Installation Instructions - ENVE Composites ForksCongratulations on the purchase of your ENVE Composites Fork!
To ensure the best performance and longest service life from your ENVE Composites Fork, please read and carefully follow these installation instructions. Failure to follow preparation, installation, and maintenance instructions will result in a void warranty.
Carbon bicycle forks are subject to wear and stress during their lifetime. If the fork’s useful life is exceeded it can suddenly and catastrophically fail, which could cause serious injury or death. Scratches, cracks, fraying, discoloration, and softening areas of the part can all be signs that the product has reached the end of its useful life and needs to be replaced. Quality of materials and workmanship of your fork are covered by its warranty but the product is not guaranteed to last the full term of the warranty. Product life can be related to the kind of riding and maintenance that the fork is subjected to. The warranty does not imply that the fork will last forever, but that the fork’s workmanship and material is covered per the terms of the warranty.
ENVE forks are designed and built for road riding. They are intended for use on smooth surfaces and paved roads. When riding, take care to avoid pot holes, sewer grates, railroad tracks, expansion joints, construction areas, and debris that could catch in your front wheel and cause severe impact to the fork.
ENVE forks are not intended for use on rough surfaces such as dirt and rock trails. They are not intended for stunt riding, jumping or other aggressive riding where sudden, drastic steering movements might be executed. These actions can put large, unpredictable loads on the fork in ways which it was not intended to sustain and could cause serious damage to the fork and consequently the rider.
ENVE forks are not approved for tandem bicycle use.
All ENVE components must be prepared, installed and maintained by a qualified bicycle mechanic using the appropriate professional tools. Failure to follow the installation instructions can result in component failure. Component failure can lead to loss of control of your bicycle and result in serious injury or death.
ENVE assumes no liability for improperly installed products and components.
Failure to follow these instructions can result in component failure. Component failure can lead to loss of control of the bicycle and result in serious personal injury or death.
- 1 ENVE Compression Adjustment Plug w/ Top Cap
- Hacksaw with Fine Tooth Blade or Ideally a Tile Saw
- Cutting Guide
- Race Setting Tool
- 4mm Hex
- 5mm Hex
- 6mm Hex
- Fine Grit File/Sandpaper
- Calibrated Torque Wrench
Verify that the fork and the headset have compatible diameters. Verify that the stem steerer clamp diameter is compatible with the fork steerer tube diameter. Incorrect mating of components can cause component failure.
- Confirm the headset parts are free of any burrs or sharp edges. Remove any burrs or sharp edges with 320/400 grit sandpaper.
- Confirm your stem is free of any burrs or sharp edges at the steerer clamp slot. Remove any burrs or sharp edges with 320/400 grit sandpaper.
- Avoid scratching or scoring the steerer tube surface. Any damage to the steerer tube could cause failure.
- Apply a small amount of grease to the fork crown race seat. Do NOT make any modifications to the crown race area of the fork. Only use a headset race with the correct inside diameter for your fork steerer tube.
- Hold one leg of the fork securely and, using an appropriate race seating tool, install the headset crown race. Do not place the fork on the dropout tips or crown while installing the race. Doing so can damage the fork and could cause failure.
- Assemble the fork, headset and any spacers in the head tube of the bicycle and slide on the stem.
- The spacer stack between the top of the upper bearing and the bottom of the stem must not exceed 40 mm .
- The compression plug assembly will add 1mm to the top of the steerer tube.
- Carefully measure and mark the amount of steerer tube that you will need to remove. ENVE recommends that the steerer tube with compression plug extend 1mm past the top of the stem/spacer stack and that a 5mm spacer be placed on top to ensure proper compression from the top cap.
- Remove the fork from the bicycle.
- Make absolutely certain that you do not cut the steerer tube too short. Incorrectly cut steerer tubes are not covered under warranty.
- Using a new fine tooth hacksaw with a proper cutting guide, cut the steerer tube to exact specifications.
- Carefully sand or file off any loose fibers or burrs until the edges are smooth.
- Clean the steerer tube and inside of the stem clamp with alcohol to remove grease and dirt; then let dry.
Installing the Fork:
- Insert compression plug into cut steerer tube. Tighten compression plug using a torque wrench with 6mm Allen attachment to no more than 62 in-lbs (7 Nm).
- CAUTION! Never use a star-fangled nut with a carbon steerer tube.
- Assemble the fork, headset, spacers, top cap and top cap bolt in the head tube of the bicycle and slide on the stem.
- Adjust headset tension using an appropriate hex wrench and according to the headset manufacturer’s instructions. If the headset manufacturer has not specified torque, tighten to 1.6 Nm (15 in-lbs).
- Torque the stem steerer clamp bolts as specified by the stem manufacturer (do not exceed 6Nm).
- Install the front brake following the brake manufacturer’s instructions.
- Follow the wheel manufacturer’s instructions for correct clamping of the wheel quick release and install the front wheel. Failure to properly adjust the quick release and secure the wheel can result in serious injury or death.
- Adjust the front brake following the brake manufacturer’s instructions.?Failure to properly install and adjust brakes can result in serious injury or death.
- When using a dropout clamping bicycle rack, always clamp the dropouts securely to prevent dropout and/or bike damage. If the clamp is loose, the bike may fall out of the rack. When removing the fork from the clamp, be sure to remove both dropouts evenly at the same time. Do not tilt the bike to one side, because dropout damage may result. Dropout damage can cause component failure, which can result in serious injury or death.
- Do not modify the fork in any way, other than cutting the steerer tube to the correct length for your bike. Modifying the fork could cause fork or other component failure resulting in serious injury or death.
- Always loosen the stem’s steerer clamp bolts before attempting to make stem/fork alignment adjustments.
- Periodically remove, clean, and inspect your fork for any damage or cracks. If you have any questions about a mark on the fork, consult ENVE Composites immediately.
- Inspect your components often. If you have any doubts about the integrity of any part, REPLACE IT. Consult your ENVE dealer if you are unsure about the condition of your components or any other part of your bicycle.
- During your inspection, check for any delamination of fiber on the fork. This is an area where fiber is no longer bonded together. These areas can often be identified by a bulging, soft, or deformed shape. The areas can also be located by tapping gently on the surface. The sound should be consistent and sharp. If you encounter an area of delamination, the sound will be different: often dull and less sharp. If you encounter signs of delamination, do not ride the fork. Report the damage to your ENVE dealer for further inspection.
- Beware of unusual noises coming from your bicycle. These noises can be indicators of damage. Before riding, find the source of the noise and correct it.
- In case of a crash or any impact, carefully check your bars, stem, fork, seat post, wheels, and frame for any visible damage. As with any component under stress, there is a limited fatigue life that is proportional to the use and abuse of the part. Inspect your components frequently. If you have any concerns about the integrity of any part, discontinue riding the bicycle and have it inspected by a qualified bicycle technician, or contact ENVE Composites.