Part Number 281540 Fork Owner's Manual Fork owner's Manual read this Manual beFore you ride Please read this instruction manual thoroughly before using your new fork; it contains important safety and maintenance information. Also check our web site for further information or updates. If you do not understand the information, or you have a question about your fork that this manual does not cover, consult your Bontrager dealer. If you have a question or problem that your Bontrager dealer can't handle, contact us at: Bontrager Components 920.478.4678 Attn: Customer Service http://www.bontrager.com 801 W. Madison Street Waterloo, Wisconsin 53594 in this manual, the safety alert symbol is used to alert you to potential personal injury hazards. obey all safety messages that follow this symbol to avoid possible injury or death. 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 remove the existing fork ....................................................... 6 To prepare the new fork for installation .................................... 6 To install the new fork ............................................................... 6 Bontrager limited warranty ............................................................ 8 Carbon crash replacement policy.................................................... 8 i Conditions for use Each model of Bontrager fork is intended to be used in a specific set of conditions. Riding a Bontrager fork in a manner other than its intended use can cause the fork to fail. Determine the type of Bontrager fork you have purchased, and avoid conditions beyond the intent of your fork, as listed below: use Condition Riding on a paved surface where the tires do not lose ground contact bontrager fork type Forks with caliper-type brake mounts (only) For riding on pavement only Condition plus smooth gravel roads and improved trails with moderate 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 improved paths and roadways only No jumping Conditions and 2 plus rough trails, small obstacles, and smooth technical areas, including areas where momentary loss of tire contact with the ground may occur. not jumping. For riding on unimproved trails with small obstacles Forks for 26" or 29" wheels Conditions , 2, and 3 plus rough technical areas, moderately sized obstacles, and small jumps. none For riding on rough trails with medium obstacles For extreme riding Jumping, hucking, high speeds, or aggressive riding on rougher surfaces, or landing on flat surfaces. This type of riding is extremely hazardous and puts unpredictable forces on a bicycle which may overload the frame, fork, or parts. none User caution advised beFore every ride: CheCklist Before every ride, follow this check list to inspect the fork and its connected parts: the headset, stem, and front wheel. If any part of the bicycle fails the inspection, repair the bicycle by following the information provided by us or take it to your dealer for service. Never ride a bike with a damaged part; have it replaced. This is not a comprehensive maintenance program. q Check the headset q Check the stem q Check that the wheel is properly attached q Check the fork for fatigue or impact damage 1. Apply the front brake firmly while you rock the bicycle forward and backward. 2. With the front wheel off the ground, slowly rotate the fork and handlebar to the right and left. If the headset bearings rock in the frame or do not turn smoothly, do not ride the bicycle; take the bike to your dealer for service. Adjustment of headset bearings requires special tools and training, so these services should only be performed by your dealer. 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 tighten the stem. If the stem attachment still fails the test, take your bike to your dealer for service. Test for proper wheel attachment. Pick up the bike, and sharply hit the top of the tire. The wheel must not come off, be loose, or move from side to side. If the wheel fails this test, re-attach the wheel by following the instructions in your bicycle or wheelset owner's manual. If the wheel still fails the test, take your bike to your dealer for service. Before and after each ride, carefully inspect your fork for signs of impact or fatigue stress: · Dents · Cracks · Scratches · Deformation · Discoloration · Noise 3 q Check the headset 3 q Check the stem 3 q Check that the wheel is properly attached 3 q Check the fork for fatigue or impact damage 2 warninG a damaged carbon fiber part can fail suddenly, causing serious injury or death. inspect a carbon fiber bicycle or parts for damage frequently. if you suspect a carbon fiber part is damaged, immediately stop riding the bicycle. before riding, replace the part or take the bike to your dealer for service. Even if you perform regular inspections, if you exceed the limit of strength of a given part, it may fail if overloaded. After any high force load, thoroughly inspect all the parts of your bike. High force loads include crashes, but you don't have to crash to put a high force load on your bike. For example, hitting a large hole in the road or a sharp bump such as a railroad track can put large forces on your bike. The manner in which you ride will determine whether your bike and its parts will last. If you ride hard or aggressively, you should replace the bike and/or its parts more often than riders who ride smoothly or cautiously. When evaluating your use of the fork, there are many variables: weight, speed, technique, terrain, maintenance, riding environment (humidity, salinity, temperature, etc.), and the frame or part itself--so it is impossible to give a precise timetable for replacement. But as a rule, it is better to err on the safe side and replace the bike or parts more frequently. If you aren't sure, ask your dealer. Carbon fiber composite inspection procedures Carbon fiber is among the strongest materials used in bicycle manufacture. 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. Use the following procedures to inspect carbon fiber parts: · Check for scratches, gouges, or other surface problems. · Check the part for loss of rigidity. · Check the part for delamination. · Listen for unusual creaking or clicking noises. These tests may not be conclusive. The tests are difficult to describe, so as an aid to describing the tests we provide a movie of inspecting a carbon fiber part in the owner's manual section of the Bontrager web site. If you have any doubts about the integrity of a part, do not ride the bicycle. 3 saFety requireMents use a front brake WARNING! Failure to follow the following requirements may result in failure of the fork resulting in serious personal injury or death. For some models, the brake bolt goes through both the carbon fork crown and the aluminum steerer. In the event of a frontal impact, the brake bolt functions as a key part of the impact absorption function; do not ride without a brake bolt through the fork crown and make sure the brake bolt is properly tightened. Do not overtighten the brake attachment bolt. The maximum torque for the brake bolt is 70-85 lb·in (7.9-9.6 N·m). use a proper stem design and installation The stem has several design requirements, which if not fulfilled, could damage the fork and cause it to break: A · Do not use a stem with a wedge-type steerer clamp (Figure 1), except for a Bontrager King Earl stem, which has a special design that will not damage forks. Improper clamp design can deform the steerer, adding to fatigue stress. · Always use at least two spacers between the B stem and headset. If the stem sits directly against the headset, any fatigue stress will be concentrated in a small area, which may damage the steerer. Figure - Stem clamp de· Never use more than 40mm of spacers signs under the stem. Additional spacers create A: pinch clamp more stress on the steerer, which could B: wedge clamp 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. use a proper headset configuration Make sure the headset is the correct size and that the lower crown race has a generous radius to the lower edge where it contacts the fork (Figure 2). A crown race where the lower, inside edge of the crown race is sharp and more square may not seat correctly against the fork crown, or may require excessive force to install. If the crown race does not go onto the fork with normal force, use a headset with the correct design. Do not alter the fork to fit the crown race. use the proper size of disc brake rotor For Bontrager forks equipped for disc brakes, the fork should only be used with road-size rotors: 165mm, 6", or smaller. Larger rotors place greater force on the fork and could cause damage or cause the fork to break. Figure 2- Proper shape for lower inside corner of crown race 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 adjustments 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. 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. to inspect the fork 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. 5 installation instruCtions The correct installation of your new Bontrager fork is critical to your safety, so this work should be performed only by an experienced mechanic. The installation portion of these instructions is written for an experienced mechanic. If you are not sure of your ability to correctly install this fork, have the fork installed by your Bontrager dealer. Changing the forks on your bicycle could alter the steering of the bicycle. Before installing t ...