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Fuji Bikes Carbon Team (Int'l) User's Manual

1. allowed stack height 40mm of headset spacers unless the desired stem height is pre determined Place the spacers above or below the stem to adjust your position Once a precise stem height is achieved a cut can be made to eliminate any spacers that are above the stem 3 CUTTING THE FORK STEERER TUBE Make a mark on the steerer tube at the top of the stem once the desired stem height is achieved The actual cutting line must be 2mm below the mark Before cutting the steerer tube wrap the area where you intend to cut with several layers of masking tape or duct tape This will limit the amount of fraying of fibers resulting in a cleaner cut Once wrapped determine the exact location of the desired cut by a pen mark on the tape NOTE It is recommended that a fine tooth 36 teeth saw blade be used to avoid the fraying of composite fibers A carbide grit toothless saw blade is also acceptable Please abide by the adage check twice cut once It s much easier than buying a new fork NOTE Fuji recommends that when cutting a steerer tube a steerer tube cutting guide tool be used It is very important that the steerer tube be cut straight Once the steerer tube is cut round out the top edge of the steerer tube by using an emery board or fine grit sandpaper Wipe off excess dust DO NOT breathe carbon dust 4 FORK INSTALLATION Install the steerer tube plug Insert the fork back into the headset and place the desired amount of
2. leg extension Using an allen head tighten seat post clamp to recommended torque spec NOTE Recommended torque is 50 in Ibf 5 65 Nm Do no exceed maximum torque of 60 in Ibf 6 78 Nm Exceeding this limit can result in damage to the seat post All Fuji carbon seat posts are marked with a minimum insertion line This is the minimum amount of insertion required for the seat post to remain structurally safe Some frames will require additional insertion to ensure that the frame remains structurally sound as well The base of the seat post should be inserted enough into the seat tube to extend below the bottom of the top tube A Warning Fuji carbon seat posts are made to be lightweight and are not suitable for all riders and all possible uses If the rider is approaching 250 Ibs 113 4 kg in weight Fuji recommends against the use of this seat post This seat post should be used only for road riding and not mountain bike use Failure to follow this warning may result in a catastrophic failure of the seat post causing serious personal injury or death Warning Seat post is NOT to be extended beyond the minimum insertion line Extension beyond the minimum line can result in failure causing serious injury or death Warning It may be visually difficult to identify damage to the composite material If the external composite surface is dented frayed gouged deeply scratched fractured chipped or otherwise damaged the component should be rep
3. Dear Fuji Customer Congratulations The carbon fiber Fuji bike that you have chosen is among the finest of advanced products available in cycling And while Fuji s frames and forks pass the very highest of safety standards during production carbon fiber remains a unique material that requires care and maintenance once you ve taken your bike home Please take a moment to review these carbon fiber care instructions so that you can get the most out of your ride Also please note that Fuji is proud to offer a Limited Lifetime Warranty on all of our bicycles For more information contact your local authorized Fuji dealer You can find a list as well as other valuable information about Fuji s products at www fujibikes com Sincerely Patrick J Cunnane President Advanced Sports Inc Fuji Bicycles CARBON FORK INSTALLATION GUIDE Please read the following instructions regarding carbon fork installation If you have any doubt about your mechanical ability please visit your local authorized Fuji dealer Fuji recommends that the fork be installed according to recommended torque specifications Also please heed the following warnings Failure to follow any warnings may result in a catastrophic failure of the fork which may in turn result in serious injury or death A Warning The recommended torque specs in the guide are specific for this Fuji product Refer to owners manual for the mating component s recommended torque Always use
