about this manual
ABOUT THIS 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 is otherwise not able to
understand this information.
Even if you have ridden a bicycle for years, it is
important for EVERY person to read Chapter 1 before
you ride your new bicycle!
Chapter 1 covers safety and bicycle care. Understanding
and following this information will help you and
your Trek bicycle avoid injury and damage.
Chapter 2 gives a maintenance schedule for a bicycle
under normal riding conditions.
Chapter 3 gives basic instructions for inspection, lubrication, and adjustment of the parts of a bicycle.
This manual covers all models of Trek bicycles. 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.
Note: For suspension forks and some other parts, we may refer
you to the manual supplied by the manufacturer of the part. If
you did not receive a referenced manual, download one from the
internet, get one from your dealer, or contact us at the phone
number or web site listed below and we’ll send you the proper
manual.
There may be a more current manual available for your
bicycle. For the most current Owner’s Manual, please check
the Trek web site. If you have any questions after reading
this manual or the information on the Trek web site, consult
your Trek dealer. If you have a question or problem, which
your Trek dealer can’t handle, contact us using mail, phone,
or internet:
Trek Bicycle Corporation
(800) 369-8735
Attn: Customer Service
http://www.trekbikes.com
801 W. Madison Street
Waterloo, Wisconsin 53594
© Copyright Trek Bicycle Corporation 2003
All rights reserved
YOUR TREK BICYCLE
Thank you for buying a Trek bicycle. Your bicycle meets the
highest safety and performance standards. You have chosen the
size and model that meets your needs, and your Trek dealer
has assembled and adjusted it.
Assembly and the first adjustment of your Trek®
bicycle take special tools and skills, so this should only
be done by an authorized Trek bicycle dealer.
Steerer
(inside
the head
tube)
Top tube
Head tube
Seat stay
Down tube
Fork blade
Chain stay
Bottom bracket
shell
Rear derailleur hanger
Figure 1 Names of frame parts
The Owner’s Manual bag supplied with your bike, or
frameset, includes a warranty card. Complete this card, and
send it to Trek Bicycle Corporation. We must have this card
before we can process a warranty claim.
Your bicycle:
Model Name or No.
Color
Size
Your serial number:
The serial number of your bicycle is attached to the underside of the down tube, just ahead of
the bottom bracket shell (Figure 1).
Your Trek dealer:
Your dealer's phone:
ii
DEFINITIONS
In this manual, the Warning sign indicates a potentially
hazardous situation which, if
not avoided, could result in
death or serious injury.
WARNING
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.
CAUTION
Bold letters
indicate important text, or points to note.
Examples include OPEN or CLOSED.
Italicized letters indicate a reference to another section within
the manual. Examples include the Wheels
section.
This manual covers the entire line of Trek bicycles, which
includes several bicycle types. The following pictures help you
identify the type of bicycle you own:
Mountain bike- uses a "flat" handlebar and wide, knobby tires. It may
have front suspension, rear suspension, or both. It has wheels with a
26" or 29" nominal diameter.
Road bike- uses "drop" handlebars,
road caliper brakes, and 700c or
650c nominal wheel diameter.
Figure 2 Road bike
Hybrid bike- a combination of road
and mountain designs, this bike uses
a "flat" handlebar, but medium-width
road tires on 700c nominal wheel
diameter.
Touring bike- a road bike designed
to carry camping gear. Equipped
with large-diameter tires to carry
the extra weight, and equipped
with high-clearance brakes.
Figure 3 Touring bike
Figure 5 Mountain bike
Figure 7 Hybrid bike
Juvenile bike- may look like an adult
bike, but scaled to size for a smaller
rider; includes BMX, mountain,
hybrid, and road styles.
Cyclo-cross bike- a road bike designed
to allow skilled riders to ride on nonpaved surfaces, equipped with highclearance brakes.
Figure 6 Juvenile bike
Figure 4 Cyclo-cross bike
Tricycle- three wheels for stability
when the young rider is learning
about wheeled vehicles.
iii
Figure 8 Tricycle
Wear, fatigue, maintenance, and hard use can decrease
the life and safety of your bicycle.
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:
• Dents
• Cracks
• Scratches
• Deformation
• Discoloration
Fatigue can be accelerated by large forces from unsafe riding
practices:
• Jumping your bicycle
• Performing bicycle stunts
• Severe off-road riding
• Downhill riding
• Any abnormal bike riding
Carefully inspect your frame and components for signs of
fatigue before and after each ride.
WARNING
The following riding practices increase your risk of injury:
• Jumping your bicycle
• Performing bicycle stunts
• Severe off-road riding
• Downhill riding
• Any abnormal bike riding
Each of these conditions 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. Avoid these riding
practices to decrease your risk of injury.
iv
TABLE OF CONTENTS
Chapter 1
Guide to Safe On-and-Off Road Operation
IMPORTANT!
Read this chapter before you ride
Make sure your bicycle fits you properly .......................... 1
Know how your bicycle performs ................................... 1-2
Before every ride: Check your bike ................................ 3-9
During every ride: Ride safely. ................................... 10-13
Before, during, & after every ride:
Take care of your bike............................................................ 14-16
Use your pedal system safely. .................................. 17-19
Supervise your cycling child. ....................................... 20
.
Chapter 2
Periodic Maintenance
Chapter 3
Inspection, Adjustment, and Lubrication
Periodic maintenance schedule................................... 21-22
Recommended tools for proper bicycle maintenance...... 22
Some maintenance and repair should only be performed by your Trek
dealer, as indicated in this manual.
A word about torque specifications ................................. 23
Handlebars, bar-ends, and stem ................................. 24-28
Seat and seatpost ........................................................ 29-31
Drivetrain: pedals, crank, chain, and cassette ........... 32-34
Derailleur shifting systems ........................................ 35-39
Internal shift systems ................................................. 40-45
Headset and fork......................................................... 46-47
Brake systems ............................................................. 48-63
Wheels ......................................................................... 64-69
Reflectors ......................................................................... 70
Tire installation........................................................... 71-73
Tubeless-compatible wheel system ............................. 74-78
Suspension systems
Suspension forks........................................................... 79
Rear suspension....................................................... 80-84
Care of your frame or fork.......................................... 85-87
Folding bike ................................................................ 88-89
Trekking accessories .................................................. 90-91
Trek Bicycle Corporation limited warranty..................... 92
v
IMPORTANT!
READ THIS CHAPTER BEFORE YOU RIDE
A bicycle is smaller and less powerful than other vehicles, so
safety cannot be overemphasized. This chapter contains
suggestions that will help you ride as safely as possible. Read
this entire chapter before you ride your new Trek bicycle.
Before your first ride:
page
Make sure your bicycle fits you properly........................... 1
Know how your bicycle performs. .................................. 1-2
Before every ride: Check your bike
Checklist: Before every ride............................................... 3
Check that your wheels are straight. ................................ 3
Check your tire inflation.................................................... 3
Check your brakes. ......................................................... 4-5
Check the attachment of both wheels. ........................... 6-8
Check your handlebars and stem for signs of stress
or fatigue ........................................................................ 9
Check your suspension adjustment................................... 9
During every ride:
Ride safely. .................................................................. 10-13
Before, during, and after every ride:
Take care of your bike................................................. 14-16
Use your pedal system safely. ..................................... 16-19
Supervise your cycling child............................................ 20
Handlebars
Seat
Rear
wheel
Front
derailleur
Crankset
Front
wheel
Rear
derailleur
Pedal
vi
Figure 8 Names of bicycle components
BEFORE YOUR FIRST RIDE
Make sure your bicycle fits you properly.
Your Trek dealer should fit you with the proper
size of bicycle.
Make sure there is adequate top tube clearance.
There should be at least one inch (25mm)
clearance between the top tube and the rider
when standing over the bicycle (Figure 1.1). For
mountain bikes, two to three inches (50-75mm)
clearance is recommended.
Some models have maximum weight limits:
Tricycle
80lbs. (36kg.)
Adjust the seat and handlebar.
The seat and handlebars may be adjusted to
offer the best comfort and performance. Before
making these adjustments, refer to Chapter 3.
1 inch
Figure 1.1 Minimum standover
height:
1" (25mm) for most bicycles
2-3" (50-75mm) for mountain
bicycles
Know how your bicycle performs.
The features of your bicycle, if misused, may cause you to
lose control of the bike. These features give you better comfort,
control, pedaling efficiency, and stopping power.
Practice at slow speeds first.
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 Trek dealer. As an example, the
stopping power on Trek 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 Trek dealer about brake
adjustments or other brake options for your bicycle.
WARNING
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 on page 12 under ‘Use your brakes
carefully’ and ‘Be careful when riding in wet conditions.’
CHAPTER ONE
Guide to Safe On-and-Off Road Operation
1
Prevent contact of the toe-clip and front wheel.
Figure 1.2 Toe-clip overlap
When riding slowly, do not pedal if the handlebar
is turned. Modern, high-performance bicycles use
a short-wheelbase design, with the front wheel
close to the pedals. 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 1.2). At normal riding speeds the handlebar
does not turn enough for this to occur.
WARNING
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 slowly.
Avoid shimmy or front-wheel wobble.
In very rare cases some riders, such as heavier riders on
larger bikes, may experience a “shimmy” or “harmonic oscillation” or “frame vibration” at certain speeds. Experts disagree
on what can cause a shimmy, but some believe it may be caused
by a loose headset, improper spoke tension, or frame alignment.
Riding “no-hands,” or front wheel impact, are among other
possible causes. If you believe you are experiencing a shimmy,
slow down immediately and take your bicycle directly to a Trek
dealer for inspection and repair.
WARNING
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 Trek dealer for inspection and repair.
Make sure accessories are compatible and safe.
To make your bicycle more personally useful, you may
choose to change parts or add accessories. Not all accessories
are compatible or safe. If you are unsure whether a part is
appropriate or safe, consult your Trek dealer.
CAUTION
Improper components or improper assembly can place unknown
stress on your bike or components. Stress can lead to failure,
which can cause you to lose control and fall. Before adding or
changing any part of your bike, consult your Trek dealer.
2
Before Your First Ride: Know How Your Bicycle Performs
BEFORE EVERY RIDE:
CHECK YOUR BIKE
Before each ride, check your bike and its components against
the following checklist. The following information explains
how to perform these checks. This is not a comprehensive
maintenance program. If you are not certain if your bike has a
problem, take your bike to your Trek dealer for service.
Checklist: Before every ride
 Check that your wheels are straight.
 Check your tire inflation.
 Check your brakes.
 Check attachment of both wheels.
Check your handlebars and stem for signs of
 stress
or fatigue.
 Check your suspension adjustment.
CAUTION
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.
Check that your 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, take
your bike to your Trek dealer for service.
your tire inflation.
 Check

Inflate your tires to the air pressure
recommended on the tire sidewalls (Figure 1.3).
Some tires offer a range of inflation. When inflating a
tire, consider the weight of the rider (and any load).
Within the range, higher pressure usually gives the
best performance on hard surfaces like pavement,
while lower pressure works best for off-road riding.
Figure 1.3 Inflation label
CAUTION
A gas station hose may inflate a bicycle tire too rapidly, and
the indicated pressure is often inaccurate, causing the tire to
fail. Use a hand-operated pump with an appropriate gauge.
CHAPTER ONE
Guide to Safe On-and-Off Road Operation
3
 Check your brakes.

Trek bikes come with a variety of types of brakes:
• Hand-rim brakes, where a brake lever, connected to the
brake by a cable, causes the brake pads to squeeze the rim.
• Disc brakes, where a hand lever connected to the brake
squeezes a disc mounted on the wheel hub.
• Internal drum or roller brakes, where a hand lever
operates a brake inside the hub.
• Coaster brakes, where the brake is engaged by pedaling
backwards.
Follow the inspection instructions for the type of brake on
your bike. If your brakes do not pass inspection, refer to the
Brake Systems section of Chapter 3, or take your bicycle to your
Trek dealer for service.
WARNING
If your brakes are not working properly, you can lose control
and fall. Inspect the brakes thoroughly before every ride, and
do not ride the bicycle until any problem has been corrected.
Hand-rim brakes
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. When
the brakes are not applied, the brake pads should be 1 to 2mm
from the rim. 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 1.4).
Brake pad
aligned with the
rim surface
Pad and rim
should be
parallel
Direction of rim rotation
0.5 - 1 mm toe-in
Figure 1.4 Brake pad alignment
Disc brakes
Squeeze each brake lever toward the handlebar to make sure
the brake moves freely and stops the bike. If the brake lever
4
Before Every Ride: Check Your Bike
can be pulled to the handlebar, the brake is too loose. The brake
pads should be 0.25 to 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-aligned.
Hard braking causes the disc, and the brake caliper, to
get hot. After braking, do not touch the disc for at least 30
minutes. As with other rotating parts on a bicycle, avoid
placing your fingers in the disc.
CAUTION
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.
Internal drum or roller brakes
Internal drum or roller brakes are actuated by a brake lever
which is connected to the hub by a cable. 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 than 15mm of lever
movement to stop the bike, the brakes are too tight. Hard
braking causes the hub shell to get hot. After braking, do not
touch the hub shell for at least 30 minutes.
CAUTION
Internal hub brakes get very hot during use and could burn
skin. Avoid touching the hub or cooling fins when hot.
