Cannondale Scalpel Owner's Manual Supplement
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Cannondale Scalpel Owner's Manual Supplement

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OWNER'S MANUAL SUPPLEMENT
116378.PDF

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  • Page 1 Scalpel OWNER’S MANUAL SUPPLEMENT 116378.PDF...

  • Page 3: Table Of Contents

    About This Supplement ....... 2 Spindle Removal ...........14 Bearing Inspection ........14 Special Manual Messages ......2 Scalpel Intended Use ........3 Bearing Removal .......... 15 Cross-Country/ Marathon Riding ....3 Circlip and Bearing Installation ....16 Building Up A Frameset ....... 3 Spindle &...

  • Page 4: Introduction - General Safety Information

    WARNING), so be sure to observe them. • All Cannondale bikes must be completely CAUT000 assembled and inspected for proper operation by a Cannondale Dealer before delivery to the NOTE: owner. A NOTE provides helpful information or tips intended to make the information presented clearer.

  • Page 5: Scalpel Intended Use

    116378.PDF Scalpel Intended Use Building Up A Frameset Cross-Country/Marathon Riding: Our Scalpel Consult with your Cannondale Dealer and the model bikes and framesets are made for cross- component manufacturers and frankly discuss country riding and racing. Scalpels are not your riding style, ability, weight, and interest in made for use in extreme forms of jumping/riding and patience for maintenance.

  • Page 6: Technical Information

    Power Pyramid has a slimmer diameter for compatibility with the head tube and a beefier wall for added strength. The Scalpel also boasts easy portability, with an open, uncluttered front triangle that places all of the suspension components aft of the seat tube. And for enhanced stand-over clearance, the Scalpel’s top tube has a downward bend just forward of the saddle - a feature that we fittingly call the Crotch...

  • Page 7: Chainstays

    Pre-loading the stays also moves the rear wheel’s axle to a level just below the Scalpel’s mid-stay pivot. The result is that, through the first part of its travel, the rear wheel is able to move back out of the way of impacts as it also moves upward.

  • Page 8: Head Tube

    Head Tube The head tube accepts Cannondale HeadShok System Integration™ headsets (shown), and OnePointFive 1.5 (38.1mm) headsets. 137.7mm 134.6mm 4.5” Figure 4 SI Head tube Figure 3 SI Head tube Headshok Headset Parts Identification 1. SI Upper Bearing Seal 2. SI Bearing...

  • Page 9: Maximum Fork Length

    116378.PDF MAXIMUM FORK LENGTH Your Cannondale bike frame was designed and tested to a specific MAXIMUM FORK LENGTH. See below. Installing a fork with a MAXIMUM FORK LENGTH that is longer that specified for the frame, can overload the frame causing it to fail and break suddenly while riding. A rider can be severely injured or killed as a result.

  • Page 10: Sag

    Selecting Rear Shocks Recommended Sag WARNING for Scalpel of shock travel SELECT ONLY COMPATIBLE SHOCK/ FORKS Sag is the distance the bike suspension FOR YOUR BIKE. DO NOT MODIFY YOUR compresses with a rider (wearing all appropriate BIKE IN ANY WAY TO MOUNT ONE. HAVE...

  • Page 11: Mounting Rear Shocks

    116378.PDF Mounting Rear Shocks 13 N•m (115 In•Lbs) 16mm 22mm 13 N•m (115 In•Lbs) Figure 6 Scalpel Rear Shock Mounting...

  • Page 12: Brakes

    The angle stress it puts on a chain. Because the Scalpel is of the cage should be run with the rear slightly a high performance race bike, riders should not inboard.

  • Page 13: Line/Cable Frame Protection

    Also, be sure to follow the manufacturer’s recommendations of your front fork and rear shocks. Ask your Cannondale Dealer for the right tires for your bike and its particular components! WARN004 Figure 7 Typical Location for Guard Material...

  • Page 14: Housing Guides And Cable Stops

    Also, adhesive frame guards are not a fix for incorrectly installed or routed cables or lines. If you find that applied guards are wearing out very quickly, consult with your Cannondale Dealer about the routing on your bike. Housing Guides and Cable Stops...

  • Page 15: Right Chainstay Protector

    Chainstay Protector Location WARNING DO NOT RIDE YOUR SCALPEL IF YOU SEE ANY SIGN OF DAMAGE, SUCH AS BROKEN, SPLINTERED, OR DELAMINATED THERMOPLASTIC CARBON FIBER. A delamination or break in the adhesive bond between the bottom bracket or dropouts and the carbon fiber chain stays may be present if the seam has turned white.

  • Page 16: System Integration Cranksets

    CRANKSET INFO Repeat steps 1-4 for the other crankarm. Spindle Removal Crankarm Removal Use Cannondale tool - KT013/. Be sure to clean Remove the crankarms. and grease the threads of the spindle, crankarm, Remove the wave washer, shims, spacer and tool parts before removing.

  • Page 17: Bearing Removal

    However, should the bearing suffer damage due KT011/ to wear or contamination, they can be replaced easily using Cannondale service tool - KT011/. CAUTION Following removal, install new bearings. The The two circlips in the bottom bracket shell can be left in place.

