May 16, 2010 Hi all How about some collective advice with regard to carbon steerer tube expander plugs? I've just bought a replacement carbon fork for my.

Built up several steel and Alu frames over the past 3-4 years but just about to start my first carbon frame build after bagging a PX Pro Carbon frameset in the 'Clearance Sale' a month or so back. Now equipped with a shiny new torque wrench which I've never had to use previously. However after a bit of googling I've not yet found any definitive guidance on what torque should be used on the installation of the carbon steerer bung.

I know I could employ trial and error eg - pick a setting then install stem (without tightening the clamp bolts) and try to set bearing pre-load. If this fails and the bung moves then up the torque setting and try again Would like to try and avoid that by doing a once and for all installation.

Also, what's the received wisdom on whether to use assembly paste on the inside of the steerer to anchor the bung more securely. The correct torque is the amount needed to correctly ensure there is no play in the headset - and no more.

Once the stem bolts are then tightened the top cap torque is irrelevant. The bung shouldn't creep up the steerer if is installed properly using carbon paste. If you are needing excessive torque to elminate play in the headset something is wrong somewhere. Either there isn't enough gap between the top of the steerer tube and the edge of the top spacer (should be 3mm approx), or you need to shim the conical top bearing cap so it isn't bottoming on the head tube. Daniel B wrote:Can't answer the exact question relating to this bike, but on my Scott, I found an online video where they specify 8nm - I tried this, and wowsas it did make me wince a bit, but it hasn't budged. This is the vid I located: Different frame and expander of course, so no idea if that is too much or too little, but might give you something to start with. Hi Daniel TKS for that - had found that video earlier but didn't watch it all the way through so missed the comment about torquing the plug fixing bolt to 8Nm.

I'm using a Zenith expander bung courtesy of Malcolm at Cycleclinic who swears by them. Torque setting should be in the same ball park so I will have a go at 8Nm to begin with. Daniel B wrote:Can't answer the exact question relating to this bike, but on my Scott, I found an online video where they specify 8nm - I tried this, and wowsas it did make me wince a bit, but it hasn't budged. This is the vid I located: Different frame and expander of course, so no idea if that is too much or too little, but might give you something to start with.

Hi Daniel TKS for that - had found that video earlier but didn't watch it all the way through so missed the comment about torquing the plug fixing bolt to 8Nm. I'm using a Zenith expander bung courtesy of Malcolm at Cycleclinic who swears by them. Torque setting should be in the same ball park so I will have a go at 8Nm to begin with.

Cool, let us know how you get on - I have to put one in to my Exocet 2 when I eventually get around to building it up!

To ensure the best performance and longest service life from your ENVE Composites Fork, please read and carefully follow these installation instructions. Failure to follow preparation, installation, and maintenance instructions will result in a void warranty.

Are you a visual leaner? Here are our tech videos for and. Parts Included: • 1 ENVE Compression Adjustment Plug w/ Top Cap • 1 ENVE Brake Cable Clip (Road Disc and CX Disc Fork) • 2 ENVE Cable Clips (MTN Rigid Fork) • 1 ENVE Fender (MTN Fork) • 1 ENVE Thru-Bolt (MTN Fork) • 1 ENVE Brake adaptor (MTN Fork) Recommended Tools: • Hacksaw with Fine Tooth Blade or Ideally a Tile Saw • Cutting Guide • Race Setting Tool • 4mm Hex • 5mm Hex • 6mm Hex • Fine Grit File/Sandpaper • Calibrated Torque Wrench Preparation: • Verify that the fork and the headset have compatible diameters. Verify that the stem steerer clamp diameter is compatible with the fork steerer tube diameter. Incorrect mating of components can cause component failure. • Confirm the headset parts and stem are free of any burrs or sharp edges.

Remove any burrs or sharp edges with 320/400 grit sandpaper. • Avoid scratching or scoring the steerer tube surface. Any damage to the steerer tube could cause failure. • Apply a small amount of grease to the fork crown race seat (pick any grease you desire- carbon prep is also acceptable). Do not make any modifications to the crown race area of the fork. Only use a headset race with the correct inside diameter for your fork steerer tube. You do not need a split crown race for installation on our forks.

• Hold one leg of the fork securely and, using an appropriate race seating tool, install the headset crown race. Do not place the fork on the dropout tips or crown while installing the race. Doing so can damage the fork and could cause failure.

• Assemble the fork, headset and any spacers in the head tube of the bicycle and slide on the stem. • The spacer stack between the top of the upper bearing and the bottom of the stem must not exceed 40 mm (this distance includes the headset dust cap or tapered spacer on top of the bearing). • The compression plug assembly will add 1mm to the top of the steerer tube. • Carefully measure and mark the amount of steerer tube that you will need to remove. ENVE recommends that the steerer tube extend 1mm past the top of the stem, and that a 5mm spacer be placed on top to ensure proper compression from the top cap.

• Remove the fork from the bicycle. • Make absolutely certain that you do not cut the steerer tube too short. Incorrectly cut steerer tubes are not covered under warranty. • Using a new fine tooth hacksaw with a proper cutting guide, cut the steerer tube to exact specifications. • Carefully sand or file off any loose fibers or burrs until the edges are smooth. • Clean the steerer tube and inside of the stem clamp with alcohol to remove grease and dirt; then let dry. Tech Note: Never use a star-fangled nut with a carbon steerer tube.

