Cannondale Claymore Configuration guide

WARNING

READ THIS SUPPLEMENT AND YOUR

CANNONDALE BICYCLE OWNER’S MANUAL.

Both contain important safety information.

Keep both for future reference.

126561.PDF (04/11)

This manual meets EN standards

14764, 14766, and 14781.

Vélo certiﬁé conforme aux exigences du décret

N 95-937 du 24 août 1995 norme NFR030

In this supplement, particularly important information is presented in the following ways:

WARNING Indicates a hazardous situation which, if not

avoided, could result in death or serious injury.

NOTICE Indicates special precautions that must be taken to

avoid damage.

TIP A TIP provides helpful information.

126561.PDF

04/11

SAFETY INFORMATION

ABOUT THIS SUPPLEMENT

Cannondale Owner’s Manual Supplements provide

important model speciﬁc safety, maintenance, and

technical information. They are not replacements for

your Cannondale Bicycle Owner’s Manual.

This supplement may be one of several for your bike.

Be sure to obtain and read all of them.

If you need a manual or supplement, or have a question

about your bike, please contact your Cannondale

Dealer immediately, or call us at one of the telephone

numbers listed on the back cover of this manual.

You can download Adobe Acrobat PDF versions of any

Cannondale Owner’s Manuals or Supplements from our

website: http://www.cannondale.com/bikes/tech.

• This manual is not a comprehensive safety or

service manual for your bike.

• This manual does not include assembly

instructions for your bike.

• All Cannondale bikes must be completely

assembled and inspected for proper operation by

a Cannondale Dealer before delivery to the owner.

WARNING

This supplement 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.

INTENDED USE

ASTM F2043

For extreme

o-road riding

The intended use of all

models is ASTM CONDITION 4,

OverMountain.

NOT INTENDED - For Hardcore

Freeriding, Extreme Downhill,

Dirt Jumping, Slopestyle, or very

aggressive or extreme riding.

WARNING

UNDERSTAND YOUR BIKE AND ITS INTENDED USE.

USING YOUR BIKE THE WRONG WAY IS DANGEROUS.

Please read your Cannondale Bicycle Owner’s

Manual for more information about Intended Use

and Conditions 1-5.

YOUR CANNONDALE DEALER

To make sure your bike is serviced and maintained

correctly, and that you protect applicable warranties,

please coordinate all service and maintenance through

your authorized Cannondale Dealer.

NOTICE

Unauthorized service, maintenance, or repair

parts can result in serious damage and void your

warranty.

CABLE ROUTING

Identiﬁcation

1. Rear Derailleur

2. Front Derailleur

3. Rear Brake

4. Shock Remote

5. Seat Post Remote

Route shock cable under pivot axle.

Route rear brake line above pivot axle.

126561.PDF

INTEGRATED HEADTUBE

9.0 1.0

1.0

KP202/

Identiﬁcation

1. Diablo Headtube

2. Bearing , 52x40x45, NECO 15

3. Crown Race

4. Compression Ring

5. Top Cap

6. O-Ring , 2-029

NOTICE

Do not face, surface, or cut the head tube.

BOTTOM BRACKET

The bottom bracket shell is compatible with the BB30 Standard. See http://www.bb30standard.com/ .

The Cannondale SI bottom bracket adapter enables the use of standard English/73mm bottom bracket cranksets.

KF366/

KF368/

Loctite™ 609

KT010/

KT011/

73mm

Identiﬁcation

1. Bottom Bracket Shell a. Bb Circlip Groove

2. ISCG03 Mount b. Adapter Drive-Side Groove

3. Circlip

4. Bearing

5. 73mm Adapter

126561.PDF

Bearing Maintenance

Inspect bearing condition annually (at a minimum) and anytime the crankset assembly is disassembled or

serviced. With the crankset removed, rotate the inner bearing race of both bearings; rotation should be smooth.

No play or movement inside the shell. If the bearing is damaged, replace both bearings with new ones.

Bearing Removal/Installation (Professional Bike Mechanic Only)

Remove the old bearings with the bearing removal tool KT011/.

Reinstall bearings with a headset press and tool KT010/ . Clean inside of shell apply a high-quality bicycle

bearing grease to the inside surface. Press bearing one at a time. Press each bearing until seated against the

circlip. Following installation, apply a light coating of a high-quality bicycle bearing grease to both sides of each

bearing to help repel moisture.

