Cannondale HEADSHOK FATTY DLR80 Configuration guide

1124574 (07/11)
Owner’s Manual Supplementt
HEADSHOK FATTY DLR80
LOCKOUT
LEG
DROPOUT
BRAKE
POST
MOUNT
CROWN
REBOUND
BOOT
HD191/BLK
49 mm
33 mm
HD170/
KT031/
KF211/
KF264/
KH005/
KH047/
KH022/
KF266/ QSMSEAL/
HD169/
HDTL149/
Fork Installation Tool
INTEGRATED
HEADTUBE
DLR80 DAMPING CARTRIDGE
HD169/
OUTER TUBE
AIR VALVE
Specications
INTENDED USE - Condition 3, Cross-Country , Marathon, Hardtails
See Intended Use in your Cannondale Bicycle Owner’s Manual.
HEADTUBE COMPATIBILITY Headshok Integrated
TRAVEL 80 mm
ADJUSTMENT Rebound, Lockout, On/O
SPRING TYPE Air
RECOMMENDED SAG 10% 8 mm
DAMPING CARTRIDGE Cannondale DLR80
DAMPER OIL WT. 5W
BRAKE MOUNT Post Mount (160 mm)
WHEEL Quick Release
WARNING
Thissupplementmay includeproceduresbeyondthe scopeof generalmechanical
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.
Pre-Ride Checklist
Before every ride do the following:
1. Check the fork 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 tted over the lower collar and fork lip.
NO PART OF THE FORK INNERTUBE SHOULD BE EXPOSED.
3. Replace the boot band clamp as required. Always tighten securely.
Replacement clamps are available through a Cannondale Dealer.
If you nd boot damage, the area under the fork should be inspected
for damage. And the damaged boot must be replaced with a new one.
Do not try to x it.
4. Make sure the fork and its adjustment features are operating normally.
Replacement part numbers shown BOLD ITALIC text.
Available through Cannondale Dealers.

2
Air Pressure
Prior to riding, set fork pressure according to rider
weight.
1. Remove the front wheel. See your Cannondale Bicycle Owner’s
Manual for quick release wheel removal information.
2. Remove the Schrader valve cap at the fork crown. Make sure the
crown area is clean. See NOTICE below.
3. Attach a bicycle suspenstion pump to the valve end. Pressurize
the fork according to the table below. Add or release air pressure
using the air pump to achieve recommended sag. Replace the
valve cap when nished.
RIDER WT.
(lbs/kg)
AIR PRESSURE
(psi/bar)
NEGATIVE SPRING
(color / description)
120 / 54 80 / 5.5
Green / Soft
130 / 59 85 / 5.9
140 / 63 90 / 6.2
150 / 68 95 / 6.6
Blue / Standard
160 / 72 100 / 6.9
170 / 77 105 / 7.2
180 / 81 110 / 7.6
Red / Firm
190 / 86 120 / 8.3
200 / 90 130 / 9.0
210 / 95 135 / 9.3
220 / 100 140 / 9.7
PRESSURE LIMITS:
Minimum - 75 psi, 5.2 bar, Maximum - 150 psi, 10.3 bar
NOTICE
TO PREVENT SERIOUS DAMAGE:
BE SURE TO CLEAN the fork crown area, the valve end, and
the pump end before attaching the pump to the fork. If dirt is
pumped into the fork air chamber it can cause rapid damage to
the air chamber.
OBSERVE THE PRESSURE LIMITS. The wrong air pressure can
result in damage or poor fork performance.
Lockout/ Rebound
LOCKED
UNLOCKED
REBOUND
KNOB
LOCKOUT
LEVER
TOP
CAP
Rebound - The red rebound knob located at the top of the fork
controls how fast the fork returns following compression. There are a
total of 2 ¼ turns of adjustment. Turn the knob in the “+”direction
(clockwise) for more damping and slower rebound speed. Turn the
knob in the“-”direction (counter-clockwise) for less damping and
faster rebound speed.
Lockout- The Lockout Lever controls the fork lockout. Rotate the
lever completely between the stop points to the LOCKED (no travel)
or the UNLOCKED (free fork) fork travel.
