RITCHEY User Manual Introduction Before Your First Ride

RITCHEY User Manual Introduction Before Your First Ride
RITCHEY
User Manual
Introduction
Forks and Headsets
Important information about use, care, maintenance and installation
Contents
Notes on This User Manual
Introduction
Before Your First Ride – Determined Use
Before Every Ride
Special Characteristics of Carbon
Cleaning and Care
Maintenance
General Notes on Installation
RITCHEY Liquid Torque
RITCHEY Torqkey
Headset
Checking the Headset
Adjusting the Aheadset®-Headset
Headset Maintenance
What to Bear in Mind with Carbon Steerer Forks
What to Bear in Mind with Integrated and
Semi-Integrated Headsets
Installing the Bearing Cup Races of Conventional and Semi-Integrated Aheadsets® into the Frame
Installing Forks with Threadless Carbon Steerer
Installing Aheadset®-Stems
Mounting the Front Wheel
How to Use the Quick-Releases
Warranty Terms
A Note on Wear
Manufacturer´s Guarantee
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Congratulations, when buying a RITCHEY part, you made a superb
choice. RITCHEY develops, tests and manufactures our products
with dedication to uphold the highest standards of quality. Like
all high-quality sports equipment, RITCHEY components require
careful installation in order to function properly and to provide
long-term dependability. We recommend that you ask a qualified
mechanic at your authorized RITCHEY dealer for help with installation and use RITCHEY parts (a) together whenever possible in
order to achieve optimum performance and durability. Our precise
tolerances are intended to ensure component compatibility, and
are carefully monitored during production and quality control so
that installation will be easy and trouble-free.
This manual contains important notes about use, care, maintenance and installation.
Please read this manual carefully, beginning with the general
information, followed by the chapter referring to the component
you purchased, or you intend to use. Doing so will ensure smooth
installation and trouble-free use of the product.
Keep this user manual for your records and future reference. If you
sell or lend your component or bike to someone, share this manual
with the new user.
With RITCHEY components, as with all lightweight bicycle products, special care and attention need to be paid to proper installation and intended use. Materials used by RITCHEY are extremely
strong and durable, with very low weight. However, sometimes
they can break, rather than bend, in the event of an accident. Internal damage to the component may not show up obviously or with
visible signs of damage. In the event of undue stress of any kind,
e.g. as a result of a crash, the components need to be inspected by
a qualified mechanic to ensure the product is safe to use. Therefore, consult your RITCHEY dealer after any such occurrence.
Before Your First Ride –
Determined Use
RITCHEY forks (b) and headsets (c+d) are designed for road racing,
triathlon (i.e. time trial), cyclocross or mountain bikes and their
typical use.
Road racing, triathlon and time trial bicycles are exclusively
designed for cycling on tarred and hard-surface tracks with a
smooth surface.
Cyclocross bicycles are designed for off-road cycling over typical cyclocross terrain, e.g. on field tracks and forest trails; they are,
however, not suitable for all-mountain and enduro use, downhill
(DH) riding, freeriding, dual slalom, downhill/freeride parks, jumps,
drops etc.
Mountain bikes are designed to be used for off-road cycling and
for riding over natural terrain (e.g. terrain of a mountain bike marathon and cross-country racing). Due to their design and equipment they are, however, not intended to be used on public roads.
If you intend to use this type of bicycle on public roads, it must be
fitted with the devices and equipment prescribed for this purpose.
Standard cross-country, marathon and all-mountain bikes are not
suitable for freeriding, dual slalom, downhill riding, jumps or the
like. There are special mountain bike types for these specific forms
of cycling.
We recommend that you always use RITCHEY parts together in
order to achieve optimum performance and component durability. If you intend to combine RITCHEY parts with parts from other
manufacturers, make sure they are compatible, i.e. that all dimensions are identical with the specifications given in this manual.
Forks and headsets are designed for an overall load of 110 kilos
(242 lbs) including rider and baggage, e.g. rucksack.
In case of any inquiries, please contact your RITCHEY
dealer.
After a crash, accident or other major impact, have your
RITCHEY forks, headsets, etc. checked by your RITCHEY
dealer for your own safety.
If your fork or headset produces any “creaking” or “crack
ing” noises or shows any external damage, such as
notches, cracks, dents, discolorations, etc., do not use your bike
anymore until you have consulted your local RITCHEY dealer,
who will check the part carefully and replace it, if necessary.
For more information see the specifications in our catalogue and/
or visit us at www.ritcheylogic.com.
Do not ever make any changes to forks and headsets. Do not file or
drill holes in RITCHEY components, especially in carbon parts, as it
will compromise their structural integrity and void your warranty.
(c)
RITCHEY forks are designed to be only used with threadless headsets, also referred to as Aheadset®-headset! Attempting to use a
RITCHEY fork in combination with quill-stems can lead to sudden
failure, resulting in a crash with unforeseeable consequences.
Notes on This User Manual
Pay particular attention to the following symbols:
This symbol means that your life or health may be in
danger unless you comply with provided instructions or
carry out prescribed measures.
!
