Crown Race Installation
Use a fork crown race tool such Park Tool CRS-1 or similar to seat
the crown race.
See http://www.parktool.com/tools/CRS_
1.shtml.
To aid installation of the crown race, you may apply a
small bit of bicycle bearing grease to the race area only. Do not
make any modifications to the fork crown or race. Do not rest the
fork on the dropouts when installing.
The applied force can crack
or smash the dropouts making the fork unsafe to ride. Hand
hold the fork by the legs close to the crown when seating the
race. Make sure the crown race is seated completely.
Cutting the Steerer Tube
1. With the headset already installed in the frame, insert the
fork to establish stem height.
MAXIMUM
STACK HEIGHT
ALLOY STEERER
CARBON STEERER
50mm
40mm
Exceeding this height will place excessive stress on the
steerer tube with risk of fork failure.
DO NOT USE SPACERS BETWEEN THE TOP OF THE STEM AND
TOP CAP.
2. With the stem height set, make a mark on the steerer tube
at the top of the stem. Remove the fork and make another
mark 2-3 mm below it. See page 3. Double check the
measurement and cut the steerer at the lower mark. The
resulting length should result in the steerer tube no more
than 2-3 mm below the top of the stem.
· When cutting the steerer, use a cutting jig such as Park Tool
SG-6. See http://www.parktool.com/tools/SG_6.shtml. Do
not clamp steerer tube directly in vice jaws and or cut the
steerer free hand. Vice jaws can crack or damage the surface
of the steerer. A jig will produce a straight cut, which is very
important. Locate the jig on the end of the steerer tube you
will be cutting off. This will avoid placing a clamping force on
the steerer tube which could produces cracks.
Alternatively, you can clamp the steerer in grooved wooden
blocks positioned in vice. Do not over-tighten the vice.
· Use a hacksaw blade for composites (tungsten carbide
gritted) or a very fine toothed (36 toothed) new blade. To
minimize fraying of the carbon fibers, wrap the area of cut
with masking tape.
· Make only one clean complete cut. Do not scratch, score,
or mark the steerer tube surface other than the complete
cut. Scratching, scoring or making other marks on the tube
surfaces other than the complete cut, or cutting the steerer
tube to an incorrect length for a specific stem/headset can
compromise the strength of the steerer tube.
After the steerer tube is cut, round the cut edges smooth and
remove any burrs with very fine sand paper less than 200
grit, 220 is ideal).
· Remove the fork from the bike head tube to cut it.
Surface Inspection of Stem, and Headset Parts
Burrs or sharp edges on components (stem, race, top cap) in
contact with the fork steerer tube outer surface can create
serious damage to the fork.
· Inspect all parts (head tube, fork crown race, other headset
parts, and stem surfaces; eliminate any burrs and sharp edges
by rounding them with fine grit sandpaper (220 is ideal).
WARNING
IMPROPER FORK SERVICE OR ASSEMBLY CAN RESULT IN
FAILURE LEADING TO AN ACCIDENT.
Any fork which is incorrectly prepared, serviced, or installed can
fail (come apart, break, crack, loosen) while it is being ridden
causing the rider to have a serious accident.
The following actions WILL RESULT IN SEVERE DAMAGE:
· Modifying the fork or installing parts into
the fork not specified by Cannondale.
· Cutting the fork steerer tube with the wrong tool,
scratching, scoring or making other marks on the tube
surfaces other than the complete cut, or cutting the steerer
tube to an incorrect length for a specific stem/headset.
· Scoring or scratching the steerer tube during
installation of the fork or headset parts. Scratches
and/or scores to the fork surfaces can result in stress
risers. This can result in fork failure while riding.
· Resting the fork on the dropouts when installing
the star nut, headset crown race or top cap. The
applied force can crack or smash the dropouts.
Contact Cannondale Technical Support if you have any questions
about the proper installation and service of Cannondale forks.
See contact information on page 1.
YOU OR YOUR CUSTOMER CAN BE SEVERELY INJURED, PARALYZED OR
KILLED IN AN ACCIDENT IF YOU IGNORE THIS WARNING.
