Part # BFIMANA2OP Revision of 2005

For all BUSHMASTER XM15 and C15 Models

PLEASE PRACTICE SAFE FIREARMS HANDLING!

BUSHMASTER OPERATING AND SAFETY INSTRUCTION MANUAL

WARNING: BEFORE USING THlS FIREARM, READ AND FOLLOW THESE INSTRUCTIONS.

TABLE OF CONTENTS
Warnings / Cautions / Safe Handling 1 Dangerous Procedures 2 About Your Bushmaster Rifle 3 Rifle Controls - Identification / Location 4 Carbon 15 Models - Identification 6 Clearing Your Rifle 7 Preventative Maintenance Checks 8 Safety Function Check 8 Preparing to Fire / Loading a Magazine 9 Operation of Your Rifle / Loading 10 Operation / Inserting a Magazine 10 Operation / Chambering from Open Bolt 11 Operation / Chambering from Closed Bolt 12 Immediate Actions - in Case of Trouble 14 Remedial Actions 16 Bullet Stuck in the Bore 17 Front & Rear Sights 18 Zeroing Your Sights 19 25 Meter Zeroing Procedures 19 Front & Rear Sight Adjustment 21 Disassembling Your Rifle 22 Inspection / Cleaning / Lubrication 27 Detailed Cleaning Techniques 28 Cleaning the Upper Receiver 30 Cleaning the Bolt & Carrier 31 Cleaning the Ejector 32 Cleaning the Lower Receiver 33 Lubrication / Upper & Lower Receivers 34 Lubrication / Bolt Carrier Group 35 Lubrication / Adjustable Rear Sight 36 Reassembling Your Rifle 37 Magazine Disassembly / Reassembly 43 Problems / Solutions 44 Cold Weather Shooting 52 Maintenance in Extreme Weather 52 Component Variations 53 Parts Schematics 54 Carbon 15 Models / Differences 60 Warranty 64

P.O. Box 1479 999 Roosevelt Trail Windham, Maine 04062 U.S.A. Sales: 1 800 998 7928 Customer Service: 1 800 883 6229 Tel. 207 892 3594 Fax: 1 207 892 8068 http://www.bushmaster.com E-mail: [email protected]

PLEASE PRACTICE SAFE FIREARMS HANDLING!

WARNING: IF THIS FIREARM IS CARELESSLY OR IMPROPERLY HANDLED, UNINTENTIONAL DISCHARGE COULD RESULT AND COULD CAUSE INJURY, DEATH, OR DAMAGE TO PROPERTY. CAUTION: CAREFULLY READ THIS INSTRUCTION MANUAL PRIOR TO LOADING AND FIRING THIS FIREARM. FOLLOW ALL INSTRUCTIONS ON THE PROPER HANDLING AND SAFE USE OF THIS FIREARM - LIVES MAY DEPEND ON IT! CAUTION: USE ONLY CLEAN, DRY, HIGH QUALITY COMMERCIALLY MANUFACTURED AMMUNITION IN GOOD CONDITION which is appropriate to the 5.56mm NATO / .223 Remington caliber of your firearm. Bushmaster does not recommend the use of remanufactured or hand loaded ammunition because it may damage your rifle. WARNING: THIS WEAPON COULD CHAMBER A ROUND if it is dropped or jarred with a loaded magazine in place - either with the Bolt Carrier Assembly locked to the rear, or in its forward position.

FUNDAMENTAL RULES FOR SAFE GUN HANDLING

ALWAYS KEEP THE GUN POINTED IN A SAFE DlRECTlON. NEVER LOAD THE GUN UNTIL READY TO USE. KEEP YOUR FINGER OFF THE TRIGGER UNTIL READY TO SHOOT.
Pg. 1

WARNING: BEWARE OF DANGEROUS PROCEDURES

Be sure Cam Pin is installed in the Bolt Group. If it isnt, your rifle can still fire and WILL EXPLODE. When using a Blank Firing Attachment, NEVER FIRE ANYTHING EXCEPT BLANKS! For your safety, we recommend the visible, military style blank firing attachment (BFI Part# RAY-008). If your rifle stops firing with a live round in the chamber of a hot barrel (a misfire), REMOVE THE ROUND FAST! However, if you cannot remove it within 10 seconds, remove magazine and wait 15 minutes with the Rifle Pointing in a SAFE DIRECTION! This way you wont be hurt by a possible round cooking-off (i.e. the round detonating just from the heat of the barrel). In any event, keep your face away from the ejection port while clearing a hot chamber. If your bolt fails to unlock, and you try to free it by tapping the buttstock on the ground while pulling on the charging handle, keep yourself clear of the Muzzle! If there is water in the barrel, do not fire the rifle. IT COULD EXPLODE! If you hear a noticeable difference in sound or recoil is experienced, STOP FIRING! Either condition could indicate an incomplete powder burn and/or a bullet stuck in the bore. NOTE: With the bolt carrier assembly locked to the rear, or in its forward position, if the weapon is dropped or jarred with a loaded magazine in place, a live round could be chambered.
Pg. 2

ALWAYS PRACTICE SAFE FIREARMS HANDLING!

ABOUT YOUR BUSHMASTER RIFLE

This Operating Manual covers all Bushmaster XM15 E2S and Carbon 15 models chambered for 5.56mm NATO/.223 Remington ammunition. They are lightweight, gas operated, air-cooled, magazine-fed rifles, carbines or pistols that are Semi-Automatic in operating mode (i.e., a single round will fire each time the trigger is pulled). Note: For Law Enforcement and Military markets, Bushmaster makes similar models in either Full-Automatic (continuous fire as long as the trigger is pulled) or Three Round Burst (a group of 3 shots will fire as long as the trigger is pulled) configurations. Sales of these models require special permits and are regulated by ATF. On all models, the Upper And Lower Receivers are easily opened for cleaning and inspection. XM15 Models have forged aluminum Upper and Lower Receivers. Carbon 15 Models have Receivers that are injection molded from Carbon 15 Composite. Most Bushmaster models feature fully adjustable rear sights / elevation adjustable front sights. Barrels on XM15 and Carbon 15 Models are either chrome lined Chrome Moly Vanadium Steel or 416 Stainless Steel. They are usually button rifled 1 turn in 9 with a right hand twist - 6 lands and grooves. The Bolt Group locks into the Barrel Extension with 7 locking lugs. All models can be configured with either 6 position Telescoping Buttstocks or solid A2 Trapdoor Buttstocks. Forends are of removable split design and are vented to allow heat dissipation. All models feature vertical pistol grips and detachable magazines. Magazine capacity is 30 rounds standard (depending on State Regulations), but all AR-15/M-16 Type magazines of capacities from 5 to 40 rounds will fit the Bushmaster and function in it. Pg. 3

Rifle Features & Controls - Identification / Location

Typical Bushmaster XM15 E2S Rifle - 20" Bbl. with A2 Fixed Carry Handle
Rear Sight Rear Sight Elevation Wheel Rear Sight Windage Knob A2 Carry Handle (A3 Removable type shown below) Spent Brass Deflector Ejection Port Cover
A2 Square Front Sight Post

Front Sight Assembly Compensator

Right Side
Magazine Release Button Forward Assist Knob Solid A2 Trapdoor Buttstock Trigger Pistol Grip Charging Handle 30 Rd. Magazine Two Piece Vented Forend Bayonet Lug Front Sling Swivel

Left Side

B.F.I. WINDHAM, ME. U.S.A.

Pivot Pin Bolt Release

BUSHMASTER

L099999 CAL.223-5.56MM MOD. XM15-E2S

Takedown Pin Rear Sling Loop Safety Selector Lever

At Right, A Bushmaster Flat-Top Type Upper Receiver And A3 Type Removable Carry Handle.

Pg. 4

Rifle Features & Controls - Identification / Location(contd.)

Typical Bushmaster XM15 E2S A3 Type Rifle - Flat-top Upper Receiver w. 20" Barrel & Removable Carry Handle
A3 Removable Carry Handle Flat-top Upper Receiver with Picatinny scope mount rail

Bushmaster XM15 E2S M4 Type Carbine - 16" Barrel

Carbine Length Handguards

M4 Type Barrel - designed originally for mounting M203 Grenade Launcher (restricted by ATF)

Note: ATF Regulations require a minimum barrel length of 16 on

commercially available rifles and carbines. This 16 length can be a combination of barrel and permanantly fixed (pinned & welded over) muzzle brake / flash suppressor as long as total length equals 16.

Tele-Stock Latch Telescoping 6 Position Stock

Pg. 5

Bushmaster Carbon 15 Models - Identification

Bushmaster Carbon 15 M4 Type Rifle
Carbon 15 models have no Forward Assist Mechanism Carbon 15 Models will have either a raised Picatinny Optics Mounting Rail, orFlat-top Upper Receiver with Detachable Rear Sight

Flat-top Upper Receiver with Detachable Rear Sight Carbon 15 Receivers are molded of Carbon Fiber Composite

Carbon 15 models have no Ejection Port Cover Stainless Steel Barrels on many Carbon 15 models

SEE: Carbon 15 Differences Section in this manual for further information.

Carbon 15 Buttstock Carbon 15 Forend

Bushmaster Carbon 15 R97S Rifle NOTE: All Operating Controls on Carbon 15 Rifles and Pistols function the same
manner as XM15 E2S Bushmaster models with Aluminum Receivers. Carbon 15 Safety Lever markings are red or white inset letters: S = SAFE (white letters on both sides of Receiver); F = FIRE (red letters on both sides of Receiver)

Bushmaster Carbon 15 P97S Pistol

Pg. 6

CLEARING YOUR RIFLE

ALWAYS FOLLOW THE RULES OF SAFE GUN HANDLING. First, assume the gun you are handling is loaded, and then proceed - according to the following steps - to CLEAR YOUR RIFLE 1. Point Rifle in a SAFE DIRECTION! Place Safety Selector Lever on SAFE. NOTE: If the rifle is not cocked, the Safety Selector Lever cannot be pointed toward SAFE. 2. Press Magazine Catch Button and pull Magazine down to remove.

3. To Lock Bolt Open, Pull Charging Handle rearward. Press bottom of Bolt Catch and allow Bolt to move forward until it engages Bolt Catch. Return Charging Handle to forward. If you havent before, now place Safety Selector Lever on SAFE.

Pg. 7

PREVENTATIVE MAINTENANCE CHECKS & SERVICES CHECK BEFORE YOU FIRE!

1. Check to see that there is NO EXCESSIVE OIL in the Bore. If there is, swab it out with a patch and the cleaning rod. ALWAYS CLEAN A NEW RIFLE BEFORE FIRING. WARNING! If the rifle is fired with oil - or water - in the barrel, excessive pressure will be created causing the rifle to explode. 2. Retract the Bolt to ensure free movement between Bolt Carrier and Gas Tube. 3. Perform Safety Function Check (below) to ensure that Safety Selector Lever works properly.

