Owner`s Manual Supplement
Contents
1. KF367 CHAINSTAY PLATE KF115 SEAT POST GEL KFO96 REAR DERAILLUER HANGER KP063 BRAKE GUIDE SLICE AERO KP095 SEATBINDER KP096 SEAT POST SADDLE CLAMP 5 mm Setback 25 mm Setback KP101 5MM WHT 9RCS AND 9RWC 3 4 5 6 44 51 ALL COLORS KP101 25MM WHT 9RCS AND 9RWC 3 4 5 6 54 61 ALL COLORS KP102 5MM WHT SHORT TEST RIDE 150MM LENGTH KP102 25MM WHT SHORT TEST RIDE 150MM LENGTH KB002 KIT HEADSET SI CRB W 15 TC QC778 BRAKE BOLT 35mm KP017 SI COMPRESSION ASSY 23 61D QC616 SI CIRCLIPS QTY 2 KB6810 SI BEARINGS QTY 2 KP018 SI CERAMIC BEARINGS QTY 2 QC615 SI BEARING SHIELD QTY 2 KP023 SI BEARING SHIELD SL QTY 2 QC612 SPINDLE SI ROAD QC617 SI SHIMS QTY 5 QC618 SI WAVE WASHER KT010 SI BEARING PRESS TOOL USED WITH HEADSET PRESS KT011 SI BEARING REMOVAL TOOL KT012 SI LOCKRING TOOL KT013 SI HOLLOWGRAM CRANKARM EXTRACTION TOOL KF365 SIBB 68 ADPINSTALL QC787 EXTRACT CAP TOOL FOR SI CARBON CRANKSETS KP009 ADAPTER SIBB TO 68MM TAP For an up to date list of kits available for your bike please visit our Tech Center at http www cannondale com bikes tech 202. STEERER TUBE are not expanded and not loose MAXIMUM STACK HEIGHT Measure from the top edge of the headtube to the bottom edge of the stem HEADTUBE CROWN RACE A Headset part KBO02 BRAKE BOLT Cp QC778 17 R cannondale CHAINSTAY PROTECTION The chainstay plate KF367 located on the right chainstay just behind the chain rings protects the chainstay from damage in the event the chain is dropped from the chain ring Contact your Cannondale Dealer for a replacement if it is becomes missing or damaged The clear chainstay protector above right provides limited protection against frame or finish damage caused by the chain Replacement protectors are available through a Cannondale Dealer REAR DERAILLEUR HANGER Before re installing same or new Clean dropout and inspect carefully for any cracks or damage Clean surfaces and apply a light film of bike grease to the dropout to minimize any noise or creaking that might result from very slight movement between the dropout and hanger during movement of the derailleur Apply grease and Loctite carefully Do not contaminate the male or female bolt threads with grease which would cause the Loctite to be ineffective Check derailleur adjustment after replacement Readjust wheel quick release so it is very tight See PART I Section 4 A in your Cannondale Bicycle Owner s Manual 18 1 1 Nm Loctite 242 blue _ LIG
3. 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 IMPORTANT COMPOSITES MESSAGE Your bike is made from composite materials also known as carbon fiber All riders must understand a fundamental reality of composites Composite materials constructed of carbon fibers are strong and light but when crashed or overloaded carbon fibers 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 Il 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 a Awane The intended use of your bike or frameset is CONDITION 1 HIGH PERFORMANCE ROAD UNDERSTAND YOUR BIKE AND ITS INTENDED USE CHOOSING THE WRONG 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 Canno
4. HT GREASE SS KF096 CAUTION DO NOT USE A DERAILLEUR HANGER ALIGNMENT TOOL TO STRAIGHTEN GEOMETRY AND SPECIFICATION 123952 PDF HT LENGTH RAKE 450 e a x FRONT CENTER WHEELBASE HT ANGLE l FRONT ST a TT os HORIZ HT ANGLE ST ANGLE Bh HT a CENTER cm 48 436 510 71 74 5 72 130 565 8 964 8 51 466 525 72 74 72 145 570 7 969 8 54 496 540 72 74 69 165 587 3 987 4 56 526 560 72 5 73 5 69 180 599 1 99 3 58 546 580 73 73 67 200 610 3 1011 1 61 576 600 73 72 5 67 220 624 9 1025 8 Feminine 44 396 500 70 5 76 72 125 567 5 966 5 48 436 510 71 74 5 72 130 565 8 964 8 51 466 525 72 74 72 145 570 7 969 8 54 506 535 72 50 74 72 160 578 977 1 Campy style bearings HEADSET ae i i MAXIMUM WEIGHT LIMIT SEAT POST DIA Synapse Carbon specific RIDER LUGGAGE TOTAL BINDER CLAMP MAX TORQUE 6 Nm PERT OUNEN SADDLE CLAMP TORQUE 9 12 Nm sil 10 Ibs 4 5 kg sal DROPOUT SPACING dial ally REAR 130mm Seat Bag Handlebar Bag Only FRONT DERAILLEUR TYPE BRAZE ON BB30 INTENDED USE BOTTOM BRACKET 68mm English w adapter CONDITION 1 19 cannondale REPLACEMENT PARTS KF363 BB CABLE GUIDE w fixing bolt KFO55 INLINE ADJUSTER QTY 2
5. OP CAP closely fitting the steerer inside diameter 4 Inserta 5mm Allen key through the access hole in the TOP CAP and into the EXPANDER BOLT Tighten the expander by turning clockwise to 6 8Nm 5 ftLbs 5 To set bearing preload insert a 6mm allen key into the hex shape in the TOP CAP iteself Turn the entire TOP CAP clockwise to increase preload Turn counter clockwise to decrease preload 6 When the headset preload is correct align handlebar and tighten the stem fork clamp bolts to the torque specified for the stem Consult the stem since torque values are often marked on the stem or consult the manufacturer s instructions USE ONLY ORIGINAL EQUIPMENT CANNONDALE SI COMPRESSION ASSEMBLY Do not replace it with a star nut or use any other compression or expanding wedge assembly DO NOT INSTALL HEADSET SPACERS ON TOP OF THE STEM Installing spacers above the stem will raise the TOP CAP inside the steerer removing necessary support for the steerer tube wall When stem bolts are tightened the steerer tube can be damaged PLACE HEADSET SPACERS ONLY BETWEEN THE HEADTUBE AND THE BOTTOM OF THE STEM YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IF YOUR IGNORE THESE WARNINGS 16 Do not grease Cut the steerer tube 2 3mm below the top of the installed stem 1 123952 PDF EXPLODED VIEW EXPANDER BOLT 6 8Nem 5 FteLbs R EXPANDER Thread on TOP CAP Set EXPANDER BOLT CARBON so that the the expanding parts
