESCRIPTION MODEL ODOMETER PARTS LIST NOTES 13
Front Brake Master Cylinder 11 10 12 5 9 6 7 8 1* 4 3 13 14 2* 15 4* 15 AR 5000268 14 1 5000046 13 1 5000044 12 1 5000103 11 1 5000043 10 1 5000099 9 1 5000033 8 1 5000045 7 1 5000041 6 1 5000042 5 1 5000040 * 1 5002515 4 2 5000538 3 4 5001549 * 1 5002311 * 1 5002514 2 1 5002264 * 1 5002516 1 1 5000032 ITEM QTY DEALER PART NO REQD NUMBER X X X X X X X X X X X X X S E EA MODEL NISSIN BRAKE GREASE, 2 GRAM FT BRAKE LEVER RETURN SPRING FT BRAKE LEVER FT BRAKE LEVER RUBBER COVER FT BRAKE MSTR CYL
Front Brake Caliper 13 12 5* 6 5* 3 2 11 1* 5 * 10 7 4* 13 1 5002513 12 2 5001264 11 1 5000055 10 1 5000052 9 1 5000054 8 1 5000049 7 AR 5000268 6 1 5000050 * 2 5000612 5 2 5000863 * 1 5002517 4 1 5000035 3 1 5000036 2 1 5000048 * 1 5002256 * 1 5002512 1 1 5000034 ITEM QTY DEALER PART NO REQD NUMBER X X X X X X X X X X X X X X X S E EA MODEL 8 9 FRONT BRAKE CALIPER MOUNT BHCS, M10x25mm BRAKE CALIPER BLEEDER KIT SLIDE PIN BOOT - LARGE FRONT BRAKE PAD PIN KIT FRONT BRAKE PAD SPRING NISSIN
Rear Brake Pedal 4 3 6 6 1 5 2 6 2 5000375 5 1 5000399 4 1 5000413 3 1 5000109 2 1 5000112 1 1 5001226 ITEM QTY DEALER PART NO REQD NUMBER SEAL, 15X21X3 BOLT, BRAKE PEDAL RR BRAKE COTTER PIN BRAKE PEDAL YOKE PIN SPRING, BRAKE PEDAL REAR BRAKE PEDAL X S E EA ER C MODEL DESCRIPTION REAR BRAKE PEDAL PARTS LIST INCLUDED IN 5001226 INCLUDED IN 5001226 NOTES 16
Rear Brake Master Cylinder 12 8 13 13 10 16 7 12 1 6 15 13 13 9 2 5 1 2 11 3 1 2 4 14 2 16 1 5000434 15 1 5001013 14 2 5000126 13 4 5001549 12 2 5000538 11 1 5001268 10 1 5000537 9 1 5002285 8 AR 5000268 7 1 5000085 6 1 5000104 5 1 5000105 4 1 5000107 3 1 5000267 2 1 5000106 1 1 5000086 ITEM QTY DEALER PART NO REQD NUMBER NUT, FLANGE, M6 FLANGE HEAD BOLT, M6 X 16 SHCS, M8 X 20 CRUSH WASHER BRAKE LINE BANJO BOLT RR BRAKE MSTR CYL GUARD REAR BRAKE LINE RR BRAKE MSTR CYL ASSY NISSIN BRAKE GREASE, 2
Rear Brake Caliper 1 3 8 5 9 2 10 4 6 10 1 5000082 9 1 5000052 8 1 5000055 7 AR 5000268 6 1 5000050 5 1 5000081 4 1 5000096 3 1 5000098 2 1 5000091 1 1 5000083 ITEM QTY DEALER PART NO REQD NUMBER REAR BRAKE PAD SET SLIDE PIN BOOT - LARGE BRAKE CALIPER BLEEDER KIT NISSIN BRAKE GREASE, 2 GRAM SLIDE PIN BOOT - SMALL REAR BRAKE CALIPER ASSEMBLY REAR BRAKE CALIPER BRACKET REAR BRAKE PAD PIN KIT REAR BRAKE PAD SPRING REAR BRAKE CALIPER PISTON KIT X S E EA ER C MODEL DESCRIPTION REAR BRAKE CALIPER PART
Mainframe 1 * 18 7 19 13 5 11 14 4 3 2 9 10 8 17 16 15 6 12 19 1 5002409 * 1 5002331 18 1 5002198 17 1 5002071 16 2 5002069 15 2 5000482 14 1 5000487 13 1 5000828 12 1 5000140 11 1 5001184 10 1 5000863 9 1 5002068 8 1 5001374 7 1 5001434-03 6 2 5000524 5 1 5000233-E 4 4 5000190 3 1 5001593 2 5 5000888 1 1 201-5002100 ITEM QTY DEALER PART NO REQD NUMBER CLAMP, ONE-EARED, STEPLESSS, 19.8 HOSE, BREATHER, FRAME HOSE, BREATHER, FRAME OIL LEVEL SIGHT WINDOW FHCS, M10X1.
