Fork / Stem Assembly - Specialized AETHOS User Manual

7. FORK / STEM ASSEMBLY

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HEADSET COVER
COMPRESSION RING
UPPER BEARING
LOWER BEARING
FIG. 1: Install the headset and stem.
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• Install the front end (fork, headset, headset spacers, stem, handlebar, wheels) on the frame then
determine the rider's fit. Do not install more than 35mm of spacers between the stem and the
headset cover (fig.2).
• Trim the steerer tube so the final cut is 3mm below the top of the stem (or 3mm below the top of the
spacer if a 5mm spacer is used).
• Install the steerer tube expander plug, then torque the plug to 45 in-lbf / 5.1 Nm.
• When installing the headset for the final assembly, grease the bearings and compression ring.
• Install the headset cover, spacers and stem, followed by the top cap and bolt.
• Once the bike is fully assembled, adjust the headset, using the front brake to determine if there's any
headset looseness.
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Placing more than 5mm of stem spacers above the stem is acceptable for
fit purposes only. For actual riding, the stem requires full support from the
expander plug inside the fork to function safely and as intended.
EXPANDER PLUG
Once the bike's fit has been determined, the steerer tube should be cut 3mm
below the top of the stem. Alternatively, no more than one 5mm spacer can be
placed above the stem (fig. 2).
If a 5mm spacer is used, cut the steerer tube 3mm below the top of the 5mm
spacer.
WARNING! The stem must be fully supported by the expander plug. The
maximum combined height of the stem and optional 5mm spacer (from bottom
of stem to top cap) must not exceed 45mm. Exceeding 45mm can result in an
insufficiently supported stem, which can cause the steerer tube to fail.
ALPINIST COCKPIT: Please note the Roval Alpinist steerer tube clamp is 45mm
tall. To ensure full support from the expander plug, no spacers can be installed
above the stem.
WARNING! Do not apply grease or carbon assembly compound (carbon paste)
between the stem and the steerer tube, and do not twist the stem onto the
steerer tube. This can result in damage to the composite surface, which may
result in a catastrophic failure of the fork, resulting in serious personal injury
or death.
CAUTION: The Aethos is supplied with one 5mm solid spacer (consistent inner
diameter) and 35mm of scalloped spacers.
Only use the 5mm solid spacer above the stem, between the stem and the top cap.
Only use the 5mm and 10mm scalloped spacers below the stem, between the
stem and the headset cover.