This symbol warns you about actions that could lead to
damage of property or the environment.
(a)
(b)
(d)
This symbol indicates there is special information on how
i to handle the product and may refer you to a specific
passage in this manual requiring your special attention.
The possible consequences described above are not repeated
every time one of the symbols appears!
1
2
Before Every Ride
Check the following points before setting off:
Special Characteristics of
Carbon
1. Are the quick-release levers or nuts of the front and rear wheel
properly closed (a)? For more information, see sections “How to
Use the Quick-Releases“ and “Mounting the Front Wheel”.
All RITCHEY products made of carbon fiber-reinforced resin, also
referred to as carbon (c) or abbreviated CFR, require special care
and attention.
Improperly closed quick-releases can cause the wheels
to come loose. This can lead to a serious accident!
2. Check whether the headset is free of play and moves easily (b).
Make a visual inspection!
3. Verify the tight fit of the stem on the fork steerer.
i
Read the manual of your bicycle manufacturer before
you set off!
Carbon (d) is an extremely strong material which combines high
compression resistance with low weight. Please note that carbon,
unlike metals, shows no visible deformation after undue stress
even though some of its fibers may be damaged. This makes it
very dangerous to continue using a carbon part after an impact
or undue stress, as it may fail without previous warning, thereby
causing an accident with unforeseeable consequences.
If your RITCHEY carbon part sustained this kind of impact or undue
stress, we strongly recommend that you take your complete bike
to your RITCHEY dealer for inspection. They will check the damaged bike and, if necessary, replace the deficient part. In case there
are any unanswered questions or doubts, the dealer can contact
the RITCHEY after-sales department or one of the Ritchey distributors directly.
For safety reasons RITCHEY components made of carbon must
never be repaired; they must be replaced at once. Prevent further
use by taking appropriate measures, i.e. destroy the damaged
component.
(a)
Cleaning and Care
Maintenance
Clean your fork (e) and the headset (f) with water and a soft rag at
regular intervals. If necessary, use a non abrasive soap to remove
grime. You may add a little detergent liquid for cleaning and
removing tough stains, such as oil or grease, from hard surfaces.
Do not use degreasing agents, which contain organic solvents (e.g.
acetone, trichloroethylene, methylene, etc.). Chemicals of this sort
may damage the finish or substructure of the material.
Check the tightening torque of all bolts after the first 200 to 400
km (120 to 240 miles) or 10 to 20 hours of use. Tighten them, if
necessary, with a torque wrench to the prescribed torque setting.
Thereafter, check every 2,000 km (1,200 miles) or 100 hours of use!
After your bike has dried, apply a wax based polish to painted,
carbon and metal surfaces (exception: braking surfaces). Polish the
parts after the wax has dried. With this treatment your fork and the
headset will keep their nice appearance for years.
While cleaning, look for cracks, scratches, dents, as well as for bent
or discoloured material. If you think there may be a problem, see
your local RITCHEY dealer. Have damaged or defective components replaced immediately.
Loose or overly tightened bolts may result in an
accident!
Although headsets have seals, they are not entirely tight. Therefore,
have the headset dismounted and re-lubricated by an authorized
RITCHEY dealer at least once a year, depending on the intensity of
use.
Make absolutely sure to keep the braking surfaces or
rotors free of cleaning agent, grease or oil. Otherwise the
braking performance might be drastically reduced or even rendered ineffective.
Be sure to never store the fork and the headset in the blazing sun
or near a source of heat.
Parts made of carbon must under no circumstances be exposed
to excessive heat. Therefore, never have a carbon component
enamelled or powder-coated. The temperatures required for
doing so could destroy it. Do not leave carbon fiber parts near a
source of heat or in a car or trunk during hot or sunny weather.
(e)
If any notches, tears, deformations, dents or discolora
tions etc. are visible on your carbon part, or if it makes
“creaking” or “cracking” noises, do not use the bike until the
part has been replaced! After undue stress, a crash or other
major impact, replace the part or have it inspected by your local
RITCHEY dealer before using it again.
open
close
(b)
(c)
3
(d)
(f)
4
General Notes on Installation
In general, fork, headset, stem and handlebar installation are jobs
for skilled mechanics. We therefore recommend that you have
these jobs performed by an authorized RITCHEY dealer. Each of the
following instructions must be followed strictly. Non-observance
of these instructions can lead to component failure, resulting in a
severe accident or injuries.
Installing non-matching parts can result in clamping failure and
consequently in a serious accident.
We recommend using RITCHEY forks, headsets, stems and handlebars together (a), as they are designed to fit and function as an
integrated whole. If you choose to use a part from another manufacturer, read the respective manual regarding size accuracy to
ensure proper fit and compatibility with RITCHEY components.
RITCHEY assumes no responsibility for problems resulting from a
RITCHEY component being used with a part from another manufacturer.
RITCHEY strongly advises against using stems with a large recess in
the steerer clamp pointing towards the stem. The top and bottom
collar of the steerer clamp must measure 5mm at least. Stems with
recesses on the rear side of the steerer clamp are unsuitable!