Coaster brakes.
Instead of operating by hand, coaster brakes are actuated
with the legs by pedalling the crankarms
backwards. The chain transmits the motion of
the crankarms to the rear hub, where the brakes
operate internally. To check the brakes, pedal
backwards to make sure the brake engages with
less than 60 degrees rotation (1/6 revolution).
The chain actuates the brake, so make sure
the chain cannot come off. When grasped in the
middle of the chain run between the front and
rear sprockets, there should be between 1/4 and
1/2 inches (6-12 mm) total vertical movement
(Figure 1.5). If the chain tension is incorrect,
Figure 1.5 Checking chain
refer to the Drivetrain section of Chapter 3, or
tension
take the bicycle to your Trek dealer for service.
CHAPTER ONE
Guide to Safe On-and-Off Road Operation
5
����
 Check the attachment of both wheels.

To be ridden safely, the wheels of your bicycle
Lever
must be firmly attached to the frame and fork. Bicycle
wheels are attached by either threaded axle nuts
or a quick-release, a lever-actuated wheel retention
mechanism (Figure 1.7) that allows the wheel to
be installed and removed without tools. For wheels
attached with axle nuts, see page 8.
������
Figure 1.6 Lever positions
Quick-release
adjusting nut
Quick-release adjustment and closure
For proper and safe adjustment of a quick-release,
read and follow these instructions carefully.
To adjust the tension of a quick-release
1. Move the quick-release lever to the OPEN
��
��
��
Figure 1.7 Tighten nut
��
��
Figure 1.8 Proper lever throw
��
��
��
��
• Do not tighten the quick-release wheel
retention mechanism by turning the lever
like a wing nut (Figure 1.9); it will not result
in sufficient force to hold the wheel in place.
��
��
�
���
position (Figure 1.6) and set the wheel so it
firmly touches the inside of the fork ends.
2. With the lever about halfway between the
OPEN position and the CLOSED position,
tighten the quick-release adjusting nut (Figure
1.7) until finger-tight.
3. Place the lever in the palm of your hand and
throw the lever as shown in Figure 1.8 to the
CLOSED position (Figures 1.10-1.11). At the
half-closed position of the lever, there should be
some resistance.
Figure 1.9 Do not turn the lever
WARNING
A quick-release 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 quick-release is
adjusted and closed properly before riding the bike.
6
Before Every Ride: Check Your Bike
5. If the lever is moved to the CLOSED position
with little or no resistance, clamping strength
is insufficient. Return the lever to the OPEN
position, tighten the quick-release adjusting
nut further and close the lever, and again
test for resistance. For further information
on correct adjustment of the quick-release
tension, read Figure 1.12.
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 (Figures 1.10-1.11).
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 Trek dealer for service.
Figure 1.10 Front lever position
Figure 1.11 Rear lever position
Test for proper quick-release adjustment
• Pick up the bike, and sharply hit the top of the
tire (Figure 1.13). 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 1.14).
• When the quick-release is properly tightened,
and clamped by the lever in the closed position,
the clamping force is adequate to cause metalinto-metal engagement (embossing) of the
dropout surfaces.
• See Figure 1.12.
If it requires more than 45 pounds (200
Newton) force to completely close the quickrelease 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 1.13 Test for looseness
Figure 1.14 Test for rotation
Figure 1.12 Definition of correct quick-release lever force
CHAPTER ONE
Guide to Safe On-and-Off Road Operation
7
Threaded axle-nut wheel retention
Toothed
washer
If your bicycle is equipped with threaded axlenuts instead of quick-release mechanisms, make
sure the axle nuts are tightened correctly:
• Front wheel: 180-240 lb•in (20.3-27.1 Nm)
• Rear wheel: 240-300 lb•in (27.1-33.9 Nm)
Figure 1.15 Toothed washer
For each wheel, test to ensure that you have
properly tightened the axle-nuts. If the axlenuts fail the test, either repeat these procedures,
including these tests, or take your bicycle to your
Trek dealer for service.
Test for proper axle-nut adjustment
Peg
• Pick up the bike, and sharply hit the top of the
tire (Figure 1.13). The wheel must not come off, be
loose, or move from side to side.
Redundant retention washers
Axle nut
and washer
Figure 1.16 Axle peg
For the front wheel of children's bikes and BMX
bikes with axle nuts, a special toothed washer must
be in place on both sides of the hub for correct
wheel retention. The toothed washer is placed on
the outside of the fork tip with the tooth in the
corresponding hole in the fork tip (Figure 1.15).
Pegs on BMX bikes
Some bikes have tubular axle extensions, called
pegs (Figure 1.16). For bikes with pegs on the front wheel,
the toothed washer must be against the fork tip as in Figure
1.15, with the peg installed over the toothed washer. Additional
washers and nut go inside the peg. Tighten axle-nuts in pegs:
• Using a 15 mm socket: 220-240 lb•in (24.9-27 Nm)
• Using a 19 mm socket: 350 lb•in (40 Nm)
WARNING
A wheel axle-nut that is not properly tightened may allow the
wheel to be loose or come off unexpectedly, causing you to
lose control and fall. Make sure the axle-nuts are tightened
properly before riding the bike.
8
Before Every Ride: Check Your Bike
 Check your handlebars and stem for signs of stress

or fatigue.
Carefully inspect your handlebars and stem for signs of
fatigue: scratches, cracks, dents, deformation, or discoloration. If any part shows signs of damage or fatigue, replace
the part before riding the bicycle. Also check that the
handlebar plugs are properly inserted into both ends of the
handlebars, and bar-ends.
 Check your suspension adjustment

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. Suspension action
influences how your bike handles and steers, so its proper
adjustment is very important. If the suspension can be
compressed so that the fork can no longer move, its movement
will stop abruptly and could cause you to lose control. For
more information on proper suspension adjustment, refer
to Suspension Systems in Chapter 3, and also the Suspension
Owner's Manual which may have come with your bicycle.
CHAPTER ONE
Guide to Safe On-and-Off Road Operation
9
DURING EVERY RIDE: RIDE SAFELY
Wear a helmet.
An unprotected head is highly susceptible to
injury, even from the slightest contact, but wearing
a helmet that meets CPSC or CE safety testing
standards (Figure 1.17) may help prevent injury.
Eye protection and appropriate cycling clothes are
also recommended.
Helmets should be removed when not riding
the bicycle. If the helmet is caught or stuck on or
between objects, the wearer could choke.
Figure 1.17 Bicycle helmet
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. A few of the more important
rules of riding include the following:
• Use proper hand signals.
• Ride single file when riding with other cyclists.
• Ride on the correct side of the road; never go against traffic.
• 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.
Do not use unsafe riding practices.
Many cycling accidents could be avoided by using common
sense. Here are a few examples:
• Do not ride ‘no hands’; the slightest road imperfection
could initiate a wheel shimmy, or cause the front wheel to
turn unexpectedly.
• Do not ride with loose objects attached to the
handlebars, or any other part of the bicycle. They
could get caught in the wheel spokes, cause the handlebars
to turn unexpectedly, or in other ways cause loss of control.
• Do not ride while intoxicated, or while using medications which might make you drowsy. Bicycles require
good coordination to ride in control, and riders must be alert
for hazards.
• Do not ‘ride double’. Standard bicycles are not designed to
carry the additional load of a second rider. Also, extra weight
makes a bicycle much harder to balance, steer and stop.
10
During Every Ride: Ride Safely
Ride defensively.
To motorists, pedestrians, or other bicyclists,
you are not as visible as a car. Always watch for
hazardous situations, and be ready to stop or take
evasive action at all times.
��
Watch the road.
��
Watch for, and avoid, potholes, drain grates,
soft or low shoulders, and other deviations which
could cause your wheels to slip or create an
impact. When crossing railroad tracks or drain
grates, do so carefully at a 90° angle (Figure
1.18). If you are not sure of riding surface
conditions, walk your bike.
Figure 1.18 Angle for crossing
tracks
Watch the cars you are preparing to pass.
If a car suddenly enters your lane, or someone unexpectedly 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.
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 a working headlight and tail light when
you ride in poorly lighted or low visibility conditions.
Also wear light, bright, and reflective clothing, especially at
night, to make yourself more visible. 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 Trek
dealer to find appropriate products to aid your vision and make
you more visible.
WARNING
A bicycle rider without proper lighting and safety precautions
may not have good vision, and may not be visible to others,
which can cause a collision resulting in severe injury. Use
front and rear bicycle lights and additional safety procedures
when riding in poor visibility conditions. Failure to do so will
increase your chances of being involved in an accident in low
light conditions.
CHAPTER ONE
Guide to Safe On-and-Off Road Operation
11
Avoid introducing water to any bearings of your bicycle.
The metal bearings in your bicycle allow the parts to rotate
smoothly. Water in contact with metal causes corrosion, which
will make the bearings lose their smoothness. If any bearings
on your bicycle get submerged in water, take your bicycle to
your Trek dealer for service.
Avoid high-pressure washing systems, like those at most car
washes. The high pressure may force water into the bearings.
Use your brakes carefully.
Figure 1.19 Overuse of front brake
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 frontwheel brake in an emergency, could cause the rear
wheel to lift from the ground which could cause
you to lose control (Figure 1.19).
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.
WARNING
Applying sudden or excessive stopping force with the frontwheel 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.
Be careful when riding in wet conditions.
No brakes, whatever their design, work as effectively in wet
weather as they do in dry. Even properly aligned, 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 visibility, for both you and
motorists, and reduced traction. Use slower cornering when
traction is reduced, like when riding over wet leaves, painted
crosswalks, or manhole covers.
12
During Every Ride: Ride Safely
Use special care when off-road riding.
• Ride only on the trails.
• Avoid rocks, branches, or depressions.
• Never ride a road or touring bike on unpaved roads, trails, or
off-road.
• Wear protective clothing including helmet, eye protection, and
gloves.
• When approaching a descent, reduce your speed, keep your weight
back and low, and use the rear brake more than the front.
Avoid undue stress to your bicycle.
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:
• Dents
• Cracks
• Scratches
• Deformation
• Discoloration
Fatigue can be accelerated by large forces from unsafe riding
practices:
• Jumping your bicycle
• Performing bicycle stunts
• Severe off-road riding
• Downhill riding
• Any abnormal bike riding
Carefully inspect your frame and components for signs of
fatigue before and after each ride.
Even if you perform regular inspections, if you exceed the
limit of strength of your bicycle or a given part, it will fail.
CHAPTER ONE
Guide to Safe On-and-Off Road Operation
13
BEFORE, DURING, OR AFTER EVERY RIDE:
TAKE CARE OF YOUR BIKE
Keep your bicycle clean.
To work properly, your bicycle must be 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.
Avoid leaving your bicycle out in the weather.
When not riding, store your bike where it will be protected
from rain, snow, sun, etc. 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.
Use proper storage for your 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.
Protect your bicycle from theft.
Your new bicycle may be very attractive to thieves. Protect
yourself from theft:
• Register the bicycle with your local police department.
• Make sure you return your warranty card; we will
keep the serial number of your bike on file. Also, keep a
record of the serial number in a safe place. See page ii for
the location of the serial number on your bike.
• Purchase and use a lock. A good lock is effective against
bolt cutters and saws. Follow the recommended locking
procedures. Use your lock; never leave your bike unlocked
while unattended, not even for a minute.
• With quick-release wheels, lock both of your wheels
as well as your frame. If you have a quick-release
seatpost binder, when locking your bike you may want to
remove your seat and seatpost to prevent theft. However,
avoid allowing water to enter your bicycle frame through
the open seat tube of your bike.
Protect your bike from accidental damage.
Park your bike 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
14
Before, During, or After Every Ride: Take Care of Your Bike
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, as can riding over some obstacles.
These are just a few of the potential hazards you and your bike
may encounter. If you suspect your bicycle has been damaged in
any way, or tampered with, ensure there is no problem, or take it
to your Trek dealer for inspection and repair.
Use good shifting techniques.
Some Trek bicycles are equipped with a derailleur system,
where shifting is done by derailing, or moving the chain from
one sprocket to another. Other Trek bikes may be equipped with
internal gearing where shifting is done inside the rear hub. Read
the information for your type of bicycle in the following sections:
• 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. Choose the gear combination most comfortable for riding conditions, one that allows you to maintain a
constant rate of pedaling. It is not essential that various gear
combinations be used in sequence.
When shifting, plan ahead. Shift gears only when the pedals
and chain are moving forward. Never attempt to shift gears
when stopped or back-pedaling. When you shift, reduce the
force on the pedals; excessive chain tension makes shifting
difficult. This provides quicker, smoother shifting, will help
avoid excessive chain and gear wear, and also will help avoid
bent chains, derailleurs, and chainrings. Avoid shifting when
going over bumpy surfaces, or railroad tracks; 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” the lever
for a moment before letting go of the shifter.
• Shifting a bike with internal gearing
When shifting gears, plan ahead. Shifting gears 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.
Choose the gear most comfortable for riding conditions. You
should be able to maintain a constant rate of pedaling.
CHAPTER ONE
Guide to Safe On-and-Off Road Operation
15
Prevent handlebar impact damage to your frame.
