Cannondale Synapse Carbon Configuration guide

synapse carbon
Owner’s Manual Supplement
123952.PDF
READ THIS SUPPLEMENT AND YOUR CANNONDALE BICYCLE
OWNER’S MANUAL CAREFULLY! Both contain important safety
information. Keep both for future reference.
EN - 03/09
Please note that the specications and information in this manual are subject to change for product
improvement. For the latest product information, go to http://www.cannondale.com/tech_center/

2
SAFETY
INFORMATION
About This Supplement
Cannondale Owner’s Manual Supplements
provide important model specic 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.
• 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.
WARNING
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
IMPORTANT COMPOSITES MESSAGE
Your bike is made from composite materials
also known as “carbon ber.”.
All riders must understand a fundamental
reality of composites. Composite materials
constructed of carbon bers are strong
and light, but when crashed or overloaded,
carbon bers 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.

123952.PDF
3
Intended Use
The intended use of your bike or frameset is
CONDITION 1 / HIGH PERFORMANCE ROAD.
For riding on
pavement
only
CONDITION 1 / HIGH-PERFORMANCE ROAD
bikes and framesets are designed for riding
on a paved surface where the tires do not lose
ground contact. They are not intended to be
ridden o-road, cyclocross, or touring with
racks or panniers.
Material use is optimized to deliver both
light weight and specic performance. You
must understand that (1) these types of bikes
are intended to give an aggressive racer or
competitive cyclist a performance advantage
over a relatively short product life, (2) a less
aggressive rider will enjoy longer frame life, (3)
you are choosing light weight (shorter frame
life) over more frame weight and a longer
frame life, (4) you are choosing light weight
over more dent resistant or rugged frames
that weigh more. All frames that are very
light need frequent inspection for cracks that
would indicate that the frame is worn out from
fatigue. These frames are likely to be damaged
or broken in a crash. They are not designed to
take abuse or be a rugged workhorse.
WARNING
UNDERSTAND YOUR BIKE AND ITS
INTENDED USE. CHOOSINGTHEWRONG
BICYCLE FOR YOUR PURPOSE CAN BE
HAZARDOUS. 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 Manual for more information
about Intended Use and Conditions 1-5.
Maximum Weight Limit
RIDER
lbs / kg
LUGGAGE *
lbs / kg
TOTAL
lbs / kg
275 / 125 10 / 4.5 285 / 129
* Seat Bag /Handlebar Bag Only

4
Building Up A Frameset
Before building up a frameset, consult with
your Cannondale Dealer and the component
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-o,
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.
Readand followthecomponentmanufacturers
warnings and instructions.
Protect From
Extreme Temperatures
• Protect your carbon bike from extreme
temperatures when storing or transporting it.
• Allow your bike to cool o 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 at in
a black pickup truck bed in the desert sun or
under the glass of a hatchback auto.
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.

123952.PDF
5
Inspection & Crash
Damage of Carbon Frames
WARNING
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 ber.
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 ber section
Continuing to ride a damaged frame
increases the chances of frame failure,
with the possibility of injury or death of
the rider.
Repainting Or Renishing
You should not paint over the existing nish,
renish or repaint your bike. The carbon ber
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
renishing chemicals.
WARNING
Repainting, painting over, retouching, or
renishing your frame or fork can result in
severe damage leading to an accident. You
can be severely injured, paralyzed or killed.
Renishing 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.

6
1
3
2
4
serial number
The serial number (1) printed and permanently axed barcode label. Use this serial number for
warranty registration and theft recovery. See your Cannondale Bicycle Owner’s Manual for more
information on warranty registration.
bottom bracket guide
The cable guide (2) is mounted on the lower bottom bracket. Replacements are available
through a Cannondale Dealer. The kit # is KF363/.
vent
Keep the small vent hole (3) in the bottom of the bottom bracket shell clear of any dirt so that
any water can drain out. 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.
After wet rides, remove seat post, invert bike to drain any water.

123952.PDF
7
KP063/
TOP TUBE GUIDE
FERRULE
REAR BRAKE
HOUSING
REAR BRAKE FRAME OPENING
INTEGRATED GUIDE
REAR BRAKE
HOUSING
FERRULE SEAT
BRAKE CABLE
KF363/
BB GUIDE
EXTENSION
SCREW
cable routing
The top tube guide is removable so that brake cable may be routed inside the tube. The
guide is secured in the tube opening by the installed brake cable tension. Make sure the guide
is seated properly in the top tube opening when installing and connecting the rear brake.
Be sure to use ferrules on housing ends. When installing cables, make sure ferrule is seated
inside frame opening correctly.