Changing Lockout Lever Position
The position of the lever can be changed according to your preference.
To change the position, loosen the set screw on the lockout lever,
rotate the lever where you want it, and then retighten the set screw.
Do not over-tighten.
0.9 Nm, 8 In Lbs
NOTICE
Do not over-tighten. Use a torque wrench.

3
Needle Bearing Reset Procedure
1. Release all the fork air pressure.
2. Loosen the rebound knob set screw and lift o the rebound knob.
3. Insert a Shimano TL-FW80 freewheel tool into the top cap of the
fork and turn it counter-clockwise to loosen and remove the top
cap.
4. Lower the outer tube and remove the two split rings.
5. Repeatedly cycle the outer tube upward until the the length from
the crown ange to the top edge of the tube is 285 mm.
Make sure telescope is fully
extended when taking the
measurement.
Fork Boot
BAND CLAMP
BOOT
BAND CLAMP
1
2
The boot protects the internal parts (inner tube(1) , races (2) , lubricant,
needle bearings, and other internal parts) from contamination and damage.
If the boot is loose or damaged, dirt, water, dust, salt spray or other
contaminants can quickly damage the fork.
1. Place bike in a work stand and remove the front wheel.
2. Carefully remove the upper and lower band clamps securing the boot.
3. Lift the unsecured boot up to expose the inner tube. Wipe away any
old grease with a clean lint-free shop towel. Cycle the fork and repeat
the process to remove old grease.
4. Thoroughly inspect the inner tube (1) and inner races (2) for any signs
of corrosion or damage. Some very light wear to the inner races is
normal, however, they are worn-out if any scratches or grooves are
evident. If heavy corrosion is present they must be replaced. If ridges
can be felt by the tip of a rolling ball point pen over the race, the races
should be replaced. If damage is found, the damaged parts must be
replaced new before the fork is ridden.
NOTICE
TO PREVENT SERIOUS DAMAGE: Do not use solvents or spray
chemicals to clean. Protect the exposed fork from contaminants.
6. Use a sti nylon brush to rub in a high-quality bicycle grease onto the
inner tube and bearing races.
Cycle the fork and re-apply grease. Cycling moves the new grease
inside the fork onto the outer tube races and bearing cages.
Avoid applying grease to the areas just under the boot/zip tie. Wipe it
o the inner tube and inner boot to ensure that boot does not slide up
when zip tie is re secured.
7. When you are nished, inspect the condition of the boot. Make sure
it is undamaged. Replace it if it is. Re secure the boot and reassembly
the fork.
23
4
5
4

4
Maintenance
Maintenance of your fork is important to your safety and to the useful life
of the fork. Frequent inspection by you and regular professional service
by your Cannondale Dealer can help ensure years of safe/trouble-free
operation.
YOU BEFORE AND AFTER RIDING:
INSPECT - Clean and inspect entire fork for cracks or damage. Things
that can indicate a serious problem: (1) Unusual“klunking”or knocking
noises (2) changes in travel (3) Over-extended or compressed boot (4)
Changes in the way the fork has been working (5) Loss of adjustments
features. (6). Sudden air loss or leaking uid.
Check the fork 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.
Check the attachment of the boot at the top and bottom. The upper
and lower boot lips should be tted over the lower collar and fork lip.
Replace the zip ties and cable guides (clamps) as required. Always tighten
securely. Replacement boots, zip ties, and cable clamps are available
through a Cannondale Dealer.
If you nd boot damage, the area under the fork should be inspected for
damage. And the damaged boot must be replaced with a new one. Do
not try to x it.
CHECK ADJUSTMENTS - Make sure the adjustment features of your fork
(air pressure, lockout, and rebound) function normally.
PERFORMED BY CANNONDALE DEALER :
RE-GREASE TELESCOPE Every 25 Hours
BEARING RESET Every 25 Hours
BOOT REPLACEMENT As Needed
(Annual recommended)
DISASSEMBLY, INSPECTION, REBUILD -
Inspect and disassembly of telescope and
races, bearings, main telescope parts,
damper cartridge, uids, seals, etc.
