READ THIS MANUAL CAREFULLY!

It contains important safety information.

Keep it for future reference.

lefty max 140

Owner’s Manual Supplement
120024.PDF

CONTENTS

SAFETY INFORMATION ........................... SPV Air Pressure ...................................10

About This Supplement .......................2 TPC Compression Damping ............... 11
Safety Messages ....................................2 How to Set Up Sag ............................... 11
Intended Use ..........................................3 Adjusting Spring Preload .................. 12
Warning Label ........................................3 Fork Clamps .......................................... 17
Intended Use ..........................................3 Spring Change ..................................... 19
Bicycle Suspension ................................3 Oil Change ............................................ 21
FRONT WHEEL........................................ 4 MAINTENANCE .................................... 26
WHEEL HUB ........................................... 6 Schedule ............................................... 26
Cleaning ................................................27
FRONT BRAKE ........................................ 7
Air Filter ................................................ 29
ADJUSTMENTS ....................................... 8 Frame Bumper .................................... 29
Suggested Fork Set Up .........................2 Fork Boot .............................................. 30
Fork Spring Kits ......................................2 Needle Bearing Migration ................32
Rebound Damping ................................3 REPLACEMENT PARTS .......................... 34
SPV Air Volume ....................................10
OWNER NOTES .................................... 36

Please note that the specifications and information in this manual are subject to change for product
improvement. For the latest product information, go to http://www.cannondale.com/tech/.
about this supplement safety messages
Cannondale Owner’s Manual Supplements
provide important model specific safety, In this manual, information which affects
maintenance, and technical information. your safety is emphasized in the following
They are not replacements for your ways:
Cannondale Bicycle Owner’s Manual.
This supplement may be one of several for WARNING
your bike. Be sure to obtain and read all of
them. A WARNING indicates a potentially
hazardous situation which, if not
If you need a manual or supplement, or have
avoided, can result in serious injury or
a question about your bike, please contact
death.
your Cannondale Dealer immediately, or call
us at one of the telephone numbers listed
on the back cover of this manual. CAUTION
You can download Adobe Acrobat PDF A CAUTION Indicates a potentially
versions of any Cannondale Owner’s hazardous situation which, if not
Manuals or Supplements from our website: avoided, can result in serious damage
http://www.cannondale.com/bikes/tech. to the product. The matters described
• This manual is not a comprehensive under CAUTION may, if not avoided, lead
safety or service manual for your bike. to personal injury, or results depending
on the situation and degree of damage.
• This manual does not include assembly Important matters are described in
instructions for your bike. CAUTION (as well as WARNING), so be
• All Cannondale bikes must be sure to observe them.
completely assembled and inspected
for proper operation by a Cannondale A NOTE provides helpful information or tips
Dealer before delivery to the owner. intended to make the information presented
clearer.
WARNING
This document may include procedures beyond the
scope of 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 owners always
have mechanical work done by an authorized
Cannondale retailer.

2
 120024.PDF

intended use
All-Mountain
INTENDED for trail riding and riding uphill.
All-Mountain bicycles are more heavy duty than
cross country bikes, but less heavy duty than
Freeride bikes. All-Mountain bikes are lighter and
more nimble than Freeride bikes. All-Mountain
bikes are heavier and have more suspension
travel than a cross country bike, allowing them
to be ridden in more difficult terrain, over larger
obstacles and moderate jumps. All-Mountain
bikes are intermediate in suspension travel and
use components that fit the intermediate intended bike suspension and your
use. All Mountain bikes cover a fairly wide range skills and abilities
of intended use, and within this range are models
that are more or less heavy duty. Talk to your
retailer about your needs and these models. WARNING
NOT INTENDED for Hardcore Freeriding, Extreme YOU COULD HAVE A BAD ACCIDENT IF
Downhill, Dirt Jumping, Slopestyle, or very aggressive or
YOUR SKILL IS NOT UP TO HANDLING A
extreme riding .
SUSPENSION SYSTEM.
TRADE OFF All-Mountain bikes are more rugged Suspension systems (front fork, rear
than cross country bikes, for riding more difficult shocks) can increase the handling and
terrain. All-Mountain bikes are heavier and harder stability of most bicycles. If you lack the
to ride uphill than cross country bikes. All-Mountain skills and experience necessary to ride
bikes are lighter, more nimble and easier to ride at higher speeds and maneuver over
uphill than Freeride bikes. All-Mountain bikes are difficult terrain at the greatly increased
not as rugged as Freeride bikes and must not be performance level, you can ride faster
used for more extreme riding and terrain. than your abilities. You can lose control
of the bike in these conditions and crash.
Anytime you lose control of the bike,
WARNING especially at high speed and in advanced
terrain, you risk severe injury or death in
USING YOUR LEFTY IMPROPERLY IS
a crash.
HAZARDOUS.
• Ride at reduced speeds.
• Learn the performance characteristics
warning label of your bike and suspension components
before trying any downhill or very fast
Located on the lower leg of the Lefty. Do
biking.
not remove it. If it is missing or damaged,
you can obtain a free replacement from •Ride within your skills and abilities.
Cannondale. See page 6.
•Take a bicycle training course.

