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saFety requireMents

WARNING! Failure to follow the following requirements may result in 

failure of the fork resulting in serious personal injury or 

death.

use a front brake

For some models, the brake bolt goes through both the carbon fork 

crown and the aluminum steerer. In the event of a frontal impact, 

the brake bolt functions as a key part of the impact absorption 

function; do not ride without a brake bolt through the fork crown 

and make sure the brake bolt is properly tightened. 

Do not overtighten the brake attachment bolt. The maximum torque 

for the brake bolt is 70-85 lb•in (7.9-9.6 N•m).

use a proper stem design and installation

The stem has several design requirements, which if not fulfilled, could 

damage the fork and cause it to break:

• Do not use a stem with a wedge-type 

steerer clamp (Figure 1), except for a 

Bontrager King Earl stem, which has a 

special design that will not damage forks. 

Improper clamp design can deform the 

steerer, adding to fatigue stress.

• Always use at least two spacers between the 

stem and headset. If the stem sits directly 

against the headset, any fatigue stress 

will be concentrated in a small area, which 

may damage the steerer.

• Never use more than 40mm of spacers 

under the stem. Additional spacers create 

more stress on the steerer, which could 

cause the steerer to fail.

• Do not overtighten the stem clamp; follow the stem manufacturer's 

recommendations. Overtightening can deform the steerer, adding 

to fatigue stress which may damage the steerer.

use a proper headset configuration

Make sure the headset is the correct size and 

that the lower crown race has a generous 

radius to the lower edge where it contacts the 

fork (Figure 2). A crown race where the lower, 

inside edge of the crown race is sharp and 

more square may not seat correctly against the 

fork crown, or may require excessive force to 

install. If the crown race does not go onto the 

fork with normal force, use a headset with the 

correct design. Do not alter the fork to fit the 

crown race.

use the proper size of disc brake rotor

For Bontrager forks equipped for disc brakes, 

the fork should only be used with road-size 

rotors: 165mm, 6", or smaller. Larger rotors place greater force on the 

fork and could cause damage or cause the fork to break.

Figure - Stem clamp de-

signs

A: pinch clamp

B: wedge clamp

A

B

Figure 2- Proper shape for 

lower inside corner of crown 

race 

Summary of Contents for 281540

Page 1: ...Part Number 281540 ...

Page 2: ...Fork Owner s Manual ...

Page 3: ...onsin 53594 Fork Owner s Manual Read this manual before you ride Contents Read this manual before you ride i Conditions for use 1 Before every ride Checklist 2 Check the headset 2 Check the stem 2 Check that the wheel is properly attached 2 Check the fork for fatigue or impact damage 2 Safety requirements 4 Fork maintenance 5 Installation instructions 6 Make sure your fork is compatible 6 To remov...

Page 4: ... grades where the tires do not lose ground contact Forks for 650 or 700c sized wheels with brake bosses on the fork blades for V type or cantilever brakes For riding on unimproved trails with small obstacles Conditions 1 and 2 plus rough trails small obstacles and smooth technical areas includ ing areas where momentary loss of tire contact with the ground may occur NOT jumping Forks for 26 or 29 w...

Page 5: ...ial tools and training so these services should only be performed by your dealer Check the stem Make sure the stem is in alignment with the front wheel Test the stem connection to the fork by attempting to turn the handlebar from side to side with the front wheel locked between your knees If the stem turns while the wheel is held in place follow the instructions in your bicycle owner s manual to t...

Page 6: ...r composite inspection procedures Carbon fiber is among the strongest materials used in bicycle manufac ture However carbon fiber has unique qualities different from metal parts and must be inspected carefully for damage Inspecting carbon fiber parts Unlike metal parts carbon fiber parts that have been damaged may not bend bulge or deform a damaged part may appear to be normal to a cursory glance ...

Page 7: ...any fatigue stress will be concentrated in a small area which may damage the steerer Never use more than 40mm of spacers under the stem Additional spacers create more stress on the steerer which could cause the steerer to fail Do not overtighten the stem clamp follow the stem manufacturer s recommendations Overtightening can deform the steerer adding to fatigue stress which may damage the steerer ...

Page 8: ...spect the steerer and crown Since this requires disassembling the headset bearings this procedure requires special tools and skills If you do not have the training take your bike to your dealer for inspection To inspect the fork 1 Remove the fork from the bike 2 Thoroughly clean the steerer and fork crown area 3 Look for signs of fatigue or impact damage as explained on pages 2 3 of this manual If...

Page 9: ...ny other parts to this fork If you are unsure of what items can be attached to this fork consult your Bontrager dealer This fork has the following dimensions which cannot be modified 100mm front axle O L D Over Locknut Dimension 28 6mm steerer outer diameter 30 0mm fork crown seat diameter Basic installation information Follow standard installation procedures for threadless headsets and aluminum o...

Page 10: ... 2 Attach the top cap 3 Install the front brake For a caliper brake use the special extra long brake nut provided Figure 4 For a Bontrager fork built for cantilever or V type brakes the brakes are attached with standard hardware For a Bontrager fork with a disc brake mount use only road sized rotors 165mm 6 or smaller 4 Install the front wheel 5 Re adjust the front brake 6 Put the bike on the grou...

Page 11: ...lies only to the original owner and is not transferable Bontrager is not responsible for incidental or consequential damages Some states do not allow the exclusion of incidental or consequential damages so the above exclusion may not apply to you Claims under this warranty must be made through an authorized Bontrager dealer Proof of purchase is required This warranty gives the consumer specific le...

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