Trek Bicycle Owner`s Manual
Contents
1. IMPORTANT KEEP FOR FUTURE REFERENCE About this Owner s Manual This manual explains how to ride your new bike safely Even if you have ridden a bicycle for years it is important for EVERY person to read Chapter 1 before riding this bicycle Parents should explain Chapter 1 to a child or anyone else who might not otherwise understand this information This manual also shows how to perform basic maintenance Some maintenance should only be performed by your dealer and the manual indicates these tasks If you choose to perform these tasks you should purchase a detailed repair manual from your dealer This manual includes a CD compact disc with more compre hensive 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 If your CD does not work go to the web address on the cover to access the information on the web My bicycle model Meaning of special symbols and lettering In this manual the WARNING sign indicates a hazardous situation which if not avoided could result in death or serious injury In this manual the CAUTION sign indicates a hazardous situation which if not avoided may result in minor or moderate injury Register your bicycle Bicycle registration is the only record we have of who owns this bike If there is ever a need to communicate with the owner s2. 3 Turn the low gear adjusting screw marked L until the inner chain guide of the derail leur is approximately O 5 mm from the chain 4 Pull on the cable end and down shift the left shift lever several times so that it is in the small chainring position 5 On the shifter or down tube turn the shift cable adjusting barrelto its most clockwise position 6 Insert the cable in the groove found next to the derailleur cable clamp bolt pull the cable taut andtighten the bolt Front derailleur cable clamp bolt 44 60 Ib in 5 0 6 8 N m To adjust the big chainring 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 outside chainring 4 Position the outer chain guide of the front derailleur approxi mately 0 5 mm 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 Chapter 3 Adjustment 22 6 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
3. 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 are clean and check for wear if the small indentations on the braking surface disappear replace the rim Brake pads remove material when the brake is applied If too much material is removed the rim may become weak and fail suddenly causing a loss of control Regularly inspect your rims for wear and replace them when they are worn 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 32 and set the wheel so it firmly touches the inside of the fork ends 2 With the lever about halfway Wy Pg n J E between the OPEN Figure 33 Tighten nut and CLOSE A Adjusting nut positions tighten the adjusting nut Figure 33 until finger tight Chapter 3 Adjustment 3 Place the lever in the palm of your hand and throw the lever as shown in Figure 34 to the CLOSE position Figures 36 37 At the half closed position Of throw the lever there should be some resistance Do not tighten the quick release wheel retention mechanism Figure 35 Do not turn lever b
4. adjuster out counter clockwise For most direct pull Figure 28 or cantilever Figure 30 systems the barrel adjuster is on the lever For most road caliper systems Figure 29 the barrel adjuster is on the brake itself brake A Cable clamp bolt B No contact C Pad fixing bolt D Centering screw E Arm fixing bolt A Barrel adjuster B Centering screw C Pad fixing bolt D Brake relase lever brake A Linkwire B Pad fixing bolt C Arm fixing bolt D Centering screw Figure 28 Direct pull Figure 30 Cantilever check for centering 2 If the brake has two centering screws adjust the overall spring tension while centering the brake To adjust the alignment of the brake pads on a rim brake 1 Loosen the brake pad fixing bolt 2 Align the pads as shown on page 5 and tighten the pad fixing bolts Road caliper 40 60 Ib in 4 5 6 8 Nem Direct pull or cantilever 70 80 lbein 7 9 9 Nem 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 contact the tire 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 Ib in 11 3 12 4 Nem Chapter 3 Adjustment To align a cable actuated disc brake There are several parts to this procedure To adjust right brake
5. ence a shimmy or harmonic oscillation or frame vibration at certain speeds If you are experi encing a shimmy slow down immediately Take your bicycle directly to a dealer for inspection and repair 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 inspec tion and repair Chapter 1 Guide to Safe On and Off Road Operation CHECK THE BIKE BEFORE EVERY RIDE Before every ride inspect the bike with the following check list If any part of the bicycle fails the inspection repair the bicycle by following the information provided by this manual or take the bike to your dealer for service Never ride a bike with a damaged part have it replaced This is not a comprehensive maintenance program Before every ride checklist C Wheels C Tire inflation C Brakes C Handlebar and stem C Seat and seatpost C Suspension adjustments C Lights and reflectors Cl Frame fork and components A bicycle that does not work properly 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 vf Check the wheels Check that the wheels are straight Spin each wheel and watch the rim as it passes through the brake pads or the frame If the rim wobbles up and down or from side to side repair the whee
6. 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 derailleur cage until it just touches the chain 3 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 will move in slightly no longer touching the chain Rear derailleur To adjust the small cog 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 Figure 22 Rear derailleur A Adjusting screws B Barrel adjuster C Cable clamp bolt D Cable 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 until this line is established 5 While pulling on the cable up shift until the shifter is in the small cog position 6 On the shifter or down tube turn the adjusting barrel 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 derail leur pull the shift cable taut and
7. Inspect the brakes thoroughly before every ride If your brakes are not working properly re adjust them or take the bike to your dealer for service causes the brake pads to squeeze the rim When the brakes are not applied the brake pads should be 1 to 2 mm 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 with the rim surface Figure 5 Figure 5 Brake pad alignment A Brake pad aligned with rim surface B Pad and rim should be parallel C Direction of rim rotation D 0 54 0 mm toe in Disc brake a hand lever connected to the brake by a cable or hydraulic hose squeezes a disc mounted on the wheel hub Squeeze each brake lever toward the handlebar to make sure the brake moves freely and stops Chapter 1 Guide to Safe On and Off Road Operation 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 the bike If the brake lever can be pulled to the handlebar the brake is too loose The brake pads should be 0 25 0 75 mm away from the disc when the brakes are not applied If the pads are too close the brake is too tight or mis aligne