Before installation watch out for sharp edges and burrs on all
clamping surfaces of the fork, the headset, the stem (b) and the
handlebars. Do not use these components, if they have burrs or
sharp edges. If there are burrs or sharp edges on a RITCHEY or nonRITCHEY component, have your local RITCHEY dealer inspect it to
see, whether it is usable or whether the issue can be remedied and
how.
If you fit a headset to an existing fork, check the steerer tube and
the old headset carefully for scratches, abrasion marks and notches
after removing them. Notches in the contact area indicate defective processing or deficient design of the headset in these areas.
Do not use parts, if you are not absolutely sure about their
compatibility. In case of any doubt, ask your RITCHEY
dealer who will contact, if necessary, our after-sales service hotline.
Do not use damaged parts! If you have the slightest
doubt, we recommend that you replace the part. Do not
use your bike until this has been done.
RITCHEY Liquid Torque
Installing components with RITCHEY Liquid Torque
Carbon fiber components are particularly vulnerable to damage
caused by excessive clamping force. RITCHEY Liquid Torque (c) creates extra friction between two surfaces, allowing the tightening
torque to be reduced by up to 30%.
This is especially useful in the clamping areas of fork, stem and
handlebars, i.e. areas where too much clamping force can damage
either component, causing component failure or voiding the warranty. By reducing the clamping force, RITCHEY Liquid Torque
relieves stress on sensitive carbon surfaces, preventing damage to
fibers or the cracking of the carbon substructure. It also retains its
effectiveness in wet conditions and provides maximum protection
against corrosion.
Precautions for use
RITCHEY Torqkey
Prior to applying RITCHEY Liquid Torque, remove dirt particles and
lubricant residues from the surfaces to be treated. Next, apply a
thin and even film of RITCHEY Liquid Torque to the cleaned surfaces using a brush, lint-free rag or chamois/artificial chamois.
Install components as directed by the manufacturer, by using a
torque wrench (such as the RITCHEY Torqkey recommended for
use with all RITCHEY forks, handlebars and stems) and take care
not to exceed the manufacturer’s maximum torque recommendations. After tightening to specified tightening torque, wipe off any
excess Liquid Torque.
To achieve long lasting and problem-free clamping of parts,
RITCHEY considers the use of a torque wrench absolutely necessary. The RITCHEY Torqkey (d) is designed for use with all RITCHEY
stems. It is a 4mm hex bolt/Allen wrench pre-set to 5Nm, which
is both the ideal clamp force as well as the maximum prescribed
torque, used to tighten RITCHEY stem bolts. If 5Nm of torque does
not generate sufficient clamping force, apply RITCHEY Liquid
Torque to interconnecting surfaces to increase friction.
Re-seal RITCHEY Liquid Torque container after use.
Additional information
Many manufacturer warranties will not cover damage to component due to over-tightening. Refer to manufacturer’s recommended torque limits for each component. Always use a torque
wrench to verify you are within specified torque limits, and do not
exceed them. Using RITCHEY Liquid Torque will allow you to safely
install your bicycle components – particularly in the case of carbon
fiber – without exceeding the torque limits specified by the manufacturers. In most cases, using Liquid Torque will enable you to use
as much as 30% less torque while installing your components.
RITCHEY Liquid Torque is neutral to copper and alu
minium alloys, steel and synthetic material, and will not
damage product surfaces.
Exceeding 5Nm of torque on clamp bolts of stem or handlebars
creates too much clamping force, which can lead to component
failure. This not only bears a high risk of accident, but also voids
the warranty.
Loose or overly tight bolts can result in component fail
ure and in an accident. Strictly observe the torque specifications. If you do not have a high-quality torque wrench or a
RITCHEY Torqkey, see your local RITCHEY dealer.
For bolts tightened to another tightening torque than
4Nm, please use the RITCHEY Torque Wrench (tightening torque from 2 to 16Nm)! For detailed information about
both tools, visit the online shop of Ritchey International at
www.ritchey.ch.
RITCHEY Liquid Torque can be used for all carbon, aluminium and
steel connections including:
• Stem/steerer tube clamping areas
• Seat post/frame clamping areas
• Stem/handlebars clamping areas and clamping bolts
(a)
(b)
5
(c)
(d)
6
Headset
Checking the Headset
The headset connects the fork to the frame, but allows it to move
freely. It must turn with virtually no resistance, if the bicycle is to
run straight, stabilising itself as it travels. Shocks caused by uneven
road surfaces expose the headset to considerable levels of stress.
As a result of this it can become loose and go out of correct adjustment. You should check the headset at regular intervals, readjust it,
if necessary, and have it greased at least once a year.
Pull the front wheel brake and place the fingers of your other hand
around the gap between frame and upper bearing cover (b). Bring
your weight to bear on the saddle and push the bicycle a little back
and forth. If there is movement at the gap, the headset shows too
much play. Repeat this test with the front wheel turned crossways.