Subframe 1 10 * 12 9 * 11 14 3 4 13 8 7 2 5 6 15 4 5000192 14 1 6000341 13 1 5001013 * 1 5002520 12 1 5002615 11 2 5000189 * 2 5000093 10 2 5000423 9 1 6000378 8 1 5002228 7 2 5002234 6 2 5002326 5 2 6000116 4 2 5000139 3 1 5001593 2 7 5000888 1 1 201-5002103 ITEM QTY DEALER PART NO REQD NUMBER FLAT WASHER, M6 NUT, LOCK, M6 FHB M6X16 mm X X X X X VOLTAGE RECTIFIER/REGULATOR X VOLTAGE RECTIFIER/REGULATOR THREADED INSERT, M6 X X X X X FLANGE-HEAD BOLT, M6X25 X FLANGE-HEAD BOLT, M6X50 X SPACER, REA
Frame Rail & Skid Plate 5 8 1 2 3 5 7 4 6 9 * 11 10 11 4 5001531 10 4 5001013 * 1 5001792-04 9 1 5000156-02 8 2 5000612 7 4 6000391 6 2 5000527 5 6 5000190 4 4 5001967 3 2 5000888 2 1 201-5002102 1 1 201-5002101 ITEM QTY DEALER PART NO REQD NUMBER X TOP HAT WASHER, PLASTIC FLANGE-HEAD BOLT, M6X16 X X X X SKID PLATE, ALUM X SKID PLATE, PLASTIC FLNG HD BLT, M8X35, NYLK SHCS, M8x30mm NYLK FLNG HD BLT, M10X90, NLK THREADED INSERT, M8 INSERT,M6 RIVNUT, M6 FRAME RAIL, LEFT FRAME RAIL, RIGHT X S E EA ER C
Footpegs 1 6 5 * 7 2 4 3 * 2 5000136 X X X X BHCS, M10X30, NYLKZNC 7 2 5001264 X X BHCS, M10X25, NYLKZNC 6 1 5001919 FOOTPEG BRACKET 5 1 5000526 FOOTPEG, LEFT 4 1 5000713 FLAT WASHER, M8 3 1 5000400 COTTER PIN, 2.
