SYNCROS User Manual. Before Your First Ride Intended Use. Introduction. Notes on This User Manual

Transcription

1 SYNCROS User Manual Handlebars, stem, headset Important nformaton about use, care, mantenance and nstallaton Contents Notes on Ths User Manual...1 Introducton...1 Before Your Frst Rde Intended Use...2 Before Every Rde...3 Specal Characterstcs of Carbon...3 Cleanng and Care...4 Mantenance...4 General Notes on Installaton...5 Carbon assembly paste...5 Usng a torque wrench...6 Headset...7 Checkng the headset...7 Adjustng the Aheadset -headset...7 Headset mantenance...9 What to Bear n Mnd wth Carbon Steerer Forks...9 What to Bear n Mnd wth Integrated and Sem-Integrated Headsets...10 Installng the Bearng Cups of Conventonal Aheadset -Headsets and Sem-Integrated Aheadset -Headsets nto the Frame...10 Installng Aheadset -Stems...11 Specal Characterstcs of SYNCROS FRIC Stems...11 Installng the LO-Ball Drect Mount Stem...12 Installng the Handlebars...13 Adjustng the Shfters and Brake Levers...13 Installng Bar Ends Adjustng Handlebar Heght and Fore-to-Aft Poston Aheadset -Stems Heght Adjustment wth Spacers Installng the Grps Warranty Terms...15 Addtonal manufacturer s warranty...16 A note on wear...16 Introducton Congratulatons, when buyng a SYNCROS component, you made a superb choce. SYNCROS develops, tests and manufactures our products wth dedcaton to uphold the hghest standards of qualty. Lke all hgh-qualty sports equpment, SYNCROS components requre careful nstallaton n order to functon properly and provde long-term dependablty. We recommend that you ask a qualfed mechanc at your authorzed SYNCROS dealer for help wth nstallaton and use SYNCROS components together whenever possble n order to acheve optmum performance and durablty. Our precse tolerances are ntended to ensure component compatblty, and are carefully montored durng producton and qualty control so that nstallaton wll be easy and trouble-free. Ths manual contans mportant notes about use, care, mantenance and nstallaton. Please read ths manual carefully, begnnng wth the general nformaton, followed by the chapter referrng to the component you purchased, or you ntend to use. Dong so wll ensure smooth nstallaton and trouble-free use of the product. Keep ths user manual for your records and future reference. If you sell or lend your component or bke to someone, share ths manual wth the new user. Wth SYNCROS components, as wth all lghtweght bcycle products, specal care and attenton need to be pad to proper nstallaton and ntended use. Materals used by SYNCROS are extremely strong and durable, wth very low weght. However, sometmes they can break, rather than bend, n the event of an accdent. Internal damage to the component may not show up obvously or wth vsble sgns of damage. In the event of undue stress of any knd, e.g. as a result of a crash, the components may fal and thus lead to an accdent wth unforeseeable consequences need to be nspected by a qualfed mechanc to ensure the product s safe to contnue usng. Therefore consult your SYNCROS dealer after any such occurrence. Before Your Frst Rde Intended Use SYNCROS handlebars, stems and headsets (c) are desgned for mountan bkes and ther typcal use. Mountan bkes are desgned to be used for off-road cyclng and for rdng over natural terran (e.g. terran of a mountan bke marathon and cross country racng). Due to ther desgn and equpment these bkes are, however, not ntended to be used on publc roads. If you ntend to use ths type of bcycle on publc roads, t must be ftted wth the devces and equpment prescrbed for ths purpose. Standard cross country, marathon and all-mountan bkes are not sutable for freerdng, dual slalom, downhll rdng, jumps or the lke. There are specal mountan bke types for these specfc forms of cyclng. SYNCROS components are dvded accordng to ther ntended use: Never make any changes to seat post or saddle. Do not fle or drll holes n components, especally n carbon components, as t wll compromse ther structural ntegrty and vod your warranty. We recommend that you always use SYNCROS components together n order to acheve optmum performance and component durablty. If you ntend to combne SYNCROS components wth components from other manufacturers, make sure they are compatble,.e. that all dmensons are dentcal wth the specfcatons gven n ths manual. SYNCROS handlebars, stems and headsets are desgned for an overall load of 110 klos (242 lbs) ncludng rder and baggage, e.g. rucksack. FL (Feather Lght) The SYNCROS components of the FL seres are desgned for an easy off-road use and are usually bult on cross country, marathon and tourng mountan bkes. The FL components are not sutable for use n rough terran, jumps or drops. After a crash, such as an accdent or other major mpact, have your handlebars, stem, headset and bar ends by a SYNCROS dealer, f necessary for your own safety. AM (All Mountan) The SYNCROS components of the AM seres are desgned for a moderate off-road use. and are usually bult on Enduro and all mountan bkes. The AM components are not sutable for dual, drt, downhll or freerde use. FR (Freerde) The SYNCROS components of the FR seres are desgned for a hard off-road use on secured terran and thus for extreme stress, compettve use ncluded. They are usually bult on drt, fourcross, urban and dual slalom bkes. If your handlebars, stem, headset and bar ends, f mounted, produce any creakng or crackng noses or show any external sgn of damage, such as notches, cracks, dents, dscolouratons etc., do not use your bke any longer. Ask your SYNCROS dealer to check these components thoroughly and to replace them, f necessary. If you have any questons, please contact your SYNCROS dealer. For more nformaton see the specfcatons n our catalogue and/ or vst us at Notes on Ths User Manual Pay partcular attenton to the followng symbols: (c) Ths symbol means that your lfe or health may be n danger unless you comply wth provded nstructons or carry out prescrbed measures. Ths symbol warns you about actons that could lead to damage of property or the envronment. Ths symbol ndcates there s specal nformaton on how to handle the product and may refer you to a specfc passage n ths manual requrng your specal attenton. The possble consequences descrbed above are not repeated every tme one of the symbols appears 1 2

