ax-lightness Engage HANDLEBAR User manual

by ax-lightness
HANDLEBAR / STEM

2
by ax-lightnessby ax-lightness
General notes on mounting and compatibility������������������������������������������������� 3
Mounting AX-Lightness and engage Aheadset®-stems ��������������������������������4
Mounting AX-Lightness and engage handlebars �������������������������������������������� 6
Adjusting the Aheadset®-headset����������������������������������������������������������������������� 9
road racing bicycle – Adjusting the handlebars ��������������������������������������������� 11
Mountain bike – Adjusting brake lever/shifter units������������������������������������13
Mounting bar ends....................................................................................................13
Adjusting the handlebar height ������������������������������������������������������������������������� 16
Aheadset®-stems .....................................................................................................16
Readjusting the Aheadset® by using spacers..................................................16
Grips and bar tape�������������������������������������������������������������������������������������������������� 18
Mounting the grips ......................................................................................................... 18
Wrapping the bar tape ...................................................................................................19

3
by ax-lightness
HANDLEBARS  STEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
General notes on mounting and compatibility . . . . . . . . . . . . . . . . . . . .87
Mounting AX-Lightness and engage Aheadset®-stems. . . . . . . . . . . . .88
Mounting AX-Lightness and engage handlebars. . . . . . . . . . . . . . . . . . .90
Adjusting the Aheadset®-headset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Road racing bicycle – Adjusting the handlebars. . . . . . . . . . . . . . . . . . . .95
Mountain bike – Adjusting brake lever/shifter units. . . . . . . . . . . . . . . .97
Mounting bar ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Adjusting the handlebar height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Aheadset®-stems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Readjusting the Aheadset® by using spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Grips and bar tape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Mounting the grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Wrapping the bar tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
General notes on mounting
and compatibility
Before you start mounting make sure the stem you
have chosen has a clamping diameter matching the
AX-Lightness and engage handlebars. The same ap-
plies to both the stem and the steerer tube.
Our AX-Lightness road racing handlebars have a
clamp diameter of 26.0 mm.
The clamp diameter of our AX-Lightness mountain
bike handlebars is 25.4 mm (a).
The clamp diameter of all engage handlebars is 31.8
mm (b).
Most steerer tubes measure 1 1/8“, which corresponds
to 28.6 mm. The AX-Lightness and engage stems are
designed for these clamp diameters.
Only use brake levers and shifters with symmetrical
clamps (c).
The same applies to bar ends on handlebars de-
signed to be tted with bar ends. Bar ends must have
a symmetrical clamp, as well. Be sure to mount bar
ends only on handlebars approved for bar ends. Ob-
serve the product descriptions and type labels on the
handlebars.
Do not mount aero handlebars, also referred to as
clip-ons, on standard AX-Lightness and engage han-
dlebars. If you need aero handlebars, get in touch
with us. You will obtain from us custom-made han-
dlebars with special reinforcements.
gAsymmetrical clamps or handlebar grips
fastened with a single bolt etc. can damage
AX-Lightness and engage handlebars.
gMake it a rule to use AX-Lightness car-
bon assembly paste to achieve maximum
clamping with minimum torque values.
g
If you mount new AX-Lightness
and engage handlebars to an
existing stem, check the old han-
dlebars carefully for scratches,
abrasion marks and notches after
removal. Damage in the clamping
area indicates insucient process-
ing or defective design of the stem
in these areas.
86 87
Handlebars - Stem
b
a
c
by ax-lightness

4
Mounting AX-Lightness and
engage Aheadset®-stems
Many AX-Lightness (a) and engage stems can be
mounted in either vertical orientation. These ip-op
models allow handlebars to be positioned at two dif-
ferent heights by simply inverting the stem.
Make sure the AX-Lightness and engage stem and
fork steerer tube always have matching or compati-
ble clamp diameters (b)!
