120024 07 Lefty MAX 140 OMS rev1.indd - Eighty-Aid
Contents
1. 34 120024 PDF HD185 BLK Kit Zip Ties Double Head 10 HD011 Kit Band Clamps 2 Boot Lefty HD215 Kit Frame Bumper Lefty Moto 0 679 Kit Clamp Upper MAX Silver 0 680 Kit Clamp Lower MAX Silver HD016 Kit STEERER CARBON LEFTY 040 KIT STEERER X LONG LEFTY will only work with carbon and bonded alloy Leftys HD210 Kit Steerer Tube Plug Lefty OSMSEAL Kit Seal HShok Upper Bearing OHDST EBO Kit Headset 2 cups 1 bearing HD169 Kit Bearings Headset 2 HeadShok KT020 TOOL LEFTY STEERER INSTALL HD226 Kit Oil Golden Spectro 1 Bottle KF364 KIT COMPUTER MOUNT LEFTY HD161 Kit Needle Bearings Set of 4 for all in headtube Headshok forks HDR2M 020 Kit Race Inner 11 378 289 0mmx 020 51mm 4 HDR2M 021 Kit Race Inner 11 378 289 0mmx 021 53mm 4 HDR2M 022 Kit Race Inner 11 378 289 0mmx 022 56mm 4 HDR2M 023 Kit Race Inner 11 378 289 0mmx 023 58mm 4 HDR2M 024 Kit Race Inner 11 378 289 0mmx 024 61mm 4 For an up to date list of kits available for your bike please visit our Tech Center at http www cannondale com tech 35 cannondale OWNER NOTES Record maintenance history service or set up information WORK PERFORMED 362. 3 Loosen the three fork clamp bolts See Figure C 4 Slide the fork down out of the clamp As the fork is removed the bumper will Slide off Be sure to reinstall it when the fork is repositioned in the clamps Figure E Lefty Alloy Fork Removal Reverse the step for installation Be sure to not key and slot in clamp and outer tube 18 Removing Carbon Forks For carbon lefty forks the clamps are integrated with the fork clamps The upper and lower clamps are permanently bonded to the outer tube and must not be removed Carbon Lefty forks are removed from the bicycle by sliding the steerer tube out of the fork clamps 1 v Remove the brake caliper and detach the brake line Handlebar stem from the head tube steerer Loosen the upper and lower clamp bolts See Figure D Hold the fork and use a rubber mallet to remove the steerer from the head tube and fork clamps Remove it from the bottom of the head tube SPRING CHANGE About the Lefty 140 Main Spring 1 120024 PDF Lefty 140 MAX main springs come in several different sizes matched to typical rider weight The main spring in a Lefty 140 MAX can be changed without changing any other internal parts For available spring sizes and weight range see the replacement parts section of 6 Hold the wrench flats on the lower this manual rebound shaft wrench flats with ag mm open end wrench You should apply a generous coating of grease to
3. We assemble forks at our factory using Royal Purple Ultra Performance Grease NLGI 2 ISO 46 BASE 1 Removethe front wheel 2 Release all fork air pressure 3 Carefully cut the upper and lower zip ties securing the fork boot Some forks may have an screw type band clamp securing the upper portion of the boot If this is the case loosen the clamp Lift the unsecured boot up to expose the inner tube 1 5 Wipe away any old grease with a clean lint free shop towel Cycle the fork and repeat CAUTION Do not use solvents or spray chemicals to clean Protect the exposed fork from contaminants Work in a clean area 120024 PDF the fork and carefully re apply grease Cycling moves the new grease inside the fork onto the outer tube races and bearing cages Its OK to leave a good coating under the boot Avoid applying grease to the area A just under the boot zip tie Also do not contaminate the brake disc with grease 6 Visually inspect the inner tube 1 and inner races 2 a for any signs of corrosion or damage Some very light wear to the inner races is normal however they are worn out if any scratches or grooves are evident If heavy corrosion is present they must be replaced If ridges can be felt by the tip of a rolling ball point pen over the race the races should be replaced If damage is found the damaged parts must be replaced new before the fork is ridden Wipe it off the inner tube and i
4. element Ensure zip ties and band clamps are properly tightened replace as needed ZIP TIE IF THE FORK BECOMES SUBMERGED PERFORM THE CHECKS IMMEDIATELY 28 120024 PDF Air Filter The air filter assembly is located over two Use air filter holes in the outer tube Air passes in and oil foam out of the ports as the fork moves The air filter assembly stops the passage of dirt and water which would damage the internal fork components The small holes a at the base of the air filter cover should remain open The foam filter element 1 should be cleaned and re oiled frequently The small holes at the base of the filter cover should be positioned to the sides of the and not to the front or back of the bicycle to minimize the chance dirt thrown by the wheels will plug the holes Clean the foam air filter element with warm soapy water allow to dry completely and reapply a high quality foam air filter oil before reinstallation Be sure to massage the oil into the foam A foam element without the oil is ineffective Frame Bumper The frame bumper 1 located on the outer tube 2 between the clamp cushions the frame from contact with the fork Replace it with a new one if it ever becomes damaged torn or missing 29 cannondale Fork Boot The fork boot protects the internal parts inner tube races lubricant needle bearings and other internal parts from contamination and damage It is a barrier