Noises, in particular cracking noises, are often due to a lack of
lubrication. If you have a fork with steel/aluminium steerer tube,
you can apply mounting grease on the steerer tube in the area of
the headset and the spacers, however, not in the area of the stem
clamping. Furthermore, you can apply mounting grease between
all headset components and spacers.
This does NOT apply to full-carbon forks. The surface between
steerer tube and stem as well as between the pre-load mechanism (clamping cone) and the inner side of the steerer tube must
remain free of grease, otherwise a reliable clamping of these components cannot be granted. If you have a carbon fork, the grease
must, therefore, be applied carefully and systematically between
the steel/aluminium parts of the bearing, the clamping or between
the contact areas of the aluminium spacers.
Recurring bearing play may be due to insufficient friction between
stem and fork and/or to a poor fit of the counter bearing in form of
a cone mechanism in the fork steerer. Apply a thin layer of RITCHEY
Liquid Torque on the clamping surfaces to ensure a proper and
gentle clamping.
Letting the front wheel bounce to the ground from a height of
approx. 10 cm is another method that requires, however, a certain
amount of experience. Knocking noises indicate too much bearing
play. However, rattling brake levers, cables or cycle computers may
be misguiding!
To check whether the headset turns smoothly, take hold of the top
tube and lift the front part of the bicycle until the front wheel is
about 20 cm above the ground. With a little tap on the grips, the
handlebars should turn easily until either the brake touches the
frame or the handlebars hit the top tube. Perfom this test to the
right and to the left.
If the handlebars do not turn or only half way, slacken the cables
and try again. In case there is any cracking or rubbing noise, check
where it comes from. Often these noises are due to cables that are
dry or even rusty in their cable stops. In this case, please apply thin
lubricant.
If that still does not help, check whether the fork turns freely at
the bottom of the head tube and whether the bearing cover has
enough play. The gaps as well as the seals must be even. To check
the headset turn the fork from far left to far right.
Adjusting the Aheadset®Headset
Adjusting the headset is a job for a skilled mechanic.
i Have this work done by an authorized RITCHEY dealer. If
you intend to do the adjustment on your own, please note that
you need special tools, e.g a RITCHEY Torqkey.
Release the clamping bolts on the stem side by two to three turns
without unscrewing them entirely.
The Allen bolt located in the top cap is intended to re-adjust the
bearing play (c). Turning the bolt clockwise removes play, as the
stem is pressed downward on the bearing; turning the bolt anticlockwise increases the play.
Check the headset as described in chapter “Checking the Headset”. In case there is bearing play, tighten the adjusting bolt by
another quarter or half a turn.
not overtighten the top Allen bolt, it is intended for
! Do
adjustment! Tighten the bolt carefully in quarter-turns
and check the play regularly.
Steering resistance or play in some handlebar positions
can be due to improper fit, i.e. when the bearing races in
the frame are not snug as a result of deficient processing or when
unsuitable bearings were mounted. In such an event, please contact your RITCHEY dealer.
Check the tight clamping once again. If the stem is still not tight,
fork and stem are probably incompatible. Replace the stem by a
matching model or ask your RITCHEY dealer for assistance.
With carbon steerer tubes, make sure the inside of the
tube is supported by an expander-cone mechanism (for
adjusting the headset).
Check the tight clamping of the stem by holding the
front wheel between your knees and trying to turn the
handlebars relative to the front wheel. A loose stem can lead to
an accident!
If the stem cannot be tightened on the fork steerer tube
with a tightening torque of 5Nm, in spite of RITCHEY
Liquid Torque on the clamping surfaces, stem and fork are
incompatible. Replace the stem by a matching model or ask your
RITCHEY dealer for assistance.
Once the play is properly adjusted, bring the stem in alignment
with the front wheel. Check the alignment from the top (d). The
handlebars should be at right angle to the direction of motion.
Tighten both clamping bolts alternately by using the RITCHEY
Torqkey. If you use a standard torque wrench, start with a minimum tightening torque of 4Nm (e). In case the stem clamping is
not tight enough, increase the tightening torque to 5Nm or until
the RITCHEY Torqkey clicks.
Furthermore, check whether the fork steerer ends 2 to 3mm
beneath the top edge of the stem (a), otherwise adjusting the
bearing play is impossible.
After adjusting the headset check the tight clamping of the stem
by holding the front wheel between your knees and trying to turn
the handlebars relative to the front wheel. In case the stem is not
tight, do not tighten the bolts any further, but use RITCHEY Liquid
Torque instead in order to increase friction in the clamping areas.
(d)
Headsets come in different diameters and angles. Often
i the exact headset description is printed directly on the
cartridge bearing. If not, a headset gauge that you can obtain
from your RITCHEY dealer will help you.
(a)
(b)
(c)
(e)
22cm
mm
7
8
Headset Maintenance
The maintenance of the headset, the removal of noises in spite of
correct adjustment or an insufficient steering behaviour require a
dismounting of the fork from the frame.
Apply plenty of grease (not RITCHEY Liquid Torque) on the bearing and bearing races during reassembly that will seal the bearings in addition (c). Wipe off excess grease after reassembly.
