Bicycle Owner`s Manual - Klein
Contents
1. loAolq MoU INO NO 910J9Q 19Idey pes o 405 AH3A3 40 jueyoduul SI 11 SIB9 JO e u ppu AINEY y IMPORTANT KEEP FOR FUTURE REFERENCE About this Owner s Manual This manual explains how to ride your new bike safely and how to maintain your bicycle to keep it operating safely Every person prior to riding this bicycle should read at least Chapter 1 of this manual Parents should explain Chapter 1 to a child or anyone else who might not otherwise understand this information Even if you have ridden a bicycle for years it is important for EVERY person to read Chapter 1 before riding this bicycle This manual includes a CD compact disc with more comprehensive information This CD can be viewed by inserting it into your home computer If you do not have a computer take the CD to your school work or public library and view it there In addition to reading the extensive information on the CD you should register your bike on line the CD has links to the registration site If your CD does not work go to the web address on the cover to access the information on the Web There are many models with a variety of equipment so this manual may contain some information that does not apply to your bike Some illustrations may vary from the actual bicycles If you have any questions after reading the information in this manual the CD or web site consult your dealer If y2. until this line is established 5 While pulling on the cable up shift until the shifter is in the small cog position 6 Turn the adjusting barrel on the shifter or down tube all the way clockwise Turn the adjusting barrel on the rear derailleur all the way clockwise and then one turn counter clockwise 7 Insert the cable into the clamp bolt groove on the rear derailleur pull the shift cable taut and tighten the cable clamp bolt to 44 60 lb in 5 0 6 8 Nm Figure 22 Rear derail leur To adjust the low gear position 1 Turn the low gear adjusting screw on the rear derailleur usually marked L far enough counter clockwise so that it will not restrict the movement of the derailleur 2 Carefully shift the chain onto the smallest front chainring and the largest rear cog Do not over shift the rear derailleur or the chain may wedge between the large cog and the spokes 3 Position the rear derailleur pulleys in line with the largest cog 4 Turn the low gear adjusting screw clockwise until it meets resistance If you have turned it too far the derailleur will move toward the outside of the bicycle 5 Go through the various gear combinations Make sure the chain does not fall off when you shift To align the indexing system 1 Shift the chain onto the largest front chainring and the smallest rear cog 2 Shift one click with the rear shifter 3 Check if the chain moves sm
3. the left hand shifter controls the front derailleur and the right hand shifter further In addition brakes may not work as well Adjust your riding speed accordingly or use other forms of transportation Strong winds can make a bicycle steer or turn unexpectedly In windy conditions slow down or use other forms of transportation When riding in wet weather a dynamo generator light may not work properly Avoid riding in wet weather when visibility is reduced Be careful when riding in low light conditions Your bicycle is equipped with a full set of reflectors keep them clean and in position As useful as these reflec tors are they do not help you see nor do they help you be seen unless light is directed on them Use a working headlight and tail light when you ride in poorly lighted or low visibility conditions The important thing is to see and be seen If you do any amount of riding at dusk at night or in any poorly lighted conditions consult your dealer to find appropriate products to aid your vision and make you more visible A bicycle rider without proper lighting and reflectors may not have good vision and may not be visible to others which can cause a collision resulting in severe injury or death Use front and rear bicycle lights and reflectors when riding in poor visibility conditions Failure to do so will increase your chances of being involved in an accident in low light conditions Do not
4. the lever for a moment before letting go of the shifter Shifting a bike with internal gearing is best performed when coasting stopped or back pedaling If you must shift while pedaling reduce your pressure on the pedals Excessive chain tension makes shifting difficult Change your riding to be safe in bad weather conditions No brakes whatever their design work as effectively in wet weather as they do in dry Even properly aligned Applying sudden or excessive stopping force with the front wheel brake may cause the rear wheel to lift off the ground or the front wheel to slip out lubricated and maintained brakes require greater lever pressure and longer stopping distances in wet weather Anticipate the extra distance it will take to stop Wet weather causes reduced traction Use slower cornering when traction is reduced like when riding over wet leaves painted crosswalks or manhole covers When wet weather cools to below freezing traction is reduced even from under you which can cause you to lose control and fall Apply both brakes at the same time and shift your weight backwards on the bike while braking Use good shifting techniques Shifting gears allows you to choose the gear combination most comfort able for riding conditions one that allows you to maintain a constant rate of pedaling Shifting systems are of two types derailleur external and internal Shifting a bike with a derailleur
5. on normal usage If you ride your bike more than average or in rain snow or off road conditions service your bicycle more often than the schedule suggests If any part appears to be malfunctioning inspect and service it immediately or consult your dealer If a part is damaged replace it before riding the bicycle again After initial break in new bikes should be checked for stretched cables and other normal conditions About two months after purchasing your new bike have your dealer thoroughly inspect the bicycle All bikes should be thoroughly serviced once a year even if they have not been ridden much Have the bike completely serviced every year Every ride Check the wheels 1 Check the tire inflation 1 Check the brakes Q Check the handlebar and stem 2 3 Check the seat and seatpost 3 Check the suspension adjustments 3 Check the lights and reflectors 3 Weekly Wipe off your bicycle with a damp cloth 6 Check for loose Spokes 16 Lubricate suspension forks 20 Check suspension fork bolts 18 Check rear suspension bolts 18 Monthly Check the attachment of the handlebar and Ul 2 3 8 9 Check the attachment of the seat and SEA 9 11 Check the chain cuina 11 Check the
6. repeat these procedures including the tests or take the bicycle to your dealer for service Suspension components Changing your suspension settings affects handling and braking charac teristics After making a change carefully test the bike in a low traffic area until you are familiar with its performance For an all round ride set the forks for about 15 sag and a rear shock at about 25 sag Experiment with the adjustment in small increments to find your preference If the suspension is fully compressed its movement will stop abruptly and could cause you to lose control See the CD or web site for more specific adjustment and mainte nance information or consult your dealer Accessories There are a wide variety of accesso ries installed on bicycles Once a month check any accessories to make sure they are properly attached If any part seems loose or misaligned either tighten the part or take the bike to your dealer for service To adjust training wheels See other sections of this manual as needed 1 Place the bike on a flat smooth surface with the tires properly inflated 2 Loosen the rear axle nuts Follow the procedures in the Wheels section 3 Stand the bike up very straight and set a gap of about 1 4 inch 6mm between the training wheels and the ground on both sides of the bike Make sure the gap is the same on both sides 4 Adjust the chain tension and re tighten the axle nuts To