3
 Note brake alignment shims between
front wheel Lefty brake bosses and the caliper.

REMOVAL 4. Turn hub bolt (1) counter-clockwise to

remove the hub from the spindle.
1. Place bike in a work stand with front NOTE: As the bolt is turned counter-
wheel off the ground. clockwise, it will begin to back against the
2. Loosen the brake caliper mounting bolts. hub cap bolt (2) causing the hub (3) to
be drawn out and off the spindle bearing
seats. Since the hub bolt is actually retained
inside the hub body by the hub cap, the bolt
will remain in the hub when the wheel is
removed. There is no need to remove that
cap from the hub. See the exploded view on
page 8.

CAUTION
Make sure the axle bolt is completely
loose before attempting to remove the
wheel from the spindle.

3 2
3 Tilt the lower caliper bolt out of the boss
so the caliper is up out of the way of the
disc. Snug up on the upper bolt to hold
caliper in place. 1

5. Carefully slide the wheel off of the

spindle carefully.

4
 120024.PDF

spindle so, the larger hub bearing starts

to position on it spindle seat. At this
point, the axle bolt threads can correctly
engage the threaded spindle if the
wheel is held on straight.
NOTE:
Install the front wheel by positioning the
bike horizontally with the spindle facing
up. Then place the hub straight down
onto the spindle, and tighten the axle
bolt.
3. When the axle bolt threads engage
the spindle, turn the bolt clockwise
with finger force slowly to allow the
CAUTION hub bearings to slide onto the spindle
1. Cover the opening of a removed hub/ bearing seats.
wheel with a clean towel to prevent
contamination. Once the hub has been drawn onto the
hub completely, and proper threading is
2. Protect spindle when wheel removed. evident, use torque wrench to tighten
A fall or drop to the ground can to final 15.0 N•m (133.0 In•Lbs).
destroy or damage the spindle.
4. Reinstall the brake caliper. Tighten bolts
to 78.0 In•Lbf (9.0 N•m.)
INSTALLATION CAUTION
1. Inspect the inside of the wheel hub for LOCATE DISC BETWEEN THE PADS.
contamination and and the condition Replace shims that are in use, be sure
of the hub seal. Take corrective action if the shims are positioned between the
necessary. caliper (adapter if any) and inner face of
the fork mounts not under the head of
Wipe all parts clean with a dry shop the caliper bolts.
towel and apply a high-quality bike
grease to: USE ONLY 16 MM (Cannondale kit #
I.D. of the larger hub cartridge bearing . LEFTYBOLTS. Longer bolts can result in
contact with the brake rotor causing
Both spindle bearing lands . severe damage. Check clearance
Spindle axle bolt threads. between the bolt tips and rotor after
remounting the caliper.
WARNING 5. Spin the wheel to make sure it spins
freely. Be sure to test the brakes for
Do not contaminate brake caliper, pads,
proper operation before riding.
or rotor with grease.

2. Slide the wheel straight onto the

5
 1 Extraction Cap
2 Plastic Washer
3 O-Ring (lubricate) WARNING
TO HELP AVOID SERIOUS
4 Axle Bolt - 5mm Allen OR FATAL INJURY:
READ AND FOLLOW YOUR
5 Outer hub bearing LEFTY OWNER’S
MANUAL SUPPLEMENT.
6 Hub ** Follow wheel removal and
installation instructions.
7 Inner hub bearing ** DO NOT ride without the wheel
wheel hub

axle hub bolt and front brake

8 Seal system properly installed.
HUB BOLT : 15 N•m (133 In•Lbs)
9 Brake disc
CALIPER BOLTS : 8-9 N•m (69-80 In•Lbs)
116111
10 Brake disc bolts
Loctite # 262
11 Wheel Truing Tool 6.2 N•m, 55.0 In•Lbs W
9 TO HELP
OR F
10 READ A
LE
MANU

6
** Follow w
installati
bs 8 ** DO NOT
LEFT-HAND •L GR axle hub
In system
THREADED
3.0 GR HUB BOLT
CALIPER BOL
Loctite # 242 , 13 6
Park SPA-1 m 7
N•
1 .0
15 4 5
2
GR

11
GR NO RIDE
3
GR
Apply a high-quality bicycle bearing
QCTL108/
grease to areas
, indicated “GR.”
 120024.PDF

front brake

WARNING
DO NOT RIDE WITHOUT A PROPERLY
MOUNTED, ADJUSTED, AND
FUNCTIONING FRONT BRAKE SYSTEM.
Why? In addition to providing speed
control, the front brake system on your
Lefty (disc/caliper) acts as an integral
secondary wheel retention system. If the
system is missing or improperly installed,
or if the wheel hub axle bolt should
loosen, the front wheel could slide off
the spindle end.
When mounting IS compatible brake
systems:
Follow manufacturer’s instructions
when mounting the brake caliper to the This photo shows the area where
spindle brake bosses. Do not modify incorrect bolts will interfere with disc
the fork in any way. rotation possibly causing severe damage.
PLEASE ASK YOUR CANNONDALE Correct bolts are shown above.
DEALER FOR HELP WHEN INSTALLING In addition to checking to make sure
COMPATIBLE FRONT BRAKE SYSTEMS. the bolt ends do not protrude, you must
ensure proper thread engagement.

Mount the front brake caliper using the 16 Make sure the brake disc can not make
mm bolts of Cannondale kit LEFTYBOLTS. contact with the fork boot. A rotating brake
See next figure. disc can wear through the boot allowing
contaminants into the fork.