4. ation please visit the tech section at www fujibikes com 2 SEAT POST SIZING All posts To ensure that the diameter of the seat post conforms to the diameter of the seat tube check to make sure that there is no play while the seat post is inside the frame If there is play or the seat post lowers into the frame with no resistance have an authorized Fuji dealer verify the fit tolerance Round posts If the seat post does not install in a straight smooth fashion DO NOT TWIST If the seat post does not install properly it is recommended that the fit be verified by an authorized Fuji dealer It may be necessary to have the seat tube reamed to fit properly Warning Incorrect sizing of a seat post can result in slippage or failure causing serious injury or death 3 SEAT POST SADDLE INSTALLATION Note Lightly grease saddle clamp bolt threads 4 Place the saddle in the clamp and adjust to the desired angle The adjusting bolt on the bottom side of the head of the seat post requires a 6mm allen key Recommended torque is 100 in lbf 11 3Nm Do not exceed maximum torque of 120 in lbf 13 5Nm If the nose is tilted at an undesirable angle loosen the 6mm allen bolt slightly and reset the angle of the seat Once desired seat angle is achieved tighten 6mm allen bolt per torque specs SEAT POST HEIGHT ADJ USTMENT TORQUE Once the desired angle of the saddle has been adjusted place the seat post at the required height for proper
5. headset spacers to achieve proper stem height When proper height is achieved install the preload cap NOTE Do not twist stem onto carbon steerer tube This could result in damage to the steerer tube and render the fork unsafe Adjust the headset to eliminate any free play make sure that the fork still rotates freely Make sure that the stem and fork are aligned Tighten the stem s top and bottom steerer clamp bolts in an alternating pattern Increase torque in 5 in lbf 0 56 Nm increments until the specified torque is achieved Recommended torque for the steerer tube is 75 in Ibf 8 5 Nm Do not exceed maximum torque of 90 in Ibf 10 1 Nm Install the front brake on the fork Recommended torque is 70 in Ibf 8 Nm Do not exceed maximum torque of 87 in Ibf 10 Nm A Warning It may be visually difficult to identify damage to the composite material If the external composite surface is dented frayed gouged deeply scratched fractured chipped or otherwise damaged the component should be replaced If seat post has been involved in a crash or impact even if there is no visible damage Fuji or an authorized Fuji dealer should inspect the product CARBON SEAT POST INSTALLATION GUIDE Please read the following instructions If you have any doubt regarding your mechanical ability visit your local authorized Fuji dealer Fuji recommends that the seat post be installed according to recommended torque specification Please read the foll
6. laced If seat post has been involved in a crash or impact even if there is no visible damage Fuji or an authorized Fuji dealer should inspect the product CARBON FRAME GUIDE Please read the following instructions If you have any doubt regarding your mechanical ability visit your local authorized Fuji dealer Fuji recommends that the bottom bracket headset rear derailleur and water bottle bolts be installed according to recommended torque specification A Warning Failure to follow any warning may result in a catastrophic failure of the seat post resulting in serious injury or death This phrase may not be repeated in connection with each warning Assembling a complete bicycle is a complicated task Only a trained and experienced bicycle mechanic should install components to this frame A Warning Bicycle assembly requires training and experience If you do not have the experience and training as a bicycle mechanic DO NOT attempt the assembly of this bike Failure to follow this warning may result in serious injury or death Follow all torque specifications to ensure the best assembly possible and to prevent any damage to the components or frame For correct torque specifications as well as recommended loads that the contact points of the frame are capable of accepting please refer to the owner s manual A Warning Failure to follow torque specifications will void your warranty It may also damage the frame which may not be visib
7. le to the eye If there is damage to the frame this can result in loss of structural integrity which may result in serious injury or death All bicycle components should be compatible with each other i e handlebar handlebar stem seat post saddle brakes etc Any doubt regarding compatibility should be addressed with an authorized Fuji dealer A Warning You should never clamp the frame when placing this bike in a repair stand Always clamp the seat post Clamping the frame can cause serious damage to the frame which may not be visible This will impair the structural integrity of the frame Failure to follow this warning may result in serious injury or death Your Fuji frame does not require any pre installation preparation to the bottom bracket or head tube Surfaces are prepared at the factory Grease will still need to be placed on the bottom bracket threads and the head set cups If necessary you may need to chase the bottom bracket threads BOTTOM BRACKET Clean and grease bottom bracket shell threads before installing Recommended torque is 442 in lbf 50 Nm Do not exceed maximum torque of 670 in Ibf 70 Nm HEADSET I NSTALLATI ON All Fuji road bikes come with integrated headsets No headset tool is required Clean and grease headset cups before installing bearings Do not mix headset components with other headsets For example crown races vary from headset to headset REAR DERAILLEUR Clean and lightly grease th
