07 Lefty Speed OMS web - Eighty-Aid
Contents
1. 33 How to Set Up Sag 11 OWNER NOTES 34 Rebound Adjuster 12 Lockout 12 29 INCH WHEEL COMPATIBILITY 36 Tuning 13 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 to2. READ THIS MANUAL CAREFULLY It contains important safety information Keep it for future reference LEFTY SPEED DLR2 amp SL Owner s Manual Supplement SAFETY INFORMATION 120025 PDF CONTENTS MAINTENANCE About This Supplement 2 Schedule cette 19 Safety Messages 2 Cleaning 13 Intended 3 Air Filter nui Warning 3 Frame T Intended 3 Fork sss 18 Bicycle 3 Needle Bearing Migration 20 FORK OVERVIEW 4 XC3 SI STEM 22 Rebound and Lockout 3 SUSPENSION 55 24 FRONT WHEEL REPLACEMENT PARTS 27 WHEEL HUB DLR2 DAMPER FRONT BRAKE eese eren 9 SL ADJUSTMENTS 10 TELESCOPE PARTS 32 Suggested Air Pressure 10 SERVICE TOOLS
3. 020 Steerer Installation Remioval Tool The Ernie for installing steerers HDTL146 e Castle Tool for removing and installing damping cartridge into telescope HD187 e 1 2 Shaft clamp for clamping damping cartridge shaft HDTL168 Bullet tool for installing oil caps into damping cartridge For an up to date list of kits available for your bike please visit our Tech Center at http www cannondale com tech 25 cannondale LEFTY ORDER DLR2 DLRSL DESCRIPTION Damping Cartridge Parts KF200 BLK Negative spring X FIRM KF200 BLU Negative spring STANDARD KF200 GRN Negative Spring SOFT KF200 RED Negative spring FIRM KF201 BLK Complete damping cartridge w X FIRM negative spring KF201 BLU Complete damping cartridge w STANDARD negative spring KF201 GRN Complete damping cartridge w SOFT negative spring KF201 RED Complete damping cartridge w FIRM negative spring KF202 e Seal Kit DLR2 KF204 Revalving kit shims DLR2 KF268 DLR2 Damping cartridge oil cylinder w relief cut KF213 e HD226 e Damping cartridge oil Golden Spectro 85 150 Ot KF272 Pressure compensator spring KT026 GRN e Complete damping cartridge w SOFT negative spring KT026 BLU e Complete damping cartridge w STANDARD negative s
4. 262 RED T 1 T os eL TORQUE SECTION 1 1 0 23 Nm SET 10 13 0 PRIOR TO INSTALLATION OF SPRING AND TOPOUT PERCH 122 6 410 2 ASSEMBLY NOTES 1 NLGI 2 synthetic grease is to be applied to all seals grooves 11410 102 8 18 0 102 8 18 0 102 X18X XIEX 18 surfaces and glands 8X 1430 ur 6x0 8 02 8 16 152 8 18 0 152 5X0 203 8X 8X0 203 2 See size table for shim stack and topout spring specifications REBOUND SHM STACK 8416 0 203 8 18 0 203 8X14X0 203 1400 102 152 29 cannondale SL DAMPER ITEM QTY DESCRIPTION 1 2 TOP OUT SPRING THRUST WASHER 2 2 010 O RING 6 07 ID X 178 W 3 3 2 018 O RING 18 77 ID X 1 78 W 4 2 2 111 O RING 10 77 ID X 2 62 W 5 O RING 2 00 ID X 1 00 W 6 O RING 3 00 ID X 1 00 7 O RING 9 00 ID X 1 00 W 8 O RING 9 00 ID X 1 00 W 9 2 O RING 8 00 ID X 1 50 W 10 SFHS M2 5X4 11 SEE COMPRESSION SHIM STACK CHART 12 DETENT BALL 2 B 113 QUAD RING 13 94 ID X 2 62 W 4 2 OIL CAP 15 LOCKOUT SHIM 16 PRELOAD SHIM 17 PRESSURE COMP PISTON 18 PRESSURE CO
5. 190 125 130 135 140 200 130 135 140 145 210 135 140 145 150 220 145 150 155 160 This table lists approximate air pressure values It is important after setting the air pressure to add or release pressure to set the sag See next page 10 120025 2 With the help of a second person seat the rider on the saddle with feet on pedals and hands on the handlebar Measure distance X How To Setup Sag 1 Set air pressure according to rider weight 3 To find Sag calculate 656mm X Sag mm XC 20 30 2233 TR 25 35 27 38 Add air to decrease sag Release air to increase sag Special Note The damping cartridge negative spring of both