WINWOOD Carbon Fiber Fork Installation Instructions

Please read all instructions thoroughly before proceeding with this installation. If you do not understand the instructions or possess the skills or tools to perform this installation, do not attempt it. Incorrect installation can cause product failure resulting in injury or death. We recommend that installation of this fork be done by a professional bicycle mechanic. FORK INSTALLATION (ALL

FORKS WITH CARBON FIBER STEERER TUBES)

1. Make sure you have the correct headset to work with our fork. Our 1" steerer threadless carbon fork requires a 1" threadless headset with a 26.4mm crown race. This is by far the most common size, but be sure to check your headset for compatibility. Our 1 -1/8" steerer threadless carbon fork requires a 1-1/8" threadless headset with a 30.0mm crown race, the only size that is available and compatible. 2. Install the headset cups into the frame according to the headset manufacturer's instructions. Holding the fork in one hand, install the headset's fork crown race onto the fork race seat with a headset crown race setting tool. Take care not to install the crown race with the fork dropouts resting on the floor or any other hard surface... you will damage the fork, rendering it unsafe and dangerous or deadly to ride. Now assemble the bottom half of the headset according to the manufacturer's instructions and insert the fork steerer into the headtube. Install the top half of the headset according to the manufacturer's instructions. Install any and all desired stack spacers, not to exceed 25mm of spacers. 3. The Winwood carbon fork with carbon steerer must be used with a circumferential clamp style stem. Use of a pinch clamp or wedge clamp style stem may cause damage to the carbon steerer tube, which may lead to fork failure and rider injury or death. Before installing the stem onto to the steerer, check the inside of the stem's steererclamping surface for burrs or sharp edges, which may damage the steerer tube. A scratch on a carbon steerer even a small one - could cause failure and injury or death. Once you've verified that you have the right type of stem and that it is clean and free from any sharp edges or burrs, install the stem on the steerer and slide it down to seat it firmly against the spacers or top of the headset. Gently tighten the stem's steerer clamp bolt(s) just enough to hold the assembly in place. 4. Mark the steerer tube where it pokes out the top edge of the stem. Remove the stem from the steerer and the fork from the bike, and then re-mark the steerer tube 3mm below the first mark. This will be your cutting mark. 5. Using a hacksaw with a fresh, fine-toothed metal-cutting blade or a composite-cutting blade, slowly and carefully begin cutting the steerer on the cutting mark. The use of a steerer tube-cutting guide is strongly recommended to ensure a square cut. Let the saw do the work; do not force the blade down into the material. Particularly near the end of your cut, slow down and be careful not to exert any pressure on the steerer that would cause the carbon fibers to come unraveled. 6. Using a fine file or sandpaper (100-200 grit), carefully remove any burrs on the freshly cut edge of the steerer tube. 7. Reinstall the fork/headset/stem assembly and again gently tighten the stem's steerer clamp bolt(s) just enough to hold the assembly in place. 8. Prepare the compression plug. The compression plug delivered with this fork is intended to replace the top cap, bolt, and star nut typically used and delivered with threadless headsets. Do not use a star nut with this fork. Installing a star nut can result in failure of the fork and serious injury or death to the rider. Only use a compression plug like the one delivered with this fork that has been designed to not scratch or score the inside of the steerer tube. To prepare the compression plug, turn the top cap by hand counter-clockwise until the cap threads become visible. Now, using a 5mm hex key, turn the expander bolt counter-clockwise until the expander ring is at its smallest diameter. 9. Insert the compression plug into the fork steerer, until the top cap is flush against the top of the stem. Using a 5mm hex key, turn the expander bolt clockwise until the expander ring tightens firmly against the inner diameter of the steerer tube. DO NOT OVERTIGHTEN. 10. Loosen the stem's steerer clamp bolt(s). 11. Using a 6mm hex key, turn the top cap clockwise until the desired amount of headset preload is attained, according to the headset manufacturer's instructions. 12. Attach the front wheel to the fork, and align the stem with the front wheel. Tighten the stem's steerer clamp bolts to the stem manufacturer's specifications. If the stem can be twisted around the steerer, after the stem bolts have been tightened, the stem is not tight enough. Repeat steps above as necessary to achieve proper headset adjustment, stem alignment, and stem tightness. Inspect the fork for damage before every ride.

