Cannondale ON Bedienungsanleitung

125367.PDF

1EN - 02/10

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.

HEADSHOK SOLO w/DL50 BICYCLE FORK

SUPPLEMENT

Please consult the Cannondale Solo Bicycle Fork Owner’s

Manual Supplement for care and maintenance information

concerning the fork and front wheel removal and installation.

REAR BRAKE ROTOR

WARNING

KEEP YOUR HANDS AND FINGERS CLEAR OF THE

BRAKE ROTOR AND CHAINCASE!!

CHAINCASE HUB CAP

NOTICE

DO NOT RIDE THIS BIKE WITH THE CHAINCASE HUB

CAP REMOVED. Serious damage to the hub will result.

See page 13.

BICYCLE REPAIR / WORK STANDS

The clamping jaws of a bike stand can generate a crushing

force strong enough to seriously damage your frame.

NOTICE

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 a seat post can also be damaged by clamping force,

adjust the stand clamp for the minimum clamping force

needed to secure the bike.

Also, before clamping, clean the post and protect the seat

post nish with a rag.

125637.PDF

INTENDED USE

General Purpose Riding

CONDITION 2

Bikes designed for riding Condition 1, plus smooth gravel

roads and improved trails with moderate grades where the

tires do not lose ground contact.

INTENDED

For paved roads, gravel or dirt roads that are in good condition,

and bike paths.

NOT INTENDED

For o-road or mountain bike use, or for any kind of jumping.

Some of these bikes have suspension features, but these

features are designed to add comfort, not o-road capability.

Some come with relatively wide tires that are well suited to

gravel or dirt paths. Some come with relatively narrow tires

that are best suited to faster riding on pavement. If you ride

on gravel or dirt paths, carry heavier loads or want more tire

durability talk to your dealer about wider tires.

MAXIMUM WEIGHT LIMIT

RIDER

lbs / kg

LUGGAGE

lbs / kg

TOTAL

lbs / kg

300 / 136 30 / 14 330 / 150

WARNING

UNDERSTAND YOUR BIKE AND ITS INTENDED USE.

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.

IDENTIFICATION

SERIAL NUMBER LOCATION

(7-character barcode label)

26 x 13mm

(code 3 of 9)

6-DIGIT

SEQUENCE IN YEAR

YEAR CODE

MANUFACTURING CODE

DRAIN HOLE

Serial Number

The serial number for this bicycle is printed on a barcoded label on the underside of the bottom bracket. Use this serial

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

warranty registration.

Manufacturing Code

There is also a Cannondale manufacturing stamped on the bottom bracket node. This stamped number consists of several

numbers such as factory shop order, frame code, and frame size code.

125637.PDF

Si CHAINCASE

HOLLOWGRAM SL

CRANKS

LEFTYWHEEL HUB

HEADSHOK SOLO w/DL50

SI HEADTUBE

CUSTOM

SINGLE-SIDE

i-MOTION 9

HUB ASSEMBLY

The ON bike is the rst production bike inspired by the ON Concept bike shown at Eurobike 2007.The ON makes use of the “System

Integrated Chain CaseTechnology”, where the chain case is a single sided, fully enclosed, structural part of the bike frame.This re-

sult in a clean and ecient drive system with 9 speed internal gears and disc brakes.The unique chain case structure is machined

from billet, making the structure extremely sti yet light at the same time. Cables are internally routed in the frame and the tube

shapes are edgy and aggressive.The fork is the Cannondale specic HeadShok Solo w/DL50 which makes this bike truly single

sided.The bike is the rst of its kind, very unique and innovative.

CANNONDALE URBAN TECHNOLOGY

– Handmade frame from 6061-T6 aluminum

– Double-pass smooth welds eliminate stress risers

– Internal cable routing

– SiCC - System Integration Chain Case – CNC machined structural chain case.

– Custom Single Sided SRAM i-motion 9 hub

– Hollowgram SL Cranks – lightest and stiest production crank set in the world.

– HeadShok Solo w/DL50, coil suspended, oil damped w/ lockout

FRAME TECHNOLOGY FEATURES

– SiCC - System Integration Chain Case - single sided structural chain case CNC machined in the USA

from 27kg Billet 6061-T6

– Down tube - Tapered, hydroformed, edgy evolution of the original PowerPyramid design. Oversized and triple-butted for

optimal stiness to weight ratio.

– Top tube - Tapered, hydro formed edgy triangular section at the front for maximum lateral support of the head tube.

The triangular shapes of the top tube and down tube combined with the oversized head tube maximize overall torsional

stiness.