2 Before Every Rde Check the followng ponts before settng off: 1. Verfy that the headset s free of play and moves easly. Make a vsual nspecton 2. Check the tght ft of the stem on the fork steerer and of the handlebars n the stem. 3. Are the quck-release levers or nuts of the front and rear wheel properly closed? For more nformaton see the respectve chapters of your general bke user manual. Improperly closed quck-releases or thru axles can cause the wheels to come loose. Ths can lead to a serous accdent Read the user manual of your bcycle manufacturer before you set off Specal Characterstcs of Carbon All SYNCROS products made of carbon fber-renforced resn, also referred to as carbon or abbrevated CFR (c), requre specal care and attenton. Carbon s an extremely strong materal whch combnes hgh compresson resstance wth low weght. Please note that carbon, unlke metals, shows no vsble deformaton after overstress, even though some of ts fbers may be damaged. Ths makes t very dangerous to contnue usng a carbon component after an mpact or undue stress, as t may fal wthout prevous warnng thereby causng an accdent wth unforeseeable consequences. If your SYNCROS carbon component sustaned ths knd of mpact or undue stress, we strongly recommend that you take your complete bke to your SYNCROS dealer for nspecton. He wll check the damaged bke and, f necessary, replace the defcent component. In case there are any unanswered questons or doubts, the dealer can contact SYNCROS or one of our SYNCROS dstrbutors drectly. For safety reasons components made of carbon must never be repared; they must be replaced at once. Make absolutely sure that any damaged component s never re-used; t should be destroyed to ensure that re-use s mpossble. Parts made from carbon should never be subjected to excessve heat under any crcumstances. Therefore, never have a carbon component enamelled or powder-coated. The temperatures requred for dong so could destroy t. Do not leave carbon components near a source of heat or n a car or trunk durng hot or sunny weather. Components made of carbon have, lke all lghtweght bcycle parts, only a lmted servce lfe. Therefore, to be on the safe sde t s recommended that you replace handlebars, stems and headsets dependng on use at regular ntervals (e.g. every three years), even f they were not nvolved n an accdent or smlar ncdent. Make sure the clampng areas are absolutely free of grease and other lubrcants, especally when the clampng surfaces are made of carbon Grease wll penetrate the surface of the carbon component and undermne the stablty of joned parts by reducng the coeffcent of frcton. Greased carbon components may never agan provde a safe clampng surface When you nstall carbon components, apply carbon assembly paste (e.g. from RITCHEY) to nterconnectng surfaces to ncrease frcton. Ths wll allow you to tghten bolts to prescrbed torque lmts, execute proper nstallaton and attan relable, slp-free hold. If any notches, tears, deformatons, dents or dscoloratons etc. are vsble on your carbon component, or f t makes creakng or crackng noses, do not use the bke untl the component has been replaced. After undue stress, a crash or other major mpact, replace the component or have t nspected by your SYNCROS dealer before usng t agan. Do not store carbon components n the blazng sun or near a source of heat. Cleanng and Care Clean your handlebars, stem and headset wth water and a soft cloth at regular ntervals. If necessary, use a non abrasve soap to remove grme. You may add a lttle detergent lqud for cleanng and removng tough stans, such as ol or grease, from hard surfaces. Do not use degreasng agents, whch contan organc solvents (e.g. acetone, trchloroethylene, methylene, etc.). Chemcals of ths sort may damage the fnsh or substructure of the materal. After your bke has dred, apply a wax based polsh (d) to panted, carbon and metal surfaces (excepton: brakng surfaces). Polsh the components after the wax has dred. Wth ths treatment your handlebars, stem and headset wll keep ther nce appearance for years. Whle cleanng your bke, look for cracks, scratches, dents or changes to the colour. In case of any doubt, contact your SYNCROS dealer. Have damaged or defectve components replaced mmedately. Make absolutely sure to keep the brakng surfaces or rotors free of cleanng agent, grease or ol. Otherwse the brakng performance mght be drastcally reduced or even rendered neffectve. Mantenance Check the tghtenng torque of all bolts after the frst 100 to 300 km (60 to 180 mles) or 5 to 15 hours of use. Tghten them, f necessary, wth a torque wrench to the prescrbed torque settng. Check at least every 1,500 klometres (930 mles) or 75 hours of use thereafter (e). Please note that adjustng bearngs are jobs best left to sklled mechancs. Ask your SYNCROS dealer to do these routnes. Loose or overly tghtened bolts may result n an accdent After about three years the handlebars, stem and headset have aged to an extent that they need to be checked thoroughly and have to be replaced, f necessary. Ask your SYNCROS dealer for advce. Although headsets have seals, they are not entrely tght. Therefore, have the headset dsmounted and re-lubrcated by an authorzed SYNCROS dealer at least once a year, dependng on the ntensty of use. (c) (d) (e) carbon 3 4