5. 36 Please note that the specifications and information in this manual are subject to change for product improvement For the latest product information go to http www cannondale com tech cannondale 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 http www cannondale com bikes tech This manual is not a comprehensive safety or service manual for your bike This manual does not include assembly instructions for your bike All Cannondale bikes must be completely assembled and inspected for proper operation by a Cannondale Dealer before delivery to the owner This document 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
6. caliper bolts USE ONLY 16 MM Cannondale kit LEFTYBOLTS Longer bolts can result in contact with the brake rotor causing severe damage Check clearance between the bolt tips and rotor after remounting the caliper 5 Spin the wheel to make sure it spins freely Be sure to test the brakes for proper operation before riding cannondale WHEEL HUB 18011120 sede aseai3 Ayijenb ysiy Addy 591 O GG U N 2 9 COC 91150 LLLOLL 9070 08 69 Wen 6 8 34 2 Sq7 Ul WeN peje1sur A piedoud 5 pue yoq qnu epu LON OQ xy suononijsul 5 pue zx AN3aNWaladns WANVA S H3NMO AL331 YNOA ANY AYAH 5 5 GIOAV d 13H OL CVC 911507 1 14 1 001 Sunaj 504 251 exeg 251 9 295 qnu Jauu qnH duueaq qnu 1910 108 JOUSEM 2nse d de uonoenx sb A N CO 120024 PDF FRONT BRAKE DO NOT RIDE WITHOUT A PROPERLY MOUNTED ADJUSTED AND FUNCTIONING FRONT BRAKE SYSTEM Why In addition to providing speed control the front brake system on your Lefty disc caliper acts as an integral secondary wheel retention sys
7. death in a crash Ride at reduced speeds Learn the performance characteristics of your bike and suspension components before trying any downhill or very fast biking Ride within your skills and abilities a bicycle training course Cannondale Note brake alignment shims between FRONT WHEEL Lefty brake bosses and the caliper 4 Turn hub bolt 1 counter clockwise to REMOVAL remove the hub from the spindle 1 Place bike in a work stand with front NOTE As the bolt is turned counter wheel off the ground clockwise it will begin to back against the hub cap bolt 2 causing the hub 3 to be drawn out and off the spindle bearing seats Since the hub bolt is actually retained inside the hub body by the hub cap the bolt will remain in the hub when the wheel is removed There is no need to remove that cap from the hub See the exploded view on page 8 CAUTION 2 Loosen the brake caliper mounting bolts Make sure the axle bolt is completely loose before attempting to remove the wheel from the spindle 3 Tilt the lower caliper bolt out of the boss so the caliper is up out of the way of the disc Snug up on the upper bolt to hold caliper in place 5 Carefully slide the wheel off of the spindle carefully CAUTION 1 Cover the opening of a removed hub wheel with a clean towel to prevent contamination Protect spindle when wheel removed A fall or drop to the ground can
8. destroy or damage the spindle INSTALLATION 1 Inspect the inside of the wheel hub for contamination and and the condition of the hub seal Take corrective action if necessary Wipe all parts clean with a dry shop towel and apply a high quality bike grease to I D of the larger hub cartridge bearing Both spindle bearing lands Spindle axle bolt threads Do not contaminate brake caliper pads or rotor with grease 2 Slide the wheel straight onto the 120024 PDF spindle so the larger hub bearing starts to position on it spindle seat At this point the axle bolt threads can correctly engage the threaded spindle if the wheel is held on straight NOTE Install the front wheel by positioning the bike horizontally with the spindle facing up Then place the hub straight down onto the spindle and tighten the axle bolt 3 When the axle bolt threads engage the spindle turn the bolt clockwise with finger force slowly to allow the hub bearings to slide onto the spindle bearing seats Once the hub has been drawn onto the hub completely and proper threading is evident use torque wrench to tighten to final 15 0 Nem 133 0 IneLbs 4 Reinstall the brake caliper Tighten bolts to 78 0 IneLbf 9 0 Nem CAUTION LOCATE DISC BETWEEN THE PADS Replace shims that are in use be sure the shims are positioned between the caliper adapter if any and inner face of the fork mounts not under the head of the
