Operating instructions

Headset maintenance
The maintenance of the headset, the removal of nois-
es in spite of correct adjustment or an insucient
steering behaviour require a dismounting of the AX-
Lightness and engage fork from the frame.
The maintenance of the AX-Lightness and engage
headset is a job for a skilled bicycle mechanic. Have
this work solely done by an authorized AX-Lightness
and engage dealer.
If you want to try it on your own, you should have
the know-how and experience of a mechanic as well
as special tools, e.g. a high-quality torque wrench, if
necessary.
Undo the front brake and remove the front wheel.
Unscrew the top Allen bolt
(a) completely and re-
move the top cap (b). Release the bolt(s) on the stem
side by two to three turns
(c).
Pull o the handlebars including stem, keep hold of
the AX-Lightness and engage fork with one hand
and let the handlebars/stem hang down. Make sure
frame, levers, handlebars and stem remain undam-
aged.
Remove the spacers (d), the bearing cover and the
upper bearing cone. Clean the parts with a rag and
arrange them in the order you removed them. Keep
the order in mind.
Carefully pull out the AX-Lightness or engage fork
and wipe o any dirt from the parts. Check on the
dismounted fork, whether the crown race was in-
stalled horizontally, whether it is in sound condition
(i.e. without notches), and whether the steering tube
is free of scratches, notches, colour changes etc. over
its entire length and circumference
(e).
Remove the bearings and wipe o the grease from
the bearing cup races. Check whether the bearings
turn freely and without play and make sure they are
free from chips etc. If you have an open bearing head-
set, you should check in addition, whether they are
well greased. Make sure there are no chafe marks or
notches. Asymmetrical marks of that kind indicate a
careless processing.
Apply plenty of grease
(f) (not AX-Lightness and
engage carbon assembly paste) on the bearing and
bearing races during reassembly that will seal the
bearings in addition. Wipe o excess grease after re-
assembly.
Observe the correct order of assembly and place the
lower bearing on the crown race. The bevel of the car-
tridge bearing’s outer ring, normally, shows in direc-
tion of the head tube, whereas the bevel of the car-
tridge bearing’s inner ring shows to the crown race.
Slide the AX-Lightness and engage fork from below
into the head tube of the frame.
Slide the upper bearing that is greased on the out-
side, the upper bearing cone, the bearing cover and
the spacers completely on the steerer tube until the
AX-Lightness and engage fork is mounted almost free
of play. Make sure the clamping area of the stem is
absolutely free of grease and apply AX-Lightness and
engage carbon assembly paste. Slide the stem on
the steerer tube and plug in the top cap (g). Adjust
the headset, as described in chapter “Adjusting the
Aheadset®-headset“.
g
The top clamping area of AX-Lightness and
engage carbon steerer tubes must remain
free of grease.
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Fork - Headset
a
b
c
d
g
f
e