White brothers cycling 2004COILTM1.0 User Manual

O W N E R S M A N U A L F O R

580 N. Westgate Dr.

Grand Junction, CO 81505 USA

1.800.999.8277

www.whitebrotherscycling.com

A division of

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TABLE OF CONTENTS

APPLICATIONS..........................................PAGE 3

FORK INSTALLATION..............................PAGE 3

TUNING.......................................................PAGE 4

MAINTENANCE........................................PAGE 5

EXPLODED VIEWS...................................PAGE 6

WARRANTY...............................................PAGE 7

SAFETY

WARNING: RIDING A BIKE IS DANGEROUS. NOT PROPERLY MAINTAINING OR INSPECTING YOUR BIKE AND
IT’S COMPONENTS IS EVEN MORE DANGEROUS. IT IS ALSO DANGEROUS TO NOT READ AND FOLLOW
THESE INSTRUCTIONS.

1. NEVER REMOVE STEERER TUBE FROM CROWN. THIS IS A PRESSED IN PART. REMOVING IT WILL

RENDER BOTH THE CROWN AND STEERER INOPERABLE.* MAKE SURE THE FORK CAPS AND ALL FORK
HARDWARE (brake studs, pinch bolts, etc.) ARE TIGHT.

2. DO NOT PERFORM ANY MODIFICATIONS OR ADJUSTMENTS THAT ARE NOT OUTLINED IN THIS

MANUAL. SEE THE TUNING SECTION FOR MORE DETAILS.

3. INSPECT YOUR FORK BEFORE EVERY RIDE. INSPECT THE CROWN, TUBES, AND AXLE SEAT AREAS FOR

ANY SIGNS OF FATIGUE, BENDING, CRACKING OR OTHER DAMAGE. IF YOU NOTICE ANY TYPE OF
DAMAGE, DO NOT RIDE IT. RETURN IT TO YOUR DEALER OR TO WHITE BROTHERS FOR A COMPLETE
INSPECTION AND NECESSARY REPAIR OR WARRANTY STEPS. PLEASE REFER TO THE WARRANTY
SECTION OF THIS MANUAL.

4. PERFORM ALL RECOMMENDED MAINTENANCE ACCORDING TO THE MAINTENANCE SECTION OF THIS

MANUAL. FAILURE TO PERFORM MAINTENANCE COULD DRASTICALLY REDUCE THE FORK’S LIFE,
PERFORMANCE AND CAUSE YOUR FORK TO BE A SAFETY HAZARD.

5. WHITE BROTHERS RECOMMENDS THAT YOU WEAR PROPER SAFETY EQUIPMENT EVERY TIME YOU

RIDE, INCLUDING A APPROVED BICYCLE HELMET. NEVER RIDE AT NIGHT WITHOUT LIGHTS.

6. ALWAYS USE GENUINE WHITE BROTHERS PARTS. USE OF AFTERMARKET REPLACEMENT PARTS AND

UPGRADES VOIDS THE WARRANTY AND COULD CAUSE STRUCTURAL FAILURE.

*IF SERVICE BECOMES NECESSARY OR REMOVAL OCCURS, PLEASE CALL WHITE BROTHERS CUSTOMER SERVICE FOR PRODUCT

EVALUATION AND DIAGNOSIS.

