Cannondale Synapse Carbon Configuration guide

SYNAPSE CARBON
Owner’s Manual Supplement
118153.PDF
Revision 1

READ THIS MANUAL CAREFULLY!
It contains important safety information.
Keep it for future reference.
Please note that the specifications and information in this manual are subject to change for
product improvement without notice. For the latest product information, go to http://
www.cannondale.com/bikes/tech/.
1
05/01/2005
GENERAL SAFETY INFORMATION ......... 2
About This Supplement ............................... 2
Special Manual Messages ........................... 2
Intended Use (HP Road Bikes) ................... 3
Inspecting for Crash or Ride Damage ...... 3
Protect From Extreme Temperatures ....... 3
Bike Stands ...................................................... 4
Cleaning ........................................................... 4
Drain Out Water ............................................. 4
Building Up A Frameset ............................... 4
About Repainting or Refinishing ............... 5
Warning Label ................................................ 5
UNDERSTANDING
COMPOSITE MATERIALS 101 .................. 6
Fundamental Reality Composites ............6
What are Composites? .................................6
Why are Composite Used? ..........................6
What are the Limits of Composites? ........ 7
Crash Damage ................................................ 7
Inspection .......................................................8
TECHNICAL INFORMATION ...................9
System Integration SI Carbon Crankset
Removal ...........................................................9
Installation ......................................................9
Bearing Installation .................................... 10
Spindle Insertion ...........................................11
Bearing Removal ...........................................12
Circlip Removal .............................................. 13
Circlip Reinstallation ....................................13
Expolded View ..............................................14
SI Carbon Crankarm/Chainrings .............. 16
SI-to-Standard BB Adapter ......................... 17
Seat Post & Seat Tube Info .........................18
Rear Derailleur Hanger ...............................20
Chainstay Protector .....................................21
Bottom Bracket Cable Guide .................... 22
GEOMETRY ........................................... 23
SERIAL NUMBER .................................. 24
SPECIFICATIONS ....................................25
REPLACEMENT PARTS (KITS) ................ 26
OWNER NOTES .....................................27
CONTENTS
SYNAPSE CARBON
Owner’s Manual Supplement
118153.PDF
Revision 1

2
GENERAL 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 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.
Go to: 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 to the owner.
* * IMPORTANT * *
This manual may include procedures
beyond the scope of general mechanical
aptitude. Special tools, skills, and
knowledge may be required.
If you have any doubt about your ability
to properly inspect, adjust, or service
your bicycle, do not attempt to perform
the work described; please take it to a
Cannondale Dealer.
Special Manual Messages
In this manual, information which affects
your safety is emphasized in the following
ways:
The Safety Alert Symbol means :
“ATTENTION....BECOME
ALERT, YOUR SAFETY IS INVOLVED.”
WARNING
A WARNING indicates a potentially
hazardous situation which, if not avoided,
can result in serious injury or death.
WARN000
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 depending on
the situation and degree of damage.
Important matters are described in
CAUTION (as well as WARNING), so be
sure to observe them.
CAUT000
NOTE:
A NOTE provides helpful information or
tips intended to make the information
presented clearer.

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3
Intended Use of High-
Performance Road Bikes
The Synapse is a road bike. It is designed
to be ridden on paved roads only. It is not
designed for touring with racks or panniers.
It is not designed for cyclocross or off road.
WARNING
Using your bicycle improperly is
hazardous.
WARN001
Inspecting for
Crash or Ride Damage
WARNING
AFTER A CRASH OR IMPACT:
Inspect frame carefully for damage (See
page 8.). Do not ride your bike if you
see any sign of damage, such as broken,
splintered, or delaminated carbon fiber.
A delamination or break in the adhesive
bonds between aluminum and carbon
components may be present if the
following are present: an unusual or
strange feel to the frame such as carbon
tubes which have 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.
WARN002
Protect From
Extreme Temperatures
• Protect your bike from extreme
temperatures when storing or
transporting it.
• Allow your bike to cool off or warm up
before you ride
• 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, 0r, under the
glass of a hatchback auto. )

