Changing The Fork Spring - Cannondale Lefty MAX Owner's Manual

CHANGING THE FORK SPRING

To remove the fork spring:
1. Secure the bike on a work stand.
2. Loosen theupper clamp bolt.
3. Remove the red rebound adjustment knob
using a 2mm Allen wrench.
NOTE :
If you are working on a Lefty MAX, be sure to
note the springs and balls under the adjustment
knob. Be sure to reinstall
reassembly later.
5
2
4
Lefty MAX rebound adjuster assembly (exploded view)
Set screw
1.
O-ring
2.
Springs (2)
3.
Outer cap
4.
Adjuster knob (Lefty MAX)
5.
Ball (2)
6.
4. Remove the upper collar from the outer tube
using a green Park pin spanner or a 40mm
headset wrench.
5. Compress the fork exposing the spring
assembly.
6. Push the bottom out assembly down below
the top of the spring.
7. Slightly pull down on the spring so that you
can remove the black aluminum sleeve, the
plastic preload spacer nested behind it, and
any metal preload shims that may have been
added.
them during
NOTE :
Metal preload shims are not installed at the
factory.
1
8. Once the two sleeves are removed, take
notice of the 8mm wrench flats.
6
9. Using an 8mm open ended wrench, hold the
3
shaft on the flats and unthread the outer cap
using a 30mm open ended wrench.
10.Remove the top washer and spring by pulling
up on it.
Installing a new spring
1. Compress the telescope while pulling up on
the shaft by hand until it is fully extended.
2. Next, install the new spring making sure that
the colored shrink-wrap is positioned on the
top half of the spring. Lubricate the spring.
3. Make sure that the bottom out assembly is
pushed down below the top of the spring.
4. Slip the washer over the shaft and onto the top
of the spring.
5. Before installing the outer cap, place a small
drop of Loctite #242 (blue) onto the shaft
threads. Tighten using an 8mm open ended
wrench and a 30mm crows foot on a torque
wrench.
TORQUE : Outer cap - 89.0 lbf•in (10.0N•m).
6. With the washer against the underside of the
outer cap, slightly compress the spring and
install the new corresponding preload spacer
and aluminum damper sleeve.
"Spring Kits" starting on page 11.
CAUTION :
It is important to position the washer up
against the underside of the outer cap. If this
washer is below the preload assembly, you
will significantly reduce the amount of travel
in the fork. The washer will prematurely
bottom-out on the bottom-out assembly.
7. Extend the fork and reinstall the upper collar
using a coat of grease on the threads.
TORQUE : Upper collar
(28.0N•m).
8. Tighten the upper clamp bolts.
TORQUE : Upper clamp bolts - 60.0 lbf•in (7.0
N•m).
Refer to
- 250.0 lbf•in
17