Lefty DLR2 and CARBON SL forks is specific to the rider weight See table below If you find that you set the air pressure much higher or lower than suggested we recommend the corresponding negative spring for best performance Ask your Cannondale Dealer about negative spring kits for your fork CANNONDALE KIT CARBON SL DLR2 KTO25 GRN KF200 GRN KTO25 BLU KF200 BLU KTO25 RED KF200 RED KTO25 BLK KF200 BLK RIDER WT Lbs FORK SIZE BIKE SIZE NEG SPRG COLOR 11 cannondale Rebound Adjuster 1 The red rebound adjuster at the top of the fork controls the speed at which the fork extends following compression CARBON SL DLR2 10 clicks 14 clicks To adjust rebound Turn the adjuster clockwise in the directi
6. BBO 318 5 120 BBQ QSD09005318 BBO 318 5 90 BBQ QSD10005318 BBQ 318 5 100 BBQ 05012005318 0 318 5 120 BBQ QSD09020318 BBO 318 20 90 BBQ QSD10020318 BBQ 318 20 100 BBQ QSD12020318 BBQ 318 20 120 BBQ XC3 Stem 05 11020318 31 8 20 110 BBO 05 13020318 0 318 20 130 BBO 05 09020318 0 318 20 90 BBO QSC08005318 BBO 318 5 80 BBO QSC10005318 BBQ 318 5 100 BBO QSC12005318 BBO 318 5 120 BBO QSC14005318 BBO 31 8 5 140 BBO 05 09005318 0 318 5 90 BBO QSC11005318 BBO 318 5 110 BBO QSC12020318 BBO 318 20 120 BBO 05 11020254 0 25 4 0 10 BBO 05 13020254 0 25 4 0 130 BBO 05 09020254 0 25 4 0 90 BBO 05 08005254 0 25 4 5 80 BBO 05 10005254 0 25 4 5 100 BBO QSC12005254 BBO 25 4 5 120 BBO 05 14005254 0 254 5 140 BBO 05 09005254 0 25 4 5 90 BBO 05 11005254 254 5 110 BBO QSC12020254 BBO 25 4 5 120 BBO Holey Stem 05 10035254 0 25 4 35 100 BBO 05 12035254 25 4 35 120 BBO 05 13035254 25 4 35 130 BBO 05 08035254 0 25 4 35 80 BBO 27 cannondale DLR2 DAMPER 40 2 1 2 u cuP 39 DLR 110 TOPOUT SPRING SPACER 38 DLR 110 OIL CYLINDER WASHER 31 DLR 110 MAIN PISTON 36 DLR 110 CONICAL SPRING WASHER 35 1 DLR 110 SHAFT PRELOAD NUT 34 PISTON RING 33 2 OLR 110 BUMPER 2 DLR 110 TOPOUT T
7. 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 service programs available for your model fork 14 120025 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 any 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 U
8. a professional mechanic Explanation Inside the fork the four needle bearing cages 1 move independently up and down 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 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 20 Evidence of migration is 1 An unusual top out noise If an unusual noise is heard the extended fork length should be measured to confirm the condition 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 parts Inspection and replacement of damage parts will be required to correct a persistent problem with bearing migration ALIGNED MIGRATED Resetting Migrated Needle Bearings 1 Place the bike in a work stand Release all the air pressure through the Schrader valve 2 Remove the rebound knob and lockout lever Remove the outer cap with the Shimano bottom bracket tool TL FC32 See page 5 3 Compre
9. and tears AIR FILTER COVER Inspect and renew grease under fork boot 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 element Ensure zip ties and band clamps are properly tightened replace as needed ZIP TIE IF THE FORK BECOMES SUBMERGED PERFORM THE CHECKS IMMEDIATELY 16 Air Filter The air filter assembly is located over two holes in the outer tube Air passes in and 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 befo