8
seat post
Seat Tube/Binder Preparation
Burrs or sharp edges of the seat tube insert opening can scratch the seat post. Before inserting
the seat post into the frame, do the following:
1. Remove the seat binder exposing the seat tube insert.
2. Lightly round the opening of the insert using 240 grit or lighter sand paper.
3. Apply carbon gel into the opening of the seat tube. Carbon gel has been included in the parts
boxes of 2009 Synapse Carbon. It is also available by ordering Cannondale kit KF115/.
4. To improve clamping force, lightly grease the outside surface of the seat tube insert before
reinstalling the seat binder.
5. Reinstall the seat binder.
6. Before inserting the seat post, apply carbon gel to the seat post.
7. Use a torque wrench to tighten the seat binder bolts to 6 Nm.
6.0 Nm, 53 In Lbs
KP095/
LIGHTLY GREASE THE SEAT TUBE INSERT
UNDER THE SEAT BINDER
APPLY CARBON GEL INSIDE THE TUBE.
LIGHTLY ROUND OR SMOOTH THE EDGE
OF THE OPENING WITH 240 GRIT OR
LIGHTER SANDPAPER
SEAT BINDER SHOWN REMOVED

123952.PDF
9
Saddle Clamp Assembly
1. Apply Loctite® 242 (blue) to the clamp bolt threads.
2. Make sure the seat post head is clean and dry. Do not apply grease.
NOTE: The saddle head is bonded in place. Do not attempt to remove or adjust it.
3. Assembly the parts as shown above.
4. Install the saddle so that the saddle rails locate in the slots between the inner and outer
clamps.
5. Use a torque wrench to tighten the seat saddle clamp 9 - 12 Nm.
9 - 12 Nm
DO NOT APPLY GREASE TO
THE SADDLE CLAMP PARTS
SEAT POST HEAD
INNER
CLAMP
OUTER
THREADED
CLAMP
INNER
CLAMP
OUTER
CLAMP
CLAMP BOLT
SEAT POST
Loctite® 242 (blue)
Loctite® 242
(blue)
KP096/
M6X50
WARNING
Incorrect alignment of the saddle clamp
parts can result in the saddle moving
unexpectedly while riding. When adjusting
the saddle angle of your Synapse Carbon,
make sure the saddle rails on both sides of
the saddle are aligned with the inner and
outer clamp on both sides of the saddle.
Ask your Cannondale Dealer for assistance.
YOU CAN BE SEVERELY INJURED, PARALYZED,
OR KILLED IF YOU IGNORE THIS WARNING.
Saddle rails aligned
with inner and outer clamp grooves.
SADDLE
RAILS
CORRECT

10
Cutting the Seat Post
Depending on the frame size of your Synapse Carbon, the seat post may require cutting to a
shorter length. This must be performed by a professional bike mechanic. The Synapse Carbon
frame has seat post depth in the seat tube that varies with the frame size. Small frame sizes can
accept between 110-130mm. Larger frame sizes can accept between 110-150mm.
To maximize saddle height adjustment range as well as maintain the necessary minimum insert
depth of 80mm of any seat post, the seat post must be tted (cut) to the frame.
To cut the seat post
1. Insert an uncut post into the seat tube. Insert it until it stops inside the frame. It should slide
in easily. Do not force it into the seat tube. This is the maximum distance inside the seat tube
the post will insert.
2. Determine the maximum desired adjustment range of the saddle that maintains the required
80mm of seat post inside the seat tube.
3. Remove the excess section from the end of the seat post. You should use a cutting guide
such as Park Tool SG-7 and a carbon specic saw blade. See Figure 2. You should also lightly
sand the cut post to round and smooth the cut.
4. Re-mark the MINIMUM INSERT line 80mm up from the bottom of the cut seat post. Mark the
seat post without scoring, scratching or otherwise damaging the surface of the seat post.
Use a thin decal (automotive pin striping) or a paint marker.
NOTE: U.S. Consumer Product Safety Commission (CPSC) bicycle regulations require minimum
seat post insertion be marked on the seat post.
WARNING
If the seat post requires cutting, have it done by a professional bike mechanic with experience
cutting high-performance carbon components.
YOU CAN BE SEVERELY INJURED, PARALYZED OR KILLED IF YOUR IGNORE THIS
WARNING.
More Information on Carbon Seat Posts
For more information about carbon ber seat posts, see also “APPENDIX D. Care and Maintenance
of Carbon Fiber Seat Posts” in your Cannondale Bicycle Owner’s Manual.