The maintenance of the headset is a job for a skilled
mechanic. Have this work done by an authorized RITCHEY
dealer. If you want to try it on your own, you should have the
know-how and experience of a mechanic as well as special tools,
if necessary.
!
Undo the front brake and remove the front wheel.
Unscrew the top Allen bolt completely and remove the top cap.
Release the bolt(s) on the stem side.
Pull off the handlebars including stem, keep hold of the fork with
one hand and let the handlebars/stem hang down. Make sure
frame, levers, handelbars and stem remain undamaged.
Remove the spacers (a), the bearing cover and the upper bearing
cone. Clean the parts with a rag and arrange them in the order you
removed them. Keep the order in mind.
Carefully pull out the fork and wipe off any dirt from the parts
(b). Check on the dismounted fork, whether the crown race was
installed horizontally, whether it is in sound condition (i.e. without notches), and whether the steering tube is free of scratches,
notches, colour changes etc. over its entire length and circumference.
The top clamping area of carbon steerer tubes must
remain free of grease.
the correct order of assembly and place the
! Observe
lower bearing on the crown race. The bevel of the cartridge bearing’s outer ring, normally, shows in direction of the
head tube, whereas the bevel of the cartridge bearing’s inner
ring shows to the crown race. Slide the fork from below into the
head tube of the frame.
Slide the upper bearing that is greased on the outside, the upper
bearing cone, the bearing cover and the spacers completely on
the steerer tube until the fork is mounted almost free of play. Make
sure the clamping area of the stem is absolutely free of grease and
apply Liquid Torque. Slide the stem on the steerer tube and plug in
the top cap. Adjust the headset as above described.
What to Bear in Mind with
Carbon Steerer Forks
Carbon steerer tubes must remain free of grease, otherwise a
reliable and sufficient clamping of the stem will not be achieved.
You would require high tightening torques damaging the steerer
tube or the stem and resulting in a failure. Degrease the stem and
the fork with benzine or spirit, if necessary. Apply RITCHEY Liquid
Torque subsequently (d)!
Pre-load mechanisms acting as counter bearing for the adjusting bolt inside the fork steerer are often delivered without being
greased. In this case increased inner friction prevents the transformation of bolt force into clamping force. Apply grease specifically
on the inner, bevelled surfaces of the slotted sleeve and the inner
cone.
The outer surface of the sleeve must remain free of grease. Apply
RITCHEY Liquid Torque in this area, as well, bevor tightening the
mechanism in the fork steerer (e).
Never use a star nut as counter bearing inside the fork
steerer! Risk of breakage!
What to Bear in Mind with Integrated and SemiIntegrated Headsets
(b)
Remove the bearings, wipe off the grease from the bearing cup
races. Check whether the bearings turn freely and without play and
make sure they are free from chips etc. If you have an open bearing headset, you should check in addition, whether they are well
greased. Make sure there are no chafe marks or notches. Asymmetrical marks of that kind indicate a careless processing.
With integrated headsets the upper and lower bearing cup races
are part of the head tube, with semi-integrated headsets they are
normally pressed in by the manufacturers. This allows smooth transitions between headset, fork and stem.
The crown race is normally provided with a slit that allows an easy
installation on the fork steerer.
grease on the entire headset including bearing
! Apply
cup races to ensure smooth running and to prevent corrosion!
Verify that the gaps between bearing cover and head tube as well
as between fork crown and lower bearing cup race are evenly parallel. If they are not, the bearings possibly run rough.
(a)
(c)
9
(d)
Installing the Bearing Cup Races of Conventional
Aheadset®-Headsets and Semi-Integrated
Aheadset®-Headsets into the Frame
installation of the Aheadset®-headset is a job for a
! The
skilled mechanic. Have this work done by an authorized
RITCHEY dealer. If you want to try it on your own, you should
have the know-how and experience of a mechanic as well as
special tools, if necessary.
Place the crown race horizontally onto the fork crown. Slide the
crown race onto the steerer either manually or with an appropriate special tool. With the desired, minor undersize of the crown
race towards the fork crown you need to tap slightly on the crown
race to bring it into the correct position without leaving any gap
between crown race and fork crown. Keep the fork in hand during
tapping and do not put it down – risk of breakage!
installation thoroughly check the cleaned fork
! Before
steerer, in particular the fork crown and the stem clamping area, for damage, such as cracks.
Perform the installation only with headset tools. An appropriate press fit of the bearing cup races into the frame can only be
achieved with these tools. Precondition is, however, that the tolerances are observed and that the surfaces gliding on top of one
another are well greased. Verify not to slide on the bearing cup
races in oblique position and make sure they are flush. Tighten the
special tool evenly and observe as the bearing cup races slide into
the head tube.
Bearing cup races that you can slide in manually will cause cracking or rattling noises during cycling. Degrease the bearing cup
races and the inner face of the headset in a metal frame and apply
some two-component adhesive, according to the manufacturer’s
instructions. If you have a carbon frame apply RITCHEY Liquid
Torque!
!
Let the adhesive harden before re-installing the fork.
