Crown race setting tool
Hacksaw with carbide cutting blade
Steerer tube cutting guide
Torque wrench with 4, 5, 6mm hex bits
100 grit sandpaper
Marking tool (pencil, fine tip marker)
- Install crown race: apply a small amount of grease to the crown race seat area. Hold the fork in one hand and use a crown race setting tool and a hammer/mallet to install the crown race onto the steerer tube, following the manufacturer’s instructions.
- Install the headset cups in the headtube following the headset manufacturer’s instructions.
- Install the lower headset assembly and insert the fork into the headtube. Install the upper headset assembly.
- Add spacers to the steerer tube. Ensure the total spacer stack does not exceed 40mm.
Install the stem onto the steerer tube.
• Warning: Do not use wedge-clamp style stems on carbon steerers.
- Add up to 10mm of spacers above the stem, and mark the steerer tube on the top edge of the spacer.
- Remove the fork from the headtube and set aside the headset assembly and spacers.
- Measure 3mm down from the mark you made on the steerer tube and make a new mark. This is where you will cut.
- Double check your measurements to make sure the steerer tube will not be cut too short.
- Use the cutting guide and a hacksaw to cut the steerer tube.
- Remove burrs and sharp edges with sandpaper.
- Clean the steerer tube and the inside of the stem clamp with isopropyl alcohol.
- Place the compression plug into the top of the steerer tube and tighten with a 6mm hex bit to 6-8Nm.
Re-install the fork, headset, spacers, and stem into the headtube. Torque stem bolts to 5-6 Nm.
• Warning: Do not apply grease or carbon assembly compound to the interface between the stem and the steerer tube.
- Install the handlebar, following manufacturer’s instructions.
Install the wheel onto the fork and tighten the axle to the manufacturer’s torque spec. (15Nm on 15mm axles, 12Nm on 12mm axles).
• Warning: There must be at least 6mm clearance between the tire, wheel, and any element of the fork or other components. Improper clearance can cause a crash resulting in serious injury.
• Warning: Failure to properly adjust the thru-axle to secure the wheel can result in serious injury.
- Align the handlebar perpendicular to the front wheel. Tighten the stem cap bolt to the manufacturer's spec using a torque wrench and hex bit.
Tighten stem clamp bolts to manufacturer’s spec. Do not exceed 6Nm.
• Warning: Failure to properly install the handlebar and stem can result in serious injury.
Install and adjust the front brake following the brake manufacturer’s instructions.
• Warning: Failure to properly install and adjust brakes can result in serious injury.
Flip Chip System:
The swappable machined dropouts allow this fork to be native for post mount or flat mount. Add the fork to a drop bar bike with flat mount brakes or to a mountain bike with post mount brakes. Best of all, when the flip chip is changed to alter offset, the brakes won’t need to be adjusted because they are mounted to the same machined aluminum dropout.
Note: For Flat Mount, the rotor size is +20mm from what is listed on your brake caliper's mounting bracket. For example, if you are using a Flat Mount caliper bracket in the position marked 140mm, you would use a 160mm rotor on this fork.
- Remove the axle and wheel.
- Thread the axle into the threaded chip from the outside. Holding the left fork leg, pull the axle to remove the flip chip from the fork.
- Loosen the M6 bolt with a 5mm hex wrench. Slide the brake mount dropout to the desired position, and reinstall the flip chip. Torque the M6 bolt to 10Nm.
- Holding the right fork leg, use a 5mm hex wrench to push through the hex hole in the unthreaded flip chip and press out the dropout from the fork.
- Replace the right dropout in the desired position, and reinstall the flip chip.
- Reinstall wheel and axle. Torque axle to 15Nm.
Routine Fork Inspection and Ongoing Maintenance:
Every bicycle component has a finite life. Normal wear and tear, impact, careless use, and neglect of routine maintenance can cause an unexpected failure resulting in serious injury. Before each ride, examine your bicycle for signs of wear, stress, or impact related damage. If a component doesn’t operate properly or you detect scratches, cracks, bending, fraying, or discoloration, or notice creaking sounds, have your bicycle inspected immediately by your dealer.
Other than cutting the steerer tube to the proper length, do not modify the fork in any way. Modifying the fork could cause the fork or other components to fail, resulting in serious injury.
Visually inspect your entire bike before every ride. Pay particular attention to carbon components like the fork or handlebar. Look for any cracks, chips, splinters, or signs of delamination. If you detect any, do not ride your bicycle. If you are unsure about the condition of any component on your bicycle, consult your dealer. Do not ride a bicycle with a damaged component.
It is a rare occurrence, but in the event you receive a Lithic fork with a manufacturing defect, you can be confident that your fork is covered by a limited warranty. All Lithic products are warrantied to the original owner, to be free from manufacturing defects in materials and workmanship from the date of retail purchase, subject to the limitations detailed below. Remember to keep your sales receipt/order number to make any defect claim. This ensures the quickest best possible outcome for you, your shop, and Lithic.
All Lithic forks are warrantied against defects in materials and workmanship for a period of two years from the date of retail purchase.
This warranty does NOT cover the following:
- Any damage due to improper assembly, follow-up maintenance, lack of skill, competence or experience of the user or assembler.
- Products that have been modified, neglected, used for commercial purposes, misused or abused, involved in accidents or anything other than normal use
- Installation of components, parts or accessories not originally intended for or compatible with the component as sold
- Damage or deterioration to the paint, surface finish, aesthetics or appearance of the product
- Normal wear and tear
Lithic does not guarantee the compatibility of original components with a warranty replacement fork. Lithic is not responsible for parts or labor required to remove and/or refit and re-adjust the product within the bicycle assembly, including wheel rebuilds. This limited warranty is expressly limited to the repair or replacement of the defective component at the option of Lithic, and is the sole remedy of the warranty.
This limited warranty applies only to the original purchaser of the Lithic fork and is not transferable. This warranty applies only to products purchased through an authorized dealer or distributor. In no event shall Lithic be liable for any loss, inconvenience or damage, whether direct, incidental, consequential, or otherwise resulting from breach of any express or implied warranty or condition, of merchantability, fitness for a particular purpose, or otherwise with respect to our products except as set forth herein. This limited warranty gives the consumer specific legal rights, and those rights and other rights may vary from place to place. This limited warranty does not affect your statutory rights.