With some bicycles, as the front wheel turns to extreme
angles, the handlebar may contact the frame. Prevent damage
from handlebar impact by padding the handlebar parts, the
frame, or both, at the points of contact. See your Trek dealer
for recommended protection devices or materials.
Never modify your fork, frame, or components.
Modifying the parts of your bike in any way, including the
frame, fork, and all the components, may make your bike
unsafe. As an example, some bike frames have special surface
treatments which add strength; these could be removed
through poor paint stripping techniques. Removing the
redundant wheel retention tabs on fork tips or peg-and-eyelet
style redundant retention devices is another example of how
modifying a bicycle could make it less functional.
Changing the forks on your bicycle could alter the steering of
the bicycle, or add additional, unwanted stress:
• Never add a suspension fork to a road bike
• Some Trek models are not compatible with dualcrown, triple-clamp forks.
If you must replace the fork on any bike, check with your
dealer or Trek Bicycles' technical service department to ensure
the new forks are compatible with the frame.
Any modification of your frame, fork, or components means
that your bike no longer meets our specifications and will
therefore void the bike’s warranty.
WARNING
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. An
improperly modified frame, fork, or component can cause you
to lose control and fall.
Take care of your frameset.
Trek bicycles use a variety of materials in the construction of
framesets (frame and fork). Your frameset may require special
attention in its care and maintenance. See pages 85-87 for
information about your frameset.
16
Before, During, or After Every Ride: Take Care of Your Bike
USE YOUR PEDAL SYSTEM SAFELY
Use pedal systems keep your feet from slipping off the pedals.
The pedals are where your feet are placed on a bicycle;
control and safety demand that your feet be secure on the
pedals. For recreational riding on smooth surfaces, this
requires only a pair of soft-soled shoes. As you ride harder, or
the riding surface gets rough, pedal systems can help to keep
the rider's feet on the pedals.
There are several types of pedal systems on Trek bikes.
Read the general information in Pedal system use- all systems
as well as the specific information for your type of pedals:
• Toe-clips and straps (Figure 1.20) attach your feet to the
pedals with a strap with a metal locator
• Clipless pedals, like a ski binding, mechanically engage a
cleat attached to the sole of a special cycling shoe.
If you are uncertain about the operation of the pedal system
on your bike, consult your Trek dealer. If your bicycle has a
pedal system that does not fit, or you do not want it, have your
Trek dealer change your pedals to your desired system.
If your bike came without pedals, you should choose the
pedals that are best for you. Follow the manufacturer’s instructions for installation and use of your pedals.
WARNING
While riding, your shoes must remain on the pedals or you may
lose control of the bike and fall. When bringing the bike to a
stop, your shoes must easily disengage from the pedals or you
may fall off the bike. Always remove one foot from the toe-clip
or pedal before bringing the bike to a complete stop.
Pedal system use- all systems
Before your first ride, familiarize yourself with your pedal
system, and practice entry and exit in a stationary position.
When the motions for entry and exit become natural, then
practice in a flat, empty parking lot. While riding, watch
the road; looking at your pedals will make it difficult to see
upcoming obstacles.
Using toe-clips and straps
Properly fitted toe-clips place the ball of your foot over the
pedal axle for improved pedaling power; make sure your toeclips fit you correctly.
CHAPTER ONE
Guide to Safe On-and-Off Road Operation
17
Use proper shoes with toe-clips.
Do not allow your feet to become entrapped in the
toe-clips or straps. Use shoes which allow your foot
to easily pass by the toe strap; do not use shoes
with wide, heavily patterned soles. Always adjust
the toe strap length with the buckle (Figure 1.20)
to allow quick removal of your feet from the pedals.
To enter toe-clips
Figure 1.20 Loosening the toe
strap
1. Straddle the bike.
2. With your left foot on the ground, move the
right crank arm to its two o’clock position.
3. Place the toe of your shoe on the back edge of
the upside-down pedal, with your toes pointed
slightly downward (Figure 1.21).
4. With a motion similar to scraping something off the
bottom of your shoe, flip the pedal into an upright
position, and insert your foot into the toe-clip.
5. Push off with the left foot, and sit on the bicycle
seat. Pedal one or two strokes to get moving,
and use the same technique to flip the pedal and
put your other foot into the second toe-clip.
To exit toe-clips
Figure 1.21 Ready to flip the
pedal
1. Raise the heel so the sole of your shoe clears the
top of the pedal (Figure 1.22).
2. Withdraw your foot in an up-and-back motion,
and make sure your foot clears the pedal.
3. As you bring the bike to a stop, place your
weighted foot on the ground.
Using clipless pedals
Figure 1.22 Lift foot to remove
from pedal
Clipless pedals use a spring-loaded mechanism to
engage a cleat, a small plate attached to the bottom
of a special cycling shoe. If you did not receive
clipless pedal information for your bike, get a copy
from your dealer, or contact us and we’ll send them
to you. The following information is only meant to
supplement the pedal manufacturer’s instructions.
Use proper shoes and cleats with clipless pedals.
Do not ride clipless pedals in 'street' shoes on clipped-in
platforms, or without engaging the cleats; the attachment of
your feet to the pedals will be insecure. Always remove at least
18
Before, During, or After Every Ride: Use Your Pedal System Safely
one shoe from the pedals before bringing the
bicycle to a complete stop. Use only the cleats
supplied by, or approved by, the pedal manufacturer. Cleats from other pedal systems may not
release properly.
Install and adjust cleats and pedals correctly.
Before attempting to engage your cleated shoe
into the pedal, always clean both the cleats and
the pedals. Debris or contamination in the pedals,
or on the cleats, may interfere with entry or exit
of clipless pedals. If the cleat is worn, the cleat
may not properly function with the clipless pedal.
To enter clipless pedals
1. Engage the front of the cleat into the front of
the pedal (Figure 1.23) and press down with
the ball of your foot. An audible click signifies
completed entry into the pedal.
2. Check the attachment by attempting a rolling
motion on the pedal (Figure 1.24). If you
can roll your shoe off the pedal, start the
procedure again.
3. To mount the bike, push down on this pedal
while pushing off with the other foot, and at
the same time, sit on the bicycle seat.
4. Once moving, put your other foot into the
second pedal using the same technique.
To exit clipless pedals

Keep your cleats and pedals in good condition
Figure 1.23 Engaging the cleat

Incorrect installation of the cleats could cause
physical injury, so cleat installation should be
done by your Trek dealer. On most pedals, the
force required for entry and exit is adjustable.
Incorrect adjustment of the clipless pedal release
force could prevent your foot from disengagement
from the pedal. For adjustment information, read
the pedal manufacturer’s instructions supplied
with your pedals.
Figure 1.24 Test for cleat
engagement
Figure 1.25 Release by twisting
sideways
1. Twist your heel laterally away from the centerline of the bike (Figure 1.25).
2. As you bring the bike to a stop, place your foot on the
ground.
CHAPTER ONE
Guide to Safe On-and-Off Road Operation
19
SUPERVISE YOUR CYCLING CHILD
Your supervision of your children as they learn
about bikes, safety, and cycling rules of the road is
critical to your children’s education (Figure 1.26).
Explain the material in this section, Chapter 1,
to your child before he or she enters the world of
cycling. And instill in your children this cardinal
rule for all young cyclists:
Children should wear a helmet whenever
they ride a bicycle or tricycle.
Figure 1.26 Riding with supervision
Training Wheels
Some models of Trek bicycles come equipped with
training wheels (Figure 1.27). As your child learns
to ride a bicycle with training wheels, make sure
the child has the skills necessary to stop the bike.
Until this skill is mastered, the child must never
ride the bike without supervision.
The training wheels may be adjusted to promote
the learning of skills such as balancing and
turning.
To adjust the training wheels
Figure 1.27 Training wheel clearance from ground
1. Check that the tires of the bicycle are correctly
inflated.
2. Place the bike on a flat, smooth surface.
3. Loosen the rear axle nuts. Follow the procedures in the
Drivetrain section of Chapter 3.
4. 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.
5. Re-tighten the axle nuts as shown in the Drivetrain section
of Chapter 3, including adjusting the chain tension.
6. Inspect the wheel attachment as shown in the Wheels
section of Chapter 3.
Re-adjust as the child's skill level grows
As the child’s skill level grows, you may gradually increase
the clearance between the training wheels and the ground until
the child no longer requires the training wheels.
20
Before, During, or After Every Ride: Supervise Your Cycling Child
PERIODIC MAINTENANCE SCHEDULE
Frequency
Service Required
page
Every ride
Check that your wheels are straight ................................. 3
Check your tire inflation.................................................... 3
Check your brakes ............................................................. 4
Check attachment of both wheels................................... 6-8
Check your handlebar and stem for signs of stress
or fatigue ....................................................................... 9
Check your suspension adjustment................................... 9
Inspect your tires for wear or damage ............................ 64
Weekly
Wipe off your bicycle with a damp cloth ......................... 14
Check for loose spokes................................................ 64-65
Lubricate suspension forks.............................................. 56
Check suspension fork bolts for tightness ...................... 79
Check rear suspension bolts for tightness ................. 80-83
Monthly
Check the attachment of the handlebar and stem ..... 24-25
Check the attachment of the seat and seatpost............... 29
Check the cassette and chain .......................................... 32
Check the chainguard ...................................................... 32
Inspect shift cables for wear.......................... 36, 40, 42, 44
Check the operation of the shifters ................................. 36
Inspect and lubricate derailleurs ..................................... 39
Check the gear adjustment of internal shift system ....... 40
Check headset bearing adjustment ................................. 46
Check brake cables............................................... 50, 54, 60
Check brake pads ................................................. 50, 57, 59
Check brake bolts....................................................... 50, 62
Inspect a rotor for proper function ................................. 53
Check chain tension......................................................... 62
Inspect Trekking accessory bolts ............................... 64-65
Check wheel bearing adjustment..................................... 65
Check rims for wear......................................................... 65
Every 3 Months
Clean and polish finish .............................................. 14, 86
CHAPTER TWO
Periodic Maintenance
21
Check the pedals and toe-clips ................................... 32-34
Check the crankset and bottom bracket.......................... 33
Inspect and lubricate brake levers................. 52, 55, 57, 61
Inspect reflectors ............................................................. 70
Every year
Lubricate handlebar stem ........................................... 26-27
Lubricate seatpost............................................................ 31
Re-grease pedal threads and bearings ............................ 34
Re-grease bottom bracket bearings................................. 34
Re-grease wheel bearings .............................. 41, 43, 45, 69
Re-grease headset bearings ............................................. 46
Lubricate wheel quick-releases........................................ 69
Re-grease suspension forks ............................................. 79
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 Trek dealer.
Recommended tools for proper bicycle maintenance:
Torque wrench with lb•in or Nm gradations
2, 4, 5, 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
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 Trek bikes require all these tools
22
Periodic Maintenance Schedule
INSPECTION, ADJUSTMENT, AND
LUBRICATION
page
A word about torque specifications ................................. 23
Handlebars, bar-ends, and stem ................................. 24-28
Seat and seatpost ........................................................ 29-31
Drivetrain- pedals, crank, chain, and cassette ........... 32-34
Shifting systems ......................................................... 35-45
Headset and fork......................................................... 46-47
Brake systems ............................................................. 48-63
Wheels ......................................................................... 64-69
Reflectors ......................................................................... 70
Tire installation........................................................... 71-73
Tubeless-compatible wheel system ............................. 74-78
Suspension systems .................................................... 79-84
Care of your frame or fork.......................................... 75-87
Folding bike ................................................................ 88-89
Trekking accessories .................................................. 90-91
This chapter lists the intervals for inspecting the parts of
your bicycle, and instructions for adjustment and lubrication
of those parts. If any part fails any inspection, do not ride your
bicycle. Either repair or replace the part, or take your bicycle
to your dealer for service.
WARNING
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 in this manual are listed to
help you determine the correct tightness of parts and their
threaded fasteners.
The torque specifications should be used to make sure you do
not over-tighten the fasteners. Slight differences in a similar
part may require a different torque, so in most cases we offer a
range of torque. 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.
CHAPTER THREE
Inspection, Adjustment & Lubrication
23
HANDLEBARS, BAR-ENDS, AND STEM
Stem
expander
bolt
Handlebar
clamp bolts
Angle
adjusting
bolt
Figure 3.1.1 Adjustable-rise
quill stem
Steerer clamp bolts
The handlebars, the part you hold with your
hands when riding a bicycle, is primarily responsible for your ability to steer and control the bike.
In addition, handlebars work with the seat to
define your posture on the bike, adding comfort
and efficiency to your cycling. The handlebars are
connected to the bike by the stem (Figures 3.1.13.1.4). This section explains how to inspect, adjust,
and lubricate your handlebars, stem, and bar-ends.
There are two types of stems:
• Quill stems have a tube, or quill (Figure 3.1.3),
fastened inside the fork by an expanding wedge.
• Direct-connect stems (Figure 3.1.2) clamp to
the outside of the fork steerer.
Some bikes also have extensions attached to the
handlebars, called bar-ends (Figure 3.6).
Inspection
Handlebar clamp bolts
Figure 3.1.2 Direct-connect stem
Stem expander bolt
Handlebar
clamp bolts
Quill
Stem wedge
Figure 3.1.3 4-bolt BMX quill
stem
If you are unsure of the safety of your handlebar
system, do not ride the bicycle; take the bicycle to
your dealer for adjustments.
