LEFTY SPEED FOX RLC 110mm - eighty
Contents
1. _ j Clean dry and oil breather filter element Ensure zip ties and band clamps are properly tightened replace as ZIP TIE needed IF THE FORK BECOMES SUBMERGED Figure 10 hi PERFORM THE CHECKS IMMEDIATELY la 15 Cannondale Removing And Reinstalling The Adjusters To remove 1 Hold the rebound knob from turning with your finger tips while using a 2mm hex to remove the rebound knob set screw 1 Turn counter clockwise Then lift of the rebound knob 2 CAUTION Forcing the rebound knob to its stop with a wrench to loosen the screw will result in damage 2 Use a 1 5 hex to loosen all three lever set screws 3 Turn counter clockwise DO NOT REMOVE THEM Then lift off the lockout lever 5 3 Lift off the low speed compression dial 6 Be sure to capture the ball 7 and spring 8 from hole a in the top of the compression valve assembly To reinstall Make sure the parts are clean Apply a very light film of grease to adjuster contact surfaces during assembly 1 Insert spring 8 into a Use a bit of grease to stick ball 7 onto top of spring 8 2 Align pin b with groove c in 6 and insert into top of fork Make sure the dial rotates smoothly and the ball ratchet functions correctly as dial is rotated 3 Insert 5 into 6 Hold very slight downward pressure on 5 and finger tighten each 3 Tighten evenly This locks 5 into 6 by moving b2. Loctite Outer Collar 28 0 248 0 Lefty Steerer Clamp Bolts 9 0 80 0 Rebound Knob Set Screw fe 10 6 Loctite 222 purple Blowoff Threshold Set Screw 2 0 18 0 Lefty Wheel Axle Bolt 15 0 133 0 grease Lefty Brake Disc Bolts 6 2 55 0 Loctite 242 blue Lefty Brake Caliper Bolts 9 0 80 0 cannondale FORK OVERVIEW DESCRITION Rebound Knob Lockout Lever i Low Speed Compression Knob Outer Collar Upper Clamp Clamp Bolts 9 0Nm Outer Tube Bumper E ME o RS Lower Clamp Ss Serial Number Cable Guide Zip Tie Air Filter Assembly Cable Guide Boot KF364 Zip Tie i Ju d Se Y n Spindle Brake Mounts Brake Bolts LEFTYBOLTS Inner Bearing Seat Outer Bearing Seat Spindle Threads WARNING LABEL Blowoff Threshold Knob Lefty Computer Mount optional Figure 3 120867 PDF WHEEL HUB gt Loctite 262 6 2 N m 55 0 In Lbs 10 11 QCTL108 Park SPA 1 Loctite 242 Blue fi Smm 15 0 Nm 133 0 InLbs DESCRIPTION KIT ITEMS 00117 1 2 3 4 Extraction Cap left hand thread aan Plastic Washer KB61805 7 ye 0C081 Kit Hub Lefty 24h6 Bolt BLK O Ring lubricate 0 627 KitHub Lefty 32h6 Bolt BLK Axle Bolt 0C118 8 Outer hub bearing Hub Inner hub bearing Hub Seal Brake Disc Brake disc bolts SS E a e Wheel Tr
3. TOPOUT PERCH UPPER 22 NEGATIVE SPRING 23 TOPOUT SPRING PERCH 24 PISTON ASSY LENGTH mm TRAVEL mm 130 110 A 137 3 117 3 B 664 3 644 3 C 4224 422 4 NOTE Apply NGLI 2 synthetic grease to all O Rings Figure 37 32 120867 PDF G Ka 16 M1 5 0 5Nm Loctite 262 red M10 CONE M8 TET TTT ANNEE 270 RS EZ SS Z ea eri Sy r Oo n CH E CO m E oy Ll ef E dy op 5 rb ha 26 e wv SZ Op wN E pie d 56 OEZ o Z U e AS TIT AS ee ee EE E AS N A E EI AO IEEE i i y e E rm 5 I EN D 4 a SET eN E H SE W Z DI n i ESS 2035 32 5 eto n A TA r 4110 I i i 24 Ser ls SE cont hi Figure 38 33 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 done 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 a jump 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 fron
4. MOUNTED ADJUSTED AND FUNCTIONING FRONT BRAKE SYSTEM The Lefty disc caliper acts as an integral secondary wheel retention system If the system is missing or improperly installed or ifthe wheel hub axle bolt should loosen the front wheel could slide off the spindle end When mounting IS compatible brake systems 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 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 CAUTION USE ONLY 16mm 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 See Figure 3 item 19 120867 PDF SPECIFICATIONS Travel 110mm External Adjustments Rebound Lockout Low Speed Compression Blowoff Threshold Internal Adjustments Spring Spring Preload Sag 10mm 10 turns Maximum Spring Type Coil Spring Material Titanium Steel Oil Volume 125cc Oil Weight Golden Spectro 85 150 Up to 10wt oil can be used if firmer low speed compression is desired Recommended Sag 25 27 5mm TIGHTENING TORQUES ltem Nm InLbs