SAFETY FUNCTION CHECK UNLOAD RIFLE - REMOVE MAGAZINE - CHECK CHAMBER

1. Remove Magazine if installed. Pull Charging Handle assembly to rear. Check that Chamber is clear. Let the Bolt and Bolt Carrier close. Do not pull Trigger. Leave Hammer in cocked position. WARNING: If Rifle fails any of the following tests, continued use of the Rifle could result in injury to, or death of, people around you. 2. Place Selector Lever in SAFE position, point rifle ina safe direction, and pull Trigger. THE HAMMER SHOULD NOT FALL. Continued on Next Page Pg. 8

SAFETY FUNCTION CHECK (Continued)

3. Place Selector Lever in FIRE position. Pull the Trigger. THE HAMMER SHOULD FALL. NOTE: For purposes of the following check, SLOW is defined as one fourth to one half the normal rate of trigger release. 4. Hold Trigger to the rear, pull Charging Handle to the rear and release Charging Handle. Then release pressure on the Trigger with a slow, smooth motion, without hesitations or stops, until the Trigger is fully forward. AN AUDIBLE CLICK SHOULD BE HEARD - THE HAMMER SHOULD NOT FALL. 5. Repeat the FIRE position test FIVE TIMES. The Rifle must not malfunction during any of these five tests. If the Rifle malfunctions during any of these five tests, have the Rifle checked by a qualified gunsmith.

PREPARING TO FIRE - LOADING A MAGAZINE

1. Use only quality 5.56mm or .223 Remington Ammunition suitable for your firearm. Examine each Cartridge - particularly around the primer. Look for dents, scratches, and other signs of damage. DO NOT LOAD DAMAGED AMMUNITION! 2. With the Magazine facing forward as shown in the illustration, place a Round between the Feed Lips of the Magazine with the Bullet Tip forward. Push the Round down until it is held by the Magazine Feed Lips. 3. If necessary, give the Round a slight push backward to seat it against the inside back edge of the Magazine Feed Lips. Place next Round on top of the previous Round and repeat steps until desired number of Rounds are loaded into Magazine. CAUTION: Safe Firearms Handling dictates that you ONLY LOAD LIVE AMMUNITION INTO YOUR RIFLE WHEN YOU ARE ABOUT TO SHOOT.

Pg. 9

OPERATION OF YOUR RIFLE LOADING

CAUTION: ALWAYS POINT THE MUZZLE IN A SAFE DIRECTION! 1. With the Hammer cocked, place Selector Lever on SAFE. 2. Open Bolt and check Firing Chamber. Make sure it is CLEAR!

INSERTING A MAGAZINE

Pg. 10

1. Return Charging Handle to forward, locked position. Push Magazine up into Magazine Well until Magazine Catch engages and holds the Magazine.

2. Slap upwards on Magazine bottom to make sure it is seated correctly.

OPERATION OF YOUR RIFLE (Continued) CHAMBERING A ROUND FROM AN OPEN BOLT

NOTE: The Magazine may be inserted into the Rifle with the Bolt Assembly Open or Closed. BOLT CATCH

FORWARD ASSIST

1. Depress upper portion of Bolt Catch. Bolt should spring forward. This will chamber a round from the Magazine.

2. TAP the Forward Assist with the heel of your hand to ensure that the Bolt is fully forward and locked. Pg. 11

RIFLE IS NOW READY TO BE AIMED AND FIRED!

OPERATION OF YOUR RIFLE (Continued) CHAMBERING A ROUND FROM A CLOSED BOLT

1. With a Magazine in the Rifle, pull the Charging Handle fully to Rear. Then release the Charging Handle allowing the Bolt to spring forward - chambering the first round. NEVER Ride or push the Charging Handle forward (as depicted below). Let it move forward on its own.

2. TAP the Forward Assist to ensure that the Bolt is fully forward and locked. RIFLE IS NOW READY TO BE AIMED AND FIRED! Pg. 12 NOTE: If Rifle is not going to be fired immediately, make sure the Selector Lever is still on SAFE, and close the Ejection Port Cover to keep dirt out of the Chamber and Upper Receiver.

OPERATION OF YOUR RIFLE (Continued)

CONDITION: Rifle is now Loaded, a Round is Chambered, and Safety Selector should be on SAFE.

CAUTION: ALWAYS POINT THE MUZZLE IN A SAFE DIRECTION!

To FIRE the Rifle in SEMI-AUTOMATIC MODE (one Round fired with each pull of the Trigger), move the Safety Selector from SAFE to FIRE. Aim at Target Pull Trigger Release. The Rifle will automatically eject the spent Cartridge and chamber another in preparation for the next shot. The cycle of pulling the Trigger to shoot, and the Rifle automatically reloading, can be continued until the Magazine is empty. NOTE: After the last Round is fired, the Bolt Carrier will lock in the rear position. You can then push the Magazine Release Button to drop out the empty magazine, insert a fresh Magazine, release the Bolt Catch, and a new Round will be automatically chambered in preparation for the next firing sequence.

WARNING IF A NOTICEABLE DIFFERENCE IN SOUND OR RECOIL IS EXPERIENCED, STOP FIRING. Either condition could indicate an incomplete powder burn and/or a bullet stuck in the bore. Retract the Bolt slowly and remove the fired cartridge case. Clear the weapon and check for unburned powder grains in the Receiver or Bore, and for a Bullet stuck in the Bore (see Page 17). Clean out any unburned powder before resuming firing. If a Bullet is stuck in the Bore, do not attempt to remove it. Take the Rifle to a qualified Gunsmith. Pg. 13

IMMEDIATE ACTIONS IN CASE OF TROUBLE!

IF YOUR RIFLE STOPS FIRING: Perform the following IMMEDIATE ACTIONS FIRING CHAMBER

1. SLAP upward on Magazine to make sure it is properly seated.

2. PULL Charging Handle all the way back. Observe the ejection of the Case or Cartridge. Check Firing Chamber for any obstruction.

WARNING DO NOT LOAD WITH A HOT CHAMBER A ROUND MAY COOK OFF.
Cooking Off means that a Round may Detonate (Fire) unexpectedly just from being exposed to the Pg. 14 heat of the Rifles Firing Chamber.

IMMEDIATE ACTIONS IN CASE OF TROUBLE!

3. If Cartridge or Case is ejected, or Chamber is clear, RELEASE Charging Handle to feed a new Round. Dont ride the Charging Handle forward.

(Continued)

4. Tap Forward Assist to ensure Bolt is locked.

5. Now FIRE. If the Rifle will not fire, look for trouble and apply the Remedial Actions described on the next Page. Pg. 15

REMEDIAL ACTIONS
WARNING: IF YOUR RIFLE STOPS FIRING WITH A LIVE ROUND IN THE CHAMBER OF A HOT BARREL, REMOVE THE ROUND FAST. However, if you cannot remove it within 10 seconds, remove the magazine and wait 15 minutes with the rifle pointing in a safe direction (always check that the SAFE direction remains safe during that time). This way you and those around you won't get hurt by the possibility of a round cooking off. KEEP YOUR FACE AWAY FROM THE EJECTION PORT WHILE CLEARING A HOT CHAMBER.

1. If your Rifle still fails to fire after performing Immediate Action Steps 1 through 5 on previous Pages, check again for a jammed cartridge case.

2. If a cartridge case is in the chamber, open the receivers, remove the bolt carrier, and try to tap out the case with a cleaning rod.

Pg. 16

IF RIFLE STILL FAILS TO FIRE, CHECK THE TROUBLESHOOTING SECTION IN THIS MANUAL OR TAKE THE RIFLE TO A QUALIFIED GUNSMITH.

BULLET STUCK IN THE BORE

WARNING: IF AN AUDIBLE POP OR REDUCED RECOIL IS EXPERIENCED DURING FIRING, IMMEDIATELY CEASE FIRE: Then, (1.) Remove the Magazine, (2.) Lock the Bolt to the rear, (3.) Place the Selector Lever on the SAFE and (4.) visually inspect and/or insert a Cleaning Rod into the Bore to ensure there is not a Bullet stuck in the Bore. 1. Remove the Magazine 2. Lock the Bolt to the rear. 3. Place the Selector Lever on SAFE 4. Check for a Bullet in the Bore

DO NOT APPLY THE IMMEDIATE ACTIONS DESCRIBED ON PREVIOUS PAGES. IF A BULLET IS STUCK IN THE BARREL OF THE WEAPON, DO NOT TRY TO REMOVE IT. TAKE THE RIFLE TO A QUALIFIED GUNSMITH.

Pg. 17

FRONT SIGHT Adjustable for Elevation

The Front Sight Post is threaded - allowing it to be moved up or down for Elevation Adjustments when Zeroing the Rear Sight (see Zeroing Your Sights on next page). Once the Rear Sight is Zeroed, the Front Sight Post should not be moved.

A2 DUAL APERTURE REAR SIGHT SIGHT Adjustable for Elevation and Windage
SHORT RANGE APERTURE: is used for ranges of 0 - 200 meters. In the illustration below, the sight is set to 0 - 200 meters. The larger aperture is only used when the 8/3 marking is aligned with the vertical mark on the left side of the upper receiver. NOTE: For A3 sights on Removable Carry Handles (as on the flat-top model shown right), the dial setting will be marked 6/3 instead of 8/3. Short Range Aperture Normal Range Aperture

Pg. 18

NORMAL RANGE APERTURE: The smaller Aperture is unmarked and is used for most firing situations. It is used in conjunction with the Elevation Knob for 300, 400, 500, 600, 700, and 800 meter targets.

ZEROING YOUR SIGHTS

By following the steps below to establish a Zero at 25 meters, your Bushmaster Smaller Aperture Flipped UP M16A2 Type Rifle Sights will be set with a 300-meter battlesight. With this procedure, only the Front Sight Post and Rear Sight Windage Knob are adjusted so that you can hit your Point of Aim at 300 meters.