INTRODUCTION

Thanks for purchasing your new White Brothers fork. Our forks are designed so you can perform at your absolute peak.
Your new White Brothers fork has oil damping and is coil and air sprung for light weight performance. The coil /air spring
and damper is set stock to satisfy a wide range of rider weights and riding styles. Fine tuning can be easily accomplished by
changing air pressure. See the adjustment and maintenance section. For very heavy or very light riders the external damper
can be adjusted to give a wide range of compression and rebound damping. Steering accuracy is improved over conventional
MTB forks by utilizing superior materials and design. These include oversized 32mm fork tubes, a torsion box design steering
crown, a one piece billet brake arch and extra thick drop-outs. The WB forks bootless design allows a considerable amount
more slider/stanchion overlap than competitor forks which contributes to fork steering accuracy. Fork travel has been chosen
to offer the best performance possible for each fork’s intended use. Every effort has been made to make the White Brothers
forks very light and perform at a level superior to other forks on the market. To insure peak performance, proper installation
and periodic maintenance is required. White Brothers forks are designed for off road use only. They are not equipped with
reflectors for on road use. If you are going to use your fork on road, have a dealer or mechanic install reflectors that meet the
Consumer Product Safety Commission’s requirements. When riding on public land, please respect the rights of others and stay
on established paths and trails. By riding responsibly, you are helping ensure the future of our sport.

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FORK INSTALLATION

White Brothers forks feature a 1-1/8” threadless steerer tube. If you have a threaded type fork on your bicycle, consult
your dealer for the appropriate upgrade parts necessary to convert to a 1-1/8” threadless steerer tube. Check with your
frame manufacturer to insure your bike is designed for a triple clamp fork. If not, you may void your warranty.

1. Remove your old fork from the bicycle. Measure the diameter and length of your old fork’s steer tube to insure that

the White Brothers steer tube is the correct diameter and sufficient length for the installation.

2. Remove the crown race from your old fork.

The knob, cap and lockout stop must be removed from the right fork leg in order to remove the upper triple clamp

3.

and install the headset. Lift the dust cover on top of the left leg and release the air pressure by depressing the valve
core (do not look directly down at the schrader valve when releasing air, since a small amount of oil may exit in the
air stream). Turn the knob on the right leg clockwise to the locked position. Remove the screw and knob, noting
the knob's position for reassembly. Remove the cap with the lockout hex key attached, noting the position of the
lockout stop.

4. Press the crown race onto your new White Brothers fork.(see Figure #1)

5. Preassemble the headset by sliding the fork steerer tube through the bearings. Then install the head sets upper race,

upper triple clamp, headset spacer (optional), and stem onto the fork steerer tube. Adjust with optional spacers to
your preferred height. (See Figure #2) Refer to the head set owners manual if there is any questions about the
preassemble.

6. Mark the steerer tube at the top of the stem. The steerer tube will now need to be cut to the correct length.

Disassemble and cut 3mm (1/8”) below the mark. Consult your dealer or mechanic if you don’t have the proper
tools to cut the steerer tube.

7. The star fangled nut must now be installed into the steerer tube. If you don’t have the set tool we recommend
dealer installation of this part. (See Figure #3)

8. Clean and grease all headset bearings and races to prepare them for assembly. Note: Replace the bearings if there is

any sign of wear or corrosion.

8. Now loosely assemble the headset, stem and handle bars as done in step four. (See Figure #2)

9. Install the headset top cap into the star fangled nut. Tighten until there is no play in the steering. The fork should

rotate freely in the head tube. Straighten the stem in relation to the front tire and tighten the pinch bolts on the stem
Tighten the pinch bolts on the upper clamp and double check the lower clamp bolts are tight. These can easily be
over tightened. We recommend tightening to 5 foot pounds. If there are any questions consult your dealer or
mechanic.

When headset installation is complete and with the upper triple clamp tightened, reinstall the cap and lockout stop

10.

in the right leg. As you do, make sure the end of the hex key is inserted into the damper shaft several inches down
inside the leg. As you screw the cap down, move the lockout stop to the approximate position it was in previously
and tighten the cap. Replace the knob in the same position it was previously and tighten the screw (do not
overtighten!). Release the lockout by turning the knob counter-clockwise. Inflate the fork as described under
"Tuning" below.

Steering Stem

Figure #1

Headset Race

Upper Triple Clamp

Optional Headset Spacer

Figure #2

Headset Upper Race

Frame with
Headset Cups

Stanchion Tube

Lower Triple Clamp

Star Fangled Nut

Steerer Tube

Figure #3

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