4
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.
CAUT000
Cleaning
When cleaning your bike, use only a mild
soap and water solution. Wipe off road film
with a clean soapy towel. Rinse with clean
water and wipe dry. Never power wash
your bike. Avoid spraying water directly
at frame openings (bottom bracket, water
bottle rivnuts, seat tube opening, head tube
seals).
Drain Out Water
Water can enter into frame tubes through
washing, condensation, wet rides, or rain.
It penetrates or can be sprayed in through
water bottle bosses, seat tube, head tube
and seat post openings.
Water will not chemically harm your bike.
If it freezes, the ice expansion can burst or
crack the frame making it unsafe to ride.
This damage is NOT covered under your
warranty.
Building Up A Frameset
Before building up a frameset, consult with
your Cannondale Dealer and the component
manufacturers, and frankly 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.
Generally speaking, lighter weight
components 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 frequently.
If you are a heavier rider or have a rough,
abusive or “go for it” riding style, buy heavy
duty components.
Read and follow the component
manufacturers warnings and instructions.

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5
About Repainting Or Refinishing
You should not paint over the existing
finish, 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.
WARNING
Repainting, painting over, retouching, or
refinishing your frame or fork can result
in severe damage leading to an accident.
You 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.
WARN003
Warning Label
The following warning label is located on
the seat tube of your bike.

6
UNDERSTANDING COMPOSITE MATERIALS 101
Fundamental Reality of Carbon Composites
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.
WHAT ARE COMPOSITES?
The term “composites” refers to the fact that a part or parts are made up of different
components or materials.
You’ve heard the term “carbon fiber bike” and now you own one. This really means
you own a “composite bike” with carbon fibers being the primary material used to
make it.
Carbon fiber composites are typically a strong, light fiber in a matrix of plastic, molded
to form a shape.
The composites with the best strength-to-weight ratios are made of carbon fiber in a
matrix of epoxy plastic. The epoxy matrix bonds the carbon fibers together, transfers
load to other fibers, and provides a smooth outer surface. The carbon fibers are the
“skeleton” that carries the load.
WHY ARE COMPOSITES USED?
Unlike metals, which have uniform properties in all directions (engineers call this
isotropic), carbon fibers can be placed in specific orientations to optimize the structure
for particular loads.
Engineers may also orient fibers to suit other goals such as comfort and vibration
damping.
The choice of where to place the carbon fibers gives engineers a powerful tool to
create strong, light bicycles.
Carbon fiber composites are very corrosion resistant, much more so than most metals.
Think about fiberglass boats.

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7
WHAT ARE THE LIMITS OF COMPOSITES?
Well designed “composite” or carbon fiber bicycles and components have long fatigue
lives, usually better than their metal equivalents.
While fatigue life is an advantage of carbon fiber, Cannondale still urges you to
regularly inspect your carbon fiber frame, fork, or components.
Carbon fiber composites are not ductile. Once a carbon structure is overloaded, it
will not bend; it will break. At and near the break, there will be rough, sharp edges
and may be delamination of carbon fiber or cloth layers. There will be no bending,
buckling, or stretching.
IF YOU HIT SOMETHING OR HAVE A CRASH, WHAT CAN
YOU EXPECT FROM YOU CARBON FIBER BIKE?
Let’s say you hit a curb, ditch, rock, car, fallen cyclist or other object. First, read the
Important warnings at the beginning of PART II Section A. Bicycles Cannot Protect
You in your Cannondale Bicycle Owner’s Manual.
At any speed above a fast walk, your body will continue to move forward, the
momentum carrying you over the front of the bike. You cannot and will not stay on
the bike and what happens to the frame and fork is irrelevant to what happens to
your body.
What should you expect from your carbon frame? It depends on many complex
factors, which is why we tell you that crash worthiness cannot be a design criteria.
With that important note, we can tell you that if the impact is hard enough, the
fork or frame may be completely broken. Note the significant difference in behavior
between carbon and metal. Even if the carbon frame was twice as strong as a metal
frame, once the carbon frame is overloaded it will not bend, it will break completely.
Cannondale carbon frames are designed for normal riding loads with a factor of
safety. These carbon frames will not survive some crash or impact loads which may
result in complete failure.
SEE “INSPECTION OF COMPOSITE FRAME, FORK, AND COMPONENTS”
ON THE NEXT PAGE.