10. 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 CAUTION hub bearings to slide onto the spindle 1 Cover the opening of a removed hub bearing seats wheel with a clean towel to prevent contamination Once the hub has been drawn onto the hub completely and proper threading is 2 Protect spindle when wheel removed evident use torque wrench to tighten A fall or drop to the ground can to final 15 0 Nem 133 0 IneLbs destroy or damage the spindle 4 Reinstall the brake caliper Tighten bolts to 78 0 In Lbf 9 0 INSTALLATION SRUTION 1 Inspect the inside of the wheel hub for LOCATE DISC BETWEEN THE PADS contamination and and the condition Replace shims that are in use be sure of the hub seal Take corrective action if the shims are positioned between the necessary caliper adapter if any and inner face of the fork mounts not under the head of Wipe all parts clean with a dry shop the caliper bolts towel and apply a high quality bike grease to USE ONLY 16 MM Cannondale kit of the larger hub cartridge bearing LEF
11. 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 We assemble forks at our factory using Royal Purple Ultra Performance Grease NLGI 2 ISO 46 BASE 1 Remove the front wheel 2 Release all fork air pressure 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 4 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 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
12. poor traction in corners Faster rebound damping increase air pressure or stiffer coil springs Rebounds too quickly after bumps poor traction in corners Slower rebound damping lower air pressure or softer coil springs Fork tops out harshly Lower air pressure slower rebound firmer negative spring bearing reset 13 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 establishing 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 BEFOREAND AFTER EVERY RIDE 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
13. 10 SCHRADER CAP 8 1 07 DLR 110 AIR PISTON SPACER 32 10 Nm TIGHTENING TORQUE TORQUE WHILE HOLDING LOCKOUT KNOB 120025 CANNONDALE SERVICE TOOLS HDTL146 Castle Tool HD187 1 2 in Shaft Clamps HDTL168 Bullet Tool 33 cannondale OWNER NOTES Record maintenance history service or set up information DATE WORK PERFORMED 34 120025 35 cannondale 29 INCH WHEEL COMPATIBILITY Travel reduction parts are factory installed into Lefties adapted for use with 29 inch wheels The travel reduction parts limit the travel to 80mm Lefties that have travel reduction parts installed are identified with the compatibility label illustrated below left Travel reduction parts limit telescope travel necessary to prevent wheel interference with the frame See below right V WHEEL TO TIRE CLEARANCE AREA LEFTY 80MM TRAVEL REDUCTION IS REQUIRED TO MAINTAIN THE WHEEL TO FRAME CLEARANCE NEEDED FOR 29 INCH WHEELS Lefties with travel reduction factory installed are indentifed with a compatibilty label on the lower fork If the frame contacts the rotating wheel while riding the tire can be stopped suddenly This can throw you off the bicycle or cause you to loose control and crash Do not install a 10mm travel lefty onto a bicycle frame designed for 29 inch wheels If you have any questi
14. GHTEN THIS GR 9 TOP Rebound Knob O Ring lubricate Set Screw Lockout Lever Nut Lockout Lever O Ring lubricate Outer Collar Washer Split Ring Nut gt GR Apply bicycle bearing grease cannondale FRONT WHEEL REMOVAL 1 Place bike in a work stand with front wheel off the ground 2 Loosen the brake caliper mounting bolts 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 Note brake alignment shims between Lefty brake bosses and the caliper 4 Turn hub bolt 1 counter clockwise to remove the hub from the spindle NOTE As the bolt is turned counter 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 Make sure the axle bolt is completely loose before attempting to remove the wheel from the spindle 5 Carefully slide the wheel off of the spindle carefully 120025 spindle so the larger hub bearing starts to position on
