2009 Fox Racing Shox Owner's Manual - Bike-Components

Caution: Fox Racing Shox does not manufacture a direct mount
stem. Be sure to refer to your stem manufacturer’s installation instructions.
Measure at least twice to be certain of all measurements,
before cutting the fork steerer!
a. Install your new 40 on the bicycle with all of the headset parts, stem spacers, and
upper crown. The deep–pocketed side of the upper crown faces downward on the
bicycle.
b. After eliminating play in the headset, lightly tighten the steerer pinch bolt on the
upper crown with a 5 mm hex wrench.
c. Add any additional stem spacer(s) or steerer-mounted stem onto the steerer above
the upper crown that will affect the steerer tube finished cut length. This will depend
on personal preference.
d. Mark the steerer with a scribe at the top edge of the uppermost installed part. With a
direct mount stem, you can scribe the mark on the steerer at the top edge of the
upper crown.
e. Remove the 40 from the bicycle and cut the steerer 3 mm below the scribed mark.
This 3 mm clearance allows room for the stem cap to lightly tension the headset and
eliminate any free play.
Warning! Do not cut the steerer more than three (3) mm below
the uppermost installed part. If the steerer length is mistakenly
cut too short, it MUST BE REPLACED! Using a fork with clamped
steerer engagement that is too short can lead to sudden fork failure,
which can cause irrecoverable loss of control of the bicycle
resulting in serious or fatal injuries.
f. Use a file to de-burr the outer and inner top edges of the newly cut steerer.
4. Install the star-fangled nut and steering stop bumpers:
a. With a star-fangled nut installation tool, install the star-fangled nut into the steerer to
the proper depth (see Figure 3: “Star-fangled Nut Installation Depth” on page 165).
Fox Racing Shox 2009 Owners Manual Installing a 40 mm Fork Page 164