MANUALETTING IN TOUCH WITH CANNON 3 For technical assistance with any Cannondale, HeadShok, or CODA product, please contact our Technical Support department. Account Number: Account Manager's Name: Inside Rep’s Name: USA & Canada: —_ Cannondale Corporation 800-726-2453 Friendship Road, RD#7 814-623-2626. Bedford, PA 15522 Europe (EC): Cannondale Europe BV (31) 5415-89898 Postbus 5100 Hanzepoort 27 7570 GC Oldenzaal, Netherlands Japan: Cannondale Japan (81) 72-99-9399 5-12-5 Harayamadai Sakai City Osaka 590-01 Australia: Cannondale Australia (61) 2-997-95851 P.O. Box 445 Mona Vale, N.S.W. 2103 All other areas: Please contact your local Cannondale distributor. World Wide Web: — hittp:/www.cannondale.com E-mail: tech@cannondale.comaN a Section 1. Introduction - it ioneicy fee de nae tan catonon tilkemneeryl Section 2. HeadShok Identification Fork Identification henitds arbieieer ed Cartridge Identification... 25 Section 3. HeadShok Service Procedures ‘Wiel. 52 Sears qian DD/ RDC... 1 Lata: be 38 Fatty 50 eee eh 39 Fatty 70 osu hhieshne hie 3-21 DBZ 2c 8 eee Seeds Apt aa OS BOSON. 28 a Keiembeawaareaeeel DD60 3-43 MCSO/EDM . . +351 CGD Sisco dea bias, a atfaeicichs Sees: Si Ac ues Gh veda ak can hvee ats e eam eo) p15 BRE yoresa drngaisaemacoaes tind gb 3 OOS Ld es eee err errr es cote 3-69 General Fork Service (Incl. Needle Bearings)...... 3-77 Section 4. HeadShok Kits and Small Parts 4-1 Section 5. Cannondale Frames . - ie ia Section 6. Cannondale Frame Kits and Small Parts ..... . sine Section 7. CODA Components... 0.0. .ssrsreeee wae te Section 8. CODA Kits and Small Partsteat We at Cannondale are committed to providing our dealers and our end customers with the finest cycling products in the world. As part of this commitment, we have compiled this comprehensive service manual to provide the bicycle service technician with the latest technical information, This manual is intended to be used as a resource for our dealers, helping them to service the ever expanding range of Cannondale, HeadShok, and CODA products. We have included detailed speci- fications and service information for all HeadShok front suspension systems, Cannondale frames and rear suspension systems, and CODA components that have been produced up through the 1997 model year. Our plan is ta produce updates to this book and send them out periodically as new products are introduces, or as existing products are refined Ifyou have any questions regarding the procedures or information contained in this book, please contact our Technical Support department. Likewise, if you have any suggestions for changes that may improve later updates, please forward them on, as well, HEADSHOK FRONT SUSPENSION The HeadShok section of this manual is split into three distinct chapters: Identification, Service, and Parts List. The Identification chapter will help you to determine exactly what type of fork or cartridge you have before you, and where to look for service information. The Service chapter con- tains instructions for all pertinent service procedures, The Parts List covers all small parts, kits, and special tools. If you're not sure of exactly what type of HeadShok fork (or cartridge) you have before you, see the Identification chapter first, Remember that most HeadShok forks and cartridges are inter- changeable, and the cartridge may have been upgraded or replaced since the bike was new. ‘Once the exact type is determined, proceed to the Service chapter for further instructions. CANNONDALE FRAMES & REAR SUSPENSION The “Cannondale Frames” section of this manual covers all Cannondale frames and rear suspen- sion systems. This section is split into two chapters: Service and Parts List. The Service chapter contains specifications and service instructions for various areas of Cannondale rigid and rear suspension frames. The Parts List contains item numbers for all kits and small parts that are currently available. CODA COMPONENTS: The CODA section of this manual covers all CODA components. It contains two chapters: Service and Parts List. 1N TR O DUC¢&tTttio wn 1-4‘ rRooUCTION 'MEADSHOK SUSPENSION FORKS: A BRIEF EXPLANATION HeadShok forks consist of 3 distinct components: Fork blades Telescoping steerer tube Cartridge (guts) Fork Blades ‘Since its introduction in 1991, there have been several different types of forks made with the HeadShok design. Most were made for 26" mountain bike wheels, but 700c versions for Hybrids and for Road bikes have also been manufactured. Telescoping Steerer Tube The Telescoping Steerer Tube has undergone several changes, the most notable being the switch 1993) from adjustable needle bearings to fixed, pre-adjusted needle bearings. There have also been minor changes and differences in steerer tube length and needle bearing race length over the years. Cartridges ‘There have been a large variety of different cartridges made over the years. See the Cartridge Identification section for complete information on the various HeadShok cartridges. The fork blades and the telescoping steerer tube are permanently assembled at the factory, but the cartridges are interchangeable (with a few exceptions). Any suspension system must