PADEMELON IS-INTEGRATED, ZS/ES-ZERO Stack External Cup Mount Kits Installation Guide
- August 8, 2024
- PADEMELON
Table of Contents
INSTALLATION INSTRUCTIONS
IS-INTEGRATED AND ZS/EC-ZERO
STACK/EXTERNAL CUP
MOUNT KITS
50-0028-00 Rev 1
SAFETY INFORMATION
DISCLAIMER: Pademelon Performance Products PTY, Ltd hereby absolves
itself of any liability for damage to bicycle frames or components, or
personal injury arising from the installation, removal, or use of this
product. Users are advised to strictly adhere to all relevant specifications
provided by bicycle frame or component manufacturers.
We strongly recommend that the installation be carried out by a qualified
bicycle mechanic.
WARNING: Pademelon recommends using a qualified, professional bicycle
mechanic for all adjustments, assembly, installation, and pre-ride checks.
CAUTION: Pademelon Steering Dampers are not compatible with carbon
steerers.
VISIT WWW.PADEMELON.CC FOR VIDEOS AND COMPLETE
INFORMATION
Instagram: @pademelon.cc
YouTube: @padmelonperformanceproducts
TOOLS AND SUPPLIES
TOOLS AND PARTS REQUIRED
Safety glasses
Isopropyl alcohol
Lint-free rag
Ruler or measuring tape
Torque wrench
12 mm socket ⅜” with 150-225 mm extension
16 or 13 mm wrench
3, 5, and 6 mm hex wrench
Headset cup remover (ZS-Zero Stack only)
Headset press
Carbon friction paste or bearing retaining compound
High-quality bearing grease
Hacksaw
File
Star nut removal tool or long punch
Hammer
Tools to remove your existing headset, topcap, and stem according to your
manufacturer’s instructions
Kit Contents:
- Steering Damper
- Headset Preloader
- Mounting Post
- 3 mm headset spacer x1
- 1 mm dust cover spacer x1
- 0.2 mm dust cover spacer x3
- ZS/EC Kit: Mounting Bracket, or
- IS Kit: Mounting Bracket and Adapter Cup
PARTS DIAGRAM
Specific parts may vary in appearance. Contact Pademelon for more information.
A Adjuster Knob
B Damper Arm
C Preload Nut
D Damper Body
E Expander Bolt
F Expander Plates
G Top Cap
H Top Cap Bolt
INSTALLATION
WARNING: Pademelon offers Zero Stack/External Cup (ZS/EC) or Integrated
(IS) Mount Kits. Consult with your bicycle retailer or
www.pademelon.cc to understand which one is right
for your bicycle. Make sure to follow the correct installation instructions
below, depending on your specific bicycle setup.
ZS-ZERO STACK OR EC-EXTERNAL CUP MOUNT KITS
PREPARATION
Follow your frame and component manufacturer’s instructions for the following
preparation steps:
- Remove the top cap, spacers, stem, dust cover, compression wedge, fork, and upper bearing from the headtube.
- Use a head cup removal tool and a hammer to remove the headset top cup.
- Use isopropyl alcohol and a lint-free rag to clean the headtube, headset bearing, and upper cup. Grease the headset bearing to prepare for installation at a later step.
Apply a thin layer of carbon paste inside the head tube.
NOTE: A bearing retaining compound can be used in place of carbon paste to provide increased retention.
INSTALLATION
-
Place the ZS (Figure 1) or EC (Figure 2) headset top cup into the corresponding Mounting Bracket.
IMPORTANT: Do not tighten the Mounting Bracket on the headset top cup. -
Use a headset press to evenly press the top cup back into the headtube per the manufacturer’s instructions.
NOTE: The ZS/EC Mounting Bracket raises the headset 2 mm. -
Reinstall the greased headset bearing, compression wedge, dust cover, and headset spacers per the manufacturer’s instructions (Figure 3).
Be sure to make any needed adjustments to the headset spacers to account for the 2 mm height increase. -
Reinstall the fork and stem per the manufacturer’s instructions.
-
Go to the HEADSET PRELOAD section on the back page to continue installation.
IS-INTEGRATED MOUNT KIT
PREPARATION
Follow your frame and component manufacturer’s instructions for the following
preparation steps:
- Measure your stack height at the headset. The IS Adapter Cup adds 8-10 mm, so you will need to note your existing setup to adjust the number and/or size of spacers at a later step.
- Remove the top cap, spacers, stem, dust cover, fork, and bearing from the headtube.
- Use isopropyl alcohol and a lint-free rag to clean the headtube and headset bearing. Grease the headset bearing to prepare for installation at a later step. Apply a thin layer of carbon friction paste to the inside the headtube. Make sure to cover the entire bearing bore; both the vertical and 45 degree surfaces.
NOTE: A bearing retaining compound can be used in place of carbon paste to provide increased retention.