8. Wear a bicycle unexpected A cyclist is hard to helmet is caught see and many drivers simply stuck on or stuck are not trained to recognize between objects the wearer could the rights and special consider choke ations of a bicycle rider Wear protective clothing including helmet eye protection and gloves Watch for cars pedestrians and Avoid loose fitting pants that could other obstacles get caught in the chain Watch for and avoid potholes Also wear light bright and reflec drain grates soft or low shoulders tive clothing to make yourself more and other deviations which could visible especially at night 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 Change your riding to be safe in variable conditions Ride carefully in wet weather No brakes whatever their design work as effectively in wet a weather as they do in dry Even of riding surface properly aligned lubricated conditions walk and maintained brakes require your bike Figure 8 Angle tor cross greater lever pressure and longer ing tracks 9 Chapter 1 Guide to Safe On and Off Road Operation stopping distances in wet weather taillight when you ride in poorly Anticipate the extra distance it will lighted or low visibility conditions take to stop Wet weather causes reduced traction Use slower cornering when traction is reduc
9. by attempting to turn the seat and seatpost in the frame and attempt to move the front of the seat up and down It should not move or be loose Chapter 1 Guide to Safe On and Off Road Operation vf Check the suspension adjust ments Make sure your suspension components are adjusted to your riding style and that no suspen sion component can bottom out or be so compressed that there is no further suspension travel or movement remaining vf 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 attach ment hardware is tight Make sure reflectors are clean and in position vf Check frame fork and components Carefully inspect your frame fork and components for signs of fatigue before and after each ride Regularly inspect your entire bicycle for signs of fatigue stress Dents Cracks Scratches Deformation Discoloration Unusual noises Even if you perform regular inspections if you exceed the limit of strength of your bicycle or a given part it may fail if overloaded After any high force load thoroughly inspect all the parts of your bike High force loads include crashes but you don t have to crash to put a high force load on your bike For example hitting a large hole in the road or a sharp bump such as a railroad track can put large forces on your b
10. by using common sense Here are a few examples Do not ride no hands Do not ride with loose objects attached to the handlebar or any other part of the bicycle Do not ride while intoxicated or while using medications which might make you drowsy Do not ride double continued next page The following riding practices increase your risk of injury e Jumping your bicycle Performing bicycle stunts Severe off road riding Downhill riding 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 Chapter 1 Guide to Safe On and Off Road Operation 10 Use special care when off road slip or that a small bump can riding Ride only on the trails create a significant impact to your Avoid rocks branches or depres frame or fork Keep your bicycle sions When approaching a under control at all times For descent reduce speed keep your children the limit of speed for safe weight back and low and use the riding is much lower so parents rear brake more than the front should strictly enforce this rule Do not ride in an abusive manner ride within the Use Classification for your type of bicycle see pages 1 2 Bicycles are not indestructible As with anything me
11. damp Clot EE 14 Check for loose spokes 29 Lubricate suspension forks 34 Check suspension fork bolts 31 Check rear suspension bolts 18 Monthly Check the attachment of the handlebar and stem 17 Check the attachment of the seatQand sea Check the chain 21 Check the chainguard accesso TICS Pc pO 31 Inspect cables for wear 22 Check the operation of shifters22 Inspect derailleurs 22 Lubricate derailleurs 34 Check the internal shift system24 Check headset bearing adjust IHOHL ceo REOR Te toda 21 Check brake pads 27 Check brake bolts 27 Check chain tension 6 Inspect Trekking accessory bolts 31 Check wheel bearing adjustment 29 Check rims for wear 29 Every 3 Months Clean and polish finish 13 Check the crankset and bottom Lubricate brake levers 34 Every year Lubricate handlebar stem 33 Lubricate seatpost 33 Re grease pedal threads and pearing S ccsicssseisnsdaonaedevsceaness 21 Re grease bottom bracket DEALINGS ep 33 Re grease wheel bearings 34 Re grease headset bearings 34 Lubricate wheel quick releases34 Re grease suspension forks 34 Chapter 2 Maintenance Recommended tools for proper bicycle maintenance Torque wrench with lb in or Nem gradations 2 4 5
12. pedals turn the right pedal spindle counter clockwise but turn the left clockwise 33 Chapter 4 Lubrication 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 derail leur pulleys on the rear derailleur with chain lube Headset Once a year have your dealer 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 have your dealer re grease the wheel bearings Every year lubricate wheel quick releases Apply several drops of synthetic lube or a 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 suspension bike Avoid all lubricants Chapter 4 Lubrication 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 loose
13. so they are parallel to the seat tube 3 Loosen the seatpost binder bolt or quick release 4 Extend the Figure 18 Leg extension with seatpost proper seat height until with your heel resting on the bottom pedal your extended leg is straight Figure 18 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 tricycle 1 Loosen and 2 Move the 3 Install and the minimum insertion mark on the seatpost Figure 19 is not visible above the bike frame A minimum of 21 2 64 mm of seatpost must remain in the frame Figure 19 Minimum insertion mark on seatpost A This line must be inside the bike frame 6 Close the seatpost quick release or tighten the bolt to 85 125 Ibein 9 6 14 1 Nem 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 remove the clamp bolts Figure 20 seat mast to the desired position Figure 20 Tricycle seat tighten the mast A Seat mast seat mast B Clamp bolts clamp bolts to 85 125 lbein 9 6 14 1 N m Chapter 3 Adjustment 20 21 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 slo
14. tight 2 Pull outwards away from the 6 Place the lens on the bulb frame on the end of the frame mount rotate the lens 1 4 turn lavoh amet tie latok openi counter clockwise 3 While avoiding pinching yourself or cables fold the bike in half To unfold the frame reverse the steps of the folding procedure 7 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 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 Chapter 3 Adjustment 32 CHAPTER 4 LUBRICATION 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 Clean the stem and wipe any old grease 3 Ap
