Cannondale castle tool for dl80 / dlr80 fatty headshok

To remove the HeadShok cartridge, Cannondale uses a proprietary "castle" tool. These are often expensive and difficult to find for purchase.

This 3D print serves as an alternative for removal and installation:

• Four nub key: Used for removing the shock assembly from the steerer tube.
• Three nub key: Used for removing the oil reservoir cap to service and top up the oil.

Recommendations:

• Single-use only: The nubs will deform during removal and installation. I recommend printing two copies; one for removal and another for installation.
• Print orientation: Print the tool horizontally. Vertical prints lead to immediate shearing of the nubs when even light force is applied.
• Torque settings: Recommended torque is difficult to measure with this tool. Use it at your own risk. For installation, tighten until the tool (PLA) begins to fail.
• print in [mm]

Other important notes:

• Not all Cannondale cartridges use the same castle tool. This print is only compatible with the DL80 and DLR80 HeadShok models.
• Alternative methods of removal found online, such as using needle nose pliers, lead to marring the cartridge head (see the example in the included photo). By using this tool, such cosmetic and structural damage is preventable.

Other necessary specialty tools:

-1.5mm hex key to remove rebound dial

• freewheel removal tool is necessary to remove the steerer tube top cap !!!A freehub tool is not compatible!!! a universal freehub/freewheel tool will is compatible.