SUPERMAX. - Cannondale
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1. gt a 37 mm D DIMENSIONS FOR WHEEL BUILDING SUPERMAX Pa A Disc Flange Diameter 68 0 mm B B Non Disc Flange Diameter 94 0 mm C Disc Flange To Center 25 8mm 18 8 mm D Non Disc Flange To Center 34 6mm 31 6 mm cannondale Setting Sag Sag Is the distance the SUPERMAX compresses when the bike is statically loaded with your body weight in your riding position Set it according to the SUPERMAX travel Sag Is set by changing the air pressure through the Schrader valve at the bottom of the SUPERMAX Set Recommended Initial Air Pressure Set before measuring sag RIDER WT 29ER Lbs Kg PSI Bar 1207 993 64 4 4 130 60 66 4 6 140 65 70 4 8 155 70 74 B 165779 78 5 4 175 80 80 SKS 185 85 83 5 7 200 90 87 6 0 210 95 90 6 2 220 100 93 6 4 230 105 95 6 6 Be aware that conventional pump gages have variations Therefore we recommend you to fine tune your set up with the Recommended Sag Fine Tune to 25 Recommended Sag Adjust the air pressure to set this sag SUPERMAX TRAVEL mm 130 120 100 90 25 SAG mm 22 30 25 ae 20 SAG Minimum 26 24 20 18 30 SAG Maximum 39 36 30 2 SUPERMAX AIR PRESSURE LIMITS Minimum 50 psi 3 4 bar Maximum 225 psi 15 5 bar 129975 PDF To set sag 1 Remove the Schrader valve cap 1 at the bottom of the2. _ gt SUPERMAX OWNER S MANUAL SUPPLEMENT In this supplement particularly important information is presented in the following ways A WARN NG Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates special precautions that must be NOTICE taken to avoid damage TIP A TIP provides helpful information This manual meets EN standards 14764 14766 and 14781 V lo certifi conforme aux exigences du d cret N 95 937 du 24 ao t 1995 norme NFRO30 About This Supplement Cannondale Owner s Manual Supplements provide important model specific safety maintenance and technical information They are not replacements for your Cannondale Bicycle Owner s Manual This supplement may be one of several for your bike Be sure to obtain and read all of them If you need a manual or supplement or have a question about your bike please contact your Cannondale Dealer immediately or call us at one of the telephone numbers listed on the back cover of this manual You can download Adobe Acrobat PDF versions of any Cannondale Owner s Manuals or Supplements from our website www cannondale com bikes tech e This manual is not a comprehensive safety or service manual for your bike e This manual does not include assembly instructions for your bike e All Cannondale bikes must be completely assembled and inspected for proper operation by a Cannondale
3. For use in extreme forms of jumping riding such as hardcore mountain Freeriding Downhill North Shore Dirt Jumping Hucking etc Ay WARNING UNDERSTAND YOUR LEFTY AND ITS INTENDED USE USING YOUR LEFTY THE WRONG WAY IS DANGEROUS Industry usage Conditions 1 5 are generalized and evolving Consult your Cannondale Dealer about how you intend to use your bike fork Please read your Cannondale Bicycle Owner s Manual for more information about Intended Use and Conditions 1 5 YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING RIDING WITH DAMAGE IS DANGEROUS STOP RIDING IMMEDITE IF DAMAGE IS PRESENT The following conditions indicate that serious fork damage is present Any unusual klunking or knocking noises Change in travel Changes in normal functions Loss of adjustments features oil leaks or alr leaks Crash or impact damage deep scratches gouges dents or bending Any small cracks under the bolt head of upper and lower clamp bolts This inspection requires the removal of the bolts Horizontal cracks above and below the intersection of the upper and lower clamps with the outer tube portion of the Lefty Structure Vertical cracks in the outer tube where the races and needle bearings run These may show as long straight lines perhaps several lines parallel to each other Please read Inspect For Safety in PART II Section D