16mm

7
adjustments
suggested fork setup
LEFTY MAX 140 LEFTY MAX 140
SPV TPC or FFD
RIDER WT.
BIKE SIZE INSTALLED SPV REBOUND REBOUND
SPRING
FORK SPRING AIR PRESSURE Clicks out Clicks out
COLOR
COLOR (psi/bar) from closed from closed
Lbs Kg
120 53 PT GREEN 40 / 2.8 9 BLUE 9
130 58 SM GREEN 50 / 3.4 9 BLUE 9
140 63 SM GREEN 60 / 4.1 9 BLUE 9
150 68 MD BLUE 50 / 3.4 9 RED 9
160 72 MD BLUE 60 / 4.1 8 RED 8
170 77 LG RED 60 / 4.1 8 BLACK 8
180 81 LG RED 60 / 4.1 8 BLACK 8
190 86 XL BLACK 60 / 4.1 8 BLACK 8
200 90 XL BLACK 70 / 4.8 7 BROWN 7
210 95 XL BLACK 70 / 4.1 7 BROWN 7
220 100 XL BLACK 80 / 5.5 6 BROWN 6

fork spring kits

RIDER WT. RANGE ORDER SPRING
Lbs Kg CANNONDALE KIT # COIL COLOR MATERIAL Wt. (g)
KF213/GRN Steel 156
120 - 149 54 - 67 GREEN
KF214/GRN Titanium 114
KF213/BLU Steel 174
LEFTY MAX 140 150 - 169 68 - 76 BLUE
SPV KF214/BLU Titanium 108
(Carbon or Alloy) KF213/RED STEEL 197
170 - 189 77 - 85 RED
KF214/RED Titanium 151
190 - 220 86 - 100 KF213/BLK BLACK STEEL 253
120 - 149 54 - 67 KF213/BLU BLUE STEEL 174

LEFTY MAX 140 150 - 169 68 - 76 KF213/RED RED STEEL 197

TPC or FFD
(Carbon or Alloy) 170 - 199 77 - 90 KF213/BLK BLACK STEEL 253
200
91 - 100 KF213/BRN BROWN STEEL 262
- 220

8
 120024.PDF

rebound damping CAUTION

adjustment Use only finger force. Do not force
Rebound damping controls how fast the adjuster past the stop points.
Lefty extends following compression. The
rebound adjustment knob is red in color and 1¾ turns total (14 clicks)
located at the top of the fork.
Each position in the rotation of the
adjustment knob can be considered a click
although no audible sound is made. The
knob is stopped at each position by the
detent balls and spring in the rebound
knob assembly. From the fully closed to
fully open position the knob can be turned.
Be sure to consult “Lefty Upper Rebound
Assembly Exploded View” in this manual.

CLOSE
Slower Rebound
More Damping
“Sluggish” feel
Turn in direction “+”
OPEN
Faster Rebound
Less Damping
Springier” feel
Turn in direction “-”

9
spv air volume spv air pressure
Stable Platform Valve (SPV) air volume Stable Platform Valve (SPV) air pressure is
is changed by turning the red 16 mm regulated through the Schrader valve. This
hex clockwise or counter-clockwise. This adjustment control pedaling platform of
adjustment changes the volume of the the fork. Pedaling platform is the fork’s
internal compression bladder. tendency to resist compression under the
force of pedaling.

1. Remove the black vave cap (1) and

attach a bicycle suspension pump to the
Schrader valve (2).
Set air pressure within the limits.
Replace the valve cap when finished.

2
Increases bottoming
Turn clockwise (in)
resistance -
( when viewed from bottom)
Progressive
Turn counter-clockwise Decreases bottoming
Higher pressure Stiffer pedaling platform
(out) resistance -
( when viewed from bottom) Linear
Less pressure Softer pedaling platform

CAUTION SPV Air Pressure Limits:

Do not force the red hex nut past the MINIMUM - 30 psi (2.0 bar)
stop points.
MAXIMUM - 100 psi (6.8 bar)
Optional Tool Available:
CAUTION
SPV 16 mm volume adjust socket (Answer
Products part #85-3007) is needed. Clean the valve and pump end before
attaching a pump. Pumping in dirt can
quickly ruin the fork. Stay within the
pressure limits

10
 120024.PDF

tpc compression how to set up sag

damping 1. Match FORK SPRING (color) to rider
The TPC compression damping adjustment weight. See Suggested Fork Set Up on
knob (1) is located at the bottom of the page 8..
spindle. The knob is blue in appearance. 2. With the help of a second person, seat
Compression adjustment controls the rate the rider on the saddle with feet on
or speed of fork compression. pedals and hands on the handlebar.
Measure X.
3. Calculate Sag:
686mm - X = Sag(mm)
XC 25-30% 35-45mm

TR 30-35% 40-50mm

Fine tune sag by changing the spring

preload adjusters inside the fork.

Turn in direction “+” More Damping

(clockwise when
viewed from bottom) Stiffer
Turn in direction “-”
(counter-clockwise Less Damping
when viewed from Softer
bottom)
X

CAUTION
Do not force the knob past the stop
points. The adjustment range is 130°.

