8/13/2019 How to Fit a New Fork

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HOW TO FITA NEW FORK

DIFFICULTY

TIME 1 hourCOST Depends on the forkPlugging in a new fork to the frontof your bike is far simpler than youmight think. Here’s how to do it…

07 Grease where the crown race will sit onthe fork. For a split crown race, slide itover the steerer tube, pressing it in place

at the bottom of the steerer. For a press-t crownrace, slide it over the steerer tube. Rest the fork ona solid surface and slide the crown race tter overthe steerer tube. Use a hammer to hit the crownrace tter until the crown race sits in place.

06 Place the crown race to one side. Hookyour thumb under the headset’s topbearing cover and remove it. Use both

rst ngers to ‘hook’ under the top bearing andremove it. Put all the parts safely to one side, inthe order they were removed. Clean each partcarefully with a rag, keeping them in the sameorder. You’re now ready to t the new fork.

08 Sit the headset bearings back into theframe ready to dry t the fork. Slide thefork up through the fully assembled

headset, then sit any stem height spacers ontothe fork, along with the stem. Pinch up one of thestem’s steerer clamp bolts if you need to, to holdit in place. Mark the line where the top of the stemsits with permanent marker on the steerer tube.

12 Apply a thin smearing of grease aroundthe internal faces of both headset cupsbefore reinserting the bearings. Once the

bearings are sat in the head tube, apply anotherthin smearing of grease to the outside of thebearing cartridges and to all parts of the headsetas you assemble it. Make sure that every part islocated correctly.

14 Your fork should now be sat securely inthe frame. Tighten the steerer clampbolts on the stem with an Allen key to the

manufacturers torque specication. The headsetshould turn freely. If it doesn’t, double check youhave all the headset parts located in the rightorder. Now t the brake adapter to the new fork,then loosely t the brake calliper to the adapter.

13 Slide the fork up through the headsetassembly, making sure all the headsetparts are in the right order. Wipe excess

grease from the top of the steerer tube, then slideon the stem height spacers and your stem. Fit theheadset top-cap, with a small amount of grease onthe bolt. Use a 5mm Allen key to nip the top capbolt up to nger tight.

01 When choosing a new fork, you needto make sure it’s compatible with yourframe and headset size. Also make sure it

will t your front wheel’s axle and that you have acompatible brake mount or brake. Once you haveyour new fork, clamp your bike in a workstand.

02 Remove your front wheel and use a 5mmAllen key to remove your brake calliperfrom its mount, or the fork. Remove

any cable guides or cut away any zipties thatare holding the brake hose to the fork. With thecalliper fully removed, wrap the brake back overthe handlebars so it hangs out of the way.

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8/13/2019 How to Fit a New Fork

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M A N U A L

1 Snips2 Flat-head screwdriver

3 Hacksaw4 Star-nut setter5 Saw guide6 Rags

7 Allen key set

8 Plastic mallet9 File10 Crown race puller11 Grease12 Permanent marker13 Crown race setter

Tools for the job Essential kit

04 Remove the stem by pulling it upwardsaway from the fork’s steerer tube. If it’sreluctant to move, twisting it can help.

Remove any stem height spacers and put themsafely to one side. Pull the fork downwards and outthrough the headset. If it’s reluctant to move, a tapwith a plastic mallet should get it going.

03 Use the appropriate Allen key to loosenthe stem’s steerer clamp bolts. Use a5mm Allen key to loosen the stem’s top

cap bolt, holding the fork in the head tube withyour other hand to stop it from dropping out ofthe frame. Loosen the stem cap bolt and removeit, taking the stem cap too.

05 Remove the lower headset bearing fromthe crown race if it’s fallen out of theheadset cup. The crown race should

now be visible. If it’s a split crown race, a twistingmotion in the split with a at-head screwdrivershould be enough to pop it off. If it doesn’t havea split in it, use a crown race puller to remove thecrown race from the fork’s steerer tube.

10 Fit the cutting guide into your vice.Slide the fork through the cutting guide,clamp-side rst, so the fork is clamped,

rather than the bit you cut off. Clamp the steerertube in the cutting guide so you can clearlysee your pen mark. With the hacksaw, cut justabove the line, erring on the side of caution.Check your measurements.

09 Double check the assembly beforeensuring you’ve marked the right spot.You can’t add steerer tube back on once

it’s been cut down! Alternatively, you can simplymeasure your old steerer tube. When you’rehappy with this, remove the stem and stem heightspacers, then pull the fork back through theheadset and remove it from the frame.

11 Use a le to remove any burrs or sharpedges from the top of the steerer tube. Fitthe star-nut to the setting tool and use a

hammer to hit the top of the tool, setting the star-nut around 15mm below the top of the steerer.Make sure there are no burrs left on the top of thesteerer tube and clean away any waste from thecutting from the fork.

16 Rock the bike forwards and backwardsholding the fork crown and lower headsetcup while checking for play. If there is

play in the headset, undo the stem clamp boltsthen turn the top cap bolt a quarter turn at a timeuntil there is no play left in the system. Retightenthe stem clamp bolts and do a nal check for play.

15 Fit the front wheel. Pull the front brakelever, locking the brake on. Now tighten thecalliper’s securing bolts. This should align

the calliper. Now spin the wheel – the brake shouldbe rub-free. If it’s rubbing, loosen the calliper’ssecuring bolts and repeat this step. Once thebrake is properly tted, remove the bike from theworkstand.

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W O R K S H O P W I S D O M

Replacing your fork iseasy, but make sure youdo it properly to avoiddamaging an expensivefork. Follow this guide andyou’ll be ne, but if youhave any problems, don’thesitate to get in touchwith your local bike shop toask for some help.If your headset is a bitworn, this is an ideal timeto service it. It’s worthmaking sure the bearings

are still running smoothlywhile they’re removedand clean too, and greasethem if you can.Once the new fork is tted,ride a couple of times andcheck the headset is stilltight – chances are it’llall bed in a bit. Take timesetting up the new fork too– it’s unlikely the bike willride the same as it did withthe old fork, so take it easyfor the rst few rides!

How to switch rimsOur 16-step guide will make it simpleON SALE 20 SEPTEMBERNEXT MONTH

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W O R K S H O P W I S D O M

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