Front Rack Instructions
Hi there. Thanks for spending your hard-earned cash on this Surly product. Surly stuff is designed to be useful and durable. We’re confident it will
serve you well for years to come.
WARNING: Cycling can be dangerous. Bicycle products should be installed and serviced by a professional mechanic. Never modify your
bicycle or accessories. Read and follow all product instructions and warnings including information on the manufacturer’s website.
Inspect your bicycle before every ride. Always wear a helmet.
Do not carry any live cargo (i.e. pets) as this may cause a shift in balance and a crash resulting in serious injury to both you and your cargo.
Bicycle steering and braking may behave differently with loaded rack.
Position reflectors and lights so that they are not obscured when rack is loaded.
Evenly distribute weight on both sides of rack.
An improperly modified rack can cause you to lose control and fall. NEVER MODIFY YOUR RACK OUTSIDE
Additional Product and Safety Information can be found at the website
The Surly Front Rack is fully adjustable to accommodate most forks. It works on forks that have 26–29˝ wheel with or without fenders, including
most Surly forks. NOTE: The Pugsley and Moonlander forks (due to the offset of the Pugsley fork’s driveside blade and the width of the
Moonlander fork) are not compatible with the Surly Front Rack. The stock rack and hardware is designed to fit Surly touring forks. Additional
hardware is needed to accommodate other forks, and can be found by contacting Surly or your local bike shop. The height of The Surly Front Rack
can be fine tuned to keep the weight of your cargo as low as possible. And, you can get the angle of your rack parallel to the horizon, regardless
of your fork rake, curve radii, or braze-on locations. Your panniers can ride high or low. Keeping your weight low keeps your bike stable. But, in
some cases you’ll want to run your panniers high to keep ‘em out of the tall grass or mud. This rack is truly versatile.
The Surly Front Rack is constructed of 4130 CroMoly tubing because it’s durable and repairable. It can be welded, brazed, and soldered in the rare
instance that you’d need to repair it while you’re on a tour. Aluminum racks won’t afford you the same luxury. The tubing wall thicknesses vary
according to the stress loads they will have to bear, because we want to optimize the strength-to-weight ratio of the rack. We’ve included braze-ons
that may be useful to you: front through-eyelet...use it to attach a light or home-made flat fender; rear through-eyelet...attach a flat fender
or add an additional/alternate rack strut to the crown of your fork; bottom braze-ons…these keep your rope, bungies, or panniers in check.
Your rack is phosphated and powdercoated to keep corrosion at bay. The included hardware is made from aluminum, CroMoly, and stainless steel.
These materials were chosen for their corrosion resistance and superior strength-to-weight ratios for their given applications.
Intended Use
ASTM Condition 2
Riding in Condition 1 plus smooth gravel roads and groomed trails with low-angle grades and drop-offs of less than 6˝ (15cm).
Surly racks are compatible with bicycle forks that have threaded mounting points, and can accept bolts on mounts midblade and near the dropout
that are already integrated into the frame design, or can safely accept rubber-coated clamps around the fork blades (additional hardware will be
WARNING: Carbon fiber forks are not compatible with Surly Racks. Surly Racks are intended for recreational riding, not aggressive or
stunt riding. Your Rack will haul up to 32kg (70 lb) of well-secured, well-balanced gear over roadways and maintained off-road trails.
Tools Needed
• 4mm hex wrench
• L
inseed oil, Framesaver, Boeshield, or engine fogging oil
(optional, but highly recommended)
• 8mm open-end wrench
• Level (optional)
• Grease
Hardware Included
(2) Upper offset sliding plate
(8) M5 nylon insert lock nuts
(2) Lower offset sliding plate
(20) M5 x 12mm O.D. stainless
steel flat washer
(2) Uni-crown sliding plate
(12) M5 x 12mm
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Assembly Instructions
Read all of the instructions before assembling and installing your rack. If you are unsure of your ability to install your rack correctly,
take it to your local bike shop mechanic for installation.
WARNING: Failure to install correctly may void warranty, and result in serious injury
1. Find a clean space on a workbench or table for assembly. Work in an area that gives you adequate room to move around your bike.
A cluttered workspace will complicate the assembly and installation procedure.
