Cannondale SCALPEL 100 User's Manual
Contents
1. Identification 10 Shock Link Assembly i Top Tube 11 Seat Stay Bridge 2 Top Tube Shock Mount 12 seat Stay 3 Head Tube 13 Right Seat Stay 14 Left Chainstay 15 Chainstay Bridge 16 Right Chainstay 17 Right Dropout 18 Rear Derailleur Hanger 19 Left Dropout 20 Rear Disc Brake Mounting 4 Integrated Bearing Cup 5 Downtube 6 Bottom Bracket Shell 7 Seat Tube 8 Rear Shock 9 Seat tube Shock Mount 120871 PDF QSISEAL HD169 KP058 adapters w headset HEADSHOK Integrated Head Tube In both alloy and carbon frame models the SI bearing cups are intergrated within the head tube In alloy frames the cups are machined in the head tube In carbon models cups are permanently bonded into the head tube Cannondale Headshok System Integration bearings are accepted directly into both type An adapter cup kit KP058 for 1 steering tubes and headsets is available above right for either frame type CAUTION 1 Do not face surface or cut the head tube bearing cups 2 Please note that when removing bearings from bonded cups extra care must be used so that the tool used to drive out the bearing is NOT located on any part of the bonded cup cannondale SI BB30 Crankset Compatability The BB shell is compatable with the BB30 Standard See http www bb30standard com For information see SI Cranksets Owner s Manual Supplement See http www cannondale com2. 00 FRONT SHOCK MOUNTING HARDWARE ORDER KIT KP050 SHOCK MOUNTING HARDWARE ITEM OTY G 1 L 1 1 2 H 3 KP051 SHOCK LINK ASSY W 0 LINK KP052 COMPLETE SHOCK LINK ASSY 120871 PDF Cable Routing Route rear brake line and rear derailluer cable above the rear shock between the top tube mount as shown Locate guides KP057 in the postions indicated as rear brake line and rear derailluer cable pass through the through the shock mount 15 cannondale Frame Guards Normal line and cable movement against the frame can wear away painted finishes and decals Overtime cable rubbing can wear into the frame itself causing very serious frame damage KF103 To apply the guard material 1 Clean the frame with a mild detergent and wipe dry with a clean towel Do not use solvents or harsh chemicals to clean the frame OPTIONAL Trim the adhesive guard material to the shape reguired 2 Remove the backing and position the guard under the cable line 3 Rub the guard firmly against the frame with your fingers to fix it in place 4 Periodically recheck the guards and other areas of the frame as you continue to ride Replace the guards if they wear out PLEASE NOTE Damage to your bike caused by cable rubbing is not a condition covered under your warranty Also adhesive frame guards are nota fix for incorrectly installed or routed cables or lines If you find that applied guar
3. 18 Guides And Cable Stops Lines and cables on your bike are routed through frame guides using cable stops 1 and or cable thru guides 2 Periodically you should check to make sure the stops and guides are in good condition and seated properly in the frame guides For stops make sure the stop is seated securely in the frame guide and the housing is fixed within the stop Cannondale Kit H KFO14 Kit 1 KF086 10 PK 120871 PDF 1 1 Nem 10 IneLbs Loctite 242 blue 2 5mm KH048 Rear Derailleur Hanger Before re installing same or new Clean dropout and inspect carefully for any cracks or damage Clean surfaces and apply a light film of bike grease to the dropout to minimize any noise or creaking that might result from very slight movement between the dropout and hanger during movement of the derailleur Apply grease and Loctite carefully Do not contaminate the male or female bolt threads with grease which would cause the Loctite to be ineffective Check derailleur adjustment after replacement Readjust wheel quick release so it is very tight See PART Section 4 A in your Cannondale Bicycle Owner s Manual CAUTION Do not use a derailleur hanger alignment tool to straighten 19 cannondale MAINTENANCE The following table lists only supplemental maintenance items Please consult your Cannondale Bicycle Owner s Manual for more information on basic bike maintenance Consult wi