6. OWNER S MANUAL CAREFULLY Both contain important safety information Keep both for future reference READ THIS SUPPLEMENT AND YOUR CANNONDALE BICYCLE SYNAPSE CARBON Owner s Manual Supplement 123952 PDF 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_center EN 03 09 cannondale 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 e This manual is not a comprehensive safety or service manual for your bike e This manual does not include assembly instructions for your bike e All Cannondale bikes must be completely assembled and inspected for proper operation by a Cannondale Dealer before delivery to the owner This supplement may include procedures
7. SMOOTH THE EDGE OF THE OPENING WITH 240 GRIT OR LIGHTER SANDPAPER KP095 6 0 Nm 53 In Lbs 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 Usea torque wrench to tighten the seat saddle clamp 9 12 Nm DO NOT APPLY GREASE TO THE SADDLE CLAMP PARTS SEAT POST HEAD OUTER M6X50 CLAMP CLAMP BOLT oe Loctite 242 blue i X 9 12 Nm TID ji o __ KPO96 A CA e e xXx OUTER INNER THREADED CLAMP CLAMP Loctite 242 blue Saddle rails aligned with inner and outer clamp grooves 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 SEAT POST 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 SADDLE RAILS YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IF YOU IGNORE THIS WARNING CORRECT cannondale Cutting the Seat Post Depending on the frame size of your Synapse Carbon the seat post may requi
8. acturers 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 Generally speaking lighter weight components have shorter lives In selecting lightweight components you are making a trade off 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 Read and follow the component manufacturers warnings and instructions Protect From Extreme Temperatures e Protect your carbon bike from extreme temperatures when storing or transporting it e Allow your bike to cool off or warm up before you ride e Do not store your bike in places where the temperature will exceed 66 5C 150 F For example do not leave your bike lying flat 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 th
9. 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 cannondale SERIAL NUMBER The serial number 1 printed and permanently affixed 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 CABLE ROUTING The top tube guide is removable so that brake cable may be routed inside the tub
10. e 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 REAR BRAKE HOUSING INTEGRATED GUIDE BRAKE CABLE ME gt lt lt fn A a RSS j r h Sg rrr FERRULE SEAT J REAR BRAKE FRAME OPENING REAR BRAKE HOUSING FERRULE KP063 TOP TUBE GUIDE cannondale 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 T F a E LIGHTLY ROUND OR
11. e 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 amp Crash Repainting Or Refinishing Damage of Carbon Frames You should not paint over the existing finish 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 fiber 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 fiber section Continuing to ride a damaged frame increases the chances of frame failure with the possibility of injury or death of the rider refinish or repaint your bike The carbon fiber 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 refinishing chemicals Repainting painting over retouching or refinishing your frame or fork can result in severe damage leading to an accident You can be severely injured paralyzed or killed Refinishing chemicals Solvents and Strippers
12. e bearings into the shell as shown Press the bearing until it is seated against the circlip To finish apply a light coating of a high quality bicycle bearing grease to both sides of each bearing to help repel moisture NOTE Circlip removal is unnecessary for bearing replacement unless the circlip is damaged damage is present A damaged circlip can be removed by using a small thin blade screw driver to lift the hooked end up out of the groove and then pushing the circlip out counter clockwise SHARP EDGES Circlips can have sharp edges Wear hand protection CAUTION Do not face mill or machine the BB30 bottom bracket shell BB30 SHELL 123952 PDF Park Tool Bearing Cup PressHHP 2 cannondale SI COMPRESSION ASSEMBLY The cylindrical shape of the TOP CAP fits snugly within the carbon steering tube inside diameter I D supporting the steerer from the clamping force of the stem It must fit snugly inside the D of the steerer How to install the assembly 1 Assemble the fork headset spacers and stem Make sure that the stem bolts are loose 2 Set up the compression assembly READY TO INSERT above The length should be about 48mm as shown above You can do this by unthreading the top cap from the expander and then threading it back on about 6 7 turns The expanding parts should not be expanded 3 Insert the SI compression assembly into the fork steerer It should slide in snugly the T
