WARNING:
The steerer tube and stanchions (inner legs) are a one time precision press fit at
the factory and cannot be removed from the crown. Replacement of the entire
crown/steerer assembly must be done to change steerer tube diameters or increase length
of threaded steerer tubes. Removing and replacing the steerer tube or stanchions will result
in an unsafe condition and should never be done.
1 Remove old fork from bicycle.
2 Measure and cut the steerer tube to fit your bicycle head tube.
3 Remove crown race from old fork and press onto 2001 MARS steerer until seated on crown. See
Figure 1.
4 Clean and grease headset bearing and crown races.
5 Install lower bearings on fork crown race.
6 Install steerer tube into head tube frame.
7 Install upper bearing, spacers, and stem.
8 Install handlebars. Torque stem handlebar pinch screw and stem clamping system to manufac-
turer’s instructions.
9 Install stem cap, adjust and tighten headset per manufacturer’s instructions.
10 Install brakes and adjust per manufacturer’s instructions. When installing disk brakes, the
caliper must fit, or have an adapter to fit, post style mounts with 74mm spacing.
11 Adjust front wheel quick release to clear the 0.275 (7MM) thick secondary catch dropout. The
quick release must be tightened after it has adequate thread engagement (4 or more threads
with the release adjusted to bicycle per manufacturer’s specifications).
12 Install brake cable per manufacturer’s instructions. Route disk brake lines so that they will not
kink or be pinched through the full travel of the fork.
13 Check tire clearance with crown. Figure 2.
Note: All 2001 MARS forks are equipped with a secondary catch dropout.
WARNING:
When installing the wheel or any new tire, check the minimum tire clearance.
Measure from the highest point on the tire to the bottom of the crown. The minimum clear-
ance allowed 3.26 (83mm) for 80mm travel fork models. Any less clearance can result in
accident resulting in serious injury or death. See Figure 2
CYCLE COMPUTER INSTALLATION INSTRUCTIONS:
Follow the instructions in your owner’s manual with the following exceptions:
WARNING:
DO NOT DRILL A HOLE IN THE DROPOUT. THIS MAY WEAKEN THE DROPOUT,
WILL VOID THE WARRANTY, AND MAY CAUSE AN UNSAFE CONDITION WITH RISK OF INJURY OR
POSSIBLE DEATH.
V. SUSPENSION SETUP:
• If the fork is new, break it in with at least one hour of riding before making any changes.
• Make sure the fork is in good working condition and is properly serviced and lubricated.
• Make changes in small increments.
• Keep a record of all changes made for future reference.