5. of sag change CAUTION The preload adjust ring 4 must be set at a minimum of two full turns after it contacts the top of the spring THE MAXIMUM NUMBER OF TURN AFTER MINIMUM PRELOAD IS SET IS 10 If the desired sag for your body weight can not be achieved using the preload ajuster consider changing to a softer or firmer spring 4 See next page Tighten the 1 5mm preload adjust set screw finger tight Apply grease to the split ring groove a and reinstall the split rings 2 with the TOP marking up Raise the telescope and reinstall the outer collar 1 Tighten with Shimano tool TL FC32 to 28Nm Reinstall the adjusters See previous page 18 120867 PDF Shimano TL FC3 Figure 12 19 Cannondale Spring Change The following procedure should only be completed by a professional bike mechanic 1 Remove the adjusters See page 16 2 Use Shimano tool TL FC32 to loosen and remove the outer collar See page 18 3 Lower the telescope and remove the two splits rings 1 from the compression assembly groove a 4 Hold spring shaft flats with 16mm wrench Locate a 21mm wrench on the flats and turn it the compression valve assembly counter clockwise to remove it 5 Compress the preload tube 2 and remove the spring clip 3 from the groove b 6 Lift out the spring shaft assembly from inside the spring preload tube 2 preload adjust ring 4 O Ring 5 Spacer 6 O ring 7 7 Lift o
6. the ground and not spend time in the air landing hard 120867 PDF The Lefty FOX RLC is not intended for use in extreme forms of jumping riding such as hardcore mountain Freeriding Downhill North Shore Dirt Jumping Hucking etc UNDERSTAND YOUR FORK AND ITS INTENDED USE USING YOUR FORK THE WRONG WAY IS DANGEROUS Industry usage Conditions 1 5 are Consult your generalized and evolving Cannondale Dealer about how you intend to use your bike Please read your Cannondale Bicycle Owner Manual for more information about Intended Use and Conditions 1 5 Cannondale Bike Suspension 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 death in a crash e Ride at reduced speeds e Take time to learn the performance characteristics of your bike and suspension components Ride within your skills and abilities Take a bicycle training course Front Brake Requirement DO NOT RIDE WITHOUT A PROPERLY
7. 017 SPRING SOFT FE HD208 Lefty Outer Race Clip 5 KH018 SPRING STANDARD FE HD161 Lefty Needle Bearings KH019 SPRING FIRM FE HD175 BLK Zip Ties 50 Black KH020 SPRING X FIRM FE HD185 BLK Zip Ties Double Head 10 Black KH021 SPRING XX FIRM FE HD011 Band Clamps 2 KHO25 FOX RLC Preload Tube LEFTYBOLTS 16mm Brake Bolts 2 KH011 FOX RLC Upgrade Kit KF364 Lefty Computer Mount KHO12 FOX RLC Seal Kit oso LL l E Alloy KHO13 FOX RLC 110 Rebound Damper QHDST EBo Peadshok 1 cpu KH028 FOX RLC Rebound Shaft HD169 Headshok Headset Bearings 2 KH015 FOX RLC Compression Damper KT020 Steerer Tool The Ernie Kit Race Inner 10 197 KH029 FOX RLC Seal Head HDR2L 020 259 0mmx 020 51mm 4 Kit Race Inner 10 197 KH026 FOX RLC Compression Clamp HDR2L 021 259 0mmx 021 53mm 4 LL Kit Race Inner 10 197 KH027 FOX RLC Retaining Ring HDR2L 022 259 0mmx 022 56mm 4 Kit Race Inner 10 197 HD226 Golden Spectro 1 US QT HDR2L 023 259 0mmx 023 58mm 4 EN Kit Race Inner 10 197 KF205 Split Rings 2 HDR2L 024 259 0mmx 024 61mm 4 Kit Race Inner 10 197 di 259 0mmx 025 635mm 4 HDR2N 024 Kit Race Outer 8 110 206mmx 024 For an up to date list of kits available for your bike please visit our Tech Center at http www cannondale com tech
