System integration: TOUR gives workshop tips

Before it starts

• Read the operating instructions! All the necessary parts and their sequence are documented here. Even professionals will save a lot of time if they follow the specified steps.
• Take photos! Often helps with assembly problems.
• If the handlebars are not to be replaced, leave the brake levers and cables fitted to the handlebars.
• When replacing the handlebars, it is advisable to first pre-assemble the grips with cables, as the cable length on the lever must fit exactly to the millimetre.

Expansion

In the example, we show the disassembly and reassembly of the front on a fully integrated road bike. The aim is to remove the fork in order to shorten the steerer tube*

1. The brake hose must be cut at the lower end because the end of the hose on the brake body can only be used once. In order to have as much reserve as possible, cut the line at the end piece with the side cutter and lever the end piece out of the line.

2. Then make a clean cut with a special cutter for brake lines, removing as little material as possible.

For semi-integrated handlebars and stems or other work, steps may be omitted or the sequence may change.

Expansion

3. Drain the brake. To do this, open the bleed screw on the lever and draw the hydraulic fluid out of the line using a syringe. Carefully remove any swarf produced during cutting and, if necessary, flush it out of the line by actuating the brake lever. Otherwise they may impair the function of the brake.

System integration: lean, streamlined and tidy - but also practical?

4. Loosen the headset cap and stem. Carefully pull the stem upwards while holding the fork from below. First secure the loose handlebars to the frame with a strap so that your hands are free again.

5. Remove the spacers and all rings or caps if they are in two parts. If the spacers are one-piece or not open, all cables must be removed from the frame and fork if the handlebar height is to be changed!

6. Push a wire (approx. 1 millimetre in diameter) through the entire brake line from below. Carefully push the cable with the wire upwards through the cable duct of the fork; once the end is visible, pull the cable off the wire. The fork can now be pulled out downwards. The cable is often fixed to the fork steerer tube with adhesive tape, which is not visible in this condition. If necessary, pull the shift cables or the rear brake cable through the frame in the same way.

7. Carefully pull out the fork downwards.

System integration - Assembly

1. Take particular care to ensure that all parts are fitted in the correct order and installation direction. Do not forget anything! A mistake can be made quickly and can ruin hours of work.

2. A helper is useful when installing the fork. Slide the fork into the head tube from below and at the same time slide the cables and sleeves already attached to the handlebars over the wires.

3. Good sorting is important now! Which cable runs where? Is nothing crossing? Check in the operating instructions and with photos of the original state! Fix the cables in position with guide rings and spacers, use adhesive tape if necessary.

4. Bring the fork and stem together while simultaneously pushing the cables from above until the ends emerge from the openings. If necessary, try several times - the cable must find its way by pushing and over the wire. Pulling from below is not possible! Fit the remaining small parts (covers) and fix the stem to the steerer tube, pre-tension with the cap. Now check that the handlebars turn freely and that nothing catches. Reconnect and bleed the brakes, connect the shift cable to the components.