25 METER ZEROING PROCEDURES

For M16A2 Type Iron Rifle Sights
1. Place an appropriate 25 Meter Paper Sighting Target 25 meters downrange and follow the steps below to establish a battlesight zero. Do not move the Front Rear Sight Elevation Dial set at 300 Meter Mark Sight Post at this time. It was set at the factory and should be very close to Zero. (Note: factory height setting is 5mm from floor of Front Sight Base to top of Front Sight Post). 2. The smaller (unmarked) Rear Sight Aperture should be in the UP position. Center the Rear Sight by turning the Windage Knob left or right (the markings on back edge of the Rear Sight Base will help you). This creates what is called Mechanical Zero Windage. 3. Lower the Rear Sight all the way down by rotating the Elevation Dial counterclockwise. Then rotate the elevation dial (clockwise) UP one click PAST the 300 Meter Mark (the mark above the 8/3 on the top of the Elevation Knob should align with the corresponding mark on the left side of the Upper Receiver). From this point on, the Elevation Knob should not be moved. Any changes in elevation required in the following zeroing steps will be made by raising or lowering the Front Sight Post only. NOTE: The A3 (Removable Carry Handle) Type Rifle Rear Sight differs in that its Elevation Index is marked 6/3 instead of 8/3. The vertical Elevation shaft of the A3 Sight is shorter - with finer thread pitch - giving it 1/2 Minute of Adjustment clicks instead of the 1 Minute of Adjustments of the A2 Sight. The A3 Elevation Dial must be moved 2 clicks up to the Z (Zero) mark. Otherwise, the Windage Components and Flip-up Aperture - and their operation - are the same as on the A2 Rear Sight. Pg. 19

25 METER ZEROING PROCEDURES

(Continued)

4. Check that your field of fire is clear, and that it is safe to shoot. Carefully aim and fire a group of three shots at the center of the target bullseye. 5. Inspect your target - if your shot group is not in the center of the bullseye, the squares on the target sheet will help you calculate the required clicks necessary to move your next shot group toward the bullseye. (Remember! - any changes in elevation are to be made by moving Front Sight Post only.) 6. If you need to raise your next shot group to get closer to the bullseye, rotate the Front Sight Post clockwise one click. A Front Sight Adjustment Tool (Part# RAY-005 - see Bushmaster Catalog or Website) is recommended for this but not necessary the sight can be adjusted with the tip of a Bullet as shown at right. One click will move the the bullet strike point one vertical square on the target sheet. If you need to lower your next shot group, rotate the Front Sight Post counterclockwise. (One click - as before - equals one square.) Changes in Windage are made with the Windage Knob. (Three clicks will move the strike point of the Bullet one horizontal square on the target sheet.) To move the shot group to the left, turn the Windage Knob counterclockwise. To move the shot group to the right, turn the Windage Knob clockwise. Adjust Front Sight Post Elevation by 7. Carefully aim and fire another group at the center of the target depressing Detent with Bullet Tip, and bullseye. Repeat Steps 6 and 7 as required to get your shot groups then rotating Sight Post up or down as needed. into the bullseye. 8. Once your shot group is on target, your Sights are zeroed, or calibrated. To set your Rifles sights to a 300 meter zero, rotate the Elevation Knob one click down (2 clicks for the A3 Sight). The Range Pg. 20 Scales 300-meter mark should now be aligned with the corresponding mark on the Receiver.)

FRONT & REAR SIGHT ADJUSTMENT

FRONT SIGHT: To adjust elevation, depress detent and rotate post. To raise strike of bullet, rotate post in the direction of arrow marked UP. Reverse the direction of rotation to lower strike of Bullet. Each graduation (notch) moves the point of impact of Bullet as indicated. IMPACT 0.9 cm (3/8 in.) 3.5 cm (1 3/8 in.) 7.0 cm (2 3/4 in.) DISTANCE 25 meters 100 meters 200 meters

REAR SIGHT ADJUSTMENTS FOR WINDAGE KNOB (per click)* IMPACT DISTANCE 0.3 cm (1/8 in.) 25 meters WINDAGE KNOB POINTER 1.25 cm (1/2 in.) 100 meters 2.50 cm (1 in.) 200 meters WINDAGE 3.8 cm (1 1/2 in.) 300 meters SCALE 5.0 cm (2 in.) 400 meters 6.3 cm (21/2 in.) 500 meters 7.6 cm (3 in.) 600 meters 8.8 cm (3 1/2 in.) 700 meters 10.0 cm (4 in.) 800 meters *AII the above values have been rounded off. To remember your correct zero windage, note location of Windage Scale and Windage Knob Pointer (heavy mark on outside of knob). Once you have established your correct zero windage leave your Windage Scale and Windage Knob Pointer on these settings at all times.

DISASSEMBLING YOUR RIFLE

1. CLEAR YOUR RIFLE! (as described on Page 7). Disconnect the Sling for convenience. 2. Push in Takedown Pin (a Bullet tip can help) as far as it will go. Pivot Upper Receiver from Lower Receiver. 3. Push in Pivot Pin (a Bullet tip can help).

4. Separate Upper and Lower Receivers.

5. Pull back Charging Handle and Bolt Carrier.

Pg. 22

DISASSEMBLING YOUR RIFLE (Continued)

6. Remove Bolt Carrier and Bolt. 7. Remove Charging Handle by pulling back and up until Ears clear cutouts in Receiver.

8. Remove Firing Pin Retaining Pin. A Bullet tip can help push it out of the Bolt Carrier.

9. Drop Firing Pin out of rear of Bolt Carrier.

Do Not open or close split end of Firing Pin Retaining Pin, and Do Not substitute a common cotter pin on reassembly.

Pg. 23

DISASSEMBLING YOUR RIFLE (Continued)

10. Push Bolt in to locked position. 11. Remove Cam Pin by rotating 1/4 turn and lifting out.

12. Remove Bolt Assembly from Bolt Carrier by pulling straight out.

Pg. 24

DISASSEMBLING YOUR RIFLE (Continued)

DISASSEMBLE USING STEPS 13 THRU 16 ONLY WHEN DIRTY OR DAMAGED.
13. Remove Extractor Pin by pushing out with a punch or the tip of a Bullet. PUSH EXTRACTOR PIN OUT Dont lose it! 14. Remove Extractor with Spring.

NOTE: Press rear of Extractor to check Spring function.

CAUTION: Extractor Spring may pop out and get lost!

Pg. 25

DISASSEMBLING YOUR RIFLE (Continued)

DISASSEMBLE USING STEPS 13 THRU 16 ONLY WHEN DIRTY OR DAMAGED.
15. With Hammer cocked, depress Buffer Retainer with punch or Bullet tip to release Buffer and Spring. BUFFER The Handguards may be disassembled at any point in your cleaning procedures as necessary - see Buddy System tip in Reassembly Section. If your Rifle is equipped with the A3 Type Removable Carry Handle, remove for cleaning by loosening the 2 thumbnuts. Clean as per instructions for aluminum Upper and Lower Receivers. Lightly lubricate the thumbnut threads and the Rear Sight mechanism (as described in Lubrication Adjustable Rear Sight).

CAUTION! Buffer is under tension from Action Spring. NOTE: Hammer needs to be cocked to allow Buffer and Spring to clear Receiver. 15. Pull out Buffer and Action Spring for cleaning.

BUFFER RETAINER

STOP
Pg. 26

BUSHMASTER DOES NOT RECOMMEND ANY FURTHER DISASSEMBLY.

INSPECTION CLEANING LUBRICATION

AFTER FIRING YOUR RIFLE, clean it as soon as possible to make the job easier and to avoid allowing the development of any corrosion. When your firearm has not been fired, you should clean it at least once or twice a year if you live in a temperate climate, or as often as once a week in a tropical climate. If you get your firearm wet, clean it as soon as possible to avoid the onset of corrosion or rust. Use a high quality rifle cleaning kit that includes a cleaning rod; swab holder; cotton flannel bore patches; pipe cleaners; a small toothbrush; brass wire bristle bore and chamber brushes and a Cleaner/Lubricant/Preservative (CLP in Army terminology). After you have disassembled the rifle, thoroughly clean, inspect and lubricate all parts according to the techniques described on following pages. Cotton Flannel Bore Patches

Cleaning Kit with Patch Holder, Bore & Chamber Brushes

A Quality Gun Oil / Cleaner / Preservative

PLUS, an old toothbrush for cleaning parts and dislodging dirt build-up, and pipe cleaners or Q-tips for cleaning Gas Key and Gas Tube and other hard to reach areas. Pg. 27

DETAILED CLEANING TECHNIQUES

NOTE: The procedures below describe cleaning with a standard military issue multi-piece rod cleaning kit. Other commercial cleaning kits may include alternate cleaning instructions which may be just as effective. CLEANING THE BORE: The bore of your Bushmaster rifle has Lands and Grooves called rifling. Rifling makes the bullet spin very fast as it moves down the Bore and down range. It is difficult to push a new, stiff Bore Brush through the Bore. You will find it much easier, and more effective, to pull your Bore Brush through the Bore. Also, because the brush will clean better if the bristles follow the grooves (this is called tracking), you want the Bore Brush to be allowed to turn as you pull it through. ALWAYS CLEAN FROM FROM CHAMBER TOWARD THE MUZZLE. Follow these steps: 1. Attach three Rod Sections together but leave each one about two turns short of being tight. Attach the Patch Holder but leave it two turns short of tight also. 2. Point Muzzle down. Hold the Upper Receiver in one hand while inserting the end of the Rod with Patch Holder attached into the Chamber. Guide the Rod carefully through the Bore. CAUTION: Do not let the Rod or its threaded end scratch the Chrome Lining of the Bore or Firing Chamber. About 2 - 3 inches of the Rod should protrude out of the Muzzle. 3. Attach the Handle Section of the Cleaning Rod to the end of the Rod sticking out of the Muzzle, and swab out the Bore with a patch moistened with CLP. 4. Remove Patch Holder and attach Bore Brush (leaving it two turns short of tight). 5. Pull the Brush through the Bore and out the Muzzle. You should be able to see the Rod twisting as you pull it - this is the Brush "tracking" in the rifling. NEVER reverse the direction of the Bore Brush while it is in the Bore. Pg. 28 PATCH HOLDER AND THREE ROD SECTIONS

DETAILED CLEANING TECHNIQUES

(Continued)

6. After one pull, take off the handle section and repeat the process. After three or four pulls, the three rod sections and the Bore Brush may become screwed tightly together. Loosen them up and repeat the process. 7. Send a patch through the Bore occasionally to help clean out the crud that the brush is getting loose. Just replace the Bore Brush with the Rod Tip (Patch Holder) and a wet patch. Pull it through. If you leave the rods loose again, the patch will "track" in the rifling as before. But remember, always have the Bore wet with cleaner before trying to pull a brush through.

ATTACH HANDLE AND PULL THROUGH FROM CHAMBER TO MUZZLE

Pg. 29

CLEANING THE UPPER RECEIVER

NOTE: Check to ensure that there is no looseness between the Barrel and the Upper Receiver - if you detect any movement by twisting with your hands, the Barrel Nut must be retorqued. Bring the Rifle to your Armorer. 1. Using a CLP type product, clean all areas (inside and out) of Powder Fouling, Corrosion and Dirt. Never use a wire brush or any type of abrasive to clean the Aluminum Upper Receiver - you'll scratch and damage the finish. A Toothbrush is good for loosening any dirt buildup, and wont scratch the Receiver. 2. Clean the Firing Chamber - dip the larger Chamber Brush in CLP and use at least 5 plunge strokes and 3 - 360 clockwise rotations. Then swab out the Bore as described previously to remove contaminated solution or loosened crud. 3. Use the Bore Brush - wet with CLP - to clean carbon and powder residue from around the Gas Tube. Run a Pipe Cleaner into the Gas Tube, clean the Bolt Locking Lugs, Bolt Rings, Firing Pin, Bolt Cam Pin, lip of the Extractor, and inside the Bolt Carrier from both front and rear. 4. Wipe all components clean and dry, and inspect for excessive wear, corrosion or mechanical damage. Have your Armorer replace any worn or defective parts before firing again (or contact Bushmaster at 1-800-998-7928 for parts needs.) Pg. 30

CLEANING THE UPPER RECEIVER Cleaning the Bolt, Bolt Carrier & Components

(Continued)

1. Clean out the Gas Key on top of the Bolt Carrier with a Q-Tip or a Pipe Cleaner. Also clean out an carbon/powder residue from vent holes in the Bolt Carrier. 2. Clean and inspect Bolt, Cam Pin, Firing Pin and Firing Pin Retaining Pin thoroughly. CLEAN OUT GAS KEY AND CHECK THE BOLT: Look for cracks or fractures, CARRIER VENT especially in the Cam Pin hole area. Inspect HOLES Bolt Face - Bolts with any pitting extending into the firing pin hole should be replaced. CHECK THE CAM PIN: If it is cracked, or chipped, it should be replaced. NOTE: Cam Pin can only be installed in Bolt from one side - so Ejector will be BOLT positioned correctly. CHECK THE FIRING PIN: If it is bent, cracked, too FIRING PIN blunted or too sharp, it should be replaced. CHECK THE FIRING PIN RETAINING PIN: If it is bent, or badly worn, it should be replaced. Never use a Cotter Pin as a substitute for a real Firing Pin Retaining Pin. Cotter pins are not made of heat treated spring steel and their round head shape will cause damage.

