Step #5 - Decide where you want the upper triple clamp mounted.
Thepositionoftheuppertripleclamp ontheChubbyforks issomewhatflexible.Youcanplacetheupper triple clampdirectlyontop 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,andshouldnot be moved upordown. Thestepsbelow willshowyouhowto mounttheuppertripleclampproperlyinanylocation.
1. Withtheuppertripleclamptemporarilyinstalled,slidethestem(withhandlebarattached)ontothesteererand
position itwhereyou wouldlike 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. Ifyouwouldprefertohavethetopofthestanchiontubesflushwiththetopoftheuppertripleclamp,youwillneed
toplaceenoughheadsetspacersontopoftheheadsetinordertodoso.Measuretheamountofexposedstanchion
tubewiththeuppertripleclampinstalleddirectlyontopoftheheadset.Thisistheamountofheadsetspacersyou
willneed.
3. Installtheheadsetspacersanduppertripleclampintothedesiredpositionandtightensteererclampboltto85in-lbs.
4. InsertthetwospringstacksandpreloadadjustersintothestanchiontubesandtightenwiththeChubbyWrench.
5. Tightentheremainingboltsontheupperclampto85in-lbs.
6. Rotatetheforkandcheckforanybindingorgrindingintheheadset.Iftheforkrotatessmoothly,continueontothe
nextstep.Iftheforkbindsortheheadsetfeelsrough,loosentheuppertripleclampandrepeatstep3.
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. Installthestar-fanglednutintotopofsteerertube10-12mmfromtheuppersurfacewithstarfanglednutinstalla-
tiontool,ifitisnotinstalledalready.Donotattempttoinstallthestar-fanglednutwithoutthepropertool.
3. Wheninstallingyourstem,thedistancebetweenthetopedgeofthestemclampmustextendabovethetopofthe
steerertube1-3mm.Ifthedistanceisincorrect,removethestemandaddorremovespacersontopoftheupper
tripleclamptoachievea1-3mmdistance.
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. InserttheAheadsetcapandscrewthroughthetopofthestemandintothestar-fanglednut.Usethethreadless
headsetcaptoadjusttheheadsetasperthemanufacturer'sinstructions.Remember:Youwillneedtoloosenallof
theuppertripleclampboltsandthestemclampboltstoadjusttheheadset.
5. Tightenthetwostemboltsto90-120in-lbsorrefertothestemmanufacturer'storquespecsforthestem.Installthe
handlebarandbrake/shiftercontrols.Positionasdesiredandtightenallboltstomanufacturer'storquespecification.
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