4. 28 Volume Reducer s Loctite 242 blue i 9 Nm 80 InLbs Frame SI Headtube Clamp Steerer e 21 SS ies y 17 Size Length A Spacing B Kit 25 Thread Position FJALE SMALL 97mm 100 2mm KH118 097HT A MEDIUM 109 7mm 112 9mm KH118 109HT A 00 19 7 LARGE 122 4mm 125 6mm KH118 122HT B X LARGE 134 4mm 137 6mm KH118 134HT B Wheel Hub Either a SUPERMAX or LEFTY HYBRID wheel hub may be used with the SUPERMAX The wheel hub must be matched with its correct brake adapter See item 23 on previous page 129975 PDF The hub cap is a left hand thread It retains the axle bolt assembly within the and should only be removed when replacing the bearings or axle bolts parts not when removing the wheel The axle bolt is a right hand normal thread Insert a 5 mm allen key Turn it clockwise to install a wheel Turn it counter clockwise to remove a wheel Identification DO SO Old eS Hub Bearing Seal Inner Hub Bearing LEFTY Hub Shell Outer Hub Bearing Axle Bolt Assy Lefty Hub Wheel Building Tool Shimano TL FW30 Axle Bolt ae Cap Left hand thread 6 QCTL108 Shimano Tool TL FW30 10 Ring Clip SUPERMAX Hub Only KH105 24H KIT HUB LEFTY 24H6 BOLT BLK KH105 28H KIT HUB LEFTY 28H6 BOLT BLK KH105 32H KIT HUB LEFTY 32H6 BOLT BLK Items 1 2 3 and 4 KH119 32_ _KKIT HUB SUPERMAX 32H6 BOLT BLK Items 10 1 2 3 and 4 KB61902 Light Loctite 242 grease blue
5. Dealer before delivery to the owner AX WARNING This supplement may include procedures beyond the scope of general mechanical aptitude Special tools skills and knowledge may be required Improper mechanical work increases the risk of an accident Any bicycle accident has risk of serious Injury paralysis or death To minimize risk we strongly recommend that owners always have mechanical work done by an authorized Cannondale retailer 129975 PDF Table of Contents SAFETY INFORMATION scssscsesesseees 2 Intended USe eee 2 Damage Inspection ccceeeeeees 2 Disassembly Modification 3 Tire to Crown Clearance 3 TECHNICAL INFORMATION 00000008 4 SUPERMAX Structure 4 Wheel Hub naseer 5 Yo AAR gt oA en er aaa 6 7 Pi LOCK OUL raea cancun 8 PBR COOLING 2dyiignormnaetanatdcnetasaGoraatts 8 Wheel Removal 9 Wheel Installation wo eee 10 MAINTENANCE cccceeccecceeesesseeseeees 11 DC CCC aeaea 11 SE aE A E E E 12 Tightening Torques n 12 Frame BUMPET soeesenoereenorreerrrrreerrne 13 Moto Guai em 13 Manual Reset 14 CANNONDALE LIMITED WARRANTY 15 REPLACEMENT PARTS csccsesseeeeees 16 01 13 cannondale SAFETY INFORMATION Intended Use Damage Inspection AX WARNING SUPERMAX INTENDED USE TRAVEL All Mountain 130 mm Overmountain ASTM CONDITION 4 SUPERMAX ARE NOT INTENDED
6. SUPERMAX Attach a bicycle suspension pump to the Schrader valve 2 See Figure 1 2 Set the recommended intial starting air pressure according to your weight 3 Slide the sag O ring 3 against the wiper seal 4 See Figure 2 3 Sit on bike in riding position and dismount Note Your riding position affects weight distribution and therefore sag For example in the Attack position Figure 3 the rider s weight is distributed equally front and rear 4 Measure the sag distance See Figure 4 Sag Trouble Shooting Too much sag add air in small increments ba Attack Too little sag reduce air in small increments Excessive increasing air pressure bottom out harsh ride or reduce air pressure limited travel NOTICE A dirty pump or valve end can result in contamination damage and air loss Make sure pump and valve are clean before attachment cannondale PBR Lockout OPEN POSITION LOCKED POSITION In the open position LEFTY travel is active In the locked position LEFTY travel is The red rebound dial 1 is in the down locked The red rebound dial is up To go position To go to the locked position press back to the open position press the red the blue button 2 redound dial down until it clicks PBR Rebound Dial Rotate dial in the direction counter clockwise to increas
