Cannondale LEFTY MAX 140 User manual

OWNER’SMANUALSUPPLEMENTOWNER’SMANUAL
OWNER’SMANUALSUPPLEMENTOWNER’SMANUALSUPPLEMENT
OWNER’SMANUALSUPPLEMENTOWNER’S
WARNING READ THIS SUPPLEMENT AND YOUR
CANNONDALE BICYCLE OWNER’S MANUAL.
Both contain important safety information.
Keep both for future reference.
2010
CANNONDALE USA
Cannondale Bicycle Corporation
172 Friendship Road, Bedford,
Pennsylvania, 15522-6600, USA
(Voice): 1-800-BIKE-USA
(Fax): 814-623-6173
[email protected]
www.cannondale.com
CANNONDALE EUROPE
mail: Postbus 5100
visits: Hanzepoort 27
7570 GC, Oldenzaal, Netherlands
(Voice): + 41 61.4879380
(Fax): 31-5415-14240
[email protected]
CANNONDALE AUSTRALIA
Unit 6, 4 Prosperity Parade,
Warriewood N.S.W., 2102, Australia
(Voice): [phone]
(Fax): [phone]
[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
[email protected]
LEFTY MAX 140
125123.PDF

In this supplement, particularly important information is presented in the following ways:
WARNING Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
NOTICE Indicates special precautions that must be taken to
avoid damage.
TIP A TIP provides helpful information.
This manual meets EN standards
14764, 14766, and 14781.
Vélo certifié conforme aux exigences du décret
N 95-937 du 24 août 1995 norme NFR030

2010 LEFTY MAX 140
Owner’s Manual Supplement
125123.PDF
EN - 07/09
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/
Replacement Cannondale part numbers are shown
throughout this supplement in BOLD ITALIC text.
CONTENTS
SAFETY INFORMATION ......................................2
INTENDED FORK USE................................................ 2
FORK DAMAGE......................................................... 3
SPECIFICATION .................................................4
LEFTY MAX 140 w/ FOX RLC..................................... 4
LEFTY MAX 140 w/ PBR........................................... 4
LEFTY WHEEL HUB................................................... 4
FRONT WHEEL ..................................................6
1 1/8” STEERER ADAPTER...................................8
XC3 STEMSTEERER .........................................10
MAINTENANCE SCHEDULE ...............................12
CLEANING............................................................. 13
FRAME BUMPER................................................... 13
BOOT INSPECTION................................................ 14
CLEAN/REOIL AIR FILTER.................................... 15
NEEDLE BEARING RESET....................................... 16
CLEAN/REGREASE TELESCOPE ............................ 18
LEFTY MAX 140 W/ FOX RLC.................................
ADJUSTMENTS ..................................................... 19
SAG/PRELOAD ...................................................... 22
NEEDLE BEARING RESET....................................... 23
SPRING CHANGE................................................... 24
OIL CHANGE.......................................................... 26
LEFTY MAX 140 W/ PBR ......................................
ADJUSTMENTS ..................................................... 28
RECOMMENDED AIR PRESSURE........................... 29
NEEDLE BEARING RESET....................................... 30
REPLACEMENT PARTS .....................................31
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.

2
SAFETY INFORMATION
INTENDED FORK USE
Lefty MAX 140mm forks are intended for use in Condition 4
(All Mountain) riding. The CONDITION 4 symbol is shown next
gure.
For riding on
rough trails
with medium
obstacles
Figure 1.
CONDITION 4
Bikes designed for riding Conditions 1, 2, and 3, plus rough
technical areas, moderately sized obstacles, and small jumps.
Fork is Intended
For trail and uphill riding. All-Mountain bicycles are: (1)
more heavy duty than cross country bikes, but less heavy
duty than Freeride bikes, (2) lighter and more nimble than
Freeride bikes, (3) heavier and have more suspension travel
than a cross country bike, allowing them to be ridden in more
dicult terrain, over larger obstacles and moderate jumps, (4)
intermediate in suspension travel and use components that t
the intermediate intended use, (5) cover a fairly wide range of
intended use, and within this range are models that are more
or less heavy duty. Talk to your retailer about your needs and
these models.
Fork Not Intended
This fork is not intended for use in extreme forms of jumping/
riding such as hardcore mountain, Freeriding, Downhill, North
Shore, Dirt Jumping, Slope-style, Hucking etc.
WARNING
UNDERSTAND YOUR FORK AND ITS INTENDED USE.
USING YOUR FORK 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.

