DaFork

Regular Inspection and correct adjustment of the headset – how to properly maintain your DaFork Carbon-fork

If your bicycle is equipped with a DaFork carbon-fork it is extremely important to regularly check your headset for play and, if necessary, adjust it properly. During the break-in period (after approximately 1000km) it should be checked before and after each ride. After the break-in period a check every 1000km is sufficient.
If these checks are not conducted, you could risk material damage as well as your own safety. This guide explains how to properly check and adjust the headset to avoid costly repairs or possible accidents.

Why it is important to check the headset:

With forks that use a carbon fork-shaft it is inevitable, that through the surface pressure of the ball bearings, the fork cone will settle in. This process is perfectly normal but over time leads to play developing in the headset. If the play is not fixed, a so called “Ring of Death” may occur, which permanently damages the fork and making it no longer usable. The fork will not break immediately, but repairing the fork will not be possible and it must be replaced.

 

Important: It is crucial to regularly check the headset and adjust it if necessary. If you were to ignore this, it could lead to serious damage and in the worst case to accidents.

What happens if the headset is not set properly:

- Material Damage: An improperly adjusted headset leads to progressive damaging of the fork cone. This damage cannot be repaired, and the fork must be replaced.

- Physical Harm: In a worst-case scenario, a loose headset can lead to a crash since the occurring play negatively influences the steering and the stability of the bicycle.

- Disclaimer: We are not liable for material or physical damage which was caused by an improperly adjusted headset. It is the rider’s responsibility to regularly check and if necessary, adjust the headset.

Checking of the headset and proper adjustment:

To properly adjust the headset the following tools are necessary:
- Allen keys (4mm, 5mm and 6mm)

- Torque wrench with the appropriate bits (4mm, 5mm and 6mm). We recommend using an electronic torque wrench, such as the Topeak D-Torque.

Checking the headset for play:

How to proceed:

1. Position the bike in an upright position, so that the front wheel is pointing straight ahead.
2. Sit on the top tube.
3. Pull the front brake.
4. Put your thumb and index finger onto the gap between the steerer tube and the fork. Gently move the front wheel back and forth.
5. Important: If you notice play, the headset needs to be adjusted immediately.

Adjusting the headset:

If you noticed play while checking the headset, proceed with the following steps to adjust your headset properly.

1. Step: Checking the Top Cap and related Components

- Removing Top-Cap: Unscrew and remove the top-cap in order to check if the DaPanda (expander in the fork shaft) is touching the top cap. This should not be the case.

- Check Spacers: The stem needs to be attached to the fork shaft so that the stem clamp is entirely in contact with the fork shaft. At least one spacer (5mm or more) needs to be sitting on the stem clamp so that the top of the spacer is above the top of the fork shaft.

- Loosen stem bolts: Loosen the bolts on the stem (Only slightly to allow movement of the stem up and down the fork shaft. Over loosening of the screws may lead to the need of realigning the stem.).

- Loosen iSR (steering limiter): Loosen the bolts on the iSR (Only slightly to allow movement of the iSR up and down the fork shaft. Over loosening of the screws may lead to the need of realigning the iSR.).

- Tighten top-cap: Tighten the top-cap to 3 Nm of torque.

- Tighten iSR: Tighten the iSR to 5 Nm of torque. Do this by increasing the torque by 0,5 Nm each time until both bolts are tightened to 5 Nm.

2. Step: Check if the play is still present

- Check again if there is any play present in the headset by using the previously described method “Checking the headset for play”.

3. If the play is still present, proceed with the following steps:

- Unscrew and remove the top-cap.

- Loosen the bolts on the stem and on the iSR.

- Loosen the DaPanda (expander) by unscrewing the bolt. If applicable slide the DaPanda downwards.

4. Tighten all the bolts in the following order:

- DaPanda-Bolt: 8 Nm (maximum)

- Top-cap-Bolt: 3 Nm

- iSR-Bolt: 5Nm

- Stem bolts: 5 Nm

 

5. Final Check

- Recheck again, if play is still present. Use the procedure “Checking the headset for play” described above.

If play is still present: visit a professional idworx-dealer

If there is still play present after all the steps above have been completed, please visit one of our idworx-dealers or contact us directly. It is very important that the problem is resolved by a professional as soon as possible.