Bicycle Mechanics - Headshok repair (DIY questions)

Bike: 2001 Bad Boy Ultra, Headshok Si / Fatty Ultra DL

I just bought a this bike, unfortunately it has a problem with the Headshok. The bottom seal is leaking oil (which sounds like it could be fixed with a rebuild kit). That's the first problem.

The second problem is, when the bike gets locked onto the "rigid" setting, it isn't rigid. It still has a significant amount of travel. Not complete travel, but perhaps 1/3-1/2 of the unlocked position travel.

I started to take it apart, and I noticed that I will need a special spanner wrench to get the shock out of the headset. My LBS quoted me $26 on that spanner. Now my questions:

Will I need any other special tools other than the spanner wrench?

Any ideas on what could be wrong with it and how much these parts are going to cost?

Any advice on tackling this job? I'm pretty mechanical, I've rebuilt an automatic transmission and done a lot of engine work with cars, and I have all the standard metric tools I figure I'll need. One LBS quoted me on $50 labor on the shock, plus parts and they said it would probably take them a few weeks. I'd like to get it done ASAP so I can enjoy the bike, and I'd rather spend that $ on tools if need be.

Rob

Rob; I recently asked a Master Mechanic (and shop owner) for an example of a repair he would defer… The reply unfortunately was a Cannondale Headshok unit which he said would be immediately boxed and shipped back to Cannondale for service. This gentleman has over twenty years in the business and is an instructor in the Park School program

I really like your selection… awesome bike!

http://www.cannondale.com/bikes/01/cusa/model-1FS1B.html

I also checked out their product recall page and the 2001 Bad Boy Ultra isn’t on it.

http://www.cannondale.com/bikes/tech/recalls.html

Cannondale HeadShok Services list the following rebuild kits

Item# Description
1 FTR010 FTR, HSK stand. non air cart. rebuilt serv.
2 FTR011 FTR, HSK stand. air cart. rebuilt serv.
Item# Description
1 FTR001 FTR, HSK, single telescope fork rebuilt serv.
2 FTR002 FTR, HSK, double telescope rebuilt serv.

Please update this post as to which route you take and how pleased you are with the results. Many thanks...

Faith,

Thanks for your reply! Well here's what happened.

I thought about it and tried to work on the shock myself. I quickly realized that I did not have the right tools, and without assembly instruction I was just going to end up breaking it. I reassembled what I had taken apart to the best of my abilities.

I took it to a different LBS. At this shop, the mechanic was very cool and told me a few things which conflicted with what the first mechanic told me. Turns out the guy at the first shop was talking out of his ass. This guy at the second shop really knew his stuff, as I watched him disassemble it in front of me.

The lack of rigidity in lockout mode was caused by air which had gotten mixed in with the gas; when the valving was changed via a switch to lockout mode, the air still had room to compress, hence the sloppiness. Part of the lockout mechanism had also managed to get stripped out. Because of this, it need a new cartridge; which is a $200 part. The bike is over 1 year old, and also because I am not the original owner, the bike is out of warranty. However, this guy somehow worked it so that the repair is being done by Cannondale on warranty! (he's getting a new cartridge from them). It's costing me $35 total.

What a cool guy and what a cool shop. He's getting some Guinness from me and that shop has now gained a loyal customer.

Because of the delicacy of the Headshok, as well as the special tools that are needed (there are two tools that are needed just to get the shock out of the stem), in the future I am going to leave any Headshok work up to my LBS.

Rob