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3
FORK DAMAGE
WARNING
STOP RIDING A DAMAGED FORK IMMEDIATELY.
The following conditions indicate that serious fork damage is present:
1. Any unusual“klunking”or knocking noises.
2. A change in fork travel.
3. An over-extended, elongated, or compressed boot.
4. Changes from the way the fork had been working
5. Loss of adjustment features, oil leaks, or air leaks.
6. Crash or impact damage (deep scratches, gouges, dents, or bending)
7. Small cracks under the bolt head of upper and lower clamp bolts. This inspection requires the removal of the bolts.
Horizontal cracks above and below the intersection of the upper and lower clamps with the outer tube portion of the
Lefty carbon structure.
Vertical cracks in the outer tube (where the races and needle bearings run). These may show as long, straight lines
perhaps several lines parallel to each other.
Also, please read Inspect For Safety in PART II, Section D. of your Cannondale Bicycle Owner’s Manual.
HAVE ANY DAMAGED FORK INSPECTED AND DAMAGE REPAIRED BY YOUR CANNONDALE DEALER. YOU CAN BE
SEVERELY INJURED, PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING.
The MAINTENANCE section of this supplement includes information about regular maintenance practices that can keep your fork
in good operating condition.

SERIAL NUMBER
Located on outertube
under the air lter
foam element.
CLAMP BOLT
16mm
ONE-PIECE INTEGRATION (O.P.I.)
INNER TUBE/SPINDLE
AIR FILTER ASSEMBLY
HD209/BLK
CARBON
(FOX RLC shown)
OUTER COLLAR
International Standard
BRAKE CALIPER MOUNTS
ADJUSTMENT
PBR - AIR PRESSURE
RLC - BLOW-OFF THRESHOLD
ALLOY
(PBR shown)
9 Nm, 80 In Lbs
CLAMP KIT
HD011/
AXLE BOLT THREADS
OUTER HUB BEARING LAND
INNER HUB BEARING LAND
SENSOR MOUNT
8CM01/BLK
LEFTYBOLTS/
CALIPER MOUNTING BOLTS
UPPER CLAMP
LOWER CLAMP
INTEGRATED 3D FORGED
OUTER TUBE
UPPER /LOWER CLAMPS
CARBON OUTER TUBE
CAP
Park SPA-1
AXLE BOLT
SEAL
INNER BEARING
WHEEL HUB
OUTER BEARING
WASHER
O-RING
NO RIDE
WHEEL TRUING TOOL - QCTL108/
15.0 Nm
DISC ROTOR BOLTS
6.2 Nm, Loctite 262
LEFTY WHEEL HUB
(exploded view)
QC117/ KB61902/
KB61805/
QC118/
QC081/ (24 spk, 6bolt)
QC627/ (32 spk, 6bolt)
WIDTHHT
137.6 mm 4.5”
163.0 mm 5.5”
BOOT
KF222/
FRAME BUMPER
HD215/
9 Nm, 80 In Lbs 9 Nm, 80 In Lbs
9 Nm, 80 In Lbs
KH057/
Thread repair kit
SPECIFICATION
LEFTY MAX 140 w/ FOX RLC LEFTY MAX 140 w/ PBR
TRAVEL 140 mm 140 mm
INTENDED USE CONDITION 4, All Mountain CONDITION 4, All Mountain
ADJUSTMENTS
LOCKOUT POP-TOP
REBOUND
LOW-SPEED COMPRESSION REBOUND
BLOW-OFF THRESHOLD
MAIN SPRING AIR PRESSURE
LIMITS: MIN. 50 psi, 3.4 bar
MAX. 225 psi, 15.5 bar
SPRING PRELOAD
10mm/10 turns MAX.
RECOMMENDED SAG 25-30% 35 - 42 mm 35 - 42 mm
SPRING TYPE/MATERIAL COIL/STEEL SOLO AIR
NEGATIVE SPRING STEEL AIR AUTOMATIC
DAMPER OIL VOLUME 145cc --
DAMPER OIL WEIGHT 10W 5W
TELESCOPE LENGTH
(Needle Bearing Reset) 720 - 730 mm 720 - 730 mm
LEFTY 24 AND 32 SPOKE HUB DIMENSIONS
DISC FLANGE DIAMETER 58MM
NON DISC FLANGE DIAMETER 44.5MM
DISC FLANGE TO CENTER 35MM
NON DISC FLANGE TO CENTER 20MM