9. models that are more or less heavy duty Talk to your retailer about your needs and these models NOT INTENDED for Hardcore Freeriding Extreme Downhill Dirt Jumping Slopestyle or very aggressive or extreme riding TRADE OFF All Mountain bikes are more rugged than cross country bikes for riding more difficult terrain All Mountain bikes are heavier and harder to ride uphill than cross country bikes All Mountain bikes are lighter more nimble and easier to ride uphill than Freeride bikes All Mountain bikes are not as rugged as Freeride bikes and must not be used for more extreme riding and terrain USING YOUR LEFTY IMPROPERLY IS HAZARDOUS WARNING LABEL Located on the lower leg of the Lefty Do not remove it If it is missing or damaged you can obtain a free replacement from Cannondale See page 6 120024 PDF BIKE SUSPENSION AND YOUR SKILLS AND ABILITIES YOU COULD HAVE A BAD ACCIDENT IF YOUR SKILL IS NOT UP TO HANDLING A SUSPENSION SYSTEM Suspension systems front fork rear shocks can increase the handling and stability of most bicycles If you lack the skills and experience necessary to ride at higher speeds and maneuver over difficult terrain at the greatly increased performance level you can ride faster than your abilities You can lose control of the bike in these conditions and crash Anytime you lose control of the bike especially at high speed and in advanced terrain you risk severe injury or
10. the Lefty spring before you install it Loosen the Shaft with a19 mm open end wrench Turn counter clockwise The shrink wrap material on the Lefty 140 spring installs with the shrink wrap up This material is used to reduce noise caused by spring contact with the outer tube Turn the Rebound Knob clockwise in completely until it stops Remove the Outer Cap assembly Please read Adjusting Spring Preload in this manual for steps to remove and install the Outer Cap Assembly Remove the two Split Rings Loosen the Lock Ring and Adjust Ring to release the main spring preload Turn the Rebound Knob assembly counter clockwise to remove it Hold down knob while turning the knob assembly will pop out since it rests the pushrod which sits atop a spring BE SURE TO CAPTURE DETENT BALLS AND SPRING 19 cannondale 7 Unscrew the Shaft and lift off bottom out bumper a black rubber like material on the rebound shaft 11 Clean the thread of the rebound tuning assembly and reapply a small drop of Loctite 242 8 Lift out the Rebound tuning pushrod 12 Generously coat the entire spring with a high quality spring grease Then install a new spring with the shrink wrap on the spring facing up 9 Lift out the spring 10 Inspect the bottom out spacer a hard white plastic material and 20 OIL CHANGE 1 Apply grease to the top Clean the Outer Tube threads grease 120024 PDF Reinstal
11. to water dirt dust mud or grit encountered while riding If the boot is loose or damaged dirt water dust salt spray or other contaminants will quickly ruin the fork Checks 1 Check the boot for damage cracking splits or tears Be sure to check in the folds of the boot Check for any cables or lines rubbing the boot 2 Checkthe attachment of the boot at the top and bottom The upper and lower boot lips should be fitted over the lower collar and fork lip NO PART OF THE FORK INNER TUBE lower leg SHOULD BE EXPOSED 3 Replacethe zip ties and band clamps 30 Always tighten the zip ties and clamps securely Replacement boots zip ties and cable clamps are available through a Cannondale Dealer If you find boot damage the area under the boot should be professionally inspected for contamination or damage The damaged boot must be replaced with a new one Do not try to fix it CHECK THE BOOT BEFORE EACH RIDE DON T RIDE IF IT IS DAMAGED REPLACE IT WHEN YOU FIND DAMAGE Cleaning and Re greasing The Telescope Under the Boot The fork inner tube and inner bearing races parts of the telescopic fork assembly are located behind the fork boot Wiping off old grease with a dry shop towel and re apply a fresh heavy coating of grease helps assure that races and needle bearings remain well lubricated Any clean high quality bicycle bearing grease selected for riding temperatures and environment can be used
