Cannondale LEFTY MAX 140 Owner's Manual
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Cannondale LEFTY MAX 140 Owner's Manual

Cannondale LEFTY MAX 140 Owner's Manual

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2010
READ THIS SUPPLEMENT AND YOUR
WARNING
CANNONDALE BICYCLE OWNER'S MANUAL.
Both contain important safety information.
Keep both for future reference.
LEFTY MAX 140
125123.PDF

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Summary of Contents for Cannondale LEFTY MAX 140

  • Page 1 2010 READ THIS SUPPLEMENT AND YOUR WARNING CANNONDALE BICYCLE OWNER’S MANUAL. Both contain important safety information. Keep both for future reference. TOWNER’SM MANUALSUP UPPLEMENTO LEFTY MAX 140 125123.PDF...
  • Page 2 In this supplement, particularly important information is presented in the following ways: Indicates a hazardous situation which, if not WARNING avoided, could result in death or serious injury. Indicates special precautions that must be taken to NOTICE avoid damage. A TIP provides helpful information. This manual meets EN standards 14764, 14766, and 14781.

  • Page 3: Table Of Contents

    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. Please note that the specifications and information in this manual are subject to change for product improvement.

  • Page 4: Safety Information

    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...

  • Page 5: Fork Damage

    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.

  • Page 6: Specification

    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 LOCKOUT POP-TOP REBOUND LOW-SPEED COMPRESSION REBOUND BLOW-OFF THRESHOLD ADjUSTMENTS MAIN SPRING AIR PRESSURE SPRING PRELOAD MIN.
  • Page 7 125123.PDF ALLOY CARBON (PBR shown) (FOX RLC shown) OUTER COLLAR UPPER CLAMP 9 Nm, 80 In Lbs 9 Nm, 80 In Lbs CLAMP BOLT WIDTH 137.6 mm 4.5” FRAME BUMPER 163.0 mm 5.5” HD215/ LOWER CLAMP 9 Nm, 80 In Lbs 9 Nm, 80 In Lbs INTEGRATED 3D FORGED CARBON OUTER TUBE...

  • Page 8: Front Wheel

    FrOnT WHEEL rEMOVAL 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.
  • Page 9 Then place the hub modify the fork in any way. straight down onto the spindle, and tighten the axle bolt. PLEASE ASK YOur cAnnOnDALE DEALEr FOr HELP 3. When the axle bolt threads engage the spindle, turn the WHEn inSTALLinG cOMPATibLE FrOnT brAKE bolt clockwise with finger force slowly to allow the hub SYSTEMS.

  • Page 10: 1/8" Steerer Adapter

    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...
  • Page 11 125123.PDF 1.125 in STEERER CLAMP BOLT 9 Nm, 80 In Lbs Slot UPPER REDUCER Slot SPACERS 5 mm 10 mm 20 mm CLAMP WIDTH CLAMP BOLTS 9 Nm, 80 In Lbs CROWN RACE (A Headset part) LOWER REDUCER...

  • Page 12: Xc3 Stem-Steerer

    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 effective! See the graphic? 4.
  • Page 13 125123.PDF STEM SIZE MARKING H-BAR DIA. DATE LENGTH ANGLE STEM STEERER RING QSISEAL/ BEARING SEAL LEFTY HD169/ UPPER CLAMP BOLT HEADSHOK HEADSET BEARING HEADTUBE HD169/ LOWER CLAMP BOLT HEADSHOK HEADSET BEARING STEERER BOLT - HD152/ 9.0 Nm WArninG Keep hole clear for drainage THE STEErEr bOLT iS A STrucTurAL PArT AnD MuST bE inSTALLED.

  • Page 14: Maintenance Schedule

    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.

  • Page 15: Cleaning

    125123.PDF 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 filter. 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.

  • Page 16: Boot Inspection

    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 find boot damage, the area under the fork should also be inspected for damage.

  • Page 17: Clean/Re-Oil Air Filter

    125123.PDF cLEAn/rE-OiL Air FiLTEr The air filter assembly is located over breather air holes in the outer tube. The air filter 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 OUTER TUBE To clean and re-oil air filter...

  • Page 18: Needle Bearing Reset

    The techniques of resetting is the same for all forks, however, dis-engaging the damping cartridge differs. 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.
  • Page 19 125123.PDF DAMPING CARTRIDGE ALIGNED MIGRATED OUTER TUBE OUTER RACE INNER RACE NEEDLE BEARING CAGES INNER TUBE AIR FILTER TELESCOPE LENGTH (mm) BOOT CYCLING THE TELESCOPE GRADUALLY TO See the SPECIFICATIONS ITS FULL LENGTH WITH table for your fork. DAMPING CARTRIDGE DISENGAGED RE-ALIGNS THE NEEDLE BEARING CAGES...

  • Page 20: Clean/Re-Grease Telescope

    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.

