4
To remove the existing fork
1. Remove the front wheel, front brake, and stem (with handlebar assembly)
from the bike.
2. Remove the upper headset parts.
3. Remove the existing fork.
4. If the existing headset is to be installed on the new fork, remove the crown
race from the old fork, and clean the race thoroughly.
To prepare the new fork for installation
1. Determine the correct length for the new steerer, and cut the steerer to
length.
2. De-burr and smooth the inside and outside surfaces of the cut edge of the
steerer.
In steps 3 and 4, prevent damage to the fork while hammering. Support the fork on a firm
padded surface while hammering, such as the plastic fork block used to protect fork ends
when new bikes are shipped.
3. Install the star-fangled nut.
4. Install the crown race.
INSTALLATION INSTRUCTIONS FOR THE
EXPERIENCED MECHANIC
These instructions are written for an experienced mechanic. If you are not
sure of your ability to correctly install this fork, or do not have the proper tools
for fork installation, have the fork installed by your Bontrager dealer.
Basic installation information
Follow standard installation procedures for threadless headsets,
and aluminum or steel steerers.
When cutting the steerer, remember the saying, “Measure twice,
cut once.” Any change in the existing overall stack height (head
tube + headset stack s stem steerer clamp
height) will require a different steerer length. If no change is made
to the overall stack height, you must still check that the existing
steerer is of the correct length before determining the correct
length for the new steerer (Figure 1). If in doubt, it is much better
to leave the steerer long, and cut it shorter at a later time.
Figure 1- Stem clearance
Figure 1- Stem clearance
Stem
Steerer