8. owing warnings Failure to follow any warning may result in a catastrophic failure of the seat post resulting in serious injury or death This phrase may not be repeated in connection with each warning A Warning This product is designed for road use only This seat post is NOT intended for off road use A Warning Recommended torques in this guide are specific for Fuji seat posts Refer to the owners manual for the mating component s recommended torque Use the lowers torque recommendation 1 SURFACE PREPARATION Before installing the seat post follow the steps below a Remove all burrs and square edges from seat tube surfaces in contact with the seat post These edges and burrs can dig into the material compromising the strength of the carbon A Warning Any deep scratch or gouge in the seat post can weaken the seat post resulting in failure causing serious personal injury or death b Round posts when using a standard seat clamp mechanism the seat post collar should be positioned 180 degrees opposite the seat tube slot This reduces the possibility of the edges of the seat tube digging into the seat post which can compromise the integrity of the seat post c Remove any grease from internal surface of seat tube Since composite seat posts are noNmetallic they will not seize in the seat tube Grease reduces the friction that is critical to proper seat post grip Note DO NOT cut Fuji carbon seat posts For additional inform
9. reads prior to installation Recommended torque for the rear derailleur is 70 in lbf 8Nm Do not exceed maximum torque of 87 in lbf 10 Nm BRAKES Install the rear brake caliper on the frame Recommended torque for road brake calipers is 70 in Ibf 8 Nm Do not exceed maximum torque of 87 in Ibf 10 Nm WATER BOTTLE CAGE Recommended torque for the water bottle cage bolt is 35 in Ibf 3 9 Nm Do not exceed maximum torque of 40 in lbf 4 5 Nm A Warning You should always take extreme precaution to not damage carbon fiber or composite materials including frame or other carbon composite component Damage may result in loss of structural integrity This damage may not be visible Before each ride and after every crash you should carefully inspect your bicycle for any dents gouges fraying scratches through the paint chipping bending or any other signs of damage It is recommended by Fuji Bikes that you take your bike to a Fuji dealer for a complete inspection if it shows any of these signs WARRANTY For complete warranty provisions please see the owner s manual or visit your local authorized Fuji dealer www fujibikes com
10. the lower torque recommendation 1 COMPONENT PREPARATION Make sure that there are no burrs or sharp edges that could damage the surface in contact with each other If burrs or sharp edges exist use a fine grit sandpaper to eliminate Make sure that all edges that are in contact with the steerer are rounded out to eliminate any stress points A Warning Burrs or sharp edges can damage the steerer tube Any deep scratch or gouge in the fork can weaken the component resulting in failure causing serious injury or death NOTE Do not use internal wedge clamp style stems which can cause damage to the steerer tube when tightened Fuji recommends using an external slotted clamp See fig 1 2 FORK PREPARATION Lightly grease the base of the steerer tube before installing the crown race Seat the crown race onto the base of the steerer tube using a crown race installation tool While installing the crown race the fork should be held by the legs Placing the fork dropouts on any surface can damage the dropouts Insert the headset into the frame following the headset manufacturer s instructions Insert the steerer tube into the frame Place the desired amount of headset spacers and the stem DO NOT APPLY ANY GREASE TO THE STEERER TUBE NOTE Installing more than 40mm 1 5 stack height of headset spacers can compromise the strength of the steerer tube It is recommended that the initial installation of the fork be done with the maximum

Fuji Bikes Carbon Team (Int'l) User's Manual

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