consist of two distinct components: a spring and a damper. In the case of a bicycle suspension fork, the spring supports the rider's weight, while the damper controls the action of the spring. ‘Springs ‘Several different devices can be used for a spring. Compressed air, MCU (Microcellular Urethane), elastomer, and steel coils have all been used in HeadShok suspension at one time or another. Elastomer Elastomer is a rubbery plastic material that has a slight damping (energy absorbing) praperty, Some suspension systems utilize elastomers as a spring. However, elastomers are relatively dense, and cannot compress much beyond their original size betore “going solid”. As such, they tend to pro- duce a very steeply progressive spring rate, to the point where travel is limited, Elastomers also tend to be affected by temperature (they get markedly stiffer in colder temperatures.) D2: 1N TR ODUCTIONm@MCU Micro-Cellular Urethane (or MCU) is a porous plastic material with a rubbery consistency. The pores in the material are filled with air, reducing its density. As the material is. compressed, the air is pushed out of these pores, allowing the material ta be compressed much smaller than its original size. When used as a spring, MCU has a progressive rate, and a slight inherent damping property. However, MCU alone does not give sufficient damping for an effective suspension sys- tem. A separate damping mechanism is required. Coil Springs Coil springs are simple, reliable, and give a predictable, linear spring rate. However, the spring rate does not provide enough force in a short-travel application to prevent bottom-out on large ‘impacts. Compressed Air The benefits of using compressed air for a spring are light weight, a wide range of adjustability, and the small volume needed. Air springs have a progressive rate, which prevents the fork from bottoming out on large bumps. The curve of spring rate progression can be very steep or mare moderate depending on the air volume used. Potential drawbacks to air springs are the possibility for seal leakage (and resulting loss of air pressure) and the need for air spring preload pressure to be adjusted with a special, high-pressure pump (a minor inconvenience). ™@Coil-MCU combinations Because coil springs have a linear spring rate, they stay very supple and reactive when used in a bicycle suspension fork. However, when a large bump is hit, the rate of a coil spring does not rise quickly enough to prevent a hard bottom-out. Another type of spring with a more steeply progres- sive rate must be used to supplement the coil spring. ‘Some suspension forks use a short coil spring in series with a longer MCU or elastomer spring. This produces a suspension fork that feels soft and supple through the first bit of travel. However, when the coil spring bottoms out, the elastomer alone (with its steeply progressive rate) compress- es until it “goes solid” and limits the fork’s travel. The HeadShok Advanced Spring System uses a long coil for the suspension's primary spring. To prevent a hard bottom-out, a column of soft MCU is used to supplement the coil spring. This gives the Suspension the suppleness of a coil spring, with a steep rise in the spring rate at the very bottom of the fork's travel. The MCU columin can be trimmed shorter to retard the progres- sion of the spring, so that it begins to stiffen later in the suspension’s travel. NT RF ODUC¢&rTision 1-3‘= nTRoueTION Dampers: There have been two types of dampers used in HeadShok suspension forks. Hydraulic Damper (a.k.a. Oil Damper, Hydraulic Cartridge) A hydraulic damper is a sealed, oil-filled cylinder with a piston in it. The piston has one or more ports (holes) in it, and is attached to a shaft. As the suspension is compressed, the piston is forced from one end af the cylinder toward the other, forcing the oil to flow from one side of the piston, through the ports, to the other side. Because oil is a thick liquid that flows slowly, this slows the action of the suspension. ™ Mechanical Damper A mechanical damper is a simple nylon wear ring that contacts the inner surface of the fork’s steerer tube. The small amount of interference between the ring and the steerer tube produces a small amount of friction, slowing the suspension. GLOSSARY Travel ‘The term “Travel” refers to the amount of distance a frant (or rear) wheel can move to absorb an impact. Generous amounts of travel alone is not the mark of a good suspension system. Of equal or greater importance is the suspension's ability to absorb the energy of the impact without sacri- ficing rider control. Spring ‘A spring is an energy storage device. In a suspension system, the spring stores energy as it is compressed. The spring then expends the stored energy as it extends. Preload Preload is the force that a spring exerts when the suspension is fully extended, When preload is adjusted properly, the suspension will not compress needlessly under the rider's body weight, but will activate with even the smallest impact. Spring Rate Spring rate is a measurement of a spring's stiffness. Spring rate is typically expressed in terms of mow much weight (force) is required to