Kickstand 3 2 4 5 1 5 1 5001891 4 1 5001892 3 1 5001893 2 1 5001882-02B 1 1 5001882-02A ITEM QTY DEALER PART NO REQD NUMBER KICKSTAND PIVOT BOLT KICKSTAND TENSION SPRING NUT, HEX, LOCK, M10 KICKSTAND MOUNT KICKSTAND LEG X S E EA ER C MODEL DESCRIPTION KICKSTAND PARTS LIST NOTES 23
Swingarm 31 * 33 1 5000421 32 4 5000757 31 2 5000755 30 2 5000756 29 2 5000758 28 2 5000759 27 2 5000754 26 4 5001470 25 1 5000115 24 1 5000716 23 1 5000541 22 1 5002298 21 1 5000088 20 1 5000231 19 1 5000070 18 1 252-5002104 17 1 5000114 16 1 5001939 15 2 5000144 14 2 5000145-04 13 1 5000143-07 12 1 5000142-13 11 1 5001008 10 1 5000439 * 2 5000862 9 2 5000423 8 1 5001184 7 2 5001957 6 2 5000434 5 4 5001468 4 4 5000726 3 1 5000189 2 1 5000152 1 1 5000814 ITEM QTY DEALER PART NO REQD NUMBER HEX HEAD SET S
Rear Shock 1 2 3 7 4 3 2 1 9 17 15 8 10 11 5 6 10 12 14 * 15 16 13 5002426 5000059 5000060 5000061 5001431 5001432 17 1 5002153 16 1 5002154 15 2 5002191 * 1 5002618 * 1 5002620 * 1 5002622 * 1 5002524 14 1 5002601 13 1 5000065 12 1 SEE TABLE 11 1 5001299 10 2 5001298 9 1 5001296 8 1 5000064 7 1 5001295 6 1 5001330 5 1 5001331 4 2 5001291 3 2 5001288 2 4 5001289 1 4 5002220 ITEM QTY DEALER PART NO REQD NUMBER RR SHOCK SPG - 90 N/mm RR SHOCK SPG - 95 N/mm RR SHOCK SPG - 100 N/mm RR SHOCK
Seat & Number Plates 11 9 1 18 2 15 * 5 6 3 10 12 * 14 16 19 17 8 7 19 2 5001514 18 4 5001612 17 2 5000095 16 2 5000777 * 1 5002091 15 1 5002613 * 1 5002090 14 1 5002612 13 4 5001013 12 4 5001531 11 1 5002251 10 1 5002089 9 1 5002088 8 1 5002229 7 4 5000141 6 1 5002223 5 1 5002225 4 1 5002226 3 1 5002227 * 1 5002609C 2 1 5002610C * 1 5002609 * 1 5002527 1 1 5002610 ITEM QTY DEALER PART NO REQD NUMBER X X X X X X X X X X X X 13 X X X X X X X X X X X X X S E EA ER C MODEL 4 TOP-
Frnt Fender & Frnt Number Plte 13 15 14 * 11 16 12 10 2 1 4 7 8 1 9 4 18 3* 5 5 2 6 18 2 5001512 17 2 5000095 16 1 5002453B 15 1 5002453 * 2 5002392 14 2 5002390 13 1 5002212 12 1 5002391 11 1 5002393 10 1 5002213 9 2 5001013 8 2 5002292 7 1 5002087-01 6 4 5001013 5 6 5000192 4 5 5001514 * 1 5002525 * 1 5002259 3 1 5002093 2 3 5001184 1 1 5002092 ITEM QTY DEALER PART NO REQD NUMBER X X X X X X X X X X X X X X X X S E EA ER MODEL FENDER NUT, M6 FLANGE-HEAD BOLT, M6X20 - NYLOK BULB, HEA
Battery Plate 13 29 28 18 10 5 25 3 15 7 16 9 6 22 27 23 17 14 20 8 26 4 19 24 13 11 12 30 21 1 2 30 1 5001374 29 1 6000314 28 1 5001013 27 1 5002362 26 1 6000504 25 1 5002603 24 2 5002148 23 1 5001962-02 22 4 5001184 21 1 5000434 20 4 5001512 19 1 5001514 18 2 5001241 17 4 5001584 16 2 5001561 15 2 5001562 14 2 5001944 13 2 5000192 12 2 5000095 11 1 5002268 10 1 5001240 9 1 472-5001951 8 1 5002280 7 1 5001794 6 1 5001435 5 1 5000887 4 1 5002255 3 1 5002217-01 2 1 5002267 1 1 5002190-02
Electrical 5 2 6 9 4 1 3 8 7 9 2 5001946 8 1 5002309 7 1 5002455 6 1 5000434 5 1 5000011 4 1 5002218 3 1 5002049 2 1 5002216 1 1 5002602 ITEM QTY DEALER PART NO REQD NUMBER FHB M6X30 mm, ZINC X LIGHTING CAP SEAL X X X HARNESS CONNECTOR, LIGHTING NUT, HEX FLANGE, M6 STARTER MOTOR 12V 0.
