All-City Cycles Thunderdome User manual

Thanks for buying the Thunderdome Carbon Track Fork. This 1-1/8" aluminum steerer carbon track fork
is designed and intended for use on a Velodrome. When used as intended, we guarantee you'll enjoy
this product.
WARNING: CYCLING CAN BE DANGEROUS. BICYCLE PRODUCTS SHOULD BE INSTALLED AND
SERVICED BY A PROFESSIONAL MECHANIC. NEVER MODIFY YOUR BICYCLE OR ACCESSORIES. READ
AND FOLLOW ALL PRODUCT INSTRUCTIONS AND WARNINGS INCLUDING INFORMATION ON THE
MANUFACTURER’S WEBSITE. INSPECT YOUR BICYCLE BEFORE EVERY RIDE. ALWAYS WEAR A HELMET.
To download full product instructions and safety information go to www.allcitycycles.com
and select the Safety/Tech tab.
1. Stem & Headset Preparation
• Verifythatthefork,headsetandallrequiredpartsforproperassemblyhavecompatibledimensions
The fork, headset, headset spacers and stem steerer clamp must have compatible diameters.
Incorrect use of components can cause component failure.
Visitheadsettnder.comtoverifyfork-to-framecompatibilityoptions.Visitbicycleheadsets.comtolearnmore
aboutheadsettandthenewStandardizedHeadsetIdenticationSystem.
•Makesureheadsetpartsthatcomeintocontactwiththesteerertubearefreeofburrsorsharpedges.
Removeburrsorsharpedgesbyusingverynegritsandpaper
•Makesurestempartsthatcomeintocontactwiththesteerertubearefreeofburrsorsharpedges.
Removeburrsorsharpedgeswithverynegritsandpaper
•Onlyuserearslot-styleclampingstems.Wedgeclampstemdesignsmustnotbeusedandcouldresult
infailure(Figure1)
2. Fork Preparation
•Avoidscratchingorscoringthesteerertube.Any damage to the steerer tube could cause failure
•Applyasmallamountofgreasetothecrownraceseat.Donotmakemodicationstothecrownraceseat
ofthefork.Onlyuseaheadsetcrownracewiththecorrectinsidediameterforyourforksteerertube
Visitheadsettnder.comtoverifyforktoframecompatibilityoptions.
•Holdonelegoftheforksecurelywhileusingacrownraceinstallationtoolto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. (Figure 2)
•Assemblethefork,headsetandanyspacersintheheadtubeofthebicycleandinstallthestem(Figure3)
• The spacer stack between the headset and stem must not exceed 50mm (Figure 4)
•Carefullymeasureandmarktheamountofsteerertubetoberemoved.Rememberthat,whencut,
thetopofthesteerertubemustbe2–3mmbelowthetopoftheheadsetspacer/stemassembly(Figure5)
•Removetheforkfromtheheadtube
• Make certain that you do not cut the steerer tube too short—measure twice, cut once
•Usinganewnetoothhacksawbladeandpropercuttingguide,cutthesteerertube.Apipe-cutter
maybeusedwithaluminumsteerertubes
•Usingnegritsandpaper,removeburrsandsharpedges
•Usingrubbingalcohol,cleanthesteerertubeandinsideofthestemclamptoremovegreaseanddirt
•Usingastar-nutsettingtool,installthestarnutsuppliedwithyourheadsetintothesteerertubeperthe
headsetmanufacturer’sinstructions
NOTE: The Thunderdome fork has an aluminum steerer with an inner diameter (ID) of 24.6mm.
We recommend using a 1" star nut system or a compression plug device that ts this 24.6mm ID.
3. Fork Installation
•Assemblethefork,headset,headsetspacersintheheadtubeofthebicycleandslideonthestemand
10mmspacer.Insertheadsetcompressionadjustmentdevice(compressionplug)intosteererandadjust
headsettensionusingappropriatetoolaccordingtotheheadsetmanufacturer’sinstructions.Iftorque
specicationsarenotprovided,tightento1.6Nm(15in-lb)
•Tightenstemsteererclampboltstostemmanufacturer’srecommendedtorquespecications
WARNING: Bikes for use on Velodrome should have a xed gear rear braking mechanism.
For all other street uses, All-City does not recommend riding without front and/or rear braking mechanisms.
Please follow brake manufacturer’s instructions.