3 General Notes on Installaton In general, handlebars, stem and headset nstallaton are jobs for sklled mechancs. We therefore recommend that you have these jobs performed by an authorzed SYNCROS dealer. Each of the followng nstructons must be followed strctly. Non-observance of these nstructons can lead to component falure, resultng n a crash or njures. Installng non-matchng components can result n bolt falure and consequently n a serous accdent. We recommend that you always use SYNCROS handlebars, stems and headsets together, as they are desgned to ft and functon as an ntegrated whole. If you decde to use a component from another manufacturer, consult the user manual of ths component regardng sze accuracy to ensure proper ft and usablty wth SYNCROS components. SYNCROS assumes no responsblty for problems resultng from a SYNCROS component beng used wth a component from another manufacturer. Before nstallaton watch out for sharp edges and burrs on all clampng surfaces of the handlebars, stem and headset. Do not use these components, f they have burrs or sharp edges. If there are burrs or sharp edges on a SYNCROS or non-syncros component, have your SYNCROS dealer nspect t to see, whether t s usable or whether the ssue can be remeded and how. If you ft a headset to an exstng fork, check the steerer tube and the old headset carefully for scratches, abrason marks and notches after removng them. Notches n the contact area ndcate defectve processng or defcent desgn of the headset n these areas. Carbon assembly paste Installng components wth carbon assembly paste Carbon fber components are partcularly vulnerable to damage caused by excessve clampng force. Carbon assembly paste (e.g. from RITCHEY creates extra frcton between two surfaces, allowng the tghtenng torque to be reduced by up to 30%. Ths s especally useful n the clampng areas of seat post and seat tube,.e. an area where too much clampng force can damage ether component, causng component falure or vodng the warranty. By reducng the clampng force, carbon assembly paste releves stress on senstve carbon surfaces, preventng damage to fbers or the crackng of the clampng areas. It also retans ts effectveness n wet condtons and provdes maxmum protecton aganst corroson. Carbon assembly paste can be used for all carbon, alumnum and steel connectons ncludng: Stem/steerer tube clampng areas (c) Seat post/frame clampng areas Stem/handlebars clampng areas (d) Carbon assembly paste (e.g. from RITCHEY) s always deal for clampng, as t does not harden. Instructons for use Before applyng carbon assembly paste, remove drt partcles and lubrcant resdues from the surfaces to be treated. Then, apply a thn and even flm of carbon assembly paste to the cleaned surfaces usng a brush, lnt-free rag or chamos/artfcal chamos. Install the component, as prescrbed by the manufacturer. Use a torque wrench and do not exceed the prescrbed maxmum tghtenng torque. Remove any excess carbon assembly paste and close the contaner after use. Addtonal nformaton Many manufacturer warrantes do not cover damage to components due to overtghtenng. Always observe the maxmum tghtenng torques prescrbed by the manufacturers for each component. Use a torque wrench to verfy you are wthn the prescrbed torque lmts. Usng carbon assembly paste wll allow you to safely nstall your bcycle components partcularly n the case of carbon fber components wthout exceedng the tghtenng torques prescrbed by the manufacturers. In most cases, usng carbon assembly paste wll enable you to use a tghtenng torque reduced by 30% to nstall your components. Carbon assembly paste (e.g. from RITCHEY) s neutral to copper and alumnum alloys, steel and synthetc materals, and wll not damage product surfaces. Usng a torque wrench To acheve long lastng and problem-free clampng of components, SYNCROS consders the use of a torque wrench absolutely necessary (e). If the prescrbed tghtenng torque does not create suffcent clampng force, apply carbon assembly paste (e.g. from RITCHEY), to nterconnectng surfaces to ncrease frcton. Exceedng the maxmum tghtenng torque on clamp bolts of SYNCROS components creates a too hgh clampng force, whch can lead to component falure. Ths not only bears a hgh rsk of accdent, but also vods the warranty. Loose or overly tght bolts can result n component falure and n an accdent. Strctly observe the tghtenng torque specfcatons. If you do not have a hgh-qualty torque wrench, contact your SYNCROS dealer. (d) Do not use components, f you are not absolutely sure about ther compatblty. In case of any doubt ask your SYNCROS dealer for advce. Do not use further damaged components If there s any doubt, we recommend that you replace the component. Do not use your bke untl ths has been done. (c) (e) 5 6

4 Headset The headset connects the fork to the frame, but allows t to move freely. It must turn wth vrtually no resstance, f the bcycle s to run straght, stablsng tself as t travels. Shocks caused by uneven road surfaces expose the headset to consderable levels of stress. As a result of ths t can become loose and go out of correct adjustment. You should check the headset at regular ntervals, readjust t, f necessary, and have t greased at least once a year. Noses, n partcular crackng noses, are often due to a lack of lubrcaton. If you have a fork wth steel/alumnum steerer tube, you can apply mountng grease on the steerer tube n the area of the headset and the spacers, however, not n the area of the stem clampng. If you have a fork wth carbon fber steerer tube, you must not apply mountng grease The surface between steerer tube and stem as well as between the pre-load mechansm (clampng cone) and the nner sde of the steerer tube must reman free of grease, otherwse a relable clampng of these components cannot be granted. If you have a carbon fork, the grease must, therefore, be appled carefully and systematcally between the steel/alumnum parts of the bearng, the clampng or between the contact areas of the alumnum spacers. Recurrng bearng play may be due to nsuffcent frcton between stem and fork and/or to a poor ft of the counter bearng n form of a cone mechansm n the fork steerer. Apply a thn layer of carbon assembly paste on the clampng surfaces to ensure a proper and gentle clampng. Furthermore, check whether the fork steerer ends 2 to 3 mm below the top of the stem or spacer, f one s nstalled on top, otherwse adjustng the bearng play wll be mpossble. Steerng resstance or play n some handlebar postons can be due to mproper ft,.e. when the bearng races n the frame are not snug as a result of defcent processng or when unsutable bearngs were mounted. In such an event, please contact your SYNCROS dealer. Checkng the headset Pull the front brake lever and place the fngers of your other hand around the upper headset cup. Brng your weght to bear on the saddle and push the bcycle a lttle back and forth. If there s movement at the gap, the headset shows too much play. Repeat ths test wth the front wheel turned crossways. Lettng the front wheel bounce to the ground from a heght of approx. 