Cannondale Technologies Manual - 2005
2005
9/04
PDF
WARNING
IMPROPER FORK SERVICE OR ASSEMBLY CAN RESULT IN FAILURE LEADING TO AN ACCIDENT.
Any fork which is incorrectly prepared, serviced, or installed can fail (come apart, break, crack, loosen) while it is being ridden causing the
rider to have a serious accident.
The following actions WILL RESULT IN SEVERE DAMAGE:
· Modifying the fork or installing parts into the fork not specifi ed by Cannondale.
· Cutting the fork steerer tube with the wrong tool, scratching, scoring or making other marks on the tube surfaces other than the
complete cut, or cutting the steerer tube to an incorrect length for a specifi c stem/headset.
· Scoring or scratching the steerer tube during installation of the fork or headset parts. Scratches and/or scores to the fork surfaces can
result in stress risers. This can result in fork failure while riding.
· Resting the fork on the dropouts when installing the star nut, headset crown race or top cap. The applied force can crack or smash the
dropouts.
Contact Cannondale Technical Support (1-800-BIKE-USA) if you have any questions about the proper installation and service of Cannondale
forks.
40 mm
GENERAL INSTALLATION POINTS
· CUT THE FORK CAREFULLY - To cut the fork, assemble the headset parts and make a mark 2 mm below the top
of the stem. Use new (very sharp) hacksaw blade to cut the fork steerer tube 2 mm below the top of the stem.
Use Park Tool Threadless Fork Saw Guide SG-6. See http://www.parktool.com/tools/SG_6.shtml. DO NOT CUT
THE FORK TOO SHORT.
After cutting, carefully fi le or sand (very fi ne grit) smooth any rough edges remaining from the cut. Do this
lightly and limit any fi ling or sanding to the cut.
· READ AND FOLLOW THE INSTRUCTIONS FOR THE HEADSET TO BE INSTALLED.
· INSTALL THE DOUBLE-FLANGE STAR NUT to 40 MM USING THE CANNODNALE TOOL KT014/.
For tool information, see Cannondale Publication No. 112214.PDF.
· The top cap fi t inside the steerer tube should be snug not loose or TOO tight.
· THE MAXIMUM NUMBER OF HEADSET SPACERS THAT MAY BE USED UNDERNEATH
THE STEM IS FIVE X 5MM. Cannondale recommends that no spacers be used on top of the stem. Spacers above
the stem prevent the top cap from properly supporting the clamping load generated from the lower bolt of
the stem.
DRIVER
COLLAR
CANNONDALE STAR NUT INSTALLATION
TOOL: KT014/
FORKS - CANNONDALE SLICE PREMIUM
05020A