•Onlyusethefrontbrakenutsuppliedwiththeforktomountthefrontbrake
•Installthefrontbrakefollowingthebrakemanufacturer’sinstructions
Thunderdome Fork Instructions www.allcitycycles.com
16294/13
2
A
B
C
D
E
F
G
H
I
J
3
1
Rear steerer slot
A - Compression device or 1" star nut system
B - 10mm spacer
C - Spacers (50mm max)
D - Upper headset
E - Headtube
F - Lower headset
G - Fork crown race
H - Top of steerer tube
I - Fork steerer tube
J - Crown race seat

•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
4. Fork Mount Bicycle Racks
•Whenusingafork-mount(axledropout-clamping)bicyclerack,alwaysensuretheclampisclosedsecurely
topreventdropoutand/orbikedamage.Iftheclampissettoolooselythebikecanfalloutoftherack
•Whenremovingtheforkfromtheclampingdevicemakesuretopull/pushstraightupallowingthedropouts
toberemovedevenlyandatthesametime.Donottiltthebiketoremoveitfromtheclampingdevice,
asdropoutdamagecanresult(Figure6)
Dropout damage can cause component failure, which can result in serious injury or death.
5. Ongoing Maintenance
•Donotmodifythefork,otherthancuttingthesteerertubetothecorrectlengthforyourbicycle
Modifying the fork could cause fork or other component failure resulting in serious injury or death
•Loosenthestem’ssteererclampboltsbeforemakinganystem-to-forkalignmentadjustments
•Periodicallyremove,cleanandinspectyourforkfordamage,cracksoranyotherdamage.Anyquestions
aboutmarksorcracksontheforkshouldbedirectedtoyourAll-Citydealerimmediately
•Regularlyinspectallcomponentsforanydamage(cracks,chips,etc.)andreplacecomponents
upondetection
•Intheeventofacrashorimpact,carefullyinspecthandlebars,fork,stem,seatpost,wheelsandtheframe
foranyvisibledamage.Aswithanycomponentundervaryingdegreesofstressthereisafatiguelifethat
isproportionaltothetypeofuseandabuseappliedtothepart.Alwaysinspectyourcomponentsbeforea
ride.Ifyouhavedoubtsabouttheintegrityandconditionofanypart,replaceit.Consultyourdealerifyou
areunsureabouttheconditionofyourcomponentsoranypartofyourbicycle
Limited Warranty
ThisAll-City®productiswarrantedagainstdefectsinmaterialsandworkmanshipforthreeyearsfrom
thedateofretailpurchaseoftheproduct,subjecttothelimitationsdetailedbelow.Save your dated receipt.
Thislimitedwarrantyisexpresslylimitedtotherepairorreplacementoftheoriginalproduct,
attheoptionofAll-City,andisthesoleremedyofthewarranty.Thislimitedwarrantyappliesonlyto
theoriginalpurchaseroftheAll-Cityproductandisnottransferable.InnoeventshallAll-Citybeliableforany
loss,inconvenienceordamage,whetherdirect,incidentalorconsequentialorotherwiseresultingfrombreach
ofanyexpressorimpliedwarrantyorcondition,ofmerchantability,tness
foraparticularpurpose,orotherwisewithrespecttothisproductexceptassetforthherein.Thiswarranty
onlyappliestoAll-Citybrandedproduct.Anyotheroriginalpartorcomponentshallbecoveredbythestated
warrantyoftheoriginalmanufacturer.
TOTHEEXTENTNOTPROHIBITEDBYLAW,THISWARRANTYISEXCLUSIVEANDTHEREARENOOTHER
EXPRESSORIMPLIEDWARRANTIESORCONDITIONSOFMERCHANTABILITYANDFITNESSFORA
PARTICULARPURPOSE.
Thiswarrantydoesnotcoverthefollowing:
• Damageduetoimproperassemblyorfollow-upmaintenanceorlackofskill,competence
orexperienceoftheuserorassembler
• Productsthathavebeenmodied,neglected,usedincompetitionorforcommercialpurposes,misused
orabused,involvedinaccidentsoranythingotherthannormaluse
• Damageordeteriorationtothesurfacenish,aestheticsorappearanceoftheproduct
• Normalwearandtear
• Laborrequiredtoremoveand/orretandre-adjusttheproductwithinthebicycleassembly
Other Products
CheckourwebsiteforthefullrangeofAll-Citybikes,frames,partsandaccessories.
Contact Us
Questions,comments,anecdotes,buildpicsandhipsterjokescanandshouldbedirectedto:
All-CityCycles
6400West105thStreet
Minneapolis,MN55438
Phone:1.888.4AC.BIKE
Web:www.allcitycycles.com
E-mail:[email protected]
Thunderdome Fork Instructions www.allcitycycles.com
16294/13
50mm
46
5
B
H2–3mm