15. tighten the cable clamp bolt to 44 60 lIb in 5 0 6 8 Nem To adjust the large cog position 1 Turn the low gear adjusting screw on the rear derailleur usually marked L far enough counter clockwise 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 23 Chapter 3 Adjustment If you have turned it too far the derailleur will Nexus 4 7 ors speed systems 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 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 the cog joint 7 bracket 3 If the red lines do not line up adjust the gear cable 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 8 Check if the chain moves smoothly to the next gear If the chain makes excessive noise or does not shift turn the barrel adjuster counter clockwise in small increments and check again for a smooth sh
16. un ordenador y desea obtener una versi n impresa p ngase en contacto con nosotros mediante la direcci n indicada en esta p gina Una versione italiana del presente manuale riportata sul CD Se non possibile accedere a un computer ed pertanto necessaria una copia cartacea siete pregati di contattarci ai recapiti sopraelencati Een Nederlandstalige versie van deze handleiding vind je op de cd Als je geen toegang hebt tot een computer en een gedrukte handleiding wilt ontvangen kun je schrijven naar het adres op deze pagina En version af denne manual findes p cd en Hvis du ikke har adgang til en computer og gerne vil have en trykt version kan du kontakte os p adressen p denne side Uma vers o deste manual encontra se no CD Se n o tem acesso a um computador e gostava de ter uma vers o impressa contacte nos na morada nesta p gina AN IAPIWON PYAV CDICMRENTWRG DYEI BAAP IL ZTF DHWECHEOBEE COXN VICHSEMECCHR lt K KEE Us nnns g gupeeuuauudaudaudagdgaggagdgadd 9 2006 Trek Bicycle Corporation All rights reserved The Trek Logo is a registered trademark of Trek Bicycle Corporation Part 1t 278709
17. 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 Learn the power of your brakes 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 Avoid toe clip overlap 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 contact the front wheel or fender Figure 2 At normal riding speeds the handlebar does not turn enough for this to occur Figure 2 Toe clip overlap 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 Chapter 1 Guide to Safe On and Off Road Operation Stop riding if you have frame problems Occasionally riders experience problems with their frame or fork If frame or fork has any problem do not ride the bicycle As an example in very rare cases some riders may experi
18. 10 Bicycles are normally manufac tured with the left brake lever controlling 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 Figure 10 Overuse of the front wheel brake 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 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 for adjustment or replacement of the braking system Use good shifting techniques Shifting gears allows you to choose the gear combination most comfortable for riding conditions one that allows you to maintain a constant rate of pedaling Shifting systems are of two types derail leur external and internal Shifting a bike with a derailleur The left hand shifter controls the front derailleur and the right hand shifter 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
19. 6 8 mm allen wrenches 9 10 15 mm open end wrenches 15 mm box end wrench Socket wrench 14 15 and 19 mm socket T25 Torx wrench No 1 phillips head screwdriver Bicycle tube patch kit tire pump with gauge and tire levers Special high pressure air pump for rear shock or suspension fork Note Not all bikes require all these tools Chapter 2 Maintenance CHAPTER 3 ADJUSTMENT This chapter lists instructions for adjustment of the parts of 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 specifica tions 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 If a part fails inspection at the recommended torque take the bike to your dealer An improperly adjusted or tightened handlebar stem or bar ends can ca
20. Some models of Trek bikes have 1 Place the bike on a flat smooth a large hinge in the middle to fold surface with the tires properly the bike by following these steps inflated 2 Loosen the rear axle nuts To lower the saddle Follow the procedures in the 1 Open the seatpost quick Wheels section release and lower the saddle 3 Stand the bike up very 2 Close the quick release to hold straight and set a gap of the seatpost in position about 1 4 6 mm between the training wheels and the ground To fold the pedals on both sides of the bike Make 1 Push the end of the pedal sure the gap is the same on directly inward toward the both sides crankset 4 Adjust the chain tension and 2 Fold the pedal over re tighten the axle nuts 3 Repeat for the other pedal To install a light bulb To fold the handlebar stem 1 Locate the lens set screw on 1 Rotate the lever lock away the back of either the taillight from the lower quick release or head light 2 Hold the handlebar with the 2 Remove the screw cables out of the way to prevent 3 Rotate the lens 1 4 turn pinching and open the lower clockwise and lift the lens quick release assembly off the bulb mount 3 Fold the handlebar assembly to 4 Unscrew the bulb its down position Be careful not to crush the glass of the bulb Do not dislodge the wire in the base of the bulb To fold the main frame mount 5 Screw a new bulb in until 1 Open the latch lock finger
21. 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 partic ularly when shifting from the smallest chainring to the middle if you hold the lever for a moment before letting go of the shifter Shifting a bike with internal gearing Shifting with internal gearing Chapter 1 Guide to Safe On and Off Road Operation 12 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 TAKE CARE OF YOUR BIKE 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 Record and keep your serial number 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 write the serial number in the front of this manual and keep the manual in safe place Park your bike safely When not riding keep you
22. apter 1 for further details Condition 1 bike types For riding on pavement only z Drop type Bicycles or their parts can be handlebars including touring broken or damaged by riding in a bikes but not cyclocross bikes manner more stressful than the S intended use of the bike If the Triathlon time trial or speed bike is damaged you could lose bikes control and fall Do not ride beyond Tandems of any design the design limits of the bike If you are unsure of the limits of the bike consult your dealer Cruisers with wide 26 tires and swept back handlebar Any bike that folds Child bike e Weight limit 275 lbs 125 kg These bikes Tandems 550 Ib 250 kg are designed for children riding where parental supervision is always required Riders shall avoid areas used by automobiles as well as inclines curs stairs or areas near drop offs Child Bike Condition 2 Bikes designed for riding Condition 1 plus smooth gravel roads and improved trails with moderate grades where the For riding on improved or pools paths and roadways only tires do not lose No jumping i roun n Child bike types ground contact Maximum seat height of 680 mm generally bicycles with 16 or 20 wheels and kids tricycles Condition 2 bike types Hybrid bikes with 700c wheels tires wider than 28c and flat N a heel handlebars No quick release whee Sri aa POA fastening systems City bikes specially