130°

11
adjusting spring CAUTION
preload
The outer cap (1) is aluminum; the tool
1. Place bike in work stand with front (2) is steel; Be sure to locate all the
wheel off the ground . points of tool on all the cap notches
squarely before attempting to turn the
CAUTION cap. Apply force carefully. This will help
avoid marring the cap. When loose,
Clean area around the top of the fork unscrew cap by hand.
so dirt does not enter when the fork is
opened in the following steps.
4. Make sure the wheel is off the ground
2. Close the rebound knob; turn clockwise and the lower leg is extended. Unscrew
until it stops. Count the clicks to return outer cap by hand and lift it off.
the setting later. NOTE: If needed, hold the Rebound Knob
with your fingertips to keep it from rotating
3. Turn the Outer Cap (1) counter-clockwise with the Outer Cap as it is removed.
(A) to loosen it. Use Shimano tool TL-
FC32 (2). (Hollowtech bottom bracket NOTE: Be sure to note location and condition
wrench). of 2 O-rings. Be sure to recover it. Check
both O-ring in the Adapter for damage and
replace new if necessary. See “ Lefty Outer
Cap Assembly Exploded View.”
1
2

12
 120024.PDF

1 1
1

3
2 a
4

1. Outer Cap 3. O-Ring (large)

2. O-Ring (small) 4. Adapter NOTE: Do not remove the rebound knob
assembly from the shaft top. Its not required
in this procedure. Just make sure it is screwed
5. Compress the fork to cause the rebound
in (clockwise) fully.
assembly to rise up out of the outer fork
tube. 7. Turn the Lock Ring (1) counter-clockwise
(A) to loosen it.
8. Turn the Adjust Ring (2) counter-
clockwise (A) to decrease preload
(increase sage)

Turn the Adjust Ring (2) clockwise to

increase preload (decrease sag).

6. Remove the two Split Rings (1) in the

groove (a) of the Shaft (2) .

Note the “TOP” markings on the rings;

they install up.

13
 A
B
1

NOTE: Pull the damper shaft assembly 10. Apply a high-quality bicycle bearing
upward to ensure the shaft is fully extended grease to the Shaft groove. Insert the
while adjusting the spring preload - if you do two Split Rings with the ‘TOP’ marking
not do this you may get an inaccurate setup up.
NOTE: Make a pencil mark on top of the ring
so the turn count is accurate. 1 full turn of the Then, apply a ring of grease to the top of
adjustment ring = 1 mm change in installed the Split Rings.
spring height.

ADJUST RING TURN LIMITS

(clockwise after ring first contacts top of spring)
1 Turn MINIMUM

8 Turns - MAXIMUM

9. When adjustment is complete, with

fingers, hold the Adjust Ring and tighten
the Lock Ring securely against the Adjust
Ring.

14
 120024.PDF

11. Lower the spring assembly back into the

outer tube by extending the lower fork CAUTION
leg. Only use the tool only once the cap is
NOTE: Be sure to clean the Outer Cap threads screwed on fully. Do not over-tighten.
and the threads of the fork outer tube
and reapply a light film of grease. Wipe 14. Reset Rebound Knob position.
clean with a dry towel. Do not use spray (Recorded earlier).
cleaners!

NOTE: If the Rebound Knob is not turned in

completely, when the Outer Cap assembly
is installed the knob threads can be
damaged or the knob will be difficult
to turn. Make sure the knob is turned
in fully clockwise before the Outer Cap
assembly is reinstalled.
12. Apply a film of grease to the Outer Cap
O-rings and threads.
13. Install the Outer cap by hand. Tighten
with Shimano #TL-FC32. See following
illustration for tightening method.

Figure 31
Tighten Outer Cap
A = Tighten Snug
B = Continue 1/4 Turn

15
upper rebound assembly exploded view
1

2 3
5
4

6 6

19 mm
9

10 7
1 Rebound Knob
8
2 Adapter
3 O-Ring (small) 11
4 O-Ring (large)
5 Outer Cap 13
6 Split Ring(s)
14
7 Detent Ball(s) 12
8 Detent Spring
9 Preload Lock Ring
10 Preload Adjust Ring Loctite #242

11 Shaft
12 Outer Tube 9 mm
Rebound Tuning
13
Pushrod 15

14 Main Spring
Bottom Out Spacer (A 16
15
hard plastic material)
Bottom Out Bumper (A
16
rubber-like material)

16
 120024.PDF

fork clamps CAUTION

Do not over-torque the clamp bolts.

Figure C
Lefty Alloy Fork Clamp Bolts

Creaking noise can be an indication of loose Figure D

fork clamp bolts. Lefty Carbon Fork Clamp Bolts

Check the clamp bolt tightness periodically.

When tightening is required, re-apply
Loctite #242 (blue) and tighten with a good
torque wrench.
Tightening Torque
ALLOY (Figure C) 7.0 N•m (60 In•Lbs)
CARBON (Figure D) 9.0 N•m (80 In•Lbs)

17
Removing Alloy Forks Removing Carbon Forks
The upper and lower fork clamps are For carbon lefty forks, the clamps are
integrated with the head tube steerer. The integrated with the fork clamps. The upper
fork can be removed for service, by sliding it and lower clamps are permanently bonded
down out of the clamps: to the outer tube and must not be removed.
Carbon Lefty forks are removed from the
1. Remove the brake caliper and bicycle by sliding the steerer tube out of the
detach the brake line.
fork clamps.
2. Remove the outer cap assembly. 1. Remove the brake caliper and
detach the brake line.
3. Loosen the three fork clamp bolts.
See Figure C. 2 Handlebar stem from the
head tube steerer.
4. Slide the fork down out of the clamp.
As the fork is removed, the bumper will 3. Loosen the upper and lower
slide off. Be sure to reinstall it when clamp bolts. See Figure D.
the fork is repositioned in the clamps.
4. Hold the fork and use a rubber mallet
to remove the steerer from the head
tube and fork clamps. Remove it
from the bottom of the head tube.