CAM PIN

FIRING PIN RETAINING PIN INSPECT BOLT FACE

WARNING: IF THE CAM PIN IS MISSING, DO NOT FIRE THE RIFLE - IT WILL EXPLODE!

Pg. 31

CLEANING THE UPPER RECEIVER Cleaning the Bolt, Bolt Carrier & Components

(Continued)
EXTRACTOR

3. CHECK THE EXTRACTOR AND EXTRACTOR SPRING: If the Extractor is chipped, or has broken edges in the area of the lip that engages the cartridge rim, it should be replaced. Check that the rubber insert is inside the Extractor Spring. Clean off any Carbon buildup or powder residue.

Cleaning / Lubricating the Ejector

NOTE: The design of the Ejector makes its disassembly for cleaning somewhat impractical (i.e. we don't recommend it). Make sure your Bushmaster ejects empty cases efficiently by following these steps on a monthly basis (more frequently if firing blanks). 1. With the Bolt removed from the Bolt Carrier and the ROCK EMPTY CASE AGAINST Extractor installed, hold it as shown, and dribble a few EJECTOR TO LUBRICATE drops of CLP around the Ejector to form a puddle. 2. Take a fired or dummy case and place it under the lip of the Extractor. With a rocking motion, press the case down against the Ejector. Since the Ejector is spring loaded, some resistance will be felt. Press on the case until it stops against the bolt face. Ease off with your thumb slightly and press down again. Repeat several times. Replace the CLP frequently. Once the spring action of the Ejector is smooth and strong, dry off any excess lubricant. Pg. 32

EJECTOR

CLEANING THE LOWER RECEIVER

1. Clean all areas of Powder Fouling, Corrosion, Dirt and Rust. Again, never use a wire brush or any type of abrasive to clean the Aluminum Lower Receiver. 2. Wipe any dirt from the Trigger Mechanism. Carefully clean the Magazine Release Button and the cavity for the Magazine Catch on the left side of the Receiver. Also inspect and clean the Bolt Catch Mechanism and Receivers Takedown and Pivot Pins. Clean the Buffer, Action Spring, and inside the CLEAN INSIDE OF BUFFER TUBE Lower Receiver Extension (the Buffer Tube). A piece of rag attached to the Cleaning Rod and Patch Holder can be used to wipe inside the Buffer Tube. CLEAN OUT 3. If rifle has been used in very dirty/muddy DRAIN HOLE conditions, the Vent Screw in the A2 Solid IN THE Buttstock (shown) or the Vent Hole in the Telestock BUTTPLATE Receiver Extension may need to be cleaned out. SCREW Use a Pipe Cleaner or piece if wire to ensure that Vent Hole is clear. 4. Buttstocks may require cleaning as necessary. Telescoping Stock Latch can be pulled down to remove Stock. Clean the 6 Position Lock Holes, and lightly lube the Receiver Extension and Latch Mechanism to ensure proper telescoping action. A2 Solid Buttstocks may require cleaning / lubrication of Storage Compartment Door Latch and Hinge, and interior of Storage Compartment. Pg. 33

LUBRICATION UPPER & LOWER RECEIVERS LUBRICATE LUGS Upper Receiver

Lightly Lubricate the inside of Upper Receiver, the Bore and Chamber (using the cleaning rod and a patch), the outer surfaces of the Barrel and Front Sight, and surfaces under the Handguards. Be sure you lubricate in and around all the Locking Lugs (as in photo above). The Forward Assist should also be lightly lubed inside the Receiver and checked for function. Front Sight Detent: Depress and apply two or three drops of CLP to it. Depress the detent severaI times to work the lubricant down into the Spring.

FRONT SIGHT DETENT

Lower Receiver
Lower Receiver Extension: Lightly lubricate inside the Lower Receiver Extension (Buffer Tube), the Buffer and the Action Spring. Also lightly lubricate the Telestock Latch and exterior of the Receiver Extension. Lower Receiver: Generously lubricate ALL MOVING PARTS INSIDE THE LOWER RECEIVER including the Trigger, Hammer, Safety, Bolt Catch, Magazine Release, etc), and their various Pins and Detents. Don't forget the Takedown and Pivot Pins and their Detents. Use an oiled rag to wipe off any fingerprints on the exterior surfaces (they can start the corrosion process). A black cloth Pg. 34 is best as it wont leave visible lint.

LUBRICATION BOLT CARRIER GROUP

Firing Pin: Lightly lubricate the Firing Pin with CLP - also the Firing Pin recess in the Bolt. Bolt: Generously lubricate the Bolt, its Cam Pin area, the Bolt Gas Rings. A lighter application is good on the Extractor and its Pin.

Charging Handle: Lightly lubricate the Charging Handle and its Latch and Spring. Bolt Carrier: Lightly lubricate the inner and outer surfaces of the Bolt Carrier. Generously lubricate the Cam Pin area and the Slide Rail areas of the Bolt Carrier where they contact the inside of the Receiver. Carrier Key: The inside of the Carrier Key on the Bolt Carrier should be dried with a Q-Tip or Pipe Cleaner - then place one drop of CLP inside.

LATCH

SLIDE RAIL AREAS (each side) CARRIER KEY

Pg. 35

LUBRICATION ADJUSTABLE REAR SIGHT

NOTE: Record how far you move the rear sight so it can be returned to its original position upon the completion of this task. Rear Sight Moving Parts: Use 1 or 2 drops of CLP. Rotate these parts to ensure that the lubricant is spread evenly above, below and around the threads of the: DETENT 1. Elevation Knob SPRING HOLE 2. Elevation Screw Shaft WINDAGE 3. Windage Knob KNOB 4. Windage Screw 5. Detent Holes Elevation Screw Shaft: Also lube from inside the Upper Receiver as follows: WINDAGE 1. Turn Upper Receiver upside down. SCREW 2. Remove Charging Handle. 3. Put 2 or 3 drops on bottom of Elevation Screw Shaft and in Elevation Detent Spring Hole. 4. Rotate the Elevation Dial back and forth a few times while keeping Upper Receiver upside-down. ELEVATION
DIAL BOTTOM OF ELEVATION SCREW SHAFT AND DETENT SPRING HOLE

Pg. 36

REASSEMBLING YOUR RIFLE

1. Insert Action Spring and Buffer (the Spring will lock onto the Buffer if you slide it on - then push and twist counterclockwise). Depress Buffer Detent and push Buffer in past the Detent, then release.

RUBBER INSERT

2. Insert Extractor and Spring. NOTE: Extractor Assembly has a Rubber Insert within the INSERT Spring. Be sure not to lose it. If the Spring comes loose, put the large end of the Spring in the extractor and seat EXTRACTOR INTO BOLT it (a Bullet tip works well). 3. Then push down on Extractor to depress Spring, and reinsert Extractor Pin. Pg. 37

REASSEMBLING YOUR RIFLE

4. At the back end of the Bolt, stagger the Gas Ring Gaps to reduce gas pressure loss. Position the three ring gaps 120 apart around the bolt (3rd gap not seen at back side of bolt). The rings will slide around in their groove by pushing them into position with a small sharp object. 5. Insert Bolt into Bolt Carrier. Twist into position so Cam Pin can be inserted (remember Cam Pin can only be installed in Bolt from one side, so if it doesnt fit right away, twist the Bolt 180 and try again).

(Continued)
GAPS IN GAS RINGS

BOLT BODY

6. Once Cam Pin is inserted, twist it 90 (this will allow insertion of the Firing Pin).

Pg. 38

WARNING: THE CAM PIN MUST BE INSTALLED IN THE BOLT GROUP. IF IT ISNT, YOUR RIFLE CAN STILL FIRE AND WILL EXPLODE!

REASSEMBLING YOUR RIFLE

(Continued)

7. Drop in and seat Firing Pin. Pull Bolt out, then reinsert Firing Pin Retaining Pin. NOTE: After inserting Firing Pin Retaining Pin, Firing Pin should not fall out when Bolt Carrier Group is turned upside down.
PULL BOLT OUT

INSERT FIRING PIN

INSERT FIRING PIN RETAINING PIN

CAUTION: BUSHMASTER DOES NOT RECOMMEND THE PRACTICE OF SWAPPING BOLTS BETWEEN DIFFERENT RIFLES. DOING SO COULD RESULT IN DAMAGE, PERSONAL INJURY OR DEATH. Pg. 39

REASSEMBLING YOUR RIFLE

8. Insert Charging Handle into Upper Receiver and lower the ears at front end of Handle into cutouts in Receiver. Then slide Charging Handle partially into Receiver.
B A

(Continued)

9. Lower complete Bolt Carrier Assembly into Upper Receiver. Gas Key will fit into groove in the Charging Handle. REMEMBER, Bolt must be pulled to out position in the Carrier so Cam Pin will fit into the channel in the Upper Receiver.
A
B

10. Then slide the Bolt Carrier Assembly and Charging Handle all the way into the Upper Receiver until Charging Handle Latch locks onto the Receiver. NOTE: If Ejection Port Cover is closed, you will feel some resistance as you push Carrier and Handle in until you pop the Cover open. If Cover is already open, Handle and Carrier should slide in easily. Pg. 40

REASSEMBLING YOUR RIFLE

(Continued)

11. To join Upper and Lower Receivers, position Pivot Pin Lug of Upper Receiver into slot at front of Lower Receiver and push Pivot Pin into place. CAUTION: ALWAYS place the Safety Selector Lever on SAFE before pivoting the Upper Receiver to a closed position on the Lower Receiver. 12. After Receivers are closed, push in Takedown Pin.

Pivot Pin Takedown Pin

NOTE: Pivot Pin and Takedown Pin are captivated in the Lower Receiver - meaning that they are held in by their Detents and Springs so they cannot fall out and get lost.

