Step 1: Locate the top two headset adjuster nuts that sit just above the head tube and loosen off the top nut. NOTE: using two 36mm spanners
will help
Step 2 : (a) Now completely remove the top lock nut from the fork tube. (b) Repeat this step for the lower headset nut. While doing this be
careful that the forks don’t slide out from the deck head tube so no bearings are lost or damaged.
Step 3: Now carefully slide the forks down and out from the deck. Do not knock the bearings when doing this or you could damage them.
Step 4: With the fork removed you can now change or service the bearings. Carefully slide the lower bearing up and off the fork tube. When
re-installing the bearings ensure the bearing unit is the correct way round as seen in image 4(b). Wrong fitment will result in damage!
Step 5: Now carefully remove the top bearings.
Make sure the bearings are the correct way round when putting in the new unit like in image 5.
Step 6: With the bearings removed check the bearings condition and remove any dirt or old grease with a dry cloth from both bearings and
cups. Apply a thin even coverage to the bearing and inner cup lips, but not too much as it could result in the bearings becoming clogged. Now
install the bearings!
Step 7: Slide the forks back up into the head tube. IMPORTANT! Take care not to damage the bearings when doing this!
Step 8: Screw the lower nut back on first, followed by the top nut. Take care not to cross thread the nuts!
Now finally follow the Headset Adjustment instructions in this manual and you’re good to go!
To help maximize the life of your headset and keep it performing at it’s best, the inner bearings must be serviced. However they may still eventually
need replacing with a new unit. The following steps explain how to either service or replace the inner headset bearings.
1
2
a
2
b
4
4
b
3
5
6
7
8
Adult Assistance required!
