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5

Fork MaintenanCe

In addition to the checklist on page 2, your fork may require 

additional maintenance. This section provides information about such 

maintenance.

re-alignment of the fork is not possible

Bontrager carbon fiber or aluminum forks, and their aluminum 

dropouts, are not as ductile as steel. Never attempt to make adjust-

ments to a part by bending or twisting it. If the fork has been 

damaged, take it to your Bontrager dealer for inspection.

keep the fork clean

Keep your fork clean with a soft rag and a solution of mild detergent 

and water. 

avoid chemicals or heat

Do not use solvents or harsh chemicals on the fork, as they can 

damage the paint and also the adhesive which joins the fork parts. 

Excessive heat over 180º F. (82º C.) can also damage the adhesive.

Completely inspect the fork every six months

Every six months, take the fork out of the bike and inspect 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 the fork shows any signs of stress, replace it. Do not ride a fork with 

signs of stress.

do not modify the fork in any way

Modifying the fork in any way will void the manufacturer's warranty 

and may be unsafe. 

Removing paint from a Bontrager carbon fork requires special 

techniques, so should only be done at the Bontrager factory. See your 

Bontrager dealer for more information.

warninG

never modify your fork in any way, including sanding, 

drilling, filing, removing redundant retention devices, or 

by any other technique. such modifications will void your 

warranty, may cause your fork to fail, and may contribute to 

loss of control resulting in personal injury or death.

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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