12. 2 MD BLUE 60 41 8 RED 8 70 7 LG RED 60 41 8 BLACK 8 180 81 LG RED 60 41 8 BLACK 8 190 86 XL BLACK 60 41 8 BLACK 8 200 90 XL BLACK 70 4 8 7 BROWN 7 210 95 XL BLACK 70 41 7 BROWN 7 220 100 XL BLACK 80 5 5 6 BROWN 6 FORK SPRING KITS RIDER WT RANGE ORDER SPRING Lbs Kg CANNONDALE KIT COIL COLOR MATERIAL Wt g KF213 GRN Steel 15 120 149 54 67 GREEN D KF214 GRN Titanium 14 KF213 BLU Steel 174 LEFTYMAX140 150 169 68 76 BLUE SPV KF214 BLU Titanium 108 Carbon or Alloy KF213 RED STEEL 197 170 189 77 85 RED KF214 RED Titanium 151 190 220 86 100 KF213 BLK BLACK STEEL 253 120 149 54 67 KF213 BLU BLUE STEEL 174 LEFTY MAX140 150 169 68 76 KF213 RED RED STEEL 197 TPC or FFD Carbon or Alloy 170 199 77 90 KF213 BLK BLACK STEEL 253 pue 91 100 KF213 BRN BROWN STEEL 262 120024 PDF REBOUND DAMPING CAUTION ADJUSTMENT Use only finger force Do not force Rebound damping controls how fast the adjuster past the stop points Lefty extends following compression The rebound adjustment knob is red in color and 1 turns total 14 clicks located at the top of the fork Each position in the rotation of the adjustment knob can be considered a click although no audible sound is made The knob is stopped at each position by the detent balls and spring in the rebound knob assembly From the fully closed to fully open position the knob can be turned Be sure to consult Lefty Upper Rebound Assem
13. READ THIS MANUAL CAREFULLY It contains important safety information Keep it for future reference LEFTY MAX 140 Owner s Manual Supplement 120024 PDF CONTENTS SAFETY INFORMATION SPV Air 10 About This Supplement 2 TPC Compression Damping 11 Safety 2 How to Set Up 5 Intended 3 Adjusting Spring Preload 12 Warning Eala 3 Fork Clamps S E 17 Intended 3 Spring 19 Bicycle Suspension 3 Oil Change 21 2 1 4 44 4 4 eene 26 WHEEL 6 5 26 FRONT 1 Cleaning 27 Ait 29 5 lt 5 5555 8 Frame 29 Suggested Fork Set Up 2 Fork Boot 30 Fork Spring 2 Needle Bearing Migration Pes 32 Rebound Damping 3 REPLACEMENT 5 34 SPV Air 10 OWNER NOTES
14. bly Exploded View in this manual K SN Slower Rebound PIOS ape Sluggish feel Turn in direction OPEN Less Damping Turn in direction Faster Rebound Springier feel cannondale SPV AIR VOLUME SPV AIR PRESSURE Stable Platform Valve SPV air volume Stable Platform Valve SPV air pressure is is changed by turning the red 16 mm regulated through the Schrader valve This hex clockwise or counter clockwise This adjustment control pedaling platform of adjustment changes the volume of the the fork Pedaling platform is the fork s internal compression bladder tendency to resist compression under the force of pedaling 1 Remove the black cap 1 and attach a bicycle suspension pump to the Schrader valve 2 Set air pressure within the limits Replace the valve cap when finished Increases bottoming resistance Progressive Turn clockwise in when viewed from bottom Turn counter clockwise Decreases bottoming out de Higher pressure Stiffer pedaling platform hen viewed from bott Li ene Less pressure Softer pedaling platform CAUTION SPV Air Pressure Limits Do not force the red hex nut past the MINIMUM 30 psi 2 0 bar stop points MAXIMUM 100 psi 6 8 bar Optional Tool Available AUTION SPV 16 mm volume adjust socket Answer CAUTIO Products part 85 3007 is needed Clean the valv
15. ce programs available for your model fork 26 120024 PDF FORK PROBLEMS The following are conditions that can indicate a serious fork problem If you find one don t ride the fork Have the fork inspected by your Cannondale Dealer and problems corrected first 1 Any unusual klunking or knocking noises 2 Achange in fork travel 3 An over extended or compressed boot 4 Changes in the way the fork has been working 5 Loss of adjustments features air or oil loss 6 Crash or impact damage deep scratches gouges dents or bending DO NOT RIDE ON A DAMAGED FORK Stop riding a damaged fork immediately YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED RIDING ON A BROKEN OR POORLY MAINTAINED FORK Please ask your Cannondale Dealer to help you develop a complete maintenance program Frequent checks are necessary to identify the problems that can lead to an accident Cleaning USE ONLY A MILD SOAP AND WATER SOLUTION Clean water and a common dish washing liquid will work best COVER SENSITIVE AREAS WITH A CLEAN PLASTIC BAG Secured temporarily with a rubber band or masking tape a bag can prevent water damage to various bike components bearings seals fork shock adjustment features SPRAY OFF BEFORE WIPING To preserve the appearance of paint finish and decals use a low pressure water hose to first spray off heavy soils and dirt CAUTION DO NOT POWER WASH OR SPRAY WATER UNDER HIGH PRESSURE TO CLEAN Power