15. HETIC GREASE TO ALL O RINGS SEAL GROOVES SURFACES AND GLANDS 2 SEE SIZE TABLE FOR SHIM STACK AND NEGATIVE SPRING SPECIFICATIONS 3 REFERENCE DRAWING 1020355 FOR DAMPER SHIMS cannondale TELESCOPE PARTS J APPLY LOCTITE 262 RED ez eo ec 299 szg lt Wo MW 28 vos WARNING 5 E ee 55 HIGH PRESSURE HAZARD 5 Do not attempt to service 5 5 a pressurized fork You can severely injured or killed by pressurized forcefully ejected fork parts Release all air pressure before performing any work AN APPLY NLGI 2 SYNTHETIC GREASE ITEM QTY DESCRIPTION 1 1 SCHRADER CAP 2 1 SCHRADER CORE 3 2 SPLIT LOCATING RING 4 1 TOP CAP SEAL PLASTIC 5 1 2 019 O RING 20 35 ID X 1 78 W 6 1 2 020 O RING 21 95 ID X 178 W zz 7 1 2 020 O RING 21 95 ID X178 W 2 ae 8 2 2417 O RING 20 29 ID X 2 62 W oa 5 E 2 9 1 SHSS ES 8 4 lt e 0 1 DLR 110 AIR PISTON Jj e 8 5 e ow TuS E T 1 DLR 110 LOCKOUT KNOB One C 2 1 DLR 110 REBOUND KNOB 5 gt 3 1 DLR TIO SHAFT PRELOAD 75 ES 2 zw 4 1 07 DLR 110 DAMPER Ez 5 1 07 CARBON LEFTY TELESCOPE Ter 6 1 07 UPPER COLLAR CARBON 17 1 07 DLR 1
16. MP SPRING 19 TOPOUT PERCH 20 2 TOPOUT TOPHAT 22 TOPOUT SPRING SPACER 23 See Chart DLR NEG SPRING 24 SHAFT PRELOAD NUT M75 25 DLR UPPER SHAFT SL 26 DLR TUNING SHAFT SL 27 DLR TOPOUT BUMPER PERCH 28 DLR THRUSHAFT SL 29 DLR OUTER CAP SL 30 DLR OIL CYLINDER SL 31 DLR LOWER SHAFT SL 32 DLR LOCKOUT PISTON SL 33 LOCKOUT WASHER 34 DLR 100 DETENT SPRING SL 35 DLR QUAD CHECK UPPER SL 36 DLR QUAD CHECK LOWER SL 37 2 UCUP 5X75 NEGATIVE SPRINGS SIZE COLOR RATE SOFT GREEN 6 4N mm STANDARD BLUE 8 6N mm FIRM RED 10 7N mm XFIRM BLACK 132N mm 30 120025 COMPRESSION SHIM STACK ORDER Site 12 14 102 12 20 5 102 12 16 102 12 18 102 4 rpm 120171 119732 120083 120172 z Negative Blue Standard Spring 7 ALIGN SLOTS IN REBOUND CHECK UPPER NEGATIVE SPRING Black a WITH HOLES THRUSHAFT COMPRESSION SHIM STACK ASSEMBLE QUAD SEAL ONTO REBOUND CHECK LOWER BEFORE roe nes LOCTITE 609 GREEN FINAL ASSEMBLY TORQUE 7 9 LOCTITE 262 RED en EM cl TORQUE 3 4 N TORQUE 3 4 N 107 9 SECTION ie SCALE 1 000 ITH LOCKOUT SHINS FULLY COMPRESSED TIGHTEN THE NUT UNTIL IT CONTACTS PLASTIC WASHER LOCTITE 262 RED ALIGN HOLES IN TOPOUT PERCH 117 2 WITH HOLES IN LOCKOUT PISTON SET TO 73 0 PRIOR TO INSTALLATION OF SPRING AND TOPOUT PERCH 368 6 ASSEMBLY NOTES 1 APPLY NLGI 2 SYNT
17. OPHAT 3 DLR 110 TOPOUT PERCH 30 2 DLR 110 PISTON SPACER 29 DLR 110 TOPOUT COLLAR 28 DLR 110 UPPER SHAFT 27 DLR 110 PISTON CONNECT 26 1 DLR PRESSURE COMP SPRING 25 1 PRESSURE COMP PISTON 24 DLR 110 TUNING SHAFT 23 1 DLR 110 REBOUND NEEDLE 22 DLR 110 LOWER SHAFT 21 DLR 110 THRU SHAFT 20 DLR 110 PRELOAD SHIM 1 1 DLR 110 LOCKOUT SHIM DLR 110 LOCKOUT PISTON 2 DLR 110 OIL CAP TEE DLR 110 OUTER CAP DLR 110 OIL CYLINDER 14 DOWEL PIN MI X 5 13 2 CHROME STEEL BALL 3am 2 1 DAMPER SHIM 8 X 20 X 0 102 nfo SOCKET FLAT HEAD SCREW M2 5 X 4 1 O RING 9 00 10 X 1 00 4 1 O RING 9 00 1D X 1 00 W 8 1 O RING 2 00 1D X 1 00 2 111 O RING 10 77 10 2 62 W 2 018 O RING 18 77 1D X 1 78 W 53 2 018 O RING 18 77 1D X 1 78 2 011 O RING 7 56 10 X 1 78 W 2 2 010 O RING 6 07 1D X 1 78 W 1 2 006 O RING 2 90 1D X 1 78 W TOPOUT SPRING THRUST WASHER ITEM DESCRIPTION 28 120025 PDF TORQUE LOCTITE 262 1 9 TORQUE 0 23 Nm LOCTITE 262 RED LOCTITE 609 GREEN LOCTITE 609 GREEN RED TORQUE 3 4 N 107 0 115 0 211 8 E p sa ee E Sn e 9 6927 Se 25 2 7 Bu Be s e 96 re S gt gt o gt Cy y 8 TORQUE 1 7 Nm T LOCTITE
