Cannondale Synapse Carbon Configuration guide

synapse carbon

Owner’s Manual Supplement

123952.PDF

READ THIS SUPPLEMENT AND YOUR CANNONDALE BICYCLE

OWNER’S MANUAL CAREFULLY! Both contain important safety

information. Keep both for future reference.

EN - 03/09

Please note that the specications and information in this manual are subject to change for product

improvement. For the latest product information, go to http://www.cannondale.com/tech_center/

SAFETY

INFORMATION

About This Supplement

Cannondale Owner’s Manual Supplements

provide important model specic 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.

WARNING

IMPORTANT COMPOSITES MESSAGE

Your bike is made from composite materials

also known as “carbon ber.”.

All riders must understand a fundamental

reality of composites. Composite materials

constructed of carbon bers are strong

and light, but when crashed or overloaded,

carbon bers do not bend, they break.

For your safety, as you own and use the

bike, you must follow proper service,

maintenance, and inspection of all the

composites (frame, stem, fork, handlebar,

seat post, etc.) Ask your Cannondale Dealer

for help.

We urge you to read PART II, Section D.

“Inspect For Safety” in your Cannondale

Bicycle Owner’s Manual BEFORE you ride.

YOU CAN BE SEVERELY INJURED,

PARALYZED OR KILLED IN AN ACCIDENT

IF YOU IGNORE THIS MESSAGE.

123952.PDF

Intended Use

The intended use of your bike or frameset is

CONDITION 1 / HIGH PERFORMANCE ROAD.

For riding on

pavement

only

CONDITION 1 / HIGH-PERFORMANCE ROAD

bikes and framesets are designed for riding

on a paved surface where the tires do not lose

ground contact. They are not intended to be

ridden o-road, cyclocross, or touring with

racks or panniers.

Material use is optimized to deliver both

light weight and specic performance. You

must understand that (1) these types of bikes

are intended to give an aggressive racer or

competitive cyclist a performance advantage

over a relatively short product life, (2) a less

aggressive rider will enjoy longer frame life, (3)

you are choosing light weight (shorter frame

life) over more frame weight and a longer

frame life, (4) you are choosing light weight

over more dent resistant or rugged frames

that weigh more. All frames that are very

light need frequent inspection for cracks that

would indicate that the frame is worn out from

fatigue. These frames are likely to be damaged

or broken in a crash. They are not designed to

take abuse or be a rugged workhorse.

WARNING

UNDERSTAND YOUR BIKE AND ITS

INTENDED USE. CHOOSINGTHEWRONG

BICYCLE FOR YOUR PURPOSE CAN BE

HAZARDOUS. USING YOUR BIKE THE

WRONG WAY IS DANGEROUS.

Industry usage Conditions 1 - 5 are

generalized and evolving. Consult your

Cannondale Dealer about how you intend

to use your bike.

Please read your Cannondale Bicycle

Owner’s Manual for more information

about Intended Use and Conditions 1-5.

Maximum Weight Limit

RIDER

lbs / kg

LUGGAGE *

lbs / kg

TOTAL

lbs / kg

275 / 125 10 / 4.5 285 / 129

* Seat Bag /Handlebar Bag Only

Building Up A Frameset

Before building up a frameset, consult with

your Cannondale Dealer and the component

manufacturers, and discuss your riding style,

ability, weight, and interest in and patience for

maintenance.

Make sure the components chosen are

compatible with your bike and intended for

your weight and riding style.

Generallyspeaking,lighterweightcomponents

have shorter lives. In selecting lightweight

components, you are making a trade-o,

favoring the higher performance that comes

with less weight over longevity. If you choose

more lightweight components, you must

inspect them more frequently. If you are a

heavier rider or have a rough, abusive or“go for

it” riding style, buy heavy duty components.

Readand followthecomponentmanufacturers

warnings and instructions.

Protect From

Extreme Temperatures

• Protect your carbon bike from extreme

temperatures when storing or transporting it.

