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to adjust your position. Once a more precise stem height is determined, a second cut can
be made to eliminate any spacers that may have been placed above the stem to achieve the
desired position.
CUTTING THE FORK STEERER TUBE
Once the initial stem height is 1.
achieved, make a mark on the steerer
tube at the top of the stem. Place the
cutting line 3mm below the mark to
allow for the space needed for the
1mm lip of the expander plug. The
end result is 2mm of space. (Fig. 2).
Wrap the area where you intend to cut 2.
the fork with several layers of masking
tape. This will limit fraying of the
bers, resulting in a cleaner cut. Once
you’ve wrapped the layers of tape, determine the precise location of the desired cut
with a pen mark on the tape. To avoid fraying the composite bers, it is recommended
that a carbide grit toothless saw blade be used. A ne tooth (36 teeth) saw blade is
also acceptable. Double check all measurements to make sure the steerer tube will not
be cut too short. It’s easier to measure twice than to buy a new fork.
NOTE: It is very important that the steerer tube is cut straight. For best results, use a steerer
tube cutting guide tool.
Once the steerer tube is cut to the desired length, remove all burrs at the top of the 3.
steerer tube by rounding out the edge with emery paper or a ne grit sand paper.
Only sand the edge, not clamping surface! Wipe off all excess dust. Be sure not to
breathe carbon dust!
For additional information on carbon ber preparation, please visit the tech section
at www.specialized.com.
INSTALLING THE FORK
Install the 48mm Long Expander Plug (Fig.2). Recommended 1.
torque is 100 in-lbf (11.3 N-m).
The E100/S90/S120 steerer tube requires the use of the RED
(22.5mm O.D.) Specialized 48mm Long Expander Plug (Fig.
2) supplied with the fork. Do not use a star nut, as it can
damage the inside surface of the steerer tube. Damage to
the steerer tube can result in failure, causing serious personal
injury or death.
Place the fork back into the head tube and clean the stem 2.
interface of the steerer tube with isopropyl alcohol.
Place the desired amount of headset spacers to achieve 3.
proper stem height, followed by the stem and the top preload
cap.
NOTE: Do not twist the stem onto the steerer tube. This can result in
damage to the surface, which can render the fork unsafe.
Install the disc brake and brake housing guide on the fork. 4.
Make sure the brake housing routing doesn’t touch the tire
when the fork is fully compressed and that it doesn’t interfere
with the controls on the handlebar when rotated. Do not
overtighten the bolts. Refer to the disc brake manufacturer’s
owner’s manual for recommended torque specications.
2mm
Steerer
Tube
Headset Upper
Bearing Race
Max Stack
Height:
40mm
48mm Long
Expander Plug
Head Tube
22mm
Steerer
Tube
Headset Upper
Bearing Race
Max Stack
Height:
40mm
48mm Long
Expander Plug
Head Tube
2
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Fork install steps continued on next page.