23. at adjustment of 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 25 27 2 Loosen the Figure 26 Lever clamp clamp bolt 2 3 a Lever clamp bot turns B Reach adjustment T Screw 3 Position the C Cable lever D Barrel adjuster 4 Tighten the clamp bolt Regular brake levers 53 69 lb in 6 0 7 8 N m On mid bar levers Figure 27 20 30 b in 2 3 3 3 Figure 27 Mid bar brake lever Ne m A Lever clamp bolt Chapter 3 Adjustment Hayes hydraulic levers 25 35 lbein 2 8 4 Nem 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 Figure 26 and turn To decrease the reach turn the screw in clockwise To increase 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 Hayes hydraulic type 1 Locate the reach adjustment screw between the lever and the handlebar near the lever pivot 2 To decrease the reach turn the screw in clockwise To increase the reach turn the screw out counter clockwise To change which lever controls the front brake cable type See the Brakes section
24. chanical 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 Avoid riding too fast Higher speeds create higher risks and greater forces in the event of a crash At higher speeds it is more likely that wheels will Training wheels prevent the normal inward lean of a bicycle during a turn If the bicycle is turned too quickly the bike may tip over resulting in an accident With training wheels do not ride fast or turn sharply Chapter 1 Guide to Safe On and Off Road Operation 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 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
25. d Internal hub brake hand lever connected to the brake by a cable activates a mechansim inside the hub Internal hub brakes get very hot during use and could burn skin Avoid touching the hub or cooling fins when hot If it takes more than 5 8 15 mm of brake lever movement to stop the bike the brake is too loose If it takes less than 7 mm of lever movement to stop the bike the brakes are too tight Coaster brake the brake is engaged by pedaling backwards When pedaling backwards the brake should engage with less than 60 degrees rotation 1 6 revolution Figure 6 Checking chain tension The chain actuates the brake so make sure the chain cannot come off There should be between 1 4 1 2 6 12 mm total vertical movement of the chain Figure 6 vf 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 ff the handlebar from side to side with the front wheel locked between your knees Figure 7 Test the security of the handlebar by attempting to rotate it in the stem It should not move or be loose Make sure that no cables are stretched or pinched by rotating the handlebar Check that the handlebar plugs are properly inserted into both ends of the handlebar and bar ends Figure 7 Function testing the handlebar and stem vf Check the seat and seatpost Make sure the seat is secure
26. d carrier places weight high on the bike affecting the stability of the vehicle Although most of our bikes can be fitted with a child carrier Never 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 Chapter 1 Guide to Safe On and Off Road Operation the rider must use extra caution to compensate for the decreased stability The list of incompatible parts is too long for this manual If you are unsure whether a part is approved consult your dealer Keep the bike clean If your frame or a component is dirty clean it with a soft damp cloth and bike cleaner or a solution of dish soap and water Use of industrial solvents or harsh chemicals for cleaning may damage the paint Avoid clamping the frame during transportation or repair Never clamp the bike frame by its finished or painted surfaces This type of clamp this may damage the paint or even dent crush or break the light weight tubing used in high performance bicycle frames NOTICE Clamping devices used by work stands and car carriers can damage the finish on a bike or even crush the
27. d puts unpredictable forces on a bicycle which may overload the frame fork or parts If you choose to ride in Condition 5 terrain you should take appropriate safety precau tions such as more frequent bike inspections and replacement of equipment You should also wear comprehensive safety equipment such as a full face helmet pads and body armor For extreme riding User caution advised Condition 5 bike types Freeride or jumping bikes with heavy duty frames forks and components Weight limit 300 lbs 136 kg Chapter 1 Guide to Safe On and Off Road Operation BEFORE A FIRST RIDE Make sure the bicycle fits Your dealer should fit you with the proper size of bicycle There should be at least 1 25 mm clearance between the top tube and the rider when standing over the bicycle Figure 1 For mountain bikes 2 3 50 75 mm Figure 1 Minimum stand clearance is over height recommended A z 1 25 mm for most bicycles The seat and handlebar may be adjusted to offer the best comfort and performance Before making these adjustments refer to Chapter 3 2 3 50 75 mm for mountain bicycles 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
28. e and use classification Child Pikse issoro a bi Condition 1 oct vecisOvee decks 1 Condition 9 5 5 eee cess ed eeex y 1 ConditlOTl O icteoeei enmenar 2 COBCIUlOI 4 oreet yere 2 Condition 5 eee eem 2 Before a first ride Make sure the bicycle fits 3 Know how the bicycle performs 3 Check the bike before every ride Before every ride checklist 4 Carbon fiber inspection 7 Rules for safe riding Know and observe local bicycle riding laws eere 9 Watch for cars pedestrians and other obstacles 9 Wear a helmet and proper cycling CLOT OS Cn 9 Change your riding to be safe in variable conditions 9 Riding instructions Use your brakes carefully 12 Use good shifting techniques 12 Take care of your bike Protect your bike when parking Or Strine IG cinsncisdesyesesinsscays 13 Carry repair items 14 Only install and use approved acCOSSOTIOS sass ses adsoversastecdseans 14 Keep the bike clean 14 Avoid clamping the frame during transportation or repair 14 Protect your bicycle during SHIPPING eresi 14 Maintenance schedule 15 Recommended tools for proper bicycle maintenance 16 Chapter 3 Adjustment 17 Handlebar ren 17 ln 1 Bar ends eere etre tes 19 Saddle reise reete veis 19 HeadSet ets 21 CPankSeb eere iiec 21 Crank a
29. e changed 2 Position the stem to the desired bolt two to three turns angle 2 Tap the top 3 Tighten the angle adjusting of the stem bolt to 150 170 lbein 17 20 3 expander bolt N m with a wood or plastic To change the angle of a Bontrager faced mallet to adjustable rise stem Figure 12 Adjustable rise loosen the stem quill stem 1 Slide the wedge s eee clamp locking button olts 3 Adjust the B Stem expander bolt Figure 14 handlebar to C Angle adjusting bolt forward and the desired lift the quick release lever height but with the 2 Position the minimum stem and insertion handlebar to line inside the desired Figure 14 Bontrager the frame angle adjustable rise stem Figure 13 A 3 Close the ph iL minimum of quick release B Quick release lever 23 4 70 mm lever C Locking button of the stem Figure 13 Minimum Make sure the quill must insertion markon quill lever is completely closed and the always remain A this tine must be locking button has returned to its in the frame inside the bike frame locked position 4 Tighten to 120 Ib in 13 6 Nem To adjust the clamping force of the quick release lever of the Bontrager adjustable rise stem x id m r TU T 1 Open the quick release lever ever ride your bicycle with a qui ee stem raised above the minimum ae cue s oer adjusting insertion mark A quill stem that screw Figure 14 is positioned too high can damage 3 Check t