compress the spring one inch. 1-4 IN TR ODUC¢G TiO NProgressive Spring Rate A progressive spring rate is one that gets 300 : stiffer at a dispropartionately to the amount 250 it is compressed. The degree to which a pro- gressive spring stiffens as it is compressed Force 200 varies. Some types of springs. get stiffer very (POUNDS) y5q | _,f ___ gradually while others stiffen very abruptly. z 100 Example of progressive spring rate: 50 = t oe Fully extended: 0 ibs. a ee cig ‘Compressed 1"; 50 Ibs. TRAVEL (NCES) Compressed 2": 150 Ibs. Compressed 3”: 300 Ibs. Linear Spring Rate A linear spring rate is one that gets stiffer in direct proportion to the amount it is ‘compressed, Coil springs in particular have a linear progression rate, Example of linear spring rate: Fully extended: O Ibs. Compressed 1”; 100 Ibs. Compressed 2”: 200 Ibs. ‘Compressed 3”: 300 Ibs. Damping Damping controls the speed at which the suspension compresses and rebounds. There: are several different types of damping devices. Most bicycle suspension systems use simple friction-ring devices or more versatile hydraulic shock absorbers. Some systems have no damping device at all, and rely an elastomer bumpers to provide a very small amount of damping. Stiction Bad. “Stiction” refers to static friction; the tendency for two surfaces to resist sliding against each other. The problem of stiction is most prevalent in conventional telescoping-blade type sus~ pension forks. The bushings that these forks have in between the stanchion and slider tubes pro- duce a great deal of stiction. In order for the suspension to compress, this resistance must first be overcome, preventing the fork from reacting to many small bumps and reducing the efficiency of the suspension overall. The needle bearings in HeadShok forks produce almost zero stiction ee 1n TR ODUeEtTti oO N 41-5FORK IDENTIFICATION ® POC eee a7 a Cream Td (curved rake) (straight rake) * Towel fs mecsced wi corre remaved Iron fc Trea i mocsred wih corde removed fe fer HEADSHOK IDENTIFICATION <2-1FORK IDENTIFICATION Pee TA Sanity Aacemmanded Dot: (fd -HOI3I/ * Yoel is messed wth ridge removed frm fk ovals mensred wth aridge reared fom fer 2-2 Coat with grease- ALIS O-ring HEADSHOK SERVIC E£3-31REMOVAL OF CARTRIDGE 1. Turn the Damping Dial to the left, leaving the fork in it's “on” position, Remove the screw from the center of the Damping Dial and remove the dial from the top of the fork. Back the mm preload screw out so that it is flush with the top of the fork. 2. Loosen the stem binder bolt and remove the stem from the steerer tube. Hang the handlebar/stem assembly out of the way. 3. Using a pin-spanner wrench (Park SPA-1, green), unthread the outer cap of the fork (Fig.1). 4, With the outer cap completely unthreaded, compress the fork from beneath, This will expose the outer cap and piston shaft of the oil damper cartridge. 5. Using a HeadShok pin wrench (part #101103), unthread ‘the oil damper cartridge from the inner steerer tube, and re- move the cartridge from the fork (Fig.2). 6. Turn the fork upside-down. The MCU spring element will drop out of the steerer tube. 7. With the fork still inverted, push the bottom plug down into the steerer tube about 1* to expose the circlip. Pry the circlip out of its groove with a small screwdriver and remove it from the steer- er tube. Discard the circlip and use @ new one upon reassembly. 8. Turn the fork upright again. Insert a long dowel into the steer er tube (from the top) and push the bottom plug out through the bottom of the steerer tube (Fig.3) INSTALLATION OF CARTRIDGE 1. With the fork upside down, insert the bottom plug into the fork crown with its reduced end pointed up. push the plug in far enough to allow access to the groove around the inside surface of the fork i crown. Install a new circlip in the groove, making sure that it is firm- ly and completely seated in its groove. Do not reuse the old circlip. . When the new circlip is in place, turn fork upright and seat the tJ plug against the circlip by pushing down on it from the top (Fig.4). Sy HEADSHOK SERVICE,“3-33poz 2. Coat the MCU spring element (or coil spring) with grease. Drop the spring element into the steerer tube from the top. 3. Install a new #015 O-ring just above the threads an the outside of the oil damper cartridge. Apply a drop of Loctite #242 (blue) to these threads. Insert the preload piston into the bottom of the oil damper housing, Turn the large hex nut on the top of the housing to the right until you hear a click (this will lock the cartridge out.) 4. To thread the oil damper cartridge into the steerer tube, it will be necessary to compress the spring element slightly. This is easiest to do with the bike out of the work stand and standing on the floor. Insert damper cartridge into the steerer tube from the top. While pushing dawn on the outer cap of the damper cartridge, turn the cartridge clockwise with a HeadShok cartridge pin wrench (part #101103) to get the threads started. Continue turning wrench clockwise until cartridge is tight in steerer tube. Be very care- ful not to damage the threads on the damper cartridge (Fig 5). 