NORMAL: Every 100 Hrs
Safety Information
WARNING
NOT FOR JUMPING USE. See “ SECTION B. Intended Use”in your Cannondale
Bicycle Owner’s Manual.
SERVICE BY PROFESSIONAL BIKE MECHANIC ONLY. Special tools are required.
All air pressure must be released before servicing any fork. Never attempt to
work on a pressurized fork.
DO NOT MODIFY THE FORK IN ANY WAY. Do not attempt to alter or modify the
fork in an attempt to install accessories. Please consult with your Cannondale
Dealer.
DO NOT RIDE ON A DAMAGED FORK. STOP RIDING A DAMAGED FORK
IMMEDIATELY. Follow the fork maintenance schedule of this supplement.
Additionally, 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.
Our Factory Tech Room (North America) and Headshok Service Centers (Europe)
provide professional services through Cannondale Dealers for all Headshok sus-
pension forks. Please ask your dealer about the service programs available for
your model fork.
YOU CAN BE YOU SERIOUSLY INJURED, PARALYZED OR KILLED IF YOU
IGNORE THESE WARNINGS.
Cannondale Limited Warranty
Cannondale Headshok (Lefty, Fatty, Solo) suspension products are covered
under the terms and conditions of the Cannondale Limited Warranty. It is
availableonthePoliciespageofourwebsiteat: http://www.cannondale.com
Be sure to read the exclusions listed in the limited warranty. For example,
damage from accidents and improper maintenance are not covered.
Denitions related to forks:
The fork structure is covered in the FRAMES section of the Cannondale
Limited Warranty.
“Fork structure” means certain structural parts of the fork, specically the
fork legs, outer tube, the steerer tube, steerer tube clamps and the inner
tubes with attached dropouts or spindle. The boot, air lter assembly, cable
clamps, needle bearings, races, and bushings which are part of the telescopic
assembly are normal wear and tear items and ARE NOT covered by the limited
lifetime warranty.
The internal fork internal parts are covered by the 1 year (2 years in EU
countries) warranty against defects in materials or workmanship described
in the COMPONENTS section of the Cannondale Limited Warranty. “Internal
fork parts”are dened as items such as damping cartridges and their internal
parts, seals, o-rings, air cylinders, air pistons, springs, elastomers, bumpers,
bushings, needle bearings, races, and oil. Normal wear and tear on these
items is NOT covered by this 1 year (2 in EU) warranty. Like brake pads on a
car, you should expect to have these items professionally replaced or renewed
as you use the fork and they wear.
Fork Warranty Claims
For any warranty claim to be considered, the bicycle/fork must be brought
into an Authorized Cannondale Retailer on the continent on which the
bicycle/fork was purchased. The bicycle/fork must be in assembled condition
and accompanied by the original, dated sales receipt for the bicycle/fork.
Dealer Locator at: http://www.cannondale.com/Dealerlocator
Contact Cannondale
CANNONDALE USA
Cycling Sports Group, Inc.
172 Friendship Road,
Bedford, Pennsylvania, 15522 , USA
(Voice): 1-800-BIKE-USA
(Fax): 814-623-6173
[e-mail]
CANNONDALE EUROPE
Cycling Sports Group Europe, B.V.
mail: Postbus 5100
visits: Hanzepoort 27
7570 GC, Oldenzaal, Netherlands
(Voice): + 41 61.4879380
(Fax): 31-5415-14240
[email protected]
CANNONDALE AUSTRALIA
Cycling Sports Group Australia Pty Limited
Unit 8, 31-41 Bridge Road
Stanmore, NSW 2048, Australia
(Voice): 61-2-85954444
(Fax): 61-2-85954499
[email protected]
CANNONDALE JAPAN
Namba Sumiso Building 9F,
4-19, Minami Horie 1-chome,
Nishi-ku, Osaka 550-0015, Japan
(Voice): 06-6110-9390
(Fax): 06-6110-9361
[e-mail]
CANNONDALE UK
Cycling Sports Group
Vantage Way, The Fulcrum,
Poole, Dorset, BH12 4NU
(Voice): [phone]
(Fax): [phone]
[email protected].uk