Pg. 41

REASSEMBLING YOUR RIFLE

(Continued)

HANDGUARD REMOVAL / REATTACHMENT - THE BUDDY SYSTEM To Remove the Handguards for cleaning, or to Reinstall them, use the Buddy System. Because the Slip Ring (often called Delta Ring) which holds the handguards in place has a strong spring (the Weld Spring), it is necessary to have a buddy help you. CAUTION: THE RIFLE SHOULD BE UNLOADED AND CLEARED. 1. Place the Rifles Buttstock on the ground or a table, and press down on the Slip Ring with both hands. 2. Have your buddy remove or install one Handguard on top and the other on the bottom. There are notches designed to align and hold the Handguards on the Handguard Cap (located just behind the Front Sight Base). NOTE: The Half-Round Handguards are identical and can be used interchangeably in top or bottom positions. There are also special tools designed to aid in Handguard removal / reinstallation. See Bushmasters website (www.bushmaster.com) or call 1-800-998-7928 SLING REATTACHMENT If the Sling, or any other Accessories were removed for cleaning or maintenance, they should be reattached now. Pg. 42

MAGAZINE DISASSEMBLY / REASSEMBLY

Most Mil. Spec. design M-16 / AR-15 type Magazines can be disassembled for cleaning. The Magazine Spring, Magazine Follower and Magazine Baseplate can be replaced if broken or excessively worn. 1. To disassemble Magazine, pry up on bottom of Baseplate using Bullet Tip or Punch, and push indentations in Baseplate past Magazine Body 2. Slide Baseplate out of Magazine Body.

3. Jiggle Magazine Spring and Follower out of Body.

TO CLEAN and LUBRICATE: Wipe all dirt from the Magazine Body, Spring, Baseplate and Follower. Then lightly lubricate the Spring. REASSEMBLY is the REVERSE of these steps. Make sure to slide the base under all four tabs until it snaps back under the catch. NOTE: Do not remove Follower from Spring.

PROBLEMS / SOLUTIONS
PROBLEM: RIFLE WONT FIRE CHECK FOR: SELECTOR LEVER ON SAFE IMPROPER ASSEMBLY OF FIRING PIN WHAT TO DO: PUT IT ON FIRE ASSEMBLE CORRECTLY RETAINING PIN GOES IN BACK OF LARGE SHOULDER ON FIRING PIN

TOO MUCH OIL IN FIRING PIN RECESS

WIPE OUT WITH PIPE CLEANER

DEFECTIVE AMMUNITION

REMOVE AND DISCARD

Pg. 44

TOO MUCH CARBON ON FIRING PIN OR IN FIRING PIN RECESS

CLEAN

PROBLEMS / SOLUTIONS
PROBLEM: BOLT WONT UNLOCK CHECK FOR: DIRTY OR BURRED BOLT

(Continued) WHAT TO DO: CLEAN, OR SEE YOUR GUNSMITH

WONT EXTRACT

BROKEN EXTRACTOR SPRING DIRTY OR CORRODED AMMO

SEE YOUR GUNSMITH

REMOVE STUCK ROUND PUSH OUT WITH CLEANING ROD

CARBON IN CHAMBER FOULING OR CARBON IN EXTRACTOR RECESS OR LIP

CLEAN CHAMBER CLEAN EXTRACTOR

Pg. 45

PROBLEMS / SOLUTIONS
PROBLEM: WONT FEED CHECK FOR: DIRTY OR CORRODED AMMO DIRTY MAGAZINE DEFECTIVE MAGAZINE TOO MANY ROUNDS IN MAGAZINE

(Continued) WHAT TO DO: CLEAN CLEAN REPLACE TAKE OUT EXCESS TAKE OUT BUFFER AND SPRING - CLEAN THEM

ACTION OF BUFFER ASSEMBLY IS RESTRICTED MAGAZINE NOT FULLY SEATED

ADJUST MAGAZINE CATCH: PRESS MAGAZINE CATCH BUTTON ON RIGHT SIDE

Pg. 46

PROBLEMS / SOLUTIONS
PROBLEM: WONT FEED (continued) CHECK FOR:

(Continued) WHAT TO DO: TURN CATCH CLOCKWISE TO TIGHTEN AND COUNTERCLOCKWISE TO LOOSEN

TURN CATCH ON LEFT SIDE DOUBLE FEED DEFECTIVE MAGAZINE REPLACE

WONT CHAMBER

DIRTY OR CORRODED AMMO DAMAGED AMMO CARBON IN CHAMBER OR ON GAS TUBE

CLEAN REPLACE

CLEAN Pg. 47

PROBLEMS / SOLUTIONS
PROBLEM: WONT LOCK CHECK FOR: DIRT, CORROSION, OR CARBON BUILDUP IN BARREL LOCKING LUGS

(Continued) WHAT TO DO: CLEAN LUGS

CLEAN WONT EXTRACT FROZEN EXTRACTOR REMOVE AND CLEAN REMOVE AND CLEAN

RESTRICTED BUFFER ASSEMBLY

RESTRICTED MOVEMENT OF BOLT CARRIER GROUP Pg. 48

REMOVE, CLEAN, AND LUBE (BEFORE PUTTING BOLT BACK IN, MAKE SURE GAS TUBE FITS INTO CARRIER KEY AND THAT THE CARRIER MOVES FREELY)

PROBLEMS / SOLUTIONS
PROBLEM: SHORT RECOIL CHECK FOR: CORRECT ALIGNMENT OF GAPS IN BOLT GAS RINGS

(Continued) WHAT TO DO: GAPS IN THE 3 GAS RINGS SHOULD BE STAGGERED 120 AROUND THE BOLT BODY FOR MAXIMUM EFFECTIVENESS

TIP: Gas Rings should be replaced every 3,000 Rounds

Note: Third Gap not visible in this picture - position on back side of bolt CLEAN CARRIER KEY OR AROUND THE GAS TUBE

CARBON OR DIRT IN CARRIER KEY OR ON OUTSIDE OF GAS TUBE

Pg. 49

PROBLEMS / SOLUTIONS
PROBLEM: SHORT RECOIL (continued) CHECK FOR:

(Continued) WHAT TO DO: CLEAN OUT IF POSSIBLE OR HAVE RIFLE CHECKED BY YOUR GUNSMITH

Q-TIP, PIPE CLEANER PIECES, OR OTHER DEBRIS STUCK INSIDE CARRIER KEY

BOLT FAILS TO LOCK AFTER LAST ROUND

DIRTY OR CORRODED BOLT LATCH

CLEAN - OR REPLACE - BOLT CATCH CHECK FOR BUFFER ENDCAP BACKOUT OR OBSTRUCTION CHECK FOR FULL TRAVEL OF BOLT CARRIER REPLACE LUBRICATE WITH CLP CLEAN

FAULTY MAGAZINE SELECTOR LEVER BINDS Pg. 50 NEEDS OIL DIRT OR SAND UNDER TRIGGER

PROBLEMS / SOLUTIONS
PROBLEM: BOLT CARRIER HUNG UP CHECK FOR: ROUND JAMMED BETWEEN BOLT AND CHARGING HANDLE AND/OR DOUBLE FEED

(Continued) WHAT TO DO: 1. REMOVE MAGAZINE. 2. PUSH IN ON THE BOTTOM OF THE BOLT LATCH. 3. WHILE PULLING DOWN ON CHARGING HANDLE, TAP THE RIFLE BUTT ON THE GROUND. BOLT SHOULD LOCK TO THE REAR. 4. WHILE BOLT IS HELD TO THE REAR, ROUND SHOULD FALL THROUGH THE MAGAZINE WELL. NOTE: IF THIS PROCEDURE FAILS, USE A SECTION OF CLEANING ROD TO PUSH THE BOLT FULLY TO REAR THROUGH THE EJECTION PORT.

WARNING: KEEP CLEAR OF MUZZLE

CAUTION: AFTER ROUND IS REMOVED, BOLT IS UNDER TENSION Pg. 51

COLD WEATHER SHOOTING

If cold weather requires it, your Bushmaster can be shot with gloved or mittened hands. The Trigger Guard is designed to open and swing down allowing better access to Trigger when the shooter is wearing gloves or mittens. 1. Push in Forward Trigger Guard Pin with Bullet tip to release Trigger Guard.

CAUTION: Be careful of accidental discharges when inserting gloved fingers into Trigger Guard area.

2. Swing Trigger Guard down for shooting with gloves or mittens.

MAINTENANCE IN EXTREME WEATHER

EXTREME COLD: Clean and lubricate Rifle in a warm room with Rifle at room temperature. Do not lay a warm Rifle directly on snow or ice. Moving Rifle from cold into warmth will cause condensation which could keep Rifle from functioning. HOT, WET CLIMATES: Clean and lube Rifle more frequently in moist climates. Inspect hidden surfaces of Bolt and Carrier Assembly, Upper Receiver, and Chamber / Barrel Extension (Locking Lugs), and Lower Receiver and Receiver Extension Assembly (Buffer Tube) for rust or corrosion. Also pay close attention to the Spring Loaded Detents on the rifle. Wipe off any hand / finger prints on the Rifle as they can accelerate the onset of rust or corrosion. HOT, DRY CLIMATES: Take extra care with cleaning and lubrication as rifle will be exposed to blowing sand and fine dust, and extreme temperature shifts (hot in the daytime, freezing at night). Corrosion is less likely to form on metal parts in a dry climate. Lightly lube functional parts only - too much lubrication can attract and hold dust and sand. RAINS: DO NOT FIRE THE RIFLE IF WATER IS PRESENT IN THE BARREL. Excess pressure can cause the Rifle to explode. Pg. 52 ALWAYS drain any water from Barrel prior to firing. Dry the Bore with a Swab and Cleaning Rod if wet.

COMPONENT VARIATIONS within the Bushmaster Weapon System

This manual is intended to instruct the Bushmaster Rifle Operator in all necessary aspects of Maintenance, Disassembly, Reassembly, Operation and Troubleshooting of any Bushmaster Rifle. Within the Bushmaster Weapon System, there can be infinite variations of Barrel Length, Stock Type, Receiver, Forend and Sights.

For purposes of this manual, the most common Bushmaster Model sold - the M4A3 Type Carbine - has been illustrated and photographed. A Parts Schematic for this model is shown on the next two pages - many parts are common to all models in the Bushmaster System. The Bushmaster you own, or are using, may vary in appearance from the photographs and illustrations in this Manual, but the concepts, procedures and practices recommended in this Manual are universal to the Bushmaster Weapon System. Pg. 53

PARTS SCHEMATIC Typical Bushmaster XM15 M4A3 Type Carbine

B K

M4A3 TYPE CARBINE, 5.56MM PART # BCWA3F 14M4 IZ

NOTE: See Carbon 15 Models Differences for comparison and instructions specific to Disassembly and Maintenance for those Models.

