AS1 HEADSET
INSTALLATION INSTRUCTIONS
Thank you for selecting a new Nukeproof headset. With proper care and installation, it will give you
trouble-free, enjoyable use.
In order to maximise the safe enjoyment of this product, you should read and carefully follow the
following installation instructions and warnings. Failure to do so could result in unexpected wear and or
failure, possibly resulting injury. We recommend having your parts fitted by a qualified bicycle mechanic.
Nukeproof assumes no responsibility for malfunction or injury due to faulty installation.
AS1 Headset Installation Instructions:
Note: Prior to installation please ensure that the headtube of the frame is properly faced, has an
internal diameter (I.D.) of 49mm and that the reamed area is deep enough to accommodate this
headset.
1)
Prepare frame, fork and other assembling tools;
2)
Apply a small amount of Teflon grease to all surfaces, which will make contat with the
3)
headset cup inside the headtube;
To slacken the head angle on your frame by 1 degree, position the "front centre -1"graphic
on the (A) upper cup to the front of the headtube, ensuring it is perfectly central. (If you
4)
wish to steepen your head angle position the "front centre +1" graphic to the front);
Using a headset press, carefully press the (A) upper cup into the frame until it is flush with
5)
the headtube as shown in figure 1;
As you have decided to slacken your head angle, position the "front centre -1"graphic on
the (B) lower cup to the front of the headtube ensuring it is perfectly central. (If you wish to
6)
steepen your head angle position the "front centre +1" graphic to the front);
Using a headset press, carefully press the (B) lower cup into the frame until both the (A)
7)
upper cup and (B) lower cup are pressed flush with the headtube as shown in figure 1;
Press the (C) crown race on to the fork's steerer tube, leaving the split perpendicular to the
8)
front wheel. Make sure that you have put it on correct side up as shown in figure 2;
Apply a small amount of Teflon grease to the inside of the (A) upper and (B) lower cups and
press the (D) + (E) bearings into the cups with your fingers. Note that the bearings are fitted
9)
correct side up as shown in figure 3;
Carefully fit one of the (G) seals into each cup on top of the fitted bearings as shown in
10)
figure 3;
11)
Insert the steerer tube into the headtube as shown in figure 4;
Place the (F) upper lock ring and bearing top cap onto the top of the headset assembly as
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shown in figure 5;
Fit the stem onto the fork steerer tube and adjust to desired height using spacers as shown
13)
in figure 6;
Mark where you want to cut, check again and then cut the steerer tube using appropriate
tools so that the stem sits 2-3mm higher than the top of the cut steerer tube as shown in
14)
figure 6;
Remove the fork from the bike and fit the star fangled nut into the steerer tube using the
15)
appropriate tool;
Now re-insert the fork into the correctly assembled headset, fit the spacers/stem, place
the top cap onto the top of the assembly and screw the (H) bolt into the star nut until it is
16)
finger tight as shown in figure 6;
Tighten the (H) bolt with a 5mm Allen key until there is no play in the headset but it can still
17)
turn freely;
Follow the manufacture's installation instructions for your stem and other controls before
riding the bike.
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