If you t a new AX-Lightness and engage stem on
a fork with carbon steerer tube, check the clamping
area of the fork for notches or abrasion marks. In case
damage is visible, ask your AX-Lightness and engage
dealer whether the fork must be replaced.
Make sure the clamping areas are absolutely free of
grease, especially when the clamping surfaces are
made of carbon. Use AX-Lightness carbon assembly
paste (c) on the clamping areas to optimize the xing.
Grease the threads and the connecting surfaces/
heads of the steerer clamp bolts (d). Keep lubricants
away from clamping surfaces.
Slide the AX-Lightness and engage stem on the fork
steerer tube (e). It must t snugly on the fork. Do not
t stems which have play on the steerer tube.
Depending on the steerer tube length and the de-
sired stem position, insert spacers (f) on the fork
steerer above the upper cover of the headset, and/
or above the stem. You can stack them up to a maxi-
mum height of 30 mm.
Spacers are available in dierent heights. You have
installed the correct number of spacers, when the
steerer tube ends 2 mm below the top edge of the
stem.
Make sure the stem provides sucient support for
the steerer tube and the steerer tube ends 2 mm at
the most below the top edge of the AX-Lightness and
engage stem. This ensures a reliably clamping when
tightening the clamping bolts of the steerer tube
clamp to the prescribed torque value.
If the preferred height of your AX-Lightness and
engage stem results in a deeper position of the stem
on the steerer tube, the steerer tube projects from the
stem. To check whether you have found the proper
position, slide spacers on the steerer by making sure
that the steerer tube ends 2 mm below the top edge
of the stem. After the test ride the steerer tube of a
carbon fork must be shortened.
For proper load distribution during clamping the
clamp bolts of AX-Lightness and engage stems are
designed to be screwed in in a determined direction
(g). Be sure not to change the screw-in direction.
Tighten the stem bolts only a little, if you intend to
mount the handlebar right afterwards. The headset
has to be adjusted afterwards (h) (see chapter “Ad-
justing the Aheadset®-headset”).
iAX-Lightness and engage stems are ip-
op models, i.e. they allow an upward or
downward oriented mounting.
gThe space between the top of the steerer
tube and the upper edge of the AX-Light-
ness and engage stem should not exceed
a maximum of 2 mm. The space between
the top of the steerer tube and the upper
edge of the AX-Lightness and engage stem
should not exceed a maximum of 2 mm.
gObserve the maximum spacer height of 30
mm and do not insert permanently more
than 5 mm of spacers above the stem, if
your fork steerer tube is made of carbon.
88 89
Handlebars - Stem
a
b
c
d
h
g
f
e
by ax-lightness

5
Mounting AX-Lightness and
engage Aheadset®-stems
Many AX-Lightness (a) and engage stems can be
mounted in either vertical orientation. These ip-op
models allow handlebars to be positioned at two dif-
ferent heights by simply inverting the stem.
Make sure the AX-Lightness and engage stem and
fork steerer tube always have matching or compati-
ble clamp diameters (b)!
If you t a new AX-Lightness and engage stem on
a fork with carbon steerer tube, check the clamping
area of the fork for notches or abrasion marks. In case
damage is visible, ask your AX-Lightness and engage
dealer whether the fork must be replaced.
Make sure the clamping areas are absolutely free of
grease, especially when the clamping surfaces are
made of carbon. Use AX-Lightness carbon assembly
paste (c) on the clamping areas to optimize the xing.
Grease the threads and the connecting surfaces/
heads of the steerer clamp bolts (d). Keep lubricants
away from clamping surfaces.
Slide the AX-Lightness and engage stem on the fork
steerer tube (e). It must t snugly on the fork. Do not
t stems which have play on the steerer tube.
Depending on the steerer tube length and the de-
sired stem position, insert spacers (f) on the fork
steerer above the upper cover of the headset, and/
or above the stem. You can stack them up to a maxi-
mum height of 30 mm.
Spacers are available in dierent heights. You have
installed the correct number of spacers, when the
steerer tube ends 2 mm below the top edge of the
stem.