7. chainguard accessories 18 Inspect cables for vvear 11 Check the operation of shifters 11 12 13 Inspect derailleurs 11 13 Lubricate derailleurs 20 Check the internal shift system 13 Check headset bearing adjustment 11 Check brake DA BL LL aa rastas 14 Check brake bolts 14 16 Inspect a rotor for proper function 16 Check chain TENSION scsi 2 11 Inspect Trekking accessory bolts 18 19 Check wheel bearing adjustment 16 Check rims for Wear 16 Every 3 Months Clean and polish 16 Check the crankset and bottom bracket11 Lubricate brake levers 20 Every year Lubricate handlebar stem 19 19 Re grease pedal threads and bearings 19 Re grease bottom bracket bearings 19 Re grease wheel bearings 19 20 Re grease headset bearings 19 Lubricate wheel quick releases 19 20 Re grease suspension forks 20 Recommended tools for proper bicycle maintenance Torque wrench with lb in or Nm gradations 2 4 5 6 8mm allen wrenches 9 10 15mm open end vvrenches 15mm box end wrench Socket wrench 14 15 and 19mm socket T25 Torx vvrench No 1 phillips head screvvdriver Bicycle tube patc
8. deviations which could impact your wheels or cause them to slip When crossing railroad tracks or drain grates do so carefully at a 90 angle Figure 8 If you are not sure of riding surface conditions walk your bike If a car suddenly enters your lane or someone unexpect edly opens the door of a parked car you could be involved in a serious accident Mount a horn or bell on your bicycle and use it to alert others of your presence Figure 8 Angle for crossing tracks Wear a helmet and proper cycling clothes Wear a helmet that meets CPSC or CE safety testing standards Figure 9 it may help prevent injury Helmets should be removed when not riding the bicycle because if the helmet is caught stuck on or stuck between objects the wearer could choke Wear protective clothing including helmet eye protection and gloves Avoid loose fitting pants that could get caught in the chain Also wear light bright and reflective clothing especially at night to make yourself more visible Figure 9 Wear a bicycle helmet RIDING INSTRUCTIONS Use your brakes carefully Always keep a safe stopping distance between you and other vehicles or objects Adjust stopping distances and braking forces to suit riding conditions If your bike has two hand brakes apply both brakes at the same time Over use or mis use of a
9. direct pull brakes replace the pads Replace disc brake pads that are thinner than 1 0mm To adjust brake pad clearance to the rim 1 Turn the barrel adjuster To increase the pad clearance turn the barrel adjuster in clockwise To reduce the pad clearance turn the barrel adjuster out counter clockwise For most direct pull Figure 29 cantilever Figure 31 or U brake Figure 32 systems the barrel adjuster is on the lever For most road caliper systems Figure 30 the barrel adjuster is on the brake itself 2 If the brake pads cannot be adjusted properly loosen the cable clamp bolt and re attach the cable To center a V type cantilever or road brake 1 Rotate the centering screw Turn in small increments and check for centering 2 If the brake has two centering screws adjust the overall spring tension while centering the brake To center a U ms brake 1 Hold the 13mm centering nut with a wrench 2 Loosen the arm fixing bolt with a 5mm allen wrench 3 Rotate the centering nut 4 Re tighten the bolt To adjust the alignment of the brake pads on caliper type brake 1 Loosen the brake pad fixing bolt 2 Follow the procedures in Inspection to align and tighten the brake pads 3 After adjusting the brakes test them by applying force to the levers Ensure the cable does not slip the pads close toward the rim at right angles and the pads do not co
10. frame 2 Wipe any old grease off the seatpost and clean if necessary 3 Apply a thin layer of grease to the section of the seatpost that will be inside the frame 4 Insert the seatpost into the frame 5 Adjust the seat to the proper height align it and tighten the seatpost binder bolt Bottom bracket Once a year re grease the bottom bracket bearings Pedals Once a year re grease the pedal bearings Once a year re grease the pedal axles 19 where they thread into the crank arms Note There are right and left pedals usually marked with a letter stamped on the end of the pedal axle or on the wrench flats 1 Remove the pedals turn the right pedal spindle counter clockwise but turn the left clockwise 2 Apply a this layer of grease over all the threads 3 Install the pedals on the proper side put the right pedal on the right crank arm and the left pedal on the left crank arm 4 Tighten the pedals Derailleurs Every month lubricate all pivot points on both the front and rear derailleurs including the derailleur pulleys on the rear derailleur with chain lube Headset Once a year re grease the headset bearings Brakes and Brake Levers Every 3 months lubricate your brake lever pivots and brake arm fixing pivots with a light oil Wheels Once a year re grease the wheel bearings Every year lubricate wheel quick release Apply several drops of Wrench Force synthetic lube or a
11. latch opens 3 While avoiding pinching yourself or cables fold the bike in half To unfold the frame reverse the steps of the folding procedure Riding a folding bike with movement at the lower stem quick release or main frame hinge could cause you to lose control and fall If the folding frame moves at the stem or frame hinge take the bike to your dealer for service This section explains the parts that require lubrication their frequency and brief instructions See your dealer for recommended lubrications If you need more detailed information see other sections of this manual as needed or consult your dealer Re greasing bearings requires special tools and training so this should only be done by your dealer Some bearings are permanently sealed and do not require yearly re greasing Stem Once a year lubricate the stem Note Lubricating a direct connect stem requires adjustment of the headset bearings so should only be done by your dealer 1 Remove the stem from the frame 2 Wipe any old grease off the stem and clean it 3 Apply a thin layer of grease to the section of the quill that will be inserted into the frame including the stem wedge 4 Install the stem Seatpost Once a year lubricate the seatpost except for a bike with a carbon fiber seat tube where no lubrication is recommended 1 Loosen the seatpost binder bolt or open the quick release and remove the seatpost from the
12. ride in an abusive manner ride vvithin the Use Classification for your type of bicycle see page 1 Bicycles are not indestructible As with anything mechanical every part of a bicycle has a limited useful life due to wear stress and fatigue Fatigue refers to a low stress force that when repeated over a large number of cycles can cause a material to fail or break The length of the life of a part varies according to its design materials use and maintenance Although lighter frames or parts may in some cases have a longer life than heavier ones it should be expected that light weight high performance bicycles and parts require better care and more frequent inspections Regularly inspect your entire bicycle for signs of fatigue stress e Dents e Cracks e Scratches e Deformation e Discoloration Carefully inspect your frame and components for signs of fatigue before and after each ride Go to the web address on the cover to find special instructions on how to inspect carbon fiber parts Even if you perform regular inspec tions if you exceed the limit of strength of your bicycle or a given Do not use unsafe riding practices part it will fail Many cycling accidents could be avoided by using common sense Here are a few examples Do not ride no hands Do not ride with loose objects attached to the handlebars or any other part of the bicycle Do not ride while intoxicated or while usin
13. similar light oil where the quick release lever rotates in the quick release body Suspension forks Once a month apply a light oil to the upper fork leg where the lower leg slides on it Wipe clean Rear suspension No lubrication is required for the shock or the pivot of your full suspen sion bike Avoid all lubricants 20 Control cables Lubricate cables whenever they are installed To install a cable Installing a cable in a cantilever brake requires special tools and training so should only be done by your dealer 1 Note the path of the old cable and loosen the cable anchor bolt and remove the worn cable 2 Grease the new cable and reinstall feeding it along the same path as the old cable including through the cable anchor bolt 3 Make sure the leaded cable end is seated properly in the lever and the housing is properly seated in the lever If needed when installing a cable in a brake readjust the brake 4 Turn the adjusting barrel clockwise so the threads on the adjusting barrel are not exposed For a shift cable put the shifter in the position with the least cable tension For a brake hold the brake closed while you do the next step 5 Tighten the cable clamp bolt 52 69 Ib in 6 8 Nm 6 Cut the cable so that no more than 2 inches 51mm extends beyond the anchor bolt 7 Crimp a metal cap or place a bit of solder on the end of the cable to prevent fraying 8 Follow the instr