8. READ THIS MANUAL CAREFULLY It contains important safety information Keep it for future reference LEFTY SPEED FOX RLC 110mm Owner s Manual Supplement 120867 PDF CONTENTS SAFETY INFORMATION ns MAINTENANCE nn 13 About This Supplement 2 Schedule ss 13 Warning Label 3 Fork Damage NEEEn 14 Intended Use 3 ET las ara 14 Bicycle Suspension 3 Pre Ride Checks csssesesssecsssesecesseceeens 15 Front Brake Requirement 3 Remove Install Adjusters 16 SPECIFICATIONS eocacanananananaaanaaaananarananaanansanannes 4 Spring Preload Adjustment 18 TIGHTENING TORQUES 4 Spring Change 20 ala A en 22 FORK OVERVIEW dun 6 Wie Filter dee oil 24 LEFTY WHEEL HUB en 7 BUMP PR 24 Wheel Removal 8 Grease Renewal 25 Wheel Installation 9 Bearing Migration Reset 26 ADJUSTMENTS 2 10 XC3 SI STEM STEERER 28 RED OWING WE 10 TECHNICAL DRAWINGS n 30 Reie Set 11 SUSPENSION GLOSSARY 34 Low Speed Compression 11 Blow Off Threshold 12 OWNER NOTES cc 35 REPLACEMENT PARTS 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 SAFETY INFORMATION About This Supplement Cannondale Owner s Manual Supplements provide
9. age Inspections STOP RIDING A DAMAGED FORK IMMEDIATELY The following conditions indicate serious fork damage 1 Any unusual klunking or knocking noises A change in fork travel Anover extended elongated or compressed boot Changes from the way the forks had been working Loss of adjustments features oil or air leakage Crash or impact damage deep scratches gouges dents or bending For next items 7 10 please read Inspect For Safety in PART II Section D of your Cannondale Bicycle Owners Manual 7 AREA 1 Small cracks under the bolt head of clamp bolts This inspection requires the removal of the bolts AREA 2 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 AREA 3 Horizontal cracks above and below the intersection of the upper and lower clamps with the outer tube portion of the Lefty structure AREA 4 Vertical cracks at the back of the Lefty spindle directly behind the safety roll pin This may happen in a big event crash and the spindle twists slightly HAVE ANY DAMAGED FORK INSPECTED AND DAMAGE REPAIRED BY YOUR CANNONDALE DEALER YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING Cleaning When cleaning use only a mild soap and water solution Clean water and a common dish washing liquid will work best Cover the adjusters with a clean
10. alls 4 into groove in 6 Do not over tighten Set lever resistance by adjusting tightness of 3 until good lever action is achieved 4 Install 2 and tighten 1 to 1 2 Nm No Qty FOX P N CANNONDALE 1 1 019 01 007 2 1 210 22 210 3 3 019 01 006 A 3 010 01 004 A Cannondale kit KHO30 is a complete adjuster assembly It iincludes all parts shown in this 5 1 210 22 228 table 6 1 210 22 208 7 1 039 00 005 A 8 1 010 01 000 A 16 Figure 11 120867 PDF 2mm 1 2Nm Loctite 222 purple 1 5mm Loctite 242 blue 3 4 O KHO30 17 cannondale Spring Preload Adjustment Sag Sag is the distance the fork compresses when a rider sits on the bike The recommended Sag for the Lefty is 25 of the total travel or 27 5mm Sag is adjusted by changing the spring preload with the preload adjustment ring 1 Start by measuring length A the fork length without a rider Next Measure B fork length with a rider B Calculate A B SAG mm To set adjust the Sag remove adjusters See page 16 Use Shimano tool TL FC32 to loosen and remove the outer collar 1 Slightly compress fork telescope and remove both split rings 2 Use 1 5mm hex to loosen the preload adjuster set screw 3 Turn the preload adjuster 4 to increase or decrease SAG To decrease sag turn the adjuster clockwise cw To increase sag turn the adjuster counter clockwise ccw 1 turn is equal to 1mm
