carbon fork steerer instructions

carbon fork steerer instructions
CARBON FORK STEERER INSTRUCTIONS
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.
Additional safety info can be found at:
hellerbikes.com/safety
Compatibility & Intended Use
Heller forks are intended for ASTM 3
conditions, defined as rough trails, rough
unpaved roads, rough terrain, and
unimproved trails that require technical
skills. Jumps and drops should not exceed
24" (61cm). They are NOT INTENDED for
hardcore freeriding, extreme downhill, dirt jumping,
slopestyle, or very aggressive or extreme riding.
Intended Wheel
& Tire Size
26 x 4.0" on 80mm rim
Alternative Wheel
& Tire Size(s)
26 x 3.8–4.25" on up to 100mm rim
26 x 4.3–4.7" on up to 80mm rim
27.5 x 3.0–3.25" (27.5-plus)
29 x 2.3–3.0" (includes 29-plus)
Steerer Tube
1-1/8– 1.5" (28.6–40mm) tapered
Hub
150 x 15mm thru-axle
Brake
74mm post mount (160–180mm rotor)
IMPORTANT NOTE: Tire compatibility guidelines above
are for general reference purposes only. Heller Bikes
recommends no less than 6mm of clearance between
the tire, wheel, fork, and frame.
Tools Required
Stem & Headset Preparation
1. Verify that the fork, headset and all required parts
for proper assembly have compatible dimensions.
The fork, headset, headset spacers, and stem steerer
clamp must have compatible diameters. Incorrect
use of components can cause component failure.
Visit headsetfitfinder.com to verify fork-to-frame
compatibility options.
Visit bicycleheadsets.com to learn more about
headset fit and the new Standardized Headset
Identification System (SHIS).
2.Make sure any stem or headset parts that come into
contact with the steerer tube are free of burrs or
sharp edges. Remove burrs or sharp edges with
fine-grit sandpaper.
2.Assemble the fork, headset and any spacers in the
headtube of the bicycle and install the stem (figure 3).
A - Compression device
A
B - 10mm spacer
B
C - Spacers (50mm max)
D - Upper headset
E - Headtube
C
F - Lower headset
D
G - Fork crown race
H - Top of steerer tube
I - Fork steerer tube
E
J - Crown race seat
3.Only use rear slot-style clamping stems on carbon
steerers. Wedge-clamp stems must not be used and
could result in failure (figure 1).
F
G
H
I
J
3
3.The spacer stack between the headset and stem must not
exceed 50mm (figure 4).
Rear steerer slot
1
4.A carbon steerer tube must extend 7–8mm above the top
of the stem clamp and have a 10mm spacer installed
between the stem and top cap (figure 5).
Fork Preparation
1. Install crown race according to manufacturer’s
instructions. Do not place the fork on the dropout
tips or crown while installing the race. Doing so can
damage the fork and could cause failure (figure 2).
B
50mm
7–8mm
Crown race setting tool
Hammer/mallet
Hacksaw with a fine 32 tpi tungsten carbide steel blade
Steerer tube cutting guide (recommended)
Allen wrenches: 4, 5, 6mm
4
Torque wrench that measures in Newton meters
5
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5.Carefully measure and mark the amount of steerer tube
to be removed. Remember that, when cut, the top of the
steerer tube must be 2–3mm below the top of the headset
spacer/stem assembly (figure 6).
B
H
2–3mm
Fork Installation
Ongoing Maintenance
1. Assemble the fork, headset, headset spacers in the
headtube of the bicycle and slide on the stem and 10mm
spacer. Insert headset compression adjustment device
(compression plug) into steerer and adjust headset
tension using appropriate tool according to the headset
manufacturer’s instructions. If torque specifications are
not provided, tighten to 1.6Nm (15 in-lb).
WARNING: Do not modify the fork, other than cutting the
steerer tube to the correct length for your bicycle. Modifying
the fork could cause fork or other component failure
resulting in serious injury
2.Tighten stem steerer clamp bolts to stem manufacturer’s
recommended torque specifications.
3.Install and adjust the front brake following the brake
manufacturer’s instructions.
6
6.Remove the fork from the headtube.
7. Make certain that you do not cut the steerer tube too
short—measure twice, cut once.
CARBON STEERER CUTTING
1. Using a new fine-tooth hacksaw blade (preferably
a carbon-specific blade) and proper cutting guide,
cut the steerer tube.
2.Using a synthetic scouring pad, remove burrs and
sharp edges.
3.Using rubbing alcohol, clean the steerer tube and inside
of the stem clamp to remove grease and dirt.
WARNING: Never use a star nut with a carbon steerer
tube fork (figure 7). Star nuts can only be used with
aluminum steerer tube forks. Use only a compression
device designed for carbon steerers.
WARNING: Failure to properly install and adjust brakes
can result in serious injury.
4.Install the front wheel according to the thru-axle
manufacturer’s instructions. WARNING: Failure to properly adjust the quick release
thru-axle to secure the wheel can result in serious injury.
Fork-Mount Bicycle Racks
1. When using a fork-mount (axle dropout-clamping)
bicycle rack, always ensure the clamp is closed securely
to prevent dropout and/or bike damage. If the clamp
is set too loosely the bike can fall out of the rack.
2.When removing the fork from the clamping device make
sure to pull/push straight up allowing the dropouts to be
removed evenly and at the same time. Do not tilt the bike
to remove it from the clamping device, as dropout
damage can result (figure 8).
WARNING: Dropout damage can cause component
failure, which can result in serious injury.
1. Loosen the stem’s steerer clamp bolts before making any
stem-to-fork alignment adjustments.
2.Periodically remove, clean, and inspect your fork for
damage, cracks, or any other damage. Any questions
about marks or cracks on the fork should be directed
to your Heller Bikes dealer immediately.
3.Regularly inspect all components for any damage (cracks,
chips, etc.) and replace components upon detection.
4.In the event of a crash or impact, carefully inspect
handlebars, fork, stem, seatpost, wheels, and the frame
for any visible damage. As with any component under
varying degrees of stress there is a fatigue life that is
proportional to the type of use and abuse applied to the
part. Always inspect your components before a ride.
If you have doubts about the integrity and condition
of any part, replace it. Consult your dealer if you are
unsure about the condition of your components or any
part of your bicycle.
Warranty Registration:
Proof of purchase is required before a warranty claim
is processed. Heller Bikes therefore strongly encourages
warranty registration at hellerbikes.com. Failure to register
will not affect consumer rights under the limited warranty,
so long as the consumer can show in a reasonable manner
proof of original ownership and the date the Heller Bikes
product was purchased.
If you have any questions contact [email protected]
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