14. tenha acesso a um computador e queira uma vers o impressa do manual envie pelo correio uma solicitac o para o endereco relacionado acima En el CD incluido encontrar una versi n en espa ol de este manual as como en www kleinbikes com Si no tiene acceso a un ordenador y desea una versi n impresa del manual solicitela por correo a la direcci n indicada anteriormente 2007 Trek Bicycle Corporation All rights reserved The Klein Logo is a registered trademark of Trek Bicycle Corporation Part 278711
15. than 7mm of lever movement to stop the bike the brakes are too tight Internal hub brakes get very hot during use and could burn skin Avoid touching the hub or cooling fins when hot Coaster brakes the brake is engaged by pedaling backwards When pedaling backwards the brake should engage with less than 60 degrees rotation 1 6 revolution The chain actuates the brake so make sure the chain cannot come off There should be between 1 4 and 1 2 inches 6 12mm A total vertical Figure 6 Checking chain movement of the tension Chain Figure 6 ca Check the handlebar and stem Make sure the stem is in alignment with the front wheel Test the stem connection to the fork by attempting to turn the handlebars from side to side with the front wheel locked between your knees Figure 7 Test the security of the handlebars by attempting to rotate them in the stem Make sure that no cables are stretched or pinched by rotating the handlebars Figure 7 Function test Check that ing the handlebar and stem the handlebar plugs are properly inserted into both ends of the handlebars and bar ends Carefully inspect your handlebar and stem for signs of fatigue scratches cracks dents deforma tion or discoloration Af Check the seat and seatpost Make sure the seat is secure by attempting to turn the seat and seatpost in the frame and attempt to move the front of the seat up and down It shou
16. the crank arms so they are parallel to the seat tube 3 Loosen the seatpost binder bolt or quick release 4 Extend the seatpost until with your heel resting on the bottom pedal Figure 18 your extended leg is straight When wearing your shoes there should be a slight bend in your knee in a proper riding position with the ball of your foot on the pedal 5 Make sure the minimum insertion mark on the seatpost Figure 19 is not visible above the bike frame A minimum of 2 1 2 inches 64mm of seatpost must remain in the frame 6 Close the seatpost quick release or tighten the bolt to 85 125 1bsin 9 6 14 1 Nm Figure 18 Leg extension with proper seat height This line must be inside the bike frame Figure 19 Minimum insertion mark on seatpost A seatpost that is positioned too high can damage the bike and can cause you to lose control and fall Make sure the minimum insertion mark Figure 19 is inside the frame To adjust the seat position of a tricycle 1 Loosen and remove the clamp bolts Figure 20 2 Move the seat mast to the desired position 3 Install and tighten the seat mast clamp bolts to 85 125 1bein 9 6 14 1 Nm Headset To check if the headset is loose or tight 1 Apply the front brake firmly while you rock the bicycle forward and backward 2 With the front wheel off the ground slowly rotate the fork and handle bars to the right and left If the hea
17. the brake pads or the frame If the rim wobbles contact the front Figure 2 Toe clip TE up and down or from side to side wheel or fender repair the wheel Figure 2 At normal riding speeds Check that the wheels are properly the handlebar does not turn enough attached Bicycle threaded axle nuts a quick release where a Muda aaa an lever actuated HT wheel retention mechanism Figure 3 allows the wheel to be installed and for this to occur wheels are attached NX by several systems Q i r Contact between your foot or toe clip and the front wheel or fender can cause you to lose control and fall Avoid pedaling when turning at slow speed In very rare cases some riders may removed without MS nle experience a shimmy or harmonic tools or a through oscillation or frame vibration at axle where the axle certain speeds If you are experiencing is threaded through a shimmy slow down immediately the ends of the Take your bicycle directly to a dealer frame or fork For for inspection and repair information about adjustment and closure of the wheel attachment devices on your bicycle see Chapter 3 Test for proper 7 4 Test for loose vvheel attachment Pick up the bike and sharply hit the top Of the tire Figure 4 The vvheel CHECK THE BIKE must not come off be loose or move from side to side Further tests are BEFORE EVERY RIDE provided in Chapter 3
18. 5 Figure 46 Test for looseness Figure 47 Test for rotation To install an axle nut wheel Some wheels are attached by tightening nuts threaded onto the axle The front wheel may require a toothed washer to be placed between the nut and fork tip Some bicycles also have pegs tubular axle extension 1 Tighten the axle nuts e Tighten a regular front wheel to 180 240 lb in 20 3 27 1 Nm e Tighten a regular rear wheel to 240 300 lb in 27 1 33 9 Nm e For a front wheel with peges tighten to 220 240 lb in 24 9 27 Nm iv e For a rear wheel with pegs tighten to 350 lb in 40 Nm 2 Test to ensure that you have properly tightened the axle nuts e Pick up the bike and sharply hit the top of the tire Figure 46 The wheel must not come off be loose or move from side to side If the wheel attachment fails the test repeat these procedures including the tests or take your bicycle to your dealer for service To install a thru axle wheel 1 Open the quick release or loosen the clamp bolts on both fork ends 2 With the wheel in place slide the axle into the fork tips 3 Close the quick releases or tighten the clamp bolts to 45 55 lbein 5 1 6 2 Nm 4 Test to ensure that you have properly attached the thru axle e Pick up the bike and sharply hit the top of the tire Figure 46 The wheel must not come off be loose or move from side to side If the wheel attachment fails the test
19. Before every ride inspect the bike vvith the follovving check list If any part of the bicycle fails the inspection A wheel attachment device that is repair the bicycle by following the not properly adjusted and closed information provided by us or take it may allow the wheel to be loose or come off unexpectedly causing you to lose control and fall Make sure the wheels are properly attached before riding the bike A shimmy or steering wobble can cause you to lose control and fall If you experience a shimmy slow down immediately Take your bicycle to your dealer for inspection and repair A bicycle that does not work properly can cause you to lose control and fall Inspect the entire bicycle thoroughly ivf Check the tire inflation before every ride and do not ride it Inflate the tires to the air pressure until any problem has been corrected recommended on the tire sidewalls Check the brakes Follow the inspection instructions for the type of brake on your bike Never ride a bike if you are not certain the brakes are working properly or you if suspect a problem with the brake cables or hydraulic hose Malfunctioning brakes can cause you to lose control and fall Inspect the brakes thoroughly before every ride f your brakes are not working properly re adjust them or take the bike to your dealer for service Hand rim brakes a brake lever connected to the brake by a cable causes the brake pad