7. for damage Pre Post ride Bike owner Check for Tightening Torques First Ride Every 4 5 rides Bike owner Replace Frame Bumper Guard As Needed Bike owner Manual Reset 50 hours Bike owner Telescope Lubrification 100 hours Dealer Damper Service 100 hour or every year Dealer Air spring Damping Cartridge Inspection Full Service Telescope Rebuild Damper 200 hours Headshok Service Center service RACING If you race with your SUPERMAX you will have to perform the items listed twice as often i e 50hrs becomes 25hrs SCHEDULE PROFESSIONAL FORK SERVICE ANNUALLY Minimum Annually or when problems are indicated you must have your SUPERMAX serviced through a Cannondale Dealer or an Authorized Headshok Service Center Disassembly and inspection by a suspension professional is required to evaluate the internal and external parts identify wear or damage Damaged parts must be replaced with new ones and the work must also include any work described in any technical bulletins or product recalls Ay WARNING FREQUENT MAINTENANCE AND INSPECTION IS IMPORTANT TO YOUR SAFETY YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED RIDING ON A BROKEN OR POORLY MAINTAINED FORK Ask your Cannondale Dealer to help you develop a complete maintenance program one that suits where and how you ride 11 cannondale Cleaning Clean using only a mild soap and water solution Clean water and common liquid dish washing so
8. D WARRANTY Cannondale Headshok SUPERMAX LEFTY Fatty Solo suspension products are covered under the terms and conditions of the Cannondale Limited Warranty It is available on the Policies page of our website at www cannondale com Be sure to read the exclusions listed in the limited warranty For example damage from accidents and improper maintenance are not covered Definitions related to forks The fork structure is covered in the FRAMES section of the Cannondale Limited Warranty Fork structure means certain structural parts of the fork specifically the fork legs outer tube the steerer tube steerer tube clamps and the inner tubes with attached dropouts or spindle Cable clamps needle bearings races and bushings which are part of the telescopic assembly are normal wear and tear items and ARE NOT covered by the limited lifetime warranty The internal fork internal parts are covered by the 1 year 2 years in EU countries warranty against defects in materials or workmanship described in the COMPONENTS section of the Cannondale Limited Warranty Internal fork parts are defined as items such as damping cartridges and their internal parts seals o rings air cylinders air pistons springs elastomers bumpers bushings needle bearings races and oil Normal wear and tear on these items is NOT covered by this 1 year 2 in EU warranty Like brake pads on a car you should expect to have these items professionally replaced
9. EFERENCE CANNONDALE USA CANNONDALE EUROPE CANNONDALE UK Cycling Sports Group Inc Cycling Sports Group Europe B V Cycling Sports Group 172 Friendship Road mail Postbus 5100 Vantage Way The Fulcrum Bedford Pennsylvania 15522 6600 USA visits Hanzepoort 27 Poole Dorset BH12 4NU Voice 1 800 BIKE USA 7570 GC Oldenzaal Netherlands Voice 44 0 1202 732288 Fax 814 623 6173 Voice 41 61 4879380 Fax 44 0 1202 723366 custserv cyclingsportsgroup com Fax 31 5415 14240 sales cyclingsportsgroup co uk servicedeskeurope cyclingsportsgroup com CANNONDALE AUSTRALIA CANNONDALE JAPAN WWW CANNONDALE COM Cycling Sports Group Namba Sumiso Building 9F 2013 Cycling Sports Group Unit 8 31 41 Bridge Road 4 19 Minami Horie 1 chome 129975 01 13 Stanmore NSW 2048 Nishi ku Osaka 550 0015 Japan Phone 61 0 2 8595 4444 Voice 06 6110 9390 Fax 61 0 8595 4499 Fax 06 6110 9361 askus cyclingsportsgroup com au cjcustserv cannondale com S SE CYC ve A D Qh L
10. ap will work best Be sure to cover the adjusters with a clean plastic bag secured with a rubber band or masking tape Spray off heavy dirt before wiping Spray indirectly NOTICE e DO NOT USE A PRESSURE WASHER Use a low pressure garden hose Power washing will force contaminants into the fork promoting corrosion immediately damaging or result in accelerated wear e DON T DRY WITH COMPRESSED AIR FOR THE SAME REASON Tightening Torques Correct tightening torque for the fasteners bolts screws nuts on your bicycle is very important to your safety the durability and performance of your bicycle We urge you to have your Dealer correctly torque all fasteners using a torque wrench If you decide to tighten fasteners yourself always use a good torque wrench Description Loctite Upper Lower Clamp Bolts 7 9 62 80 242 blue Guard Screws 1 0 9 242 blue Wheel Axle Bolt to 133 Brake Adapter Mouting Bolts 9 80 242 blue 12 129975 PDF Frame Bumper The bumper cushions the frame from contact with the SUPERMAX Replace it with a new one if it ever becomes damaged torn or missing REPLACEMENT Clean surfaces well Remove the backing from the new bumper position and affix by pressing firmly against the outer tube IMPORTANT Be sure to position the bumper so that when the handlebar is rotated to the left the bumper prevents fork contact with the the frame Frame damage can result from using t