4. 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 Important Composites Message Your bike is made from composite materials also known as carbon fiber All riders must understand a fundamental reality of composites Composite materials constructed of carbon fibers are strong and light but when crashed or overloaded carbon fibers do not bend they break For your safety as you own and use the bike you must follow proper service maintenance and inspection of all the composites frame stem fork handlebar seat post etc Ask your Cannondale Dealer for help We urge you to read PART II Section D Inspect For Safety in your Cannondale Bicycle Owner s Manual BEFORE you ride YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS MESSAGE Intended Use Scalpel 100 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 lo
5. can be severely injured paralyzed or killed Refinishing chemicals Solvents and Strippers can attack weaken or destroy the important composite chemical bonds holding your frame together Using abrasives or sanding the frame fork structure original paint decals or coatings through the use of mechanical actions such as plastic or glass bead blasting or other abrasive methods such as sanding or scraping can remove frame material or weaken it cannondale Tire Size OBSERVE THE MAXIMUM TIRE WIDTH FOR YOUR BIKE FOUND IN THE SPECIFICATIONS PAGE OF THIS MANUAL Mounting the wrong size tires can result in the tires hitting the fork or frame when riding If this happens you can lose control of your bike and you can be thrown off a moving tire can be stopped because it touches the fork or frame Do not mount oversized tires ones that rub or hit the fork or frame ones that result in too little clearance or ones that can hit the fork or frame when the suspension is fully compressed or when riding Take care that the tires you select are compatible with your bikes fork or frame design Also be sure to follow the manufacturer s recommendations of your front fork and rear shocks When you are considering tires for your bike consider The actual measured size of a tire may be different than its sidewall marking Each time you mount a new tire take the time to inspect the actual clearance between the rotating tire and a
6. http www cannondale com bikes tech cannondale OWNER NOTES Record maintenance history service or set up information WORK PERFORMED 24
7. SINOCK asnaq usai 12 Rear Shock SPECS an sanotussa 22 Recommended Sag 12 REPLACEMENT PARTS 23 gied AL SNS Eesen OWNER NOTES rrn 24 Shock Link Parts 14 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 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 guestion 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
8. ETER 6mm DROPOUT SPACING 135mm REAR HUB SPACING 135mm REAR HUB AXLE QR REAR BRAKE MOUNT INTERNATIONAL STANDARD 6 ONLY LEVERAGE RATIO 2 6 1 PROGRESSIVE 22 REPLACEMENT PARTS 120871 PDF KP048 KIT DER HANGER SINGLE SIDED 3 KP051 KIT LINK HWARE SCALPEL 100 KP052 KIT LINK ASSY SCALPEL 100 KP053 KIT CH STAY PROTECT SCALPEL 100 54 KIT GUARD SCUFFGUARD DOWNTUBE KF103 KIT GUARD SCUFFGUARD 8PK KF014 KIT CABLE STOP INSERTS 2 KF086 KIT GUIDES HYDR BRAK 10PCS KF085 KIT GUIDES BB CABLE SINGLE QC841 BBQ KIT SEATBINDER MTN 31 8 BLK KF012 KIT RIVNUTS BAG OF 5 KP002 KITBADGE HEADSHOK OSISEAL KIT SEAL UPPER BEARING 58MM OD HD169 KIT BEARINGS HEADSET 2 KP058 KIT HEADSET INT HEADSHOK TO 1 1 8 ORDER SI BB30 BOTTOM BRACKET QC616 SI CIRCLIPS QTY 2 KB6810 SI BEARINGS QTY 2 KP018 SI CERAMIC BEARINGS OTY 2 QC615 SI BEARING SHIELD QTY 2 KP023 SI BEARING SHIELD SL QTY 2 QC617 SI SHIMS OTY 5 QC618 SI WAVE WASHER TOOLS KT010 SI BEARING PRESS TOOL USED WITH HEADSET PRESS KTO11 S BEARING REMOVAL TOOL KTO12 SI HOLLOWGRAM LOCKRING TOOL KTO13 SI HOLLOWGRAM CRANKARM EXTRACTION TOOL KF365 SIBB 68 ADP INSTALL QC787 EXTRACT CAP TOOL FOR SI CARBON CRANKSETS KP009 ADAPTER SIBB TO 68MM TAP For an up to date list of kits available for your bike please visit our Tech Center at
9. READ THIS MANUAL CAREFULLY It contains important safety information Keep it for future reference SCALPEL 100 Owner s Manual Supplement 120871 PDF CONTENTS SAFETY INFORMATION 1 Cable Routing ess 15 About This Supplement 2 Frame Guards 16 Important Composites Message 3 Right Chainstay Protector 17 Intended 3 Right Chainstay Plate 17 Building Up A Erarmeset 4 Downtube Protection 17 Bike Stands 4 Front Der Cable Guide 18 Extreme 4 Guide and Cable Stops 18 Inspection and Crash Damage 5 Rear Derailluer Hanger 19 Repainting and Refinishing 5 MAINTENANCE 20 Jl EE 6 Schedule III III IL L La 20 Maximum Fork Length 7 Cleaning 21 FRAME INFORMATION t 8 Tightening Torques 21 Indentification 8 GEOMETRY SPECIFICATION 22 Integrated Head Tube 3 Geometry 22 SI BB30 Crankset seen eio ranes 10 Frame Specs aban 22 Rear