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5
SERIAL NUMBER
Located on outertube
under the air lter
foam element.
CLAMP BOLT
16mm
ONE-PIECE INTEGRATION (O.P.I.)
INNER TUBE/SPINDLE
AIR FILTER ASSEMBLY
HD209/BLK
CARBON
(FOX RLC shown)
OUTER COLLAR
International Standard
BRAKE CALIPER MOUNTS
ADJUSTMENT
PBR - AIR PRESSURE
RLC - BLOW-OFF THRESHOLD
ALLOY
(PBR shown)
9 Nm, 80 In Lbs
CLAMP KIT
HD011/
AXLE BOLT THREADS
OUTER HUB BEARING LAND
INNER HUB BEARING LAND
SENSOR MOUNT
8CM01/BLK
LEFTYBOLTS/
CALIPER MOUNTING BOLTS
UPPER CLAMP
LOWER CLAMP
INTEGRATED 3D FORGED
OUTER TUBE
UPPER /LOWER CLAMPS
CARBON OUTER TUBE
CAP
Park SPA-1
AXLE BOLT
SEAL
INNER BEARING
WHEEL HUB
OUTER BEARING
WASHER
O-RING
NO RIDE
WHEEL TRUING TOOL - QCTL108/
15.0 Nm
DISC ROTOR BOLTS
6.2 Nm, Loctite 262
LEFTY WHEEL HUB
(exploded view)
QC117/ KB61902/
KB61805/
QC118/
QC081/ (24 spk, 6bolt)
QC627/ (32 spk, 6bolt)
WIDTHHT
137.6 mm 4.5”
163.0 mm 5.5”
BOOT
KF222/
FRAME BUMPER
HD215/
9 Nm, 80 In Lbs 9 Nm, 80 In Lbs
9 Nm, 80 In Lbs
KH057/
Thread repair kit

6
FRONT WHEEL
REMOVAL
1 Loosen the brake caliper mounting bolts.
Tilt the lower caliper bolt out of the boss so the caliper is
up out of the way of the disc. Snug up on the upper bolt
to hold caliper in place.
Take note of brake alignment shims between brake
bosses and the caliper. Be sure to reposition correctly.
2. Turn the hub extraction bolt counter-clockwise (ccw) to
remove the wheel.
NOTICE
■ Make sure the bolt is completely disengaged
before attempting to remove the wheel. Never
try to pull the wheel o forcefully.
■ When the wheel is o, to keep dirt out, cover the
hub opening.
■ Protect spindle from damage when wheel is
removed.
Continue turning the bolt until the wheel can be
removed easily from the spindle.
1
5mm
cw
ccw

