Line the top bearing race and the bottom bearing race on the
headset with fresh grease.
And do them up enough to collapse the rubber well about to
about 75% of itys size. It doesnt need to be too tight.
Make sure you know which way around the two wheel spacers go,
they are different sizes.
They are marked, the wider one of the two has two grooves around
its centre, the smaller one has one.
The larger one with two grooves goes on the left side as you sit on
the bike.
Line the bearings with fresh grease. They are sealed bearings so
its just for water protection, not lubrication, and place the
spacers in.
Offer up the wheel and slide the axle through.
Line the race on the lower yolk with fresh grease.
Place the freshlypacked lower bearing over the race on the bottom
yolk and the freshly packed upper bearing in the top race on the
headset.
Then offer up the bottom yolk into position
Place the lightly greased top race onto the bearing and push it into
place.
Push the bearing cover into place.
If at any point during the last few steps you have let go of the lower
yolk without it being firmly supported it will have most likely
fallen on your foot.
Please please, email me and let me know if this happens to you.
Screw the first castle nut finger tight while keeping a firm upwards
pressure on the bottom yolk.
Now you can let go of it.
Torque it up to 40Nm, wiggle it from side to side and check torque
again. This pre loads the bearings.
Supporting the very firmly so it doesnt drop at all, loosen the nut
and torque it up to 15Nm.
Tabbed washer
Second castle nut.
Torque it up to XXNm
Put the top yolk in place and srew the top yolk nut finger tight.
Do not tighten it.
Slide the fork legs into place, make sure you dont have left and
right mixed up.
Hold them roughly in place with one of the bottom yolk clamp
bolts.
Position the forks accurately using a steel rule.
In my case, 4mm showing on the same point on both fork legs
including the top cap.
Tighten one clamp bolt a little on the top yolk just to hold each
one in place.
Check and readjust if needed.
When you are happy torque up all the bottom and top yolk clamp
bolts to xxNm
Now torque up the top yolk nut to 65Nm
Replace the rubber well nuts into the rear half of the front
mudguard
Offer up the wheel into position and slide the axle through.
