Hope Tech Top Crown - Manual

BOXXER or MARZOCCHI Forks TOP CROWN with INTEGRATED STEM - INSTRUCTIONS
Product specifications :
Replacement upper crown for : Boxxer forks all MY - Marzocchi 888 forks starting from MY2008 (
φ38mm stanchion)
Handlebar clamp diameter : φ31.8mm (oversize) only
Bar position : 50mm reach - 0mm stack
Before you start :
Warning : Don’t overestimate your technical capacities. This upper crown must be fitted by a competent cycle mechanic using the correct tools.
Incorrect installation could result in loss of steering control that could cause serious or fatal injuries.
This top crown with integrated stem is designed to be a straight replacement of the original upper crown. If everything is correct you shouldn’t have to cut the
steerer tube or use more or less headset spacers.
Ensure the steerer tube and handlebar clamp areas are both clean and dry (no grease!).
Remove all bolts from the crown and apply a small amount of grease to the threads and under the head of the bolt. Because all hardware is made of Titanium
alloy, it is preferable to use copper slip grease or Ti-Prep to avoid seizing.
Installation :
Remove the existing upper crown.
Slide Hope upper crown on steerer tube and stanchion tubes. Identically to the original upper crown, the
crown should sit, once installed, on top of all headset parts and spacers, so that the steerer tube is approxi-
mately 2 to 4mm below the top face of the crown or any spacer above the crown (this is to allow sufficient
adjustment of the headset to take place). Check that that everything is correct before continuing with the
installation. (see Figure A)
Install the top cap and compression bolt of the head doctor (or other adjustment device) as per
manufacturer’s specifications (typically preload the headset bearings until all play is removed but rotation is
still smooth).
Install the M5x16mm steerer tube pinch bolt and tighten it to 7-8Nm. (see Figure B)
Install the 2 stanchion tube M5x20mm pinch bolts and tighten them to 7-8Nm (see Figure B)
Install the handlebar and position the handlebar clamp making sure the etched logo on the front is facing
up and etching on the top is matching the one of the crown. Install the 2x M6x20mm top clamp bolts
(previously greased) and slightly tighten them.
When you are satisfied with the handlebar position, first tighten the 2 top clamp bolts to 9-10 Nm. Alternate
between the 2 bolts until torque setting is achieved and the top of the front plate is sitting flush against the
stem body. (see Figure C)
Install and tighten the 2x M6x20mm bottom clamp bolts to 9-10 Nm. Alternate between the 2 bolts until
torque setting is achieved. There should be an assembly gap between the front plate and the stem body. (see
Figure D and E)
Maintenance :
Periodically check the hardware for tightness. Be careful not to over-tighten the bolts !
Periodically regrease hardware using appropriate grease.
Regulary inspect all parts of the stem for damage and cracks, especially after any big crash !
Note :
All bolts used in the crown are Ti 6Al 4V and custom made for Hope. Do not use any lower strength bolts.
Do not use shorter bolt length than the one specified here. Full thread engagement is required.
Warranty :
All Hope Technology stems are covered for one year from original date of purchase against manufacturer defects in material and workmanship. Proof of
purchase is required. Products must be returned to the original place of purchase or to Hope Technology to process any warranty claim.
This warranty does not cover any damage caused through mis-use or failing to comply by the recommendations given in this manual.
This warranty does not affect your statutory rights.
Hope Technology, Calf Hall Road, Barnoldswick, Lancashire, BB18 5PX, United Kingdom Tel : 00 44 (0) 1282 851 200
Tools: 5mm allen key, 4mm allen key, torque wrench required.
Figure E
TOP
Assembly gap
Flush mount
Figure A
2
m
m4
-
Figure B
M5 x 20mm
7-8 Nm
M5 x 20mm
7-8 Nm
M5 x 16mm
7-8 Nm
Figure C M6 x 20mm
9-10 Nm
Logo
facing up
Figure D
M6 x 20mm
9-10 Nm
Issue1 05/2011