Figure E
Lefty Alloy Fork Removal

Reverse the step for installation. Be sure to

not key and slot in clamp and outer tube.

18
 120024.PDF

spring change Knob

About the Lefty 140 Main Spring

g
rin
Ball Ball

Sp
1. Lefty 140 MAX main springs come in several
different sizes matched to typical rider weight.
The main spring in a Lefty 140 MAX can be
changed without changing any other internal
parts. For available spring sizes and weight
range, see the replacement parts section of 6. Hold the wrench flats on the lower
this manual. rebound shaft wrench flats with a 9 mm
open end wrench.
2. You should apply a generous coating of grease
to the Lefty spring before you install it. Loosen the Shaft with a 19 mm open
3. The shrink wrap material on the Lefty 140 end wrench . Turn counter-clockwise.
spring installs with the shrink wrap up. This
material is used to reduce noise caused by
spring contact with the outer tube.
19 mm

1. Turn the Rebound Knob clockwise in

completely until it stops.
2. Remove the Outer Cap assembly. Please
read “Adjusting Spring Preload” in this
9 mm
manual for steps to remove and install
the Outer Cap Assembly.
3. Remove the two Split Rings.
4. Loosen the Lock Ring and Adjust Ring to
release the main spring preload.
5. Turn the Rebound Knob assembly
counter-clockwise to remove it. Hold
down knob while turning; the knob
assembly will pop out since it rests the
pushrod which sits atop a spring. BE
SURE TO CAPTURE DETENT BALLS AND
SPRING.

19
7. Unscrew the Shaft and lift off. bottom out bumper (a black rubber-
like material) on the rebound shaft.

11. Clean the thread of the rebound

tuning assembly and reapply a
small drop of Loctite #242.

8. Lift out the Rebound tuning pushrod.

12. Generously coat the entire spring
with a high-quality spring grease.
Then, install a new spring with the
shrink wrap on the spring facing up.

9. Lift out the spring.

10. Inspect the bottom out spacer (a

hard white plastic material) and

20
 120024.PDF

13. Reinstall the Shaft and tighten it damper, continue to the next step.
securely. DO NOT OVER-TIGHTEN
3. Remove the air bleed screw. There is
14. Reinsert the Rebound Tuning Pushrod. no air bleed screw on an SPV damper.
Make sure it drops into the assembly
fully. If it does not drop initially, rotate CAUTION
it until it does. Never force it down.
Make sure the fork, tools, and work area
15. Reset the preload Adjust Ring. Once it are very clean before performing an oil
contacts the SPRING turn it 1 FULL turn. change. If dirt or grit falls inside the
! turn is the minimum preload. Be sure fork, or remove parts are contaminated
to adjust sag as needed later. Tighten fork performance will decrease or serious
the Lock Ring against it securely. damage can result.
16. Apply grease to the Shaft groove
and install the two split rings
with the “TOP” marking up.

17. Extend the fork lowering the rebound

assembly into the outer tube.

18. Apply grease to the top

of the splits rings.

19. Clean the Outer Tube threads, grease

them and reinstall the Outer Cap
assembly. Be sure to lubricate the
O-rings with a bit of grease.

oil change
1. Place bike in work stand and Releasing SPV Air Pressure
remove the fork from the bike.

2. If you have an SPV compression damper,

remove the Schrader valve cap at the
bottom of the fork and release all air
pressure by depressing the valve end.
Wait for hissing to end.

If you have a TPC compression damper

loosen the compression damping knob
set screw and remove the knob from
the shaft end. Be sure to capture the
small O-ring in the knob groove.

If you have a FFD compression

21
 Loosening the Damping Assembly

Carefully lift out the damper.

Removing TPC Compression Damping

Knob

4. Hold the fork upside down. Use

a socket to loosen the damper.
Removing the SPV Damping Assembly
Turn counter-clockwise.

22
 120024.PDF

Carefully lift out the damper. on the floor and cycle it. About
15cc of oil will come out which a rag
can handle. Wipe up any spills.

Removing the TPC Damping Assembly

Draining Oil From The Lefty

6. Refill with the specified oil

from a clean container.

Golden Spectro
Fork Oil Motorcycle Cartridge Fork
Fluid, 85/150
Volume (cc) 155 (approximate)

Removing the FFD Damping Assembly

5. With the damper out, invert the fork

over a waste oil container and allow to
drain. Dispose of waste oil responsibly.

To expel the small amount above

the rebound piston, with the spring
installed, place the spindle on a rag

23
 If you have a TPC compression damper, dip
the piston end clean fluid and check the cap
O-ring.
If you have a FFD compression damper, check
the cap O-ring and continue to the next
step.
8. Slowly insert the damper, moving it up
and down in the oil until the cap can be
threaded in. Do not insert the damper
too quickly; oil might be forced out .

Re-Filling Oil

7. If you have an SPV compression

damper, hold the air valve end in,
allowing the bladder to expand fully.
Then release the valve. The bladder
shape should be cylindrical prior to
insertion. Make sure the bladder is
affixed properly, FULLY EXPANDED, and
the cap O-ring in good condition.

Inserting the TPC Damper

9. When the cap threads are engaged,

remove the air bleed screw of the
TPC and FFD dampers. There is no
air bleed screw on an SPV damper.

10. Thread the cap in carefully using

finger force. If sufficient oil volume
is present, oil should start to be
expelled through the air bleed hole.

11. Tighten the cap to 10.0

N•m (89.0 In•Lbs).