5. Apply grease or anti-seize compound to the threads on the outer cap. Tighten the outer cap into the steerer tube with a pin-spanner wrench (Park SPA-1, green). See Fig.6. 6, Install the stem, then adjust spring preload. Install the Damping Dial. Make sure the Damping Dial is turned to the left (open position}, and remove the retaining bolt in the center of the dial. Turn the 3mm Allen set screw (accessed through the center of the dial) until the desired preload is achieved (Fig,7). With correct pre- load, the fork should compress 1/16" to 1/8" when the rider sits on the bike in a neutral, relaxed riding position, Once adjustment is complete, install the supplied 6mm screw into the center of the Damping Dial. This screw serves two very important purposes: to retain the dial on the fork, and to seal fork from water, dirt and other contaminants. NOTE: This procedure for setting preload is a guideline only. We encourage riders to experiment with preload adjustment. Some prefer a stiffer suspension, some a softer, compliant suspension. 3-34/ HEADSHOK SERVICEADVANCED SPRING SYSTEM UPGRADE The HeadShok DD2 originally came equipped with an MCU spring element. This spring can be replaced with a HeadShok Advanced Spring System. This spring system upgrade consists of a coil spring with @ column of MCU foam running through its center. The coil spring provides a more supple and active suspension feel at the upper end of the fork's travel, while the MCU column provides a progressive spring rate toward the lawer end af the travel. The Advanced Spring System kit is available in three color-coded spring rates. Rider weight range Recommended spring Spring Kit code 150 Ibs. or less Green HD110/GRE 180 Ibs. or more HD110/RED DAMPING DIAL The Damping Dial on the HeadShok DD2 is designed to rotate approximately 1/6 turn. Turning the dial clockwise to its stop will lock the fork out completely. Turning it counter-clockwise to its stop will open the damping port and allow the fork to compress, HEADSHOK SERVICE £3-35DD2 Piston 150%—q —T > _, Prelod Feson ——_ 3-36/HEADSHOK SERVICEOD. De This section covers 1995 and 1996 HeadShok DD50 and DD25 cartridges. The DDSO isa hydraulic damper cartridge GES that features 50mm of travel. The DD25 is very similar, but it allows 25mm of travel and was originally installed in * Path" hybrid bikes with 700c wheels. Both cartridges have a Damping Diel, allowing the rider to lock out the fork while riding, See the “HeadShok Identificatio ‘of this manual for more information. 1. Turn the Damping Dial to the left, leaving the fork in it's “on” position. Remove screw from the center of the Damping Dial and remove dial from the top of the fork. Back the 3mm preload screw out so that it is flush with the top of the fork. 2. Loosen the stem binder bolt and remove the stem from the steerer tube. Hang handlebar/stem assembly out of the way. 3. Using @ pin-spanner wrench (Park SPA-1, green), unthread the outer cap of the fork (Fig. 1). 4. With outer cap completely unthreaded, compress the fork from beneath. This will expose the outer cap and piston shaft. 5. Using a HeadShok Castle tool (part #104110), un- thread the oil damper cartridge from the inner steerer tube, and remove the cartridge from the fork (Fig. 2). 6. Turn the fork upside-down. The MCU spring element will drop out of the steerer tube. © 7. With the fork still inverted, push the bottom plug 2 down into the steerer tube about 1° to expose the circlip. Pry the circlip out of its groove with a small screwdriver eS and remove it from the steerer tube. Discard the circlip. 8. Turn the fork upright again. Insert a long dowel into the steerer tube (from the top) and push the bottom plug out through the bottom of the steerer tube (Fig.3). HEADSHOK SERVICE “3-37™pp50/0025 INSTALLATION OF CARTRIDGE 1. With the fork upside down, insert the bottom plug into the fork crown with its reduced end pointed up. push the plug in far enough to allow access to the groove around the inside surface of the fork crown. Install a new circlip in the groove, making sure that it is firmly and completely seated in its groove. Do not reuse the old circlip. When the new circlip is in place, turn the fork upright and seat the plug against the circlip by pushing down on it from the top (Fig.4). 2. Coat the MCU spring element (or coil spring) with grease. Drop the spring element into the steerer tube from the top. 3. Install a new #015 O-ring just above the threads on the outside of the oil damper cartridge. Apply a drop of Loctite #242 (blue) to these threads. insert the preload piston into the bottom of the oil damper cartridge. Turn the large hex nut on the top of the cartridge to the right (this will lock the damper car- tridge out.) 4. In order to thread the oil damper cartridge into the steerer tube, it will be necessary to compress the spring element slightly. This is easiest to do with the bike out of the work stand and standing ‘on the floor. Insert the damper cartridge into the steerer tube from the top. While pushing downward on the outer cap of the damper cartridge, turn the cartridge clock- wise with a HeadShok Castle tool (part #104110) to get the threads started (Fig.5). Continue turning the wrench clockwise until the cartridge is tight in the steerer tube. Be very careful not to damage the threads on the damper cartridge. 