K2 Bike Chubby - Manual (Page 6)

Step #5 - Decide where you want the upper triple clamp mounted.
The position of the upper triple clamp on the Chubby forks is somewhat flexible. You can place the upper triple clamp directly on top of the
headset, or you can space it up so that it clamps up higher on the stanchions. Remember: the position of the lower triple clamp is
FIXED, and should not be moved up or down. The steps below will show you how to mount the upper triple clamp properly in any location.
1. With the upper triple clamp temporarily installed, slide the stem (with handlebar attached) onto the steerer and
position it where you would like it. Tighten the stem cinch bolts and sit on the bike to check the handlebar
height. Do not ride the bike like this. You are only checking handlebar position now. Note: If you want a
lower stem position, the stanchion tubes will probably extend above the top of the upper triple clamp.
Make sure this is what you want before making any alterations to the steerer tube.
2. If you would prefer to have the top of the stanchion tubes flush with the top of the upper triple clamp, you will need
to place enough headset spacers on top of the headset in order to do so. Measure the amount of exposed stanchion
tube with the upper triple clamp installed directly on top of the headset. This is the amount of headset spacers you
will need.
3. Install the headset spacers and upper triple clamp into the desired position and tighten steerer clamp bolt to 85 in-lbs.
4. Insert the two spring stacks and preload adjusters into the stanchion tubes and tighten with the Chubby Wrench.
5. Tighten the remaining bolts on the upper clamp to 85in-lbs.
6. Rotate the fork and check for any binding or grinding in the headset. If the fork rotates smoothly, continue on to the
next step. If the fork binds or the headset feels rough, loosen the upper triple clamp and repeat step 3.
Step #6 - Install the star-fangled nut, stem, handlebar and brakes. That's it!
1. If you will want to cut the steerer tube, make sure that you have enough room for your stem. DO NOT cut
the steerer tube too short! Also, make sure the star-fangled nut is properly placed in the steerer tube
before you do any cutting.
2. Install the star-fangled nut into top of steerer tube 10 - 12mm from the upper surface with star fangled nut installa-
tion tool, if it is not installed already. Do not attempt to install the star-fangled nut without the proper tool.
3. When installing your stem, the distance between the top edge of the stem clamp must extend above the top of the
steerer tube 1-3mm. If the distance is incorrect, remove the stem and add or remove spacers on top of the upper
triple clamp to achieve a 1-3mm distance.
CAUTION: Assembly with the top of the stem extending more than 3mm above the top of the top of the
steerer tube can result in fork failure during use and severe injury.
4. Insert the Aheadset cap and screw through the top of the stem and into the star-fangled nut. Use the threadless
headset cap to adjust the headset as per the manufacturer's instructions. Remember: You will need to loosen all of
the upper triple clamp bolts and the stem clamp bolts to adjust the headset.
5. Tighten the two stem bolts to 90-120 in-lbs or refer to the stem manufacturer's torque specs for the stem. Install the
handlebar and brake / shifter controls. Position as desired and tighten all bolts to manufacturer's torque specification.
CAUTION: If the two steerer pinch bolts are not securely tightened, the stem may rotate or pull off of the
steerer tube, resulting in loss of control and severe injury.
CAUTION: All Chubby fork bolts should be tightened to the proper torque when installation is completed.
Failure to torque all bolts properly can result in failure during use and severe injury. Refer to Maintenance:
Service Table for all torque, lubrication, and Loc-tite specifications for all Chubby bolts.
Option 2
Option 1
!
!
Proper Star-Fangled
Nut Installation
10-12mm
!
Proper Stem
Installation
1-3mm
5