• Allow your bike to cool o or warm up before

you ride

• Do not store your bike in places where the

temperature will exceed 66.5C° (150°F). For

example, do not leave your bike lying at in

a black pickup truck bed in the desert sun or

under the glass of a hatchback auto.

Bike Stands

The clamping jaws of an ordinary bike stand

can generate a crushing force strong enough

to seriously damage and ruin your bike frame.

CAUTION

Never place your bike in a bike stand by

clamping the frame.

Place your bike in a stand by extending the

seat post and positioning the stand clamp

on the extended seat post. Don’t extend

beyond the MINIMUM INSERT line marked

on the seat post.

Since your carbon seat post can also be

damaged by clamping force, adjust the

stand clamp for the minimum clamping

force needed to secure the bike.

123952.PDF

Inspection & Crash

Damage of Carbon Frames

WARNING

AFTER A CRASH OR IMPACT:

Inspect frame carefully for damage (See

PART II, Section D. Inspect For Safety in your

Cannondale Bicycle Owner’s Manual.)

Do not ride your bike if you see any sign

of damage, such as broken, splintered, or

delaminated carbon ber.

ANY OF THE FOLLOWING MAY INDICATE

A DELAMINATION OR DAMAGE:

An unusual or strange feel to the frame

Carbon which has a soft feel or altered

shape

Creaking or other unexplained noises,

Visible cracks, a white or milky color present

in carbon ber section

Continuing to ride a damaged frame

increases the chances of frame failure,

with the possibility of injury or death of

the rider.

Repainting Or Renishing

You should not paint over the existing nish,

renish or repaint your bike. The carbon ber

composites making up the frame are held

together by some extremely strong bonding

chemicals. However, these bonds can be

attacked or weakened by paint stripping or

renishing chemicals.

WARNING

Repainting, painting over, retouching, or

renishing your frame or fork can result in

severe damage leading to an accident. You

can be severely injured, paralyzed or killed.

Renishing chemicals : Solvents, and

strippers can attack, weaken, or destroy

the important composite chemical bonds

holding your frame together.

Using abrasives or sanding the frame/fork

structure, original paint, decals, or coatings

through the use of mechanical actions

such as plastic or glass bead blasting or

other abrasive methods such as sanding

or scraping can remove frame material or

weaken it.

serial number

The serial number (1) printed and permanently axed barcode label. Use this serial number for

warranty registration and theft recovery. See your Cannondale Bicycle Owner’s Manual for more

information on warranty registration.

bottom bracket guide

The cable guide (2) is mounted on the lower bottom bracket. Replacements are available

through a Cannondale Dealer. The kit # is KF363/.

vent

Keep the small vent hole (3) in the bottom of the bottom bracket shell clear of any dirt so that

any water can drain out. Water can enter into frame tubes through washing, condensation, wet

rides, or rain. It penetrates or can be sprayed in through water bottle bosses, seat tube, head

tube and seat post openings. Water will not chemically harm your bike. If it freezes, the ice

expansion can burst or crack the frame making it unsafe to ride. This damage is NOT covered

under your warranty.

After wet rides, remove seat post, invert bike to drain any water.

123952.PDF

KP063/

TOP TUBE GUIDE

FERRULE

REAR BRAKE

HOUSING

REAR BRAKE FRAME OPENING

INTEGRATED GUIDE

REAR BRAKE

HOUSING

FERRULE SEAT

BRAKE CABLE

KF363/

BB GUIDE

EXTENSION

SCREW

cable routing

The top tube guide is removable so that brake cable may be routed inside the tube. The

guide is secured in the tube opening by the installed brake cable tension. Make sure the guide

is seated properly in the top tube opening when installing and connecting the rear brake.

Be sure to use ferrules on housing ends. When installing cables, make sure ferrule is seated

inside frame opening correctly.

seat post

Seat Tube/Binder Preparation

Burrs or sharp edges of the seat tube insert opening can scratch the seat post. Before inserting

the seat post into the frame, do the following:

1. Remove the seat binder exposing the seat tube insert.

2. Lightly round the opening of the insert using 240 grit or lighter sand paper.

3. Apply carbon gel into the opening of the seat tube. Carbon gel has been included in the parts

boxes of 2009 Synapse Carbon. It is also available by ordering Cannondale kit KF115/.