18. SE ONLY 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 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 15 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
19. TYBOLTS Longer bolts can result in contact with the brake rotor causing severe damage Check clearance Spindle axle bolt threads between the bolt tips and rotor after remounting the caliper WARNING C s spin the wheel to make sure it spins freely Be sure to test the brakes for proper operation before riding Both spindle bearing lands Do not contaminate brake caliper pads or rotor with grease 2 Slide the wheel straight onto the cannondale WHEEL HUB 180 OL Sq Ul OGG 9 c9c 919907 pa3e ipui 8 ep oiq Ayyjenb ysiy Addy 001 5104 251 axe4g 251 ayelg leas auu qnH Suueaq Je3no ually 30g 80 l9useM 215214 de gz C mM N 91207 QNVH 1431 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 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 When mounting IS compatible brake systems Follow manufacturer s instructions when mo
20. 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 120025 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 Wipe it off the inner tube and inner boot to ensure that boot does not slide up when zip tie is re secured X S S 9 4 2 S lt b S lt 9 gt 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 7 Usea stiff nylon brush to apply high quality bicycle grease onto the inner tube and bearing races Cycle ARE CORRODED RUSTED OR CRACKS ARE PRESENT cannondale Needle Bearing Migration Reset NOTE Ideally reset the bearings after 25 hours of normal riding or 10 hours of hard riding racing to maintain optimum fork performance We recommend that the needle bearing reset procedure should be performed by
21. n structures dirt embankments requiring long suspension travel or heavy duty components Cross country and marathon equipment tires shocks frames drive trains are light weight favoring nimble speed over brute force Suspension travel is relatively short since the bike is intended to move quickly on the ground and not spend time in the air landing hard and hammering through things NOT INTENDED for use in extreme forms of jumping riding such as hardcore mountain Freeriding Downhill North Shore Dirt Jumping Hucking etc TRADE OFF Cross Country bikes are lighter faster to ride uphill and more nimble than All Mountain bikes Cross Country and Marathon bikes trade off some ruggedness for pedaling efficiency and uphill speed USING YOUR BICYCLE 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 next page 120025 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 co
22. ne with oil but can be done with air and friction as well Spring The part of a suspension fork or shock that holds the rider bike up Springs can be metal coils steel or titanium or high pressure air Compression The process of squeezing together The front and rear suspension compress when hitting a bump landing off ajump or braking for corners Compression can refer to the spring or damping compression damping Rebound The process of extending back from a compressed state The front and rear suspension rebound after being compressed from a bump or jump landing Rebound can refer to the spring or damping rebound damping Low Speed compression or rebound Low speed damping references the speed at which the fork damper travels through its stroke Itdoes NOT refer tothe speed at which the rider is moving Low speed bumps are typically round in shape or smooth actions like jump landings and pedal bob In the case of rebound it mostly refers to rebound speed caused by smaller bumps where the fork does not get fully compressed High Speed compression or rebound High speed damping references the speed at which the fork damper travels through its stroke It does NOT refer to the speed at which the rider is moving High speed bumps are typically square in shape or harsh terrain like sharp edged rocks that may cause pinch flats In the case of rebound it mostly refers to rebound speed caused by larger bumps where
