Replace supension fork

Rebuilding a suspension fork

1. Remove the front wheel. Picture 1

2. Push the pad spacer into the brake caliper. Picture 2

3. Remove the brake caliper and the brake cable mount on the fork. Picture 3 Bild 4

4. Slacken off the stem bolts. Picture 5

5. Unscrew the headset screw and remove the Ahead cap. Picture 6 Picture 7 Then you can remove both the stem and handlebar together. Picture 8

Caution: The fork can out drop out of the frame. Rest the handlebar in front of the fork as shown in the image. Picture 9

6. Remove the spacers. Picture 10

7. The fork can now be removed from the head tube. It may be necessary to use a rubber hammer to gently tap out the fork steerer from the top as shown. Picture 11 You can also gently tap on the fork crown from below. Picture 12

8. Now pull the fork out of the headtube. Picture 13

9. Now remove the bearings from the fork steerer. Tip: Make a note of the position of the bearings and their order on the fork steerer. This will make reassembly so much easier later on.

10. Clean the fork steerer with a dry, soft cloth. Check all parts for damage. Damaged bearings should be replaced. Picture 14 The cleaned bearings should also move freely.

Re-fitting the fork

To re-fit the fork follow the steps previously described exactly the other way round:

1. Grease the bearings and the bearing seats sparingly before re-fitting. The grease doesn’t just lubricate, but also repels water and dirt. Picture 15 Warning: When fitting carbon fork steerers ensure that no grease gets on the part of the steerer which is clamped to the stem!

2. Push the fork steerer right down into the headtube as far as it will go.

3. Place the bearings in the relevant bearing casings. Ensure that the bearings are in the correct order and positions. On the current Acros headset you must position a plastic ring between the bearing and fork steerer. Picture 16

4. Wipe off excess grease. Picture 17

5. Place the spacers and then the stem onto the fork steerer. The stem should be 2mm above the fork steerer as shown in the image. Picture 18

6. Put the Ahead cap on.

7. Adjust the headset by tightening the headset bolt until there is no noticeable play. Picture 19

8. Tighten the stem bolts to the correct torque indicated on the stem. Picture 20

9. If the suspension fork has a brake line guide fitted, then position the cable through this guide. Please note the guidelines of the fork manufacturer as well as the notes here in the Technical Support Center.

10. Now fit the brake caliper and adjust the brake. The brake disc must run exactly through the middle of the brake caliper. Please observe the guidelines of the relevant fork manufacturer or the Technical Support Center before doing any work on your bike’s braking system!

Canyon consistently strives to ensure the quality and accuracy of the information contained in this Technical Support Center. Any repairs or adjustments which you carry out on your bike are entirely at your own risk. If you are in any doubt about what to do, you should send your bike to Canyon or take it to another qualified repair specialist. Canyon gives no guarantee or accepts no liability for the any of the information contained in this Technical Support Center.