Cannondale LEFTY SPEED DLR2, Owner'S Manual Supplement

Page 1: ...MENTS 10 Suggested Air Pressure 10 How to Set Up Sag 11 Rebound Adjuster 12 Lockout Lever 12 Tuning Tips 13 MAINTENANCE 14 Schedule 13 Cleaning 13 Air Filter 17 Frame Bumper 17 Fork Boot 18 Needle Bearing Migration 20 XC3 SI STEM STEERER 22 SUSPENSION GLOSSARY 24 REPLACEMENT PARTS 27 DLR2 DAMPER 28 SL DAMPER 30 TELESCOPE PARTS 32 SERVICE TOOLS 33 OWNER NOTES 34 29 INCH WHEEL COMPATIBILITY 36 Pleas...

Page 2: ... before delivery to the owner WARNING This document 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...

Page 3: ...OPERLY IS HAZARDOUS Warning Label Located on the lower leg of the Lefty Do not remove it If it is missing or damaged you can obtain a free replacement from Cannondale Bike Suspension And Your Skills And Abilities WARNING YOU COULD HAVE A BAD ACCIDENT IF YOUR SKILL IS NOT UP TO HANDLING A SUSPENSION SYSTEM Suspension systems front fork rear shocks can increase the handling and stability of most bic...

Page 4: ...teerer Tube 2 Lockout Lever 3 Rebound Knob 4 Outer Collar 5 Upper Clamp 6 Outer Tube 7 Bumper 8 Lower Clamp 9 Cable Guide 10 Zip Tie 11 Boot 12 Spindle 13 Brake Mounts 6 IS Standard 14 Air Filter Assembly 15 Clamp Bolts 16 WARNING Label ...

Page 5: ...P TOP 9 1 8 CAUTION DO NOT LOOSEN OR TIGHTEN THIS NUT GR GR 1 Rebound Knob 2 O Ring lubricate 3 Set Screw 4 Lockout Lever Nut 5 Lockout Lever 6 O Ring lubricate 7 Outer Collar 8 Washer 9 Split Ring 10 Nut GR Apply bicycle bearing grease Use a Shimano TL FC32 Crank Adapter Installation Tool Shimano Y 130 09210 to remove and install ...

Page 6: ...o remove the hub from the spindle NOTE As the bolt is turned counter clockwise it will begin to back against the hub cap bolt 2 causing the hub 3 to be drawn out and off the spindle bearing seats Since the hub bolt is actually retained inside the hub body by the hub cap the bolt will remain in the hub when the wheel is removed There is no need to remove that cap from the hub See the exploded view ...

Page 7: ...ont 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 finger force slowly to allow the hub bearings to slide onto the spindle bearing seats Once the hub has been drawn onto the hub completely and proper threading is evident use ...

Page 8: ...N m 55 0 In Lbs 9 GR GR GR GR GR NO RID E QCTL108 11 1 Extraction Cap 2 Plastic Washer 3 O Ring lubricate 4 Axle Bolt 5mm Allen 5 Outer hub bearing 6 Hub 7 Inner hub bearing 8 Seal 9 Brake disc 10 Brake disc bolts 11 Wheel Truing Tool wheel hub Apply a high quality bicycle bearing grease to areas indicated GR ...

Page 9: ...hen 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 Mount the front brake caliper using the 16 mm bolts of Cannondale kit LEFTYBOLTS See next figure This photo shows the area where incorrect bolts will interfere with disc rotation possibly causing severe damage Correct ...

Page 10: ...ttaching a pump Pumping in dirt can quickly ruin the fork Stay within the pressure limits CARBON SL DLR2 NEG SPRG RIDER WT lbs RUSH SCALPEL RUSH SCALPEL 120 80 85 85 90 130 85 90 90 95 140 90 95 100 105 150 100 105 105 110 160 105 110 110 115 170 110 115 120 125 180 120 125 125 130 190 125 130 135 140 200 130 135 140 145 210 135 140 145 150 220 145 150 155 160 This table lists approximate air pres...

Page 11: ...ge negative spring of both Lefty DLR2 and CARBON SL forks is specific to the rider weight See table below If you find that you set the air pressure much higher or lower than suggested we recommend the corresponding negative spring for best performance Ask your Cannondale Dealer about negative spring kits for your fork RIDER WT Lbs FORK SIZE BIKE SIZE NEG SPRG COLOR CANNONDALE KIT CARBON SL DLR 2 to ...

Page 12: ...increase the damping which slows the rebound speed Turn the adjuster counter lockwise in the direction marked to decrease the damping which increases the rebound speed Lockout Lever 2 The Lockout Lever turns fork travel on and off Be sure to rotate the lever completely to either position until it stops Do not force the lever past the stops Lever Position LOCKED Travel off Fork locked in fully exte...