BUR

SEM ST

I SAF

CAR. BUFFER SPRING 1005 914 4564 6 POSITION CARBINE RECEIVER EXTENSION
BUFFER ASSEMBLY 8448730-M

Caliber: 5.56mm NATO or .223 Rem. Mode of Fire: Safe / Semi-Auto 30 Round Magazine Length Overall: 34.75" (88.27 cm) Barrel Length w. Suppressor: 16" (40.64 cm) Rifling: 1 in 9" Weight w/o Mag.: 6.57 Lbs. (2.98 Kg)
BUFFER RETAINER 8448582 BUFFER RETAINER SPRING 8448583 HAMMER WITH J PIN 8448612-SK HAMMER SPRING 8448611 SAFETY SELECTOR LEVER 9381367-S BOLT CATCH 8448628 BOLT CATCH ROLL PIN MS16562-119 BOLT CATCH PLUNGER 8448634 BOLT CATCH SPRING 8448633 MAGAZINE CATCH 8448638 PIVOT PIN DETENT 8448585

MAGAZINE, 30RD. - 8448670 (SOLD AS COMPLETE ASSEMBLY) OR 20 RD. - 8448670-20

MAGAZINE FOLLOWER 8448672

PIN, BUTTSTOCK SLIDE LOCK LOCKPIN SPRING

RECEIVER EXTENSION NUT 53109171153 COLLAR, BUTTSTOCK TUBE LOCK 1015-914-2942

TAKEDOWN PIN SPRING 8448586 TAKEDOWN PIN DETENT 8448585 TAKEDOWN PIN 8448584 SAFETY DETENT 8448631 SAFETY DETENT SPRING 8448516
FIR E SAF

COMPLETE TELESTOCK ASSEMBLY 1005-087-8988-PK

TELESTOCK LATCH LOCKPIN NUT
PISTOL GRIP 9349127

LOWER RECEIVER 9349102-S

TRIGGER GUARD PIVOT ROLL PIN MS16562-35 MAGAZINE CATCH SPRING 8448637 MAGAZINE RELEASE BUTTON 8448636

PIVOT PIN SPRING 8448586 PIVOT PIN 8448621 DISCONNECTOR SPRING 9349116 DISCONNECTOR 9349114-S TRIGGER 8448592-S TRIGGER SPRING 8448593 MAGAZINE BOX ASSY. MAGAZINE SPRING 8448671 MAGAZINE FLOOR PLATE 8448673

ROLL PIN

LOCK WASHER MS35335-61 PISTOL GRIP SCREW AN501D416-18 HAMMER AND TRIGGER PINS 8448609

TRIGGER GUARD ASSEMBLY 8448587

Pg. 54

Made With Pride In The U.S.A.

2005, Bushmaster Firearms, Inc., Windham, Maine

PARTS SCHEMATIC Typical XM15 M4A3 Type Carbine (Continued)

BARREL ASSEMBLY AND COMPONENTS CARBINE GAS TUBE 1005-914-3504 THERMOSET HANDGUARD (2) 1005-914-4572 HANDGUARD CAP SGW-10F

NOTE: See Carbon 15 Models Differences for comparison and instructions specific to Disassembly and Maintenance for these Models.

HAND GUARD SNAP RING MS16626-1137 WELD SPRING 8448555 FRONT SIGHT POST 9349056 DELTA RING 8448712 BARREL INDEXING PIN 9349054BIP BARREL EXTENSION 9349054BE BARREL NUT 9349054BN THERMOSET HANDGUARD (2) 1005-914-4572
M4 Ba rrel Diam eter Redu ced He re To Ac com mod ate M 203 Gren ade La unch er

FRONT SIGHT DETENT 8448573 FRONT SIGHT DETENT SPRING 8448574 GAS TUBE ROLL PIN MS16562-106 FRONT SIGHT BASE WITH BAYONET LUG 9349054FSHA BARREL SUBASSEMBLY - A BBL-14M4 CRUSH WASHER 12991533B IZZY FLASH SUPPRESSOR IZ-102660-FH (PINNED & WELDED ONTO BBL.) FRONT SIGHT TAPER PINS (2) 9349054BTP

Made With Pride In The U.S.A.

2005, Bushmaster Firearms, Inc., Windham, Maine

CHARGING HANDLE LATCH ROLL PIN MS16562-96

FRONT SLING SWIVEL 8448571

CHARGING HANDLE ASSEMBLY 8448517

CHARGING HANDLE LATCH 8448519 CHARGING HANDLE LATCH SPRING 8448520

FRONT SLING SWIVEL RIVET 8448697 REAR SIGHT WINDAGE KNOB PIN MS16562-98 REAR SIGHT WINDAGE KNOB 9349077

REAR SIGHT ASSEMBLY/COMPONENTS REAR SIGHT WINDAGE SCREW 9349076

REAR SIGHT ASSEMBLY 9349072-1

INDEX SCREW 9349065 INDEX, ELEVATION 9349066-1

8/ 3

CHARGING HANDLE 8448518

UPPER RECEIVER, BOLT AND BOLT CARRIER ASSEMBLIES / COMPONENTS

KNOB, ELEVATION 9349067-1 ELEVATION SPRING 9349070 REAR SIGHT ELEVATION SPRING PIN MS16562-121

BALL BEARING MS19060-4808 INDEX SPRING 9349069

FIRING PIN 8448503 BOLT CARRIER KEY SCREW (2) 8448508 BOLT CARRIER KEY 8448506

REAR SIGHT BASE 9349074-1 REAR SIGHT HELICAL SPRING 9349069 REAR SIGHT BALL BEARING MS19060-4808 REAR SIGHT APERTURE 9349075 REAR SIGHT FLAT SPRING 8448536 REAR SIGHT BALL BEARING MS19060-4808 REAR SIGHT HELICAL SPRING 9349069

FORWARD ASSIST ASSEMBLY 9349086KIT

FIRING PIN RETAINING PIN 8448504 CAM PIN 8448502 BOLT CARRIER 8448507

PAWL DETENT 8448544 FORWARD ASSIST PLUNGER 9349085PAWL SPRING 8448542 FORWARD ASSIST SPRING PIN MS16562-121 PAWL SPRING PIN MS16562-103

THUMB NUT ASSEMBLY 9349063-7 (2 PLACES) CLAMPING BAR 9349063-3 CROSS BOLT 9349063-4 (2 PLACES) CARRY HANDLE - FORGED 9349063-2

BOLT CARRIER ASSEMBLY 8448501

EXTRACTOR PIN 8448513 BOLT GAS RINGS (3) 8448511K EJECTOR ROLL PIN MS16562-98 EJECTOR SPRING 8448516

FORWARD ASSIST PAWL 8448543 FORWARD ASSIST SPRING 8448540 EJECTION PORT COVER PIN 8448533 EJECTION PORT COVER SPRING 8448532 EJECTION PORT COVER 8448525

BOLT 8448510 EXTRACTOR SPRING 8448755SP EXTRACTOR SPRING INSERT 8448754 EXTRACTOR 8448512

BOLT ASSEMBLY 8448509

EJECTOR 8448515

COMPLETE UPPER RECEIVER & BARREL ASSEMBLY BURA3B 14M4

UPPER RECEIVER 8448524-V RING, RETAINING COVER MS16632-1012

CARRY HANDLE ASSEMBLY 9349063-9

Pg. 55

PARTS SCHEMATIC Typical XM15 A2 Type Target Rifle

NOTE: See Carbon 15 Models Differences for comparison and instructions specific to Disassembly and Maintenance for those Models. Caliber: 5.56mm NATO or .223 Rem. Mode of Fire: Safe / Semi-Auto 30 Round Magazine Length Overall: 39.5" (100.3 cm) Barrel Length: 20" (51 cm) Rifling: 1 in 9" Weight w/o Mag.: 8.43 Lbs. (3.82 kg)
XM15 E2S TARGET RIFLE, 5.56MM PART # BCWA2S 20

FIR

SAF

ACTION SPRING 8448629

BUTTCAP SPACER 12597640 BUTTSTOCK 9349121 BUTTPLATE 9349130 BUTTPLATE SCREW 9349128 BUFFER RETAINER 8448582 BUFFER RETAINER SPRING 8448583 RECEIVER EXTENSION 8448581 TAKEDOWN PIN SPRING 8448586 TAKEDOWN PIN DETENT 8448585 TAKEDOWN PIN 8448584
FIR E SAF E

BUFFER ASSEMBLY 8448615 HAMMER WITH J PIN 8448612-SK HAMMER SPRING 8448611 SAFETY SELECTOR LEVER 9381367-S BOLT CATCH 8448628 BOLT CATCH ROLL PIN MS16562-119 BOLT CATCH PLUNGER 8448634 BOLT CATCH SPRING 8448633 MAGAZINE CATCH 8448638 PIVOT PIN DETENT 8448585 LOWER RECEIVER 9349102-S TRIGGER GUARD PIVOT ROLL PIN MS16562-35 MAGAZINE CATCH SPRING 8448637 HAMMER AND TRIGGER PINS 8448609 MAGAZINE CATCH BUTTON 8448636 TRIGGER GUARD ASSEMBLY 8448587 PIVOT PIN SPRING 8448586 PIVOT PIN 8448621 DISCONNECTOR SPRING 8448594 DISCONNECTOR 9349114-S TRIGGER 8448592-S TRIGGER SPRING 8448593

MAGAZINE, 30RD. - 8448670 (SOLD AS COMPLETE ASSEMBLY) OR 20 RD. - 8448670-20

MAGAZINE FOLLOWER 8448672

ACCESS DOOR ASSEMBLY 8448658 REAR SWIVEL SCREW 9349120 ACCESS DOOR HINGE PIN 8448655 Made with Pride ACCESS DOOR HINGE 8448653 REAR SLING SWIVEL 8448652 SAFETY DETENT 8448631 SAFETY DETENT SPRING 8448516 PISTOL GRIP 9349127 LOCK WASHER MS35335-61 PISTOL GRIP SCREW AN501D416-18

MAGAZINE BOX ASSY. MAGAZINE SPRING 8448671 MAGAZINE FLOOR PLATE 8448673

In the U.S.A.
2005, Bushmaster Firearms, Inc., Windham, Maine

Pg. 56

PARTS SCHEMATIC Typical XM15 A2 Type Target Rifle (Continued)

GAS TUBE 8448567 HANDGUARD SNAP RING MS16626-1137 BARREL ASSEMBLY AND COMPONENTS

NOTE: See Carbon 15 Models Differences for comparison and instructions specific to Disassembly and Maintenance for these Models.