8
INSPECTION OF COMPOSITE FRAME, FORK, COMPONENTS
Cracks:
Inspect for cracks, broken, or splintered areas. Any crack is serious. Do not ride any
bicycle or component that has a crack of any size.
Delamination:
Composites are made from layers of fabric. Delamination means that the layers
of fabric are no longer bonded together. Delamination is serious. Do not ride any
bicycle or component that has any delamination.
Delamination clues:
• A cloudy or white area. This kind of area looks different from the ordinary
undamaged areas. Undamaged areas will look glassy, shiny, or “deep,” as if
one was looking into a clear liquid. Delaminated areas will look opaque and
cloudy.
• Bulging or deformed shape. If delamination occurs, the surface shape may
change. The surface may have a bump, a bulge, soft spot, or not be smooth and
fair.
• A difference in sound when tapping the surface. If you gently tap the surface
of an undamaged composite you will hear a consistent sound, usually a hard,
sharp sound. If you then tap a delaminated area, you will hear a different
sound, usually duller, less sharp.
Unusual Noises:
Either a crack or delamination can cause creaking noises while riding. Think about
such a noise as a serious warning signal. A well maintained bicycle will be very
quiet and free of creaks and squeaks. Investigate and find the source of any noise.
It may not be a crack or delamination, but whatever is causing the noise must be
fixed before riding.

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9
TECHNICAL INFORMATION
1
2
Figure 1
System Integration SI Carbon Crankset
Removal
The crankarms are removed by turning the self extracting fixing bolt counter-clockwise.
To remove, insert a 10 mm Allen key through the retaining ring (1) into the fixing bolt, hold
the arm, and turn the bolt counter-clockwise until the crankarm can be removed. It is not
necessary to remove the retaining ring when removing or installing the crankarms.
Installation
1. Consult the exploded view parts drawing for parts arrangement for the drive and non-
drive sides.
2. Prior to installation, always be sure to thoroughly clean and grease the spindle splines
and threads and the arm sockets with a high-quality bicycle bearing grease. Insufficient
grease coverage can result in “creaking” of the crankarm assembly when riding.
3. Tighten the fixing bolt to 34-41 N•m (25-30 Ft•Lbs).
Insert a 10 mm Allen key
through retaining ring (1).
Turn counter-clockwise to
remove both crankarms.
Turn clockwise to install.
See “Reminders” on page 15.

10
Bearing Installation
The two circlips must be installed before the bearings are pressed into the bottom bracket
shell using a special 3-piece bearing driver tool KT010/. The tool parts are designed for
use with a headset cup bearing press with 1” adapters. such as Park Tool HHP-2 . Consult
the graphic below for the arrangement of the tool parts. The headset press needed is not
shown.
1. Drive one bearing at a time and apply a high-quality bicycle bearing grease to the BB
shell inside surfaces prior to installing the bearings.
Cannondale Tools
Kit # KT010/
1
1
Figure 2
Install the first bearing like this.
Install the second bearing like this. Notice the one
tool part is not in use.

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11
Spindle Insertion
Once the bearings have been installed, the spindle may be inserted into the non-drive
side.
1. Apply a light coat of a high-quality bicycle bearing grease to the spindle (1). Be sure to
grease the bearing seats (c), raised ridge (b), and spindle splines (d).
2. Install the bearing shield (2) onto the spindle (1) with the flat side (a) facing the non-
drive side spindle splines (d).
3. Apply a light coat of grease to the bearing seal and inner races of both bearings. Insert
the spindle assembly into the bearing, and tap lightly with a non-marring plastic mallet
until the spindle is seated in the bearings; the bearing shield (2) is seated against the
bearing.
4. Clean and apply a coating of grease to the threads (e).
(a)
(b)
1
2
(c) (c)
(d)
(e)
Figure 3
NON-DRIVE SIDE (left)

12
Bearing Removal
Remove the crankarm spindle. Position Cannondale special tool KT011/ behind bearing (1).
Install the tool as shown. Insert a driver from the opposite side. Locate it on the back of
the tool and use light tapping to drive the bearing from the shell. Repeat for other side. Do
not reinstall the removed bearings. Replace with a new set.
b
a
a
b
Use a headset cup bearing press with 1” adapters. with tool such as Park Tool - HHP-2.
c
1
4
3
2
KT011/
Figure 4