– Seat tube - Integrated seat post clamp. Butted for lightweight performance.

– Head tube - SI externally machined to remove material in the middle section for minimum weight. Integrated headset for

elegant transition to fork.

– Fork - The unique HeadShok Solo w/DL50 uses a coil spring system for maintenance-free pot hole eating performance. The

easy access lockout lever allows on-the-y changes so you are always in control no matter what the terrain is.The single

sided Solo with its bolt on wheel, allows wheel-on at xes and oers theft deterrence when making a quick stop.

125637.PDF

CRANKARMS

The following procedures should only be performed

by a professional bike mechanic.

Removal

1. Chain tension must be slackened in order to remove the

right crank arm as it is connected to the the chain ring.

See CHAIN TENSION.

2. Remove the chain ring cover screws and remove the chain

cover by sliding it over the crank arm.

TIP: Note orientation of crank cover when removing - the hole

in cover is not central and the cover should be rotated on

assembly so the hole position matches the position of the

crank when the ecccentric is tightened.

3. Insert a 10 mm Allen key fully into the crank arm xing

bolt.

4. Hold crank arm with your hand and turn the Allen key

counter-clockwise to loosen and remove the xing bolt

from the crank arm .

Make sure you remove the thin steel washer under the

bolt head. It is black in color; check the bolt or use a pencil

tip to remove it from the crank arm seat.

5. Apply some bicycle bearing grease to the Cannondale

tool KT013/ .

Thread tool part 1 into spindle until the top of the stud is

ush with the top of the spindle.

Install the tool body part 2 into the crank arm completely

and tighten it snug with a 15mm open end wrench.

The left side crank arm is removed in the same way.

KT013/

10 mm

Allen Key

SPINDLE

CRANKARM

part 1

part 2

Insert a 10 mm Allen key through the tool part 2 and

into part 1. Hold the crank arm and turn the Allen key

counter-clockwise until the crank arm can be removed

from the spindle end.

The right side crank arm is connected to the chain

ring. Both the chain ring and right crank arm will be

disconnected from the spindle end. Be sure to note the

exploded view for the bearing shield, spacers located on

the spindle end.

The left side crank arm is removed in the same way. You

should also note the spacers, bearing shield, and wave

washer.

SPINDLE END

CRANKARM

w/CHAINRING

Crank arm Installation

Install and tighten the right crank arm/chain ring rst, then

assemble and install the left crank arm. Consult the illustra-

tion on the following page for part order.

1. Clean the spindle ends, spindle threads, crank arm

sockets and apply a high-quality bicycle bearing grease

to all. Align the splines and install the crank arm onto the

spindle end.

2. Apply grease to the bolt threads and thin steel washer.

Install the thin steel washer and xing bolt into the crank

arm and carefully thread into the spindle. Tighten to 34

Nm, 25.0 FtLbs.

CRANKARM

SOCKET

SPLINES

THREADS

FIXING

BOLT

WASHER

125637.PDF

13.0 Nm, 115 InLbs

Loctite™ 242

A181/

KP103/

122629

LOCKRING TOOL

KT012/

LOCKRING

KP021/

CRANKARM

FIXING BOLT

KP022/

RH CRANKARM

KP020/172R

KP020/175R

KB6180/

SI BEARING

KP023/

SI BEARING SHIELD WAVE WASHER

QC618/

LH CRANKARM

KP020/172L

KP020/175L

118506

9 mm

SPACER

112538

SHIMS

QC617/

0.5 mm

ECCENTRIC ASSY

WEDGE

SI HOLLOWGRAM SPINDLE

EXTERNAL

BB30 BEARING CUP

123351LA

EXTERNAL

BB30 BEARING CUP

123351RA

SHIMS

QC617/

CHAINRING - 34T

125201

KB6180/

SI BEARING

KP023/

SI BEARING SHIELD

123351LA

FIXING BOLT

125256 M3X8

125339

CHAINRING COVER

34.0 Nm, 25.0 FtLbs

grease

SIZE

47-54 Nm

34-40 FtLbs

Loctite™ 242

BEARING SEAL

112537

BEARING SEAL

112537

125339

M3X6

http://www.zipp.com/accessories/vuma-bb-wrench

ECCENTRIC BOTTOM BRACKET & CRANKARM PARTS

Eccentric Installation

1. Route rear brake and shifting cable through the bottom braket. See INTERNAL CABLE ROUTING diagram.

2. Install the drive side bearing cup into the eccenctric. Tighten with ZIPPVUMA BB tool.

3. Apply a high-quality bicycle bearing grease to the inside surfaces of the bottom bracket shell and the eccentric wedges.