16. d that the needle bearing reset procedure should be performed by a professional mechanic ALIGNED MIGRATED Bearing Migration If a cage or cages shifts out of alignment up or down in relation to the others it is said to have migrated This migrated condition will limit travel Needle bearing migration is normal and expected However if the fork is ridden in this state for extended periods the fork can be damaged 32 Resetting Migrated Needle Bearings 1 120024 PDF Place the bike in a work stand Release all the air pressure through the Schrader valve Remove the rebound knob and lockout lever Remove the outer cap with the Shimano bottom bracket tool TL FC32 Compress the telescope and remove the two split rings from the top cap Fully extend the fork and measure from top edge of outer tube to bottom edge of spindle See right If the length is out of specification do the following 720 730 Firmly extend the telescope until it stops tip listen for the knocking at full extension to change from a hollow sound to a solid sound this indicates full extension has been achieved Do this several times using only moderate force extend the lower fork leg using a pumping action After you have performed this action several times re measure CAUTION If fork is out range following reset attempt it may be damaged internally The fork should be disassembled and in
17. e and pump end before attaching a pump Pumping in dirt can quickly ruin the fork Stay within the pressure limits 10 TPC COMPRESSION The TPC compression damping adjustment knob 1 is located at the bottom of the spindle The knob is blue in appearance 2 Compression adjustment controls the rate or speed of fork compression Turn in direction More Damping clockwise when viewed from bottom Stiffer Turn in direction counter clockwise Less Damping when viewed from Softer bottom CAUTION Do not force the knob past the stop points The adjustment range is 130 130 11 120024 PDF HOW TO SET UP SAG DAMPING 1 Match FORK SPRING color to rider weight See Suggested Fork Set Up on page 8 With the help of a second person seat the rider on the saddle with feet on pedals and hands on the handlebar Measure X Calculate Sag 686mm X Sag mm XC 25 3076 35 45mm TR 30 35 40 50mm Fine tune sag by changing the spring preload adjusters inside the fork cannondale ADJUSTING SPRING CAUTION PRELOAD The outer cap 1 is aluminum the tool 1 Place bike in work stand with front 2 is steel Be sure to locate all the wheel off the ground points of tool on all the cap notches squarely before attempting to turn the cap Apply force carefully This will help avoid marring the cap W
18. he valve The bladder shape should be cylindrical prior to insertion Make sure the bladder is affixed properly FULLY EXPANDED and the cap O ring in good condition Inserting the TPC Damper 9 When the cap threads are engaged remove the air bleed screw of the TPC and FFD dampers There is no air bleed screw on an SPV damper 10 Thread the cap in carefully using finger force If sufficient oil volume is present oil should start to be expelled through the air bleed hole 11 Tighten the cap to 10 0 Nem 89 0 IneLbs Expanding the SPV Bladder 24 120024 PDF 12 If you have an SPV compression damper attach an air pump and pressurize the SPV bladder MINIMUM 30 psi MAXIMUM 100 psi Be sure to replace the valve cap If you have a TPC compression damper reinstall the air bleed screw and tighten to 2 3 Nem 20 0 IneLbs Reinstall the adjustment knob with O ring and tighten the set screw to 1 0 Nem 9 0 IneLbs If you have a FFD compression damper reinstall the air bleed screw and tighten to 2 3 Nem 20 0 IneLbs SPV Compression Damper Assembly Exploded View 10 mm Allen Key Loctite 262 red 1 Bladder 4 Schrader Valve 7 Volume Adjust Nut 2 O Ring 5 Volume Adjust Housing 8 Schrader Cap 3 Schrader Housing 6 O Ring 25 cannondale MAINTENANCE SCHEDULE Fork maintenance is important to your safety and longtime performance of the fork The following table is intended as a guide to estab
19. hen loose unscrew cap by hand CAUTION Clean area around the top of the fork so dirt does not enter when the fork is opened in the following steps 4 Make sure the wheel is off the ground 2 Close the rebound knob turn clockwise and the lower leg is extended Unscrew until it stops Count the clicks to return the setting later NOTE If needed hold the Rebound Knob with your fingertips to keep it from rotating 3 Turn the Outer 1 counter clockwise with the Outer Cap as it is removed A to loosen it Use Shimano tool TL FC32 2 Hollowtech bottom bracket NOTE Be sure to note location and condition wrench of 2 O rings Be sure to recover it Check both O ring in the Adapter for damage and replace new if necessary See Lefty Outer Cap Assembly Exploded View 12 120024 PDF 1 Outer Cap 3 O Ring large 2 O Ring small 4 Adapter NOTE Do not remove the rebound knob assembly from the shaft top Its not required in this procedure Just make sure it is screwed 5 Compress the fork to cause the rebound in clockwise fully assembly to rise up out of the outer fork tube 7 Turn the Lock Ring 1 counter clockwise A to loosen it 8 Turn the Adjust Ring 2 counter clockwise A to decrease preload increase sage Turn the Adjust Ring 2 clockwise to increase preload decrease sag 6 Remove the two Split Rings 1 in the groove a of the Shaft 2 Note