10. ds are wearing out very quickly consult with your Cannondale Dealer about the routing on your bike 16 THIS PHOTO SHOWS A TYPICAL USE OF GUARD MATERIAL AT A CONTACT POINT Check over your bike after your first few rides Apply the guard material where rubbing is found When applied correctly the guards material is good protection for your bike 120871 PDF KP053 includes items 1 and 2 KP054 Right Chainstay Protector The clear film adhesive chainstay protector 1 protects the right chainstay from contact with the chain The protector is replaceable Check the condition of the chainstay protector before each ride Replace it if it is missing or damaged You can order Cannondale kit 53 through your Cannondale Dealer Right Chainstay Plate The chainstay plate 2 located on the right chainstay just behind the chainrings protects the chainstay from damage in the event the chain is dropped from the chainring The protector is replaceable Contact your Cannondale Dealer for a replacement if it is becomes missing or damaged Downtube Protector Carbon Scalpel 100 The clear film adhesive downtube protector 3 protects the downtube Itis replaceable Replace it if it is missing or damaged You can order Cannondale kit KP054 through your Cannondale Dealer 17 cannondale Front Derailleur Cable Guide This snap in front derailleur cable guide is mounted under the bottom bracket shell KF085
11. ll parts of the frame The U S Consumer Product Safety Commission CPSC requires at least 1 16 1 6 mm tire clearance from any part of the bike Allowing for lateral rim flex and a wheel or rim that is out of true will likely mean choosing a rear tire that provides even more clearance than the CPSC recommends ASK YOUR CANNONDALE DEALER FOR THE RIGHT TIRES FOR YOUR BIKE AND ITS PARTICULAR COMPONENTS YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING 120871 PDF HEADSET PARTS or ADAPTERS MAXIMUM FORKLENGTH 500 mm Maximum Fork Length 500mm Maximum Fork Length is an important frame safety testing specification You must observe the measurement when installing headset parts headset adapters installing and adjusting a fork and selecting replacement forks In this manual the number is also listed in the specifications section HOWTO MEASURE 1 Install headset and fork 2 Extendforkand measure the distance from the bottom of the head tube to the center of the wheel axle Do not measure from the bottom of headset bearing cups or head tube adapters The measurement MUST be taken from the bottom of the head tube DO NOT EXCEED MAXIMUM FORK LENGTH Exceeding the MAXIMUM FORK LENGTH limit can overload the frame causing it to fail break while riding YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING cannondale FRAME INFORMATION
12. ms that can lead to an accident 20 120871 PDF 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 an 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 Tightening Torques ITEM Loctite Rear Derailleur Hanger Bolt 1 1 10 242 blue Rear Shock Mounting Bolts 13 115 Shock Link Pivot Bolts 7 62 242 blue 21 cannondale GEOMETRY SPECIFICATION _ GEOMETRY SCALPEL 100 SCALPEL 100 FEMININE cm i
13. n SIZE SMALL MEDIUM LARGE X LARGE PETITE SMALL MEDIUM SEAT TUBE LENGTH STL 40 5 15 9 43 0 16 9 48 0 18 9 50 0 19 7 40 5 15 9 40 5 15 9 41 5 16 3 TOP TUBE HORIZONTAL 57 5 22 6 60 0 23 6 62 5 24 6 65 0 25 6 54 4 21 4 57 5 22 6 58 7 23 1 HEAD TUBE ANGLE B 69 5 69 5 69 5 69 5 69 5 69 5 69 5 SEAT TUBE ANGLE A 74 0 74 0 74 0 74 0 74 0 74 0 74 0 WHEEL BASE H 107 9 42 5 110 6 43 5 113 5 44 7 116 2 45 7 104 8 41 3 107 9 42 5 109 2 43 0 FRONT CENTER DISTANCE L 65 5 25 8 68 2 26 9 71 1 28 0 73 8 29 1 62 4 24 6 65 5 25 8 66 8 26 3 BOTTOM BRACKET DROP K 0 5 0 2 0 5 0 2 0 5 0 2 0 5 0 2 0 5 0 2 0 5 0 2 0 5 0 2 FORK RAKE F 4 5 1 8 4 5 1 8 4 5 1 8 4 5 1 8 4 5 1 8 4 5 1 8 4 5 1 8 CHAINSTAY LENGTH E 42 4 16 7 42 4 16 7 42 4 16 7 42 4 16 7 42 4 16 7 42 4 16 7 42 4 