20. Condition 1 plus smooth gravel roads and smooth improved trails with moderate grades where the tires do not lose ground Juvenile Smaller bikes contact designed for kids but Condition 3 includes Conditions also fitting smaller 1 and 2 plus rough trails rough adults Includes BMX unpaved roads and rough technical with coaster brake areas with unimproved trails where Condition 1 momentary loss of tire contact with the ground may occur NOT jumping Condition 4 Any riding in excess of Condition 3 Tandem Built for two with either drop road handlebars or flat handlebars as on a hybrid Condition 1 Cruiser Wide sweeping handlebars wide saddle and balloon tires Condition 1 TABLE OF CONTENTS BEFORE A FIRST RIDE Chapter 1 Guide to Safe On and Off Road Operation Make sure the bicycle fits you properly ii Know how the bicycle performs ii Check the bike before every ride 1 3 Check the vvheels 1 Check the tire inflation 1 Check the brakes criadas 2 Check the handlebar and stem 2 3 Check the seat and seatpost 3 Check the suspension adjustments 3 Check the lights and reflectors 3 Rules for safe ridimg 3 Riding instructions das 4 6 Chapter 2 Maintenance Some maintenance and repair should only be performed by your dealer as indicated in this ma
21. EIN Customer Service 920 478 4676 www kleinbikes com 801 West Madison Street Waterloo Wisconsin 53594 Op de meegeleverde cd en ook op www klienbikes com treft u een Nederlandstalige versie van deze handleiding aan Mocht u niet over een computer beschikken en een gedrukt exemplaar van de handleiding wensen stuur dan een verzoek daartoe aan het bovenstaande adres Une version francaise de ce manuel est incluse dans le CD ci joint et peut galement tre obtenue a www kleinbikes com Si vous ne pouvez acc der a un ordinateur et souhaitez obtenir une copie imprim e de ce manuel envoyez une demande a l adresse sus mentionn e Eine deutsche Version dieses Handbuches finden Sie auf der beiliegenden CD und auch im Internet unter www kleinbikes com Wenn Sie keinen Zugang zu einem Computer haben und eine gedruckte Version dieses Handbuches haben m chten schicken Sie bitte eine entsprechende Anfrage an die oben aufgef hrte Adresse Una versione italiana di questo manuale si trova nel CD allegato e anche nel sito www kleinbikes com Nel caso in cui non si abbia accesso ad un computer e si desideri avere una versione stampata del manuale inviare una richiesta all indirizzo sopra indicato AYVYIaTyIVOBABIRISAHO CD CCHICANET SLT JITHA k www kleinbikes com Th Elan 21 EaI A HACE NX AVIA IVOIRE CAS IRA 4 ERE Cink ES Uma vers o em Portugu s deste manual est no CD anexo e tamb m em www kleinbikes com Caso n o
22. For riding on rougher surfaces Front suspension or light weight full suspension Condition 3 NOT Condition 4 Freeride or hucking VVide tires riser handlebars double crovvn triple clamp suspension forks and disc brakes only Por aggressive riding on rougher surfaces Compared to a standard mountain bike a freeride bike has a heavy duty and reinforced frame Condition 4 Touring Similar to a road bike except with direct pull brakes and wider tires Designed for self contained touring Condition 1 Cross Similar to a road bike except wider tires and cantilever brakes With a skilled rider in mind designed for riding off pavement Condition 2 Hybrid Flat handlebars like a mountain bike but 700c wheels like a road bike Condition 2 City bike A hybrid BMX BM X style bikes with riser handlebar and 20 inch vvheels Condition 3 Jumping BMX style bikes with heavy duty Folding Hybrid features reinforced frame and but with a hinged frame fork and 48 spoke wheels Models and stem Condition 1 TR30 and Vert 2 only Condition 4 equipped with accesso ries like fenders rack Condition 1 Conditions for Use Riding a bicycle in a manner other than its intended use can cause the bicycle or part of the bicycle to fail Read the safety information in Chapter 1 for further details Condition 1 riding on a paved surface where the tires do not lose ground contact Condition 2 includes
23. and wear If you suspect a problem with a cable do not ride the bicycle follow the instruc tions to replace a cable or have your dealer service the bicycle Shifters The position of the shifters can be adjusted on the handlebars Follow the instructions for adjusting the lever position on page 14 Front derailleur To adjust the low gear position 1 Shift the chain onto the smallest front chainring and the largest cassette cog 2 Loosen the front derailleur cable clamp bolt Figure insa X 21 until the cable Figure 21 Front derail is free leur 3 Turn the low gear adjusting screw marked L until the inner chain guide of the derailleur is approximately 0 5mm from the chain Adjusting crews ac a 4 Pull on the cable end and down shift the left shift lever several times so it is in the small chainring position 5 Turn the shift cable adjusting barrel to its most clockwise position 6 Insert the cable in the groove found next to the derailleur cable clamp bolt pull the cable taut and clamp the cable e Front derailleur cable clamp bolt to 44 60 lb in 5 0 6 8 Nm To adjust the high gear position 1 Shift the rear derailleur to the smallest rear cog 2 Turn the high gear adjusting screw marked H counter clockwise until it cannot interfere with the motion of the derailleur 3 Hand turn the cranks and use the shifter to carefully shift the chain onto the outsid
24. dset bearings rock in the frame or do not turn smoothly do not ride the bicycle take the bike to your dealer for service Adjustment of headset bearings requires special tools and training These services should only be performed by your dealer Pedals To adjust the release force on clipless pedals refer to the information on the CD supplied with your bicycle or consult your dealer Tighten pedals into the crankarms to 350 380 lb in 40 2 42 9 Nm Adjustment of pedal bearings requires special tools and training These services should only be performed by your dealer Figure 20 Tricycle seat mast Crank arms Some bicycles offer adjustable crankarm length To change the crank length remove the pedals and install them into the second set of holes Tighten by following the instructions for Pedals Bottom bracket Adjustment of bottom bracket bearings requires special tools and training These services should only be performed by your dealer Chain To adjust the chain tension on a single speed bike 1 Gradually loosen the rear wheel axle nuts on alternate sides of the wheel 2 Slide the wheel to re tension the chain and center the wheel in the frame Some models have a chain tensioning device which helps position the wheel 3 Complete the wheel installation Cables Check the cables for kinks rust broken strands or frayed ends Also check the housing for loose wire strands bent ends cuts
25. e adjustment Figure 24 Three speed bell crank SRAM DualDrive system To adjust the rear hub shifting 1 Place the shifter mode 2 Align the indicator on the Clickbox window by rotating the barrel adjuster Figure 25 4 Shift to Uphill mode then back to Standard mode and re check the adjustment in the Standard HO Ke Figure 25 Clickbox on rear hub Brake levers The brake system allows you to slow or stop your bike a function critical to your safety The brake system is difficult to adjust properly without the proper tools and training It is strongly recommended that adjustment of a brake be done by your dealer If you need more specific information regarding your brake system contact your dealer To adjust the position of a lever 1 Locate the lever clamp bolt Figures 26 28 13 2 Loosen the clamp bolt 2 3 turns 3 Position the lever 4 Tighten the clamp bolt on regular brake levers to 53 69 lb in 6 0 7 8 Nm e On mid bar levers Figure 28 to 20 30 Ib in 2 3 3 3 Nm e On Hayes hydraulic levers to 25 35 lbein 2 8 4 Nm Figure 26 Lever clamp bolt road lever To adjust the reach to the brake lever cable type With some brake levers you can change the reach the distance from the handlebar to the lever 1 Locate the reach adjustment screw and turn Figure 27 Lever clamp bolt mountain lever Figure 28 Mid bar brake T
26. e chainring 4 Position the outer chain guide of the front derailleur approximately 0 5mm from the chain 5 Re tighten the high gear adjusting screw until it meets resistance If you have turned the screw too far the front derailleur will move toward the small chainring Go through the various gear combinations Make sure the chain does not fall off when you shift and the derailleur cage does not rub on any part of the crankset To adjust the middle gear position with three chainrings 1 Shift the chain onto the largest front chainring and the smallest rear cog 2 Rotate the cable tension barrel adjuster on the downtube or on the lever counter clockwise increasing cable tension to align the inner derail leur cage until it just touches the chain Go through the various gear combinations to ensure the chain smoothly lines up with all the chainrings Note some front shifters have a tab feature slightly downshift the lever and the derailleur moves in slightly no longer touching the chain Rear derailleur To adjust the high gear position 1 Shift the chain onto the smallest rear cog and the largest front chainring 2 Loosen the cable clamp bolt Figure 22 until the cable is free 3 Stand behind the bicycle to see that the smallest rear cog the chain and the two derailleur pulleys are in line 4 If they are not aligned turn the high gear adjusting screw usually marked H