11. boot up to expose the inner tube F 4 Wipe off the old grease with a dry shop towel 5 Re apply a fresh heavy coating of grease Any clean high quality bicycle bearing greaseselectedforridingtemperaturesand environment can be used We assemble forks at our factory using Royal Purple Ultra Performance Grease NLGI 2 ISO 46 BASE Cycle the fork several times between applying grease to the new grease is worked into the bearings 6 Reposition the boot and replace the zip ties Make sure the zip ties are very tight Loose zip ties may allow water or dirt to pass behind the boot CHECK THE BOOT BEFORE EACH RIDE DON T RIDE IF IT IS DAMAGED REPLACE IT WHEN YOU FIND DAMAGE 29 Cannondale Bearing Migration Reset 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 if have migrated This migrated condition will Figure 29 limit travel 5 Needle bearing migration is normal and expected However if the fork is ridden in this state for extended periods the fork can be damaged Evidence of migration is 1 An unusual top out noise If an u
12. d must be installed 1 When removing or installing steerer bolt 10 insert 5mm Allen key completely to prevent stripping the bolt 2 The drain hole a in 10 enables accumulated moisture inside the headtube to drain out Use a toothpick to keep it clear ITEM DESCRITION D Cap O Ring Stem Handlebar Clamp Clamp Bolt Plastic Ring Bearing Seal Bearing GEES OR E EE Bearing Cup Stem Steerer Bolt e Figure 34 29 cannondale ADJUSTERS COMPRESSION VALVE ASSY TELESCOPIC STRUCTURE SPRING Figure 35 120867 PDF SANT Er AIR FILTER ASSY e F n E gt wa an emu mits aga FX i a CO SPRING OUTER TUBE PRELOAD ADJUSTER hence Bae EE BRERA OE Figure 36 31 Cannondale ITEM DESCRIPTION DAMPER BODY ASSY 1 DAMPER BODY 110mm 2 COUPLER 3 O RING 17 00 ID x 1 00 W 4 O RING 20 00 ID x 1 00W 5 O RING 2 020 21 95 ID x 1 78 W 6 7 8 O RING 8 00 ID x 1 00 W O RING 3 00 ID x 1 00 W CRUSH WASHER PLASTIC 9 NUT 10 BLOWOFF KNOB 11 SET SCREW 12 BASE CAP REBOUND SHAFT ASSY 13 SHAFT COUPLER 14 RING 15 REBOUND SHAFT 16 ADJUST ROD LOWER 17 SEAL HEAD 18 O RING 10 00 ID x 1 50 W 19 O RING 12 50 ID x 2 00 W 20 O RING 14 50 ID x 1 00 W 21
13. d 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 Normal movement when a suspension fork compresses resulting in a downward change in the the angle of the bicycle 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 your bike s suspension 120867 PDF OWNER NOTES Record maintenance history service or set up information WORK PERFORMED 35 Cannondale REPLACEMENT PARTS KITS KIT DESCRIPTION KIT DESCRIPTION KH007 SPRING SOFT TI KH016 FOX RLC Outer Collar KH008 SPRING STANDARD TI HD215 Lefty Bumper KH009 SPRING FIRM TI QC678 Lefty Boot 110mm KH010 SPRING X FIRM TI HD209 BLK Lefty Air Filter Assy KH
14. e to your riding style and conditions NORMAL RACE In Hours WHAT TO DO CHECK FOR DAMAGE See Damage Inspections on the next page CHECK THE BOOT Make sure its in good shape and in place See page 15 BEFORE AND AFTER EVERY RIDE CHECK TIGHTENING TORQUES See Tightening Torques on page 5 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 ANNUAL Minimum 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 any technical bulletins or product recalls 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 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 fork maintenance program one that suits where and how you ride 13 Cannondale Dam
15. ends after compressing Turn the knob clockwise cw to close it slower rebound and counter clockwise ccw to open it faster rebound CLICKS OUT from full in SETTING 1 SLOW 15 FAST To use the knob First turn it completely clockwise cw until it stops then turn counterclockwise ccw and count each click Seven clicks out from closed is a good middle starting point 10 120867 PDF Lockout The blue compression lockout lever 2 allows you to close the compression damping circuit in the fork This keeps the fork at the top of its travel making it harder to compress Rotate the lever 2 fully clockwise cw until it stops The fork will blow off in the event that a big hit is encountered with the fork locked out See 4 Blow off Threshold on next page TO LOCKOUT NOTE The fork may cycle