16 7 FORKTRAIL 7 5 3 0 7 5 3 0 7 5 3 0 7 5 3 0 7 5 3 0 7 5 3 0 7 5 3 0 BOTTOM BRACKET HEIGHT G 32 5 12 8 32 5 12 8 32 5 12 8 32 5 12 8 32 5 12 8 32 5 12 8 32 5 12 8 STANDOVER TOP TUBE MIDPOINT J 75 6 29 8 75 5 29 7 74 2 29 2 74 2 29 2 75 1 29 6 75 6 29 8 75 5 29 7 REAR WHEEL TRAVEL 100mm 100mm 100mm 100mm 100mm 100mm 100mm FRAME SPECIFICATION SHOCK SPECIFICATION BOTTOM BRACKET SHELL WIDTH BB30 68mm SAG 8 10mm MAXIMUM FORK LENGTH 500mm STROKE 1 5 3 8cm MAXIMUM TIRE WIDTH 2 1 in EYE TO EYE 6 5 in 16 5cm SEAT POST DIAMETER 27 2mm FRONT BUSHING WIDTH 19 05mm 0 15 FRONT DERAILLUER 31 8mm REAR BUSHING WIDTH 19 05mm 0 15 CHAINLINE 50mm MOUNTING BOLT DIAM
14. nt manufacturers and discuss your riding style ability weight and interest in and patience for maintenance Make sure the components chosen are compatible with your bike and intended for your weight and riding style Generallyspeaking lighterweightcomponents have shorter lives In selecting lightweight components you are making a trade off favoring the higher performance that comes with less weight over longevity If you choose more lightweight components you must inspect them more freguently If you are a heavier rider or have a rough abusive or go for it riding style buy heavy duty components Readandfollowthecomponentmanufacturers warnings and instructions Bike Stands The clamping jaws of an ordinary bike stand can generate a crushing force strong enough to seriously damage and ruin your bike frame CAUTION Never place your bike in a bike stand by clamping the frame Place your bike in a stand by extending the seat post and positioning the stand clamp on the extended seat post Don t extend beyond the MINIMUM INSERT line marked on the seat post Since your carbon seat post can also be damaged by clamping force adjust the stand clamp for the minimum clamping force needed to secure the bike Its a good idea to remove your current seat post and use an old one when mounting your bike in a stand Protect From Extreme Temperatures e Protect your carbon bike from extreme temperatures when storing or
15. on design The living hinge seat and chainstays work in conjunction with the rear shock and provide some of the spring rate Thisintegrated spring force results in riders requiring much less air pressure than normal The key is to set sag 8 10mm The effect of 5 psi is much greater at these lower pressures Percentage wise the difference between 50 and 55 on the new Scalpel is comparable to the difference between 150 and 160 on more traditional suspension designs So little changes mean a lot Adjust air pressure to achieve 8 10mm of rear shock sag SELECT ONLY COMPATIBLE SHOCKS AND FORKS FOR YOUR BIKE DO NOT MODIFY YOUR BIKE IN ANY WAY TO MOUNT ONE HAVE YOUR SHOCK OR FORK INSTALLED BY A PROFESSIONAL BIKE MECHANIC e Riding with the wrong rear shock can damage the frame You could have a serious accident Make sure the total travel eye to eye length and stroke length of the rear shock you select meet the specifications listed in this manual e When selecting different shocks or forks for your bike make sure that the shock or fork you select is compatible with your bike s design and how you will use your bike 12 Shock Link Tightening Torgues 4mm Allen 7 Nm 62 In Lbs Loctite 242 blue 5mm Allen ke VY i 13 Nm 115 In Lbs 4mm Allen 7 Nm 62 In Lbs Loctite 242 blue 13 120871 PDF 4mm Allen 7 Nm 62 In Lbs Loctite 242 blue A Ph 5mm Allen 13 Nm 115 In Lbs cannondale Shock Link Parts
16. ss of tire 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 aggressive 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 reguiring 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 120871 PDF The Scalpel 100 is not intended for use in extreme forms of jumping riding such as hard core mountain Freeriding Downhill North Shore Dirt Jumping Hucking etc UNDERSTAND YOUR BIKE AND ITS INTENDED USE USING YOUR BIKE THE WRONG WAY IS DANGEROUS Industry usage Conditions 1 5 are generalized and evolving Consult your Cannondale Dealer about how you intend to use your bike Please read your Cannondale Bicycle Owner s Manualfor more information about Intended Use and Conditions 1 5 cannondale Building Up A Frameset Before building up a frameset consult with your Cannondale Dealer and the compone