30. e part thoroughly with a damp cloth 2 With a coin tap the part near any possible damage and places where the part is known to be in good condition or use a similar part 3 Listen carefully for variations in sound especially a hollow sound dead tone or any sound indicating that the part is not solid Chapter 1 Guide to Safe On and Off Road Operation RULES FOR SAFE RIDING Know and observe local bicycle If a car suddenly enters your lane riding laws or someone unexpectedly opens Most state and local areas have the door of a parked car you could specific laws for cyclists and you be involved in a serious accident should follow them Local cycling Mount a horn or bell on your clubs or your state s Department bicycle and use it to alert others of of Transportation or equivalent your approach should be able to supply this information to you The require Wear a helmet and proper ments for items such as lights and cycling clothes reflectors change between areas Wear a helmet so check ahead that meets CPSC These are a few of the more or CE safety important rules of riding testing standards Use proper hand signals Figure 9 it may help prevent injury Helmets should Ride single file when riding with other cyclists Ride on the correct side of the road never inst traffi be removed when oad never go against traffic not riding the Ride defensively expect the bicycle If the Figure 9
31. ed such as when riding over wet leaves painted crosswalks or manhole covers When wet weather cools to below freezing traction is reduced even further In addition brakes may not work as well Adjust your riding speed accordingly 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 Strong winds can make a bicycle steer or turn unexpectedly In windy conditions slow down or use other forms of transportation 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 reflectors are they do not help you see nor do they help you be seen unless light is directed on them Use working headlight and A bicycle rider without proper lighting and reflectors may not have good vision and may not be visible to others Use front and rear bicycle lights and reflec tors when riding in poor visibility conditions Failure to do so will increase your chances of being involved in an accident in low light 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 Do not use unsafe riding practices Many cycling accidents could be avoided
32. equipped hybrids Weight limit 80 lbs 36 kg e Cyclocross bikes with drop type handlebars knobby 700c tires and cantilever or disc brakes e Weight limit 300 lbs 136 kg Chapter 1 Guide to Safe On and Off Road Operation Condition 3 Bikes designed for riding Conditions 1 and 2 plus rough trails small obstacles and smooth technical areas including areas where momentary loss of tire contact with the ground may occur NOT jumping All mountain bikes without rear suspension are Condition 3 and so are some light weight rear suspen sion models For riding on unimproved trails with small obstacles Condition 3 bike types Standard or cross country mountain bikes with wide knobby 24 26 or 29 tires May include short travel rear suspension 3 75 mm or less Weight limit 300 lbs 136 kg Condition 4 Bikes designed for riding Conditions 1 2 and 3 plus rough technical areas moderately sized obstacles and small jumps For riding on rough trails with medium obstacles Condition 4 bike types Heavy duty or all mountain mountain bikes with wide knobby 24 26 or 29 tires May include medium travel rear suspension 4 100 mm or more Weight limit 300 lbs 136 kg Condition 5 Bikes designed for jumping hucking high speeds or aggres sive riding on rougher surfaces or landing on flat surfaces However this type of riding is extremely hazardous an
33. f the original manufac turer This warranty does not cover Normal wear and tear 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 LIMITED WARRANTY 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 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 Bicycle Corporation is not responsible for incidental or consequential damages Some states do not allow the exclusion of incidental or consequential damages so the above exclusion may not apply to you Claims under this warranty must be made through an authorized Trek dealer Proof of purchase is required The subject item must be registered with Trek Bicycle Corporation either through on line registration or by the receipt of a warranty registration card by Trek Bicycle Corporation before a warranty claim may be processed Warranty duration and detail may differ by frame type and or by country This warranty gives the consumer Specific legal rights and those rights may vary from place to place This warranty does n
34. for brake adjustment procedures 1 Open the brake 2 For a road bike disconnect the brake cable and completely remove it from the lever 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 Hayes hydraulic type Changing the levers with Shimano hydraulic brakes requires special tools and training so should only be done by your dealer 1 Loosen and remove both lever clamp bolts 2 Remove the levers and re position according to your preference 3 Re install the clamp bolts and tighten to 25 35 Ib in 2 8 4 Nem Chapter 3 Adjustment 26 Brakes Once a month inspect brake pads for wear If the grooves in the braking 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 surface are less than 2 mm deep or 1 mm deep for direct pull brakes road brake 1 Rotate the centering screw Turn in small increments and replace the pads Replace disc brake pads that are thinner than 1 0 mm 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
35. gnolo levers there is release button at the top of the lever Slightly depress the brake lever and push the button until it is flush with the lever body Release the lever and the brake will open To close reverse the instruc tions For eantilever 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 Chapter 3 Adjustment 28 For direct pull type brakes disconnect the pipe from the link arm With one hand squeeze the pads firmly against the rim With 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 disconnect 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
