How to Install a New Bike Fork

Many people eventually choose to upgrade their mountain bikes to suspension forks or their road bikes to carbon fiber forks. If you have the right tools, this is relatively easy. Otherwise, bring your bike to a bike shop.

Difficulty: Easy

Instructions

1. Follow the instructions in related eHow "Install a Bike Headset" if you are installing a new headset at the same time.

2. Remove the crown race from your old fork. This can be done with a screwdriver and a hammer. Place the end of the screwdriver against the bottom of the crown race and tap lightly. Turn the fork, put the end of the screwdriver on the opposite side of the crown race and tap lightly. Repeat until the crown race comes off. Remember to wear eye protection!

3. Install the crown race on the new fork's crown. This requires a crown race slide punch. Pound the crown race down until it sits flat on the fork crown.

4. Insert the fork into the headtube and measure where you will need to cut the steer tube. Measure twice - you don't want to cut it too short. You can always cut it again or add headset spacers. For a threaded fork, you will need to allow room for the headset and a cable hanger if you plan to use one. For a threadless headset, you want to cut roughly 3mm below the top of the stem, to allow the stem cap to seat properly.

5. Remove the fork from the headtube and clamp it in a fork saw guide. Cut the fork with a hacksaw. Again, make sure not to cut it too short!

6. Use a deburing tool to remove any burs from the inside of the steer tube, and file off any rough edges on the top of the steer tube.

7. Install the star nut if you are using a threadless headset. Tap it gently into the top of the steer tube using a hammer and the star nut installation tool.

8. Insert the fork, install the stem, insert the front wheel, adjust the headset, adjust the front brake, and you're ready to roll!

Tips & Warnings

• Use extreme caution when cutting carbon fiber steer tubes. They can splinter or crack if you are not careful. In general, this is best left to qualified mechanics.

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on 11/22/2005 When installing a new crown race, prop the fork above ground with a 2x4 between the fork legs. The fork dropouts do not get damaged (by contact with the ground) when you are hammering down.

on 11/22/2005 Throw the new fork in the freezer for a half hour to an hour. After removing the crown race from the old fork, hit it with a heat gun or blow drier. Take the new fork out of the freezer and drop the heated crown race on the chilled steer tube. In most cases, it'll drop right into place with little or no pounding.