Page 13: ...mps but uses full travel Lower air pressure or softer coil springs softer compression damping reduce spring preload decrease bump threshold firmer negative spring revalve Fork dives under braking ncrease air pressure or stiffer coil springs firmer compression damping increase SPV pressure decrease SPV volume revlave Harsh on repeated bumps packs down feels like less travel poor traction in corners F...

Page 14: ...ent Check tightening torque of the fasteners and bolts listed in Tightening Torques in this manual Grease telescope 50 25 Needle bearing reset 25 25 Clean air filter 25 10 Damping cartridge oil and seal change 100 25 Inspect Replace Bumper AS NEEDED PROFESSIONAL SERVICE Annually or when problems are indicated you must have your Lefty fork serviced through a Cannondale Dealer or an Authorized Headsh...

Page 15: ...dentify the problems that can lead to an accident Cleaning USE ONLY A MILD SOAP AND WATER SOLUTION Clean water and a common dish washing liquid will work best COVER SENSITIVE AREAS WITH A CLEAN PLASTIC BAG Secured temporarily with a rubber band or masking tape a bag can prevent water damage to various bike components bearings seals fork shock adjustment features SPRAY OFF BEFORE WIPING To preserve...

Page 16: ... tears 2 Inspect and renew grease under fork boot 3 Clean dry and oil breather filter element 4 Ensure zip ties and band clamps are properly tightened replace as needed POST RIDE CHECKS The following service and checks are recommended above and beyond typical scheduled maintenance after riding in severely wet conditions 1 Inspect and renew grease under fork boot wipe dry if water is present 2 Inspe...

Page 17: ...uld be positioned to the sides of the and not to the front or back of the bicycle to minimize the chance dirt thrown by the wheels will plug the holes Clean the foam air filter element with warm soapy water allow to dry completely and reapply a high quality foam air filter oil before reinstallation Be sure to massage the oil into the foam A foam element without the oil is ineffective AIR HOLES FOAM ...

Page 18: ...rea under the boot should be professionally inspected for contamination or damage The damaged boot must be replaced with a new one Do not try to fix it WARNING CHECK THE BOOT BEFORE EACH RIDE DON T RIDE IF IT IS DAMAGED REPLACE IT WHEN YOU FIND DAMAGE Cleaning and Re greasing The Telescope Under the Boot The fork inner tube and inner bearing races parts of the telescopic fork assembly are located b...

Page 19: ...ts must be replaced new before the fork is ridden 1 2 7 Use a stiff nylon brush to apply a high quality bicycle grease onto the inner tube and bearing races Cycle the fork and carefully re apply grease Cycling moves the new grease inside the fork onto the outer tube races and bearing cages Its OK to leave a good coating under the boot Avoid applying grease to the area A just under the boot zip tie...

Page 20: ... a cage or cages shifts out of alignment up or down in relation to the others it is said to have migrated This migrated condition will limit travel Needle bearing migration is normal and expected However if the fork is ridden in this state for extended periods the fork can be damaged Evidence of migration is 1 An unusual top out noise If an unusual noise is heard the extended fork length should be...

Page 21: ...pecification do the following Firmly extend the telescope until it stops tip listen for the knocking at full extension to change from a hollow sound to a solid sound this indicates full extension has been achieved Do this several times using only moderate force extend the lower fork leg using a pumping action After you have performed this action several times re measure CAUTION If fork is out range...

Page 22: ...onto the top of the tool 6 Remove the cap 1 from the top of the steerer Use a rubber mallet to drive the stem steerer into the head tube until it stops Return the cap 1 7 Clean and apply grease to the steerer bolt threads and install into the bottom of the stem steerer Align handlebar and tighten the bolt to 9 N m 8 Tighten the upper and lower clamp bolts to 9 N m Removal 1 Loosen upper and lower ...

Page 23: ...e drain hole in 10 clear WARNING The steerer bolt 10 is a structural part and must be installed Follow installation instructions Notes 1 Ensure that the plastic ring 6 is on the stem before inserting into head tube 2 When you tighten or loosen the steerer bolt 10 be sure to loosen the lower clamp bolt and insert the 5mm Allen key completely to avoid stripping the steerer bolt 3 The XC3 SI stem is ...

Page 24: ...are typically square in shape or harsh terrain like sharp edged rocks that may cause pinch flats In the case of rebound it mostly refers to rebound speed caused by larger bumps where the fork gets fully compressed Bottom Out When the front or rear suspension fully compresses to absorb a bump or jump landing A hard stop is usually felt at bottom out Top Out When the front or rear suspension fully ex...