5. Apply grease or anti-seize compound to the threads on the outer cap. Tighten the outer cap into the steer- er tube with a pin-spanner wrench (Park SPA-1, green). See Fig.6. 6. Install the stem, then adjust the spring preload. Install the Damping Dial. 3-38 AH EADSHOK SERVICEDps0/p025 ‘SPRING PRELOAD Make sure the Damping Dial is turned to the left (open position), and remove the retaining bolt in the center of the dial. Turn the 3mm Allen set screw (accessed through the center of the dial) until the desired preload is achieved, With correct preload, the fork should compress 1/16" to 1/8" when the rider sits on the bike in a neutral, relaxed riding position. ‘Once the adjustment is complete, install the supplied 6mm screw into the center of the Damping Dial. This screw serves two very important purposes: to retain the dial on the fork, and to seal the fork from water, dirt and other contaminants. NOTE: This procedure is ta be used as a guideline only. We encourage riders to experiment with preload adjustment. Some prefer a stiffer suspension, some a softer, more compliant suspension. ADVANCED SPRING SYSTEM UPGRADE The HeadShok DDS50 (and HeadShok DD25) originally came equipped with an MCU spring element. This spring can be replaced with a HeadShok Advanced Spring System. The Advanced ‘Spring System upgrade consists of a coil spring with a column of MCU foam running through its center. The coil spring provides a more supple and active suspension feel at the upper end of the fork’s travel, while the MCU column provides a progressive spring rate toward the lower end of the travel, The Advanced Spring System kit is available in three color-coded spring rates. Rider weight range Recommended spring Spring Kit code 150 Ibs, or less HD11O/GRE 140 - 200 Ibs. HD110/BLU 180 Ibs. or more. HD110/RED Green The Damping Dial on a HeadShok DDSO or DD25 cartridge is designed to rotate approximately 1/8 turn, Turning the dial clockwise to its stop will lock the fork out completely. Turning it caunter-clockwise to its stop will open the damping port and allow the fork to compress. OIL CHANGE / BLEEDING PROCEDURE The hydraulic oil in a DD50 or DD25 cartridge should be replaced and the cartridge bled at least once a year. The damper cartridge originally came with SW oil installed, however, the oil may be changed to a different viscosity to change damping performance. A heavier oil (as heavy as LOW) may be used to provide heavier damping, but the fork's ability to absorb large impacts will be re- duced. Likewise, a lighter weight oil (as light as 2.5W) may be used to "quicken up" the suspen- sion action. NOTE: Do not use a “seal swelling” hydraulic oil in a HeadShok cartridge. Only use hydraulic oil that is approved for use in suspension systems with natural rubber seals. HEADSHOK SERVICE “3-39mpps0/0025 1, Remove the oil damper cartridge from the fork. 2, Hold the oil damper cartridge upside down over a buck- et or similar container. Unthread the lower cap from the cartridge body with a pin-spanner wrench (Park SPA-1, green). See Fig.7. 3. Pour the oil from the cartridge into the container (Fig.8). Stroke the piston up and down in the cartridge to pump out any oil that may be trapped above the piston. 4, Remove the brass brad (nail) from the lower cap and set it aside. The brad is reusable, 5. Holding the cartridge upside down, pour in fresh hydraulic oil. Fill the cartridge all the way to the top. 6. Stroke the piston up and down very slowly to expel any trap- ped air. (You will see air bubbles rise to the top of the oil, and the oil level may drop.) Continue stroking until all air is purged from the system 7. Pour more oil into the cartridge until it is again filled to the top. Repeat step 6 if necessary. 8. Screw the lower cap back into the cartridge and tighten with a pin-spanner wrench. Some ail will be forced out through the brad hole in the lower cap. NOTE: Do not overtighten the upper cap! Overtightening the upper cap will result in binding of the cartridge and unrespon- sive suspension action, 9. Replace the brass brad in the iower cap (Fig.9). Cycle the cartridge several times and check to make sure the lock-out switch functions correctly. If there is any air in the system, the stroke of the cartridge will feel rough and irregular, and the lock-out may not function. If this is the case, repeat the oil change procedure, paying close attention to step 6. It is not unusual for the cartridge to make some noise just after being rebuitt. 