(e)
10
Installing Forks with Threadless
Carbon Steerer
If there is hardly any resistance when sliding on the crown race due
to an improper fit, apply some two-component epoxy adhesive to
fix it additionally.
The cutting of the steerer tube, the press fitting of the crown
race and the installation of the fork into the frame are jobs for a
mechanic. Have this work done by an authorized RITCHEY dealer.
An unauthorized installation and maintenance will render the warranty void.
Assemble all parts of the headset, insert the desired number of
spacers under the stem and mark the top edge of the stem.
Improper installation increases the risk of breakage for
the fork and the stem. Risk of an accident!
Each of the following instructions must be followed
strictly. Non-observance of these instructions can result
in a fork failure and lead to a crash with serious consequences.
Measure the crown race and the fork crown first. Forks with
1“-steerer tubes (steerer tube diameter 25.4mm) require bearing
races at a nominal diameter of 26.4mm (with partly large tolerances). Forks with 1 1/8”- steerer tubes (steerer tube diameter
28.6mm) require crown races at a nominal diameter of 30.0mm.
Verify that the fork crown is circular and that the dia­meter is not 0.1
or 0.2mm bigger than the inner diameter of the crown race.
1“-forks the fork crown should not be smaller than
! With
26.4mm and with 1 1/8“-forks not smaller than 30.0mm,
otherwise a tight press fit of the precise crown race cannot be
ensured.
Verify that the contact area of fork crown and crown race is clean
and apply a little grease (except one of the clamping surfaces is
made of carbon!).
Hit the crown race with an appropriate special tool until it is in
horizontal position and until any gap between crown race and fork
crown has disappeared. Keep the fork in hand during hitting and
do not put it down – risk of breakage!
(a)
Do not apply grease or oil on the steerer tube in the
clamping area of the stem, as this will prevent a reliable
clamping!
Do not clamp the fork into a vice to cut it, as this could damage the
fork steerer. Clamp the fork steerer into a suitable device instead,
e.g. into a special bracket. Use a sharp, fine-toothed metal saw (24
teeth) and cut the fork steerer at low pressure 2mm below your
marking. Make sure to keep the inner steerer tube free of chips and
dust.
Use a file to gently remove any burrs from the area of the cut (a).
Insert the file from the outside to the inside and not vice versa, otherwise the fibres will fray out.
Do not blow off the saw chips. Remove the chips with a
damp rag and dispose of them together with the rag!
Seal the cut with two-component adhesive (epoxy resin), clear varnish or super glue.
Wipe off excess adhesive from the steerer tube side immediately
upon sealing.
The stem clamping area must be free of burrs and the
fork steerer must have enough support inside the stem.
Stems with many recesses in the clamping area or with a cut-out
in the clamping area pointing towards the stem are not suitable. The top and bottom collar should measure 5mm at least.
The steerer tube clamp must be closed, i.e. it must be free of any
recesses.
i
(b)
Make sure all spacers and the clamping area of the sleeve
are free of burrs.
RITCHEY carbon steerer tubes are manufactured with fine tolerances. For this reason the stems normally fit snugly on the
fork steerer tube. Do not install stems that have play on the fork
steerer.
If you have not yet found your preferred position of the stem, insert
more spacers under the stem to begin with. Observe the maximum
stacking height of spacers of 30mm under the stem.
!
i
Use RITCHEY Liquid Torque to ensure a reliable fit and
low tightening torques!
If you have strictly followed the above instructions, you will not
need high tightening torques for the clamping bolts. The recommended tightening torque is 4 - 5Nm depending on the stem type.
With a standard torque wrench start from the minimum value and
approach the maximum value by proceeding in small 0.5Nm (4.45
inlbs) increments. With a RITCHEY Torqkey turn until it clicks. Check
the tight fit of the stem and the fork by trying to turn the handlebar
relative to the front wheel (b).
Do not exceed the tightening torque prescribed by the
stem manufacturer and a maximum tightening torque of
5Nm for the fork. Check the tightening torque of all bolts after
200 to 400 km (120 to 240 miles) or 10 to 20 hours of use and
then every 2,000 km (1,240 miles) or 100 hours of use.
Install the brake callipers to the fork.
If there is no extra long nut delivered with the road racing fork,
use the sleeve nut of the brake manufacturer for brake installation.
Verify that the nut has a minimum grip of 8 turns!
Installing Aheadset®-Stems
Many RITCHEY stems can be installed in either vertical orientation.
These “flip-flop” models allow handlebars to be positioned at two
different heights by simply inverting the stem (c).
Verify that the stem and fork steerer tube always have matching or
compatible clamp diameters (d)!
If you intend to install a 1 1/8“-stem on a 1”-fork steerer, use a
reduction sleeve at the suitable length.
Make sure the slots of stem and sleeve are accurately on top of one
another.
If you fit a new stem on a fork with carbon steerer tube, check the
clamping area for notches or abrasion marks. In case such damage
is actually visible, ask your RITCHEY dealer whether it is necessary
to have the fork replaced.
Make sure the clamping areas are absolutely free of grease, especially when the clamping surfaces are made of carbon. Apply
RITCHEY Liquid Torque in the clamping areas.
