5
7
5
mm
5
mm
min.
max.
flush!
6
mm
BRAKE
The Compression Adjustment Plug
provided with this product is an
integral and necessary component
of the Ouzo Pro carbon fork, and
must be installed to maintain the
structural integrity of the Ouzo
Pro carbon fork system.
Failure
to properly install the Compres-
sion Adjustment Plug or use of a
substitute part may result in the
failure of the fork, resulting in
serious bodily injury or possibly
death.
5.1
To prepare the Compression
Adjustment Plug, turn the top cap
counter-clockwise by hand until the
threads are visible. The plug should
now be fully extended.
5.2
Using a 5mm hex key, turn the
expander bolt counter-clockwise
until the expander ring is at its
smallest width.
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
6
5
mm
5
mm
min.
max.
flush!
6
mm
BRAKE
6.1
Insert the Compression
Adjustment Plug into the
steerer tube until the top cap
seats flush against the top of
the stem.
6.2
Using a 5mm hex key,
turn the expander bolt clock-
wise to a torque of 80 kgfcm
(70 in. lb.). This will secure
the pressure plug in the inner
diameter of the steerer tube.
5
mm
5
mm
min.
max.
flush!
6
mm
BRAKE
7.1
With a 6mm hex key, turn
the top cap clockwise to a
torque of 25 kgfcm (22 in.lb.)
This step “pre-loads” the
bearings only. Tightening the
top cap does not keep the
headset from becoming loose.
Be sure to complete Step 8
before riding!
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
8
9
8.1
Attach front wheel to fork
8.2
Align stem with front wheel
8.3
Tighten both stem bolts to
manufacturer’s specifications.
If handle bars can be twisted
while holding front wheel still,
the stem is
NOT
tight enough!
5
mm
5
mm
min.
max.
flush!
6
mm
BRAKE
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
5
mm
5
mm
min.
max.
flush!
6
mm
BRAKE
9.1
Slide aluminum brake
spacer on the brake stud
9.2
Fit brake onto fork
9.3
Insert brake nut in rear
of fork
9.4
Tighten bolt to brake
manufacturer’s specs
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
2
2.1 Seat the steerer tube firmly in the
head tube and the stem firmly against
the compressing ring
2.2 Tighten one stem bolt just enough
to keep the assembly snug
2.3 Mark or scribe the steerer tube at
the top edge of the stem (a)
2.4 Remove the stem from the steerer
tube, and the fork from the head tube
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
3
3.1
Re-mark the steerer tube 3mm down
(b) from the first mark (a). It is necessary to
cut the steerer tube 3mm down from the
top of the stem, as this allows for sufficient
compression.
Any cut made longer or shorter may result in
a loose headset or insufficient clamping area.
3.2
Using a hacksaw blade designed for cut-
ting ceramic tile, cut steerer at a 90° angle
on the second measured mark (b). If using
a vise to hold steerer tube, use wooden
blockstop to protect it from damage. Do not
over tighten vise!
3.3
Using a file or sandpaper, remove all
burrs on the front edge of steerer tube.
4.0
Re-assemble fork, headset, head tube
and stem as in Step 1.
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