27. e that does not properly support your pelvic area can cause short term or long term injury to your nerves and blood vessels If your saddle causes pain or numbness re adjust the saddle position If after adjustment your saddle still causes pain or numbness consult your dealer about further positioning or replacing the saddle with one that fits you better To adjust the angle of the seat 1 Loosen the seat fixing bolt Figure 16 just far enough so the seat can be tilted fore and aft Some seatposts use two bolts where angle adjustment is done by loosening one bolt and tightening the other bolt 2 Place a straight edge such as a bubble level or ruler across the top of the seat to better see the angle 3 Adjust the seat and re tighten the seat fixing bolt With double bolts using a 5mm allen wrench tighten to 80 125 lb in 9 6 14 1 Nm e With a bolt using a 13 or 14mm open end vvrench tighten to 180 220 lb in 20 3 24 9 Nm e VVith a single bolt using a 6mm allen vvrench tighten to 150 250 Ibein 17 28 3 Nm Seatpost Seatpost binder bolt Figure 17 Bontrager seatpost e With double bolts using a 4mm allen wrench tighten to 45 60 lb in 5 6 8 Nm To adjust the seat height of a bicycle Never engage the seatpost binder with the seatpost out of the frame 1 Sit on the seat in riding lir do position b a without shoes while someone holds the bicycle up 2 Position
28. er informa tion on correct adjustment of the quick release tension read Figure 45 6 Orient the quick release levers so they do not interfere with any other bicycle part or accessory part such as rack or fenders and so obstacles in the path of the bicycle cannot snag the levers 7 Test that you have properly adjusted and closed the quick release If the quick release fails any test either repeat these adjustment procedures including these tests or take your bicycle to your dealer for service If it requires more than 45 pounds 200 Newton force to completely close the quick release lever open the lever and slightly loosen the quick release adjusting nut If it requires less than 12 pounds 53 4 Newton force to begin to open the lever from the fully closed position open the lever and slightly tighten the quick release adjusting nut Repeat the adjustment if necessary Figure 45 Actual measurements 8 Test for proper quick release adjustment Pick up the bike and sharply hit the top of the tire Figure 46 The wheel must not come off be loose or move from side to side Make sure the quick release lever cannot be rotated parallel to the wheel Figure 47 VVhen the quick release is properly tightened and clamped by the lever in the closed position the clamping force is adequate to cause metal into metal engagement embossing Of the dropout surfaces e See Figure 4
29. er modify your frameset or parts in any way including sanding drilling filing removing redundant retention devices installing incompatible forks or by any other method Improper components or improper assembly can place unknown stress on your bike or components An improperly modified frame fork or component can cause you to lose control and fall Before adding or changing any part of your bike consult your dealer Keep the bike clean If your frame or a component is dirty clean it with a soft damp cloth and Wrench Force bike cleaner or a similar product Do not use solvents or harsh chemicals Use of industrial solvents for cleaning may damage the paint Use care when holding the bike during transportation or repair Never clamp the bike frame by its finished or painted surfaces because this may damage the paint or even dent crush or break the lightweight tubing used in high performance bicycle frames When holding the bicycle for repairs clamp the seatpost When holding the bicycle for transpor tation on a motor vehicle clamp the bicycle by the wheels and fork tips Clamping devices used by work stands and car carriers can damage the finish on a bike or even crush the tubing When putting a bike in a repair stand clamp the seatpost When carrying a bike in a car carrier clamp the wheels and the fork tips CHAPTER 2 MAINTENANCE Maintenance schedule This maintenance schedule is based
30. front wheel brake such as using only the front wheel brake in an emergency could cause the rear wheel to lift from the ground which could cause you to lose control Figure 10 Bicycles are normally manufac tured with the left brake lever control ling the front wheel brake To change so that the right lever controls the front wheel brake see Chapter 3 Many models of modern brakes are very powerful they are designed to stop a bike in wet or muddy conditions If you feel your brakes are too powerful for your riding needs take your bike to your dealer for adjustment or replacement of the braking system Figure 10 Overuse of the front wheel brake controls the rear derailleur Use only one shifter at a time Shift gears only when the pedals and chain are moving forward When you shift reduce the force on the pedals to provide quicker and smoother shifting to help avoid excessive chain and gear wear and to help avoid bent chains derailleurs and chainrings Avoid shifting when going over bumps the chain may not shift properly or may fall off With modern indexed shifting systems a movement of the shifter from one position to the next or movement of the shifter to the shift position should promptly move the Chain from one gear to the next However bikes equipped STI road shifters and triple chainrings may shift better particularly when shifting from the smallest chainring to the middle if you hold
31. g medications which might make you drowsy Do not ride double Use special care when off road riding Ride only on the trails Avoid rocks branches or depres sions When approaching a descent reduce speed keep your weight back and low and use the rear brake more than the front The following riding practices increase your risk of injury e Jumping your bicycle e Performing bicycle stunts e Severe off road riding e Downhill riding e Any abnormal bike riding Each of these practices increases the stress on every part of your bicycle Frames or parts under high stress may fatigue prematurely causing them to fail and increasing the risk of injury to the rider To decrease your risk of injury avoid these riding practices Protect your bike when parking or storing it Protect your bike from theft Purchase and use a lock that is effective against bolt cutters and saws Never leave your bike unlocked while unattended Register your bicycle with your local police department Complete our on line warranty registration we will keep the serial number of your bike on file Also keep a record of the serial number in a safe place Park your bike safely in a place where it will be out of the way and make sure it cannot fall over Do not lay the bike on its derailleurs as you may bend the rear derailleur or get dirt on the drivetrain Don t let the bike fall down as this may cut the handlebar grips or tear t
32. h kit Bicycle tire pump with gauge Tire levers Wrench Force synthetic chain lube or similar lubricant Wrench Force synthetic grease or similar bicycle grease Wrench Force frame polish or similar frame protectant Special high pressure air pump for rear shock or suspension fork Note Not all bikes require all these tools CHAPTER 3 ADJUSTMENT This chapter lists instructions for adjustment of the parts of a bicycle After any repair inspect the bike as explained in Chapter 1 A bicycle that malfunctions can cause you to lose control and fall Inspect the entire bicycle thoroughly before every ride and do not ride it until any problem has been corrected A Word About Torque Specifications Torque is a measurement of the tightness of a threaded fastener such as a screw or bolt determined by using a torque wrench The torque specifications should be used to make sure you do not over tighten the fasteners Applying more than the recommended torque to a fastener does not provide extra holding power and may actually lead to damage or failure of a part Always perform the simple function tests listed in this chapter to make sure a part is properly tightened whether or not the part was tightened with a torque wrench Handlebars To adjust the angle of the handle bars 1 Loosen the handlebar clamp bolt s on the stem Figures 11 12 just enough that the handlebars can be rotated in the stem 2 Positio