Expanding the SPV Bladder

24
 120024.PDF

12. If you have an SPV compression damper,

attach an air pump and pressurize
the SPV bladder. (MINIMUM 30 psi,
MAXIMUM 100 psi). Be sure to replace
the valve cap.

If you have a TPC compression

damper, reinstall the air bleed
screw and tighten to 2.3 N•m (20.0
In•Lbs). Reinstall the adjustment
knob with O-ring and tighten the
set screw to 1.0 N•m (9.0 In•Lbs).

If you have a FFD compression damper,

reinstall the air bleed screw and
tighten to 2.3 N•m (20.0 In•Lbs).

SPV Compression Damper Assembly Exploded View

1

2 10 mm Allen Key
Loctite 262 (red)
3

4
5
#017
6

1. Bladder 4. Schrader Valve 7. Volume Adjust Nut

2. O-Ring 5. Volume Adjust Housing 8. Schrader Cap
3. Schrader Housing 6. O-Ring

25
maintenance schedule
Fork maintenance is important to your safety and longtime performance of the fork. The
following table is intended as a guide to establishing a schedule appropriate to your riding
style and conditions.
NORMAL RACE
WHAT TO DO?
(In Hours)
Clean fork and visually inspect for damage. Check the fork
externally for any sign of damage (e.g., bent fork, cracks, fluid
leaks, tears, deep scratches, loose parts).

Check and adjust air pressure.

Check the fork function. Make sure it operates normally and all
BEFORE AND AFTER EVERY RIDE
adjustments are normal. See Fork Problems next page

Inspect the fork boot. Check damage (e.g., cuts, holes, rips, rub
marks, and loose attachment).

Check tightening torque of the fasteners and bolts listed in

Tightening Torques in this manual.

Grease telescope. 50 25

Needle bearing reset* 25 25

Clean air filter 25 10

Damping cartridge oil and seal change* 100 25

Inspect, Replace Bumper AS NEEDED

PROFESSIONAL SERVICE*
Annually, or when problems are indicated you must have
your Lefty fork serviced through a Cannondale Dealer or an
Authorized Headshok Service Center. Your fork should be
ANNUAL (Minimum)
disassembled by a suspension professional and evaluated for
interal and external part wear and damaged parts replaced with
new ones. It should also include any work described in technical
bulletins or product recalls.

Our “Factory Tech Room,” (in the USA) provides professional services through Cannondale
dealers for Headshok suspension forks . Please ask your dealer about the service programs
available for your model fork.

26
 120024.PDF

FORK PROBLEMS
The following are conditions that can indicate a serious fork problem: If you find
one, don’t ride the fork. Have the fork inspected by your Cannondale Dealer and any
problems corrected first.`
1. Any unusual “klunking” or knocking noises
2. A change in fork travel.
3. An over-extended or compressed boot
4. Changes in the way the fork has been working
5. Loss of adjustments features, air or oil loss.
6. Crash or impact damage (deep scratches, gouges, dents, or bending).

WARNING
DO NOT RIDE ON A DAMAGED FORK. Stop riding a damaged fork immediately.
YOU CAN BE SEVERELY INJURED, PARALYZED OR KILLED RIDING ON A BROKEN OR
POORLY MAINTAINED FORK. Please ask your Cannondale Dealer to help you develop a
complete maintenance program. Frequent checks are necessary to identify the problems
that can lead to an accident.

Cleaning
USE ONLY A MILD SOAP AND WATER SOLUTION. Clean water and a common dish washing
liquid will work best.
COVER SENSITIVE AREAS WITH A CLEAN PLASTIC BAG. Secured temporarily with a rubber
band or masking tape, a bag can prevent water damage to various bike components
(bearings, seals, fork / shock adjustment features).
SPRAY OFF BEFORE WIPING. To preserve the appearance of paint, finish, and decals, use a
low pressure water hose to first spray off heavy soils and dirt.

CAUTION
DO NOT POWER WASH OR SPRAY WATER UNDER HIGH PRESSURE TO CLEAN. Power
washing will force contaminants into parts where they will promote corrosion,
immediately damage, or result in accelerated wear.
DO NOT USE COMPRESSED AIR TO DRY.
DO NOT USE ABRASIVE OR HARSH CHEMICAL CLEANER/SOLVENTS which can damage
the finish or attack and destroy both the outside and internal parts.
When rinsing, avoid directing the spray directly at shock/fork adjusters or bearings.

27
IMPORTANT INFORMATION ABOUT RIDING IN WET, VERY
HUMID, OR COASTAL CONDITIONS
The Cannondale Headshok needle bearing system uses precise components such as
bearings and races that are made of high strength steel. These components require
proper maintenance before and after riding in severely wet conditions.

PRE-RIDE CHECKS
The following service and checks are
recommended above and beyond typical
scheduled maintenance if riding in ZIP TIE
severely wet conditions.

1. Inspect fork boot for rips and tears. AIR FILTER

COVER
2. Inspect and renew grease under fork
boot.
CLAMP
3. Clean, dry, and oil breather filter
ZIP TIE
element.
4. Ensure zip-ties and band clamps
are properly tightened (replace as
needed)

BOOT
POST-RIDE CHECKS
The following service and checks are
recommended above and beyond typical
scheduled maintenance after riding in
severely wet conditions.