20. l the Shaft and tighten it damper continue to the next step securely DO NOT OVER TIGHTEN 3 Remove the air bleed screw There is Reinsert the Rebound Tuning Pushrod no air bleed screw on an SPV damper Make sure it drops into the assembly fully If it does not drop initially rotate CAUTION it until it does Never force it down Make sure the fork tools and work area Reset the preload Adjust Ring Once it are very clean before performing an oil contacts the SPRING turn it 1 FULL turn change If dirt or grit falls inside the turn is the minimum preload Be sure fork or remove parts are contaminated to adjust sag as needed later Tighten fork performance will decrease or serious the Lock Ring against it securely damage can result Apply grease to the Shaft groove and install the two split rings with the TOP marking up Extend the fork lowering the rebound assembly into the outer tube of the splits rings them and reinstall the Outer Cap assembly Be sure to lubricate the O rings with a bit of grease Place bike in work stand and remove the fork from the bike Releasing SPV Air Pressure If you have an SPV compression damper remove the Schrader valve cap at the bottom of the fork and release all air pressure by depressing the valve end Wait for hissing to end If you have a TPC compression damper loosen the compression damping knob set screw and remove the knob from the shaft end Be sure to capture the
21. lishing a schedule appropriate to your riding style and conditions NORMAL RACE WHAT TO DO In Hours Clean fork and visually inspect for damage Check the fork externally for any sign of damage bent fork cracks fluid leaks tears deep scratches loose parts Check and adjust air pressure Check the fork function Make sure it operates normally and all adjustments are normal See Fork Problems next page REPORT ANEI ATTER EVERY E Inspect the fork boot Check damage e g cuts holes rips rub marks and loose attachment Check tightening torque of the fasteners and bolts listed in Tightening Torques in this manual Grease telescope 50 25 Needle bearing reset 25 25 Clean air filter 25 10 Damping cartridge oil and seal change 100 25 Inspect Replace Bumper AS NEEDED PROFESSIONAL SERVICE Annually or when problems are indicated you must have your Lefty fork serviced through a Cannondale Dealer or an Authorized Headshok Service Center Your fork should be disassembled by a suspension professional and evaluated for interal and external part wear and damaged parts replaced with new ones It should also include any work described in technical bulletins or product recalls ANNUAL Minimum Our Factory Tech Room in the USA provides professional services through Cannondale dealers for Headshok suspension forks Please ask your dealer about the servi
22. ngs and threads 13 Install the Outer cap by hand Tighten with Shimano TL FC32 See following illustration for tightening method A B Figure 31 Tighten Outer Cap Tighten Snug B Continue 1 4 Turn 120024 PDF CAUTION Only use the tool only once the cap is screwed on fully Do not over tighten 14 Reset Rebound Knob position 15 Recorded earlier Cannondale UPPER REBOUND ASSEMBLY EXPLODED VIEW Te men Ls Pushrod hard plastic material rubber like material 1 16 Loctite 242 9mm 120024 PDF FORK CLAMPS CAUTION Do not over torque the clamp bolts Figure C Lefty Alloy Fork Clamp Bolts Creaking noise can be indication of loose Figure D fork clamp bolts Lefty Carbon Fork Clamp Bolts Check the clamp bolt tightness periodically When tightening is required re apply Loctite 242 blue and tighten with a good torque wrench Tightening Torque ALLOY Figure C 7 0 Nem IneLbs CARBON Figure D 9 0 Nem 80 IneLbs 17 Cannondale Removing Alloy Forks The upper and lower fork clamps are integrated with the head tube steerer The fork can be removed for service by sliding it down out of the clamps 1 Remove the brake caliper and detach the brake line 2 Remove the outer cap assembly