WELD SPRING 8448555 DELTA RING 8448712 INDEXING PIN 9349054BIP BARREL EXTENSION 9349054BE BARREL NUT 9349054BN METAL HANDGUARD LINER (2) (INCLUDED WITH HANDGUARD) THERMOSET HANDGUARD (2) 9349059 CHARGING HANDLE LATCH 8448519 CHARGING HANDLE LATCH SPRING 8448520 CHARGING HANDLE 8448518 FRONT SIGHT TAPER PINS (2) 9349054BTP

FRONT SIGHT POST 9349056 FRONT SIGHT DETENT 8448573 FRONT SIGHT DETENT SPRING 8448574 HANDGUARD CAP 9349053 GAS TUBE ROLL PIN MS16562-106 FRONT SIGHT 9349054FSHA BARREL - FULL LENGTH HEAVY STYLE - CHROME MOLYBDENUM STEEL WITH HARD CHROME LINED BORE AND CHAMBER. STANDARD MODEL RIFLE AVAILABLE WITH 20", 24" OR 26" BBL. CRUSH WASHER 12991533B FLASH SUPPRESSOR 9349051

CHARGING HANDLE LATCH ROLL PIN 8448521-2

UPPER RECEIVER, BOLT AND BOLT CARRIER ASSEMBLIES / COMPONENTS BOLT CARRIER KEY SCREW (2) 8448508 BOLT CARRIER KEY 8448506

FRONT SLING SWIVEL 8448571 FRONT SLING SWIVEL RIVET 8448697 REAR SIGHT ASSEMBLY / COMPONENTS REAR SIGHT ASSEMBLY 9349072 INDEX SCREW 9349065 REAR SIGHT ELEVATION INDEX 9349066 ELEVATION KNOB 9349067 REAR SIGHT ELEVATION SPRING 9349070 REAR SIGHT ELEVATION SPRING PIN MS16562-121 FORWARD ASSIST SPRING PIN MS16562-103 PAWL SPRING 8448542 PAWL DETENT 8448544 UPPER RECEIVER 9349063 FORGED OF 7075T6 AIRCRAFT QUALITY ALUMINUM REAR SIGHT WINDAGE KNOB PIN MS1656-103 REAR SIGHT WINDAGE KNOB 9349077
8 /3

FIRING PIN 8448503 FIRING PIN RETAINING PIN 8448504 CAM PIN 8448502 BOLT CARRIER 8448507 BOLT GAS RINGS (3) 8448511K EXTRACTOR PIN 8448513 BOLT & BOLT CARRIER ASSEMBLY 8448501-S BOLT 8448510 EXTRACTOR SPRING 8448755SP EXTRACTOR SPRING INSERT 8448754 EXTRACTOR 8448512 BOLT ASSEMBLY 8448509 EJECTOR ROLL PIN MS16562-98 EJECTOR SPRING 8448516 EJECTOR 8448515

REAR SIGHT WINDAGE SCREW 9349076 REAR SIGHT BASE 9349074 REAR SIGHT HELICAL SPRING 9349069 REAR SIGHT BALL BEARING MS19060-4808 REAR SIGHT APERATURE 9349075 REAR SIGHT FLAT SPRING 8448536 REAR SIGHT BALL BEARING MS19060-4808 REAR SIGHT INDEX SPRING 9349069

BALL BEARING MS19060-4808 ELEVATION INDEX SPRING 9349069

FORWARD ASSIST PLUNGER 9349085 PAWL SPRING PIN MS16562-103 Made with Pride FORWARD ASSIST ASSEMBLY 9349086

FORWARD ASSIST PAWL 8448543 FORWARD ASSIST SPRING 8448540

In the U.S.A.
2005, Bushmaster Firearms, Inc., Windham, Maine

Pg. 57

PARTS SCHEMATIC Typical Carbon 15 Rifle & Pistol

Schematic for Carbon 15 Type R97 Rifle and Carbon 15 Type P97 Pistol
REPRESENTATION OF COMPLETE TYPE 97 RIFLE
Made With Pride In The U.S.A.
2005, Bushmaster Firearms, Inc., Windham, Maine

Note: For Carbon 15 Flat-top & M4 Models, refer to

previous XM15 E2S M4 Carbine diagram. The differences would be the substitution of molded Carbon 15 Receivers in place of forged aluminum receivers.

RECOIL SPRING AZ15998 TAKEDOWN LEVER AZ15176 DOWEL PIN AZ15117 SPIRAL LOCK (2) AZ15063 BUFFER PAD AZ15065 SET SCREW AZ15118

HAMMERWITH J PIN 8448612-SK HAMMER SPRING 8448611

SAFETY SELECTOR W. INSERT AZ15177 RIFLE BUFFER TUBE AZ15123 O-RING AZ15077 BUFFER BODY AZ15240 BOLT CATCH 8448628 BUFFER ASSEMBLY AZ15009 SET SCREW AZ15118 TAKEDOWN PIN SPRING AZ15013 TAKEDOWN PIN DETENT 8448585 REAR TAKEDOWN PIN AZ15032 SELECTOR DETENT 8448631 SAFETY DETENT SPRING 8448516 FRONT TAKEDOWN PIN DETENT 8448585 FRONT TAKEDOWN PIN SPRING 8448586 FRONT TAKEDOWN PIN AZ15033 LOWER RECEIVER AZ15180 (97 / 97S / 21 RIFLES) LOWER RECEIVER AZ15179 (97 / 21 PISTOLS) DISCONNECTOR SPRING 8448594 DISCONNECTOR 9349114-S TRIGGER 8448592-S TRIGGER SPRING 8448593 MAGAZINE CATCH 8448638 BOLT CATCH ROLL PIN MS16562-119 BOLT CATCH PLUNGER 8448634 BOLT CATCH SPRING 8448633

BUTTSTOCK AZ15183

YOUTH STOCK ALSO AVAILABLE - AZ 15297 8.5 LONG / 11.25 LENGTH OF PULL HOGUE PISTOL GRIP 15000 (ON TYPE 97S & 97 RIFLES, AND TYPE 97 PISTOL)

MAGAZINE, 10RD. - 8448670-10 SOLD AS COMPLETE ASSEMBLY. MAY BE SOLD WITH 30 ROUND MAGAZINE IN SOME STATES

LOCK WASHER MS35335-61 PISTOL GRIP 9349127 PISTOL GRIP SCREW AZ15022 HAMMER AND TRIGGER PINS 8448609

MAGAZINE CATCH SPRING 8448637 MAGAZINE RELEASE BUTTON 8448636

NOTE: ANY PART NUMBER NOT PRECEEDED BY AZ IS AN AR-15 INTERCHANGEABLE PART

Pg. 58

PARTS SCHEMATIC Typical Carbon 15 Rifle & Pistol (Continued)

HANDGUARD RETAINER AZ15324 O-RING AZ15077 BARREL ASSEMBLY AND COMPONENTS PISTOL BARREL ASSEMBLY AND COMPONENTS PISTOL BUFFER TUBE AZ15078 HANDGUARD TUBE AZ15093 CERAMIC HANDGUARD LINER INSERT AZ15139 INCL. W. 97S OPTIONAL ON OTHER RIFLES O-RING AZ15077

REPRESENTATION OF COMPLETE TYPE 97 PISTOL

FOR TY (WIT PE 97S RI H CERA FL MIC LI ES, PART FOR # NER TY STAN AZ15159 IS PA PE 97 AN DARD IS TH D RT # EQUI AZ15 21 RIFLES PMEN E COMPL 184 , THE ETE FO T). COM REGR PLET IP E FORE GRIP

END CAP SCREW AZ15029 PISTOL RECEIVER END CAP AZ15307 O-RING AZ15077 GAS TUBE SHROUD AZ15345 GAS TUBE - PISTOL AZ15049 BARREL EXTENSION 9349054BE

BARREL NUT AZ15334

BARREL INDEXING PIN AZ15054 HANDGUARD STABILIZING PIN AZ15054

WAVE WASHER - AZ15050 FLUTED BARREL W. BBL. EXTENSION FOR TYPE 97 PISTOL - AZ15314 NON-FLUTED BARREL W. BBL. EXTENSION FOR TYPE 21 PISTOL - AZ15313 HANDGUARD RETAINER AZ15324 GAS BLOCK W. INTEGRAL FRONT SIGHT FOR PISTOL - AZ15326 GAS TUBE - RIFLE AZ15092 FLUTED BBL. W. BARREL EXTENSION - TYPE 97 & 97S RIFLE - AZ15368 BARREL W. BBL. EXTENSION - TYPE 21 RIFLE - AZ15367 (NON-FLUTED) GAS BLOCK LOCKING SCREW AZ15005

REAR SIGHT COMPONENTS OPTICS BASE LOCKING SCREW AZ15230 (ONLY ON TYPE 97S) REAR SIGHT WINDAGE SCREW 9349076 REAR SIGHT APERTURE 9349075 REAR SIGHT FLAT SPRING 8448536 WINDAGE KNOB PIN MS16562-98 WINDAGE KNOB 9349077 REAR SIGHT BALL BEARING MS19060-4808 REAR SIGHT HELICAL SPRING 9349069 BARREL EXTENSION 9349054BE OPTICS BASE SCREW AZ15108 OPTICS BASE SCREW AZ15235

FOREGRIP RETAINER SCREW AZ15096 GAS BLOCK - RIFLE AZ15327 OPTICS BASE SCREW AZ15235 FRONT SIGHT POST 9349056 FRONT SIGHT DETENT 8448573 FRONT SIGHT DETENT SPRING 8448574 OPTIC RAIL PLUG AZ15238 COMPENSATOR ASSEMBLY AZ15003

FULL LENGTH OPTICS BASE AZ15343 (ONLY ON TYPE 97S RIFLE) COMPLETE ASSEMBLY: AZ15198 CHARGING HANDLE LATCH ROLL PIN AZ15277

FIRING PIN 8448503-S

UPPER RECEIVER, BOLT AND BOLT CARRIER ASSEMBLIES / COMPONENTS BOLT CARRIER ASSEMBLY - CHROME W. KEY AZ15178 BOLT CARRIER ASSEMBLY - BLACK OXIDE W. KEY AZ15267 FIRING PIN RETAINING PIN 8448504 BOLT CARRIER KEY SCREW (2) 8448508 BOLT CARRIER GAS KEY AZ15331

CHARGING HANDLE LATCH AZ15275 CHARGING HANDLE LATCH SPRING 8448520

CHARGING HANDLE ASSEMBLY BOLT CARRIER - CHROME AZ15242 AZ15011 BOLT CARRIER - BLACK OXIDE AZ15271 CAM PIN 8448502 BOLT GAS RINGS (3) 8448511K

CHARGING SIGHT SET SCREW AZ15994 HANDLE AZ15001 PISTOL REAR SIGHT AZ15351T

GAS BLOC K LO CKIN G SC REW

AZ15 005

OPTICS BASE SCREW AZ15108 OPTICS BASE AZ15336 (USED ON TYPE 97 & 21 RIFLES) PISTOL BASE AZ716 UPPER RECEIVER AZ15105 W. BRASS DEFLECTOR AZ15181 PISTOL UPPER RECEIVER AZ15067 W. REAR SIGHT AZ15282 DEFLECTOR SCREW AZ15103 BRASS DEFLECTOR AZ15175

EXTRACTOR PIN 8448513 BOLT 8448510 EXTRACTOR SPRING 8448755SP EXTRACTOR SPRING INSERT 8448754 EXTRACTOR 8448512 BOLT AND BOLT CARRIER ASSEMBLY with CHROMED CARRIER AZ15008 / with BLACK OXIDE CARRIER AZ15269 EJECTOR ROLL PIN MS16562-98 EJECTOR SPRING 8448516 EJECTOR 8448515 BOLT ASSEMBLY 8448509

Made with Pride

In the U.S.A.
2005, Bushmaster Firearms, Inc., Windham, Maine

Pg. 59

Bushmaster Carbon 15 Models Differences

Carbon 15 Sighting Systems:
Sights on Carbon 15 Rifles and Pistols vary from traditional AR-15 Type Rifle systems as shown below. All Rails on Carbon 15 Upper Receivers are machined from hard anodized aircraft aluminum in Picatinny configuration, and will accept a wide variety of scopes, optics, holographic, and red dot sights.
B.M.A.S. Flip-up Rear Sight - The Rear Sight is a B.M.A.S. Flip-up with windage adjustment. The A3 Removable (Part# YHM-9440) Carry Handle (Part# 9349063-9) will fit this Upper, and its sight will align with the A2 Standard Square Post Front Sight which is elevation adjustable.
Part# AZ-C1516M4FT

Carbon 15 Flat-top Carbine

Carbon 15 Model 4 Carbine Dual Aperture Rear Sight (windage adjustable) and A2 Post Front Sight (elevation adjustable) integral on full length Picatinny Optics Rail. Carbon 15 R97S Rifle

Dual Aperture Rear Sight (windage adjustable) integral on Picatinny Optics Rail. A2 Standard Square Post Front Sight (elevation adjustable).