36. hat at about halfway the bike and can cause you to lose through the lever throw there is control and fall Make sure the some resistance minimum insertion mark Figure If the clamp force is too high or too low re 13 is inside the frame adjust the screw Chapter 3 Adjustment 18 Bar ends Bar ends Figure 15 are designed for climbing only Ensure the bar ends face forward and away from you but at an angle not less than 15 from parallel to the ground Figure 15 Bar ends A Bar end clamp bolt 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 3 Tighten the bar end clamp bolt to 85 125 lbein 9 6 14 1 Nem Saddle The correct adjustment of the seat angle is largely a matter of personal preference With proper adjustment the right bike seat will be reasonably comfortable even for long rides To select the saddle angle 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 level seat The seat may also be moved forward or backward along the seatpost to increase comfort as well as adjust the distance to the handlebar Extended riding with a poorly adjusted saddle or one that does not properly support your pelvic area can ca
37. ift 4 Shift to 1st tension by rotating the barrel adjuster until this Figure 23 Pulley and cog lignment i joint bracket E ent as A Pulley achieved B Cog joint bracket C Cable clamp bolt gear then If instead the chain moves to back to 4th and re check the the third smallest cog turn the adjustment barrel adjuster clockwise until the derailleur pulleys align with 3 speed systems the second smallest cog 4 Go through the gear combina To adjust the rear shifting tions to ensure the chain 1 Rotate the smoothly lines up with all the shifter to rear cogs the 2nd gear If the derailleur cannot be position adjusted in this manner the 2 Align the derailleur hanger may be out of alignment take the bike to your dealer for service indicator on the bell crank window with the line on the push rod Figure 24 Three speed Figure 24 bell crank A Bell crank window Chapter 3 Adjustment 24 25 3 If the indicators 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 the adjust ment Brake levers The brake system allows you to slow or stop your bike function critical to your safety The brake system is difficult to adjust properly without the proper L S Figure 25 Lever clamp tools and training po road lever It is strongly A Lever clamp bolt recommended th
38. ike The manner in which you ride will determine whether your bike and its parts will last If you ride hard or aggressively you should replace the bike and or its parts more often than riders who ride smoothly or cautiously There are many variables weight speed technique terrain maintenance riding environment humidity salinity temperature etc and the frame or part itself so it is impossible to give a precise timetable for replacement If you aren t sure ask your dealer But as a rule it is better to err on the safe side and replace the bike or parts more frequently Carbon fiber inspection procedures Carbon fiber is among the strongest materials used in bicycle manufacture However carbon has unique qualities different from metal parts and must be inspected carefully for damage Unlike metal parts carbon composite parts that have been damaged may not bend bulge A damaged carbon fiber part can fail suddenly Inspect your carbon fiber bicycle or parts for damage frequently If you have crashed or impacted your bicycle or suspect a carbon part is damaged IMMEDIATELY STOP RIDING YOUR BICYCLE Take it to your dealer for inspection service and evaluation under the crash replacement policy Chapter 1 Guide to Safe On and Off Road Operation or deform a damaged part may appear to be normal to a cursory glance If you have any doubts about the integrity of a part do not ride the bicycle Be
39. ke and sharply hit the top of the tire Figure 39 The wheel must not come off be loose or move from side to side Make sure the quick release lever cannot be Figure 39 Test for rotated parallel looseness to the wheel Figure 40 7 V P 5 w Aa A E Figure 40 Test for rotation Chapter 3 Adjustment When 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 See Figure 38 To install an axle nut wheel Some wheels are attached by 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 Tighten a regular front wheel to 180 240 Ib in 20 3 27 1 N m Tighten a regular rear wheel to 240 300 Ib in 27 1 33 9 N m 2 Test to ensure that you have properly tightened the axle nuts Pick up the bike and sharply hit the top of the tire Figure 39 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
40. l Check that the wheels are properly attached Bicycle wheels are attached by several systems threaded axle nuts a quick release where a lever actuated wheel retention mechanism Figure 3 allows the wheel to be installed and removed without tools or a thru axle where the axle is threaded through the ends of the frame or fork For informa tion about adjust ment and closure of the wheel attachment devices on your bicycle see Chapter 3 Test for proper wheel attachment Pick up the bike and sharply hit the top of the tire Figure 4 The wheel must not come off be loose or move from side to side Further tests are provided in Chapter 3 Figure 3 Wheel quick release Figure 4 Test for loose ness A wheel attachment device that is not properly adjusted and closed 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 Vf Check the tire inflation Inflate the tires to the air pressure recommended on the tire sidewalls vf Check the brakes Follow the inspection instructions for the type of brake on your bike Hand rim brake hand lever connected to the brake by a cable 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
41. n 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 re adjust 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 to52 69 lbein 6 8 Nem 6 Cut the cable so that no more than 2 51 mm 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 instructions for adjustment 34 FOR MORE INFORMATION If you would like additional information about your bicycle maintenance 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 librarie
42. only be performed by your dealer 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 In small increments loosen the rear wheel axle nuts on alternate sides of the wheel If you fully loosen one side before loosening the other you may cause the bearings to come out of adjustment Chapter 3 Adjustment 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 installa tion Cables Check the cables for kinks rust broken strands or frayed ends Also check the housing for loose wire strands bent ends cuts and wear If you suspect a problem with a cable do not ride the bicycle follow the instructions to replace a cable page 34 or have your dealer service the bicycle Shifters The position of the shifters can be adjusted on the handlebar Follow the instructions for adjusting the lever position on pages 25 26 Front derailleur To adjust the small chainring position 1 Shift the chain onto the smallest front chainring and the largest rear cog 2 Loosen the front derail leur cable clamp bolt Figure 21 until the cable is free pS m Figure 21 Front derail leur A Cable B Adjusting screws C Cable clamp bolt