FORK INSTALLATION

(ALL FORKS WITH STEEL OR ALUMINUM STEERER TUBES)

1. Make sure you have the correct headset to work with our fork. Our 1" steerer threadless carbon fork requires a 1" threadless headset with a 26.4mm crown race. This is by far the most common size, but be sure to check your headset for compatibility. Our 1 -1/8" steerer threadless carbon fork requires a 1-1/8" threadless headset with a 30.0mm crown race, the only size that is available and compatible. 2. Install the headset cups into the frame according to the headset manufacturer's instructions. Holding the fork in one hand, install the headset's fork crown race onto the fork race seat with a headset crown race setting tool. Take care not to install the crown race with the fork dropouts resting on the floor or any other hard surface you will damage the

fork, rendering it unsafe and dangerous or deadly to ride. Now assemble the bottom half of the headset according to the manufacturer's instructions and insert the fork steerer into the headtube. Install the top half of the headset according to the manufacturer's instructions. Install any and all desired stack spacers, not to exceed 25mm of spacers. 3. Inspect your stem to make sure the steerer clamp area is clean and free from burrs. Install the stem on the steerer and slide it down to seat it firmly against the spacers or top of the headset. Gently tighten the stem's steerer clamp bolt(s) just enough to hold the assembly in place. 4. Mark the steerer tube where it pokes out the top edge of the stem. Remove the stem from the steerer and the fork from the bike, and then re-mark the steerer tube 3mm below the first mark. This will be your cutting mark. 5. Using a hacksaw with a fine-toothed metal-cutting blade, begin cutting the steerer on the cutting mark. The use of a steerer tube-cutting guide is strongly recommended to ensure a square cut. Using a file, remove any burrs on the freshly cut edge of the steerer tube. 6. Install the star nut supplied with your headset into the steerer tube per the manufacturer's instructions. Take care not to install the star nut with the fork dropouts resting on the floor or any other hard surface... you will damage the fork, rendering it unsafe and dangerous or deadly to ride. 7. Reinstall the fork/headset/stem assembly and tighten the stem's steerer clamp bolt(s) enough to hold the assembly in place. 8. Install the top cap and bolt supplied with your headset per the manufacturer's instructions. Loosen the stem's steerer clamp bolt(s), and preload the top cap to attain proper headset adjustment in accordance with the headset manufacturer's instructions. 9. Attach the front wheel to the fork, and align the stem with the front wheel. Tighten the stem's steerer clamp bolts to the stem manufacturer's specifications. If the stem can be twisted around the steerer, after the stem bolts have been tightened, the stem is not tight enough. Repeat steps above as necessary to achieve proper headset adjustment, stem alignment, and stem tightness. Inspect the fork for damage before every ride. BRAKE INSTALLATION (ROAD FORKS ONLY) 1. We have provided a brake fixing nut with all Winwood road forks that is longer than that delivered with most caliper brakes to accommodate the extra width of our fork crown. 2. Insert the caliper brake stud into the brake-mounting hole. Insert the provided long brake nut into the back of the fork, and thread it onto the brake caliper stud. Tighten the brake nut according to the brake manufacturer's specifications. Note: It may be necessary to insert a washer between the fork and the brake caliper to provide clearance between the fork legs and the rear portion of the brake pads.

Limited 2 Year Warranty:

This Winwood product is warranted against defects in materials and workmanship for two (2) years, from the original date of retail purchase by the consumer, subject to the limitations detailed below. This limited warranty is expressly limited to the repair or replacement of the original product, at the option of Winwood, and is the sole remedy of the warranty. This limited warranty applies only to the original purchaser of the Winwood product and is not transferable. In no event shall Winwood be liable for any loss, inconvenience or damage, whether direct, incidental or consequential or otherwise resulting from breach of any express or implied warranty or condition, of merchantability, fitness for a particular purpose, or otherwise with respect to this product except as set forth herein. This warranty does not cover the following: Damage due to improper assembly or follow-up maintenance or lack of skill, competence or experience of the user. Products that have been modified, neglected, used in competition or for commercial purposes, misused or abused, involved in accidents or anything other than normal use. Damage or deterioration to the surface finish, aesthetics or appearance of the product. Normal wear and tear. Labor required to remove and/or refit and re-adjust the product within the bicycle assembly. This warranty gives the consumer specific legal rights, and those rights and other rights may vary from state to state. Contact Us: Winwood 6400 W. 105th St. Bloomington, MN 55438 888.255.6922 www.qbp.com