10 cm s another method that requres, however, a certan amount of experence. Knockng noses ndcate too much bearng play. However, rattlng brake levers, cables or cycle computers may be msgudng To check whether the headset turns smoothly, take hold of the top tube and lft the front part of the bcycle untl the front wheel s about 20 cm above the ground. Wth a lttle tap on the grps, the handlebars should turn easly untl the front wheel s at least at rght angle to the drecton of moton. Perfom ths test to the rght and to the left. If the handlebars do not turn or only half way, slacken the cables and try agan. In case there s any crackng or rubbng nose, check where t comes from. Often these noses are due to cables that are dry or even rusty n ther cable stops. In ths case, please apply thn lubrcant. If that stll does not help, check whether the fork turns freely at the bottom of the head tube and whether the bearng cover has enough play. The gaps as well as the seals must be even. To check the headset turn the fork from far left to far rght. Adjustng the Aheadset -headset Adjustng the headset s a job for a sklled mechanc. Have ths work done by an authorzed SYNCROS dealer. If you ntend to do the adjustment on your own, please note that you need specal tools, e.g a torque wrench wth bts. Check the headset as descrbed n chapter Checkng the headset. In case there s bearng play, tghten the adjustng bolt by another quarter or half a turn. Do not over-tghten the headset; otherwse there s the rsk of headset falure. Do not over-tghten the top Allen bolt, t s ntended for adjustment Tghten the bolt carefully n quarter-turns and check the play regularly. Once the play s properly adjusted, brng the stem n algnment wth the front wheel. Check the algnment from the top. The handlebars should be at rght angle to the drecton of moton. Tghten both clampng bolts alternately by usng a torque wrench (d). If you use a standard torque wrench, start wth a mnmum tghtenng torque of 4 Nm. In case the stem clampng s not tght enough, ncrease the tghtenng torque to 5 Nm (e). After adjustng the headset check the tght clampng of the stem by holdng the front wheel between your knees and tryng to turn the handlebars relatve to the front wheel. In case the stem s not tght, do not tghten the bolts any further. Use carbon assembly paste nstead to ncrease frcton n the clampng areas. Check the tght clampng once agan. If the stem s stll not tght, fork and stem are probably ncompatble. Replace the stem by a matchng model or ask your SYNCROS dealer for assstance. Wth carbon steerer tubes, make sure the nsde of the tube s supported by an expander-cone mechansm (for adjustng the headset). Strctly observe the nstructons about stem tghtenng n the user manual of the fork manufacturer. Check the tght clampng of the stem by holdng the front wheel between your knees and tryng to turn the handlebars relatve to the front wheel. A loose stem can lead to an accdent If the stem cannot be tghtened on the fork steerer tube wth a tghtenng torque of 5 Nm, n spte of carbon assembly paste on the clampng surfaces, stem and fork are ncompatble. Replace the stem by a matchng model or ask your SYNCROS dealer for assstance. Observe the specfc nstructons for the LO-Ball Drect Mount Stem n chapter Installng the LO-Ball Drect Mount Stem. Please also observe the specfc nstructons regardng nstallng for the FRIC Stem n chapter Specal Characterstcs of SYNCROS FRIC Stems. (d) Headsets come n dfferent dameters and angles. Often the exact headset descrpton s prnted drectly on the cartrdge bearng. If not, a headset gauge that you can obtan from your SYNCROS dealer wll help you. Release the clampng bolts on the stem sde by two to three turns wthout unscrewng them entrely. The Allen bolt located n the top cap s ntended to re-adjust the bearng play (c). Turnng the bolt clockwse removes play, as the stem s pressed downward on the bearng; turnng the bolt antclockwse ncreases the play. (c) (e) 2 mm 7 8

5 Headset mantenance The mantenance of the headset, the removal of noses n spte of correct adjustment or an nsuffcent steerng behavour requre a dsmountng of the fork from the frame. The mantenance of the headset s a job for a sklled mechanc. Have ths work done by an authorzed SYNCROS dealer. If you want to try t on your own, you should have the know-how and experence of a mechanc as well as specal tools, f necessary. Undo the front brake and remove the front wheel. Unscrew the upper Allen bolt completely and remove the top cap. Release the bolt(s) on the stem sde. Pull off the handlebars ncludng stem, keep hold of the fork wth one hand and let the handlebars/stem hang down. Make sure frame, levers, handelbars and stem reman undamaged. Remove the spacers, the bearng cover and the upper bearng cone. Clean the components wth a rag and arrange them n the order you removed them. Keep the order n mnd. Carefully pull out the fork and wpe off any drt from the components. Check on the dsmounted fork, whether the crown race was nstalled horzontally, whether t s n sound condton (.e. wthout notches), and whether the steerng tube s free of scratches, notches, colour changes etc. over ts entre length and crcumference. Remove the bearngs, wpe off the grease from the bearng cup races. Check whether the bearngs turn freely and wthout play and make sure they are free of chps etc. If you have an open bearng headset, you should check n addton, whether the bearngs are well greased. Make sure there are no chafe marks or notches. Asymmetrcal marks of that knd ndcate a careless processng of the frame. Apply plenty of grease (not carbon assemply paste) on the bearng and bearng races durng reassembly that wll seal the bearngs n addton (c). Wpe off excess grease after reassembly. Verfy that the top clampng area of carbon steerer tubes s free of grease Observe the correct order of assembly and place the lower bearng on the crown race. The bevel of the cartrdge bearng s outer rng, normally, shows n drecton of the head tube, whereas the bevel of the cartrdge bearng s nner rng shows to the crown race. Slde the fork from below nto the head tube of the frame. Slde the upper bearng that s greased on the outsde, the upper bearng cone, the bearng cover and the spacers completely on the steerer tube untl the fork s mounted almost free