K2 Bike Chubby - Manual (Page 4)

Frame Preparation
Proper frame preparation will make installing your new Noleen Chubby fork easier and allow your fork to function properly.
Notes : All Noleen suspension forks require the use of a threadless headset, such as a Dia-Compe Aheadset. If you do not have a
threadless headset, you will need to install one before you install your new Noleen fork.
1. Remove the old stem and fork from your bicycle. If you are installing the Noleen fork on a new frame that has never
had a fork installed, move on to the next step.
2. In order for the headset on your frame to function properly, the ends of the headtube should be perpendicular to the
sides of the headtube. Some headtubes need to be “faced” in order to hold the headset cups properly. If you believe
that your headtube needs to be faced, consult your local K2 Bike / Noleen dealer or other qualified bicycle dealer.
3. Lubricate the inside of the frame's headtube as well as the headset cups and press the upper and lower headset cups
into your frame. Make sure that the headtube and headset cups are free of dirt and grime.
NOTE: Headset cups should be installed using a headset press. Do not substitute this tool for anything else. See your local Noleen
dealer for assistance installing headset cups. Damage to the frame and/or headset can occur if not installed properly.
Fork Preparation / Installation - 6 Easy Steps!
Once you have a properly prepared frame, you can now install your Noleen fork. While your Noleen Chubby has been assembled with care at the
factory, partial disassembly and reassembly is required for mounting. Follow these steps:
Step #1 - Remove the Upper Triple Clamp from the fork.
1. Loosen the three bolts on the upper triple clamp.
2. Using the Chubby Wrench (preload adjuster removal tool), loosen and remove the preload adjusters and spring stack.
2. Slide the upper triple clamp off of the top of the fork.
Step #2 - Check the ”Critical Measurement“ for the Chubby / Chubby LT.
CAUTION: The lower triple clamp on the Chubby and Chubby LT must remain a certain distance above the
front tire. The Chubby needs this amount of room allow the suspension to compress fully without the tire
striking the lower triple clamp. Improper fork installation could result in a loss of control and severe injury.
As stated in the caution above, the Chubby needs this amount of room allow the suspension to compress fully without the tire
striking the lower triple clamp. This measurement is different for the two Chubby forks. This measurement DOES NOT change for the different
sizes of each fork model. This measurement should be taken from the middle of the dropout (or the middle of the front hub axle) to the
bottom of the lower triple clamp. We call this measurement the “Critical Measurement.” See below for the Critical Measurement for
the Chubby and Chubby LT forks.
Dim A: Chubby (both Standard and Long sizes) = 4 4 2 m m
Chubby LT (both Standard and Long sizes) = 4 6 7 m m
Follow these instructions to set the ”Critical Measurement“ on your Chubby or Chubby LT:
1. Using a tape measure or ruler, measure the distance from the center of the fork dropout to the bottom of
the lower triple clamp.
2. Check this measurement against the ”Critical Measurement“ above.
3. Loosen the two bolts on the lower triple clamp and slide the triple clamp up or down so that both sides
are set to the ”Critical Measurement.“ Torque all of the lower triple clamp bolts to 85 in-lbs.
INSTALLATION
In this section:
• Frame Preparation
• Fork Preparation /
Installation
!
Dim A
”Critical Measurement“
Dim A
Remove Upper
Triple Clamp
3