Once a month 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 3.1.5). 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.
Check that all bolts are tight. The correct
tightness varies according to the type of stem on
your bike. If you are unsure of which type of stem
your bike is equipped with, consult your Trek
dealer. The bolts to tighten are:
• Stem expander (Figures 3.1.1 and 3.1.3): 175-260 lb•in (19.829.4 Nm).
• Handlebar clamp (Figures 3.1.1-3.1.2) on:
- welded stems: 100-120 lb•in (11.3-13.6 Nm).
WARNING
An improperly adjusted or tightened handlebar, stem, or barends 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.
24
Handlebars, Bar-ends, and Stem
- forged stems: 150-180 lb•in (17-20.3 Nm)
- 4-bolt BMX stems: 80-100 lb•in (9-11.3 Nm).
• Steerer clamp on direct-connect stems:
- mountain bike or road (Figure 3.1.2): 100-120 lb•in
(11.3-13.6 Nm).
- BMX: 145 lb•in (16.4 Nm).
• Bar-end clamp (Figure 3.1.6): 85-125 lb•in (9.6-14.1 Nm)
• Stem angle adjustment (Figure 3.1.1 and 3.1.4): 150-170 lb•in
(17-20.3 Nm)
Bar-ends
Never allow your bar-ends to come in contact
with objects which may cause you to lose control
of your bicycle. Bar-ends are designed for climbing
only. Ensure the bar-ends face forward and away
from you, at an angle not less than 15° from
parallel to the ground.
Handlebar
clamp bolts
Angle
adjustment
clamp bolts
Figure 3.1.4 Adjustable-rise
quill stem
Adjustment
Handlebar position, the angle, width, and
height of the handlebars, is largely a matter of
personal preference blending comfort, efficiency,
and balance. Your hands should be comfortable,
and able to easily operate all controls. If your
hands, arms, or shoulders are uncomfortable or
numb you may need to adjust the handlebars or
select components more suitable to your personal
needs; consult your Trek dealer.
Some handlebars may have their width adjusted
by cutting, indicated by cut marks on the bars.
Do not cut handlebars that do not have cut
marks, including Bontrager Race XXXLite carbon
fiber handlebars. When cutting bars, do not cut
them shorter than the marks, or you may remove
internal reinforcements. If you are unsure,
consult your Trek dealer.
To adjust the angle of the handlebars
Figure 3.1.5 Function testing the
handlebar and stem
Bar-end
clamp bolt
Figure 3.1.6 Bar end
1. Loosen the handlebar clamp bolt(s) on the stem
just enough that the handlebars can be rotated
in the stem.
2. Position the handlebars to the desired angle, making sure
they are centered in the stem.
3. Tighten as shown in Inspection.
CHAPTER THREE
Inspection, Adjustment & Lubrication
25
To change the angle of an adjustable-rise stem
There are two types of these stems: Figure 3.1.1 and Figure
3.1.4.
1. Loosen the angle adjusting bolt(s) until the stem can be
rotated.
2. Position the stem to the desired angle.
3. Tighten the angle adjusting bolt as shown in Inspection.
To change the handlebar height with a quill stem
Adjusting the handlebar height on a direct-connect stem affects the headset
bearing adjustment. This procedure requires special tools and
training so this should only be done by your Trek dealer.
To adjust the height of the adjustable-rise stem in figure
3.1.1, first change the stem angle, which gives access to
the stem expander bolt.
This line
must be
hidden
inside the
bike frame
Figure 3.1.7 Minimum insertion
mark on stem quill
1. Loosen the stem expander bolt two to three turns.
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 3.1.7). A minimum of 23/4 inches
(70 mm) of the stem quill must always remain
in the frame.
4. Tighten as shown in Inspection.
WARNING
Never ride your bicycle with a quill 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 3.1.7)
is inside the frame.
Lubrication
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 Trek dealer.
To lubricate a quill stem
1. Follow the instructions To change the handlebar height with
a quill stem, and remove the stem from the frame.
2. Wipe any old grease off the stem, and clean it.
26
Handlebars, Bar-ends, and Stem
3. Apply a thin layer of Wrench Force® synthetic grease or
a similar lubrication to the section of the quill that will be
inserted into the frame, including the stem wedge.
4. Insert the stem into the frame, and follow the instructions
To change the handlebar height with a quill stem.
Installation and use of Bar-Keeper accessories
The Bar-Keeper
handlebar system
is designed to
accept the attachment of a variety
of custom accessories. Although
Insertion point for
some attachments
Bar-Keeper accessory
may be unique to
rail channel
the accessory, all
generally attach
Figure 3.1.8 Bar-Keeper, rider view
following one of
several methods. These instructions explain the attachments
generally, while using specific examples.
If force is applied to the side of the handlebars while you are
riding, the bicycle will turn. If this happens unexpectedly, it
could cause you to lose control of the bike. Accessories that
weigh more, like water bottles, should be placed as close as
possible to the center of the handlebars to minimize any effect
on the steering. Directional accessories, like lights, may need
to be exactly centered. Avoid applying force to the handlebars
when riding, like dialing a cell phone or attaching an item to its
carrier. Instead, bring the bike to a stop and enjoy the break.
WARNING
Pushing on the handlebar accessories may cause the bike to
turn unexpectedly, causing you to lose control and fall. Place
accessories in the middle of the handlebar, or stop the bike to
operate accessories.
When transporting your bicycle on a car rack or other vehicle,
always remove any accessories from the handlebar. As an
example, do not leave a cell phone, computer, or waterbottle
attached to the Bar-Keeper when carrying your bike on a car
roof rack. The vibration from the vehicle, or the wind, could
knock the accessories off the handlebars.
CHAPTER THREE
Inspection, Adjustment & Lubrication
27
Mounting
bolt
To install the Bar-Tab
This attachment is used to attach a
water bottle mount to the Bar-Keeper
accessory rail.
1. Insert the head of the Bar-Tab mounting
bolt (Figure 3.1.9) into the left end of
the Bar-Keeper channel (Figure 3.1.8).
Thumbwheel
2.
Slide the mounting bolt to the desired
Figure 3.1.9 Bar-Tab mounting
location and tighten the thumbwheel.
diagram
3. Make sure the Bar-Tab does not move on the Bar-Keeper.
4. Use the two accessory screws to attach the water bottle
cage, or other Bar-Tab accessories.
Accessory
screws
To install a Trek computer
1. Remove the rubber cover on the right side of the accessory
rail.
2. Identify the computer mounting plate for your computer
type: wired or wireless.
3. Thread the two small front mounting screws several turns
into the underside of the mounting plate.
4. Slide the mount in place.
Hook the two front screws into the slots built into the BarKeeper mount.
5. Engage the large central plastic tab.
6. After sliding the computer mount fully into place, install the
two rear mounting screws.
To install a wrap clamp
Some accessories, like a bicycle computer from a company
other than Trek, attach to the Bar-Keeper handlebar with a
wrap-around type clamp.
1. Remove the clamp screw from the wrap clamp.
2. Gently spread the wrap clamp and slide over the handlebars
with the screw hole facing forward.
3. Slide the wrap clamp to the desired location.
4. Apply a small amount of grease to the threads and bearing
surfaces of the clamp screw.
5. Attach the desired accessory to the wrap clamp.
6. Make sure the wrap clamp does not move on the Bar-Keeper.
28
Handlebars, Bar-ends, and Stem
SEAT AND SEATPOST
The seat, the part you sit on when riding a bike,
is held in place by the seatpost (Figure 3.2.1).
The seatpost binder secures the seatpost in the
frame. Proper adjustment of each component
is important for your comfort and pedaling
efficiency. This section explains how to inspect,
adjust, and lubricate your seat, seatpost, and
seatpost binder.
Seat
fixing
bolts
Seatpost
Seatpost
binder bolt
Inspection
Every month inspect the seatpost quickrelease lever, or seat post binder bolt, and
seat fixing bolt(s) (Figures 3.2.1 and 3.2.2) for
proper tightness. 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. If the seat rotates, is loose, or
moves up and down, tighten the binder bolt or
quick-release, or seat fixing bolts, and repeat the
test. Never engage the seatpost binder with the
seatpost out of the frame.
Tighten the following bolts:
Figure 3.2.1 Seatpost parts
Seat fixing bolt
• Seat post binder (Figure 3.2.1): 85-125 lb•in (9.6-14.1 Nm).
• Seat fixing bolts of these types:
Figure 3.2.2 Seat fixing bolt
- using a 13 or 14 mm open-end wrench (Figure 3.2.2):
using 13 or 14mm wrench
180-220 lb•in (20.3-24.9 Nm).
-single, using a 6 mm allen wrench (Figure 33.8): 150250 lb•in (17-28.3 Nm).
-double, using a 5 mm allen wrench: 80-125 lb•in (9.6-14.1 Nm).
-double, using a 4 mm allen wrench: 45-60 lb•in (5-6.8 Nm).
• Tricycle seat mast clamp bolts: 85-125 lb•in (9.6-14.1 Nm).
For a seatpost binder using a quick-release lever, the
mechanism works the same as a wheel quick-release. Adjust
the lever tension, and make sure it is in the closed position, by
following the instructions Quick-release adjustment and closure
on pages 65-66. Do not operate the quick-release while riding:
on a Trek Liquid model, your fingers could be pinched by
movement of the suspension parts.
Adjustment
The height of the seat is very important for comfort, safety,
and efficiency. Seat angle (tilt) and fore-aft position affect
comfort at both the seat and handlebar by changing the distribution of your weight between them.
CHAPTER THREE
Inspection, Adjustment & Lubrication
29
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
comfortable even for long rides.
WARNING
Extended riding with a poorly adjusted saddle, or one that
does not properly support your pelvic area, can cause shortterm 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 Trek 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 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 as in Inspection.
To adjust the seat height on a bicycle
1. Sit on the seat in riding position
without shoes, while someone holds the
bicycle up.
2. Position the crank arms so they are
parallel to the seat tube.
3. Loosen the seatpost binder bolt, or
quick-release.
Figure 3.2.3 Leg extension with proper seat
height
30
Seat and Seatpost
4. Extend the seatpost until, with your heel
resting on the bottom pedal (Figure 3.2.3),
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
(Figure 3.2.4) on the seatpost is not visible
above the bike frame. A minimum of 2 1/2
inches (64 mm) of seatpost must remain in
the frame.
6. Re-tighten the seatpost quick-release, or bolt,
as described in Inspection.
This line
must be
hidden
inside the
bike frame
Figure 3.2.4 Minimum insertion
mark on seatpost
WARNING
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 3.2.4) is inside the frame.
To adjust the seat position on a tricycle
1. Loosen and remove the seat mast clamp bolts
(Figure 3.2.5).
2. Move the seat mast to the desired position.
Seat mast
3. Install and tighten the seat mast clamp bolts.
Lubrication
Lubricate the seatpost every year (except
for OCLV bikes where no lubrication is
recommended; see Care of Your Frame or Fork on
pages 85-87).
Clamp bolts
Figure 3.2.5 Tricycle seat position adjustment
To lubricate the seat post
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 Wrench Force synthetic grease or a
similar lubricant to the section of the seatpost that will be
inside the frame.
4. Insert the seatpost into the frame.
CHAPTER THREE
Inspection, Adjustment & Lubrication
31
DRIVETRAIN:
PEDALS, CRANK, CHAIN, AND CASSETTE
Cassette
Crank bolt
Chain
Chainring
Pedal
The drivetrain (Figure 3.3.1) consists
of the parts of the bicycle that transmit
power to the rear wheel:
• Pedals (and toe-clip assemblies on
some models)
• Crankset- left and right crank arms,
chainring(s), and bottom bracket
(the axle and bearings on which the
crankset rotates).
• Chain
• Cassette, or freewheel.
This section explains how to inspect, adjust, and lubricate your
drivetrain. For bikes equipped with a shift system inside the
rear hub, also refer to the section Internal Shift Systems.
Figure 3.3.1 Parts of the bicycle drivetrain
Inspection
Figure 3.3.2
When the drivetrain is working properly, shifting is easy, your
bike is quiet, and its efficiency can reach its maximum.
Once a month check that the chain and cassette are clean,
free of rust, and properly oiled. All links of the chain should pivot
smoothly and without squeaking, and no links of the chain should
be deformed. Take off the rear wheel, and rotate the cassette in
your hands. If you hear a grinding noise or your cassette stops
immediately after spinning it, the cassette may need adjustment or
replacement; take your bicycle to your Trek dealer for service.
Once a month on a bike with a chainguard,
check that the chainguard is firmly attached and
correctly aligned. Push the chainguard side-toside, and tap on it. Lift the rear wheel off the
ground and rotate the crankarms, and listen for
any sounds which might indicate the crank or
chain is rubbing on the chainguard. Re-align the
chainguard so that it does not move, rattle, or rub,
and tighten the attachment hardware.
Every 3 months inspect your pedals and
toe-clips. Make sure your toe-clips are securely
tightened to the pedal, and the pedal reflectors
Tightening pedals
are clean and securely in place. Tighten the pedals
into the crank arms; turn the right pedal clockwise, but the left
pedal counter-clockwise (Figure 3.3.2):
• Pedals: 350-380 lb•in (40.2-42.9 Nm).