2. Inventory hardware. Gather tools and supplies.
3. Optional—apply oil or Framesaver to the inside of the rack tubes (through the vent holes) to aid in corrosion prevention. For best results,
allow time for the oil or Framesaver to soak in with the vertical holes covered and rotate occasionally.
4. Attach lower offset plates to the bottom of the rack. Hardware
assembly sequence for attaching each plate, from outside to
inside: 12mm cap screw, washer, rack, offset plate, washer,
locking nut. See assembly references in Figure 1. Don’t tighten
the hardware, yet. It must be loose enough to allow the assembly
to slide up and down. Apply grease to the 12mm bolts before
Figure 1
5. It may be easiest to complete this step with the wheel removed
and the bike resting upside-down on the floor or in a repair stand.
Attach the offset plates to the fork using the 12mm cap screws.
The cap screws should be snug, but loose enough to allow the rack
to pivot. This allows you to level the rack before all the hardware
is tightened. See Figure 2.
Figure 2
6. Install the wheel in the fork, rest the bike upright on a level floor, and adjust your rack up and down to attain your desired height.
tBe sure to allow clearance between the rack and tire, for debris accumulation and fender installation (if desired). NOTE: Minimum
clearance of 4mm for Road, 6mm for MTB between tire, rack and fender. Tighten the nuts of each lower offset plate to 3–4N-m in order
to hold your rack’s vertical position. Adjust the angle of your rack so its top surface is parallel to the floor.
7. If using a uni-crown fork, use the supplied uni-crown sliding plate. If using a lugged-crown fork, use the supplied upper offset sliding
plate. Attach upper sliding plates to the rack. The hardware assembly sequence is the same as step 4 above.
8. U
se a 12mm cap screw to loosely attach each sliding plate to the mid-blade eyelet. Level the rack. Tighten the sliding plate hardware.
Tighten the 12mm sliding plate-to-eyelet bolt to 6N-m. Tighten the lower sliding plate-to-fork eyelet bolt to 6N-m. Check all of the
hardware once more. Tighten if necessary. Final assemblies should look similar to Figure 3. Your rack should be level and centered
on the fork and the wheel, assuming it’s dished properly. If not, you’ll need to loosen the appropriate hardware and move the rack
around until proper adjustments are made.
Figure 3
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Ongoing Maintenance
If you lack proper tools, knowledge, or patience to get the job done right, visit your friendly local bike mechanic for assistance. Spare parts are
available in the event that you break or lose something.
Your new rack requires little maintenance. Check the tightness of the hardware once frequently. Spray a little oil inside the tubes on occasion,
esspecially if you’re prone to riding in wet conditions.
Limited Warranty
This Surly product is warranted against defects in materials and workmanship for one year from the date of retail purchase of the product,
subject to the limitations detailed below. Save your dated receipt for proof of purchase.
This warranty does NOT cover the following:
•Damage due to improper assembly or follow-up maintenance or lack of skill, competence or experience of the user or assembler
•Products that have been modified, neglected, used in competition or for commercial purposes, misused or abused, involved in accidents
or anything other than normal use
•Installation of components, parts or accessories not originally intended for or compatible with Surly product as sold
•Damage or deterioration to the paint, surface finish, aesthetics or appearance of the product
•Normal wear and tear
•Labor required to remove and/or refit and re-adjust the product within the bicycle assembly
This limited warranty is expressly limited to the repair or replacement of a defective product, at the option of Surly, and is the sole remedy
of the warranty. This limited warranty applies only to the original purchaser of the Surly product and is not transferable. This warranty applies
only to products purchased through an authorized dealer or distributor. In no event shall Surly be liable for any loss, inconvenience or damage,
whether direct, incidental, consequential, or otherwise resulting from breach of any express or implied warranty or condition, of merchantability,
fitness for a particular purpose, or otherwise with respect to our products except as set forth herein.
This limited warranty gives the consumer specific legal rights, and those rights and other rights may vary from place to place. This limited
warranty does not affect your statutory rights.
Give us a call for a free catalog or visit our website to check out all our stuff–you won’t be disappointed.
6400 West 105th Street
Bloomington, MN 55438
The Watts Line: 877.743.3191
The Email:
The Web Address:
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