125123.PDF
7
INSTALLATION
1. Inspect inside the wheel hub for contamination and
the condition of the hub seal. Take corrective action if
necessary.
Wipe the spindle clean with a dry shop towel and apply a
high-quality bike grease to the spindle bearing lands and
end threads.
2. Slide the wheel straight onto the spindle so, the larger
hub bearing starts to position on it spindle seat. At this
point, the axle bolt threads can correctly engage the
threaded spindle if the wheel is held on straight.
NOTE: Install the front wheel by positioning the bike
horizontally with the spindle facing up. Then place the hub
straight down onto the spindle, and tighten the axle bolt.
3. When the axle bolt threads engage the spindle, turn the
bolt clockwise with nger force slowly to allow the hub
bearings to slide onto the spindle bearing seats.
Once the hub has been drawn onto the hub completely,
use torque wrench to tighten to nal 15.0 N•m (133.0
In•Lbs).
4. Reinstall the brake caliper. Tighten bolts to 78.0 In•Lbf
(9.0 N•m).
5. Spin the wheel to make sure it moves freely. Be sure to
test the brakes for proper operation before riding.
WARNING
DO NOT CONTAMINATE BRAKE CALIPER, PADS, OR
ROTOR WITH GREASE.
WARNING
DO NOT RIDE WITHOUT A PROPERLY MOUNTED,
ADJUSTED, AND FUNCTIONING FRONT BRAKE
SYSTEM.
The Lefty (disc/caliper) acts as an integral secondary
wheel retention system. If the system is missing or
improperly installed, or if the wheel hub axle bolt should
loosen, the front wheel could slide o the spindle end.
When mounting IS compatible brake systems:
Follow brake manufacturer’s instructions when mounting
the brake caliper to the spindle brake bosses. Do not
modify the fork in any way.
PLEASE ASK YOUR CANNONDALE DEALER FOR HELP
WHEN INSTALLING COMPATIBLE FRONT BRAKE
SYSTEMS.
NOTICE
■ LOCATE BRAKE ROTOR BETWEEN THE PADS.
Replace shims that are in use, be sure the shims are
positioned between the caliper (adapter if any) and
inner face of the fork mounts, not under the head of
the caliper bolts.
■ USE ONLY THE LEFTY 16mm CALIPER BOLTS TO
MOUNT THE BRAKE. Longer bolts can result in
contact with the brake rotor causing severe damage.
Check clearance between the bolt tips and rotor after
remounting the caliper. Order replacement bolts -
Cannondale p/n LEFTYBOLTS/.
■ MAKE SURE THE BRAKE DISC CAN NOT MAKE
CONTACT WITH THE FORK BOOT. A rotating brake
disc can wear through the boot allowing contaminants
into the fork.

8
20 mm
CROWN RACE
(A Headset part)
(A)
CLAMP WIDTH
UPPER REDUCER
Slot
Slot
LOWER REDUCER
1.125 in STEERER
SPACERS
10 mm
5 mm
CLAMP BOLTS
9 Nm, 80 In Lbs
CLAMP BOLT
9 Nm, 80 In Lbs
1.125 in STEERER ADAPTER
The 1.125 in steerer adapter assembly enables fork installation into a standard 1.125 head tube. Consult the table on the next
page to determine if the 1.125 steerer adapter system is compatible with the 1.125 head tube before attempting to install the
fork. The adapter system only be installed by a professional bike mechanic.
INSTALLATION POINTS
• When installing the steerer into the headtube with the Lefty, make sure the lower reducer is inserted completely into the
lower clamp.
• Install the upper reducer so that the top is ush with top of upper clamp or raised slightly. Do not install upper reducer with
the top below the below the top of the upper clamp.
• Locate the upper reducer slot 180° opposite the Lefty upper clamp slot.
• Install a combination of adapter kit spacers (5 mm, 10 mm, and 20 mm) to close the gap between the headset top cap and
the upper reducer.
• Install all handlebar stem spacers above the upper reducer.
• Tighten the upper and lower Lefty Clamp bolts AFTER the stem top cap has been installed and preload set. Tighten the Lefty
Clamp bolts to 9 Nm, 80 In Lbs.
MAXIMUM 1.125 HEADTUBE LENGTH (mm)
CANNONDALE KIT 1.125 HEADSET If (A) = 137.7 mm If (A) = 163.0 mm
KH058/ Kit, Steerer,Lefty 1 1/8”w/ Standard Headset 112.3 mm 137.7 mm
KH059/ Kit, Steerer,Lefty 1 1/8”w/ Hiddenset Headset 124.3 mm 149.7 mm
KH060/ Kit, Steerer,Lefty 1 1/8”w/ Zero Stack Headset 127.1 mm 152.5 mm

125123.PDF
9
20 mm
CROWN RACE
(A Headset part)
(A)
CLAMP WIDTH
UPPER REDUCER
Slot
Slot
LOWER REDUCER
1.125 in STEERER
SPACERS
10 mm
5 mm
CLAMP BOLTS
9 Nm, 80 In Lbs
CLAMP BOLT
9 Nm, 80 In Lbs