Make sure the stem provides sucient support for
the steerer tube and the steerer tube ends 2 mm at
the most below the top edge of the AX-Lightness and
engage stem. This ensures a reliably clamping when
tightening the clamping bolts of the steerer tube
clamp to the prescribed torque value.
If the preferred height of your AX-Lightness and
engage stem results in a deeper position of the stem
on the steerer tube, the steerer tube projects from the
stem. To check whether you have found the proper
position, slide spacers on the steerer by making sure
that the steerer tube ends 2 mm below the top edge
of the stem. After the test ride the steerer tube of a
carbon fork must be shortened.
For proper load distribution during clamping the
clamp bolts of AX-Lightness and engage stems are
designed to be screwed in in a determined direction
(g). Be sure not to change the screw-in direction.
Tighten the stem bolts only a little, if you intend to
mount the handlebar right afterwards. The headset
has to be adjusted afterwards (h) (see chapter “Ad-
justing the Aheadset®-headset”).
iAX-Lightness and engage stems are ip-
op models, i.e. they allow an upward or
downward oriented mounting.
gThe space between the top of the steerer
tube and the upper edge of the AX-Light-
ness and engage stem should not exceed
a maximum of 2 mm. The space between
the top of the steerer tube and the upper
edge of the AX-Lightness and engage stem
should not exceed a maximum of 2 mm.
gObserve the maximum spacer height of 30
mm and do not insert permanently more
than 5 mm of spacers above the stem, if
your fork steerer tube is made of carbon.
88 89
Handlebars - Stem
a
b
c
d
h
g
f
e
by ax-lightness

6
Mounting AX-Lightness
and engage handlebars
Apply AX-Lightness carbon assembly paste in the
area of the clamping (a+b) on the AX-Lightness and
engage handlebars as well as on the stem.
Position the stem clamp in the middle of your new
AX-Lightness and engage handlebars (c) so that the
handlebars extend the same distance from the stem
on each side. If the handlebars do not slide easily
into the stem clamp or if there is play between the
two components, ask your AX-Lightness and engage
dealer whether both components are compatible.
Mountain bike handlebars are normally mounted
with the sweep supporting a natural ergonomic
hand position, i.e. bent slightly rearward. The handle-
bar position is correct when your wrists are relaxed
and your elbows not ared out too much.
In the case of road racing bicycles the straight piece
of the drops should be in parallel to the ground or
point with the ends slightly downwards.
Tighten the greased bolts of the stem faceplate with
your ngers by a few turns (d). Do not apply grease
on the clamping surfaces. Tighten the bolts of the AX-
Lightness handlebars with a 3 mm Allen key and the
bolts of the engage handlebars with a 4 mm Allen
key until the clamping slots are identical in width on
all sides.
If you have a four-bolt stem, the upper and lower
clamping slots must be identical in width and parallel
in addition (e).
Finish by checking the position of the handlebars.
Tighten the xing bolts evenly in a cross pattern, i.e.
alternately and in small increments to the minimum
limit of the recommended torque values by using a
high-quality torque wrench with a 3 mm hexagon
bit socket in the case of AX-Lightness handlebars (f)
and a 4 mm hexagon bit socket in the case of engage
handlebars (g). If you have a four-bolt stem, tighten
the bolts in a cross pattern.
The recommended maximum torque value for the
AX-Lightness Zeus stem is 3-4 Nm. Always use a
high-quality torque wrench and observe the torque
value indicated on the component in case of doubt.
Check the brake lever/shifter or the brake grips for
burrs and sharp edges (h). Do not use shifters or brake
levers with burrs or sharp edges to prevent your
AX-Lightness and engage handlebars from damage
or notches.
Components that are aected by burrs or sharp edg-
es should be checked by your AX-Lightness and en-
gage dealer. They will see, whether this is a problem
that can be solved or whether the component has to
be replaced.