Page 25: ...ve cap HD208 Kit Outer Race Clip Lefty 5 QC681 Upper fork clamp alloy QC682 Lower fork clamp alloy KF257 Inner Leg w spindle DLR2 HD175 BLK Kit Zip Ties Black 50 HD185 BLK Kit Zip Ties Double Head 10 HD209 BLK Air filter assembly filter element and cover QC678 Fork Boot HD210 Steer tube upper plug KT029 Inner Leg w spindle DLR SL KT028 Schrader cap assembly cap O ring Schrader valve valve cap KF209 ...

Page 26: ... spring KT026 RED Complete damping cartridge w FIRM negative spring KT026 BLK Complete damping cartridge w X FIRM negative spring KT025 GRN Negative spring SOFT KT025 BLU Negative spring STANDARD KT025 RED Negative spring FIRM KT025 BLK Negative spring X FIRM KT024 Seal kit DLR SL KT030 Revalving kit shims DLR SL Needle Bearings Races HD161 Needle Bearings Qty 4 HDR2L 020 Kit Race Inner 10 197 259...

Page 27: ...0 90 BBQ QSC08005318 BBQ 31 8 5 80 BBQ QSC10005318 BBQ 31 8 5 100 BBQ QSC12005318 BBQ 31 8 5 120 BBQ QSC14005318 BBQ 31 8 5 140 BBQ QSC09005318 BBQ 31 8 5 90 BBQ QSC11005318 BBQ 31 8 5 110 BBQ QSC12020318 BBQ 31 8 20 120 BBQ QSC11020254 BBQ 25 4 0 110 BBQ QSC13020254 BBQ 25 4 0 130 BBQ QSC09020254 BBQ 25 4 0 90 BBQ QSC08005254 BBQ 25 4 5 80 BBQ QSC10005254 BBQ 25 4 5 100 BBQ QSC12005254 BBQ 25 4 5...

Page 28: ...28 dlr2 damper ...

Page 29: ...120025 PDF 29 T O P O U T S P R I N G ASSEMBLY NOTES 1 NLGI 2 synthetic grease is to be applied to all seals grooves surfaces and glands 2 See size table for shim stack and topout spring specifications ...

Page 30: ...HIM 16 1 PRELOAD SHIM 17 1 PRESSURE COMP PISTON 18 1 PRESSURE COMP SPRING 19 1 TOPOUT PERCH 20 2 TOPOUT TOPHAT 22 1 TOPOUT SPRING SPACER 23 1 See Chart DLR NEG SPRING 24 1 SHAFT PRELOAD NUT M75 25 1 DLR UPPER SHAFT SL 26 1 DLR TUNING SHAFT SL 27 1 DLR TOPOUT BUMPER PERCH 28 1 DLR THRUSHAFT SL 29 1 DLR OUTER CAP SL 30 1 DLR OIL CYLINDER SL 31 1 DLR LOWER SHAFT SL 32 1 DLR LOCKOUT PISTON SL 33 1 LOC...

Page 31: ...TON COMPRESSION SHIM STACK ORDER 4 3 2 1 1 2 3 4 12x14x 102 12x20 5x 102 12x16x 102 12x18x 102 120171 119732 120053 120172 Green Soft 2 1 1 Blue Standard 2 1 1 Red Firm 2 1 1 Black X Firm 2 1 1 Negative Spring SIZE P N ...

Page 32: ...HSS M3X3 10 1 DLR 110 AIR PISTON 11 1 DLR 110 LOCKOUT KNOB 12 1 DLR 110 REBOUND KNOB 13 1 DLR 110 SHAFT PRELOAD NUT M75 14 1 07 DLR 110 DAMPER 15 1 07 CARBON LEFTY TELESCOPE 16 1 07 UPPER COLLAR CARBON 17 1 07 DLR 110 SCHRADER CAP 18 1 07 DLR 110 AIR PISTON SPACER WARNING HIGH PRESSURE HAZARD Do not attempt to service a pressurized fork You can severely injured or killed by pressurized forcefully ...

Page 33: ...120025 PDF 33 HD187 1 2 in Shaft Clamps HDTL146 Castle Tool HDTL168 Bullet Tool cannondale service tools ...

Page 34: ...34 owner notes Record maintenance history service or set up information DATE WORK PERFORMED ...

Page 35: ...120025 PDF 35 ...

Page 36: ...UIRED TO MAINTAIN THE WHEEL TO FRAME CLEARANCE NEEDED FOR 29 INCH WHEELS Lefties with travel reduction factory installed are indentifed with a compatibilty label on the lower fork If the frame contacts the rotating wheel while riding the tire can be stopped suddenly This can throw you off the bicycle or cause you to loose control and crash Do not install a 110mm travel lefty onto a bicycle frame d...