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    2007 Headshok DL DLR Air Cylinder Repair Technote en

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    xjcai
    Air cylinder repair guide for 2007 fatty.

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    Download as PDF, TXT or read online from Scribd

    2007 Headshok DL DLR Air Cylinder Repair Technote en

    Uploaded by

    xjcai
    9K views2 pages
    Air cylinder repair guide for 2007 fatty.

    Original Title

    2007 Headshok Dl Dlr Air Cylinder Repair Technote En

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    © Attribution Non-Commercial (BY-NC)

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    Air cylinder repair guide for 2007 fatty.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    9K views2 pages

    2007 Headshok DL DLR Air Cylinder Repair Technote en

    Uploaded by

    xjcai
    Air cylinder repair guide for 2007 fatty.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 2

    tech note

    HEADSHOK, DL80/DLR80
    2005 and Later Headshok DL80/DLR80 KH005/
    Damping Cartridge Air Cylinder Repair
    Kit - KH005/ Thrust washer

    Kit Information O-Ring


    Cannondale kit KH005/ is an air cylinder sleeve repair
    kit for forks with a worn (scratched, scaly) inner tube Top Hat
    I.D. resulting in air loss. The kit only fits 2005 and later
    Headshok forks with DL80 or DLR80 damping cartridges.
    Following kit installation, set fork pressure according to Negative spring
    the table below. The kit Schrader plug included in the kit
    is blue indicating revised air pressure. Kit KH022/ is a
    seal kit for the air cylinder.
    O-Ring
    Cannondale Tools Needed
    Headshok Cartridge (Castle) Tool - HDTL146/
    Headshok ½” Shaft Clamp Tool - HDTL187/
    Air Piston
    5 Nm, Loctite 262 (red)
    Kit Installation
    This kit should only be installed by a professional bike
    mechanic. Follow the steps on page two. Damper Loctite Quad Seal
    removal is NOT described in this Tech Note. 242 (blue) Apply grease/
    Phil Wood Tenacious Oil

    Air Pressure
    RIDER WT. AIR PRESSURE NEGATIVE SPRING
    DL80 Air Cylinder*
    lbs kg psi bar Color/Desc
    120 54 80 5.5 or
    130 59 85 5.9 GREEN/SOFT DLR80
    140 63 90 6.2
    150 68 95 6.6
    160 72 100 6.9 BLUE/STD
    * - pre-assembled
    170 77 105 7.2
    180 81 110 7.6
    190 86 120 8.3
    200 90 130 9.0 RED/FIRM
    210 95 135 9.3 O-Ring *
    220 100 140 9.7
    22/
    KH0
    MINIMUM 75 5.2 Schrader Plug*
    MAXIMUM 150 10.3 Lower Shaft

    WARNING
    This Tech Note may include procedures beyond the scope of Schrader Valve *
    general mechanical aptitude. Special tools, skills, and knowledge
    may be required. 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
    Schrader Valve Cap
    owners always have mechanical work done by an authorized
    Cannondale retailer.

    CANNONDALE USA (CUSA) CANNONDALE AUSTRALIA (CA) CANNONDALE JAPAN (CJ) CANNONDALE EUROPE (CE)
    Cannondale Bicycle Corporation Unit 6, 4 Prosperity Parade 12-5 Harayamadai mail: Postbus 5100
    172 Friendship Road Warriewood N.S.W 2102 5-cho Sakai City visits: Hanzepoort 27
    Bedford, Pennsylvania 15522 Australia Osaka, Japan 590-0132 7570 GC Oldenzaal
    (Voice): 1-800-BIKEUSA Phone: (02) 9979 5851 (Voice): 011.81.722.99.9399 Netherlands
    (Fax): 814-623-6173 Fax: (02) 9979 5688 (Fax): 0722-93-6166 (Voice): + 41 61.4879380
    [email protected] [email protected] [email protected] (Fax): 31-5415-14240
    URL: http//www.cannondale.com [email protected]

    Information and specifications subject to change without notice.


    © 2007 Cannondale Bicycle Corporation - All Rights Reserved
    120865.PDF
    Installation 5. Clamp the lower shaft with tool HDTL187/. Apply O-Ring
    grease to the small O-Ring and install the air piston onto
    1. Clamp the damping cartridge lower shaft with the lower shaft end. Figure 3. Tighten to 5Nm. Figure 3.
    Cannondale tool HDTL187/. Figure 1. The air piston is
    installed with Loctite 262; with heat gun, carefully apply Make sure the O-Ring is not pinched and is full seated into
    heat to the lower shaft piston connection to loosen the the lower shaft. Figure 4.
    Loctite bond. Insert a 4mm allen key into the piston and 6. Apply grease to air piston quad seal and coat lightly the
    turn counter-clockwise to remove it and then remove the greased seal with Phil Wood Tenacious Oil. Figure 5.
    negative spring assembly. parts from the lower shaft.
    7. Apply a few drops of Phil Wood Tenacious Oil to the inside
    3. Now, install the kit thrust washer, O-Ring, and the top of the air cylinder. Figure 6.
    hat with the small end toward the end of the lower shaft
    onto the lower shaft . Select the correct negative spring 8. Insert the damping cartridge completely into air cylinder.
    according to rider weight and install it onto the lower Figure 7. The completed assembly is shown in Figure 8.
    shaft. 9. Before installing the completed cartridge into the fork
    4. Assemble the kit quad seal and O-ring onto the kit air (Figure 9), wipe clean the oil cylinder threads and apply
    piston and apply Loctite 262 (red) to the piston threads. Loctite 242 (blue).
    Figure 2.

    HDTL187/
    Loctite 262

    4mm

    1. 2. 3.

    Grease with Phil Wood Tenacious Phil Wood Tenacious Oil or


    Oil or Pedros Syn Lube Pedros Syn Lube

    4. 5. 6.

    Loctite 242

    7. 8. 9.

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