To check that the pedal bearings are properly adjusted,
rotate and move the pedals right to left and up and down
32
Drivetrain: Pedals, Crank, Chain, and Cassette
with your hand. If you feel any looseness or
roughness in the pedal bearings, have your
pedal adjusted, re-greased, or replaced by your
Trek dealer.
Every 3 months inspect the crankset, check
the bottom bracket adjustment, and tighten the
crank bolts:
• Crank bolts
-single 6 or 8mm bolt on each arm: 350-435 lb•in (39.549.2 Nm)
-double pinch bolts on each arm (Figure 3.3.3) : 88-132
Lb•in (10-15 Nm)
• Chainring bolts: 70-95 lb•in (7.9-10.7 Nm)
Crank bolt
Figure 3.3.3 Pinch-type crank
bolts
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 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 Trek dealer.
Clean the chainrings and inspect them for
damage. If any teeth are bent or broken, have the
Pedal
chainring replaced by your Trek dealer. Note that
holes
on some chainrings, a few teeth have a special
shape to enhance shifting.
Every 3 months check your chain for wear with
a chain wear gauge or a ruler. Each full link of a
new chain measures one inch. If 12 links of your
chain measures 121/8 inches or more, it should be
replaced. With good maintenance, a chain usually
lasts 1000 to 1500 miles on a road bike, less on a
mountain bike. Replacing the chain takes special
Figure 3.3.4 Adjustable crantools and training and should only be done by your
karms
Trek dealer.
Adjustment
To adjust the release force of clipless pedal, or to adjust the
cleats, read Use Your Pedal System Safely in Chapter One.
Some Trek bicycles offer adjustable crankarm length. To
CHAPTER THREE
Inspection, Adjustment & Lubrication
33
change the crank length, remove the pedals and install them
into the second set of holes (Figure 3.3.4).
Adjustment of any bearings in the drivetrain including the
bottom bracket, cassette, or pedals, requires special tools and
training. These services should only be performed by your
Trek dealer.
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. Follow the Inspection and Adjustment procedures in the
Wheels section to re-install the wheel.
Adjusting training wheels is covered in Chapter One.
Lubrication and cleaning
Once a month clean the cassette and oil the chain. Always
place a rag behind the chain to avoid getting oil on the rest of
the bicycle. Use Wrench Force® synthetic chain lube or similar
lubrication. After oiling your chain, wipe off the excess oil with
a rag. See your Trek dealer for a recommended oil.
To clean the cassette
Do not use gasoline; it’s too flammable and leaves a grease-contaminating
film after evaporating.
1. Remove the surface dirt around the cog teeth with Wrench
Force® de-greaser or a similar solvent, and a brush.
Once a year re-grease the pedal bearings, the bottom
bracket bearings, and re-grease the part of the pedal axles that
thread into the crank arms. Some pedal bearings and bottom
bracket bearings are permanently sealed and do not require
yearly re-greasing. Re-greasing bearings requires special tools
and training, so this should only be done by your Trek dealer.
To re-grease the pedal threads
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 counterclockwise, but turn the left clockwise.
2. Apply a light coat of Wrench Force® synthetic grease or a
similar lubricant over all the threads. See your Trek dealer
for a recommended grease.
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. Follow the instructions for tightening pedals in Inspection.
34
Drivetrain— Pedals, Crank, Chain, and Cassette
DERAILLEUR SHIFT SYSTEMS
Derailleur Shifting Systems
Some Trek bikes are equipped with a derailleur
shifting system that changes gears by de-railing
the chain, pulling it off one cog or sprocket onto
another. The shift system consists of those parts
of the bicycle which allows the derailleur to shift
gears, including the front derailleur (Figure
3.4.1) or rear derailleur (Figure 3.4.2), the
shifters (Figures 3.15-3.19), and the shift cables.
There are several different types of shifters on
Trek bikes:
• Twist shifters, shifted by rotating a section of
the handlebar grip (Figure 3.4.3)
• RapidFire or E-Z Fire shifters, with one thumbactivated shift lever and one finger-activated shift
lever, both beneath the handlebar (Figure 3.4.4)
• Shimano STI Dual Control road shifters where
both levers shift gears (Figure 3.4.5)
• Bar end shifters (Figure 3.4.6)
• Campagnolo Ergopower shifters (Figure 3.4.7)
Inspection
In these instructions, we refer to shifting terms:
• Up-shifting is changing to a gear that is
harder to pedal: a larger chainring, or a
smaller rear cog.
• Down-shifting is changing
to a gear that is easier to
pedal: a smaller chainring, or
a larger rear cog.
Large
lever
Adjusting
screws
Cable
Cable
clamp
bolt
Figure 3.4.1 Front derailleur
Adjusting
screws
Cable
clamp
bolt
Adjusting
barrel
Cable
Figure 3.4.2 Rear derailleur
Figure 3.4.3 Twist
Small
lever
Thumb trigger
Figure 3.4.5 STI Dual Control
Thumb
button
Shift
lever
Figure 3.4.6 Bar-con
CHAPTER THREE
Figure 3.4.7 Ergopower
Finger trigger
Figure 3.4.4 RapidFire
Inspection, Adjustment & Lubrication
35
If your derailleur system is properly adjusted, it is quiet. If an
unusual noise follows any shift, your derailleur cable may need
to be adjusted. If, after adjustment, the noise persists or grows
louder, stop the bicycle and try to locate the noise. If necessary,
ask your Trek dealer to identify and correct any problems.
Once a month check the shift 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 your shift cables, do not ride your bicycle; follow the
instructions To replace a shift cable, or have your Trek dealer
service your bicycle.
Once a month check the operation of the left shift levers/
front derailleur. When down-shifted, the front derailleur should
shift the chain from a larger chainring to a smaller one. When
up-shifted, the derailleur should shift the chain from a smaller
chainring to a larger one. After the shift, by moving the shifter
slightly, you should be able to position the front derailleur such
that it does not rub on the chain. The chain should not fall off
the inner-most or outer-most chainrings at any time.
Once a month check the operation of the right shift levers/
rear derailleur. When down-shifted, the rear derailleur should
shift the chain from a smaller cog to a larger one. When upshifted, the rear derailleur should shift the chain from a larger
cog to a smaller one. After the shift, the rear derailleur should
be positioned such that the chain runs smoothly without
jumping. The chain should not fall off the inner-most or outermost cogs at any time.
Adjustment
Derailleur adjustment should be done with the bike held firmly
in a workstand, or with someone holding the rear wheel off
the ground, such that the drivetrain and shift system can be
operated while the bike remains stationary.
To adjust the low gear position of the front derailleur
1. Shift the chain onto the smallest front chainring and the
largest cassette cog.
2. Loosen the front derailleur cable clamp bolt (Figure 3.4.1)
until the cable is free.
3. Turn the low gear adjusting screw (marked “L”, Figure
3.4.8) until the inner chain guide of the derailleur is
approximately 0.5 mm from the chain.
4. Pull on the cable end, and down-shift the left shift lever
several times so it is in the small-chainring position.
36
Derailleur Shift Systems
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:
• Front derailleur cable clamp bolt: 44-60 lb•in (5.0-6.8 Nm).
To adjust the high gear position of the front
derailleur
1. Shift the rear derailleur to the smallest rear
cog.
Figure 3.4.8 Inner limiting
screw effects (low gear)
2. Turn the high-gear adjusting screw (marked
“H”, Figure 3.4.9) counter-clockwise until
it cannot interfere with the motion of the
derailleur.
3. While hand-turning the cranks, use the
shifter to carefully shift the chain onto the
outside chainring.
4. With the shifter, position the outer chain
guide of the front derailleur approximately 0.5
mm from the chain.
5. Re-tighten the high gear adjusting screw until
it meets resistance. If you have turned the
Figure 3.4.9 Outer limiting screw
screw too far, the front derailleur will move
effects (high gear)
toward the small chainring.
Check your adjustments; 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 of the front derailleur,
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 derailleur 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. By slightly downshifting
the lever, the derailleur should move in slightly, and should no longer be
touching the chain.
CHAPTER THREE
Inspection, Adjustment & Lubrication
37
To adjust the high gear position of the rear
derailleur
Figure 3.4.10 Outer limiting
screw effects (high gear)
1. Shift the chain onto the smallest rear cog and
the largest front chainring.
2. Loosen the cable clamp bolt (Figure 3.4.2) 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”, Figure
3.4.10) 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
clamp the cable:
• Rear derailleur cable clamp bolt: 44-60 lb•in (5.0-6.8 Nm).
Figure 3.4.11 Inner limiting
screw effects (low gear)
To adjust the low gear position of the rear derailleur
1. Turn the low gear adjusting screw on the rear
derailleur (usually marked “L”, Figure 3.4.11) 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 of the rear derailleur
1. Shift the chain onto the largest front chainring and the
smallest rear cog.
38
Derailleur Shift Systems
2. Shift one click with the rear shifter.
3. Check if the chain moves smoothly to the next gear.
4. 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 shift.
If instead, the chain moves to the third smallest cog, turn the
barrel adjuster clockwise until alignment with the derailleur
pulleys and the second smallest cog is achieved. Go through the
various gear combinations 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 Trek dealer for service.
To replace a shift cable
1. Shift the chain onto the smallest front chainring and the
smallest rear cog.
2. Note the path the derailleur cable follows, loosen the derailleur cable clamp bolt holding the bad cable, and remove the
cable through the shift lever.
Some shifters have a covered cable access: either a screw, or a cover held by a screw.
If you can't find the cable access for your shifter, check with your dealer.
3. Inspect the housings; if they are damaged or rusty, replace them.
Note: If you replace any housings, make sure the pieces are of the correct
type of housing, and cut them to the proper length (use the old pieces as
guides). Make sure the housing ends are free of burrs; the cable should
pass freely through these ends.
4. Grease the new cable and feed it through the lever and all
of the cable guides and housings, and the cable clamp bolt
following the same path as the old cable.
5. Follow the directions for derailleur adjustment.
6. Cut the cable so no more than 2 inches (51 mm) of cable
length extends beyond the cable clamp bolt.
7. Crimp on a metal end-cap to prevent fraying of the cable
end, or apply some solder to the end of the cable.
Lubrication
Every month, lubricate all pivot points on both the front
and rear derailleurs, including the derailleur pulleys on the rear
derailleur, with Wrench Force® synthetic chain lube or similar
lubrication.
Whenever a cable is replaced, lubricate the cable, where it
passes through the housing, with a light grease.
CHAPTER THREE
Inspection, Adjustment & Lubrication
39
INTERNAL SHIFT SYSTEMS
Introduction
Some Fisher bicycles are equipped with an internal shift
system, where gear changes are made inside the rear hub.
Determine which of the four types of internal shift systems is
on your bike and read the information for that system covered
on the following pages:
• Shimano Nexus 8 speed has 8 gear position indicated on
the shifter
• Shimano 3 speed has 3 gear position indicated on the
shifter
• SRAM DualDrive 2 x 7 speed mixes an internal shift
system with a rear derailleur
Nexus 4 or 8 speed systems
Pulley
Cog joint
bracket
The internal shift system consists of those parts
of the bicycle which allow you to shift gears
including the shifter, rear hub, and shift cable.
The shifting mechanism is enclosed, keeping the
shifting system lubricated for low maintenance.
These instructions explain how to inspect, adjust,
and lubricate an internal shift system.
Inspection
Shift cable clamp bolt
Figure 3.5.1 Pulley and cog joint
bracket
Cable end
cover
Shift cable
barrel adjuster
Figure 3.5.2 Nexus shifter
40
A properly adjusted shift system is quiet. If an
unusual noise follows any shift, or while pedaling,
your shift cable may need to be adjusted. If after
adjustment the noise persists or grows louder, stop
the bicycle and try to locate the noise. If necessary,
ask your Trek dealer to identify and correct any
problems. For more information about your shift
system consult your Trek dealer.
Once a month, make sure the hub gears are
properly adjusted:
• On a Nexus 7 speed, or Nexus 4 speed, system
with the shifter in 4th gear, the red lines on the
pulley and the cog joint bracket (Figure 3.5.1)
should line up.
Once a month, check the shift cable for kinks,
rust, broken strands, or frayed ends. Also check
the housing for bent ends, cuts, broken coils
and wear. If you suspect a problem with your
Internal Shift Systems
shift cable, do not ride your bicycle. Replace the cable and/or
housing before riding your bicycle by following these instructions, or take your bike to your Trek dealer for service.
Adjustment
To adjust the rear shifting
1. Rotate the shifter to the 4th gear position.
2. Align the indicator on the rear hub pulley with the cog joint
bracket (Figure 3.5.1)
3. If the red lines do not line up, adjust the gear cable tension
by rotating the barrel adjuster (Figure 3.5.2) until this
alignment is achieved.
4. Shift to 1st gear, then back to 4th, and re-check the
adjustment.
To replace the shift cable
1.
2.
3.
4.
4.
Loosen the cable fixing bolt.
Remove the phillips head screw holding the cable-end cover.
Slide the cable-end cover (Figure 3.5.2) forward.
Note the path of the old cable, and remove the cable.
Install a new cable in the shifter, housing, and cable guides,
following the old path.
