Super Fatty Ultra DLR80

[Julien BONNET]

Hello,
I have a Bad Boy with a Super Fatty Ultra DLR80 from 2005/2006.
There is a Red damper cartridge (with a 2005 sticker on it) and a red knob on the top.
Since a few month, the rebound and lockout buttons were out of order with an oil leakage. I tried to add air at the bottom, but without effect.
I bought some tools and replacement pieces (castle tool, park tool SP-1 & 2, freewheel tool, 5W oil, Seal Kit KH022,...) and after long hours on youtube and different websites, I disassembled the fork and the cartridge.
But after the complete "service" it is worse... there is no more damping and rebund.
I had a doubt on the shims/slotted holes order and position during the rebuild and I imagine it could be the reason...
For a few days, I tried to find some pictures or some tutorial on the shim stack of the damper, but I didn't find anything with such a details.
Could you please help me before I try to fix it?
Thank you in advance and sorry for my English if it is not clear...
Julien

 

[black lightning 1987]

Hi Julien,

I'm no help. You might try sending MikeA a message. See this thread.

http://community.vintagecannondale.com/threads/need-seal-kit-for-fatty-50-with-5-8“-piston.733/

 

[Julien BONNET]

Hi Julien,
I'm no help. You might try sending MikeA a message. See this thread.
http://community.vintagecannondale.com/threads/need-seal-kit-for-fatty-50-with-5-8“-piston.733/

Thank you @black lightning 1987
Hi @MikeA : any idea?

 

[MendonCycleSmith]

Wish I could help, but if it was fully disassembled, and reassembled in the same order, with no damaged or cracked components noted and replaced, then at that point, I'd have to see it personally, as guess work rarely turns up solid results.

 

[Julien BONNET]

Thank you.
I will try to disassemble it again this week-end and take some pictures, specially on these shims.
I'll be back

 

[Julien BONNET]

Some news: it works
I think it was effectively the shims.
I spent lots of hours to find the correct arrangement, but without success, so I decided to try by myself.
And here are some pictures for next newbies who will try to repair the fatty wiithout any pictures of the proces...
The flat washer is in contact with the red "piston" and the convex washer under it.
And I add also the different Manual of the fatty I found.
I hope it will help somebody.
Thank you for your support.

 

[Julien BONNET]

I added a detailed shim stack for a different fork (blue one) but it helps me a lot for the arrangement

 

[black lightning 1987]

It sounds like you have been successful.

Thanks for posting those documents. Did you find them on the current Cannondale website?

Perhaps Craig (MendonCycleSmith) can explain the shimming process, but I know he is busy and doesn't check in here daily.

 

[Julien BONNET]

No, not on the Cannondale website.

For the Air Cylinder Repair, HERE.
For the others PDF, I don't remember I have them since a few years.
For the shims, it is from MTBR.com forum but didn't note the post.
And this PAGE gives also instructive information, and the guy answered me in english.

 

[MikeA]

Sorry I missed this post earlier. I think you still have the lockout shim assembled wrong (the slotted shims). The concave side of the lower shim should be facing the flat shim. Here is a slightly different DLR80 showing the correct order of assembly:

Also, It looks like your negative spring is broken or bent? be careful it doesn't scratch the air cylinder.

 

[black lightning 1987]

Thanks Mike. Hope that you can continue to check in.

 

[Julien BONNET]

Thanks @MikeA
I will have a look on the spring during my next service