of play. Make sure the clampng area of the stem s absolutely free of grease and apply carbon assembly paste. Slde the stem on the steerer tube and nstall the top cap. Adjust the headset as descrbed n chapter Adjustng the Aheadset -headset. What to Bear n Mnd wth Carbon Steerer Forks Carbon steerer tubes must reman free of grease, otherwse a relable and suffcent clampng of the stem wll not be acheved. You would requre hgh tghtenng torques damagng the steerer tube or the stem and resultng n a falure. Degrease the stem and the fork wth benzne or sprt, f necessary. Apply carbon assembly paste subsequently (d) Pre-load mechansms actng as counter bearng for the adjustng bolt nsde the fork steerer are often delvered wthout beng greased. In ths case ncreased nner frcton prevents the transformaton of bolt force nto clampng force. Apply grease specfcally on the nner, bevelled surfaces of the slotted sleeve and the nner cone. The outer surface of the sleeve must reman free of grease. Apply carbon assembly paste n ths area, as well, bevor tghtenng the mechansm n the fork steerer. Never use a star nut as counter bearng nsde the fork steerer Rsk of breakage What to Bear n Mnd wth Integrated and Sem-Integrated Headsets Wth ntegrated headsets the upper and lower bearng cup races are part of the head tube, wth sem-ntegrated headsets they are normally pressed n by the manufacturers. Ths allows smooth transtons between headset, fork and stem. The fork crown race s normally provded wth a slt that allows an easy nstallaton on the fork steerer. Apply grease on the entre headset ncludng bearng cup races to ensure smooth runnng and to prevent corroson Verfy that the gaps between bearng cover and head tube as well as between fork crown and lower bearng cup race are evenly parallel. If they are not, the bearngs possbly run rough and wear down fast. Installng the Bearng Cups of Conventonal Aheadset - Headsets and Sem-Integrated Aheadset -Headsets nto the Frame The nstallaton of the Aheadset -headset s a job for a sklled mechanc. Have ths work done by an authorzed SYNCROS dealer. If you want to perform ths task yourself, you should have the know-how and experence of a mechanc as well as specal tools, f necessary. Place the crown race horzontally onto the fork crown. Slde the crown race onto the steerer ether manually or wth an approprate specal tool. Wth the desred mnor undersze of the crown race towards the fork crown you need to tap slghtly on the crown race to brng t nto the correct poston wthout leavng any gap between crown race and fork crown. Keep the fork n hand durng httng and do not put t down. Rsk of breakage Before nstallaton thoroughly check the cleaned fork steerer, n partcular the fork crown and the stem clampng area, for damage, such as cracks. Perform the nstallaton only wth headset tools. An approprate press ft of the bearng cup races nto the frame can only be acheved wth these tools. Precondton s, however, that the tolerances are observed and that the surfaces gldng on top of one another are well greased. Verfy not to slde on the bearng cup races n oblque poston and make sure they are flush. Tghten the specal tool evenly and observe as the bearng cup races slde nto the head tube. Bearng cup races that you can slde n manually wll cause crackng or rattlng noses durng cyclng. Degrease the bearng cup races and the nner face of the headset n a metal frame and apply some two-component adhesve, accordng to the manufacturer s nstructons. If you have a carbon fber frame, use carbon assembly paste (e.g. from RITCHEY) Let the adhesve harden before re-nstallng the fork. (c) (d) 9 10

6 Installng Aheadset -Stems The SYNCROS FL and AM stems can be nstalled n ether vertcal orentaton. These flp-flop models allow handlebars nstallaton at two dfferent heghts by smply nvertng the stem. Verfy that the stem and fork steerer tube always have matchng or compatble clamp dameters If you ft a new stem on a fork wth carbon steerer tube, check the clampng area for notches or abrason marks. In case such damage s actually vsble, ask your SYNCROS dealer whether t s necessary to have the fork replaced. Make sure the clampng areas are absolutely free of grease, especally when the clampng surfaces are made of carbon. Apply carbon assembly paste (e.g. from RITCHEY) to optmse the clampng. Grease the threads and the connectng surfaces/heads of the steerer clamp bolts. Keep lubrcants away from clampng surfaces. Slde the stem onto the fork steerer tube. It must ft snugly onto the fork. Do not ft stems whch have play on the steerer tube. Dependng on the steerer tube length and the desred stem poston, nstall spacers on the fork steerer above the upper cover of the headset and / or above the stem. You can stack them up to a maxmum heght of 30 mm. These spacers are avalable n dfferent heghts. You have nstalled the correct number of spacers, when the steerer tube ends 2 mm below the top edge of the stem or spacer, f one s nstalled above the stem. Verfy that the stem provdes suffcent support for the steerer tube and that the steerer tube ends 2 mm at the most below the top edge of the stem. Ths ensures a relably clampng when tghtenng the clampng bolts of the steerer tube clamp to the the prescrbed tghtenng torque. If your preferred stem heght results n a deeper poston of the stem on the steerer tube, the steerer tube projects from the stem. To check the correct poston, nsert spacers at an approprate heght on top of the steerer tube. After the test rde the steerer tube of a carbon fork must be shortened. The space between the top of the steerer tube and the upper edge of the stem should not exceed 3 mm. Tghten the stem bolts only a lttle, f you ntend to nstall the handlebar rght afterwards. Fnsh by adjustng the headset. The clamp bolts of SYNCROS stems are desgned to oppose each other for proper load dstrbuton durng clampng. Please check that the bolt heads are always orented n opposton to each other. Specal Characterstcs of SYNCROS FRIC Stems The nstructons gven for our standard product range, n general, also apply to the SYNCROS FRIC stem. The followng nstructons about the specal characterstcs should be regarded as supplementary Installng the Stem to the Handlebars and the Steerer Tube Before