23. ntrol 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 death in 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 FORK OVERVIEW a 2 DLR2 AND DLR SL 1 ON DUN A U N Dum FP WUW N Steerer Tube Lockout Lever Rebound Knob Outer Collar Upper Clamp Outer Tube Bumper Lower Clamp Cable Guide Zip Tie Boot Spindle Brake Mounts 6 IS Standard Air Filter Assembly Clamp Bolts WARNING Label TO HELP AVOID SERIOUS OR FATAL INJURY READ AND FOLLOW YOUR LEFTY OWNER S MANUAL SUPPLEMENT 16 Follow wheel removal and installation instructions DO NOT ride without the wheel axle hub bolt and front brake system properly installed HUB BOLT 15 Nem 133 In Lbs CALIPER BOLTS 8 9 Nem 69 80 InLbs 116111 120025 DLR2 AND DLR SL REBOUND amp LOCKOUT ASSEMBLY 1 5mm 3 2 0 Nem 1 18 0 In Lbs 2 2 10mm O 5 0 Nem 44 0 In Lbs Use a Shimano TL FC32 Crank Adapter Installation Tool Shimano Y 130 09210 to remove and install 10 CAUTION DO NOT LOOSEN OR TI
24. om the top of the steerer Use a rubber mallet to drive the stem steerer into the head tube until it stops Return the cap 1 7 Clean and apply grease to the steerer bolt threads and install into the bottom of the stem steerer Align handlebar and tighten the bolt to 9 N m 8 Tighten the upper and lower clamp bolts to 9 Nem Removal 1 Loosen upper and lower clamp bolts 2 Remove steerer bolt 10 3 Insert the small end of KTO20 into the bottom of the stem steerer and drive the stem steerer up out of the head tube 22 120025 PDF Cap O Ring lubricate Stem Handlebar clamp Clamp boltsr Plastic ring Seal Upper Bearing Bearing cup Steerer bolt OMAN Co Ensure that the plastic ring 6 is on the stem before inserting into head tube The steerer bolt 10 is a structural part and must be installed Follow installation instructions 2 When you tighten or loosen the steerer bolt 10 be sure to loosen the lower clamp bolt and insert the 5mm Allen key completely to avoid stripping the steerer bolt 3 XC3 SI stem is only compatibile with Carbon and Bonded Alloy Lefties Keep the drain hole in 10 clear 9 Nem 23 cannondale SUSPENSION GLOSSARY Damping The process of dissipating energy and slowing down the suspension motion Damping absorbs the force of a bump or landing Damping is usually do
25. on marked to increase the damping which slows the rebound speed Turn the adjuster counter lockwise in the direction marked to decrease the damping which increases the rebound speed Lockout Lever 2 The Lockout Lever turns fork travel and off Be sure to rotate the lever completely to either position until it stops Do not force the lever past the stops Lever Position LOCKED Travel off Fork locked in fully extended position UNLOCKED Travel on Fork is unlocked and travel is active 12 Suspension Tuning Tips 120025 PDF Condition Possible Solutions Not using full travel feels harsh poor cornering traction Lower air pressure softer compression damping lighter negative spring damper revalve Bottoms out soft throughout travel excessive sag Increase air pressure or stiffer coil springs firmer compression damping revalve Harsh over large bumps but good over small ones Softer compression damping lower air pressure or softer coil springs revalve Harsh over small bumps but uses full travel Fork dives under braking Lower air pressure or softer coil springs softer compression damping reduce spring preload decrease bump threshold firmer negative spring revalve ncrease air pressure or stiffer coil springs firmer compression damping increase SPV pressure decrease SPV volume revlave Harsh on repeated bumps packs down feels like less travel