43. ot affect the statutory rights of the consumer Carbon crash replacement policy Assessing any damage done to carbon fiber part requires more experi ence than is needed to inspect metal parts If you crash or impact your bike and the force of the impact is absorbed by a carbon part we strongly encourage you to replace the part even if there are no indications of damage If such a crash or impact occurs Trek offers crash replacement program for carbon parts substantially reducing any replacement cost To take advantage of this program contact us using the information listed above and ask for the Warranty department Limited warranty 36 Customer Service 920 478 4678 www trekbikes com 801 West Madison Street Waterloo Wisconsin 53594 USA FR z PT JA ZL An english version of this manual is on the CD If you do not have access to a com puter and would like a printed version contact us at the address on this page Une version fran aise de ce manuel se trouve sur le CD Si vous n avez pas acc s un ordinateur et si vous souhaitez obtenir une version papier contactez nous l adresse qui figure sur la page Eine deutsche Version dieses Handbuchs finden Sie auf der CD Wenn Sie keinen Computer zur Verf gung haben und eine Druckversion des Handbuchs w n schen wenden Sie sich an uns unter der hier angegebenen Adresse Una versi n espa ol de este manual se encuentra en el CD Si no tiene acceso a
44. pad clearance to the disc 1 Turn the fixed pad adjuster Figure 31 2 If the pads cannot be adjusted properly in this manner follow the instruc tions To adjust left brake pad clearance to the disc and re set the right pad 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 Tighten the cable clamp bolt to 50 70 Ib in 5 7 7 9 N m 3 After adjustment turn the locking nut clockwise to help prevent rotation of the barrel adjuster To align the brake with the disc 1 Loosen the brake mounting bolts Figure 3t Disc brake A Mounting bolts B Fixed pad adjuster C Cable clamp bolt 2 Slide a business card or similar thin object between the right brake pad and the disc 3 Apply the lever fully and gradually tighten the bolts to 100 110 Ib in 11 3 12 4 N m To remove disc brake pads 1 Remove the wheel 2 With your fingers or thin tipped pliers grasp the installa tion tang of the brake pad and pull out 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 Campa
45. ply 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 Choose the method for your frame and seatpost material Aluminum seatpost in a metal frame 1 Loosen the seatpost binder bolt or open the quick release and remove the seatpost from the 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 Carbon fiber seatpost or carbon fiber frame 1 Loosen the seatpost binder bolt or open the quick release and remove the seatpost from the frame 2 Wipe the seatpost and inside the seat tube with a soft cloth and clean water 3 Let the seeatpost dry then insert it into the frame 4 Adjust the seat to the proper height align it and tighten the seatpost binder bolt Bottom bracket Once a year have your dealer re grease the bottom bracket bearings Pedals Once a year have your dealer re grease the pedal bearings Once a year re grease the pedal axles 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
46. r bike in 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 the seat Incorrect use of bike racks may bend your wheels Store your bike carefully When not riding keep your bike where it will be protected from rain snow sun etc Do not store the bike near electric motors as ozone from motors destroys rubber and paint 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 Chapter 1 Guide to Safe On and Off Road Operation Before storing your bike for an extended period of time clean and lubricate it and polish the frame with frame polish Hang the bicycle off the ground with the tires at approximately half pressure 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 and batteries for your lights Only install and use approved accessories Not all accessories are compat ible or safe so only add accessories that are approved by the manufac turer As an example a chil
47. rms veeveeeuesce utens 21 Pedals erecto Et Rei pecess 21 Bottom bracket 21 CHAI RN 21 Cables 5 iei cies epe oai 22 e ahb r e RT ETT OTT 22 Front derailleur 22 Rear derailleur 23 Nexus 4 7 or 8 speed systems24 3 speed systems 24 Brake levers ss 25 Brakes icscicscsindetnmaiivassseaces eens 27 IWHCOIS erene o coole see sari ave euros 29 Suspension components 31 Accessories eesseeeeeeee 31 Folding bike 32 Sj aE A TT 33 Seavtpost ereenn eer te re res 33 Bottom bracket 33 Pedals rette ee tbo ens 33 Chapter 4 Lubrication Derailleurs 2 rre 34 Headset eter etes 34 Brakes and brake levers 34 Wheels ebrei te ete ritas 34 Suspension forks 34 Rear suspension 34 Control cables 34 For more information 35 Limited warranty 36 BICYCLE TYPE AND USE CLASSIFICATION Riding a bicycle in manner Condition 1 beyond or more severe than its Bikes designed intended use can cause the bicycle for riding on a or part of the bicycle to fail The paved surface following information explains where the tires do the type of riding intended for not lose ground different types of bikes Read the contact safety information in Ch
48. s 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 computer and you will find much more information 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 For more information All Trek bikes are sold exclusively through our network of Authorized Dealers who we entrust with profes sional assembly and service of your bicycle Trek Bicycle Corporation warrants each new Trek frame rigid fork or original component part of the bicycle against defects in workmanship and materials For the lifetime of the original owner The bicycle frame except the fork and the Session model For five years Rigid forks All Bontrager components and accessories except consumables such as tires and inner tubes For three years The Session model frame For one year Paint and decals All original parts excluding suspension forks and rear shock absorbers All original parts excluding Shimano parts suspension forks and rear shock absorbers All Shimano parts suspension forks and rear shock absorbers shall be covered by the stated warranty o
49. the fork tips 3 Close the quick releases or tighten the clamp bolts to 45 55 lbein 5 1 6 2 Nem 4 Test to ensure that you have properly attached the thru axle Pick up the bike and sharply hit the top of the tire Figure 39 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 the bicycle to your dealer for service Suspension components Changing your suspension settings affects handling and braking characteristics After making a change carefully test the bike in a low traffic area until you are familiar with its performance Sag is the compression of shock that occurs when the rider sits on the bike in a normal position For an all round ride set the forks at 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 adjust ment and maintenance informa tion or consult your dealer Accessories 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 Chapter 3 Adjustment To adjust training wheels Folding bike See other sections of this manual as needed