10
HEADTUBE
LEFTY
F
RON
T
BRA
KE L
IN
E
Grease!
Grease!
Grease!
STEM SIZE MARKING
LENGTH ANGLE
H-BAR DIA.
DATE
6.0 Nm
9.0 Nm
RING
Apply grease to threads before installing!
9.0 Nm
Keep hole clear for drainage
STEERER BOLT - HD152/
QSISEAL/
BEARING SEAL
CAP
STEM STEERER
HD169/
HEADSHOK HEADSET BEARING
HD169/
HEADSHOK HEADSET BEARING
9.0 Nm
UPPER CLAMP BOLT
LOWER CLAMP BOLT
F
RONT BRAKE LINE
STEM STEERER
KT020/
“Ernie”
BEARING SEAL
XC3 SI STEM STEERER
The following procedures should only be completed by
a professional bike mechanic.
INSTALLATION
1. Loosen both clamp bolts .
2. Position the Lefty clamps onto the headtube assembly as
shown.
NOTE: Be sure to route the front brake line between Lefty
and Headtube when mounting the fork.
3. Insert Cannondale tool KT020/ (a.ka.“Ernie”) through
the bottom clamp, into the head tube, and out the upper
clamp. The tool aligns and guides the steerer. Its really
quite eective! See the graphic?
4. Use a rubber mallet to drive the stem-steerer into the
head tube until it stops.
5. Clean and apply grease to the steerer bolt threads and
install into the bottom of the stem-steerer. This is an
important step. Don’t forget the grease!
Align handlebar and tighten the steerer bolt to 9 N•m.
6. Tighten the upper and lower clamp bolts to 9 N•m.
REMOVAL
Once again, make sure you have the Ernie.
1 Loosen upper and lower clamp bolts.
2. Remove steerer bolt. Use a 5mm Allen key; turn counter-
clockwise.
3. Insert the small end of KT020/ into the bottom of the
stem-steerer, hold the LEFTY, and drive the stem-steerer
up out of the head tube.
“NOW THAT’S
AN
AWESOME TOOL!”

125123.PDF
11
HEADTUBE
LEFTY
F
RON
T
BRA
KE L
IN
E
Grease!
Grease!
Grease!
STEM SIZE MARKING
LENGTH ANGLE
H-BAR DIA.
DATE
6.0 Nm
9.0 Nm
RING
Apply grease to threads before installing!
9.0 Nm
Keep hole clear for drainage
STEERER BOLT - HD152/
QSISEAL/
BEARING SEAL
CAP
STEM STEERER
HD169/
HEADSHOK HEADSET BEARING
HD169/
HEADSHOK HEADSET BEARING
9.0 Nm
UPPER CLAMP BOLT
LOWER CLAMP BOLT
F
RONT BRAKE LINE
STEM STEERER
KT020/
“Ernie”
BEARING SEAL
WARNING
THE STEERER BOLT IS A STRUCTURAL
PART AND MUST BE INSTALLED.
“NOW THAT’S
AN
AWESOME TOOL!”

12
MAINTENANCE SCHEDULE
This schedule is intended as a guide only. You must establish a schedule appropriate to your riding style and conditions.
WHAT TO DO NORMAL RACE
(In Hours)
CHECK FOR DAMAGE - See page 3.
BEFORE AND AFTER EVERY RIDE
BOOT INSPECTION - See page 14.
TIGHTENING TORQUE CHECK - Use a torque wrench:
Upper/lower clamp bolts: 9.0 Nm, 80 In Lbs
Wheel axle bolt: 15.0 Nm, 133.0 In Lbs
AFTER FIRST RIDE
CHECK EVERY 4-5 RIDES
CLEAN/RE-OIL AIR FILTER - See page 15. 25 10
CLEAN/ RE-GREASE TELESCOPE - See page 21. 50 25
NEEDLE BEARING RESET * See page 16. 25 25
Damping cartridge oil and seal change * 100 25
Inspect, replace frame bumper AS NEEDED
SCHEDULE PROFESSIONAL FORK SERVICE * ANNUALLY (Minimum)
Annually, or when problems are indicated you must have your Lefty fork serviced through a Cannondale Dealer or an
Authorized Headshok Service Center. Your fork should be disassembled by a suspension professional and evaluated for
internal and external part wear and damaged parts replaced with new ones. It should also include any work described in
any technical bulletins or product recalls.
PLEASE NOTE: Cannondale provides professional services through Cannondale dealers for Headshok /Lefty suspension
forks. Please ask your dealer about the service programs available for your model fork.
WARNING
FREQUENT MAINTENANCE AND INSPECTION IS IMPORTANT TO YOUR SAFETY. YOU CAN BE SEVERELY INJURED,
PARALYZED OR KILLED RIDING ON A BROKEN OR POORLY MAINTAINED FORK. Ask your Cannondale Dealer to help you
develop a complete fork maintenance program, one that suits where and how you ride.