1. Inspect and renew grease under fork

boot – wipe dry if water is present.
2. Inspect fork boot for rips and tears if
water is present in boot.
3. Clean, dry, and oil breather filter
element.
4. Ensure zip-ties and band clamps
are properly tightened (replace as
needed). ZIP TIE

IF THE FORK BECOMES SUBMERGED,

PERFORM THE CHECKS IMMEDIATELY.

28
 120024.PDF

Air Filter
The air filter assembly is located over two Use air filter
holes in the outer tube. Air passes in and oil foam.
out of the ports as the fork moves.
The air filter assembly stops the passage FOAM ELEMENT
of dirt and water which would damage the
internal fork components.
The small holes (a) at the base of the air
filter cover should remain open.
The foam filter element (1) should be
cleaned and re-oiled frequently.
The small holes at the base of the filter COVER
cover should be positioned to the sides
of the and not to the front or back of the AIR AIR
bicycle to minimize the chance dirt thrown HOLES HOLES
by the wheels will plug the holes.
Clean the foam air filter element with
warm soapy water, allow to dry completely,
and reapply a high-quality foam air filter oil
before reinstallation. Be sure to massage
the oil into the foam. A foam element
without the oil is ineffective.

Frame Bumper
The frame bumper (1) located on the outer
tube (2) between the clamp cushions the
frame from contact with the fork. Replace
it with a new one if it ever becomes 2
damaged, torn, or missing.

29
Fork Boot Always tighten the zip ties and clamps
The fork boot protects the internal parts securely. Replacement boots, zip
(inner tube, races, lubricant, needle bearings, ties, and cable clamps are available
and other internal parts) from contamination through a Cannondale Dealer.
and damage. It is a barrier to water, dirt,
If you find boot damage, the area under
dust, mud, or grit encountered while riding.
the boot should be professionally
If the boot is loose or damaged; dirt, water,
inspected for contamination or damage.
dust, salt spray or other contaminants will
The damaged boot must be replaced
quickly ruin the fork.
with a new one. Do not try to fix it.

WARNING
CHECK THE BOOT BEFORE EACH RIDE.
DON’T RIDE IF IT IS DAMAGED.
REPLACE IT WHEN YOU FIND DAMAGE.
A

Cleaning and Re-greasing The

Telescope Under the Boot
The fork inner tube and inner bearing races,
parts of the telescopic fork assembly are
located behind the fork boot.
Wiping off old grease with a dry shop towel
and re-apply a fresh heavy coating of grease
helps assure that ,races and needle bearings
remain well lubricated.
Any clean high-quality bicycle bearing
grease selected for riding temperatures and
environment can be used. We assemble
forks at our factory using Royal Purple Ultra
Checks Performance Grease NLGI #2 (ISO 46 BASE).
1. Check the boot for damage, cracking, 1. Remove the front wheel.
splits, or tears. Be sure to check in
the folds of the boot. Check for any 2. Release all fork air pressure.
cables or lines rubbing the boot.
3. Carefully cut the upper and lower zip
2. Check the attachment of the boot ties securing the fork boot. Some forks
at the top and bottom. The upper may have an screw type band clamp
and lower boot lips should be fitted securing the upper portion of the boot.
over the lower collar and fork lip. If this is the case, loosen the clamp.
NO PART OF THE FORK INNER TUBE
4. Lift the unsecured boot up to
(lower leg) SHOULD BE EXPOSED.
expose the inner tube (1).
3. Replace the zip ties and band clamps .

30
 120024.PDF

5. Wipe away any old grease with the fork and carefully re-apply grease.
a clean lint-free shop towel. Cycling moves the new grease inside
Cycle the fork and repeat. the fork onto the outer tube races
and bearing cages. Its OK to leave
CAUTION a good coating under the boot.
Do not use solvents or spray chemicals
Avoid applying grease to the area
to clean. Protect the exposed fork from
(A) just under the boot/zip tie.
contaminants. Work in a clean area.
6. Visually inspect the inner tube (1) Also, do not contaminate the
and inner races (2) a for any signs of brake disc with grease.
corrosion or damage. Some very light
wear to the inner races is normal, Wipe it off the inner tube and inner
however, they are worn-out if any boot to ensure that boot does not
scratches or grooves are evident. If slide up when zip tie is re secured.
heavy corrosion is present they must be
replaced. If ridges can be felt by the tip
of a rolling ball point pen over the race,
the races should be replaced. If damage
is found, the damaged parts must be
replaced new before the fork is ridden.

A
2

1
7. When you are finished, inspect the
condition of the boot. Make sure it is
undamaged. Replace it if it is. Re secure
the boot and reassembly the fork.

WARNING
NEVER RIDE YOUR LEFTY IF THE INNER
TUBE, BEARING RACES, OR BEARINGS
ARE CORRODED, RUSTED, OR CRACKS
ARE PRESENT.
7. Use a stiff nylon brush to apply a
high-quality bicycle grease onto the
inner tube and bearing races. Cycle

31
Needle Bearing Evidence of migration is:
1 An unusual "top out" noise .If
Migration Reset an unusual noise is heard, the
extended fork length should be
NOTE: Ideally, reset the bearings after 25 measured to confirm the condition.
hours of normal riding or 10 hours of hard
2. The fork’s maximum extended
riding/racing to maintain optimum fork
length is reduced.
performance.
We recommend that the needle bearing If migration re-occurs frequently
reset procedure should be performed by a (immediately after resetting), the cause
could be damage present in the inner or
professional mechanic.
outer races, ,bearings/cages or other fork
Explanation parts. Inspection and replacement of
Inside the fork the four needle bearing damage parts will be required to correct a
cages (1) move independently up and down persistent problem with bearing migration.
between each inner (2) and outer race pair
(3). This bearing arrangement provides
numerous advantages to fork performance
but requires simple periodic maintenance to
ensure proper alignment.