23. nner boot to ensure that boot does not slide up when zip tie is re secured 7 When you are finished inspect the condition of the boot Make sure it is undamaged Replace it if it is Re secure the boot and reassembly the fork NEVER RIDE YOUR LEFTY IF THE INNER TUBE BEARING RACES OR BEARINGS ARE CORRODED RUSTED OR CRACKS ARE PRESENT 7 Usea stiff nylon brush to apply high quality bicycle grease onto the inner tube and bearing races Cycle 31 cannondale Needle Bea ring Evidence of migration is 1 An unusual top out noise If Migration Reset an unusual noise is heard the extended fork length should be NOTE Ideally reset the bearings after 25 measured to confirm the condition hours of normal riding or 10 hours of hard riding racing to maintain optimum fork performance 2 The fork s maximum extended length is reduced If migration re occurs frequently immediately after resetting the cause could be damage present in the inner or outer races bearings cages or other fork Explanation parts Inspection and replacement of Inside the fork the four needle bearing damage parts will be required to correct a cages 1 move independently up and down persistent problem with bearing migration between each inner 2 and outer race pair 3 This bearing arrangement provides numerous advantages to fork performance but requires simple periodic maintenance to ensure proper alignment We recommen
24. risk we strongly recommend that owners always have mechanical work done by an authorized Cannondale retailer SAFETY MESSAGES In this manual information which affects your safety is emphasized in the following Ways A WARNING indicates a potentially hazardous situation which if not avoided can result in serious injury or death CAUTION A CAUTION Indicates a potentially hazardous situation which if not avoided can result in serious damage to the product The matters described under CAUTION may if not avoided lead to personal injury or results depending on the situation and degree of damage Important matters are described in CAUTION as well as WARNING so be sure to observe them A NOTE provides helpful information or tips intended to make the information presented clearer INTENDED USE All Mountain INTENDED for trail riding and riding uphill All Mountain bicycles are more heavy duty than cross country bikes but less heavy duty than Freeride bikes All Mountain bikes are lighter and more nimble than Freeride bikes All Mountain bikes are heavier and have more suspension travel than a cross country bike allowing them to be ridden in more difficult terrain over larger obstacles and moderate jumps All Mountain bikes are intermediate in suspension travel and use components that fit the intermediate intended use All Mountain bikes cover a fairly wide range of intended use and within this range are
25. small O ring in the knob groove If you have a FFD compression 21 Cannondale Loosening the Damping Assembly Carefully lift out the damper p Removing TPC Compression Damping Knob 4 Holdthe fork upside down Use a socket to loosen the damper Turn counter clockwise Removing the SPV Damping Assembly 22 120024 PDF Carefully lift out the damper on the floor and cycle it About 15cc of oil will come out which a rag can handle Wipe up any spills Draining Oil From The Lefty 6 Refill with the specified oil from a clean container Golden Spectro Motorcycle Cartridge Fork Fluid 85 150 Volume cc 155 approximate Removing the FFD Damping Assembly 5 With the damper out invert the fork over a waste oil container and allow to drain Dispose of waste oil responsibly To expel the small amount above the rebound piston with the spring installed place the spindle on a rag 23 Cannondale If you have a TPC compression damper dip the piston end clean fluid and check the cap O ring If you have a FFD compression damper check the cap O ring and continue to the next step 8 Slowly insert the damper moving it up and down in the oil until the cap can be threaded in Do not insert the damper too quickly oil might be forced out Re Filling Oil 7 Ifyou have an SPV compression damper hold the air valve end in allowing the bladder to expand fully Then release t