125123.PDF
13
IMPORTANT INFORMATION ABOUT
RIDING IN WET, HUMID, OR COASTAL CONDITIONS
Before and after rides, frequently, inspect and renew grease under fork boot and service the air lter. Inspect the boot
for rips and tears. Check the folds. If the boot is damaged or not attached securely by the clamps/zip ties , water or
contaminants can enter. The boot should be removed and the fork should be immediately dried and re-greased to stop
any damage occurring due to moisture.
ANYTIME THE FORK BECOMES SUBMERGED
Stop riding it. The fork is not water tight. A moving submerged fork can accumulate water inside. If your fork has
been submerged, you should perform checks immediately.
DO NOT STORE YOUR LEFTY FOLLOWING A WET RIDE WITHOUT FIRST PERFORMING THE CHECKS ABOVE.
SERIOUS DAMAGE CAN OCCUR.
CLEANING
Clean using only a mild soap and water solution. Clean water and common liquid dish washing soap will work best. Be sure
to cover the adjusters with a clean plastic bag secured with a rubber band or masking tape. Spray o heavy dirt before wiping.
Spray indirectly.
NOTICE
■ DO NOT USE A PRESSURE WASHER. Use a low pressure garden hose. Power washing will force contaminants into the
fork promoting corrosion, immediately damaging, or result in accelerated wear.
■DON’T DRY WITH COMPRESSED AIR FOR THE SAME REASON.
FRAME BUMPER
The Lefty frame bumper is located on the outer tube between the clamps. The bumper cushions the frame from contact with the
fork. Replace it with a new one if it ever becomes damaged, torn, or missing.

14
BOOT INSPECTION
The fork boot protects the internal parts (inner tube, races,
lubricant, needle bearings, and other internal parts) from
contamination and damage. It is a barrier to water, dirt, dust,
mud, or grit encountered while riding. If the boot is loose or
damaged, dirt, water, dust, salt spray or other contaminants
will quickly ruin the fork.
The boot is an important protection, so before
every ride do the following:
1. Check the boot for damage cracking, splits, or tears. Be
sure to check in the folds of the boot.
Check carefully in the folds.
Check for any cables or lines rubbing the boot.
Make sure the brake rotor does not rub or contact 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 OFTHE FORK INNER
TUBE (lower leg) SHOULD BE EXPOSED.
3. Replace clamps as required. Always tighten securely, but
do not over-tighten the clamps . Replacement cable
clamps are available through a Cannondale Dealer.
IMPORTANT:
If you nd boot damage, the area under the fork should also be
inspected for damage. And, the damaged boot must be replaced
with a new one before riding. Do not try to x it.

125123.PDF
15
CLEAN/RE-OIL AIR FILTER
The air lter assembly is located over breather air holes in the
outer tube. The air lter assembly stops the passage of dirt
and water which would damage the internal fork components.
The cleaning procedure is the same for carbon or alloy outer
tube fork
To clean and re-oil air lter
1. Loosen and remove both the upper and lower clamps.
Return the lower clamp to the top of the boot and secure
it to seal out water.
2. Slide the air lter cover up o the foam element.
3. Slide the foam element up o the breather hole.
4. Cover the breather hole by applying a ring of vinyl tape
around the tube.
5. Using warm clean soapy water, massage the foam air
lter element. Preventing water or soap from entering
the holes in the outer tube or into top of the boot. This
will clean the foam of accumulated dirt or dust.
6. Repeat the process with clean warm water to rinse the
foam. Gently squeeze the foam element to remove the
water.
7. Allow the foam element to dry completely, and massage
in a high-quality foam air lter oil.
8. Slide the foam element back into position over the
breather hole.
9 Slide the boot back over the foam element. The lower
lter cover lip should be lapped over the top of the boot.
The small holes in the lter cover should be positioned on
the fork so they are at the sides to prevent plugging from
dirt or debris thrown by the front wheel.
NOTICE
■DO NOT USE SPRAY CLEANERS.
■COVER BREATHER HOLE. MAKE SURE THE
BOOT LOWER CLAMP IS SECURE.
LOWER
CLAMP
FILTER
COVER
FILTER
FOAM
Breather hole
BOOT
Small holes
OUTER TUBE
HD209/BLK