a couple of times after enabling lockout Once complete lockout is achieved the fork may continue to move 3 5 mm This is normal and does not affect performance From LOCKED only rotate the lever 2 counter clockwise ccw 90 While it is possible to the lever counter clockwise over 360 it is only necessary to rotate counter clockwise 90 to unlock TO UNLOCK Low Speed Compression Low speed compression damping is adjusted with the blue bezel ring 3 below the blue lockout lever and has 8 clicks of adjustment Compression damping controls the speed at which the fork compresses Adjust low speed compressio
16. ilter assembly stops the passage of dirt and water which would damage the internal fork components The small holes a at the base of the filter cover 2 should remain clear and 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 The foam filter element 1 should be cleaned and re oiled frequently This can be performed without removing the filter from the fork Figure 25 Slide cover up off the foam In place massage the foam air filter element with warm soapy water preventing water or soap from entering the holes in the outer tube 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 HD209 BLK Lefty Air Filter Assy Frame Bumper The bumper 1 located on the outer tube 2 between the clamps It cushions the frame from contact with the fork Replace it with a new one if it ever becomes damaged torn or missing To remove it remove the band 3 from the bumper groove and unwrap the bumper HD215 Lefty Bumper 24 120867 PDF Periodic Grease Service Under the Boot 1 Remove the front wheel 2 Carefully release the upper and lower zip ties securing the fork boot If the boot is secured with a band clamp loosen and remove the clamp s 3 Lift the unsecured
17. 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 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 Dealer before delivery to the owner 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 Warning Label The warning label shown in Figure 1 is located on the lower leg of the Lefty Do not remove it If it is missing or damaged you can obtain a free rep
18. l mechanic before it is ridden 120867 PDF 720 730mm Figure 31 21 Cannondale XC3 SI Stem Steerer The following procedure should be completed by a professional bike mechanic STEM Installation STEERER TOOL T a KTO20 3 Position the Lefty clamps onto the t 2 headtube assembly as shown 1 Loosen both clamp bolts 1 4 Insert Cannondale tool KT020 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 from 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 Nem 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 KT020 into the bottom of the stem steerer and drive the WA stem steerer up out of the head tube z D APPLY M GREASE TO THREADS OF BOLT 28 120867 PDF An alloy frame headset with bearing cups is shown here If the frame headtube is carbon fiber the bearing cups are bonded in place and non removable The steerer bolt 10 is a structural part an
19. lacement from Cannondale TO HELP AVOID SERIOUS OR FATAL INJURY READ AND FOLLOW YOUR LEFTY OWNER S MANUAL SUPPLEMENT 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 IrLbs CALIPER BOLTS 8 9 Nem 69 80 Ind bel 116111 Figure 1 Intended Use Lefty FOX RLC 110mm is intended for Condition 3 Cross Country Marathon riding Condition 3 symbol shown in Figure 2 For riding on unimproved trails with small obstacles Figure 2 Condition 3 riding includes Conditions 1 and 2 plus rough trails small obstacles and smooth technical areas including areas where momentary loss oftire contact with the ground may occur NOT jumping All mountain bikes without rear suspension are Condition 3 and so are some lightweight rear suspension models Riding in Condition 3 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 wooden 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