13. es in good condition Improper installation or removal can result in damage and void applicable frame warranty YOU CAN BE SEVERELY INJURED PARALYZED OR KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING 123952 PDF cannondale Bearing Inspection 1 Remove the crankarms and spindle from the bottom bracket shell 2 Rotate the inner bearing race of both bearings rotation should be smooth quietly No bearing play or movement inside the shell If the bearing is damaged replace both bearings with new ones Bearing Removal 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 1 To remove the bearings position Cannondale tool KT011 behind the bearing so that the tool ridges are seated on the bearing 2 Insert a driver punch or drift from the BEARING opposite side Locate it on the back of the tool and use light tapping to drive the bearing from the shell 14 Bearing Installation 1 Clean the inside and outside surfaces of the bottom bracket shell Apply a high quality bicycle bearing grease to the inside surface of the shell Install the square end of the circlip into the groove first then moving clockwise push the clip into the groove until it is fully seated in the groove Install the other circlip the same way With a headset press and tool KT010 install th
14. ndale Dealer about how you intend to use your bike For riding on pavement only Please read your Cannondale Bicycle Owners Manual for more information about Intended Use and Conditions 1 5 CONDITION 1 HIGH PERFORMANCE ROAD bikes and framesets are designed for riding Maximum Weight Limit on a paved surface where the tires do not lose ground contact They are not intended to be RIDER LUGGAGE TOTAL ridden off road cyclocross or touring with Ibs kg Ibs kg Ibs kg racks or panniers 275 125 10 4 5 285 129 Material use is optimized to deliver both light weight and specific 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 acrash They are not designed to take abuse or be a rugged workhorse Seat Bag Handlebar Bag Only cannondale Building Up A Frameset Before building up a frameset consult with your Cannondale Dealer and the component manuf
15. re 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 fitted 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 specific 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 If the seat post requires c
16. the circlips become damaged The circlips can be lifted from the BB groove inset by lifting the hooked end with a thin blade screwdriver CAUTION 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 SI Tools KT011 is a bearing removal tool KT010 is a set of bearing installation tools to be used with a standard headset press KT013 a two piece tool set required for removing the crankarms Sl Hollowgram alloy cranksets For information see S Cranksets Owner s Manual Supplement See http www cannondale com tech Cannondale BB30 Standard Bicycle Frames Certain Cannondale bicycle frames are manufactured using the BB30 standard See http www BB30standard com It may be possible to convert a BB30 frame for use with standard English 68mm or 73mm bottom bracket cranksets using the appropriate Cannondale frame adapter Other adapters ones not specifically approved for use by Cannondale may void your warranty SERIOUS FRAME DAMAGE CAN OCCUR IF YOU ATTEMPT TO REMOVE A BB30 ADAPTER FROM A CARBON FIBER FRAME The bottom bracket shell of certain Cannondale bicycles are constructed of carbon fiber composite If a BB30 to Standard English adapter has been installed IT MUST NOT BE REMOVED All Adapters must be installed by a professional bike mechanic No adapter should be used as a frame repair part Adapters should only be used in undamaged fram
17. utting 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 More Information on Carbon Seat Posts Formore information about carbon fiber seat posts see also APPENDIX D Care and Maintenance of Carbon Fiber Seat Posts in your Cannondale Bicycle Owner s Manual 10 123952 PDF Make a new es ee Fo Vane permanent z l l mark here ae Use a 220 or lighter grit sandpaper to round the cut edge xM Saddle not shown P ASK 9 12 Nm 80 106 In Lbs Apply the supplied carbon gel Cannondale KF115 before installing the seat post Tighten bolts uniformly SEAT POST KP095 6Nm 53InLbs _ SEAT BINDER BOLTS SEAT TUBE MINIMUM INSERT JA 11 cannondale SI BOTTOM BRACKET Compatibility The BB shell is compatible with the BB30 Standard See http www bb30standard com For information see S Cranksets Owner s Manual Supplement See http www cannondale com tech Bearings Shell bearings are sealed cartridge type and do not require lubrication Inspect bearing condition annually at a minimum and anytime the crankset assembly is disassembled or serviced The bearings are a press fit within the shell Old bearings should not be reinstalled if removed Replace both bearings at the same time Replacements circlips QC616 are available if
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