17. tech Bearing Maintenance Shell bearings KB6180 are sealed cartridge type and do not reguire lubrication Inspect bearing condition annually at a minimum and anytime the crankset assembly is disassembled or serviced The bearings are a press fit within the shell Old bearings should not be reinstalled if removed Replace both bearings at the same time Replacements circlips QC616 are available if the circlips become damaged The circlips can be lifted from the BB groove inset by lifting the hooked end with a thin blade screwdriver CAUTION DO NOT FACE MILL OR MACHINE THE BOTTOM BRACKET SHELL FOR ANY REASON Doing so can result in serious damage and possibly a ruined bike frame Cannondale SI BB30 Tools KT011 is a bearing removal tool KT010 is a set of bearing installation tools to be used with a standard headset press KT013 a two piece tool set reguired for removing SI Hollowgram alloy cranksets For information see SI Cranksets Owner s Manual Supplement See http www cannondale com tech SI BB30 to 68mm Standard Adapter The adapter Cannondale kit KF365 converts the BB30 bottom bracket cranksets for use with 68mm bottom brackets The adapter IS NOT a repair part and will only work in undamaged frames in good condition Improper installation or removal can result in damage and void applicable frame warranty 10 120871 PDF 11 cannondale Rear Shock The Scalpel is a unigue suspensi
18. th your Cannondale Dealer to create a complete maintenance program for your riding style components and conditions of use Follow the maintenance recommendations given by the component manufacturers for the various non Cannondale parts of your bike Schedule WHAT TO DO HOW OFTEN CHECK FOR CABLE RUB INSTALL PROTECTIVE GUARDS AFTER FIRST RIDE FRAME INSPECTION Clean and visually inspect entire bike frame swingarm linkage assembly for cracks or BEFORE AND AFTER damage See Inspect For Safety your Cannondale EACH RIDE Bicycle Owner s Manual CHECK TIGHTENING TORQUES In addition to other component specific tightening torgues for your bike check items listed in tightening torgues in this manual BEFORE EVERY RIDE DISASSEMBLE CLEAN INSPECT RE GREASE IN WET MUDDY SANDY REPLACE WORN OR DAMAGED PARTS IN THE FOLLOWING CONDITIONS ASSEMBLIES EVERY 25 HRS IN DRY CONDITIONS e SHOCK LINK ASSY EVERY 50 HRS FORK AND SHOCK Please consult the manufacturer s owner s manual for maintenance information for your fork or rear shock ANY PART OF A POORLY MAINTAINED BIKE CAN BREAK OR MALFUNCTION LEADING TO AN ACCIDENT WHERE YOU CAN BE KILLED SEVERELY INJURED OR PARALYZED Please ask your Cannondale Dealer to help you develop a complete maintenance program a program which includes a list of the parts on your bike for YOU to check regularly Frequent checks are necessary to identify the proble
19. transporting it Allow your bike to cool off or warm up before you ride e Do not store your bike in places where the temperature will exceed 66 5C 150 F For example do not leave your bike lying flat in a black pickup truck bed in the desert sun or under the glass of a hatchback auto 120871 PDF Inspection amp Crash Repainting Or Refinishing Damage of Carbon Frames You should not paint over the existing finish AFTER A CRASH OR IMPACT Inspect frame carefully for damage See PART II Section D Inspect For Safety in your Cannondale Bicycle Owner s Manual Do not ride your bike if you see any sign of damage such as broken splintered or delaminated carbon fiber ANY OF THE FOLLOWING MAY INDICATE A DELAMINATION OR DAMAGE An unusual or strange feel to the frame Carbon which has a soft feel or altered shape Creaking or other unexplained noises Visible cracks a white or milky color present in carbon fiber section Continuing to ride a damaged frame increases the chances of frame failure with the possibility of injury or death of the rider refinish or repaint your bike The carbon fiber composites making up the frame are held together by some extremely strong bonding chemicals However these bonds can be attacked or weakened by paint stripping or refinishing chemicals Repainting painting over retouching or refinishing your frame or fork can result in severe damage leading to an accident You
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