50. 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 Protect your bicycle during shipping If you have to ship your bike make sure it is properly padded and protected to avoid damage Ask your dealer about supplies used to ship a new bike such as a fork block CHAPTER 2 MAINTENANCE Maintenance schedule This maintenance schedule is based 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 Approximately 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 Every ride Check the wheels 4 Check the tire inflation 5 Check the brakes 5 Check the handlebar and stem 6 Check the seat and seatpost 6 Check the suspension adjust MENTS repre ds e Ea 7 Check the lights and reflectors 7 Check frame fork and Components erresiren 7 Weekly Wipe off your bicycle with a
51. uch as providing updated safety information your registration is crucial There are two easy ways to register your new bicycle Click the Registration link when viewing the CD supplied with this manual Go to the web address on the back cover of this manual and follow the links The web site also provides a link to updated safety information If you choose not to register make sure you check the web site often My serial number Lock key amp My dealer D o oc o o o ra 2 o gt o a a o o x My dealer s phone Assembly of your new bicycle Assembly and the first adjust ment of your bicycle take special tools and skills so this should only be done by an authorized dealer If you have questions There are many models with a variety of equipment so this manual may contain some information that does not apply to your bike Some illustra tions may vary from the actual bicycles If you have any questions after reading the information in this manual consult your dealer If you 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 This manual conforms with these standards ANSI Z535 4 CPSC CFR 1512 BS 6102 Part 1 1992 CEN 14764 14765 14766 14872 TABLE OF CONTENTS Chapter 1 Guide to Safe On and Chapter 2 Maintenance Off Road Operation Bicycle typ
52. use 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 better fits you Never engage the seatpost binder with the seatpost out of the frame 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 bubble level or ruler across the top of the seat to better see the angle Figure 16 Seatpost parts A Seat fixing bolts B Seatpost C Seatpost binder bolt Figure 17 Bontrager seatpost A Seat fixing bolt Chapter 3 Adjustment 3 Adjust the seat and re tighten the seat fixing bolt according to the type of seatpost Double bolts using a 5 mm allen wrench 80 125 lb in 9 6 14 1 N m Single bolt using a 13 or 14 mm open end wrench 180 220 lbein 20 3 24 9 Nem Single bolt using a 6 mm allen wrench 150 250 lbein 17 28 3 N m Double bolts using a 4 mm allen wrench 45 60 Ib in 5 6 8 N m To adjust the seat height of a bicycle 1 Sit on the seat in riding position without shoes while someone holds the bicycle up 2 Position the crank arms
53. use you to lose control and fall Make sure the stem handlebar and bar ends are positioned and tightened properly before riding the bike Handlebar To adjust the angle of the handlebar 1 Loosen the handlebar clamp bolt s on the stem Figures 11 12 just enough that the handlebar can be rotated in the stem 2 Position the handlebar to the desired angle making sure it is centered in the stem 3 Tighten the handlebar clamp bolt s according to stem type Welded stems 100 120 Ib in 11 3 13 6 Nem Forged stems 150 180 lbein 17 20 3 N m Stem There are two types of stems Direct connect Figure 11 Quill type Figure 12 Adjusting the handlebar height on a direct connect stem affects the headset bearing adjustment This procedure requires special tools and training Figure 1 Direct connect so this should stem only be done by feb clam bolts your dealer To align a direct connect stem 1 Loosen the steerer clamp bolts two to three turns 2 Align the stem with the front wheel 3 Tighten the steerer clamp bolts to 100 120 Ib in 11 3 13 6 N m Chapter 3 Adjustment To align or adjust a quill type stem To change the angle of an adjust To adjust the height of the adjustable rise stem able rise stem in Figure 12 first change the stem angle which 1 Loosen the angle adjustment gives access to the stem expander bolt bolt Figure 12 until the stem 1 Loosen the stem expander angle can b
54. very careful when handling carbon fiber parts that are suspected of damage When a composite part is damaged there is a possibility that individual fibers may be exposed Carbon fibers are thinner than a human hair but quite stiff If the point of one of these fibers is pressed against your skin it could pierce your skin like a needle Inspecting carbon fiber composite frame fork or parts Use the following procedures to inspect carbon composite parts Check for scratches gouges or other surface problems Check the part for loss of rigidity Check the part for delamina tion Listen for unusual creaking or clicking noises These tests may not be conclusive The tests are difficult to describe so we provide a movie of inspecting a composite part on the owner s manual CD and on the owner s manual web site To check a part for surface problems visual test 1 Clean the part thoroughly with a damp cloth 2 Look closely for problems scratches gouges cracks loose fibers which will appear like thin hairs other surface flaws To check a part for loss of rigidity flex test Use the part in a normal manner without actually riding while someone watches carefully for unexpected movement As an example if you suspect a composite seatpost has been damaged sit gently on the saddle while someone watches to see if the seatpost flexes To check a part for delamination tap test 1 Clean th
55. wly rotate the fork and handlebar to the right and left If the headset 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 Crankset To check the bottom bracket bearing adjustment 1 Lift the chain from the chainrings 2 Rotate the crank so that one of the arms is parallel to the seat tube 3 Put one hand on the crank arm and one hand on the seat tube and attempt to move the crank arm laterally toward and away from the seat tube 4 Spin the cranks If the crank feels or sounds loose or if the motion stops abruptly or you hear a grinding noise coming from the bearings the bearings need to be adjusted or re greased by your dealer 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 Pedals To adjust the release force on clipless pedals refer to the information on the CD supplied with your bicycle or consult your dealer The left pedal is left hand threaded while the right pedal is right hand normal threaded Tighten pedals into the crankarms to 350 380 Ib in 40 2 42 9 N m Adjustment of pedal bearings requires special tools and training These services should
56. y turning the lever like a wing nut Figure 35 it will not result in sufficient force to hold the wheel in place 5 If the lever is moved to the CLOSE position with little or no resistance clamping strength is insufficient Return the lever to the OPEN position tighten the adjusting nut further close the lever and again test for resistance For further informa tion on correct adjustment of the quick release tension read Figure 38 Figure 36 Front lever position m a Figure 37 Rear lever position 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 38 Actual measurements 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 8 Test for proper quick release adjustment Pick up the bi
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