5. Re-attach the cable fixing bolt.
6. Re-attach the cover on the shifter.
7. Crimp on a metal end-cap to prevent fraying of the cable
end, or apply some solder to the end of the cable.
8. Follow the instructions To adjust the rear shifting.
Lubrication
Once a year, lubricate the Nexus hub bearings. This
procedure takes special tools and training, so should be done
by your Trek dealer.
Whenever a cable is replaced, lubricate the cable with
Wrench Force® synthetic chain lube or a similar lubricant.
CHAPTER THREE
Inspection, Adjustment & Lubrication
41
3 speed shift system
The internal shift system consists of those parts
of the bicycle which allow you to shift gears
including the shifter, rear hub, and shift cable.
The shifting mechanism is enclosed, keeping the
shifting system lubricated for low maintenance.
These instructions explain how to inspect, adjust,
and lubricate an internal shift system.
Set
screw
Inspection
Figure 3.5.3 Bell crank cover
and set screw
Bell crank
window
Set screw
Figure 3.5.4 Three-speed bell
crank set screw
A properly adjusted shift system is quiet. If an
unusual noise follows any shift, or while pedaling,
your shift cable may need to be adjusted. If after
adjustment the noise persists or grows louder, stop
the bicycle and try to locate the noise. If necessary,
ask your Trek dealer to identify and correct any
problems. For more information about your shift
system consult your Trek dealer.
Once a month, make sure the hub gears are
properly adjusted:
• On a Nexus 3 speed system, with the shifter in
2nd gear, the indicator in the bell crank window
(Figure 3.5.4) should line up with the mark on the
push rod (Figure 3.3.5).
Once a month, check the shift cable for kinks,
rust, broken strands, or frayed ends. Also check
the housing for bent ends, cuts, broken coils and
wear. If you suspect a problem with your shift
cable, do not ride your bicycle. Replace the cable
and/or housing before riding your bicycle by
following these instructions, or take your bike to
your Trek dealer for service.
Adjustment
To adjust the rear shifting
Push rod
Figure 3.5.5 Push rod
42
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.
3. If the lines do not line up, adjust the gear cable
tension by rotating the barrel adjuster (Figure
3.5.6) until this alignment is achieved.
Internal Shift Systems
4. Shift to 1st gear, then back to 2nd, and recheck the adjustment.
To replace the shift cable
Cable
barrel
1. Remove the bell crank cover set screw (Figure
adjuster
3.5.4).
2. Remove the bell crank cover.
3. Loosen the cable fixing bolt (Figure 3.5.6).
Cable
clamp
4. Note the path of the old cable, and remove the
bolt
cable.
4. Install a new cable in the shifter, housing, and Figure 3.5.6 Bell crank cable
clamp bolt
cable guides, following the old path.
5. Re-attach the cable fixing bolt.
6. Re-attach the cover on the bell crank.
7. Crimp on a metal end-cap to prevent fraying of the cable
end, or apply some solder to the end of the cable.
8. Follow the instructions To adjust the rear shifting.
Lubrication
Once a year, lubricate the Nexus hub bearings. This
procedure takes special tools and training, so should be done
by your Trek dealer.
Whenever a cable is replaced, lubricate the cable with
Wrench Force® synthetic chain lube or a similar lubricant.
CHAPTER THREE
Inspection, Adjustment & Lubrication
43
DualDrive shift system
Mode indicators
(Uphill)
Thumb
shifter
Figure 3.5.7 DualDrive shifter
The DualDrive shift system combines an
internal shift hub with an external derailleur
shifting system, consisting of those parts of the
bicycle which allow you to shift gears including
the shifter, rear hub, cassette, rear derailleur,
and shift cables. The derailleur portion of the
DualDrive system is a regular rear derailleur,
explained on pages 35-39. These instructions
explain how to inspect, adjust, and lubricate
the internal-shifting rear hub portion of the
DualDrive shift system with its two-position
thumb shifter (Figure 3.5.7).
Inspection
A properly adjusted shift system is quiet. If an unusual noise
follows any shift, or while pedaling, your shift cable may need
to be adjusted. If after adjustment the noise persists or grows
louder, stop the bicycle and try to locate the noise. If necessary,
ask your Trek dealer to identify and correct any problems. For
more information about your shift system consult your Trek
dealer.
Once a month, make sure the hub gears are properly
adjusted. Push the shifter from Uphill mode to Standard mode,
then back again. If the hub does not shift smoothly in both
directions, either follow the instructions to adjust
the shifting or take your bicycle to your Trek
Barrel adjuster
dealer for service.
Once a month, check the shift cable for kinks,
rust, broken strands, or frayed ends. Also check the
housing for bent ends, cuts, broken coils and wear.
If you suspect a problem with your shift cable,
do not ride your bicycle. Replace the cable and/or
housing before riding your bicycle by following
these instructions, or take your bike to your Trek
Indicator window
dealer for service.
Figure 3.5.8 Clickbox (found on
rear hub)
Adjustment
To adjust the rear hub shifting
1. Place the shifter in the Standard mode.
2. Align the indicator on the Clickbox window (Figure 3.5.8) by
rotating the barrel adjuster.
4. Shift to Uphill mode, then back to Standard mode, and recheck the adjustment.
44
Internal Shift Systems
To remove the rear wheel
1. With the derailleur, shift the chain to the
smallest rear cog.
2. Shift the rear hub to Uphill mode.
3. Push the Clickbox button (Figure 3.5.8) down.
4. Pull the Clickbox off the rear axle.
5. Screw out the shifting rod (Figure 3.5.9).
6. Follow the instructions To remove a wheel on
page 69.
Shifting
rod
Figure 3.5.9 DualDrive shifting
rod and rear axle washers
To install the rear wheel
1. Follow the instructions To install a wheel on
page 69.
2. Screw in the shifting rod.
3. Place the Clickbox on the rear axle.
4. Push the Clickbox button.
5. Follow the instructions To adjust the rear hub shifting on
the previous page.
To replace the shift cable
1. Snap off the Clickbox cover (Figure 3.5.10).
2. Loosen the cable clamp bolt.
3. Note the path of the old cable, and remove the cable.
There is a snap-in plastic cover over the cable head in the
shifter.
3. Install a new cable in the shifter, housing, and
cable guides, following the old path.
4. Pull the cable snug and re-attach the cable
clamp bolt.
5. Re-attach the cover on the Clickbox.
6. Follow the instructions To adjust the rear hub
shifting on the previous page.
7. Crimp on a metal end-cap to prevent fraying
of the cable end, or apply some solder to the
end of the cable.
Lubrication
Clickbox cover
Cable clamp bolt
Figure 3.5.10 DualDrive Clickbox
and cable clamp
The DualDrive hub bearings are designed to be permanently
lubricated under normal use.
Whenever a cable is replaced, lubricate the cable with
Wrench Force® synthetic chain lube or a similar lubricant.
CHAPTER THREE
Inspection, Adjustment & Lubrication
45
HEADSET AND FORK
The headset (Figure 3.6.1) is the bearing system
that allows rotation of the fork, stem, and handlebars, allowing you to steer the bike. These instructions explain inspection, lubrication, and adjustment of the headset and fork.
If your bicycle is equipped with a suspension
fork, also refer to Suspension Systems on page 79.
If your bicycle is equipped with an aluminum or
carbon fiber fork, also refer to Take Care of Your
Frame and Fork on pages 85-87.
Upper
headset
bearing
cup
Lower
headset
bearing
cup
Figure 3.6.1 Headset
Inspection
Once a month inspect the headset of your
bicycle to see that it is not loose, nor too tight. If your headset
bearings are loose or too tight, do not ride the bicycle; take
your bike to your Trek dealer for service.
To check if the headset is loose
1. Stand over the top tube of your bicycle with both feet on the
ground.
2. Apply the front brake firmly while you rock the bicycle
forward and backward.
If your bike is not equipped with a front brake, do this inspection by turning
the front wheel to be across, or perpendicular, to the pushing force.
3. Look, listen, and feel for looseness of the headset bearings.
To check if the headset is too tight
1. With the front wheel off the ground, slowly rotate the fork and
handlebars to the right and left.
2. Look, listen, and feel for any grinding noises, or stickiness
or binding at any point in the rotation; the bearings may
be too tight.
On some BMX bikes, a rotor allows the handlebars to turn 360
degrees without interference from the brake cables by bridging
across the headset. Rotor information is covered in the Brake
System section.
WARNING
An improperly adjusted headset can cause you to lose control
and fall. Make sure the headset is properly adjusted before
riding the bike.
46
Headset and Fork
Adjustment
Headset bearing adjustment requires special tools and
training, and should only be performed by your Trek dealer.
Adjustment of the rotor is covered in the section Brake System.
Lubrication
Once a year re-grease the headset. This requires special
tools and training, and should only be performed by your
Trek dealer.
CHAPTER THREE
Inspection, Adjustment & Lubrication
47
BRAKE SYSTEMS
The brake system allows you to slow or stop your bike, a
function critical to your safety.
These instructions explain how to inspect, adjust, and
lubricate a bicycle brake. Read the general information in
Braking system pointers- all systems as well as the specific
information for the type of brakes on your bike.
Brake system pointers- all systems
Different brake designs have varying amounts of stopping
power. If you are dis-satisfied, or uncomfortable, with the
stopping power of your bicycle brakes, consult your Trek dealer.
With any braking system, failure to properly adjust, maintain,
and use your brakes may result in a loss of control and injury.
If you are unsure of the brake adjustment, or suspect any
problem, do not ride your bicycle; have your Trek dealer
service your bicycle.
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 Trek dealer. If you need
more specific information regarding your brake system, contact
your Trek dealer.
Some types of brakes are not compatible with some types of
brake levers. With any brake, use only levers recognized as
compatible, like those supplied with your bike. As an example,
direct-pull brakes (Figure 3.7.2) have increased leverage and
stopping power, requiring special brake levers to manage the
power.
If your bike is equipped with brake levers offering adjustable
braking force, read and follow the manufacturers instructions
supplied with your bike before making any adjustment to the
braking force.
WARNING
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. If your brakes are not working properly, readjust them or take the bike to your Trek dealer for service.
48
Brake Systems
Rim brake with hand lever
Introduction
This system consists of one of several types of
hand-operated brake levers and brakes, including
road caliper brakes (Figure 3.7.1), direct-pull
brakes (Figure 3.7.2), U-brakes (Figure 3.7.4),
and cantilever brakes (Figure 3.7.5). With this
system, the lever is connected to the brake by a
cable. By squeezing the lever, pressure is applied
to the wheel rim by brake pads. This slows the
rotation of the wheel, which slows the bike.
This system consists of several parts:
• Rim
• Brake lever
• Brake cable and housing
• Brake caliper
Never use rims designed specifically for disc
brakes. Rim brakes require a flat sidewall on the
rim for proper braking action.
Centering
screw
Barrel
adjuster
Pad
fixing
bolt
Figure 3.7.1 Road caliper brake
Cable clamp bolt
Pad fixing bolt
No contact
Centering
screw
Inspection
Arm
When the brakes are not applied, the brake pads
fixing
should be 1-2mm from the rim. Brake pads should
bolt
be aligned with the rim surface (Figure 3.7.3). If
Figure 3.7.2 Direct-pull brake
your brakes are too tight, too loose, or not centered
on the rim, adjust them before riding the bike.
Figure 3.7.3 shows toe-in, an angular alignment of the brake
pad, which can be adjusted to prevent squealing of the brakes.
Used brake pads, or some new direct-pull type brakes, may not
require toe-in.
Brake pad
aligned with the
rim surface
Pad and
rim should
be parallel
Direction of rim
rotation
0.5 - 1 mm toe in
Figure 3.7.3 Brake pad alignment
Every month check the brake cables on your bike for kinks,
rust, broken strands, and frayed ends, and check the housing
for bent ends, cuts, stretched coils, and wear. Replace any part
which does not pass inspection.
CHAPTER THREE
Inspection, Adjustment & Lubrication
49
Cable carrier
Arm
fixing
bolt
Centering
nut
Link
wire
Pad fixing
bolt
Figure 3.7.4 U-brake
Linkwire
Centering
screw
Arm
fixing
bolt
Pad
fixing
bolt
Figure 3.7.5 Cantilever brake
Every month inspect the brake pads on your
bike for wear. Brake pads have shallow grooves in
their braking surface. If any of these grooves are
less than 2 mm deep, or 1 mm deep for direct-pull
brakes, replace the pads.
Every 3 months tighten bolts on brake
levers (Figure 3.7.6-3.7.8):
• Lever clamp (Figure 3.7.3): 53-69 lb•in (6.0-7.8 Nm)
• Mid-bar lever (Figure 3.7.7): 20-30 lb•in (2.3-3.3 Nm)
Every 3 months tighten bolts on caliper
brakes (Figure 3.7.1):
• Pad fixing: 40-60 lb•in (4.5-6.8 Nm)
• Brake fixing on:
- metal seatstays: 70-85 lb•in (7.9-9.6 Nm)
-'curved' carbon fiber seatstays: 55-60 lb•in (6.2-6.8 Nm)
Every 3 months tighten bolts on directpull brakes (Figure 3.7.2), U-brakes (Figure
3.7.4), or cantilever brakes (Figure 3.7.5):
• Pad fixing bolts: 70-80 lb•in (7.9-9 Nm).