TIP: Unless a circlip is damaged, removal is unnecessary during bearing removal . Use a small thin-blade screw

driver or pick to lift the hooked end up out of the groove and then pushing the circlip out counter-clockwise.

Adapter Removal/Installation (Professional Bike Mechanic Only)

To install, ﬁrst remove the bearings and circlips and clean the inside of the BB shell and adapter. Use a clean

lint-free shop towel dampened with alcohol. Apply Loctite™ 609 carefully to the bearing seat positions to both

shell and adapter. Install the adapter with a headset press and the installation tool KF368/. Adapter groove must

be located on the BB drive side. Press until the groove side face is ﬂush with the drive side face of shell. Allow

at least 12 hours (at 72°F) for the Loctite to cure before installing the standard bottom bracket crankset. Follow

Loctite Technical Data Sheet http://tds.loctite.com/tds5/docs/609-EN.PDF

To remove, use tool KF366/ with a headset bearing press with tool arrangement as shown. Following

removal, it will be necessary to clean all remaining Loctite residue with a before reinstalling the Si

circlips and bearings. Use Loctite 768. Use a dental pick to remove any adhesive from the grooves.

For Loctite clean-up instructions : http://tds.loctite.com/

NOTICE

BEARINGS - Frequent or routine renewal of undamaged bearings is not recommended. Repeated removal and

reinstallation can damage the inside BB shell surfaces resulting in poor bearing ﬁt. Do not face, mill or

machine the bottom bracket shell for any reason. Doing so can result in serious damage and possibly a ruined

bike frame.

ADAPTERS - Use only adapters/tool recommended by Cannondale. Other available adapters /tools may cause

damage. See Replacement Parts. An adapter isn’t a “repair” part, so the BB shell must be in good condition.

Repeated removal and reinstallation of an adapter, or improper tools can cause damage. Therefore it is not

recommended.

Loctite 609 - Prolonged contact with the frame ﬁnish may result in discoloration or damage. Be sure to

immediately wipe up any spills and remove any compound in contact with the painted surfaces.

Do not cut, face, or use abrasives to clean the inside if the BB shell.

We strongly recommend that these procedures be performed by an Authorized Cannondale Dealer. Damage

caused by improper installation/removal is not covered under your warranty.

M5X16 (4X)

M8X35

M6X35

KP169/

= 5.0 Nm, 44.0 InLbs - Loctite™ 242 (blue)

= 8.0 Nm, 71.0 InLbs - Loctite™ 242 (blue)

Identiﬁcation

1. Shock Link

2. SS Lever Axle

3. DT Link Axle

4. Main Shim

5. Link Tool (inc. KP169/)

6. Bearing (

61802-2RS, 15X24X5)

7. Seat Stay

8. Pinch bolts

9. Shock Mounting Bolt

10. Gemini Nut

11. SAG Indicator

a. gap

b. bearing inner race

c. large end

d. small end

Be sure to loosen the pinch bolts of link before assembly.

Before assembly, inspect all bearings for good condition. Replace

if necessary.

Clean and apply Loctite 242 (blue) to the pinch bolt threads.

Tighten to 5 Nm, 44 InLbs.

Clean and apply light grease to pivot axles and main shims.

Insert DT Link Axle and SS Lever axles from opposites side of the

link as shown.

Route cables correctly around pivot. See Cable Routing.

SHOCK LINK

126561.PDF

NOTICE

Incorrect assembly (pivot/shim) can result in linkage

play, accelerated wear, or damage.

Do not over-tighten. Use a torque wrench.

Use KP169/ to press link pivot axles and main shim together as shown. Before tightening pinch bolts, make

sure both the shim and axle are seated against the bearing inner race (upper), and the gaps (arrows) between

bearing and link arm should be the same on each side. You can center the link easily shifting it left or right to

do it before the bolts are tightened.

USING THE SAG INDICATOR

The sag indicator is inserted in the left side of the bike in the downtube pivot axle.

1. Set air pressure. See Setting Sag on page 16.

2. Rotate the sag arm to the frame stop,

shown above.

3. Sit on saddle, feet on pedals in riding position.

4. Dismount. Check arm travel. If the recommended

sag 33%-40% sag is present the “SAG” bar will be

at the frame stop. See above.

If the arm rotates further beyond the “SAG” mark

toward the “100%” mark, it is telling you that more

than 33-40% sag is present. See above. For more

sag, move down a row in the air pressure chart. For

less sag, move up a row.

The sag indicator assembly can be removed from the

downtube pivot by simply pulling it out.

Less Sag

More Sag

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