26. ons please ask your Cannondale Dealer for help YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING 36
27. pring KTO26 RED e Complete damping cartridge w FIRM negative spring KT026 BLK e Complete damping cartridge w X FIRM negative spring KTO25 GRN e Negative spring SOFT KT025 BLU Negative spring STANDARD KTO25 RED Negative spring FIRM 025 Negative spring XFIRM TO24 Seal kit DLR SL T030 Revalving kit shims DLR SL Needle Bearings amp Races HD161 e Needle Bearings Oty 4 HDR2L 020 Kit Race Inner 10197 259 0 020 51 4 HDR2L 021 e Kit Race Inner 10 197 259 0mmx 021 53mm 4 HDR2L 022 Kit Race Inner 10 197 259 0mmx 022 56mm 4 HDR2L 023 e Kit Race Inner 10 197 259 0mmx 023 58mm 4 HDR2L 024 e Kit Race Inner 10 197 259 0mmx 024 61mm 4 HDR2L 025 e Kit Race Inner 10 197 259 0mmx 025 635mm 4 HDR2N 024 e Kit Race Outer 8 110 206mmx 024 61mm 4 HDR1G 024 Kit Race Outer 7 480 x 024 HDR2P 020 Kit Race Inner 7 520 020 HDR2P 021 Kit Race Inner 7 520 x 021 HDR2P 022 Kit Race Inner 7 520 x 022 HDR2P 023 Kit Race Inner 7 520 x 023 HD208 Kit Outer Race Clip 5 KF119 e Kit Race Clip Metric 26 120025 DESCRIPTION ORDER H Bar dia Stem Stem Color mm Rise Length mm XC3 Stem Steerer QSD090 5318 BBQ 318 5 90 BBO OSD100 5318 BBO 318 5 100 BBQ QSD120 5318
28. re 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 120025 PDF Use air filter oil foam 17 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 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 Check the 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 Replace the zip ties and band clamps 18 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
29. ss the telescope and remove the two split rings from the top cap 4 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 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 inspected by a professional mechanic before it is ridden 120025 PDF The Rebound Lockout Assembly and Split rings is removed air is released Telescope is extended fully 21 cannondale XC3 SI STEM STEERER Installation 1 Make sure both the upper and lower Lefty clamp bolts are loose 2 Make sure the headset parts assembled as shown next page 3 Position the Lefty clamps onto the headtube as shown 4 Insert Cannondale specific tool KTO20 through the bottom clamp into the head tube and out the upper clamp 5 Make sure the plastic ring 6 is on the stem Insert the bottom of the stem steerer onto the top of the tool 6 Remove the cap 1 fr
30. the fork gets fully compressed 24 Bottom Out When the front or rear suspension fully compresses to absorb a bump or jump landing A hard stop is usually felt at bottom out Top Out When the front or rear suspension fully extends after absorbing a bump or jump landing A soft stop is usually felt at top out The fork and shock are typically topped out without a rider on the bike Compression Adjuster Used to adjust the front or rear compression damping setting Rebound Adjuster Used to adjust the front and rear rebound setting Sag Refers to how much the front and rear suspension compress when a rider sits on the bike Sag is measured as a percentage of suspension travel Typical sag values are 20 30 for XC riding and 25 35 for