33. he seat Incorrect use of bike racks may bend your wheels Store your bike carefully where it will be protected from rain snow sun etc when not riding Rain or snow may Cause the metal on your bicycle to corrode Ultraviolet radiation from the sun may fade the paint or crack any rubber or plastic on the bicycle Before storing your bike for an extended period of time clean and lubricate it and polish the frame with Wrench Force frame polish or a similar frame protectant Hang the bicycle off the ground with the tires at approximately half pressure Do not store the bike near electric motors as ozone from motors destroys rubber and paint Before riding the bicycle again be certain it is in good working order Carry repair items Carry a pump spare inner tube patch kit and appropriate tools to keep your bicycle running in the case of a flat tire of other common mechanical problem If you ride at night carry spare bulbs or batteries for your lights Only install and use approved accessories Not all accessories are compatible or safe so only add accessories that are 6 approved by the manufacturer As an example a child carrier places weight high on the bike affecting the stability of the vehicle Although any of our bikes can be fitted with a child carrier the rider must use extra caution to compensate for the decreased stability If you are unsure whether a part is approved consult your dealer Nev
34. iness card or similar thin object between the right brake pad and the disc 3 Apply the lever fully and gradually tighten each mounting bolt as specified in Inspection 8 ARUZ H ie 0010 7 101 Figure 33 Disc brake To remove disc brake pads 1 Remove the vvheel 2 With your fingers or thin tipped pliers grasp the installation tang of the brake pad and pull out 15 To adjust a rotor A rotor Figure 34 allows the rear brake cable to bypass the headset so the handlebars can be rotated a full 360 degrees 1 Ensure that both lower barrel 2 If it is tilted 3 Remove the adjusters are flush with do not show above the lower cable stop and the bearing unit is resting on the lower cable stop The rear brake adjustment must be made with the bearing unit in this position The bearing unit should be parallel to the upper and lower cable stops there is slack in one of the cables Pull each cable end one at a time to see which cable has slack at the bearing unit slack through the barrel adjuster Figure 34 Rotor 4 When even pull is achieved tighten all barrel adjuster locknuts To open the brake for wheel removal For most road calipers lift the brake release lever to the open UP position To close simply turn the lever to the Down position For Campagnolo levers slightly depress the brake lever and push the button until it is flush with the lever body Release the le
35. install a light bulb 1 Locate the lens set screw on the back of either the taillight or head light 2 Remove the screw 3 Rotate the lens 1 4 turn clockwise and lift the lens assembly off the bulb mount 4 Unscrew the bulb Be careful not to crush the glass of the bulb Do not dislodge the wire in the base of the bulb mount 4 Screw a new bulb in until finger tight 5 Place the lens on the bulb mount rotate the lens 1 4 turn counter clockwise 6 Install the lens set screw Check that the new bulb works If it does not check the wiring for correct placement and verify that the new bulb is not damaged CHAPTER 4 LUBRICATION Folding bike Some models of Trek bikes have a large hinge in the middle to fold the bike by following these steps To lower the saddle 1 Open the seatpost quick release and lower the saddle 2 Close the quick release to hold the seatpost in position To fold the pedals 1 Push the end of the pedal directly inward toward the crankset 2 Fold the pedal over 3 Repeat for the other pedal To fold the handlebar stem 1 Rotate the lever lock away from the lower quick release 3 Hold the handlebar with the cables out of the way to prevent pinching and open the lower quick release 4 Fold the handlebar assembly to its down position To fold the main frame 1 Open the latch lock 2 Pull outwards away from the frame on the end of the frame latch until the
36. ld not move or be loose ivf Check the suspension adjust ments Make sure your suspension components are adjusted to your riding style and that no suspension component can bottom out or be so compressed that there is no further Suspension travel or movement remaining V Check the lights and reflectors Make sure the lights are functioning correctly and that any batteries are charged If the lights use a dynamo make sure it is mounted correctly and all attachment hardware is tight Make sure reflectors are clean and in position RULES FOR SAFE RIDING Know and observe local bicycle riding laws Most state and local areas have specific laws for cyclists and you should follow them Local cycling clubs or your state s Department of Transportation or equivalent should be able to supply this information to you The requirements for items like lights and reflectors change between areas so check ahead These are a few of the more important rules of riding e Use proper hand signals e Ride single file when riding with other cyclists e Ride on the correct side of the road never go against traffic e Ride defensively expect the unexpected A cyclist is hard to see and many drivers simply are not trained to recognize the rights and special considerations of a bicycle rider Watch for cars pedestrians and other obstacles Watch for and avoid potholes drain grates soft or low shoulders and other
37. n the handlebars to the desired angle making sure they are centered in the stem 3 Tighten the handlebar clamp bolt s on welded stems to 100 120 lb in 11 3 13 6 Nm An improperly adjusted or tightened handlebar stem or bar ends can cause you to lose control and fall Make sure the stem handlebar and bar ends are positioned and tightened properly before riding the bike e On forged stems to 150 180 lb in 17 20 3 Nm e On 4 bolt BMX stems to 80 100 lb in 9 11 3 Nm Stem To align a direct connect stem with the front wheel 1 Loosen the steerer clamp bolts two to three turns 2 Align the stem with the front Handlebar clamp bolt wheel 3 Tighten the m steerer clamp Figure 11 Direct connect stem bolts on mountain and road bikes to 100 120 lb in 11 3 13 6 Nm On BMX bikes tighten to 145 lb in 16 4 Nm To align a quill type stem with the front wheel or to change the handlebar height Adjusting the handlebar height Stem on a direct connect lexpander stem Figure 11 affects the headset bearing adjustment This procedure requires special tools and training adjusting so this should only eae l be done by your n Adjustable rise dealer To adjust the height of the adjustable rise stem in Figure 12 first change the stem angle which gives access to the stem expander Handlebar clamp bolts bolt 1 Loosen the stem expander bolt Figure 13 Minimum t
38. ntact the tire Figure 29 Direct pull Figure 31 Cantilever Cable entering wa 2 EA q n u N Figure 32 U brake a UY To align a hydraulic disc brake 1 Loosen the brake mounting bolts 2 Apply the lever fully and gradually tighten the bolts to 100 110 Ibein 11 3 12 4 Nm To align a cable actuated disc brake There are several parts to this procedure To adjust right brake pad clearance to the disc 1 Turn the fixed pad adjuster Figure 33 To increase the pad clearance turn the barrel adjuster in clockwise To reduce the pad clearance turn the barrel adjuster out counter clockwise 2 If the pads cannot be adjusted properly in this manner follow the instructions To adjust left brake pad clearance to the disc and re set the right pad e To adjust left brake pad clearance to the disc 1 Turn the cable barrel adjuster To increase the pad clearance turn the barrel adjuster in clockwise To reduce the pad clearance turn the barrel adjuster out counter clockwise 2 If the pads cannot be adjusted properly in this manner loosen the cable clamp bolt and re attach the cable as explained in To install a brake cable page 19 but without removing the cable 3 After adjustment turn the locking nut clockwise to help prevent rotation of the barrel adjuster e To align the brake with the disc 1 Loosen the brake mounting bolts 2 Slide a bus