• Arm fixing bolts: 70-85 lb•in (7.9-9.6 Nm)
Adjustment
To adjust the reach to the brake lever
Lever
clamp
bolt
Figure 3.7.6 Lever clamp bolt
With some brake levers, you can change the reach,
the distance from the handlebar to the lever.
1. Locate the reach adjustment screw (Figure
3.7.8) and turn. To increase 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 pad clearance.
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).
Lever
clamp
bolt
Figure 3.7.7 Mid-bar lever
50
Brake Systems
For most direct-pull, cantilever, or U-brake systems, the
barrel adjuster is on lever (Figure 3.7.8). For most road
caliper systems (Figure 3.7.1), the barrel adjuster is on the
brake itself.
With a double-pull lever (Figure 3.7.9) adjust the cable
tensions so that the rear brake pads are at least as close to
the rim as the front brake pads.
2. If the brake 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, but without removing
the brake cable.
To center a V-type, cantilever, or road brake
1. Rotate the centering screw (Figures 3.7.1,
3.7.2, and 3.7.5). 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.
Lever clamp bolt
Reach
adjustment
screw
Cable
Barrel
adjuster
Figure 3.7.8 Brake lever
To center a U-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 (Figure 3.7.4).
4. Re-tighten the bolt.
To adjust the alignment of the brake pads
1. Loosen the brake pad fixing bolt.
2. Follow the procedures in Inspection to align
and tighten the brake pads.
Figure 3.7.9 Dual-pull bake lever
3. After the brakes are adjusted, test the brakes
by applying maximum braking 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 install a brake cable
Installing a brake cable in a cantilever brake requires special
tools and training, so should only be done by your Trek dealer.
1. Note the path of the old cable, and loosen the brake 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
brake lever, and the housing is properly seated in the lever.
4. If needed, follow the instructions To adjust the alignment of
the brake pads.
5. Turn the adjusting barrel clockwise so the threads on
the adjusting barrel are not exposed above the caliper, or
outside the lever.
CHAPTER THREE
Inspection, Adjustment & Lubrication
51
6. Hold the brake pads against the rim, and tighten the bolt:
• Cable clamp bolt: 52-69 lb•in. (6-8 Nm)
7. Cut the cable so that no more than 2 inches (51 mm)
extends beyond the anchor bolt.
8. Crimp a metal cap or place a bit of solder on the end of the
cable to prevent fraying.
9. Follow the instructions for Inspection and Adjustment.
To open the brake for wheel removal
After installing a wheel, follow the Inspection procedures in the
Wheels section of this chapter to complete the installation.
• For most road calipers, lift the brake release
lever (Figure 3.7.1) to the open UP position. To
close, simply turn the lever to the Down position.
• For Campagnolo Ergopower levers, slightly
Brake
release
button
Figure 3.7.10 Campagnolo brake
release button
Pipe
Link
arm
Figure 3.7.11 Disconnect the pipe
depress the brake lever, and push the button
Figure 3.7.10) until it is flush with the lever body.
Release the lever and the brake will open.
To close, reverse the instructions.
• For cantilever brakes and U-brakes, release
the linkwire (Figure 3.7.4). 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.
• For direct-pull type brakes, disconnect the
pipe from the link arm (Figure 3.7.11). 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.
Lubrication
Every 3 months lubricate your brake lever pivots and brake
arm fixing pivots with a light oil. See your Trek dealer for a
recommended oil.
Whenever a cable is replaced, lubricate the cable with a thin
layer of Wrench Force® synthetic grease or a similar lubricant.
52
Brake Systems
Rotor
Introduction
Some rim brake systems also include a rotor,
which allows the rear brake cable to bypass the
headset such that the handlebars can be rotated
a full 360 degrees. This capability is provided by
a rotor (Figure 3.7.12) mounted to the headset.
Since the rotor is a connection between the
brake lever and the brake, its function is part of
the brake operation. Proper rotor adjustment is
critical to proper brake function.
Rotor
Figure 3.7.12 Rotor
Inspection
Once a month inspect the rotor for proper function. Watch
the bearing unit as you rotate the handlebars 360 degrees.
It should not move up or down, or tilt. When the brake lever
is applied, the rotor should apply the brake firmly while the
bearing unit remains parallel to the upper and lower cable
stops. If the bearing unit tilts either when the brakes are
applied, or when the handlebars are rotated, the rotor needs
adjustment.
Adjustment
To adjust the rotor
1. Ensure that both lower barrel 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.
2. If it is tilted, 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.
3. Remove the slack through the barrel adjuster.
4. When even pull is achieved, tighten all barrel adjuster
locknuts.
Lubrication
The rotor does not require lubrication.
CHAPTER THREE
Inspection, Adjustment & Lubrication
53
Internal, or drum, brakes
Introduction
Cable
clamp
bolt
Barrel adjuster
Cable
carrier
arm
Figure 3.7.13 Internal drum
brake
The braking mechanism of an internal or drum
brake is inside a hub, but it is actuated by a hand
lever. The lever is connected to the brake by a
cable. This system consists of several parts:
• Brake lever
• Brake cable and housing
• Rear hub
Inspection
Every month check that the brake cable clamp
bolt is tight.
Every month check the brake cables on your bike for kinks,
rust, broken strands, and frayed ends, and check the housing
for bent ends, cuts, stretched coils, and wear. Replace any part
which does not pass inspection.
Adjustment
To decrease lever movement
1. Loosen the locknut on the barrel adjuster (Figure 3.7.13)
and turn the barrel adjuster.
To increase the lever travel, turn the screw in (clockwise). To reduce the
lever travel, turn the screw out (counter-clockwise).
2. After adjustment, tighten the locknut to hold this adjustment.
Rear wheel removal
To remove the rear wheel, you must first disconnect the shift
and brake cables.
To disconnect the brake cable
Be careful not to touch the rear hub which may be hot from braking.
1. Press the cable carrier arm (Figure 3.7.13) forward, and the
cable clamp bolt rearward, so the bolt aligns with the larger
diameter hole in the carrier.
2. Pull the cable clamp bolt outward to disengage it from the carrier.
3. Slide the brake cable stop forward to remove it from the
brake arm.
4. Undo brake strap bolt.
To disconnect the shift cable
1. Put the shifter in 1st gear.
54
Brake Systems
2. Pull the cable housing out of the shift cable housing stop.
3. Rotate the shift cable fixing bolt until the washer flats align
with the slit in the cog joint bracket.
4. Remove the cable.
To unbolt the axle from the frame
When loosening and tightening the axle nuts, do so gradually, in small
increments, to prevent effecting the bearing hub adjustment.
1. Slightly loosen the axle nut on one side of the hub by about
1/4 turn.
2. Slightly loosen the axle nut on the other side of the hub
about 1/4 turn.
3. Continue loosening the axle nuts in small increments until
you can slide the hub from the dropouts.
To install the wheel
1, Reverse the instructions for removing the wheel, including
gradual tightening of the axle nuts.
2. Reverse the procedure to connect the brake cable.
3. Reverse the procedure to connect the shift cable.
4. Check that the gear cable tension is correctly adjusted.
5. Follow the Inspection procedures in the Wheels section of
this chapter complete the installation.
Cable installation
Follow the instructions To install a brake cable, page 47.
Lubrication
Every 3 months lubricate the brake lever pivots with
Wrench Force synthetic chain lube or a similar light oil.
Whenever a brake cable is installed, lubricate the cable
with a thin layer of Wrench Force synthetic grease or a similar
lubricant.
CHAPTER THREE
Inspection, Adjustment & Lubrication
55
Hydraulic disc brakes
Introduction
Instead of pressing on the wheel rim to slow the
bike, this braking system presses on a disc that is
mounted on the wheel hub Figure 3.7.14). The disc
is attached to the hub with bolts, and a disc brake
caliper is attached to the left side of the frame or
fork. A special lever, which functions as the brake
fluid reservoir, is connected to a hydraulic hose to
actuate the brake.
Disc
This system consists of several parts:
Disc brake
• Brake lever/ fluid reservoir
• Hydraulic hose
• Brake caliper and disc
Read the brake manual that came with your bike. If you did not
receive a brake manual, get one from your dealer, contact us and
we’ll send you one, or download one from an internet site:
Brake
Figure 3.7.14
www.hayesbrake.com
The following information is only meant to supplement the
brake manufacturer’s manual.
Disc brake fluid is very corrosive. Avoid contact with your skin,
or the bicycle; brake fluid removes paint.
Disc brakes may be very hot after use, so use care when
inspecting them. As with other rotating parts on a bicycle,
avoid placing your fingers in the disc.
WARNING
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.
Do not operate the brake lever when the disc is not in the
caliper. If the lever is pulled with the disc removed from the
brake, the self-adjusting pad clearance will be set at almost
zero, so the disc cannot be re-inserted between the brake pads.
In this case, refer to your disc brake owner's manual.
Inspection
Before every ride squeeze the brake lever firmly. It should
not be possible to pull the lever fully to the handlebar. If the
brake lever can be pulled to the handlebar, the brake system
56
Brake Systems
must be bled. Bleeding brakes takes special tools and training;
take your bike to your Trek dealer for service.
Check that there is no oil, grease, or other dirt on the disc.
The disc (Figure 3.7.14) is part of the braking system, so keep
it clean at all times. Remove the brake pads from the caliper
during heavy cleaning. Do not use cleanser, de-greaser, or
solvents to clean the disc. To clean discs, use isopropyl alcohol.
Once a month inspect disc brake pads for wear. If disc
brake pads are less than 1.0 mm thick, replace the pads. Check
that the brake pads are in proper position, allowing 0.25 to
0.75 mm clearance from the disc when the brakes are not
applied (Figure 3.7.15). Spin the wheel; when the brake lever is
not pressed, the brake pads should touch as little
as possible on the disc.
Tighten the disc brake bolts (Figure 3.7.16):
• Caliper mounting bolts: 100-110 lb•in (11.3-12.4 Nm)
• Adapter mounting bolts using a 5mm allen wrench: 100110 lb•in (11.3-12.4 Nm)
• Adapter bolts using 4mm allen wrench: 60-65 lb•in (6.87.3 Nm).
• Disc attachment bolts holding the disc to the hub: 45-55
lb•in (5-6.2 Nm)
• Brake lever attachment bolts: 25-35 lb•in (2.8-4 Nm)
Check the brake hose for kinks or leakage.
Replace any part of hydraulic hose which does
not pass inspection. Replacing hydraulic hose
requires re-adjustment of the braking system
with special tools and training and should only
be done by your Trek dealer.
Figure 3.7.15 Disc brake pad
clearance
Adjustment
To adjust the distance from the brake lever to
the handlebar
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).
Adapter
bolts
Mounting
bolts
Figure 3.7.16 Disc brake attachment bolts
To align the brake with the disc
1. Loosen the brake mounting bolts.
CHAPTER THREE
Inspection, Adjustment & Lubrication
57
2. Apply the lever fully, and gradually tighten the
bolts as specified in Inspection.
To remove the brake pads
1. Remove the wheel.
2. With your fingers, or thin-tipped pliers, grasp
the installation tang of the brake pad (Figure
3.7.17) and pull out.
Wheel removal
Removing a wheel with a disc brake does not
require opening the brake. Follow the instructions
To remove a wheel on pages 64-65, and simply slide the disc out
of the brake.
When installing the wheel, carefully guide the disc between
the brake pads. If the edge of the disc is pressed against the
pads with force, the pads could be chipped or damaged, which
then requires replacement of the brake pads.
Figure 3.7.17 Removing disc
brake pads
Lubrication
Every 3 months lubricate the brake lever pivots with Wrench
Force® synthetic chain lube or a similar light oil.
Hydraulic disc brake calipers require no lubrication.
58
Brake Systems
Cable Actuated Disc brakes
Introduction
Instead of pressing on the wheel rim to slow
the bike, this braking system presses on a disc
that is mounted on the wheel hub (Figure 3.7.18).
The brake is actuated by a brake cable operated
with a standard brake lever. The disc is attached
to the hub with bolts, and a disc brake caliper is
attached to the left side of the frame or fork. This
system consists of several parts:
• Brake lever
Figure 3.7.18
• Brake cable and housing
• Brake caliper and disc
Disc brakes may be very hot after use, so use care when
inspecting them. As with other rotating parts on a bicycle,
avoid placing your fingers in the disc.
Brake
Disc
Disc brake
WARNING
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.
Inspection
Before every ride squeeze the brake lever
firmly. It should not be possible to pull the lever
fully to the handlebar.
Check that there is no oil, grease, or other dirt
on the disc. The disc (Figure 3.7.18) is part of
the braking system, so keep it clean at all times.
Remove the brake pads from the caliper during
heavy cleaning. Do not use cleanser, de-greaser,
or solvents to clean the disc. To clean discs, use
isopropyl alcohol.
Once a month inspect disc brake pads for
wear. If disc brake pads are less than 1.0 mm
Figure 3.7.19 Disc brake pad
clearance
thick, replace the pads. Check that the brake
pads are in proper position, allowing 0.25 to
0.75 mm clearance from the disc when the
brakes are not applied (Figure 3.7.19). Spin the wheel; when
the brake lever is not pressed, the brake pads should touch as
little as possible on the disc.