26. spected by a professional mechanic before it is ridden 33 The Rebound Lockout Assembly and Split rings is removed All air is released Telescope is extended fully cannondale REPLACEMENT PARTS KITS ORDER KIT DESCRIPTION KF205 Kit Split Ring 2 KF206 Kit Collar Upper Alloy Speed110 MAX140 KF207 Kit Collar Upper Carbon Speed110 MAX140 KF208 Kit Collar Lower Alloy KF209 Kit Collar Lower Carbon clip bushing KF213 BLK Kit Spring MAX140 FE XFIRM KF213 BLU Kit Spring MAX140 FE STD KF213 BRN Kit Spring MAX140 FE XXFIRM KF213 GRN Kit Spring MAX140 FE SOFT KF213 RED Kit Spring MAX140 FE FIRM KF214 BLU Kit Spring MAX140 TI STD KF214 GRN Kit Spring MAX140 TI SOFT KF214 RED Kit Spring MAX140 TI FIRM KF215 Kit Damper Compression MAX140 FFD KF216 Kit Damper Compression MAX140 TPC KF223 KIT BLADDER ASSY MAX140 SPV KF217 Kit Damper Rebound MAX140 FFD TPC KF218 Kit Damper Rebound MAX140 SPV KF219 Kit Damper Control ASSY MAX140 KF220 Kit Bladder ONLY SPV MAX140 KF221 Kit Knob Compression MAX140 TPC KF224 Kit Damper Piston Ring MAX140 5 KF225 Kit Seal Max140 KF222 Kit Boot Lefty MAX 140 KF233 KIT KNOB REBOUND MAX140 KF234 KIT PUSHROD MAX140 0 671 Kit Bleed Screw MAX Jake HD208 Kit Outer Race Clip Lefty 5 HD209 BLK Kit Air Filter Hood Lefty HD175 BLK Kit Zip Ties Black 50
27. tem 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 When mounting IS compatible brake systems Follow manufacturer s instructions when mounting the brake caliper to the This photo shows the area where spindle brake bosses Do not modify incorrect bolts will interfere with disc the fork in any way rotation possibly causing severe damage PLEASE ASK YOUR CANNONDALE Correct bolts are shown above DEALER FOR HELP WHEN INSTALLING In addition to checking to make sure COMPATIBLE FRONT BRAKE SYSTEMS the bolt ends do not protrude you must ensure proper thread engagement Mount the front brake caliper using the 16 Make the brake disc can not make mm bolts of Cannondale kit LEFTYBOLTS contact with the fork boot A rotating brake See next figure disc can wear through the boot allowing contaminants into the fork Cannondale 8 SUGGESTED FORK SETUP LEFTY MAX 140 LEFTY MAX 140 SPV TPC or FFD RIDER WT BIKE SIZE INSTALLED SPV REBOUND spring REBOUND FORK SPRING AIR PRESSURE Clicks out pas Clicks out COLOR psi bar from closed from closed Lbs Kg 120 53 PT GREEN 40 2 8 9 BLUE 9 1330 58 SM GREEN 50 3 4 9 BLUE 9 140 63 SM GREEN 60 41 9 BLUE 9 150 68 MD BLUE 50 3 4 9 RED 9 160 7
28. the TOP markings on the rings they install up 13 cannondale NOTE Pull the damper shaft assembly upward to ensure the shaft is fully extended while adjusting the spring preload if you do not do this you may get an inaccurate setup NOTE Make a pencil mark on top of the ring so the turn count is accurate 1 full turn of the adjustment ring 1mm change in installed spring height ADJUST RING TURN LIMITS clockwise after ring first contacts top of spring 1 Turn MINIMUM 8 Turns MAXIMUM g When adjustment is complete with fingers hold the Adjust Ring and tighten the Lock Ring securely against the Adjust Ring 14 10 Apply a high quality bicycle bearing grease to the Shaft groove Insert the two Split Rings with the TOP marking up Then apply a ring of grease to the top of the Split Rings 11 Lower the spring assembly back into the outer tube by extending the lower fork leg NOTE Be sure to clean the Outer Cap threads and the threads of the fork outer tube and reapply a light film of grease Wipe clean with a dry towel Do not use spray cleaners NOTE If the Rebound Knob is not turned in completely when the Outer Cap assembly is installed the knob threads can be damaged or the knob will be difficult to turn Make sure the knob is turned in fully clockwise before the Outer Cap assembly is reinstalled 12 Apply a film of grease to the Outer Cap O ri
29. washing will force contaminants into parts where they will promote corrosion immediately damage or result in accelerated wear DO NOT USE COMPRESSED AIR TO DRY DO NOT USE ABRASIVE OR HARSH CHEMICAL CLEANER SOLVENTS which can damage the finish or attack and destroy both the outside and internal parts When rinsing avoid directing the spray directly at shock fork adjusters or bearings 27 cannondale IMPORTANT INFORMATION ABOUT RIDING IN WET VERY HUMID OR COASTAL CONDITIONS The Cannondale Headshok needle bearing system uses precise components such as bearings and races that are made of high strength steel These components require proper maintenance before and after riding in severely wet conditions PRE RIDE CHECKS The following service and checks are recommended above and beyond typical scheduled maintenance if riding in severely wet conditions Inspect fork boot for rips and tears AIR FILTER COVER Inspect and renew grease under fork boot CLAMP Clean dry and oil breather filter element Ensure zip ties and band clamps are properly tightened replace as needed POST RIDE CHECKS The following service and checks are recommended above and beyond typical scheduled maintenance after riding in severely wet conditions 1 Inspect and renew grease under fork boot wipe dry if water is present Inspect fork boot for rips and tears if water is present in boot Clean dry and oil breather filter
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