4. Insert the eccentric into the BB shell on the drive side. Hold the cable in the BB trough as the eccentric is inserted.

5. Install the left side bearing cup and bearing into the left side of the eccentric.

6. Apply a high-quality bicycle bearing grease to the spindle and insert it into the bearings. Center it.

7. Install the parts shown below onto the ends of the spindle.

125637.PDF

i-MOTION 9 AND SPINDLE

SPINDLE

HUB CAP

OUTER

BEARING

LAND

INNER

BEARING

LAND

AXLE END

SLOTS

CHAINCASE

SRAM i-MOTION 9

REAR HUB ASSEMBLY

(disconnected)

125149

The SRAM i-MOTION 9 rear hub is housed inside a spindle which connects to the ON SiCC chaincase.

This assembly must not be removed from the chaincase. It is connected with a special manufacturing tool.

If this unit requires service, please contact Cannondale for information on how to handle the request.

Shifting set-up of the i-MOTION 9 rear hub is described on page 12.

REAR WHEEL HUB & WHEEL TRUING

REAR WHEEL TRUING TOOL

125156

125155

125170

OUTER

BEARING INNER

BEARING

REAR HUB ASSY

125154

AXLE NUT

RING CLIP

BRAKE ROTOR

ROTOR BOLTS

4.5 Nm, 40 InLbs

Loctite® 266™

M4x8

A wheel truing tool is available to Cannondale Dealers so that the wheel may be positioned in a traditional wheel stand.

It is necessary to remove the axle hub bolt from the end of the hub shell to insert the tool parts.

125637.PDF

i-MOTION 9 SHIFT ADJUSTMENT

124228A

M3X10

6094H

HUB CAP

SHIFT WINDOW

CAP BOLT

2.0 Nm, 17.7 InLbs

Loctite ® 222®

grease

Shifting adjustment should only be performed only by a professional bike mechanic.

Consult the SRAM iMOTION9 user manual for shifting set-up instructions. A printed copy was included with your bike. You

can also download it from the SRAM website at http://www.sram.com/_media/techdocs/iMOTION_9_Ins_E_5_06.pdf

To access the hub window described in the SRAM instructions, the rear hub cap will have to be removed.

Before the hub cap is removed:

1. Place the bike in a work stand with the rear wheel suspended.

2. If you haven’t already noticed the big NOTICE on the next page, please read it now.

Removing the hub cap:

The cap ts quite tightly. Carefully remove all of the bolts, then and pull the cap straight o. You will have to work slowly.

Do not pry it.

Protrusion

i-MOTION 9 Connecting Tube

HEX NUT

NOTICE

■DO NOT RIDE THE BIKE WITH THE HUB CAP REMOVED.

■DO NOT APPLY A LOAD TO THEWHEEL WHILE TURNING THE CRANK ARMS DURING SHIFT SETUP. Allow

the wheel to rotate freely when adjusting the shifting. If you hold or stop the turning wheel, the hub assembly will

spin inside the chaincase housing and may cause the plastic shift cable protrusion to strike the housing forcefully. If

this happens it will break it. Damage caused by improper servicing is not covered by your warranty.

■DO TAMPER WITH THE HEX NUT.

Before the re-installing hub cap:

Clean and apply a high-quality bicycle bearing grease

to the square hub end recess in the hub cap and the

mating surfaces of the chaincase. Be care when apply

grease, avoid contaminating chaincase bolt holes .

Only a thin lm is necessary on the mating surfaces to

minimize creaking.

Align the square recess with the hub and position the

cap onto the chaincase.

Re-apply Loctite 222 to the bolt threads and tighten

them evenly to 2.0 Nm, .

125637.PDF

i-MOTION 9 CONNECTING TUBE

ADJUSTER

COVER

CABLE END

CABLE LENGTH

Ferrule

Housing

SPRING

108 mm

This is an exploded view of the parts of the i-MOTION 9 connecting tube.

It must be removed and disassembled from the shifter housing before routing the cable through the frame. That’s probably

obvious to you. But since that involved disassmebling it, we’re showing it here.

You also need to know about the correct length of cable at the end. Its 108 mm, as you can see above.

CABLE ROUTING

SHIFTING

HIFTIN

DOWNTUBE

OPENING

BOTTOM BRACKET

OPENING

TROUGH

CABLE CLAMPREAR BRAKE

In order to install the rear shifting and brake line, the eccentric assembly ,must be removed from the bottom bracket shell.