Use RITCHEY Liquid Torque to optimize clamp hold. Grease the
threads and the connecting surfaces/heads of the steerer clamp
bolts. Keep lubricants away from clamping surfaces.
Slide the stem onto the fork steerer tube. It must fit snugly onto the
fork. Do not fit stems which have play on the steerer tube.
Depending on the steerer tube length and the desired stem position, install spacers on the fork steerer above the upper cover of
the headset, and/or above the stem. You can stack them up to a
maximum height of 30mm.
These spacers are available in different heights. You have installed
the correct number of spacers, when the steerer tube ends 2mm
below the top edge of the stem.
No matter what type of brake you install (V-brake, disc
brake or else), be sure to read the manual of the brake
manufacturer beforehand. Follow the installation instructions
and pay special attention to the tightening torques.
The brake rotor diameter approved by RITCHEY is
180mm. Larger rotors can lead to a fork failure and thus
cause an accident!
(c)
(d)
reset
MM
SET
mm/i nch
11
O/on
12
Verify that the stem provides sufficient support for the steerer
tube and that the steerer tube ends 2mm at the most below the
top edge of the stem (a). This ensures a reliably clamping when
tightening the clamping bolts of the steerer tube clamp to the the
prescribed tightening torque.
If your preferred stem height results in a deeper position of the
stem on the steerer tube, the steerer tube projects from the stem.
To check the correct position, insert spacers (b) at an appropriate
height on top of the steerer tube. After the test ride the steerer
tube of a carbon fork must be shortened.
The space between the top of the steerer tube and the
upper edge of the stem should not exceed 2mm. Tighten
the stem bolts only a little, if you intend to install the handlebar
right afterwards. Finish by adjusting the headset.
The clamp bolts of RITCHEY stems are designed to
i oppose each other for proper load distribution during
clamping. Please check that the bolt heads of RITCHEY stems are
always oriented in opposition to each other.
(a)
Mounting the Front Wheel
Once you have installed the headset and the fork, you need to
remount the front wheel.
i
Be sure to also read the manual of your bicycle manufacturer before mounting or removing the wheels.
After you have mounted the wheel, make sure it is correctly seated
in the drop-outs and accurately centred between the fork legs.
Check the correct seat of the quick-release and
• close the release lever of the rim brake (Shimano, SRAM) immediately or shift the bolt in the gear/brake lever at the handlebar
back to its original position (Campagnolo),
• if you have V-rim brakes (V-brakes) and cantilever brakes, make
sure you hook the brake cable back immediately! Verify that the
brake pads touch the rim and not the tire or the spokes.
• Re-mount the hydraulic rim brakes and close its quick-release
immediately after fixing the wheel! Verify that the brake pads
touch the rim and not the tire or the spokes.
• If you have disc brakes, check before mounting the wheel
whether the brake pads rest snugly in their seats in the brake
calliper body. The gaps between the brake pads and the wheel
should be parallel and the wear indicators in their correct position. Make sure you guide the rotor between the brake pads
carefully.
• After mounting the wheel and tightening the quick-release pull
the brake lever (c) (in the case of disc brakes several times) and
spin the wheel. The rotor should not drag on the brake caliper
or on the brake pads. Make sure the brake pads touch the rim
and not the tire or the spokes.
Always test the brakes in stationary after mounting a
wheel. By pulling the lever you should get a positive
braking response. The brake lever must, however, remain clear
of the handlebars. If it does not, check the bicycle and the brake
system according to your general bicycle manual.
Before riding on your bicycle check that after the installa
tion the brake surfaces, the rotors and the brake pads are
still free of grease or other lubricants.
No matter what type of brake you install (V-brake, disc
brake or else), be sure to read the manual of the brake
manufacturer beforehand. Follow the installation instructions
and pay special attention to the tightening torques.
How to Use the Quick-Releases
As the use of quick-releases is not always common know
ledge, they have been the cause of accidents. We recommend that you read the following instructions thoroughly and
practice the handling as outlined. Ask your RITCHEY dealer for
advice.
The wheels are attached to the frame at the hub axles. Each axle is
clamped tight in its drop-outs by means of a quick-release.
Quick-release retention mechanisms essentially consist of two
operative parts (d):
1. The quick-release lever on one side of the wheel: Release this
lever to loosen the wheel and close it to create a strong clamping force on a 180 degree axis.
2. The tightening nut on the other side of the hub with which the
initial tension on the threaded rod is set.
To remove the wheel open the quick-release lever (e) and loosen
the tightening nut by a few turns, if necessary. The front wheel is
usually additionally secured by means of drop-out catches at the
fork tips which prevent the wheel from coming off, in the event of
an unintentional loosening of the quick-release.
(d)
The clamping force should be adjusted in a way that by closing the
quick-release you feel significant resistance over the second half
of its travel (f).
The quick-release is accurately tight, when a clockwise turning in
closed condition is impossible by applying pressure to the front.
22cm
mm
(b)
(c)
13
(e)
(f)
14
Warranty Terms
Under European consumer law, the purchaser has full statutory
warranty rights within the first two years from date of purchase.
