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This document online at: http://www.cannondale.com/bikes/tech/ All information and specifications are subject to change for product Improvement without notice.© 2004 Cannondale Bicycle Corporation - All Rights Reserved

Publication Title Publication No.

Headshok Super Fatty 80Fork Telescope Replacement Instructions

117688.PDF1/12/2005

General Information These instructions are for a Cannondale field service program affecting certain 2005 Super Fatty 80 forks. The affected forks have incorrectly manufactured (steel) inner tubes resulting in air loss. This is not a safety recall.

Replacement telescopes provided under this replacement program are the alloy type and 110 grams lighter. Cannondale Dealers that received affected bicycles/forks will receive necessary service kit quantities. The existing damping cartridge must be removed and installed in the replacement fork telescope. The kits include all other parts necessary to complete the instructions.

The replacement service must only be performed at a Cannondale Retailer shop and only by a experienced bike mechanic. Please use the contact information below if you have questions or are unable to perform the service described.

Parts in Service Kits:• Alloy Super Fatty 80 fork telescope assembly• New damper air piston seal.• UPS Return label for removed fork telescope.

Tools & Supplies Needed to Complete:• 4 mm Allen Key• 5 mm Allen Key• Park Tool SPA-1 (green pin spanner) or Cannondale HD136/• Rubber Mallet• Schrader valve core tool• Small quantity clean fork oil• Small quantity bicycle bearing grease• Loctite™ 242 (blue) (or equivalent removable thread locking agent)

Required Cannondale HeadShok Tools:

HDTL146/HDTL149/ HD136/

Castle ToolUpper Bearing Driver

**OPTIONAL- Pin tool

A green pin spanner and large socket can be used

in place of this tool

2

Fork Removal & Disassembly

1. Secure bike in work stand; remove front wheel and detach brakes from fork.

2. Remove the valve cap and release the air pressure through Schrader valve in fork crown until hissing stops.

WARNING

HIGH PRESSURE HAZARDRelease all air pressure before working and always keep your face away from the top of the fork when opening.

3. Remove valve core from plug with core tool. Discard it.

4. Remove the retaining screw (1).

5. Remove the lockout lever (2).

6. Loosen the stem bolts (3) and remove the stem (4).

7. Remove upper bearing seal (5). Retain it.

3

2

1

4

5

4 mm

5 mm

8. Position a large deep-well socket over the fork hex nut. The socket you use should be larger than the hex nut (19 mm). Cannondale tool HD136/ can be used to drive out the fork. Do not strike the hex nut or top of the fork telescope. Hold the fork legs as shown and tap the socket (1) with a rubber mallet to remove the fork from the head tube.

1

9. Position removed fork upright in a fork work stand. Use Park Tool SPA-1 (green pin spanner) to unthread outer cap (1) from steerer tube (2). Or use HD136/ Turn counter-clockwise (B) - 6 turns approximate.

Park ToolSPA-11

2

AB

3

10. Compress the steerer tube (1). Position castle tool HDTL146/ in damper cartridge slots. Hold continuous downward pressure on tool as you turn it. Turn the tool counter-clockwise (B). You will have to turn the tool 10 full turns until the cartridge disengages. Remember that the thread locking agent is used to install the cartridge; this naturally slows unthreading. The important point here is to work carefully to avoid damaging the damper shaft.

CAUTION1. Use extreme care, do not scratch cartridge shaft (2)

with tool.

2. Damper cartridge body is aluminum; careless use of the tool will cause damage.

CAUT001

11. Lift the damper cartridge up out of the telescope.

AB

1

2

HDTL146/

Cartridge Reinstallation

1. Remove the old air piston seal (1). Replace it with the new one included in the service kit.

2. Lubricate the inner tube walls of the replacement telescope with clean high-quality suspension fork oil.

3. Clean and dry the cartridge threads. Apply drop of Loctite™ #242 (blue) or equivalent removable thread locking agent to the cartridge threads.

4. Brush on to the spring/piston/seal end a coating of high-quality suspension fork grease and install the cartridge into the replacement fork telescope. (Suggested: Manitou “Prepm High Performance Bicycle Suspension Grease” ) Install the cartridge into the telescope. Hold the Schrader valve in the fork crown open as you insert the cartridge into the inner tube. This will allow air pressure to escape and make installation easier. Tighten the cartridge securely with HD146/.

5. Thread the outer cap into the steerer tube. Turn clockwise; tighten securely. Use HD136/ or Park Tool SPA-1 (green pin spanner).

WARNING

ENSURE COMPLETE THREAD ENGAGEMENT; TIGHTEN DAMPING CARTRIDGE AND OUTER CAP SECURELY

242

1

Loctite™ (blue)

REPLACE THIS SEAL WITH THE ONE

INCLUDED IN THE SERVICE KIT

COAT THIS ENTIRE END WITH SUSPENSION

FORK GREASE

4

Fork Reinstallation1. Slide the fork into the head tube.

Align the lower fork bearing (1) with the lower head tube bearing cup (2).

2. Place the upper bearing over the steerer (if displaced) and align with upper head set cup.

3. Slide HDTL149/ over the steerer tube onto the upper bearing.

4. Hold firm upward force on the fork legs and tap the tool until the lower bearing is completely seated in the lower bearing cup.

5. Remove HDTL149/.

6. Apply a light film of bearing grease to the open side of the bearing seal and reinstall with the open side facing the upper head tube bearing.

7. Reinstall the handlebar stem. Tighten the stem bolts.

8. Reinstall the lockout lever onto the hex nut. Be sure to position the lever to the left side of the bike.

9. Reinstall the retaining screw. Tighten snug.

10. Attach a clean bicycle pump to the Schrader valve and pressurize the fork.

Rider Weight (Lbs) Pressure (psi)Less than 170lbs 60

170 - 180 70180 - 190 80

190 an up 90

Be sure to replace the valve cap.

11. Reinstall the brakes and test for proper operation.

12. Test fork for proper function.

1

HDTL149/

2