10. Replace the oil damper cartridge in the suspension fork 3-40 AHEADSHOK SERVICEpps0/p025 m ‘SEAL REPLACEMENT ‘As a regular service to a DD50 or DD25 cartridge, the seals in the lower cap and the O-ring seal on the piston should be replaced once a year. Replacement of the u-cup seals in the upper cap is not recommended unless significant oil leakage through these seals is noticed. It is normal and regular for a small amount of oil to “weep" past the piston seals in the upper and lower caps. This will appear as a thin film of oil on the piston shaft, This does not indicate a faulty seal, or a defective cartridge. If significant oil leakage is. noticed, if the fork loses its lock- out ability, or if the smoothness of the suspension deteriorates and the fork begins to feel rough ‘r gritty during compression, then one or more of these seals may be damaged and in need of replacement, Seal kits are available through HeadShok,(part #HD115/) 1. Remove the oil damper cartridge from the fork. 2. Hold the oil damper cartridge upside down over a bucket or similar container. Unthread the lower cap from the cartridge body with a pin-spanner wrench (Park SPA-1, green). 3. Pour the oil from the cartridge into the container. Stroke the piston up and down in the car- ‘tridge to pump out any oil that may be trapped above the piston 4, Remove the brass brad (nail) from the lower cap and set it aside. The brad is reusable. 5. Unthread the upper cap from the cartridge body with a pin-spanner wrench. Slide the cartridge body off of the piston assembly, 6. Replace the two cup seals located inside the lower cap. Be sure to orient the new seals with their larger ‘flared* ends toward | Fig.210 ¥ | the middle of the cartridge (Fig.10). Also replace the O-ring seal on the piston and the O-ring seals on the upper and lower caps, Be very careful not to tear or puncture any the new seals. 7. Apply a thin coating of hydraulic oil to the new seals. Slide the cartridge body over the piston assembly and tighten the upper cap with @ pin-spanner wrench. (00 NOTE: Do not overtighten the upper cap! Overtightening the upper cap will result in binding of the cartridge and unresponsive suspen- sion action. if 8. Go te step 5 of Oil Change/Bleeding procedure to complete the assembly. HEADSHOK SERVICE “3-41= D050/D025 pb50 025/96 Lockout Met (Outer Cop —_| Wien (0) Upper Cop. w/4 Pinales. wa, a ree SS 3-42 /HEADSHOK SERVICE60/0025 UTTER OT) This section covers 1997 HeadShok DD60 and DD25 car- tridges. The DD6O is a hydraulic damper cartridge that fea- tures 60mm of travel. The DD25 is very similar, but it allows | Fig.1 ¥ | 25mm of travel and was originally installed in “Silk Path" hybrid bikes with 700c wheels. Both cartridges have a Damp- >= ing Dial, allowing the rider to lock out the suspension fork fi Kez while riding. See the “HeadShok Identification” section of Ly YW? this manual for more information os REMOVAL OF CARTRIDGE 1, Turn the Damping Dial to the left, leaving the fork in it's “on” position. Remove the screw from the center of the Damping Dial and remove the dial from the top of the fork. Back the 3mm preload screw out so that it is flush with the top of the fork. 2. Loosen the stem binder bolt and remove stem from the steerer tube. Hang handlebar/stem assembly out of the way. 3. Using a pin-spanner wrench (Park SPA-1, green), unthread outer cap of the fork (Fig. 1). 4. With outer cap completely unthreaded, compress the fork from beneath. This will expose the outer cap and piston shaft 5. Using a HeadShok Castle tool (part #104110), un- thread the oil damper cartridge from the inner steerer tube of the fork. When the cartridge is unthreaded from the steerer tube, remove it from the fork (Fig.2) 6. Turn the fork upside-down. The coil spring and MCU element will drop out of the steerer tube. 7. With the fork still inverted, push the bottom plug down into the steerer tube about 1 inch to expose the circlip. Pry the circlip out of its groove with a small screwdriver and remove it from the steerer tube. Discard the circlip. 8. Turn the fork upright again. Insert a long dowel into the steerer tube (from the top) and push the bottom plug out through bottom of steerer tube (Fig.3). HEADSHOK SERVIC E/3-43™ pp60/0028 INSTALLATION OF CARTRIDGE 1, With the fork upside down, insert the cup-shap- ed bottom plug into the fork crown with its hollaw end pointed into the steerer tube. Push the plug down into the steerer tube about 1 inch. Install a new circlip in the groove: around the inside surface of the fork crown. It is very important that this cir- clip is firmly and completely seated in its groove. When the new circlip is in place, turn the fork up- right and seat plug against the circlip by pushing down on it from top with a long dowel (Fig.4.). 2. Apply a thin coating of grease to the MCU element. Insert the MCU into the coil spring (tapered end first) and apply a coating of grease to the spring. Drop the spring assembly into the steerer tube from the top. 3. Remove old O-ring from cartridge threads and discard. Install a new #018 O-ring just above the threads on the outside of the cartridge. Apply a drop of Loctite #242 (blue) to the threads on the outside of the cartridge (Fig.5.). 4. Insert the preload piston into the bottom of the piston shaft. Turn the large hex nut on the top of the cartridge to the right (this will lock the cartridge out). 