39. nual Maintenance schedule 7 Recommended tools for proper bicycle maintenance 7 Chapter 3 Adjustment A word about torque specifications 8 Handlebars saca aaa 8 DU dni 8 9 Bares iia aaa aa 9 9 11 LEQAL 11 Headset decidiera 11 Crank APG soria 11 Bottom bracket 11 11 l 11 LLL oa aaa 11 Front derailleur UL asinti 11 12 Rear derailleur s ciscssesveveatevassadvcctvens s 12 13 Nexus 4 7 or 8 speed systems 13 3 speed systems 13 SRAM DualDrive system 13 Brake levers cusco 13 14 Er O an 14 16 WCC IS basi 16 18 Suspension components 18 ILOCOS SOVIGCS porra cir cd 18 Folding bike A 18 19 Chapter 4 Lubrication Make sure the bicycle fits you properly Your dealer should fit you with the proper size of bicycle There should be at least one inch 25mm clearance between the top tube and the rider when standing over the bicycle Figure Figure 1 Minimum stand over height 1 For mountain 1 25mm for most bikes two to bicycles 2 3 50 75mm for mountain bicycles three inches 50 75mm clearance is recommended Some models have maximum weight limits Tricycle 80106 86kg The seat and handlebars may be adjusted to
40. o increase lever the reach turn the screw in clockwise To reduce the reach turn the screw out counter clockwise 2 If needed after adjusting the reach re adjust the brake pad clearance To adjust the reach to the brake lever hydraulic type 1 Locate the reach adjustment screw between the lever and the handlebar near the lever pivot 2 To increase the reach turn the screw in clockwise To reduce the reach turn the screw out counter clockwise To change which lever controls the front brake cable type See the Brakes section for brake adjustment procedures 1 Open the brake 2 For a road bike disconnect the brake cable and completely remove it from the lever e For a mountain bike just remove the leaded end of the cable from the lever 3 Install the cables into the opposite levers 4 Close the brakes 5 Inspect the brakes as explained in Chapter 1 and re adjust as necessary To change which lever controls the front brake hydraulic type 1 For a Hayes brake loosen and remove both clamp bolts Changing the levers with Shimano hydraulic brakes requires special tools and training so should only be done by your dealer 2 Remove the levers and re position according to your preference 3 Re install the clamp bolts and tighten to 25 35 lb in 2 8 4 Nm Brakes Inspect brake pads for wear If the grooves in the braking surface are less than 2mm deep or 1mm deep for
41. offer the best comfort and performance Before making these adjustments refer to Chapter 2 Know how the bicycle performs The features of your bicycle if misused may cause you to lose control of the bike Before riding fast or in more difficult conditions learn the function and performance of all the mechanisms of your bike by riding at slower speeds in a flat empty parking lot If you want your bicycle to perform differently or if you have special needs that require different parts for the safe operation of your bike consult your dealer AS an example the stopping power on bikes varies according to the intended use of the bike If you would like your bike to have more or less stopping power consult your dealer about brake adjustments or other brake options for your bicycle Mis use of the braking system including over use of the front brake can cause you to lose control and fall Avoid improper braking by understanding and practicing proper application of your brakes as explained in this manual When riding slowly do not pedal if the handlebar is turned It may be possible at very slow speeds when the handlebar is turned for your foot or toe clips to to your dealer for service Never ride a bike with a damaged part have it replaced This is not a comprehensive maintenance program vf Check the wheels Check that the wheels are straight Spin each wheel and watch the rim as it passes through
42. oothly to the next gear 4 If the chain makes excessive noise or does not shift turn the barrel adjuster counter clockvvise in small increments and check again for a smooth shift If instead the chain moves to the third smallest cog turn the barrel adjuster clockwise until the derailleur pulleys align with the second smallest cog Go through the gear combina tions to ensure the chain smoothly lines up with all the rear cogs If the derailleur cannot be adjusted in this manner the derailleur hanger may be out of alignment take the bike to your dealer for service Nexus 4 7 or 8 speed systems To adjust the rear shifting 1 Rotate the shifter to the 4th gear position 2 Align the indicator on the rear hub pulley Figure 23 with Seas the cog joint 1 bracket if 3 If the red lines do not line up adjust the gear cable tension by rotating the barrel adjuster until this alignment is achieved 4 Shift to 1st gear then back to 4th and re check the adjustment Cable clamp bolt Figure 23 Pulley and cog joint bracket 3 speed systems To adjust the rear shifting 1 Rotate the shifter to the 2nd gear position 2 Align the indicator on the bell crank window with the line on the push rod Figure 24 3 If the lines do not line up adjust the gear cable tension by rotating the barrel adjuster until this alignment is achieved 4 Shift to 1st gear then back to 2nd and re check th
43. ou have a question or problem that your dealer can t handle contact us Attn Customer Service 801 W Madison Street Waterloo Wisconsin 53594 920 478 4678 My bicycle model My serial number My dealer Your new bicycle Assembly and the first adjustment of your bicycle take special tools and skills so this should only be done by an authorized dealer Meaning of special symbols and lettering In this manual the WARNING sign indicates a potentially hazardous situation which if not avoided could result in death or serious injury In this manual the CAUTION sign indicates a potentially hazardous situation or unsafe practice which if not avoided may result in minor or moderate injury Bold letters indicate important text or points to note Italicized letters indicate a reference to another section within the manual Register your bicycle on line There are two easy ways to register your new bicycle e Click the link when viewing the CD supplied with this manual e Go to the web address on the cover of this manual and follow the links Lock key My dealer s phone BICYCLE TYPE AND USE CLASSIFICATION Road Drop or triathlon handlebars caliper brakes and 700c or 650c wheels with 20 25c tires Condition 1 Tricycle designed for small kids to be ridden only on sidewalks and always under parental supervision Mountain Wide tires flat handlebars and direct pull or disc brakes
44. re clean and check for wear if the small indentations on the braking surface disappear replace the rim Make sure there are no loose damaged or broken spokes Check that hub bearings are properly adjusted Make sure a rim strip is in place and all spoke holes are completely covered To adjust and install a quick release wheel 1 Move the quick release lever to the OPEN position Figure 39 and set the wheel so it firmly touches the inside of the fork ends kss CLOSED Figure 39 Lever posi tions 2 With the lever about halfway between the OPEN position and the CLOSED position tighten the quick release adjusting nut Figure 40 until finger tight 3 Place the lever in the palm of your hand and throw the lever as shown in Figure 41 to the CLOSED position Figures 43 44 At the half closed position of the lever there should be some resistance Do not tighten the quick release wheel retention mechanism by turning the lever like a wing nut Figure 42 it vvill not result in sufficient force to hold the wheel in place 5 If the lever is moved to the CLOSED position with little or no resistance throw lever Figure 43 Front lever position pts clamping strength is m Mg insufficient Figure 44 Rear lever position Return the lever to the OPEN position tighten the quick release adjusting nut further and close the lever and again test for resistance For furth
