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Fuji Bike Manual

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NOTE: Installing more than 40mm (1.5”) stack height of headset spacers can compromise the strength of the steerer tube.
(See fig. 2)
It is recommended that the initial installation of the fork be done with the maximum allowed stack height (40mm) of headset
spacers, unless the desired stem height is pre-determined. Place the spacers above or below the stem to adjust your position.
Once a precise stem
height is achieved, a cut can be made to eliminate any spacers that are above the stem.
3. CUTTING THE FORK STEERER TUBE
Make a mark on the steerer tube at the top of the stem once the desired stem height is achieved. The actual cutting line
must be 2mm below the mark. (See fig. 2)
Before cutting the steerer tube, wrap the area where you intend to cut with several layers of masking tape or duct tape.
This will limit the amount of fraying of fibers, resulting in a cleaner cut. Once wrapped, determine the exact location of the
desired cut by a pen mark on the
tape.
NOTE: It is recommended that a fine tooth (36 teeth) saw blade be used to avoid the fraying
of composite fibers. A
carbide grit toothless saw blade is also acceptable.
Please abide by the adage: “check twice, cut once!” It’s much easier than buying a new fork. NOTE: Fuji recommends that
when cutting a steerer tube, a steerer tube cutting guide tool be used. It is very important that the steerer tube be cut straight.
Once the steerer tube is cut, round out the top edge of the steerer tube by using an emery board or fine grit sandpaper.
Wipe off excess dust. DO NOT breathe carbon dust!
4. FORK INSTALLATION
Install the steerer tube plug. Insert the fork back into the headset and place the desired amount of headset spacers to
achieve proper stem height. When proper height is achieved, install the preload cap.
NOTE: Do not twist stem onto carbon steerer tube. This could result in damage to the steerer tube and render the fork
unsafe.
Adjust the headset to eliminate any free play, make sure that the fork still rotates freely. Make sure that the stem and fork are
aligned. Tighten the stem’s top and bottom steerer clamp bolts in an alternating pattern. Increase torque in 5 in-lbf (0.56 N-m)
increments, until the specified torque is achieved. Recommended torque for the steerer tube is 75in-lbf
(8.5N-m). Do not
exceed maximum torque of 90 in-lbf (10.1 N-m).
Install the front brake on the fork. Recommended torque is 70 in-lbf (8 N-m). Do not exceed maximum torque of 87
in-lbf (10 N-m).
Warning: It may be visually difficult to identify damage to the composite material. If the external composite
urface is dented, frayed, gouged, deeply scratched, fractured,chipped or otherwise damaged, the component
should be replaced. If seat post has been involved in a crash or impact, even if there is no visible damage, Fuji
or an authorizedFuji dealer should inspect the product.
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