5. To thread the oil damper cartridge into the steer- ef tube, the spring assembly must be compressed slightly while the cartridge is being turned clock- wise with a HeadShok Castle too! (part #104110). This operation is easiest with the bike (or fork) out of the work stand and standing on the floor, Make sure the lange hex nut is turned to lockout position. Insert oil damper cartridge into the steerer tube from the top. While applying downward force to the outer cap of the cartridge, turn the cartridge clockwise with a HeadShok Castle tool. Continue turning the Castle tool until the cartridge is tight in the steerer tube. Be very careful not to damage the threads on the outside of the cartridge (Fig.6.). 6. Apply grease or anti-seize compound to the threads on the outer cap. Tighten the outer cap into the outer steerer tube with a pin-spanner wrench (Park SPA-1, green). Poin Sat + — Upper Cop Bee Sore {180 ing "tea (act) Plo! Fon fares! 3-44 /HEADSHOK SERVICE7. Install the stem, then adjust the spring preload. install the Damping Dial Installation of cartridge in pre-1997 HeadShok fork If this HeadShok DD6O cartridge is being installed in a 1996 or earlier HeadShok or “Delta V" suspension fork, a 50mm adapter clip must be used. If this clip is not installed, the ‘oil damper cartridge and/or needle bearings inside the fork could become damaged during normal use. Oamage to the fork resulting from the omission of the 50mm adapter clip: will not be covered under warranty. The 50mm adapter clip is not required on 60mm travel! DD6O or MC6O forks from 1997 or later. To install the clip, simply push the bottom-out O-ring (located just below the top cap) down the cartridge shaft, then snap the clip onto the shaft just below the outer cap. Push the bottom- out O-ring up against the clip (Fig.4.). Omission of the 50mm adapter clip from the cartridge will not increase the fork’s travel. HeadShok forks from 1996 and earlier were designed to travel a maximum of 50mm. Any madifications intended to extend this travel may result in damage to the fork. The HeadShok DD6O is designed to be used with the HeadShok Advanced Spring System. This spring element consists of a metal coil spring with a column of MicroCellular Urethane (MCU) running through its middle. There are three different coil springs available to adjust the fork to riders of different sizes. The springs are color coded by stiffness (spring rate). They are also interchangeable, allowing the rider to custem-tune the performance of the fork to his or her liking. Refer to the tables below for information on which would have come with a DD60- equipped bicycle when new, and for explanation of the springs’ colar coding. 0.E.M. applications: HEADSHOK SERVICE$(“3-45™ p060/0028 Rider weight range 150 Ibs. or less Spring Kit code HD110/GRE HDLO/BLU HD110/RED 180 Ibs. or more. Pretoad adjustment rig? ¥ ] Beyond changing the coil springs in the DD6O suspension fork, the pretoad of the fork can be fine-tuned to suit the rider’s style. Make sure the Damping Dial is turned to the left (open posi- tion), and remove the retaining bolt in the center of the dial. Turn the 3mm Allen set screw (accessed through the center of the dial) until the desired preload is achieved. With correct preload, the fork should compress 1/16” to 1/8" when the rider sits on the bike in a neutral, relaxed riding position. Once the adjustment is complete, install the supplied 6mm screw into the center of the Damping Dial. This screw serves Viton two very important purposes: to retain the dial on the fork, ee and to Seal the fork from water, dirt and ather contaminants. eorst NOTE: This procedure is to be used as a guideline only. We encourage riders to experiment with preload adjust- ment. Some prefer a stiffer suspension, some a softer, more compliant suspension. OIL CHANGE / BLEEDING PROCEDURE —- A DD6O/DD25 cartridge comes from the factory with 5W oil installed. The oil may be changed to a different viscosity to ‘change the damping characteristics of the fork. A heavier oil (as heavy as 10W) may be used, but the fork’s ability to absorb large impacts will be reduced. Likewise, a lighter ‘weight oil (as light as 2.5W) may be used to “quicken up” ‘the suspension action. In all cases, only a high-quality suspension fork oil should be used. NOTE: Do not use a “seal swelling” hydraulic oil in a HeadShok cartridge. Only use hydraulic oil that is approved for use in suspension systems with natural rubber seals. 1, Remove the oil damper cartridge from the fork. 3-46 ~HEADSHOK SERVICE2. Turn the nut on top of the cartridge to the left, leaving the fork in it's “on” position. Using a Phillips screwdriv- er, turn the bleed screw (located on the side of the car- tridge) 1/2 turn counter-clockwise, (Fig.?) 3. Hold the oll damper cartridge over a bucket or similar container. Unthread the lower cap from the cartridge Filed body with a pin-spanner wrench, (Fig.8.) iniop 4. Pour the oil from the cartridge into the container. | | ‘Stroke the piston up and down in the cartridge to pump ‘out any oil that may be trapped above the piston. 5. Holding the cartridge upside down, pour in fresh hydraulic oil. Fill the cartridge all the way to the top ‘Wan (Fig.9.). oy tn hate... 6. Stroke the piston up and down very slowly to expel any trapped air. (You will see air bubbles rise to the top of the oil, and the oil level may drop.) Continue stroking until no air bubbles are seen. >) then : . | O-ratin 7. Set the cartridge aside for a few minutes to allow air . ‘eountercieck- bubbles to rise to the top of the oil level. Pour mare oil wee, into the cartridge until it is again filled to the top. Repeat steps 6&7 if necessary. 