Loosen clamping bolts completely to ensure clamps
are open all the way before sliding the shifters and
brake levers onto the handlebars. In the case of some
mountain bike brake grips a part of the clamp can be
folded upwards or removed.
90 91
Handlebars - Stem
a
b
c
d
h
g
f
e
by ax-lightness

7
Mounting AX-Lightness
and engage handlebars
Apply AX-Lightness carbon assembly paste in the
area of the clamping (a+b) on the AX-Lightness and
engage handlebars as well as on the stem.
Position the stem clamp in the middle of your new
AX-Lightness and engage handlebars (c) so that the
handlebars extend the same distance from the stem
on each side. If the handlebars do not slide easily
into the stem clamp or if there is play between the
two components, ask your AX-Lightness and engage
dealer whether both components are compatible.
Mountain bike handlebars are normally mounted
with the sweep supporting a natural ergonomic
hand position, i.e. bent slightly rearward. The handle-
bar position is correct when your wrists are relaxed
and your elbows not ared out too much.
In the case of road racing bicycles the straight piece
of the drops should be in parallel to the ground or
point with the ends slightly downwards.
Tighten the greased bolts of the stem faceplate with
your ngers by a few turns (d). Do not apply grease
on the clamping surfaces. Tighten the bolts of the AX-
Lightness handlebars with a 3 mm Allen key and the
bolts of the engage handlebars with a 4 mm Allen
key until the clamping slots are identical in width on
all sides.
If you have a four-bolt stem, the upper and lower
clamping slots must be identical in width and parallel
in addition (e).
Finish by checking the position of the handlebars.
Tighten the xing bolts evenly in a cross pattern, i.e.
alternately and in small increments to the minimum
limit of the recommended torque values by using a
high-quality torque wrench with a 3 mm hexagon
bit socket in the case of AX-Lightness handlebars (f)
and a 4 mm hexagon bit socket in the case of engage
handlebars (g). If you have a four-bolt stem, tighten
the bolts in a cross pattern.
The recommended maximum torque value for the
AX-Lightness Zeus stem is 3-4 Nm. Always use a
high-quality torque wrench and observe the torque
value indicated on the component in case of doubt.
Check the brake lever/shifter or the brake grips for
burrs and sharp edges (h). Do not use shifters or brake
levers with burrs or sharp edges to prevent your
AX-Lightness and engage handlebars from damage
or notches.
Components that are aected by burrs or sharp edg-
es should be checked by your AX-Lightness and en-
gage dealer. They will see, whether this is a problem
that can be solved or whether the component has to
be replaced.
Loosen clamping bolts completely to ensure clamps
are open all the way before sliding the shifters and
brake levers onto the handlebars. In the case of some
mountain bike brake grips a part of the clamp can be
folded upwards or removed.
90 91
Handlebars - Stem
a
b
c
d
h
g
f
e
by ax-lightness

8
In the case of road racing bicycle brake lever/shifter
units (Dual Control, Ergopower or DoubleTap) dis-
mount the clamp completely from the unit (a).
Carefully slide the clamp on the handlebars (b) and
subsequently re-mount the unit to the clamp.
Start tightening the clamping bolts slightly, so that
the unit can still rotate freely. Bring the brake lever/
shifter units to the desired position.
As soon as the unit is in the desired position, apply
some AX-Lightness carbon assembly paste in the area
of the clamping.
Tighten the bolts just enough to secure the brake
lever/shifter units (c+d). Be sure not to exceed the
prescribed torque value, as the brake levers will oth-
erwise damage the AX-Lightness and engage han-
dlebars.
Never rotate the units on the handlebars after you
have tightened the clamping bolts. Otherwise you
will scratch the surface and mar the nish. In addition
you run the risk of damaging the material.
gNever shorten AX-Lightness and engage
mountain bike handlebars by cutting o
the ends, as the handlebars are general-
ly reinforced in the clamping areas of the
shift/brake lever units. In addition, you
would cut o the bar end reinforcements.