45. rear shock absorbers e Suspension forks and rear shock absorbers shall be covered by the stated warranty of the original manufacturer This warranty does not cover e Normal wear and tear e Improper assembly Improper follow up maintenance Installation of parts or accesso ries not originally intended for or compatible with the bicycle as sold Damage or failure due to accident misuse abuse or neglect Labor charges for part replacement or changeover This warranty is void in its entirety by any modification of the frame fork or components This warranty is expressly limited to the repair or replacement of a defective item and is the sole remedy of the warranty This warranty extends from the date of purchase applies only to the original owner and is not transferable Trek is not respon sible for incidental or consequential damages Some states do not allow the exclusion of incidental or consequen tial damages so the above exclusion may not apply to you Claims under this warranty must be made through an authorized dealer Proof of purchase is required The subject item must be registered with Trek either through on line registra tion or by the receipt of a warranty registration card by Trek before a warranty claim may be processed This warranty gives the consumer specific legal rights and those rights may vary from place to place This warranty does not affect the statutory rights of the consumer KL
46. s to squeeze the rim When the brakes are not applied the brake pads should be 1 to 2mm from the rim Squeeze each brake lever toward the handlebar to make sure the brake moves freely and stops the bike If the brake lever can be pulled to the handlebar the brake is too loose If the brake pads are too close to the rim the brake is too tight Brake pads should be aligned vvith the rim surface Figure 5 Brake pad aligned Pad and rim Direction of rim rotation with rim surface should be parallel 1 nl gt 0 5 1 toe in W Figure 5 Brake pad alignment Disc brakes a hand lever connected to the brake squeezes a disc mounted on the wheel hub Squeeze each brake lever toward the handlebar to make sure the brake moves freely and stops the bike If the brake lever can be pulled to the handlebar the brake is too loose The Disc brakes and discs get very hot during use and could burn skin Also the disc edges may be sharp and could cut skin Avoid touching the disc or disc brake when hot or when rotating brake pads should be 0 25 to 0 75mm away from the disc when the brakes are not applied If the pads are too close the brake is too tight or mis aligned Internal drum or roller brakes a hand lever operates a brake inside the hub If it takes more than about 5 8 inch 15mm of brake lever movement to stop the bike the brake is too loose If it takes less
47. se lever 2 Turn the release adjusting nut Figure 14 The nut uses standard threading clockwise to tighten counter clockwise to loosen 3 Check that at about halfway through the lever throw there is some resistance If the clamp force is too high or too low readjust the nut 4 Follow the procedures in Inspection to make sure the handlebars are clamped with adequate force Bar ends Bar ends Figure 15 are designed for climbing only Ensure the bar ends face forward and away from you To adjust the angle of the bar ends 1 Loosen the bar end clamp bolt s until they can be rotated on the handlebar 2 Position the bar ends to the desired angle but an angle not less than 15 from parallel to the ground 3 Tighten the bar end clamp bolt to 85 125 lb in 9 6 14 1 Nm Figure 15 Bar ends Saddle The correct adjustment of the seat angle is largely a matter of personal preference first try riding with the top of the seat parallel to the ground For bikes with rear suspension try tilting the seat nose down slightly so that compression of the rear shock under your body weight sag results in a flat seat The seat may also be moved forward or backward along the seatpost to increase comfort as well as adjust the distance to the handlebars With proper adjustment the right bike seat will be reasonably comfort able even for long rides Extended riding with a poorly adjusted saddle or on
48. uctions for adjust ment For more information If you would like additional informa tion about your bicycle or bicycling in general there are many resources in your community First talk to your bicycle dealer They have extensive experience with bicycles and riding in your community With this background they can help you with your individual questions and help you find areas to enjoy your new bicycle In addition most dealers stock a variety of book about cycling including extensive repair manuals Second check your public library Most libraries have extensive offerings of books written by experts in the field about riding racing bicycle safety bicycle maintenance and more Third go on line The best on line resource for your bike can be found by viewing the CD that accompanies this manual Place the CD in a computer and you will find much more informa tion With internet access you can link direct from the CD to our company web site Links to some of the companies that make the parts of your bike are also provided All of this information and help is just a click away LIMITED WARRANTY Trek Bicycle Corporation Trek warrants each new frame rigid fork or original component part of the bicycle against defects in workman ship and materials For the lifetime of the original owner e The bicycle frame or rigid fork For one year e Paint and decals e All original parts excluding suspen sion forks and
49. ver and the brake will open To close reverse the instructions For cantilever brakes and U brakes release the linkwire With one hand squeeze the brake pads firmly against the rim With the other hand pull the leaded end of the linkwire from the retaining fork on the brake arm Release the brake pads and the brake will open To close the brake reverse the instructions e For direct pull type brakes disconnect the pipe from the link arm VVith one hand squeeze the pads firmly against the rim VVith the other hand pull the pipe back from the link arm and lift the pipe Once disconnected let go of the brake pads and the brake will open To close the brake reverse the instructions For internal or drum brakes to remove the rear wheel first discon nect the shift and brake cables To disconnect the brake cable press the cable carrier arm forward and the cable clamp bolt rearward so the bolt aligns with the larger diameter hole in the carrier Pull the cable clamp bolt outward to disengage it from the carrier Slide the brake cable stop forward to remove it from the brake arm Undo brake strap bolt To disconnect the shift cable put the shifter in 1st gear Pull the cable housing out of the shift cable housing stop Rotate the shift cable fixing bolt until the washer flats align with the slit in the cog joint bracket Remove the cable Wheels Inspect tires for wear and damage Make sure rims a
50. wo to three insertion mark on quill turns siem 2 Tap the top of the stem expander bolt with a wood or plastic faced mallet to loosen the stem wedge 3 Adjust the handlebars to the desired height but with the minimum insertion line inside the frame Figure 13 A minimum of 23 4 inches 70mm of the stem quill must always remain in the frame 4 Tighten to 175 260 lb in 19 8 29 4 Nm Never ride your bicycle with a guill stem raised above the minimum insertion mark A quill stem that is positioned too high can damage the bike and can cause you to lose control and fall Make sure the minimum insertion mark Figure 13 is inside the frame To change the angle of an adjustable rise stem 1 Loosen the Figure 12 until the stem can be rotated 2 Position the stem to the desired angie 3 Tighten the angle adjusting bolt to 150 170 lb in 17 20 3 Nm To change the angle of a Bontrager adjustable rise stem 1 Pull out the locking button Figure 14 2 Pull the quick release lever Figure 14 down 3 Position the stem to the desired angle 4 Pull out the locking button again and close the quick release lever Make sure the lever is completely closed and the locking button has returned to its locked position Release adjusting nut Figure 14 Bontrager adjustable rise stem To adjust the clamping force of the quick release lever of the Bontrager adjustable rise stem 1 Open the quick relea
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