INSTALLING THE 40

You can also view a Flash video of the 40 Installation.

The 40 is available in two upper crown sizes to cover the varying range of headset tube dimensions. Measure the total stack height (see the figure below) to determine the proper upper crown size.

For total stack heights of 90 – 165 mm, your 40 should have the SMALL-LARGE UPPER CROWN.

For total stack heights of 165 – 181 mm, your 40 should have the EXTRA LARGE UPPER CROWN.

 

Have a qualified bicycle mechanic install the 40. Improperly installed forks are dangerous and can cause loss of control and serious or fatal injuries. The 40 is assembled with the lower crown set to 176.4mm below the top of the upper tubes. The lower crown position is set to allow a 6mm clearance between the bottom of the crown and the top of a 2.80" tire when bottomed out. Do not change the position of the lower crown.

 

  1. Remove fork and install crown race:

    1. Place the bicycle in a repair stand.

    2. Remove the existing fork from the bicycle.

    3. Remove the crown race from the old fork with a crown race removal tool and install it with a crown race setter tool onto the new 40. The crown race must be firmly seated against the top surface of the lower crown.

If the steerer has any nicks or gouges, the crown/steerer assembly must be replaced. A nick or gouge can cause the steerer to fail prematurely, which can cause loss of control of the bicycle resulting in serious or fatal injuries.

  1. Cut steerer to proper length:

    1. Install the fork on the bicycle with all of the headset parts and upper crown. The deep pocketed side of the upper crown faces downward on the bicycle.

    2. After eliminating play in the headset, lightly tighten the steerer pinch bolt on the upper crown with a 5mm hex wrench.

    3. Install the headset spacers (not required) and stem on the steerer and lightly tighten the stem pinch bolt(s).

    4. Mark the steerer with a scribe at the top edge of the stem.

    5. Remove the 40 from the bicycle and cut the steerer 3mm below the scribed mark. This 3mm clearance allows room for the stem cap to lightly tension the headset and eliminate any play.

    6. Use a flat file to deburr the outer and inner top edges of the newly cut steerer.

  2. Install star-fangled nut and steering stop bumpers:

    1. With a star-fangled nut installation tool, install the star-fangled nut into the steerer to the proper depth (see Star-fangled nut installation depth diagram below).

    2. Install one steering stop bumper onto each uppertube and place midway on the uppertube.

Star-fangled nut installation depth
  1. Installing fork onto bicycle:

    1. Install the 40 on the bicycle with all of the headset parts and upper crown.

    2. Install stem, stem cap and M6 stem cap bolt.

    3. With all three upper crown bolts loosened, lightly tighten the headset stem cap bolt to remove play in the system so that it turns freely without drag.

    4. With a 5mm hex key socket and torque wrench, torque all three upper crown bolts (see figure below) to 65 in-lb.

    5. Check that the torque on the four lower crown bolts (see figure below) is at 65 in-lb. Do not over-torque the pinch bolts. Over-torquing can damage the bolt(s), fracture the crown or damage the threads, and can cause failure of the fork and loss of control with serious or fatal injuries.

Tire Sizes

  1. The 40 will accept tire sizes up to 2.80 inches wide. Any tire larger than 26 x 2.60 must be checked for clearance using the following method.

Determining correct tire size
    1. With the tire installed and inflated on the rim, measure the following three dimensions:

Maximum Peak Tire Diameter = 694 mm = 27.3 inch

Maximum Edge Tire Diameter = 670 mm = 26.41 inch

Maximum Tire Width =   71 mm = 2.80 inch

Do not use a tire if any measurement exceeds the maximum dimensions shown above. Using larger tires is not recommended and can cause serious or fatal injuries.

  1. Installing the front wheel:

    1. Loosen the 4 axle pinch bolts on the lower leg with a 5mm hex key wrench.

    2. Using a 5mm hex key wrench, turn counterclockwise to loosen and remove the axle.

    3. Install the front wheel into the dropouts and install the axle into the lower leg.

    4. Using a 5mm hex key wrench, turn clockwise and lightly tighten and torque the axle to the lower leg to 19 in-lb (215 N-cm).

    5. Torque the two left side dropout pinch-bolts to 19 in-lb (215 N-cm).

    6. Compress the fork on the bike a couple of times to let the right side of the dropout float and settle to its low-friction point. Torque the two right side dropout pinch-bolts to 19 in-lb (215 N-cm).

  2. Setting handlebars straight and torquing stem bolts:

    1. Set the bike on the ground and sit on your bike to set the handlebars straight relative to the front wheel.

    2. Tighten the stem pinch bolts and torque fasteners according to the stem manufacturer's specifications.

    3. Check that the handlebar pinch bolts are torqued to the stem manufacturer's specifications.

  3. Adjusting position of the steering stop bumpers:

    1. Adjust the height and angle of the steering stop bumpers on the upper tubes so that you have the maximum turning angle, and protect your frame and upper tubes from denting during a crash.

    2. Depending on the shape and size of the frame tubes, you may need to use the tall part of the bumper to contact the frame tubes (see figure below).

Disc Brake Installation

The 40 is designed only for use with DH disc brakes with disc rotor sizes of 200 – 225 mm. The 40 can use DH mechanical or hydraulic brake systems.

Never modify the lower leg or use cantilever rim brakes.

The 40 disc bolt pattern uses:

- XC Caliper

- XC Caliper Mount for International XC mount pattern

- DH Size Rotor (200 – 225 mm outside diameter)

  1. Install DH disc brake system according to disc brake manufacturer's specifications.

  2. Be sure to torque all fasteners and bolts to manufacturer's recommendations. Consult the instructions that came with your disc brakes for proper installation procedures. It is recommended that NEW disc brake pads be installed to ensure proper alignment and to minimize drag.

  3. Test brakes for proper operation on flat land before hitting the trails.

  4. Route the disc brake hose (for hydraulic disc brakes) or brake cable housing (for mechanical disc brakes) from the caliper to the inside of the lower leg and through the supplied disc brake hose guide as shown in the figure below.

  5. Assemble the supplied disc brake hose guide parts as shown in the figure below.

  6. Tighten the disc brake hose guide screw with a 2.5 mm-hex key wrench and torque to 8 in-lb (90 N-cm).

 

 

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