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  1. #1
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    Caution;  Merge;  Workers Ahead! 2006 Cannondale Headshok DLR80 Rebuild - Assistance Needed!

    I recently picked up a 2006 Cannondale Bad Boy Ultra with a DLR80 fork. I got the whole bike for cheap but the fork was leaking oil. I took the plunge to take apart the fork, pull out the dampening cartridge, and put in new seals.

    The problem is when I put everything back together, the lockout is locking out backwards! What I mean is that to lockout the fork, it's supposed to turn clockwise, but instead it now locks out when I turn it anti-clockwise.

    What did I do wrong for this to happen and how can I fix it? Any help would be greatly appreciated.

  2. #2
    I Tried Them ALL... SuperModerator
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    Go back to the drawing board, and reverse all the steps you took. If all else fails....send it to Mendon Cyclesmith....
    "This is a male-dominated forum... there will be lots of Testosterone sword-shaming here" ~ Kenfucius

  3. #3
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    Quote Originally Posted by Zachariah View Post
    Go back to the drawing board, and reverse all the steps you took. If all else fails....send it to Mendon Cyclesmith....
    Although that's an option, I don't think it's major enough to warrant me shipping it in to have it looked at. Plus, I would like to know what the issue is so that I can avoid it the next time I redo the seals.

  4. #4
    I Tried Them ALL... SuperModerator
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    Quoted from Mendon:

    "2005? Many of those had air loss issues, which are resolved with a retrofit kit which converts it back the previous style with a separate internal air sleeve as opposed to using the whole inner leg as a the air chamber.

    The kit is around $60.

    Do it right, and you have a functional fork, on a bike that you love...."
    "This is a male-dominated forum... there will be lots of Testosterone sword-shaming here" ~ Kenfucius

  5. #5
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    Quote Originally Posted by Zachariah View Post
    Quoted from Mendon:

    "2005? Many of those had air loss issues, which are resolved with a retrofit kit which converts it back the previous style with a separate internal air sleeve as opposed to using the whole inner leg as a the air chamber.

    The kit is around $60.

    Do it right, and you have a functional fork, on a bike that you love...."
    Hmmm... Sounds like an interesting option. Do you happen to have the part number for this kit?

  6. #6
    I Tried Them ALL... SuperModerator
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    Mendon can get one...
    "This is a male-dominated forum... there will be lots of Testosterone sword-shaming here" ~ Kenfucius

  7. #7
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    Quote Originally Posted by Zachariah View Post
    Mendon can get one...
    Perhaps Mendon can chime in here with the part number?

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