These reinforcements are designed to with-
stand the forces occurring in these areas.
iRead through the user manuals of all com-
ponents of the other manufacturers before
you follow the above instructions.
gDo not shorten AX-Lightness and engage
handlebars, as this would damage the han-
dlebars and result in a severe accident dur-
ing use. Any modication to an AX-Light-
ness and engage carbon component will
void the warranty.
Adjusting the Aheadset®-headset
Adjusting the headset is a job for a skilled bicycle me-
chanic. Have this work solely done by an authorized
AX-Lightness and engage dealer. If you intend to do
the adjustment on your own, read the chapter“Fork
– Headset” or the user manual of the headset manu-
facturer rst and note that you need special tools, e.g
a high-quality torque wrench.
Release the clamping bolts on the side of the
AX-Lightness and engage stem by two to three turns
(e) without unscrewing them entirely.
The Allen bolt located in the top cap is intended to
re-adjust the bearing play (f). Turning the bolt clock-
wise removes play, as the stem is pressed downward
on the bearing; turning the bolt anticlockwise in-
creases the play. In case there is bearing play, tighten
the adjusting bolt by another quarter or half a turn.
Check the headset for play (g) as described in the
general user manual of your bicycle. Do not over-
tighten the headset; otherwise there is the risk of
headset failure.
Do not overtighten the top Allen bolt. It is intended
for adjustment! Tighten the bolt carefully in quar-
ter-turns and check the play regularly.
Once the play is properly adjusted, align the AX-Light-
ness and engage stem in the direction of motion.
Check the alignment of frame and stem with the
front wheel from the top (h). The AX-Lightness and
engage handlebars should be at right angle to the
direction of motion.
92 93
Handlebars - Stem
a
b
c
d
h
g
f
e
by ax-lightness

9
In the case of road racing bicycle brake lever/shifter
units (Dual Control, Ergopower or DoubleTap) dis-
mount the clamp completely from the unit (a).
Carefully slide the clamp on the handlebars (b) and
subsequently re-mount the unit to the clamp.
Start tightening the clamping bolts slightly, so that
the unit can still rotate freely. Bring the brake lever/
shifter units to the desired position.
As soon as the unit is in the desired position, apply
some AX-Lightness carbon assembly paste in the area
of the clamping.
Tighten the bolts just enough to secure the brake
lever/shifter units (c+d). Be sure not to exceed the
prescribed torque value, as the brake levers will oth-
erwise damage the AX-Lightness and engage han-
dlebars.
Never rotate the units on the handlebars after you
have tightened the clamping bolts. Otherwise you
will scratch the surface and mar the nish. In addition
you run the risk of damaging the material.
gNever shorten AX-Lightness and engage
mountain bike handlebars by cutting o
the ends, as the handlebars are general-
ly reinforced in the clamping areas of the
shift/brake lever units. In addition, you
would cut o the bar end reinforcements.
These reinforcements are designed to with-
stand the forces occurring in these areas.
iRead through the user manuals of all com-
ponents of the other manufacturers before
you follow the above instructions.
gDo not shorten AX-Lightness and engage
handlebars, as this would damage the han-
dlebars and result in a severe accident dur-
ing use. Any modication to an AX-Light-
ness and engage carbon component will
void the warranty.
Adjusting the Aheadset®-headset
Adjusting the headset is a job for a skilled bicycle me-
chanic. Have this work solely done by an authorized
AX-Lightness and engage dealer. If you intend to do
the adjustment on your own, read the chapter“Fork
– Headset” or the user manual of the headset manu-
facturer rst and note that you need special tools, e.g
a high-quality torque wrench.
Release the clamping bolts on the side of the
AX-Lightness and engage stem by two to three turns
(e) without unscrewing them entirely.
