Current Fork Install

Objective: To install the Current Fork.

Equipment Needed:

1. 2.5mm hex wrench
2. 4mm hex wrench
3. 5mm hex wrench
4. 6mm hex wrench
5. Pipe cutter/ Reamer
6. Mallet
7. Star nut setter
8. Torque wrench

1. Remove the Front Wheel 

   1. With the bike in a repair stand, use a 6mm hex wrench to loosen and remove the front thru axle. Remove the front wheel from the fork. 

      

   2. Insert a clean brake pad spacer into the caliper. 
       
2. Remove the Front Brake Caliper

   1. Use a 5mm hex wrench to loosen and remove the 2 brake caliper bolts. Remove the caliper. 

      

   2. Use a 5mm hex wrench to loosen and remove the 2 brake caliper adapter bolts. Remove the adapter. 

      

   3. Use a 2.5mm hex to remove the front brake hose clamp, release the brake hose, and then replace the hose clamp on the fork.

      

3. Remove the Stem

   1. Use a 4mm hex wrench to loosen the two stem clamping bolts. Then use a 4mm hex wrench to loosen and remove the top cap and headset spacer. 

      

      

   2. Hold the fork with one hand and wiggle the stem up and off the of the steerer tube.

      

4. Remove the Fork

   1. Lift off the headset spacers, upper headset dust cap, and the compression ring.

      

   2. Lower the fork out of the headtube of the bike. 

      

   3. Carefully remove the crown race from the fork. 

      

5. Swap the Fork 

   

6. Install the Fork

   1. Install the crown race onto the new fork. Align the opening in the ring towards the back of the fork. Note: Ensure the fork steerer tube is cut the same length as the old fork. Install a new star nut using a star nut setter tool. Use a reamer to smooth the edges on the top end of the steerer tube. 

      

   2. Guide the new fork back into the headtube of the bike. Replace the compression ring, dust cover, and the headset spacers.

      

      

   3. Reinstall the stem followed by the last headset spacer and the top cap. Use a 4mm hex wrench to tighten the top cap assembly. Torque to 5-7Nm.

      

      

   4. Use a 2.5mm hex wrench to remove the brake hose clamp. Capture the front brake hose and reinstall the hose clamp onto the fork.

      

7.  Install the Front Brake Caliper

   1. Reinstall the front brake caliper adapter using a 5mm hex wrench. Ensure the arrow on the adapter is facing upward. Torque to 9-12Nm.

      

   2. Install the brake caliper and onto the adapter using a 5mm hex wrench to thread in both bolts. Do not tighten them fully.  

      

   3. Remove the pad spacer from the front brake caliper. Ensure the front brake hose is routed as shown. 

      

8. Install the Front Wheel

   1. Apply grease to the front thru axle threads. Install the front wheel into the fork and ensure the front brake rotor goes in between the brake pads in the caliper. Install the thru axle and tighten it using a 6mm hex wrench. Torque the front axle to 9-13.5Nm. 

      

   2. Look through the window of the brake caliper and align the brake rotor evenly between the brake pads. Tighten the caliper bolts in place to secure the adjustment. Torque the front caliper bolts to 9-12Nm.

      

   3. Align the handlebar even with the forward facing wheel. Use a 4mm hex wrench to tighten the stem clamping bolts to secure the adjustment. Alternate tightening the two clamping bolts until both reach a final torque of 10Nm.

      

   4. Be sure to set the fork's adjustments and air pressure to rider preference.