Part# AZ-C15M4PRE

Part# AZ-C15R97S

C15 P97S Pistol Carbon 15 Lady and No Sights provided - Receiver length Picatinny Rail R21 Rifle
Part# AZ-C15R21C & AZ-C15R21

Part# AZ-C15P97S also AZ-C15P21S

Dual Aperture Rear Sight (windage adjustable) and A2 Post Front Sight (elevation adjustable) integral on full length Picatinny Optics Rail.

C15 P21 Pistol

Part# AZ-C15P21 also AZ-C15P97

Ghost Ring Rear Sight and Blade Front Sight.

Pg. 60

Bush master Carbon 15 Models Differences (Continued)

Carbon 15 Upper & Lower Receivers:
Beside the fact that they are molded Carbon Fiber material, the Upper and Lower Receivers on Carbon 15 Rifles and Pistols in the R or P Series Models separate from each other in a different manner than XM15 E2S Bushmaster models with Aluminum Receivers. The disassembly steps are:

1. Weapon should be in a SAFE CONDITION. Clear Rifle (or

Pistol) and remove Magazine. Make sure Bolt Carrier is fully forward and locked.

2. Push both Takedown and Pivot Pins out from left side of
Lower Receiver.

3. Grasping the Lower by the Pistol grip and the Upper by the
Forend as shown, tilt the front end of the Upper so that Pivot Pin Lug clears the Lower Receiver.

4. This will allow you to move the Upper forward - separating

it from the Lower - while at the same time releasing the Buffer and the Action Spring from the Buffer Tube. Use Caution as the Action Spring will be under some tension.

5. Reassembly is the reverse of these steps.

NOTE: These instructions apply specifically to these Models: R97S Rifle (AZ-C15R97S) R97 Rifle (AZ-C15R97) R21 Rifle (AZ-C15R21) Lady Rifle (AZ-C15R21C) P97S Pistol (AZ-C15P97S) P21S Pistol (AZ-C15P21S) P97 Pistol (AZ-C15P97) P21 Pistol (AZ-C15P21)

Pg. 61

Bushmaster Carbon 15 Models Differences (Continued)

Carbon 15 Rifle Buttstock Removal:
The molded Carbon Fiber Buttstocks on R Series Rifles can be easily removed from the Lower Receiver for more convenient storage or cleaning, or to gain access to the Buffer Tube. The disassembly steps are: 1. Weapon should be in SAFE CONDITION. Clear the Rifle and remove Magazine. Make sure Bolt Carrier is fully forward and locked. 2. Identify the Buttstock Takedown Lever on the left side of Lower Receiver.

3. Use your finger or thumb to swivel the

Buttstock Takedown Lever downward in a counterclockwise rotation to the release position. 4. This will allow you to slide the Buttstock off the Buffer Tube and Lower Receiver. 5. Reassembly is the reverse of these steps. Be sure the Buttstock Takedown Lever is in the release position before attempting reinstallation.

6. Carbon 15 R97S Rifle and Buttstock shown completely

separated below. Do not attempt to fire the rifle without the Buttstock securly in place. You could experience injury from recoil, or loss of control of the rifle. NOTE: A Youth sized Buttstock is available (2 shorter than standard - Part# AZ15279) to make shooting more comfortable for younger shooters and smaller women. NOTE: Buttstock removal applies specifically to these Models: R97S Rifle (AZ-C15R97S) R97 Rifle (AZ-C15R97) R21 Rifle (AZ-C15R21) Lady Rifle (AZ-C15R21C)

Pg. 62

Bushmaster Carbon 15 Models Differences (Continued)

Quick Detach Compensator Removal:
The Stainless Steel Barrels on Carbon 15 R Series Rifles and P Series Pistols are fitted with an easily removed Quick Detach Compensator. The disassembly steps are: 1. Weapon should be in SAFE CONDITION. Clear the Rifle and remove Magazine. 2. Grasp the Sliding Collar of the Q.D. Compensator and push it towards the muzzle end while holding the body of the Compensator. 3. Once spring tension is released on the Ball Detent Locking mechanism, the Compensator can be slide off the end of the muzzle. 4. Reassembly is the reverse of these steps plus a twisting motion to ensure that the Balls of the Locking mechanism drop into their respective detents on the outside of the muzzle. WARNING: Do not fire the Rifle unless the Q.D. Compensator is firmly locked in place. NOTE: The Rifle may be safely fired with the Q.D. Compensator completely removed.

Carbon 15 Rifle Safety Lever Markings:

Molded Carbon Fiber Receivers on Carbon 15 Rifles and Pistols have Safety Lever Indicator Markings either engraved into the Carbon Fiber Typical Bushmaster material (most military / LE models), or inset Carbon 15 Model into the Lower with colored letters (most Commercial models). S = SAFE (white letters on both sides of Receiver); F = FIRE (red letters on both sides of Receiver). Compare with roll-stamped markings on Aluminum Receiver at right.

Typical Bushmaster XM15 Model

No Ejection Port Cover on Carbon 15 Rifles & Pistols:

While the Aluminum Receiver XM15 Models include the original military design, spring loaded, metal Ejection Port Cover, the Receivers on Carbon 15 Rifles and Pistols do not. The Bolt Carrier can be easily removed for cleaning and maintenance, so the Ejection Port Cover is not found on the Carbon 15 Models. Pg. 63

LIMITED ONE YEAR WARRANTY

Bushmaster firearms are warranted to be free from defects in materials and workmanship. Any such defect of which Bushmaster Firearms, Inc. is given written notice, as provided below, within one year and ten days from the date of first purchase by a customer will be remedied by Bushmaster Firearms, Inc. This warranty is granted by Bushmaster Firearms, Inc., P.O. Box 1479, 999 Roosevelt Trail, Windham, ME 04062. To initiate a Warranty claim, call Bushmaster Customer Service (toll free: 8:30 AM to 6:00 PM E.S.T. - Monday thru Friday - 1-800-883-6229) to get a Return Merchandise Authorization (RMA) number. Warranty claims should state (in writing) the model and serial number of the firearm concerned, a description of the difficulty experienced, and the date of purchase. The firearm concerned should be shipped (transportation charges prepaid), to the Warranty Service Department, Bushmaster Firearms, Inc., 999 Roosevelt Trail, Windham, ME 04062. Firearm shipment should be insured by the owner, as Bushmaster Firearms, Inc. will accept no responsibility for loss or damage in transit. Shipping and insurance charges for the return of a firearm to its owner will be paid by Bushmaster Firearms, Inc. if the related claim is a proper claim for warranty work. Under no circumstances shall Bushmaster Firearms, Inc. be responsible for incidental or consequential damages with respect to economic loss or injury to property, whether as a result of express or implied warranty, negligence or otherwise. Some states do not allow the exclusion of limitation of incidental or consequential damages, so the above limitation may not apply to you. Bushmaster Firearms, Inc. will not be responsible for the results of careless handling, unauthorized adjustments, defective, low quality, reloaded, or improper ammunition, corrosion, neglect, ordinary wear and tear, or unreasonable use. Furthermore, the liability of Bushmaster Firearms, Inc. under this warranty shall be limited solely to the obligation to repair or replace the firearm, and to pay transportation and insurance charges for return of the firearm to owner. NOTE: Handguns and long guns are classified as FIREARMS or DANGEROUS WEAPONS. Guns are surrendered by Bushmaster Firearms, Inc. with the express understanding Pg. 64 that it assumes no responsibility for resale handling under local laws and regulations.

PLEASE PRACTICE SAFE FIREARMS HANDLING!

WARNING: IF THIS FIREARM IS CARELESSLY OR IMPROPERLY HANDLED, UNINTENTIONAL DISCHARGE COULD RESULT AND COULD CAUSE INJURY, DEATH, OR DAMAGE TO PROPERTY. CAUTION: CAREFULLY READ THIS INSTRUCTION MANUAL PRIOR TO LOADING AND FIRING THIS FIREARM. FOLLOW ALL INSTRUCTIONS ON THE PROPER HANDLING AND SAFE USE OF THIS FIREARM - LIVES MAY DEPEND ON IT! CAUTION: USE ONLY CLEAN, DRY, HIGH QUALITY COMMERCIALLY MANUFACTURED AMMUNITION IN GOOD CONDITION which is appropriate to the 5.56mm NATO / .223 Remington caliber of your firearm. Bushmaster does not recommend the use of remanufactured or hand loaded ammunition because it may damage your rifle. WARNING: THIS WEAPON COULD CHAMBER A ROUND if it is dropped or jarred with a loaded magazine in place - either with the Bolt Carrier Assembly locked to the rear, or in its forward position. A SAFETY NOTE REGARDING LEAD... Discharging firearms in poorly ventilated areas, cleaning firearms, or handling ammunition may result in exposure to lead, a substance known to cause birth defects, reproductive harm, and other serious physical injury. Have adequate ventilation at all times. Wash hands thoroughly after exposure. This Bushmaster Operating and Safety Instruction Manual should always be kept with your Bushmaster Firearm, and in case of sale or transfer, should be passed on to subsequent owners. Model: _______________________________________________________________ Serial Number: ________________________________________________________ Sold To: ______________________________________________________________ 999 Roosevelt Trail Date Sold: _____________________________________________________________Windham, ME 04062 U.S.A.

Part # BFIMANA2OP Revision of 2005

Bushmaster Firearms, Inc. P.O. Box 1479 999 Roosevelt Trail Windham, Maine 04062 U.S.A. Tel.: 207 892 3594 Toll Free: 1 800 998 7928 Customer Service: 1 800 883 6229 Fax: 207 892 8068 Web: http://www.bushmaster.com E-Mail: [email protected]
2005, Bushmaster Firearms, Inc.
Made with Pride in the U.S.A.