Reynolds Ouzo Pro User manual

Congratulations
on purchasing the number-one
carbon fiber fork on the planet.
Reynolds engineers designed this fork with one thing in
mind – the very best, high performance ride possible.
With proper installation you will find that this fork handles
smoother, stiffer and with more assurance than any other
fork on the market. You’ll discover the impact that experi-
enced engineering makes in our proprietary 100% carbon
components.
Notice
The Ouzo Pro carbon fork must be used with a circumferential
clamp style stem. Use of a pinch or wedge clamp style stem may
cause damage to the steerer tube which may result in rider injury
or death.
Before attaching your stem to the steerer tube, make sure that the
inside of the stem is smooth and free from burrs or other defects
or materials which may score or scratch the steerer tube. Scoring
or scratching the carbon fiber steerer tube could cause it to fail,
resulting in serious bodily injury or possibly death.
When this symbol appears, take care to understand
the directions before you proceed. Your safety may
depend on it!
Parts Included:
(1) Reynolds Ouzo Pro Carbon Fork
(1) Compression Adjustment Plug
(1) Brake Nut
Recommended Tools:
a – Hacksaw blade for ceramic tile
b – Headset tools
c – 5mm hex key (w/ torque wrench adaptor)
d – 6mm hex key (w/ torque wrench adaptor)
e – File (all purpose), or
f – 100-200 grit sandpaper
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
Installation Manual
About Reynolds
When you talk about designing and manufacturing cycling components,
Reynolds is one of a handful of iconic brands. From the prestigious
531/753/853 badges on lugged, steel frames, to the legendary Ouzo
brand carbon forks, Reynolds’ historic contribution to quality, craftsmanship,
and innovation in the sport is second to none. For over a century, the name
Reynolds has stood for quality, design and performance in bicycle
components, because we’re renowned for creating products that deliver a
cycling experience unlike any other. The margin of victory has never been
more acute—in competitive cycling or in business. Therefore, our passion for
leadership drives us to continuously improve performance—in our products,
our processes, and our customers relationships.
3392 West 8600 South, West Jordan, UT 84088 •866-798-3040 •www.reynoldscycling.com
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
1.1 Press the upper and lower
cups into the head tube using
a headset press
1.2 Press the fork crown race
onto the fork race seat using
the proper race seat tools
1.3 Install headset assembly
as per headset manufacturer
specs
1.4 Insert fork steerer tube into
head tube
1.5 Slide the compression ring,
spacers and stem onto the
steerer tube. Do not exceed a
maximum stack height of 1” on
1” diameter fork or 1 1/2” on 1
1/8” diameter fork.
Never use grease between
the carbon fork steerer tube
and the stem (as commonly
done with forks featuring steel
steerer tubes).
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
1 4

5 7
5
mm
5
mm
min.
max.
flush!
6
mm
BRAKE
The Compression Adjustment Plug
provided with this product is an
integral and necessary component
of the Ouzo Pro carbon fork, and
must be installed to maintain the
structural integrity of the Ouzo
Pro carbon fork system. Failure
to properly install the Compres-
sion Adjustment Plug or use of a
substitute part may result in the
failure of the fork, resulting in
serious bodily injury or possibly
death.
5.1 To prepare the Compression
Adjustment Plug, turn the top cap
counter-clockwise by hand until the
threads are visible. The plug should
now be fully extended.
5.2 Using a 5mm hex key, turn the
expander bolt counter-clockwise
until the expander ring is at its
smallest width.
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
6
5
mm
5
mm
min.
max.
flush!
6
mm
BRAKE
6.1 Insert the Compression
Adjustment Plug into the
steerer tube until the top cap
seats flush against the top of
the stem.
6.2 Using a 5mm hex key,
turn the expander bolt clock-
wise to a torque of 80 kgfcm
(70 in. lb.). This will secure
the pressure plug in the inner
diameter of the steerer tube.
5
mm
5
mm
min.
max.
flush!
6
mm
BRAKE
7.1 With a 6mm hex key, turn
the top cap clockwise to a
torque of 25 kgfcm (22 in.lb.)
This step “pre-loads” the
bearings only. Tightening the
top cap does not keep the
headset from becoming loose.
Be sure to complete Step 8
before riding!
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
8
9
8.1 Attach front wheel to fork
8.2 Align stem with front wheel
8.3 Tighten both stem bolts to
manufacturer’s specifications.
If handle bars can be twisted
while holding front wheel still,
the stem is NOT tight enough!
5
mm
5
mm
min.
max.
flush!
6
mm
BRAKE
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
5
mm
5
mm
min.
max.
flush!
6
mm
BRAKE
9.1 Slide aluminum brake
spacer on the brake stud
9.2 Fit brake onto fork
9.3 Insert brake nut in rear
of fork
9.4 Tighten bolt to brake
manufacturer’s specs
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
2
2.1 Seat the steerer tube firmly in the
head tube and the stem firmly against
the compressing ring
2.2 Tighten one stem bolt just enough
to keep the assembly snug
2.3 Mark or scribe the steerer tube at
the top edge of the stem (a)
2.4 Remove the stem from the steerer
tube, and the fork from the head tube
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
3
3.1 Re-mark the steerer tube 3mm down
(b) from the first mark (a). It is necessary to
cut the steerer tube 3mm down from the
top of the stem, as this allows for sufficient
compression.
Any cut made longer or shorter may result in
a loose headset or insufficient clamping area.
3.2 Using a hacksaw blade designed for cut-
ting ceramic tile, cut steerer at a 90° angle
on the second measured mark (b). If using
a vise to hold steerer tube, use wooden
blockstop to protect it from damage. Do not
over tighten vise!
3.3 Using a file or sandpaper, remove all
burrs on the front edge of steerer tube.
4.0 Re-assemble fork, headset, head tube
and stem as in Step 1.
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT
a
3mm
a
b
SPACERS
LOWER CUP
LOWER BEARING
LOWER BEARING RACE
LOWER SEAL
FORK CROWN RACE
UPPER SEAL
COMPRESSION RING
UPPER BEARING RACE
UPPER BEARING
UPPER CUP
STEM
FORK STEERER TUBE
CROWN RACE SEAT