Installing the Fork: • Insert compression plug into cut steerer tube. Tighten compression plug using a torque wrench with 6mm Allen attachment to no more than 62 in-lbs (7 Nm).

• Assemble the fork, headset, spacers, top cap and top cap bolt in the head tube of the bicycle and slide on the stem. • Adjust headset tension using an appropriate hex wrench and according to the headset manufacturer’s instructions. If the headset manufacturer has not specified torque, tighten to 1.6 Nm (15 in-lbs). • Torque the stem steerer clamp bolts as specified by the stem manufacturer (do not exceed 6Nm). • Install the front brake following the brake manufacturer’s instructions. • Follow the wheel manufacturer’s instructions for correct clamping of the wheel quick release and install the front wheel.

Failure to properly adjust the quick release and secure the wheel can result in serious injury or death. • Adjust the front brake following the brake manufacturer’s instructions. Failure to properly install and adjust brakes can result in serious injury or death. • When using a dropout clamping bicycle rack, always clamp the dropouts securely to prevent dropout and/or bike damage. If the clamp is loose, the bike may fall out of the rack. When removing the fork from the clamp, be sure to remove both dropouts evenly at the same time. Do not tilt the bike to one side, because dropout damage may result.

Dropout damage can cause component failure, which can result in serious injury or death. • If using a thru-axle fork, ensure that the axle is torqued to 8nm. Tech Note: At this time, ENVE does not offer a mounting option for the DuraAce 9000 direct mount brake. Maintenance: • Do not modify the fork in any way, other than cutting the steerer tube to the correct length for your bike.

Modifying the fork could cause fork or other component failure resulting in serious injury or death. • Always loosen the stem’s steerer clamp bolts before attempting to make stem/fork alignment adjustments.

• Periodically remove, clean, and inspect your fork for any damage or cracks. Question Mark Clip Art. If you have any questions about a mark on the fork, consult ENVE Composites immediately.

• Inspect your components often. If you have any doubts about the integrity of any part, REPLACE IT. Consult your ENVE dealer if you are unsure about the condition of your components or any other part of your bicycle. • During your inspection, check for any delamination of fiber on the fork. This is an area where fiber is no longer bonded together. These areas can often be identified by a bulging, soft, or deformed shape. The areas can also be located by tapping gently on the surface.

The sound should be consistent and sharp. If you encounter an area of delamination, the sound will be different: often dull and less sharp. If you encounter signs of delamination, do not ride the fork. Report the damage to your ENVE dealer for further inspection. • Beware of unusual noises coming from your bicycle.

These noises can be indicators of damage. Before riding, find the source of the noise and correct it. •In case of a crash or any impact, carefully check your bars, stem, fork, seat post, wheels, and frame for any visible damage.

As with any component under stress, there is a limited fatigue life that is proportional to the use and abuse of the part. Inspect your components frequently.

If you have any concerns about the integrity of any part, discontinue riding the bicycle and have it inspected by a qualified bicycle technician, or contact ENVE Composites. • During your inspection, check for any delamination of fiber on the fork. This is an area where fiber is no longer bonded together.

These areas can often be identified by a bulging, soft, or deformed shape. The areas can also be located by tapping gently on the surface. The sound should be consistent and sharp. If you encounter an area of delamination, the sound will be different: often dull and less sharp. If you encounter signs of delamination, do not ride the fork.

Report the damage to your ENVE dealer for further inspection. • Beware of unusual noises coming from your bicycle. These noises can be indicators of damage. Before riding, find the source of the noise and correct it. • In case of a crash or any impact, carefully check your bars, stem, fork, seat post, wheels, and frame for any visible damage.

As with any component under stress, there is a limited fatigue life that is proportional to the use and abuse of the part. Inspect your components frequently. If you have any concerns about the integrity of any part, discontinue riding the bicycle and have it inspected by a qualified bicycle technician, or contact ENVE Composites.

Warning: Failure to follow these instructions can result in component failure. Component failure can lead to loss of control of the bicycle and result in serious personal injury or death. Carbon bicycle forks are subject to wear and stress during their lifetime. If the fork’s useful life is exceeded it can suddenly and catastrophically fail, which could cause serious injury or death. Scratches, cracks, fraying, discoloration, and softening areas of the part can all be signs that the product has reached the end of its useful life and needs to be replaced.

Quality of materials and workmanship of your fork are covered by its warranty but the product is not guaranteed to last the full term of the warranty. Product life can be related to the kind of riding and maintenance that the fork is subjected to.

The warranty does not imply that the fork will last forever, but that the fork’s workmanship and material is covered per the terms of the warranty. ENVE forks are designed and built for road riding.

They are intended for use on smooth surfaces and paved roads. When riding, take care to avoid pot holes, sewer grates, railroad tracks, expansion joints, construction areas, and debris that could catch in your front wheel and cause severe impact to the fork. Cyclocross forks about built for the CX application. The Mountain fork is built for singletrack Mountain riding.

They are not intended for stunt riding, jumping or other aggressive riding where sudden, drastic steering movements might be executed, or in situations outside of their intended application. These actions can put large, unpredictable loads on the fork in ways which it was not intended to sustain and could cause serious damage to the fork and consequently the rider. ENVE forks are not approved for tandem bicycle use. All ENVE components must be prepared, installed and maintained by a qualified bicycle mechanic using the appropriate professional tools.

Failure to follow the installation instructions can result in component failure. Component failure can lead to loss of control of your bicycle and result in serious injury or death. ENVE assumes no liability for improperly installed products and components.