16
LEFTY NEEDLE BEARING RESET
The unique advantage of the Lefty telescopic fork structure is the utilization of 4 needle bearing cages. Each cage contain 22
precision stainless steel needle bearings. The use of needle bearings requires less surface area to make the telescope perform
smoothly and eciently. This is accomplished through rolling versus sliding and results in less friction. Less friction means
smoother travel, pure and simple. Compare that with conventional forks that use bushings in their stanchions. These bushings
have more contact with the sliding part of the scope, which generates friction. That friction causes a heat build-up within the fork
and robs performance.
BUSHINGS
STICKION
NEEDLE BEARINGS
OUTER RACE
INNER RACE
REDUCED FRICTION
BETTER RESPONSE
CONVENTIONAL FORKS LEFTY FORKS
The system requires simple periodic maintenance to ensure proper bearing alignment. Why? Inside the fork the four needle
bearing cages of the telescope move independently up and down between each inner and outer race pair. Bearing cage
migration happens when a cage or cages shifts out of alignment up or down in relation to the others. Very slight migration
would not aect travel noticeably, however, as a cage continues to move out of position relative to the others, the available travel
will be reduced.
Needle bearing migration is normal and to be expected. However, if the fork in this state for extended periods, the fork can be
damaged. Indications of migration are: An usual “top out”noise , reduced travel.
RESETTING NEEDLE BEARING MIGRATION
The procedure for resetting your specic Lefty needle bearings is described in the section of the supplement specic to your
fork. The techniques of resetting is the same for all forks, however, dis-engaging the damping cartridge diers. We provide the
information in the supplement, however, we recommend that you always have this procedure performed by your Cannondale
Dealer. If migration re-occurs frequently (immediately after resetting), the cause could be damage present in the inner or outer
races, ,bearings/cages or other fork parts. Inspection and replacement of damage parts will be required to correct a persistent
problem with bearing migration.

125123.PDF
17
AIR FILTER
NEEDLE BEARING CAGES
INNER TUBE
OUTER RACE
INNER RACE
ALIGNED
MIGRATED
BOOT
DAMPING CARTRIDGE
CYCLING THE TELESCOPE
GRADUALLY TO
ITS FULL LENGTHWITH
DAMPING CARTRIDGE DISENGAGED
RE-ALIGNSTHE NEEDLE BEARING CAGES
TELESCOPE
LENGTH
(mm)
OUTER TUBE
See the SPECIFICATIONS
table for your fork.

18
BOOT
INNER TUBE
INNER RACE
WIPE OFF
OLD GREASE
WITH CLEAN
LINT-FREE
SHOP TOWEL
RE-APPLY
NEW GREASE
(shown lifted)
CLEAN/RE-GREASE TELESCOPE
Periodically, or whenever the fork is ridden in extreme
conditions or is submerged, perform the following procedure.
To clean and re-grease
1. Remove the front wheel.
2. Carefully release the upper and lower zip ties securing the
fork boot. If the boot is secured with a band clamp, loosen
and remove the clamp.
3. Lift the unsecured boot up to expose the inner tube .
4. Wipe o the old grease with a dry shop towel.
5. Re-apply a fresh heavy coating of grease. Any clean
high-quality bicycle bearing grease selected for riding
temperatures and environment can be used.
We assemble forks at our factory using
LUBRIPLATE GR-132.
http://www.lubriplate.com/pdf/pds/3_4%20GR-132.pdf
Cycle the fork several times between applying grease to
the new grease is worked into the bearings.
6. Reposition the boot and replace the upper and lower
clamps.
NOTICE
■DO NOT USE SPRAY CLEANERS OR
ABRASIVES. USE A CLEAN SHOP TOWEL
ONLY.
NOTE: Make sure the clamps are secure without over-
tightening. A loose clamp may allow water or dirt to
pass behind the boot. If the clamps are too tight, boot
damage can occur.