View and Download Cannondale SUPERMAX owner's manual supplement online. Cannondale SUPERMAX Owner's Manual. Authorized Headshok Service. The kit Schrader plug included in the kit is blue indicating revised air pressure. Kit KH022/ is a seal kit for the air cylinder. Mar 19, 2004 - Headshok Maintenance and Repair. 
Full archive of all the manuals Cannondale has on their site related are contained on this site as well.
It can be done. I did all work by myself with no help. It can be a one person job.
It's not half as bad as people will lead you to believe, and the design of the fork holds no terrible secrets -conceptually it's actually pretty simple! A cautionary note though: I found the job to be pernickety in the sense you had to do some stuff in the right order, and it makes a difference if you do. All I can say is that the order I've listed is the order I found that worked for me, and usually there's a method in the madness for a reason. Total cost for me to regrease, put a boot on, install new needle bearings and firm ride springkit and purchase any tools I needed: about $70. It took me about 8-10 hours in total to disassemble, reassemble, disassemble and reassemble again (includes thorough degreasing and cleaning). Admittedly, I do have some tools already, but everything else I needed I use in the general maintenance of bikes and is not Cannondale specific (e.g.
Hammer, Slick Honey grease, Pedros degreaser, etc). Basically I had nothing to lose. If I screwed up this fork or couldn't get if back together, it didn't really matter, I'd just go ebaying and get a set of adaptor cups and a used fork (also keep in mind I believe when you strip a Headshok, Cannondale may consider any warrantees null and void). My primary objective was to disassemble the fork and put it back together. If I could do this, I'd then invest in the necessary Cannondale parts and fit them myself. I had nothing to lose but time here. Caveat number 2.
Since I do not have access to top secret classified Cannondale documents regarding servicing/assembly of Headshoks, I am not privvy to torque specs or the like. This means that I put this fork back together the best way I could (Cannondale diagrams notwithstanding) using at best some guesswork and 'common sense' ('common sense' here is very subjective I know. Let me reveal here I'm not a professional bike mechanic, nor am I a qualified mechanic in any area. What I have done is strip various car/motorcycle engines down and put them back together -working mind you!!!! -and my wife believes I have a natural aptitude for mechanics.
Then again, she says I'm really good looking too;^). I consider myself to be confident at mechanics. Confident in knowing when I'm out of my depth).
Serial mom true story. The point here is that I'm just posting what I did -I am by no means suggesting this is the proper or appropriate way to safely reassemble a Headshok. So here you have it, caveat number 2: You mess with your Headshok at your own risk and this posting does not constitute in any way any endorsed ways of properly servicing or assembling or reassembling Headshoks. I am also not responsible for your costs or damages incurred, personal injuries, first born child, blah blah blah.
It's all your responsibility and I can't vouch for the accuracy of this post or be responsible for any mistakes contained within. Caveat number 3. OK, before I started this, I combed the internet looking for help. I googled, I yahooed, I did everything I could to search for any variation of the words 'Cannondale Headshok Headshock assembly disassembly installation removal' etc.
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View and Download Cannondale SUPERMAX owner's manual supplement online. Cannondale SUPERMAX Owner's Manual. Authorized Headshok Service. The kit Schrader plug included in the kit is blue indicating revised air pressure. Kit KH022/ is a seal kit for the air cylinder. Mar 19, 2004 - Headshok Maintenance and Repair. Full archive of all the manuals Cannondale has on their site related are contained on this site as well.
It can be done. I did all work by myself with no help. It can be a one person job.
It's not half as bad as people will lead you to believe, and the design of the fork holds no terrible secrets -conceptually it's actually pretty simple! A cautionary note though: I found the job to be pernickety in the sense you had to do some stuff in the right order, and it makes a difference if you do. All I can say is that the order I've listed is the order I found that worked for me, and usually there's a method in the madness for a reason. Total cost for me to regrease, put a boot on, install new needle bearings and firm ride springkit and purchase any tools I needed: about $70. It took me about 8-10 hours in total to disassemble, reassemble, disassemble and reassemble again (includes thorough degreasing and cleaning). Admittedly, I do have some tools already, but everything else I needed I use in the general maintenance of bikes and is not Cannondale specific (e.g.
Hammer, Slick Honey grease, Pedros degreaser, etc). Basically I had nothing to lose. If I screwed up this fork or couldn't get if back together, it didn't really matter, I'd just go ebaying and get a set of adaptor cups and a used fork (also keep in mind I believe when you strip a Headshok, Cannondale may consider any warrantees null and void). My primary objective was to disassemble the fork and put it back together. If I could do this, I'd then invest in the necessary Cannondale parts and fit them myself. I had nothing to lose but time here. Caveat number 2.
Since I do not have access to top secret classified Cannondale documents regarding servicing/assembly of Headshoks, I am not privvy to torque specs or the like. This means that I put this fork back together the best way I could (Cannondale diagrams notwithstanding) using at best some guesswork and 'common sense' ('common sense' here is very subjective I know. Let me reveal here I'm not a professional bike mechanic, nor am I a qualified mechanic in any area. What I have done is strip various car/motorcycle engines down and put them back together -working mind you!!!! -and my wife believes I have a natural aptitude for mechanics.
Then again, she says I'm really good looking too;^). I consider myself to be confident at mechanics. Confident in knowing when I'm out of my depth).
Serial mom true story. The point here is that I'm just posting what I did -I am by no means suggesting this is the proper or appropriate way to safely reassemble a Headshok. So here you have it, caveat number 2: You mess with your Headshok at your own risk and this posting does not constitute in any way any endorsed ways of properly servicing or assembling or reassembling Headshoks. I am also not responsible for your costs or damages incurred, personal injuries, first born child, blah blah blah.
It's all your responsibility and I can't vouch for the accuracy of this post or be responsible for any mistakes contained within. Caveat number 3. OK, before I started this, I combed the internet looking for help. I googled, I yahooed, I did everything I could to search for any variation of the words 'Cannondale Headshok Headshock assembly disassembly installation removal' etc.