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2005 Headshok Cartridge Removal Instructions En

2005 Headshok Cartridge Removal Instructions En

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Published by xjcai
This is cartridge removal instruction for 2005 Fattys, but I think it should apply to 1999 Fattys too.
This is cartridge removal instruction for 2005 Fattys, but I think it should apply to 1999 Fattys too.

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Published by: xjcai on May 03, 2009
Copyright:Attribution Non-commercial

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01/24/2013

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CANNONDALE USA (CUSA)
Cannondale Bicycle Corporation172 Friendship RoadBedford, Pennsylvania 15522(Voice): 1-800-BIKEUSA(Fax): 814-623-6173custserv@cannondale.com
CANNONDALE AUSTRALIA (CA)
Unit 6, 4 Prosperity ParadeWarriewood N.S.W 2102AustraliaPhone(02)9979 5851Fax(02)9979 5688
cannondaleaustralia@cannondale.com
CANNONDALE JAPAN (CJ)
12-5 Harayamadai5-cho Sakai CityOsaka, Japan 590-0132(Voice): 011.81.722.99.9399(Fax): 0722-93-6166
cjcustserv@cannondale.com
CANNONDALE EUROPE (CE)
mail: Postbus 5100visits: Hanzepoort 277570 GC OldenzaalNetherlands(Voice): +31 541 573580(Fax): 31-5415-14240
servicedeskeurope@cannondale.com
This document online at: http://www.cannondale.com/bikes/tech/All information and specifications are subject to change for productImprovement without notice.© 2004 Cannondale Bicycle Corporation - All Rights Reserved
Publication TitlePublication No.
Headshok Super Fatty 80
Fork Telescope Replacement Instructions
117688
.PDF
1/12/2005
General Information
These instructions are for a Cannondale field service program affecting certain
2005
Super Fatty
80
forks. The affected forkshave 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 Dealersthat received affected bicycles/forks will receive necessary service kit quantities. The existing damping cartridge must beremoved 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 KeyPark Tool SPA-1 (green pin spanner) or Cannondale
HD136/
• Rubber MalletSchrader valve core toolSmall quantity clean fork oilSmall 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 toolA green pin spanner andlarge socket can be usedin place of this tool
 
2
Fork Removal & Disassembly
1. Secure bike in work stand; remove front wheel and detachbrakes from fork.2. Remove the valve cap and release the air pressure throughSchrader valve in fork crown until hissing stops.
WARNING
HIGH PRESSURE HAZARDRelease all air pressure before working and alwayskeep your face away from the top of the fork whenopening.
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.
 
32145
 4  m m 5  m m
8. Position a large deep-well socket over the fork hex nut. Thesocket 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 arubber 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 outercap (1) from steerer tube (2). Or use
HD136/
 Turn counter-clockwise (B) - 6 turns approximate.
Park ToolSPA-112
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 turnthe tool 10 full turns until the cartridge disengages.Remember that the thread locking agent is used toinstall the cartridge; this naturally slows unthreading.The important point here is to work carefully to avoiddamaging the damper shaft. 
CAUTION
1. 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
12
HDTL146/
Cartridge Reinstallation
1.
Remove the old air piston seal (1). Replace it with the newone included in the service kit.2.
Lubricate the inner tube walls of the replacementtelescope with clean high-quality suspension fork oil.3. Clean and dry the cartridge threads.Apply drop of Loctite™ #
242
(blue) or equivalentremovable 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 cartridgeinto 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 youinsert the cartridge into the inner tube. This will allow airpressure 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 ToolSPA-1 (green pin spanner).
WARNING
E
NSURE COMPLETE THREAD ENGAGEMENT;TIGHTEN DAMPING CARTRIDGE AND OUTER CAPSECURELY
242
1
Loctite™
(blue)
REPLACE THIS SEALWITH THE ONEINCLUDED IN THESERVICE KITCOAT THIS ENTIRE ENDWITH SUSPENSIONFORK GREASE

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