Lefty, SuperMax, Olaf Solo Air Assembly Upgrade

Transcription

1 Page 1 of 7 Installation Instructions (EN) Lefty, SuperMax, Olaf Solo Air Assembly Upgrade About these Instructions The upgrade should be installed at a Factory Tech Room, HeadShok Service Center or qualified Cannondale Dealer as part of a stanadard 50 hour service or as a stand alone upgrade service. OLD SOLO-AIR PISTON NEW SOLO-AIR PISTON (new parts shown shaded) PLATE WAVE SPRING COIL SPRING SERVICE KITS MODEL KIT CODE DESCRIPTION Lefty 1.0, Lefty 2.0 KH220/32 KIT, SOLO AIR, COIL SPRING UPGRADE, LEFTY 32 SuperMax and Olaf KH220/36 KIT, SOLO AIR, COIL SPRING UPGRADE, LEFTY 36 PISTON recess for coil SERVICE TOOLS MODEL KIT CODE DESCRIPTION Lefty 1.0 KH103/ Super Castle Tool - white Lefty 2.0, KH123/ or KH18/ Castle Slider SuperMax KH127/ 36mm Socket Olaf KH18/ Castle Slider KH127/ 36mm Socket TABLE 1. O-Ring Sizing MODEL VALVE AIR PISTON UPPER AIR SEAL Lefty 1.0, Lefty 2.0 #00 #210 #117 SuperMax #00 #212 #212 or #11 Olaf #00 #212 #212 Figure A. Safety glasses Nitrile gloves Clean, lint-free rags Isopropyl alcohol NLGI-2 Synthetic Grease (Lubriplate SYN GR-132, available kit HD225/ Phil Wood Tenacious Oil ( Loctite 262 (red) Loctite 242 (blue) OTHER TOOLS & SUPPLIES 6mm hex wrench 2mm hex wrench Shimano TL-FC32 (Hollowtech BB Wrench) 16mm open end or box end wrench 16mm crowfoot Torque wrench Pick Small flat blade screw driver Shock pump Schrader Valve Core Tool Work in a clean shop area free from dust or other contaminants. Use lint-free shop towels when cleaning. If specified brand supplies are unavailable, use only functional equivalents. Do not improvise. WARNINGS Information intended for use only by professional mechanics at Authorized Cannondale Dealers. Special tools and skills are needed. Bike Owners must not perform the work described. Serious injury or damage can result. Release all air pressure before servicing. Remove the air valve cap at bottom of Lefty, depress the air valve and hold releasing air until hissing stops. Serious injury or damage can result.

2 PROCEDURE STEP 1: DAMPER REMOVAL 1. Figure 1. Remove the air valve cap (1) ; attach a suspension pump to the valve end (2) and record the current air pressure. Cover front brake rotor with clean shop towel to prevent oil contamination. Depress and hold the Schrader valve open until hissing stops (release all the air pressure from the air chamber Remove the valve core (3) from the valve body using valve core tool. 2. Perform the Manual Needle Bearing Reset instructions found in the Lefty Owner s Manual Supplement or at Figure Loosen stem per manufacturer s instructions and turn handle bars to be parallel with the top tube. Lightly tighten stem to hold it in place. 4. Clean the damper top cap area with isopropyl alcohol and clean towel. 5. XLR Remote only: Figure 2. Remove the two 2mm hexbolts (4) from the top of the knob assembly. Remove knob assembly by pulling up vertically. If Lefty with PBR, go next step, no removal. XLR 4 Figure 2. Page 2 of 7

3 6. Lefty 1.0 only: Figure 3: Use a Shimano Hollowtech BB tool TL-FC32, to turn the top cap (5) counterclockwise until it is completely un-threaded. 5 Remove the split rings (6) Figure 3. Lefty 2.0 or SuperMax Figure 4: Use a 36mm Socket KH127/ and a ratchet to turn the top cap (7) counter-clockwise until it is completely un-threaded. 7 Pull up on damper top cap to expose damper upper shaft (8). 8 Figure Select the appropriate tool(s) for cartridge removal: Lefty Figure 5 : Use the the white color Super Castle Tool KH103/, and a ratchet (not shown). KH103/ Figure 5. Page 3 of 7

4 7. (continued)... Lefty 2.0, SuperMax and Olaf Only: Use KH127/ and a ratchet (not shown) and KH123/ or KH18/. KH127/ Carefully engage the tool ends () into the small slots (10) or the cartridge body (11). Hold downward pressure turning counterclockwise to completely un-thread the cartridge from the inside lower leg until it can be lifted up out of the telescope. Please Note: If the tools are engaged with the cartridge incorrectly, they will feel loose and possibly slip causing damage to the cartridge when turning. When correctly engaged, the tools will not feel loose. Figure 7 shows a typical damping cartridge following removal KH123/ KH18/ (Olaf) 10 Figure 6. * * KH18/ is backwards compatible with KH123/. However, KH123/ can not be used on Olaf. 8. Clean cartridge body threads and air piston parts with isopropyl alcohol and clean rag.. Figure 8. Use a pick to remove any the Loctite ADJUSTERS TOP CAP residue from the cartridge threads. UPPER SHAFT OIL CYLINDER Cartridge threads Figure 8. LOWER SHAFT O-ring UPPER AIR SEAL SOLO AIR ASSY. Bumpers Air Piston Assy. Figure 7. Page 4 of 7