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13
Circlip Removal
Once the bearings have been removed, position a small thin blade screw driver (3) under
the curved end (b) of the circlip (4) and lift it out of the bottom bracket groove (c).
Circlip Reinstallation
Thoroughly clean the inside of the shell with a dry shop towel. Clean out the groove (c).
Position and hold the flat end (a) of the circlip in the groove. Slowly work the circlip into
the groove by sliding it inward toward the groove until completely seated. When finished,
thoroughly coat the entire inner surface of the bottom bracket shell with a high-quality
bicycle bearing grease.
b
a
a
b
c
4
3
Figure 5
WARNING
WEAR BOTH HAND AND EYE PROTECTION WHEN WORKING WITH CIRCLIPS.
WARN004
Thin blade
screw driver

14
10mm Allen key
34 - 41 N•m
(25-30 Ft•Lbs)
Park Tool SPA-2
(red pin spanner)
Loctite™
242 (blue)
1
(c)
2
3
4
6
5
78
1
2
3
4
9
8
(b)
(a)
DRIVE SIDE
(Right)
Parts Identification
1. Retaining nut
2. Washer
3. Fixing bolt
4. Washer
5. Drive side crankarm
6. Wave washer
7. Plastic shims
8. Bearing shield
9. Non-drive side crankarm
(a) spindle splines
(b) spindle threads
(c) flat side of shield (faces out)
SI Carbon Crankset Exploded View Figure 6

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15
10mm Allen key
34 - 41 N•m
(25-30 Ft•Lbs)
Park Tool SPA-2
(red pin spanner)
Loctite™
242 (blue)
1
(c)
2
3
4
6
5
78
1
2
3
4
9
8
(b)
(a)
Reminders
1. When reinstalling the crankarms, always clean the spindle splines, spindle threads,
and the crankarm sockets.
Apply a generous coating of a high-quality bicycle bearing and cover all the contact
surfaces. Also, lightly grease the exposed face of the bearing to repel moisture.
Also include the fixing bolt assembly, if removed. You should ensure grease coating
between the fixing bolt, each washer, and behind the retaining ring. If these parts
are dry, the increased friction may cause the retaining ring to back out while
attempting to extract the crankarm.
2. Use an accurately calibrated torque wrench to tighten .
NON-DRIVE SIDE
(Left)

16
b
c
Torx® T30
1
2
3
175
4
104 In•Lbs
(10.8 N•m)
39T
53T
Figure 7
Reminders
1. When assembling, be sure to align the
chain catchment pin (4) on the large
ring (1) with the crankarm as shown.
Align the bump (b) on the small ring
(2) directly above it (as shown).
2. Lightly grease the contact area between
the large (1), small (2) chainrings, and
the crankarm spider.
SIZE
MARK
SI Carbon Crankarm/Chainrings

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17
Carbon Synapse SI BB Permanent Adapter Insert
You may install a standard crankset bottom bracket with a special SI to standard bottom
bracket adapter insert (1). The threaded adapter is available from Cannondale and must
be professionally installed. Once installed, the adapter is a non-removable/ permanent
frame part.
1
Figure 8
WARNING
CARBON SYNAPSE STANDARD BOTTOM BRACKET SHELL THREADED INSERT (1) IS
PERMANENT AND NON-REMOVABLE. DO NOT ATTEMPT TO REMOVE IT. YOU CAN CAUSE
SERIOUS FRAME DAMAGE.
WARN005

18
Seat Tube and Seat Post Information
a
31
4
2
Figure 9
• YOUR SYNAPSE HAS A CARBON FIBER SEAT POST (1). AS A GENERAL RULE FOR CARBON
FIBER SEAT POSTS WITHOUT USING A SPECIALLY DESIGNED SEAT BINDER (2), THE
BINDER BOLT (3) SHOULD BE POSITIONED OPPOSITE THE SEAT TUBE (4) SLOT (a). This
reduces the possibility any distortion will push inward and deform or crack the seat
post when the clamping force is applied. Generally, damage happens when the bolt is
over-tightened. The seat binder that comes with your Synapse (shown) is designed to
be positioned either with or without the bolt over the slot since the diagonal slot of
the binder lessens the chances of this type of damage.
• ALSO CLEAN AND APPLY A FILM OF GREASE TO THE INNER SURFACE OF THE BINDER
CLAMP IN CONTACT WITH THE SEAT TUBE AND THE BOLT THREADS. This will promote
even application of the clamping force.
MAX TORQUE
6.8 N•m (60 In•Lbs)
MAX INSERT
DEPTH
200 mm