The shift cable is to be fully housed throughout.

The brake hose end tting and shift cable end (i-MOTION 9 Connecting tube) must be removed to insert through frame.

frame.

The rear brake hose and rear shifting cable enter the downtube at the top through the integrated guides.

The hose and cable pass around the installed bottom bracket eccentric by way of the small trough in the bottom bracket. The

lines should not pass between the body of the eccentric and the wedges as this would interfere with rotation of the eccentric.

Both lines are secured to the chaincase by the cable clamp.

Where the cables contact the outside surface of the frame, be sure to ax the clear adhesive frame protection so rubbing

does not occur.

When it comes to time to reassemble and reconnect this

mechanism, be sure to thread the adjuster on all the way

to allow enough slack to make the connection to the

hub. The best way to reconnect the cable end with its

hub counterpart is to connect the tube to the hub then

and use a small pick to align the connector with the hub

cable end.

NOTICE

■Apply Loctite 222 and use a torque wrench.

Tighten to 2.0 Nm, 17.7 In Lbs.

■Use correct length crew to prevent chain

interference.

125039

M5X10

125423

CABLE CLAMP

KP126/

10 mm

125637.PDF

REAR WHEEL

The following procedures should only be performed

by a professional bike mechanic.

Loctite® 641™ Retaining Compound is used to bond the hub

bearings to the spindle during wheel installation. Careful

cleaning and re-application of the adhesive is necessary

anytime the rear wheel is removed and reinstalled.

For Loctite® 641™ Retaining Compound instructions :

http://65.213.72.112/tds5/docs/641-EN.pdf

HUB AXLE NUT

Removal

1. Secure bike in a work stand by the seat post.

2. Support the brake hose to prevent the caliper from

hanging. A zip tie or masking tape works well.

3. Disconnect and remove the rear brake caliper mounting

bolts. Be sure to note the arrangement of spherical

washers/spacers so you return them correctly when

re-mounting the caliper.

3. Engage afreewheel remove/installation tool

PARK FR-1 or Shimano TL-FW30 into the hub axle

nut.

4. Hold the rim at the wheel as shown to prevent rotation.

WARNING

KEEP YOUR HANDS AND FINGERS CLEAR OF

THE BRAKE ROTOR AND CHAINCASE!!

Hold the wheel as shown at right.

Place a torque wrench with a 1”socket onto the inserted

freewheel tool and turn the hub axle nut counter-

clockwise.

5. Continue turning the hub nut counter-clockwise until the

wheel is fully disenaged from the spindle and it can be

withdrawn.

NOTICE

■Support disconnected brake caliper and hose to

prevent damage.

■While the wheel is removed, cover both the

spindle and the hub opening to protect from

contamination or damage.

■Do not tamper with center screw. See arrow at

right.

125637.PDF

Installation

1. Remove any residual Loctite on the innner and outer

bearing lands. Use a soft wire brush and the specied

solvent. Consult the Loctite instructions.

Apply a lm of Loctite® 641™ over the surface of both

the inner and outer bearing lands of the spindle.

NOTICE

1. Clean Loctite residue from the spindle

carefully. Do not to scrape or damage the

spindle surface!

2. Apply the Loctite in the same way to the inner race of

each bearing inside the hub.

3. Clean and apply a high-quality bicycle bearing grease to

the spindle threads and the slots.

4. Align the hub anges and the spindle slots and install

the hub onto the spindle until the axle nut can be

threaded onto the spindle end. You may have to hold

the axle nut, while slowly rotating the crank arm to

move the spindle slots to align them.

Turn the nut by hand to ensure that the nut and spindle

threads engage properly.

Before torquing the axle nut, thread the nut

using the freewheel tool alone until the brake

caliper can be tted over the rotor onto the

chaincase. If the caliper can not be tted

properly, the hub and spindle are not engaged

correctly.

Flange

Slots

5. After you have conrmed that the brake caliper can

be installed, use a torque wrench, a 1”socket, and the

freewheel tool to tighten the hub bolt to 40 Nm, 354

In Lbs.

WARNING

KEEP YOUR HANDS AND FINGERS CLEAR OF

THE BRAKE ROTOR AND CHAINCASE!!

Hold the wheel as shown at right.

6. Reinstall the rear brake caliper. Test the brakes for

proper operation before riding.

NOTICE

■Only torque hub axle bolt when hub

and spindle are engaged completely as

indicated by correct caliper tting.

■The Loctite must cure before riding. See

Loctite instructions.

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