Exhaust 7 1 3 5 6 2* 8 4 8 4 5001605 7 2 5001345 6 1 5000612 5 1 5000095 4 2 5002265 3 1 5002209 * 1 5002082 2 1 5002242 1 1 5002083 ITEM QTY DEALER PART NO REQD NUMBER NUT, HEX FLANGE, M6-12PT EXHAUST CRUSH WASHER FHB, M8X35 mm FHB, M6X20 mm GROMMET, EXHAUST SPRING, EXHAUST X X X X EXHAUST, SILENCER X X EXHAUST, SILENCER EXHAUST, HEADER PIPE X S E EA ER C DESCRIPTION MODEL EXHAUST PARTS LIST NOTES 30
Radiator 17 1 * 7 11 3 16 4 12 11 15 9 14 10 5 13 12 11 2 * 6 7 8 18 18 1 5000484 17 2 5000093 16 1 5000793 15 1 5002145-03 14 1 5002044 13 4 5000543 12 4 5000719-03 11 6 5000192 10 2 5000323 9 2 5001184 8 2 5000350 7 4 5000178 6 1 5001511 5 1 5002147 4 1 5002146 3 1 5000542 * 1 5002079 2 1 5002611 * 1 401-5002080 1 1 401-5002347 ITEM QTY DEALER PART NO REQD NUMBER O-RING, 2-013 FHB M6X25 mm HOSE CLAMP, 5.
Airbox 5 1 16 17 13 14 14 6 8 15 18 3 4 10 12 9 7 2 11 18 1 5000793 17 1 5002331 16 1 5001922 15 1 5001595 14 2 5000962 13 1 5002529 12 5000487 1 11 1 5000403 10 5001149 1 9 2 5002293 8 2 5000178 7 2 5000350 6 1 5002152 5 1 5002150 4 6 5001238 3 2 5001239 2 1 5002138 1 1 603-5002149-03 ITEM QTY DEALER PART X S E EA ER C NO REQD NUMBER MODEL HOSE CLAMP, 5.
Fuel Tank 8 7 13 9 5 9 1 * 6 * 3 4 11 14 12 2 10 14 2 5000799 13 2 5000765 12 4 5000192 11 2 5000862 10 2 5000802 9 3 5000137 8 1 5002398 7 1 5000175 6 1 5000873 5 1 5000169-01 4 1 5001778 * 1 5002270 3 1 5002417 2 2 5002140-02 * 1 351-5002074 1 1 351-5002244 ITEM QTY DEALER PART NO REQD NUMBER X X X X X X X X X X X S E EA ER C MODEL TOP-HAT WASHER, FUEL TANK TAB TOP-HAT WASHER FLAT WASHER, M6 FLNG HD BLT, M6X40 mm GROMMET, FUEL TANK FHCS, M6X16 ZINC SEAT CATCH FUEL TANK BREATHER HOSE FUEL
Fuel System 21 22 30 18 23 24 19 8 5 27 2 17 16 28 9 29 15 26 11 10 25 31 1 4 14 12 3 13 7 31 2 5002410 30 1 5001137 29 1 5001544 28 2 5001578 27 2 5001579 26 1 5000395 25 1 5000836 24 6 5001607 23 1 5002205-05 22 1 5002204-05 21 1 5002203-05 20 1 5002202-05 19 1 5002201-02 18 2 5002141-02 1 5000544 17 16 2 5000793 15 2 5001789 14 3 5000434 13 1 5001184 12 2 5000093 11 1 5002327 10 1 5002328 9 4 5001549 8 2 5001502 7 2 5001641 6 2 5001642 5 2 5001501 4 1 5002604 3 1 5002124 2 1 5002075
Decals 1 6* 3* 8* 9* * 2* 7* 5* 5* 11 4* 10 11 1 5002626-R 10 1 5002627 9 1 5002238 * 5002646 8 5002633 * 1 5002625 7 1 5002626 * 1 5002645 6 1 5002632 * 1 5002643 * 1 5002644 * 1 5002630 5 5002631 * 1 5002641 * 1 5002642 * 1 5002636 * 1 5002637 * 1 5002628 4 1 5002629 * 1 5002634 3 1 5002635 * 1 5002649 * 1 5002648 * 1 5002647 * 1 5002640 * 2 5002531 2 2 5002623 1 1 5002624 ITEM QTY DEALER PART NO REQD NUMBER X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
Vehicle Warnings (1) (3) (1) (2) (2) (4) (3) (4) * - Any replacement warning label can be obtained by vehicle owner's free of charge by calling 1-800-MOTO-USA.