proceedng wth nstallaton, be sure the stem and the handlebars have the proper and matchng clampng dameter. The FRIC stem s only permtted wth handlebars wth a 31.8 mm clampng dameter. We strongly recommend that you use SYNCROS handlebars. The SYNCROS FRIC stem has a symmetrcal desgn and can therefore be nstalled n ether vertcal orentaton. We recommend, however, that you nstall the stem n a way that the SYNCROS letterng s not upsde down. Release the two bolts of the steerer tube clamp and the bolts of the handlebar clamp brackets by two to three turns wthout unscrewng them entrely. To nstall the handlebars you need not dsmount the two front clamp brackets completely. Slde n the handlebars wthout fttngs from the sde nto the stem. If you have rser bars, turn the handlebars a lttle n both drectons along the longtudnal axle to slde the bends easer through the handlebar clamp brackets. Do not use brute force, otherwse you wll scratch the handlebars. Rsk of breakage Ask your SYNCROS dealer for advce nstead. Screw n the greased bolts of the handlebar clamp brackets wth your fngers by a few turns. Tghten the two lower bolts untl the clamp slots of both brackets measure approx. one mllmetre. Subsequently, the stem must be nstalled on the fork steerer tube. Slde the stem onto the fork steerer tube. Mount the the handlebar fttngs and the grps on the handlebars. Tghten them only a lttle, as they wll be fxed n the correct poston at a later date. Adjust the headset as descrbed n chapter Adjustng the Headset. Brng the stem n algnment and tghten the two bolts of the steerer tube clamp wth your fngers. Tghten the two bolts evenly,.e. alternately and n small ncrements, by usng a torque wrench to the mnmum lmt of the recommended tghtenng torque of 5 6 Nm (c). Poston the handlebars n a way that they extent the same dstance from the stem on ether sde by offerng you a comfortable grp poston. Tghten the two upper bolts of the handlebar clamp brackets evenly,.e. alternately and n small ncrements, by usng a torque wrenceh to the mnmum lmt of the recommended tghtenng torque of 4 5 Nm (d). (c) Brng the handlebars, the fttngs and the grps n the correct poston and tghten them wth a torque wrench accordng to the nstructons of the manufacturers. Fnally, check the relable ft of the handlebars n the stem, of the fttng on the handlebars and of the stem on the steerer tube. Observe the recommended maxmum tghtenng torques. Always use a torque wrench and observe the torque settngs ndcated on the component n case of doubt. Adjustng the Headset Wth a SYNCROS folder stem adjustng the headset requres dfferent procedures as wth other SYNCOR stems. You need to release the clamp bolts of the steerer tube as well as the clamp bolts of the handlebars by two to three turns at the most. After adjustng the headset tghten frst the clamp bolts of the steerer tube to the requred tghtenng torque of 5 to 6 Nm. Brng the handlebars then n the correct poston and tghten the two upper bolts of the handlebar clamp brackets accordng to the recommended tghtenng torque of 4 5 Nm. Fnally, check the relable ft of the handlebars n the stem and of the stem on the steerer tube. Installng the LO-BALL Drect Mount Stem The SYNCROS LO-Ball Drect Mount stem (e) s only compatble wth the double crown suspenson forks FOX 40 and Rock Shox Boxxer (from model year 2009). The LO-Ball Drect Mount stem s screwed wth 4 bolts drectly to the upper fork crown. The handlebars are nstalled, as descrbed n chapter Installng the Handlebars by observng the prescrbed tghtenng torque of 6 Nm. Read the user manual of your fork manufacturer before nstallng a LO-Ball Drect Mount stem. (d) (e) 11 12

7 Installng the Handlebars Before you start nstallaton verfy that the stem you have chosen has a clampng dameter matchng the handlebars Stems wth a 31.8 mm clampng are for example only compatble wth handlebars wth a clampng dameter of 31.8 mm. Poston the stem clamp n the mddle of your new SYNCROS handlebars so that the handlebars extend the same dstance from the stem on each sde. If the handlebars do not slde easly nto the stem clamp or f there s play between the two components, ask your SYNCROS dealer whether both components are compatble. Mountan bke handlebars are normally mounted wth the sweep supportng a natural ergonomc hand poston,.e. pontng slghtly rearward. The handlebar poston s correct when your wrsts are relaxed and your elbows not flared out too much. Tghten the greased bolts of the stem faceplate wth your fngers by a few turns. Gently tghten all four bolts wth a qualty torque wrench untl they are snug and verfy that the upper and lower clampng slots are dentcal n wdth. Do not exceed the prescrbed tghtenng torque. Tghten the fxng bolts evenly n a cross pattern,.e. alternately and n small ncrements to the mnmum lmt of the recommended tghtenng torque. The recommended maxmum tghtenng torque for SYNCROS 4-bolt stems s 4 to 6 Nm (dependng on model). Always use a torque wrench and observe the torque settngs ndcated on the component n case of doubt. Check shfter and brake lever clamps for burrs and sharp edges. Do not use shfters or brake levers wth burrs or sharp edges to prevent your handlebars from damage and dents. Components that are affected by burrs and sharp edges should be checked by a SYNCROS dealer. They wll see, whether ths s a problem that can be solved or whether the component has to be replaced. Loosen clampng bolts completely to ensure clamps are open all the way before sldng the shfters and brake levers onto the handlebars. Start tghtenng the clampng bolts slghtly, so that the levers can stll rotate freely. Brng the levers to the desred poston. Tghten the bolts to the prescrbed tghtenng torque to ensure a relable hold. Never rotate the levers on handlebars after you have tghtened the clampng bolts. Otherwse you wll scratch the surface and mar the fnsh. In addton you run the rsk of damagng the materal. Read through the manufacturer`s user manuals of all components before you follow the above nstructons. Never shorten carbon fber mountan bke handlebars by cuttng off the ends, as handlebars are generally renforced where shfters and brake levers are nstalled. Shortenng handlebars by cuttng off the ends can damage the handlebars