11. e rebound speed faster Rotate dial in the direction clockwise to decrease rebound speed slower 129975 PDF Wheel Removal 1 If needed loosen the brake line clamp on the front of the moto guard so the line can move freely This will make handling the brake caliper and attached adapter easier 2 See Figure 1 Use a 5 mm Allen key to loosen and back out both brake adapter mounting bolts enough so that the adapter and attached caliper can slide up and be removed from the spindle together It is not necessary to completely remove the adapter bolts Carefully move the brake caliper out of the way and protect it from damage 2 See Figure 3 Insert a 5 mm Allen key into the axle hub bolt and turn it counter clockwise Continue turning the extraction bolt until the wheel is disenaged and can be removed easily from the spindle end See Figure 4 NOTICE m Make sure the axle bolt is completely disengaged before attempting to remove the wheel Never try to pull the wheel off forcefully When the wheel is off to keep dirt out cover the hub opening Protect spindle from damage when wheel is removed cannondale Wheel Installation 1 Wipe the spindle clean with a dry shop towel Apply a high quality bike grease to D of the bearings inside the hub AX WARNING DO NOT CONTAMINATE BRAKE CALIPER PADS OR ROTOR WITH GREASE 2 Slide the wheel straight onto the spindle Turn the axle b
12. he wrong bumper or positioning a bumper incorrectly Ask your Cannondale Dealer for help HD215 Moto Guard The moto guard protects the inner tube Surface from damage It also supports the brake line Check it periodically Make sure it is in good condition and attached properly NOTICE Replace guard with a new one if it becomes damaged It is a normal wear item l Guard 2 Mounting points 3 Mounting screws Loctite 242 1 0Nm 9 0 InLbs 13 cannondale Manual Reset NOTICE Do not disaasemble or open for the following procedure Perform every 50 hours 1 With your bike on the floor 2 Cover the brake rotor with a clean shop towel Remove the Schrader valve cap and hold the valve to release all air pressure It is normal for a small amount of oil to be expelled with the escaping air AX WARNING Contamination can result in reduced or lost braking performance 3 Hold the valve open while fully compressing the SUPERMAX with the the handlebar until it bottoms out With the air out using moderate force bottom out the SUPERMAX firmly several times 4 Now measure length of exposed inner tube as shown Repeat step three until the correct measurement for your SUPERMAX Is reached 5 When you are finished reset sag 14 Lo 4 35 3mm Ir JE The Measure Fully Compressed 129975 PDF CANNONDALE LIMITE
13. of your Cannondale Bicycle Owner s Manual If your SUPERMAX is damaged do not ride it Contact your Cannondale Dealer to arrange service through an authorized service center YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING Disassembly or Modification 129975 PDF Tire to Crown Clearance AX WARNING AX WARNING DO NOT DISASSEMBLE OR MODIFY YOUR LEFTY IN ANY WAY Improper service or modification can lead to serious fork damage or serious personal injury Do not disaassemble the fork Do not attempt modification in any way Do not drill file cut or remove material from any part Do not attempt to repair damage Do not weld clamp or bond anything to the fork Do not attempt to remove the damping cartridge or other internal fork parts The MAINTENANCE section of this supplement includes information about regular owner maintenance practices that can keep your fork in good operating condition All other service and maintenance procedures must be completed through an Authorized Headshok Service Center Contact your Authorized Cannondale Dealer for more information YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING Modification or installation of damping cartridge spacers other than specified or installing over sized tires can result in incorrect tire to crown clearance If tire clea