4. To improve clamping force, lightly grease the outside surface of the seat tube insert before

reinstalling the seat binder.

5. Reinstall the seat binder.

6. Before inserting the seat post, apply carbon gel to the seat post.

7. Use a torque wrench to tighten the seat binder bolts to 6 Nm.

6.0 Nm, 53 In Lbs

KP095/

LIGHTLY GREASE THE SEAT TUBE INSERT

UNDER THE SEAT BINDER

APPLY CARBON GEL INSIDE THE TUBE.

LIGHTLY ROUND OR SMOOTH THE EDGE

OF THE OPENING WITH 240 GRIT OR

LIGHTER SANDPAPER

SEAT BINDER SHOWN REMOVED

123952.PDF

Saddle Clamp Assembly

1. Apply Loctite® 242 (blue) to the clamp bolt threads.

2. Make sure the seat post head is clean and dry. Do not apply grease.

NOTE: The saddle head is bonded in place. Do not attempt to remove or adjust it.

3. Assembly the parts as shown above.

4. Install the saddle so that the saddle rails locate in the slots between the inner and outer

clamps.

5. Use a torque wrench to tighten the seat saddle clamp 9 - 12 Nm.

9 - 12 Nm

DO NOT APPLY GREASE TO

THE SADDLE CLAMP PARTS

SEAT POST HEAD

INNER

CLAMP

OUTER

THREADED

CLAMP

INNER

CLAMP

OUTER

CLAMP

CLAMP BOLT

SEAT POST

Loctite® 242 (blue)

Loctite® 242

(blue)

KP096/

M6X50

WARNING

Incorrect alignment of the saddle clamp

parts can result in the saddle moving

unexpectedly while riding. When adjusting

the saddle angle of your Synapse Carbon,

make sure the saddle rails on both sides of

the saddle are aligned with the inner and

outer clamp on both sides of the saddle.

Ask your Cannondale Dealer for assistance.

YOU CAN BE SEVERELY INJURED, PARALYZED,

OR KILLED IF YOU IGNORE THIS WARNING.

Saddle rails aligned

with inner and outer clamp grooves.

SADDLE

RAILS

CORRECT

Cutting the Seat Post

Depending on the frame size of your Synapse Carbon, the seat post may require cutting to a

shorter length. This must be performed by a professional bike mechanic. The Synapse Carbon

frame has seat post depth in the seat tube that varies with the frame size. Small frame sizes can

accept between 110-130mm. Larger frame sizes can accept between 110-150mm.

To maximize saddle height adjustment range as well as maintain the necessary minimum insert

depth of 80mm of any seat post, the seat post must be tted (cut) to the frame.

To cut the seat post

1. Insert an uncut post into the seat tube. Insert it until it stops inside the frame. It should slide

in easily. Do not force it into the seat tube. This is the maximum distance inside the seat tube

the post will insert.

2. Determine the maximum desired adjustment range of the saddle that maintains the required

80mm of seat post inside the seat tube.

3. Remove the excess section from the end of the seat post. You should use a cutting guide

such as Park Tool SG-7 and a carbon specic saw blade. See Figure 2. You should also lightly

sand the cut post to round and smooth the cut.

4. Re-mark the MINIMUM INSERT line 80mm up from the bottom of the cut seat post. Mark the

seat post without scoring, scratching or otherwise damaging the surface of the seat post.

Use a thin decal (automotive pin striping) or a paint marker.

NOTE: U.S. Consumer Product Safety Commission (CPSC) bicycle regulations require minimum

seat post insertion be marked on the seat post.

WARNING

If the seat post requires cutting, have it done by a professional bike mechanic with experience

cutting high-performance carbon components.

YOU CAN BE SEVERELY INJURED, PARALYZED OR KILLED IF YOUR IGNORE THIS

WARNING.

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