and result n an accdent durng use Any modfcaton to a SYNCROS carbon component wll vod the warranty. Adjustng the Shfters and Brake Levers Turn the loosened grps on the handlebars so that they show slghtly downward. St on the saddle and place your hands on the grps wth your fngers on the brake levers. The back of your hands should form a straght lne wth your forearms. Adjust the shfters to the correct anatomcal poston. In case both the shfters and the brake levers are stll not tght, verfy that each bolt has been tghtened to the recommended torque (5 Nm for SYNCROS). If each bolt has been tghtened to a tghtenng torque of 5 Nm and the clampng force s stll nsuffcent, release the bolts, remove shfters and brake levers and apply carbon assembly paste to the clampng areas. Retghten each bolt ndvdually to a tghtenng torque of 5 Nm. If the shfters and brake levers are stll not tght on the handlebars, seek the assstance of your SYNCROS dealer. Installng Bar Ends Bar ends add more hand postons to your handlebar confguraton. They are usually set to a poston that provdes more leverage and more comfort when you pedal out of the saddle. Hgh-qualty bar ends are sutable for all SYNCROS handlebars. Mountng bar ends to unsutable handlebars,.e. handlebars wth thn wall thcknesses that are not desgned to wthstand the specfc load, can lead to handlebar falure durng use and result n an accdent Verfy that the clampng areas of the bar ends are free of burrs and sharp edges. Do not use bar ends wth burrs or sharp edges. Burrs are sharp and can cut nto other components. If there are any burrs or sharp edges, contact your SYNCROS dealer. Loosen the shfter and brake lever bolts and move the levers toward the stem to ensure the bar ends have suffcent clampng space. If the grps have end caps, cut them so you can move the grps toward the stem, as well. Do not use any lquds or grease to loosen the grps; f necessary, use compressed ar to loosen them. Loosen the bar end bolts on the bottom sde of the bar ends by two to three complete turns. Slde the bar ends on the respectve sde of the handlebars (c). Angle the bar ends accordng to personal preference and make sure they are both at the same angle. Observe possble rght/left references on the bar ends. Retghten the bolts carefully n small ncrements of 0.5 Nm. Do not exceed the maxmum torque of 5 Nm for the bolts of bar ends used wth SYNCROS handlebars. Never exceed the maxmum torque ndcated on the components (d). If a tght ft of the bar ends on the handlebars cannot be acheved n spte of usng carbon assembly paste on the contact surfaces, bars ends and handlebars are not compatble. Replace the bar ends or the handlebars by approprate models. The nterfacng clampng areas of stems, handlebars, bar ends, shfters and brake levers must be tghtened to specfed torque settngs. Installng bar ends to unsutable handlebars can lead to sudden falure durng use and therefore result n an accdent. Bar ends wth asymmetrc clamp styles and sharp edges are mostly unsutable for use wth handlebars. To be on the safe sde, ask your SYNCROS dealer for advce. Adjustng Handlebar Heght and Fore-to-Aft Poston Both the handlebar heght and the stem length determne how much your upper body wll be nclned forward. Lowerng the handlebars gves the rder a streamlned poston and brngs more weght to bear on the front wheel. An excessvely low handlebar poston may prove less comfortable, especally on longer rdes, and can stran wrsts, arms, upper body and neck. Seek the assstance of a qualfed bke ft expert, especally f you experence pan or dscomfort after set up and use. If necessary, your SYNCROS dealer wll help you fnd a seatng poston accordng to your needs. Aheadset -Stems Heght Adjustment wth Spacers On bkes usng a threadless headset system, or Aheadset -system (, p.15) the stem s an ntegral part of the headset. To fnd the approprate heght the stem must be dsmounted and re-mounted. If you change the poston of the stem, you must also readjust the headset (see chapter Adjustng the Headset ). The vertcal poston of the stem s determned by the arrangement of the spacers. In the case of flp-flop models t s also possble to reverse the stem n order to acheve a hgher or lower handlebar poston. Loosen the headset cap bolt at the top of the fork s steerer tube. Ths cap serves to adjust the ntal bearng pressure. Remove the cap and loosen the stem s steerer clamp bolts, then pull the stem up and off the steerer tube. Now you can remove the spacers. Reposton the spacers on the steerer tube above and below the stem n order to poston the handlebar at the desred heght. Observe the maxmum stackng heght of spacers of 30 mm below the stem. Check the relable ft of all components, as descrbed above. If you want to reduce the number of spacers, you have to shorten the steerer tube. Ths shortenng s rreversble. Cuttng the steerer tube s a job for a sklled mechanc. Have ths work performed only after you have found the deal poston. Instead of shortenng the steerer tube you have also the opton to modfy the arrangement of the spacers. Make a test rde and place the equal number of spacers you have removed from below the stem above the stem and vce versa. (c) (d) 13 14

8 Installng the Grps For a relable ft wthout play SYNCROS grps must be mounted on handlebars that are free of ol and grease. SYNCROS lockng grps (wth 2 or 4 bolts) can be mounted easly by sldng onto the handlebars. Verfy that the clampng mechansm s at the end of the handlebars. Slde the grp nto the correct poston on the handlebars and tghten the bolts to ensure a tght ft of the grp. Never exceed the maxmum tghtenng torque of 3 Nm. Other SYNCROS grps (e.g. grp model Deep Relef) adhere to the handlebars due to frcton between the handlebars and grp. The easest way to mount these grps s wth compressed ar. Inflate the grps wth ar and slde them onto the handlebars. If you don t have compressed ar, please contact your SYNCROS dealer to perform ths job for you. We dscourage the use of harspray and comparable solvents These can cause the grps to loosen durng use. Wth all types of grps desgned wth an open end, you should push plugs nto the ends of the handlebars. Ths wll avod or at least reduce potental damage to the handlebars and, more