  • Page 18: Circlip And Bearing Installation

    Circlips and Bearing Installation Install the drive side bearing first. Use the tool arrangements for each bearing side CAUTION shown in Figure 18. Press the bearing until they bottoms against the circlip.s Remove DO NOT FACE, MILL OR MACHINE THE BOTTOM the tools and press.

  • Page 19: Spindle & Crankarm Installation

    116378.PDF Spindle and Crankarm Installation Visually check the compression of the wave washer; the wave washer The following steps describe how to install the should be compressed nearly flat (0.3- spindle, crankarms and other parts after the 0.5mm of compression left is ideal). circlips and bearing are installed into the bottom bracket shell.
  • Page 20 Figure 16 Arrangement of SI Bearing Drivers Cannondale tool KT010/ items 2, 3 Headset cup bearing press with 1” adapters. such as Park Tool HHP-2 (Bearing Cup Press)). Gr = GREASE Figure 17 Installing the SI Spindle Into Bottom Bracket...
  • Page 21 116378.PDF...

  • Page 22: Maintenance

    AN ACCIDENT WHERE YOU CAN BE KILLED, SEVERELY INJURED OR PARALYZED. Please ask your Cannondale Dealer to help you develop a complete maintenance program, a program which includes a list of the parts on your bike for YOU to check regularly.

  • Page 23: About Cleaning

    116378.PDF About Cleaning When cleaning your bike , use only a mild soap and water solution. A clean water and a common dish washing liquid will work best. Be sure to cover adjustment knobs and air filter (if equipped) with a clean plastic bag secured temporarily with a rubber band or masking tape.

  • Page 24: Rear Shock Link

    REAR SHOCK LINK CAUTION DO NOT PRESSURE WASH - Dirt and water The rear shock link is also known as the “Frog can be forced into the link bearings which will Link” due to the frog-like appearance of the part. result in rapid damage.
  • Page 25 116378.PDF GREASE GREASE 13 N•m (115 In•Lbs) 13 N•M (115 In•Lbs) 5 mm Allen key Figure 20 Scalpel Frog Link Parts...

  • Page 26: Composite Seatstay

    7. Bonded Insert (Do not remove) The seatstay inserts (7) are bonded in place during manufacture and are non-removable. See “Replacement Parts” in this manual for T-Nut Screws Cannondale replacement kit/small parts The T-nut screws (4) should be checked for availability.
  • Page 27 116378.PDF 3 mm Allen key 2.25 N•m (20 In•Lbs) Figure 21 Scalpel Composite Seat Stay Parts...

  • Page 28: Rear Derailluer Hanger

    5mm Allen Key 13.0 N•m (115.0 In•Lbs) Figure 22 Scalpel Derailleur Hanger Before installing the new replacement: Apply a light film of bike grease between the hanger and dropout to minimize any noise or “creaking” that might result from very slightl movement between the dropout and hanger during movement of the derailleur.

  • Page 29: Geometry

    116378.PDF GEOMETRY Figure 23 SCALPEL SI AND SCALPEL Scalpel Team Replica Scalpel 3000, Scalpel 2000, Scalpel 900 SIZE SMALL MEDIUM LARGE X-LARGE STL Seat Tube Length (cm/in) 47.0/18.5 47.0/18.5 55.9/22.0 55.9/22.0 TTH Top Tube Horizontal (cm/in) 55.9/22.0 59.7/23.5 63.5/25.0 64.8/25.5 TTA Top Tube Actual (cm/in) 53.2/20.9...

  • Page 30: Specifications

    SPECIFICATIONS ITEM SPECIFICATION Model Scalpel Scalpel SI Frame material 6061-T6, Tig welded, Aluminum Alloy Sizes S,M,L,XL Recommended Sag Maximum tire width 2.1 in Head tube Headshok, OnePointFive Head tube height 114mm (4.5 in) Maximum fork length 500mm (19.7) Seat post diameter 27.2 mm (1.07 in)

  • Page 31: Replacement Parts

    KF051/ Kit, Derailleur Hanger - Gemini/Prophet/All Mtn/Xcross Disc/Forged Dropout Scalpel KF069/ Kit, Seat Stay, Composite, Scalpel; new lighter version w/ hware; compatible with all Scalpel frames KF035/ Seat stay Rebuild Kit 4 T-Bolts, 8 bushings, 4 washers, and 4 T-Nut...

  • Page 32: Owner Notes

    OWNER NOTES You can use a table like this to record maintenance history, service, or set up information about your bike. Date Work Performed...
  • Page 33 116378.PDF...
  • Page 36 2. We believe our people drive our success. 3. We work together as one global team. 4. We act with respect, responsibility and integrity. 5. We continue to improve. CANNONDALE USA (CUSA) CANNONDALE AUSTRALIA (CA) Cannondale Bicycle Corporation Unit 6, 4 Prosperity Parade 172 Friendship Road Warriewood N.S.W 2102...

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