In North America, these rights apply to the first year from the date
of purchase. According to these laws, your dealer is responsible for
ensuring the product is free of defects that could cause premature
wear from normal use.
The two year warranty law is only valid in countries where European (EU) regulations apply! Please ask your bicycle dealer about
the regulations in your country.
Warranty claims will only be accepted, if the bicycle has been used
solely for its intended purpose (see section, “Before Your First
Ride – Determined Use”).
A Note on Wear
Manufacturer’s Guarantee
Bicycle components are subject to wear due to normal and proper
use. The rate of wear will depend on care and maintenance, the
bicycle usage and the environmental conditions, such as rain, mud,
dust, and sand. Some components require regular care and maintenance. Nevertheless, despite the best maintenance program,
all components will eventually reach the end of their service life
depending on intensity and conditions of use.
RITCHEY products have been developed and manufactured with
great care and have gone through numerous testing controls. Our
products are examined as part of our internal quality control process to meet strict standards as well as by external, independent
test laboratories.
The following RITCHEY components are especially subject to wear
due to the nature of their intended use and not covered for wear
under this warranty:
• The lubricants and seals of the bearings
It does not cover damage resulting from wear (lubricants, seals),
neglect (insufficient care and maintenance, bearing play), accidents, overstress caused by overloading, incorrect installation,
improper treatment or as a result of changes to the components.
For the EU market we grant, independent of legal regulation, a
voluntary guarantee that your RITCHEY product is free of manufacturing and processing defects for two years from the date of
purchase.
For the North American Market we grant, independent of legal
regulation, a voluntary guarantee, that your RITCHEY product is
free of manufacturing and processing defects for one year from
date of purchase (except from lubricants and seals).
In the event of a warranty claim, RITCHEY reserves the right to
provide all or part of the current successor model in an available
colour – or if such part is not available, a higher grade model – to
remedy the claim. The guarantee does not cover assembly, refitting
costs or any new accessories that may be required (e.g. different
dimension parts).
The guarantee does not cover labour and transport costs, nor does
it cover follow-up costs resulting from defects.
Your direct contact for any issue is your RITCHEY dealer/reseller,
who is authorized to respond to your inquiries.
In case of any inquiries, please contact your national distributor. Find contact information for your national distributor at
www.ritcheylogic.com.
In the event you have not purchased the product from
i an authorized dealer, RITCHEY can possibly not guaran
tee the expected quality for the product.
Be sure to strictly follow all assembly instructions in this manual
as well as all additional instructions provided by the manufacturers of products used in conjunction with RITCHEY products, especially bolt torque specifications and the prescribed maintenance
instructions. Observe all instructions with regard to procedures
and verification processes listed in this manual as well as any other
instructions that may be included in the delivery of RITCHEY products. Also adhere strictly to any and all instructions referring to
the replacement of safety-relevant components, e.g. in the case of
colour changes of the components.
The manufacturer’s guarantee only applies to claims made by the
initial buyer, who must present the purchase receipt with date of
purchase, dealer address and model number. Guarantee claims
will only be accepted, if the bicycle has been used in accordance
with the intended use of RITCHEY products.
This guarantee does not cover damage resulting from:
•
•
•
•
•
•
Your direct contact with regard to all issues outlined in this manual
and corresponding instructions is your local RITCHEY dealer, who is
qualified to answer your questions. To handle your claim you need
to present your receipt.
In the event of a defect or if you have a warranty issue, please contact the dealer who sold you the bicycle component in question.
RITCHEY has exclusive agreements with all authorized dealers to
handle potential warranty claims. If you purchase a RITCHEY product from an unauthorized RITCHEY dealer, e.g. from an internet
auction site, the warranty granted by RITCHEY becomes void, so
you must seek resolution with the reseller who sold you the product.
wear
neglect (insufficient care and maintenance)
accidents
overstress caused by overloading
incorrect installation or improper treatment
changes or modifications to the component (e.g.: improper fork
cutting)
The instructions of this and all other RITCHEY manuals are drawn
up carefully to maximize the service life of RITCHEY products. Any
guarantees are void, if installation instructions are ignored and/or
if regular inspection and maintenance intervals are neglected.
RITCHEY International
Via Cantonale 2
CH- 6916Grancia-Lugano
RITCHEY Corporate HQ’s
620 Spice Island Drive
Sparks, NV 89431
RITCHEY Design Inc. Taiwan Branch
22-1, #123 Chungang Rd. Sec 3
Taichung 407
Taiwan R.O.C.
RITCHEY Design Inc.
Sales & Warranty Office
575 Old County Road
San Carlos, CA 94070
Technical details in the text and illustrations of this manual are
subject to change.
© No part of this publication may be reprinted, copied or transmitted by hand or with mechanical or electronic systems or used
for an another business purpose without prior written permission.
Concept and text:
Zedler Engineering,
Ludwigsburg, Germany
www.zedler.de
Edition 1, July 2009
In case of inquiries, contact your national distributor at www.ritcheylogic.com.
15
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