20. n with lockout disabled lockout lever fully counterclockwise As a starting point turn the low speed compression dial all the way counterclockwise full out until it stops then turn clockwise in 5 clicks CLICKS IN from full out SETTING 1 SOFT 8 FIRM 11 cannondale Figure 9 Blowoff Threshold Even when your fork is fully locked out there are instances when you still want your fork to be active To protect your fork s internal parts your fork will blowoff when it exceeds a certain threshold force You can adjust when the fork blows off lockout force by adjusting the blue knob 4 at the bottom of the fork Your fork will then respond to hits in the trail greater lockout force for example but will be locked out lower lockout force when you are out of your saddle on a climb In the event of a hit that exceeds this threshold the fork will blowoff During this blow off event the damper circuitry may make an audible noise This is normal CLICKS OUT from full in BLOWOFF At 1 click the blow off resistance is greatest The fork 1 requires a harder hit to blowoff the fork compression lockout It feels firmest at this setting In this setting the blows off resistance is lightest A 12 smaller bump will release the lockout The fork lockout will feel softest at this setting 12 120867 PDF MAINTENANCE Schedule This schedule is intended as a guide only You must establish a schedule appropriat
21. nusual noise is heard the extended fork length should be measured to confirm the condition 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 parts Inspection and replacement of damage parts will be required to correct a persistent problem with bearing migration ALIGNED MIGRATED Figure 30 26 To reset The following procedure should only be completed by a professional bike mechanic 1 2 S Place the bike in a work stand Remove the adjusters Remove the outer collar 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 Firmly extend the telescope until it stops tip listen forthe knocking atfull 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 professiona
22. oning 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 use torque wrench to tighten to final 15 0 Nem 133 0 IneLbs Reinstall the brake caliper Tighten bolts to 78 0 IneLbf 9 0 Nem Spin the wheel to make sure it spins freely Be sure to test the brakes for proper operation before riding 120867 PDF Do not contaminate brake caliper pads or rotor with grease 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 caliper bolts USE ONLY 16mm 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 See Figure 3 item 19 cannondale ADJUSTMENTS LOCKED cw until lever stops UN LOCKED only ecw 90 from LOCKED DO NOT FORCE ADJUSTERS PAST THE STOPPING POINTS Figure 8 Rebound The red rebound knob 1 is located on the top of the fork It has 15 clicks of adjustment Rebound controls the speed at which the fork ext
23. plastic bag secured with a rubber band or masking tape Spray off heavy dirt before wiping CAUTION Do not use a pressure washer Use a low pressure garden hose Power washing will force contaminants into the fork promoting corrosion immediately damage or result in accelerated wear Don t dry with compressed air for the same reason 14 120867 PDF IMPORTANT INFORMATION ABOUT RIDING IN WET VERY HUMID OR COASTAL CONDITIONS Cannondale Headshok needle bearing system uses precise components such as bearings and races 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 ZIP severely wet conditions AIR FILTER Inspect fork boot for rips and tears COVER Inspect and renew grease under fork boot CLAMP 14 Clean dry and oil breather filter ZIP TIE element bb AP A Ensure zip ties and band clamps are properly tightened replace as needed EI y POST RIDE CHECKS The following service and checks are recommended above and beyond typical scheduled maintenance after riding in severely wet conditions VE 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 D pu O O O