Trail Freeride Preload Refers to how much initial compression is applied to a spring In the case of an air spring preload is achieved by increasing the air pressure You use preload to adjust the sag More preload decreases the sag Less preload increases the sag Spring Rate Refers to the strength of a spring A spring with a higher rate is stiffer a lower rate softer Diving When a suspension fork compresses and causes the pitch of the bicycle drop Mostly occurs when braking Revalve Revalving is the process of changing the internal compression and rebound shims to change the flow of oil through passages in the forks and shock A suspension specialist should revalve yo
31. 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 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 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 Cross Country Marathon INTENDED for cross country riding and racing which ranges from mild to agressive over intermediate terrain e g hilly with small obstacles like roots rocks loose surfaces and hard pack and depressions There are no large sick drop or drop offs jumps or launches woode
32. unting 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 Mount the front brake caliper using the 16 mm bolts of Cannondale kit LEFTYBOLTS See next figure 120025 PDF This photo shows the area where incorrect bolts will interfere with disc rotation possibly causing severe damage Correct bolts are shown above In addition to checking to make sure the bolt ends do not protrude you must ensure proper thread engagement Make sure the brake disc can not make contact with the fork boot A rotating brake disc can wear through the boot allowing contaminants into the fork cannondale ADJUSTMENTS Suggested Air Pressure To set pressure remove the valve cap at the bottom of the fork Set the pressure according to rider weight Use a bicycle suspension pump Consult the table below Stay within the pressure limits Clean the valve and pump end before attaching a pump Pumpi At the bottom of the fork Pressure Limits MIN 50 psi MAX 225 psi CAUTION ng in dirt can quickly ruin the fork Stay VALVE within the pressure limits VALVE CAP CARBON SL DLR2 RIDER WT Ibs RUSH SCALPEL RUSH SCALPEL 120 80 85 85 90 130 85 90 90 95 140 90 95 100 105 150 100 105 105 110 160 105 110 110 115 170 110 115 120 125 180 120 125 125 130
33. ur bike s suspension 120025 REPLACEMENT PARTS KITS LEFTY ORDER DLR2 DIRSL DESCRIPTION Upper Fork Parts KF210 DLR2 Lockout lever w retaining nut KF206 Upper collar alloy telescope KF207 Upper collar carbon telescope HD016 e _ Steerer tube carbon Lefty HD215 e Frame bumper OSMSEAL Upper Headshok bearing seal QHDST EBO e e _ Headshok headset cups Oty 2 w Headshok bearing Oty 1 HD169 Headshok headset bearings Oty 2 KF211 Rebound knob with set screw and O ring KF205 e Split rings Oty 2 031 __ Lockout lever w retagining nut KT027 e _ Upper collar Lower Fork Parts KF208 Kit Collar Lower Alloy KF209 e Kit Collar Lower Carbon clip bushing KF212 Schrader cap assembly cap O ring Schrader valve valve cap HD208 Kit Outer Race Clip Lefty 5 0 681 Upper fork clamp alloy QC682 Lower fork clamp alloy KF257 e Inner Leg w spindle DLR2 HD175 BLK e Zip Ties Black 50 HD185 BLK Kit Zip Ties Double Head 10 HD209 BLK Air filter assembly filter element and cover QC678 Fork Boot HD210 e _ Steer tube upper plug KT029 e Inner Leg w spindle DLR SL KT028 e Schrader cap assembly cap O ring Schrader valve valve cap KF209 Lower collar carbon telescope Clip Bushing Headshok Service Tools
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