INSTALLATION
-
Use a headset press to evenly press the IS Adapter Cup into the headtube (see Figure 4). Tighten just until the press handle stops (snug); do not force.
NOTE: A 1-3 mm gap between the top of the headtube and the bottom of the IS Adapter Cup is common based on headtube design (see Figure 4).
NOTE: The IS Adapter Cup raises the headset 8-10 mm, depending on the frame. -
Place the IS Mounting Bracket onto the IS Adapter Cup (see Figure 5A).
IMPORTANT: Do not tighten the Mounting Bracket onto the IS Adapter Cup. -
Reinstall the greased headset bearing per manufacturer’s instructions. Reinstall the dust cover and compression assembly per the manufacturer’s instructions (Figure 5).
-
Reinstall the headset, fork, stem, and headset spacers per the manufacturer’s instructions. Be sure to make any needed adjustments to the headset spacers to account for an 8-12 mm height increase.
-
Go to the HEADSET PRELOAD section on the back page to continue installation.
HEADSET PRELOAD
-
Use a star nut removal tool or long punch to remove the star nut from the fork steerer. Please consult your professional bicycle mechanic if you do not fully understand this step, as it requires specialized tools and ability.
-
Separate the bolt and top cap from the Pademelon Headset Preloader (see Figure 6).
-
Insert the expander assembly into the top of the steerer tube. Use a 6 mm hex wrench to tighten the expander assembly just enough to allow it to slide down into the headtube, and contact the top of the steerer (see Figure 7). Once in place, torque to 10 N•m.
-
Follow the headset manufacturer’s instructions to install any above-stem headset spacers. Install the Preloader top cap and bolt (see Figure 8). Use a 5 mm hex wrench to tighten the headset to the manufacturer’s specifications.
-
Align and tighten the stem per the manufacturer’s instructions (see Figure 9).
-
Use a 5 mm hex wrench to remove the Preloader top cap. Use a 6 mm hex wrench to remove the Preloader expander.
NOTE: If there is excessive friction between the headset dust cover seal and the Mounting Bracket, insert a Dust Cover Spacer between the Headset Compression Ring and Dust Cover (see Figure 10A). -
Go to the MOUNTING POST INSTALLATION section.
MOUNTING POST INSTALLATION
NOTE: Please remember to make a note of the damper’s serial number before
proceeding with the installation for warranty registration.
- Insert the Mounting Post into the Mounting Bracket and hand-tighten it securely.
- Use a ruler or tape measure to align the Mounting Bracket with the center of the top tube, and the small notch on the Mounting Bracket (see Figure 9).
- Use a 3 mm hex wrench to torque the Mounting Bracket to 3 N•m.
- Set the Preload Nut adjusted as low as possible. To achieve this, rotate the Adjuster Knob until the Preload Nut contacts the top of the Damper Body.
- Place the Damper Body into the fork steerer tube and rotate it so the damper arm is positioned beside the Mounting Post (see Figure 10).
- Ensure the Damper Body is at least 2 mm above the top of the fork steerer tube. Rotate the Preload Nut counter-clockwise to raise it up until the damper body no longer contacts the top of the fork steerer (see Figure 11A).
- Turn the damper clockwise until the damper arm touches the post. Use a piece of tape or colored marker to mark the damper post where the bottom of the damper arm contacts (see the dotted lines in Figure 10).
- Remove the Mounting Post and cut it 10 mm above the marked line (see Figure 10).
- Use a file to eliminate all burrs and sharp edges from the cut at the top of the Mounting Post.
- Apply a thin layer of grease to the Mounting Post threads and install it into the Mounting Bracket. Use a 13 or 16 mm wrench (depending on post type) to torque it to 12 N•m.
- Apply a thin layer of grease to the top of the post.
- Go to the DAMPER INSTALLATION section.
DAMPER INSTALLATION
-
The Damper Arm and Damper Body must be aligned before installation. To align them, turn the Adjuster Knob fully clockwise. While holding the Damper Body with your hand, rotate the Damper Arm back and forth until it reaches a stable, centered position. This locks the damper in the central alignment.
-
With the handlebars straight, insert the Damper Body into the fork steerer, and place the Damper Arm over the greased Mounting Post (see Figure 11).
IMPORTANT: Ensure the Mounting Post extends no more than 10 mm into the Damper Arm bore and does not make contact with the top inside of the Damper Arm bore (see the dotted lines in Figure 11B).
Such contact may lead to excessive wear on the damper. Adjust the Preload Nut to elevate the Damper if necessary. -
From the bottom of the steerer tube, insert a 12 mm socket and extension (see Figure 12). While gently pressing down on the preload nut to keep the Damper Body in position, torque the Damper Body Expander Bolt to 30 N•m. Ensure the damper is centered by verifying that the small notch in the Damper Body is facing directly forward (see Figure 13A).
IMPORTANT: You MUST ensure the damper alignment is straight in order for the damper to function properly.