24. t 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 It does NOT refer to the 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 34 the fork gets fully compressed 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 Use
25. uing Tool Figure 4 Cannondale Wheel Removal 1 Place bike in a work stand with front wheel off the ground Loosen the brake caliper mounting bolts 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 Take note of brake alignment shims between brake bosses and the caliper Be sure to reposition correctly 2 Turn the hub extraction bolt 1 counter clockwise ccw to remove the wheel CAUTION 1 Make sure the boltis completely disenaged 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 Continue turning the bolt until the wheel can be removed easily from the spindle Wheel Installation 1 Inspect inside the wheel hub for contamination and and the condition of the hub seal Take corrective action if necessary Wipe the spindle clean with a dry shop towel and apply a high quality bike grease to the spindle bearing lands and end threads See next Figure Slide the wheel straight onto the 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 positi
26. ut the spring 8 The following Cannondale spring kits are available for the 110mm Lefty FOX RLC Note Titanium springs are a lighter wieght spring Titanium Spring Kits KH007 SOFT KH008 STANDARD KH009 FIRM KH010 X FIRM Steel Spring Kits KH017 SOFT KH018 STANDARD KH019 FIRM KH020 X FIRM KH021 XX FIRM 20 Figure 13 ANCOR Figure 14 8 9 Coat the new spring with Maxima Red Spring Grease Install the spring with the small isolator c up The large isolator d goes down 10 Apply Loctite 242 blue tothe compression valve assembly 9 e threads and install it onto the top of the preload tube 2 Be sure to align the key f with the slot g on the top of the rebound damper Make sure the compression clamp 10 orientation is as shown Hold the spring shaft on the flats with a 16mm wrench Use a 21mm wrench to tighten the compression valve assembly to 7 9Nm Turn clockwise 11 Apply grease to the split ring groove a and reinstall the split rings 1 with the TOP marking up 12 Raise the telescope and reinstall the outer collar Tighten with Shimano tool TL FC32 to 28Nm 13 Reinstall adjusters Figure 18 Figure 16 21 WI l i 120867 PDF HD225 Kit Grease HdShok Tube 14 oz Tube Royal Purple Cannondale Oil Change The follo
27. wing procedure should only be completed by a professional bike mechanic 1 Remove the adjusters See page 16 2 Use a 26mm socket to remove the compression valve assembly 3 Lift out the compression valve assembly Note the pin a 4 Invert the fork over an oil collection pan Cycle the fork several times to pump out the oil 5 At the bottom of the fork with a 24mm socket turn the damper counter clockwise and lower it out of the spindle enough to drain out oil Then return reinstall the damper and tighten to 28 0Nm per lt Figure 20 Figure 21 22 120867 PDF Pour a small amount of the specified oil into the top of the fork up to the valve assembly threads Golden Spectro 85 150 Slowly cycle the fork You will see air bubbles arise through the oil as the oil flows into the damper The damper requires 125cc of the oil Continue filling and cycling until all the oil has been poured and no bubbles are present Apply grease to the compression valve assembly threads and the O ring Carefully reinstall the assembly into the top of the fork by hand Allow the pin to drop into the slot in the top of the damper and turn the assembly by hand a few turns before using the socket to tighten Tighten to 6 0Nm Reinstall the adjusters Figure 24 PR 23 Cannondale Air Filter Clean Re Oil The air filter assembly is located over two air holes in the outer tube The air f
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