mportantly, njures n the case of a crash. Make sure the handlebars are free of lubrcants and do not use chemcal fluds to mount the grps Warranty Terms Under European consumer law the purchaser has full statutory warranty rghts for two years from the delvery of the SYNCROS product. Your dealer s lable for any lack of conformty wth the contract, namely that your purchased product s free of faults, whch are mparng ts worth or ts typcal use. In case of a lack of conformty you may requre the dealer to repar the product or to replace t, unless ths s mpossble or dsproportonate. Otherwse you may requre an approprate reducton of the prce or have the contract rescnded, the latter beng excluded f the lack of conformty s mnor. Ths warranty s vald n states havng adopted applcable European Unon (EU) regulatons nto natonal legslaton. The applcable natonal legslaton governng the sale of consumer goods s not affected by ths guarantee. Please ask your dealer about the applcable provsons n your country. Warranty clams wll only be accepted f the bcycle or component has been used for ts ntended purpose. Any bcycle or component used for an unntended purpose wll not be elgble for warranty protecton. Ths warranty does not cover damage resultng from wear (.e. tre tread wear, bearng wear, rm surface wear, or any other wear or deteroraton that s a result of regular use of the product), neglect (nsuffcent care and mantenance), accdents, stress caused by overloadng or over-torque, ncorrect mountng or mproper treatment or damage or malfuncton resultng from changes or modfcatons made to the bcycle or component. For addtonal nformaton, note the nstructons n your product manual, or consult your dealer. For all warranty nqures or clams, n order to beneft from your rghts, you must address the clam to the dealer from whch you purchased the SYNCROS product wthn a perod of two months from the date on whch you detected ts lack of conformty wth the terms of the warranty. You must nclude your orgnal proof of purchase when ntatng your clam wth the dealer from whch the SYNCROS product was purchased. Addtonal manufacturer s warranty SYNCROS products have been developed and manufactured wth great care and have been subject to qualty assurance and control tests to help ensure that your SYNCROS product performs as t s meant to. Our products are examned and tested both nternally and by external neutral test laboratores on an ongong bass. We warrant, n addton to above outlned statutory warranty, that your SYNCROS product s free of faults or manufacturng defects for two years from the purchase date. Ths warranty does not cover grps, bar tape and tres, or any part of our products that are subject to wear as a part of ther functon (bearngs, rm brakng surfaces, tre tread, chan rng wear, or the normal breakdown of foam n saddles). You shall be enttled to have your product repared or replaced subject to the followng condtons: The manufacturers guarantee only apples to clams made by the ntal buyer upon presentaton of the orgnal sales recept, whch must show the date of purchase, dealer address, prce pad, and product model name and/or number. Warranty clams wll only be accepted f the SYNCROS product and/or bcycle have been used for ts ntended purpose. Manufacturer s warranty does not cover damage resultng from: Wear as a part of the product s normal functon (as noted n the secton below enttled A note on wear ) Neglect (nsuffcent care and mantenance) Accdents ncludng falls, regardless of who or what was responsble for the accdent Overstress caused by overloadng or over-torque Incorrect mountng or mproper treatment or damage resultng from changes or modfcatons made to the bcycle or component (.e. cuttng the handlebar or seatpost, flng or drllng of any knd, and other modfcatons that can have structural, strength, or safety mplcatons of any sort) Please pay attenton to the nstructons n your SYNCROS product manual and to the note on wear below. The warranty s null and vod n any case where the mountng/nstallaton nstructons are gnored, or where nspecton ntervals are not adhered to, or n cases where the bcycle or component s not mantaned wth suffcent care. In the event of all warranty clams, SYNCROS reserves the rght to provde a bcycle or component of an equvalent or greater qualty n an avalable colour or model. SYNCROS does not guarantee that we wll be able to replace your warranted product wth an dentcal replacement. Ths warranty does not cover assembly or refttng costs, nor any costs relatng to new accessores, upgrades, replacements or modfcatons that may be requred n order to put a component or frame replaced through warranty back nto use. Ths warranty does not cover labour and transport costs, nor does t cover follow-up costs resultng from subsequent product compatblty problems, defects, or any other costs assocated wth the warranty clam. For all warranty clams please ntate the clam wth your dealer, who wll nstruct you on whether or not you have a vald warranty clam, and the correct warranty procedure. If you are unable to contact your dealer, you can contact SYNCROS drectly as ndcated below. A note on wear Components on bcycles are subject to wear due to ther functon. The rate of wear wll depend on care and mantenance, the bke s usage and the envronment t s exposed to such as ran, mud, dust, and sand. Some components requre regular care and mantenance, but despte the best mantenance program, all components wll eventually reach the end of ther servceable lfe, dependng on condtons and ntensty of use. The followng SYNCROS components are subject to wear due to ther functon and are not covered for wear as descrbed under ths warranty: Grps and bar tapes Compresson, abrason and contamnaton Headsets Lubrcants Wornout bearngs In case of any nqures, contact your natonal dstrbutor. Fnd a lst at SYNCROS EUROPE Va Cantonale 2 CH Granca-Lugano Phone: Fax: E-Mal: nfo@syncros.com Techncal detals n the text and llustratons of ths manual are subject to change. No part of ths publcaton may be reprnted, coped or transmtted by hand or wth mechancal or electronc systems or used for an another busness purpose wthout pror wrtten permsson. Concept and text: Zedler Insttut für Fahrradtechnk und -Scherhet GmbH Edton 1, September