IMPORTANT: For dual crown forks, after torquing to 30 N•m, loosen the upper crown bolts. Confirm that the torque is at 30 N•m, then re-tighten the upper crown bolts to the manufacturer’s specifications. -
Turn the Adjuster Knob fully counter-clockwise to open.
-
Verify that the handlebars rotate 90 degrees in both directions.
-
Go to the PREPARE TO RIDE section.
PREPARE TO RIDE
On your first ride with a steering damper, follow these steps to understand its effects:
- Conduct a test ride in a parking lot, which includes compressing the suspension (if applicable), to ensure there are no loose components.
- Begin your first descent with the damper fully open by turning the adjuster counter-clockwise until it stops. Ride downhill for a brief section lasting 15-60 seconds.
- Turn the adjuster 1 full turn clockwise and continue downhill for another 15-60 seconds.
- Return the adjuster to the open position and ride for an additional 15-60 seconds.
- Now, fine-tune the damping settings based on your preference. This sequence allows you to progressively experience the impact of the damper at different settings and adjust it to suit your riding style and terrain.
WARRANTY
PADEMELON PERFORMANCE PRODUCTS PTY LTD, WARRANTY
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AGAINST PADEMELON PERFORMANCE
PRODUCTS PTY LTD. YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO
STATE, COUNTRY, OR PROVINCE. THIS WARRANTY DOES NOT AFFECT YOUR STATUTORY
RIGHTS. TO THE EXTENT THIS WARRANTY IS INCONSISTENT WITH THE LOCAL LAW, THIS
WARRANTY SHALL BE DEEMED MODIFIED TO BE CONSISTENT WITH SUCH LAW. FOR A FULL
UNDERSTANDING OF YOUR RIGHTS, CONSULT THE LAWS OF YOUR COUNTRY, PROVINCE, OR
STATE.
EXTENT OF LIMITED WARRANTY
Pademelon warrants that its products will be free of defects in materials or
workmanship for period of two (2) years after the original purchase of the
product. Pademelon Performance Products considers a manufacturer’s defect in
materials or workmanship to be a reasonably foreseeable deficiency in the
actual materials it put into its products or the work done during the
manufacturing of its product.
GENERAL PROVISIONS
This warranty only applies to the original owner and is not transferable.
Original proof of purchase is required. All Pademelon warranty claims will be
evaluated by Pademelon or a Pademelon authorized service location whereupon
acceptance of the claim the product will be repaired, replaced or refunded at
Pademelon’s discretion. To the extent allowed by local law claims under this
warranty must be made during the warranty period and within one (1) year
following the date on which any such claim arises.
NO OTHER WARRANTY
EXCEPT AS DESCRIBED HEREIN, AND TO THE EXTENT ALLOWED BY LOCAL LAW, PADEMELON
MAKES NO OTHER WARRANTIES, GUARANTIES, OR REPRESENTATIONS OF ANYTYPE (EXPRESS
OR IMPLIED), AND ALL WARRANTIES (INCLUDING ANY IMPLIED WARRANTIES OF
REASONABLE CARE, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE) ARE
HEREBY DISCLAIMED.
LIMITATION OF LIABILITY
EXCEPT AS DESCRIBED HEREIN, AND TO THE EXTENT PERMITTED BY LAW, IN NO EVENT
SHALL PADEMELON OR ITS THIRD-PARTY SUPPLIERS BE LIABLE FOR DIRECT, INDIRECT,
SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. SOME STATES (COUNTRIES AND
PROVINCES) DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL DAMAGES, SO
THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
LIMITATIONS OF WARRANTY
This warranty does not apply to normal wear and tear, or products that have
been incorrectly installed, adjusted, and/or maintained according to the
respective PADEMELON installation instructions. The PADEMELON installation
instructions can be found online at pademelon.cc .
This warranty does not apply to damage to the product caused by a crash,
impact, abuse of the product, neglect of the product, non-compliance with
manufacturer’s specifications of intended usage, or any other circumstances in
which the product has been subjected to forces or loads beyond its design.
This warranty does not apply when the product has been modified, including but
not limited to, any attempt to open or repair.
This warranty does not apply when the serial number or production code has
been deliberately altered, defaced, or removed. Pademelon components are
designed for use only on bicycles that are pedal powered or pedal assisted
(e-Bike/Pedelec). This warranty shall not cover damages caused by the use of
parts of different manufacturers or parts that are not compatible or suitable
for use with PADEMELON components. This warranty shall not cover damages
resulting from commercial (rental) use.
If you would like to submit a warranty claim please email
info@pademelon.cc with the following information:
- Product name or type
- Damper serial number if applicable
- Name and contact information of the original purchaser
- Order number or receipt
- Description and photos of damage
Warranty Registration at www.pademelon.cc
Instagram: @pademelon.cc
YouTube: @padmelonperformanceproducts
© Pademelon Performance
Products PTY. LTD. 2024
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>