The Allen bolt located in the top cap is intended to
re-adjust the bearing play (f). Turning the bolt clock-
wise removes play, as the stem is pressed downward
on the bearing; turning the bolt anticlockwise in-
creases the play. In case there is bearing play, tighten
the adjusting bolt by another quarter or half a turn.
Check the headset for play (g) as described in the
general user manual of your bicycle. Do not over-
tighten the headset; otherwise there is the risk of
headset failure.
Do not overtighten the top Allen bolt. It is intended
for adjustment! Tighten the bolt carefully in quar-
ter-turns and check the play regularly.
Once the play is properly adjusted, align the AX-Light-
ness and engage stem in the direction of motion.
Check the alignment of frame and stem with the
front wheel from the top (h). The AX-Lightness and
engage handlebars should be at right angle to the
direction of motion.
92 93
Handlebars - Stem
a
b
c
d
h
g
f
e
by ax-lightness

10
With carbon steerer tubes, make sure the inside of
the tube is supported by a suitable expander-cone
mechanism for adjusting the headset. AX-Lightness
and engage recommend the gumgum from Tune for
AX-Lightness forks.
Be sure to observe the chapter “Fork – Headset” or
the instructions given in the user manual of the fork
manufacturer before tightening the stem.
Start by tightening both clamping bolts alternately
and then by using a high-quality torque wrench (a).
Start with a standard torque wrench and a minimum
torque value of 3 Nm.
Check the secure clamping of the AX-Lightness and
engage stem by holding the front wheel between
your knees and trying to turn the handlebars relative
to the front wheel (b).
In case the stem clamping is not tight enough, in-
crease the torque value to 4 Nm.
In case the AX-Lightness and engage stem is still not
tight enough, dismount the stem and once again ap-
ply some AX-Lightness carbon assembly paste (c) on
the fork steerer tube and the inside of the stem.
If the AX-Lightness and engage stem cannot be tight-
ened on the fork steerer tube to a tightening torque
of 4 Nm, in spite of the AX-Lightness carbon assem-
bly paste on the clamping surfaces, stem and fork are
incompatible.
Replace the AX-Lightness and engage stem by
a matching model or ask your AX-Lightness and
engage dealer for advice.
iAX-Lightness forks in combination with
AX-Lightness stems can also be used with-
out expander. Dismount in this case the ex-
pander after having adjusted the headset.
The maximum torque value of the stem
bolts is 4 Nm.
gAfter adjusting the headset check
the tight clamping of the stem by
holding the front wheel between
your knees and trying to turn the
handlebars relative to the front
wheel. A loose stem can lead to an
accident!
Road racing bicycle –
Adjusting the handlebars
In the case of road racing bicycles the straight piece
of the drops should be in parallel to the ground or
point with the ends slightly downwards (d). If it is not,
release the handlebar clamping bolts by two to three
turns and re-position the AX-Lightness and engage
handlebars.
Re-tighten the clamping bolts with a 3 mm Allen
key until the clamping slots of the stem faceplate are
identical in width on all sides (e).
If you have a four-bolt stem the upper and lower
clamping slots must be identical in width and parallel
in addition.
Finish by checking the position of the AX-Lightness
and engage handlebars.Tighten the xing bolts even-
ly in a cross pattern, i.e. alternately and in small incre-
ments to the minimum limit of the recommended
torque values by using a high-quality torque wrench
(f) with a 3 mm hexagon bit socket (AX-Lightness)
handlebars and a 4 mm hexagon bit socket (engage)
handlebars.
If you have a four-bolt stem, tighten the bolts in a
cross pattern.
The recommended maximum torque value for the
AX-Lightness Zeus stem is 3-4 Nm. Always use a
high-quality torque wrench and observe the torque
value indicated on the component in case of doubt.
Check the tight t of the AX-Lightness and engage
handlebars in the stem by trying to turn them down-
wards (g). You should not be able to rotate the han-
dlebars. Never exceed the torque value recommend-
ed by the manufacturer.
94 95
Handlebars - Stem
a
b
c
g
f
e
d
by ax-lightness