14. olt clockwise to engage the spindle threads Make sure the wheel and Spindle are supported while tightening the hub bolt 3 Once the hub has been drawn onto the hub completely use torque wrench to tighten to final 15 0 Nm 133 0 InLbs See Figure 1 4 Reinstall the brake adapter onto the spindle bosses making sure that the brake disc locates properly between the pads NOTICE m LOCATE BRAKE ROTOR BETWEEN THE PADS Apply Loctite 242 blue to the threads and tighten the adapter mounting bolts to 9 Nm A WARNING 78 IN Lbs See Figure 2 DO NOT RIDE WITHOUT A PROPERLY MOUNTED ADJUSTED AND FUNCTIONING FRONT BRAKE SYSTEM 5 Spin the wheel to make sure it moves freely Be sure to test the brakes for proper operation The disc caliper acts as an integral secondary before riding wheel retention system If the system is missing or improperly installed or if the wheel hub axle bolt should loosen the front wheel could slide off the spindle end Follow brake manufacturer s instructions when mounting the brake caliper to the spindle brake bosses Do not modify the fork in any way PLEASE ASK YOUR CANNONDALE DEALER FOR HELP WHEN INSTALLING COMPATIBLE FRONT BRAKE SYSTEMS 10 129975 PDF MAINTENANCE Schedule This schedule is intended as a guide only You must establish a schedule appropriate to your riding style and conditions SERVICE ITEM FREQUENCY NORMAL WHO RIDING Check
15. or renewed as you use the fork and they wear Fork Warranty Claims For any warranty claim to be considered the bicycle fork must be brought into an Authorized Cannondale Retailer on the continent on which the bicycle fork was purchased The bicycle fork must be in assembled condition and accompanied by the original dated sales receipt for the bicycle fork Dealer Locator at www cannondale com Dealerlocator 15 cannondale REPLACEMENT PARTS The following replacement part kits are available through a Cannondale Dealer CJ J KH074 HD215 iu PPRA Knobs Only LEFTYBOLT Damping Cartridge KH113 color purple Solo Air Assembly is sold separately LEFTYBOLT TERREN t lt 119 Upper Air Seal 63 mm l lt HD011 43mm Damper w clamp thread positions z are A N frame size specific Steerer is for 1 5 stems only and is frame gt size specific 5 a X CA KH118 __ _HT 180mm ADAPTER SUPERMAX HUB 180mm ADAPTER KH111 LEFTY HYBRID HUB KF272 KH112 Volume c amp OW y Use only Use the 10mm 42mm volume volume reducer reducer KH116 SMALL for only Air Piston Only a MEDIUM LARGE KH114 sizes X LARGE S frame sizes 16 cannondale WARNING READ THIS SUPPLEMENT AND YOUR CANNONDALE BICYCLE OWNER S MANUAL BOTH CONTAIN IMPORTANT SAFETY INFORMATION KEEP BOTH FOR FUTURE R
16. rance is less than minimum specified the rotating tire could come into contact with the frame causing the wheel to stop suddenly This can throw a rider off the bicycle or result in a loss of control and crash CHECK FOR MINIMUM TIRE FORK FRAME CLEARANCE 10 mm WITH ALL AIR RELEASED FROM LEFTY AND FULLY COMPRESSED Measure between the top of the properly inflated tire 1 and the bottom of the fork steerer 2 YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING cannondale TECHNICAL INFORMATION Supermax Structure Identification 1 PBR Lockout Button t 2 PBR Rebound Dial i 3 XLR Rebound Dial A B Loctite 242 blue 7 9 Nm 62 80 InLbs 4 XLR PBR Carbon Outer Collar 7 Ds Bonded Upper Clamp 6 Clamp Bolt XG Sw 10 7 Serial Number Location Tee e 8 Frame Bumper Lo ON 9 Carbon Outer Tube carbon fiber XN 10 Brake Housing Guide 11 Bonded Lower Clamp 12 Guard 13 Guard Brake Housing Clamp 14 Lower Collar Assy 15 Sag O Ring 16 OPI Inner Tube 17 Guard Mounting Screws 18 Hub Spindle 19 Inner Bearing Land 20 Outer Bearing Land 21 Axle Bolt Threads 22 Schrader Valve 93 23 Brake Adapter ee 24 System Integration Headtube ia oo 25 Steerer 1 5 Stems Only 26 Damping Cartridge shown removed 27 SOLO Air Assembly
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