2 3

1
ALIGNED MIGRATED

Bearing Migration
If a cage or cages shifts out of alignment up
or down in relation to the others it is said to
have “migrated.” This migrated condition
will limit travel.
Needle bearing migration is normal and
expected. However, if the fork is ridden in
this state for extended periods, the fork can
be damaged.

32
 120024.PDF

Resetting Migrated Needle Bearings

1. Place the bike in a work stand.

Release all the air pressure
through the Schrader valve.

2. Remove the rebound knob and lockout

lever. Remove the outer cap with the
Shimano bottom bracket tool TL-FC32.

3. Compress the telescope and remove

the two split rings from the top cap..

4. Fully extend the fork, and measure from

top edge of outer tube to bottom edge
of spindle. See right. If the length is
out of specification do the following: 720-730mm
Firmly extend the telescope until it
stops (tip - listen for the knocking at
full extension to change from a hollow
sound to a solid sound - this indicates
full extension has been achieved). Do
this several times using only moderate
force, extend the lower fork leg using a
pumping action.

After, you have performed this

action several times, re-measure.

CAUTION
If fork is out range following reset
attempt, it may be damaged internally.
The fork should be disassembled and
inspected by a professional mechanic
before it is ridden. The Rebound,Lockout Assembly and
Split rings is removed.

All air is released

Telescope is extended fully.

33
 replacement parts (kits)
ORDER KIT DESCRIPTION
KF205/ Kit, Split Ring,2
KF206/ Kit, Collar, Upper,Alloy,Speed110/MAX140
KF207/ Kit, Collar, Upper,Carbon,Speed110/MAX140
KF208/ Kit, Collar, Lower,Alloy
KF209/ Kit, Collar, Lower,Carbon,clip+bushing
KF213/BLK Kit, Spring,MAX140 FE,XFIRM
KF213/BLU Kit, Spring,MAX140 FE,STD
KF213/BRN Kit, Spring,MAX140 FE,XXFIRM
KF213/GRN Kit, Spring,MAX140 FE,SOFT
KF213/RED Kit, Spring,MAX140 FE,FIRM
KF214/BLU Kit, Spring,MAX140 TI,STD
KF214/GRN Kit, Spring,MAX140 TI,SOFT
KF214/RED Kit, Spring,MAX140 TI,FIRM
KF215/ Kit,Damper,Compression,MAX140,FFD
KF216/ Kit,Damper,Compression,MAX140,TPC
KF223/ KIT,BLADDER ASSY,MAX140,SPV
KF217/ Kit,Damper,Rebound,MAX140,FFD/TPC
KF218/ Kit,Damper,Rebound,MAX140,SPV
KF219/ Kit,Damper,Control ASSY,MAX140
KF220/ Kit,,Bladder ONLY SPV,MAX140
KF221/ Kit, Knob, Compression,MAX140,TPC
KF224/ Kit, Damper,Piston Ring,MAX140-5
KF225/ Kit,Seal,Max140
KF222/ Kit, Boot, Lefty MAX 140
KF233/ KIT,KNOB,REBOUND,MAX140
KF234/ KIT,PUSHROD,MAX140
QC671/ Kit,Bleed Screw,MAX/Jake
HD208/ Kit, Outer Race Clip-Lefty / 5
HD209/BLK Kit, Air Filter/Hood, Lefty
HD175/ BLK Kit, Zip Ties, Black / 50

34
 120024.PDF

HD185/BLK Kit, Zip Ties, Double Head /10

HD011/ Kit, Band Clamps (2), Boot - Lefty
HD215/ Kit, Frame Bumper, Lefty/Moto
QC679/ Kit, Clamp, Upper, MAX-Silver
QC680/ Kit, Clamp, Lower, MAX-Silver
HD016/ Kit, STEERER,CARBON LEFTY
KT040/ KIT,STEERER,X-LONG LEFTY-- will only work with carbon and bonded alloy Leftys
HD210/ Kit, Steerer Tube Plug, Lefty
QSMSEAL/ Kit, Seal, HShok Upper Bearing
QHDST/EBO Kit, Headset, 2 cups + 1 bearing
HD169/ Kit, Bearings, Headset - 2; HeadShok
KT020/ KIT,TOOL,LEFTY STEERER,INSTALL
HD226/ Kit,Oil,Golden Spectro, 1 Bottle
KF364/ KIT,COMPUTER MOUNT,LEFTY
HD161/ Kit, Needle Bearings, Set of 4, for all in-headtube Headshok forks
HDR2M/020 Kit, Race-Inner: 11.378”-289.0mmx.020”-.51mm (4)
HDR2M/021 Kit, Race-Inner: 11.378”-289.0mmx.021”-.53mm (4)
HDR2M/022 Kit, Race-Inner: 11.378”-289.0mmx.022”-.56mm (4)
HDR2M/023 Kit, Race-Inner: 11.378”-289.0mmx.023”-.58mm (4)
HDR2M/024 Kit, Race-Inner: 11.378”-289.0mmx.024”-.61mm (4)

For an up to date list of kits available for your bike, please visit
our Tech Center at : http://www.cannondale.com/tech/

35
 owner notes
Record maintenance history, service, or set up information .

DATE WORK PERFORMED

36