8. Begin to thread the lower cap back into the cartridge. When the cap ring seal on the lower cap contacts the lower end of the cartridge body, turn the bleed screw one full turn counter-clockwise (Fig. 10). Finish tighten- ing the lower cap into the cartridge body with a pin- When spanner tench Whenythe, ube cap i, fall threaded Ld prey into the cartridge body, tighten the bleed screw fully, here being careful not to damage the Phillips screw head (Fig.11.). 9. Cycle the cartridge several times and check to make sure the lock-out switch functions correctly. If there is G air in the system, the stroke of the cartridge will feel { Oye rough and irregular, and the lock-out may not function. If ] this is the case, repeat the oil change procedure, paying close attention to steps 6&7. It is not unusual for the cartridge to make a bit of noise just after being rebuilt. 10. Replace oil damper cartridge in the suspension fork. HEADSHOK SERVICE$£“3-47= pps0/pp25 ‘SEAL REPLACEMENT ‘As a regular service to a DD5O cartridge, the seals in the lower ‘cap and the O-ring seal on the piston should be replaced once a year, Replacement of the seals on the upper cap is not recom- mended as a regular service. It is normal for a small amount of oil to “weep” past the piston seals in the upper and lower caps. This will appear as a thin film of oil on the piston shaft. This does not indicate a faulty seal, or a defective cartridge. If significant oil leakage is noticed, if the fork loses its lock-out ability, or if the smoothness of the suspen- sion deteriorates and the fork begins to feel rough or gritty during ‘compression, then one or more of these seals may be damaged and in need of replacement 1, Remove the oil damper cartridge from the fork. idge to the left, leaving the fork screwdriver, turn the bleed screw 1/2 turn counter-clockwi 3. Hald the oil damper cartridge over a bucket or similar container. Unthread the lower cap from the cartridge body with a pin-spanner wrench (Park SPA-1, green). 4, Pour the oil from the cartridge into the container. Stroke the piston up and down in the car- tridge to pump out any oil that may be trapped above the piston. 5. Unthread the upper cap from the cartridge body with a pin-spanner wrench, Slide the cartridge body off of the piston assembly. 6. Replace the two cup seals located inside the lower cap. Be sure to orient the new seals with their larger “flared” ends toward the middle of the cartridge. Also replace the O-ring seal on the piston and the O-ring seals on the upper and lower caps. Be very careful not to tear or puncture any the new seals. See Figures 12 and 13. 7. Apply a thin coating of hydraulic oil to the new seals. Slide the cartridge body over the piston assembly and tighten the upper cap with a pin-spanner wrench. 8. Go to step 5 of Oil Change / Bleeding Procedure to complete the assembly. 3-48 “HEADSHOK SERVICEDD60 Upper Cop. 19/4 Pinole Lower Cop __| Pree Fates —— HEADSHOK D060/DD25 & pp25/'97 SERVICE$£3-49cso/EDM A Introduced in 1993, the HeadShok MCS5O (a.k.a. HeadShok EDM) is an MCU-sprung suspension fork with 5Omm of travel. The original MCU spring can be replaced with a newer coil MCU spring kit, and the mechanical damper/piston assembly can be upgraded to either a DEO or Fatty 50 system REMOVAL OF PISTON / SPRING ASSEMBLY 1, Remave the plastic mud cap from the top of the fork. Back the 4mm preload screw out so that it is flush with the top of the fork. Loosen the stem binder bolt. (It is not necessary to remove the handlebar/stem assembly from the steerer tube, but doing so may improve access to the cartridge.) 2. Unthread the outer cap from the fork with a pin-spanner wrench (Park SPA-1, green). 3. Compress the fork from beneath. The center shaft will be- come visible, along with the bottom-out bumper and plastic spacer. Slide the bottom-out bumper and nylon spacer down the center shaft to expose the 10mm wrench flats which are cut into the center shaft (Fig. 1). 4. Hold the center shaft with a LOmm open-end wrench while turning the outer cap counter-clockwise with a pin-spanner. Remove the outer cap from the center shaft, then remove the plastic spacer and battom-out bumper. 5, Insert a HeadShok pin wrench (part #101103) into the fork and engage tool in the two holes in the upper cartridge fut. Turn too! counter-clockwise to unthread the cartridge nut (Fig.2). When upper cartridge nut is completely un- threaded from the inner steerer tube, pull up-wards on the center shaft to remove the piston assembly from the fork. | | 6. Turn the fork upside-down. The spring element will | drop out of the steerer tube. | CQ } Pe ae into the steerer tube to expose the circlip. Pry the circlip out of the groave in the fork crown. Discard the circlip 7. With the fork still inverted, push the bottom plug up < eS 8. Turn fork right side up. Insert a 3/4" dowel from top of the fark, and tap bottom plug out through fork crown (Fig.3). = A HEADSHOK SERVIC E£3-51