5 STEP 2: SOLO AIR ASSY PISTON REPLACEMENT 1. Figure. Carefully remove the e-clip (12) and pull the pin (13) out. Pull out the green valve (14) out of center of piston. Remove the old O-ring (15) and discard it. Clean the valve with isopropyl alcohol and clean lint-free shop towel Use your fingers to install a new 0-ring (15) and apply NLGI-2 grease Figure 10. Position a 16mm open end or box end wrench on the air piston wrench flats. Insert a 6mm hex key through the center of the air piston and into the shaft end. Figure. Holding the 6mm shaft end turn 16mm box end wrench counter-clockwise to fully remove the air piston (16). 3. Figure 11. Remove and discard the old air piston (16), wave spring (17) (overlap style or gapped style), and old plate (18). Figure Figure 12. On the upper air seal (1) remove the old O-ring (20). Clean the upper air seal with isopropyl alcohol and a clean lint-free towel. Install a new O-ring (20) from the kit. Figure NLGI-2 20 Figure 12. Page 5 of 7

6 5. Figure 13a. Clean the shaft end threads and apply a small drop Loctite 262 (red) to the threads. Slide the new plate (21) onto the shaft end with the coil spring counter bore (22) facing out (away) from the rubber top out bumpers (23) NLGI-2 26 Install the coil spring (24) Clean the new piston (25) with isopropyl alcohol and a clean lint-free towel, install the new O-ring (26). See Table Fully thread the air piston onto the shaft end threads. Make sure the coil pring positioning stays within plate and air piston counter bores. Figure 13b. Position a 16mm open end or box end crowfoot attached to a torque wrench on the air piston wrench flats. Insert a 6mm hex key through the center of the air piston and into the shaft end. Holding the 6mm hex key, turn the 16mm crowfoot until a torque of 1.4 N-m is achieved. DO NOT OVER-TIGHTEN THE AIR PISTON!! Carefully remove any excess Loctite displaced from the threads with clean towel lint-free towel dampened with isopropyl alcohol. Loctite 262 (red) Figure 13a. Figure 13b N-m Air Piston Tightening Torque 1.4 N-m 7. Figure 14. Reinstall the green valve (14) with the new O-ring (15) into center of air piston orienting cross holes of valve and shaft end. Insert pin (13) through hole in side of silver plate. Reinstall the E-clip (12) into the pin groove NLGI Figure 14. Page 6 of 7

7 STEP 3: DAMPER REINSTALLATION 1. Liberally apply grease to the topout bumpers, and the entire air piston assembly. 2. Figure 15. Apply 2-5cc of air piston oil (Phil Wood Tenacious Oil) to topout bumpers and air piston assembly. 3. Figure 16. Clean the cartridge body threads with isopropyl alchol and a clean shop towel. Then apply a small bead of Loctite 242 (blue) to entire circumference of cartridge body threads. 4. Carefully insert the damping cartridge vertically into into the upper structure taking care not to use a rocking or wiggling motion to avoid O-ring damage. Figure 15. PLEASE NOTE: Upper Air Seal O-ring can be damaged (cut) during cartridge installation. It is important to apply the specified grease and always install the cartridge carefully. Hand thread the cartridge into the lower leg as much as possible. 5. Lefty 1.0 Only: Use KH103/ - white Super Castle Tool and ratchet to tighten the damping cartridge to 20 N-m. Figure 16. Lefty 2.0, SuperMax and Olaf Only: Use KH127/, the 36mm socket, a ratchet wrench and the KH123/ or KH18/castle slider. 6. Apply grease to the Schrader valve and reinstall it into the Schrader body. Tighten to 0.45 N-m. Do not over-tighten it. 7. Pressurize Lefty to 50psi. 8. Remove Slider Castle Tool or Super Castle Tool from the underside of top cap. Lefty 1.0 Only: Use a Shimano Hollowtech BB wrench to tighten the top cap to 20 N-m. Damping Cartridge Tightening Torque 27 N-m * * KH18/ is backwards compatible with KH123/. However, KH123/ can not be used on Olaf. Lefty 2.0, SuperMax and Olaf Only: Use a 36mm socket KH127/ 10. Pressurize fork to previously recorded pressure or refer to Lefty setup chart. 11. Return handlebars to original position and tighten stem per manufacturer s instructions. Page 7 of 7