  • Page 21: Lefty Max 140 W/Fox Rlc

    125123.PDF LEFTY MAX 140 W/FOX rLc REBOUND ADJuSTMEnTS LOW-SPEED COMPRESSION rEbOunD When setting rebound , First, turn completely clockwise to close, then turn counterclockwise and count each click. Seven clicks out from closed is a good middle starting point. LOCKOUT...
  • Page 22 bLOW OFF THrESHOLD Even when your fork is fully locked out, there are instances when you still want your fork to be active. To protect your fork’s internal parts, your fork will “blow off” when it exceeds a certain threshold force. You can adjust when the fork blows off—lockout force—by adjusting the blue knob (4) at the bottom of the fork.
  • Page 23 125123.PDF rLc ADJuSTEr DiSASSEMbLY The following procedure should only be completed by a 2mm, 1.2Nm professional bike mechanic. Loctite 222 (purple) 1. Hold the rebound knob from turning with your finger tips while using a 2mm hex to remove the rebound knob set screw (1).

  • Page 24: Sag/Preload

    rLc PrELOAD /SAG ADJuSTMEnT Shimano TL-FC32 The following procedure should only be completed by a 28Nm, 248 In Lbs professional bike mechanic. OUTER COLLAR Sag is the distance the fork compresses when a rider sits on the bike. The recommended sag for the Lefty is 25% of the total travel or 27.5mm.

  • Page 25: Needle Bearing Reset

    125123.PDF rLc nEEDLE bEArinG rESET O-RING Shimano TL-FC32 grease The following procedure should only be completed by a OUTER COLLAR professional bike mechanic. 28 Nm, 248 In Lbs See LEFTY nEEDLE bEArinG rESET on page 14. SPLIT RINGS 1. Remove the RLC adjusters from the top of fork. See grease previous page.

  • Page 26: Spring Change

    rLc SPrinG cHAnGE KH027/ The following procedure should only be completed by a SPLIT RINGS professional bike mechanic. 1. Remove the adjusters. See rLc ADJuSTEr DiSASSEMbLY. 2. Use Shimano tool TL-FC32 to loosen and remove the outer collar. 3. Lower the telescope and remove the two splits rings from the compression assembly groove.
  • Page 27 125123.PDF ADJUSTERS Loctite 242 (blue), 7.9Nm COMPRESSION VALVE ASSEMBLY OUTER COLLAR COMPRESSION VALVE ASSY Ridge down! Align! PRELOAD ADJUSTER OUTER TUBE COMPRESSION CLAMP KH026/ SPRING SPRING KH029/ PRELOAD TUBE SMALL ASSY ISOLATOR O-RING LARGE REBOUND SHAFT ISOLATOR SPACER INNER CAP O-RING INNER TUBE...

  • Page 28: Oil Change

    rLc OiL cHAnGE The following procedure should only be completed by a professional bike mechanic. 1. Remove the adjusters. See RLC ADjUSTER DISASSEMBLY. 2. Use a 26mm socket to remove the compression valve assembly. 3. Lift out the compression valve assembly. Note the pin. 4.
  • Page 29 125123.PDF 5. Fill the compression valve assembly with the specified fork oil. See SPEciFicATiOnS. Fill oil until it reaches the top of the threads. Slowly cycle the fork. You will see air bubbles arise through the oil as the oil flows into the damper. Continue filling and cycling until all the oil has been poured and no bubbles are present.

  • Page 30: Lefty Max 140 W/Pbr

    LEFTY MAX 140 W/Pbr POP TOP REBOUND rEbOunD The red rebound knob has two functions: 1. rOTATE TO cOnTrOL rEbOunD. Turn in the -- direction (counter-clockwise) to increase rebound speed (faster). Faster Rebound Slower Rebound Turn in the + direction (clockwise) to decrease rebound speed (slower).

  • Page 31: Recommended Air Pressure

    125123.PDF rEcOMMEnDED Air PrESSurE To set air pressure 1. Make sure the bottom of the fork is clean. Remove the Schrader valve cap. Attach a bicycle suspension pump to the valve end. Pressurize the fork according to the table. BOTTOM OF FORK riDEr STArTinG PrESSurE (Lbs/Kg)

  • Page 32: Needle Bearing Reset

    Pbr nEEDLE bEArinG rESET Shimano TL-FC32 The following procedure should only be completed by a OUTER COLLAR O-RING professional bike mechanic. grease XXXXXX/ 28 Nm, 248 In Lbs See LEFTY nEEDLE bEArinG rESET on page 14. To reset KH027/ PLASTIC WASHER SPLIT RINGS 1.

  • Page 33: Replacement Parts

    125123.PDF KH063/ - carbon KH064/ - alloy (OPI) KH065/ HD215/ 41 mm (guide) HD011/ color = RED SOLO AIR ASSEMBLY #112 O-RING #112 O-RING #117 O-RING Upper air seal HD209/BLK 35 mm KF222/ #01 O-RING KT028/ #014 O-RING...
  • Page 36 UPPLEMENT NTOWNER’SM SMANUALSU CANNONDALE USA CANNONDALE EUROPE CANNONDALE AUSTRALIA CANNONDALE JAPAN Cannondale Bicycle Corporation mail: Postbus 5100 Unit 6, 4 Prosperity Parade, Namba Sumiso Building 9F, 172 Friendship Road, Bedford, visits: Hanzepoort 27 Warriewood N.S.W., 2102, Australia 4-19, Minami Horie 1-chome,...

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