CHAPTER THREE
Inspection, Adjustment & Lubrication
59
Tighten the disc brake bolts (Figure 3.7.20):
Adapter
bolts
Mounting
bolts
Cable clamp bolt
Figure 3.7.20 Disc brake attachment bolts
Lever clamp bolt
• Caliper mounting bolts: 100-110 lb•in (11.3-12.4 Nm)
• Adapter mounting bolts using a 5mm allen wrench: 100-110
lb•in (11.3-12.4 Nm)
• Adapter bolts using 4mm allen wrench: 60-65 lb•in (6.8-7.3
Nm).
• Disc attachment bolts holding the disc to the hub: 45-55
lb•in (5-6.2 Nm)
• Cable clamp bolt: 50-70 lb•in (5.7-7.9 Nm).
Every month check the brake cables on your
bike for kinks, rust, broken strands, and frayed
ends, and check the housing for bent ends, cuts,
stretched coils, and wear. Replace any part which
does not pass inspection.
Adjustment
To adjust the reach to the brake lever
With some brake levers, you can change the reach, the
distance from the handlebar to the lever.
Reach
adjustment
screw
Cable
Barrel
adjuster
Figure 3.7.21 Brake lever
1. Locate the reach adjustment screw (Figure
3.7.21) and turn. To increase 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 pad clearance.
To adjust right brake pad clearance to the disc
Fixed pad adjuster
1. Turn the fixed pad adjuster (Figure 3.7.22).
To increase the pad clearance, turn the barrel
adjuster in (clockwise). To reduce the pad
clearance, turn the barrel adjuster out (counterclockwise).
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.
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 47, but without removing the cable.
Figure 3.7.22 Fixed pad adjustment knob
60
Brake Systems
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.
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 each mounting
bolt as specified in Inspection.
To remove the brake pads
1. Remove the wheel.
2. With your fingers, or thin-tipped pliers, grasp
the installation tang (Figure 3.7.23) of the
brake pad and pull out.
Wheel removal
Removing a wheel with a disc brake does not
require opening the brake. Follow the instructions Wheel removal and installation on pages 6465, and simply slide the disc out of the brake.
When installing the wheel, carefully guide the
disc between the brake pads. If the edge of the
disc is pressed against the pads with force, the
pads could be chipped or damaged, which then
requires replacement of the brake pads.
Figure 3.7.23 Disc brake pads
Lubrication
Every 3 months, lubricate the brake lever pivots, and the part of
the brake caliper that rotates when the brake lever is pulled, with a
light oil. See your Trek dealer for a recommended oil. Be careful not
to get oil on any other part of the brakes.
Whenever a cable is installed, lubricate cables with a thin
layer of Wrench Force® synthetic grease or a similar lubricant.
Cable installation
Follow the instructions To install a brake cable, page 47.
CHAPTER THREE
Inspection, Adjustment & Lubrication
61
Coaster brakes
Introduction
Brake
strap
Brake arm
attachment
bolt
Figure 3.7.24 Coaster brake
parts
Instead of operating by hand, coaster brakes are
actuated with the legs by pedalling the crankarms
backwards. The chain transmits the motion of
the crankarms to the rear hub. The braking
mechanism is actually inside the rear hub. This
system consists of several parts:
• Rear hub
• Chain and crankset
Inspection
Once a month check that the brake arm attachment bolt is tight and that the brake strap is securely fastened
to the chainstay (Figure 3.7.24).
Once a month, or whenever the wheel is installed,
check the chain tension. Without proper tension, the chain can
come off, and the brake will not work. See Drivetrain on pages
32-34 for Inspection and Adjustment of chain tension.
Adjustment
See Drivetrain on pages 32-34 for Adjustment procedures.
Rear wheel removal
To unbolt the brake arm
1. Loosen and remove the brake arm attachment bolt
(Figure 3.7.24).
To unbolt the axle from the frame
When loosening and tightening the axle nuts, do so gradually, in small
increments, to prevent effecting the bearing hub adjustment.
1. Slightly loosen the axle nut on one side of the hub by about
1/4 turn.
2. Slightly loosen the axle nut on the other side of the hub
about 1/4 turn.
3. Continue loosening the axle nuts in small increments
until both nuts are loose enough to slide the hub from the
dropouts.
With bikes equipped with training wheels, there is a second set of axle
nuts under the training wheel brackets. Loosen and remove them in thee
same manner.
62
Brake Systems
To install the wheel
1. Loop the chain over the hub (not the rear cog), and slide the
hub into the dropouts.
2. Push the wheel fully forward, lift the chain onto the rear
cog, and pull the wheel back until the proper chain tension
is achieved.
3. While holding the wheel straight in the frame, maintain
chain tension and reverse the instructions for removing the
wheel, including gradual tightening of the axle nuts.
4. If necessary, re-tension the chain (with the chain tensioners,
if so equipped).
5. Re-adjust training wheels, if so equipped, and tighten the
secondary axle nuts.
6. Re-install the coaster brake arm, and tighten the brake arm
attachment bolt, if so equipped.
7. Follow the Inspection procedures in the Wheels section of
this chapter complete the installation.
8. Spin the wheel to see that it is centered and the wheel turns
freely without rubbing.
9. Make sure the brake is working properly.
Lubrication
Coaster brakes do not require additional lubrication. Follow
the recommendations in the Wheels section for lubricating hub
bearings.
CHAPTER THREE
Inspection, Adjustment & Lubrication
63
WHEELS
Introduction
The wheels (Figure 3.8.1) of a bicycle allow the bike to roll
down the road smoothly, so their integrity and structural
soundness is crucial. In addition, their relationship to the
performance of your brakes is of great importance.
These instructions explain how to inspect, adjust, and
lubricate the wheels of a bicycle.
Inspection
The best maintenance of a wheel is preventative
maintenance. Be aware of the things that can go
wrong, so you can stop trouble before it happens.
Before every ride check that your quickSpokes
release hubs are in their CLOSED (locked)
position, or that your wheel axle nuts are tight.
For further information on adjusting quick-release
Hub
hubs, see the Adjustment section, or consult your
Trek dealer. Check that the wheels are straight
and round by spinning them. If the rim (Figure
3.8.1) does not spin evenly, have your wheel trued
Rim
(straightened) by your Trek dealer. Make sure
Figure 3.8.1 Rear wheel
your tires are inflated to the pressure indicated on
the tire sidewalls. Use a gauge and a bicycle pump whenever
possible. Avoid filling your tires at gas stations. Because of
the greater pressure and volume of air their pumps release,
blowouts are very possible. Inspect your tires for wear and any
other damage. If a tire has any cuts or separations which go
through the tire, making any part of the inner tube visible,
or if any part of the tire casing shows through the tire tread
(running surface) or knobs are worn or missing, replace the
tire. Make sure your rims are clean. Dirty or greasy rims
render your brakes ineffective. Wipe your rims with a clean rag
or wash them with soap and water, rinse, and let them air dry.
Every week make sure there are no loose, damaged, or
broken spokes. If a wheel is not in good condition, both the
effectiveness of the brakes and the strength of the wheel are
greatly reduced.
Tire
WARNING
An improperly adjusted hub, where there is movement
between the hub and axle, can cause you to lose control and
fall. Inspect the hubs thoroughly before every ride, and do
not ride the bicycle until any problem has been corrected.
64
Wheels
Every month check that both hub bearings are properly
adjusted. Lift the front end of the bicycle off the ground with
one hand and attempt to move the rim laterally, left to right.
Look, feel, and listen for any looseness in the hub bearings.
Spin the wheel, and listen for any grinding or other unusual
noises. If the hub feels loose or makes any noise, the hub needs
an adjustment. Repeat these procedures for the rear wheel.
Every month, check your rims for wear. On adult-size
bicycles there may be wear indicators in the braking surface,
either a continuous indented band or several small spherical
indentations at even intervals around the rim. If the braking
surface has worn so that any part of these indicators is no
longer visible, have your dealer replace the rim.
Before installing tires make sure a rim strip is in place
which completely covers the rim web (wall to wall) so that all
spoke holes are completely covered.
WARNING
Make sure the rim strip covers all of the spoke holes or spoke
heads. If they are exposed, the inner tube could be punctured
and lose air suddenly causing you to lose control and fall.
Make sure the rim strip properly covers all spoke holes.
Adjustment
To adjust wheel bearings
This procedure requires special tools and training, so should
only be done by your Trek dealer.
Quick-release adjustment and closure
For proper and safe adjustment of a quick-release, read and
follow these instructions carefully.
WARNING
A quick-release 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 quick-release is
adjusted and closed properly before riding the bike.
CHAPTER THREE
Inspection, Adjustment & Lubrication
65
To adjust the tension of a quick-release
1. Move the quick-release lever to the OPEN position
����
(Figure 3.8.2) and set the wheel so it firmly touches
the inside of the fork ends.
2. With the lever about halfway between the OPEN
position and the CLOSED position, tighten the
quick-release adjusting nut (Figure 3.8.3) until
finger-tight.
3. Place the lever in the palm of your
hand and throw the lever as shown in
Figure 3.8.4 to the CLOSED position
(Figures 3.8.6-3.8.7). At the half-closed
position of the lever, there should be
some resistance.
�
�
������
��
��
��
Figure 3.8.2 Lever positions
��
Figure 3.8.3 Tighten nut
��
��
��
��
��
��
�
���
Figure 3.8.5 Do not turn
the lever
Figure 3.8.6 Front lever
position
• Do not tighten the quickrelease wheel retention
mechanism by turning the lever
like a wing nut (Figure 3.8.5);
it will not result in sufficient force to hold the
wheel in place.
Figure 3.8.4 Proper
lever throw
5. If the lever is moved to the CLOSED position
with little or no resistance, clamping strength is
insufficient. Return the lever to the OPEN position,
tighten the quick-release adjusting nut further
and close the lever, and again test for resistance.
For further information on correct
adjustment of the quick-release
tension, read Figure 3.8.8.
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
Figure 3.8.7 Rear lever
snag the levers (Figures 3.8.6-3.8.7).
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 3.8.8 Definition of correct quick-release lever force
66
Wheels
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 Trek dealer for service.
Test for proper quick-release adjustment
• Pick up the bike, and sharply hit the top of the
tire (Figure 3.8.9). 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 3.8.10).
• When the quick-release is properly tightened,
and clamped by the lever in the closed position,
the clamping force is adequate to cause metalinto-metal engagement (embossing) of the
dropout surfaces.
• See Figure 3.8.8.
Figure 3.8.9 Test for looseness
Threaded axle-nut wheel retention
If your bicycle is equipped with threaded axlenuts instead of quick-release mechanisms, make
sure the axle nuts are tightened correctly:
Figure 3.8.10 Test for rotation
• Front wheel: 180-240 lb•in (20.3-27.1 Nm)
• Rear wheel: 240-300 lb•in (27.1-33.9 Nm)
For each wheel, test to ensure that you have properly
tightened the axle-nuts. If the axle-nuts fail the test, either
repeat these procedures, including these tests, or take your
bicycle to your Trek dealer for service.
Test for proper axle-nut adjustment
• Pick up the bike, and sharply hit the top of the tire (Figure
3.8.9). The wheel must not come off, be loose, or move from
side to side.
WARNING
A wheel axle-nut that is not properly tightened may allow the
wheel to be loose or come off unexpectedly, causing you to
lose control and fall. Make sure the axle-nuts are tightened
properly before riding the bike.
CHAPTER THREE
Inspection, Adjustment & Lubrication
67
Redundant retention washers
Toothed
washer
For the front wheel of children's bikes and BMX
bikes with axle nuts, a special toothed washer must
be in place on both sides of the hub for correct
wheel retention. The toothed washer is placed on
the outside of the fork tip with the tooth in the
corresponding hole in the fork tip (Figure 3.8.11).
Pegs on BMX bikes
Figure 3.8.11 Toothed washer
Peg
Some bikes have tubular axle extensions, called
pegs (Figure 3.8.12). For bikes with pegs on the
front wheel, the toothed washer must be against
the fork tip as in Figure 3.8.11, with the peg
installed over the toothed washer. Additional
washers and nut go inside the peg. Tighten axlenuts in pegs:
• Using a 15 mm socket: 220-240 lb•in (24.9-27 Nm)
• Using a 19 mm socket: 350 lb•in (40 Nm)
Tricycle wheel retention
On a tricycle front wheel, make sure the axle
clamp bolts (Figure 3.8.13) on both sides of the
fork are tight:
Axle nut and washer
Figure 3.8.12 Axle peg
• Front wheel: 150-280 lb•in (17-20.3 Nm).
Adjusting tire pressure
If you cannot keep the proper pressure in a tire,
it probably has a leak in the tube. The section on
pages 71-73, Tire Installation, includes instructions
to fix the tube leak. If you do not have the proper
tools, take the bike to your Trek dealer for repair.
Wheel removal and installation, for bikes
with a rear derailleur
Clamp bolt
Figure 3.8.13 Tricycle front
wheel clamp bolt
These instructions explain how to remove and
install a wheel. For some parts of these procedures,
the instructions refer you to information already
covered earlier in the Wheels and Brake Systems
sections of this chapter.
Note: For rear wheels with internal brakes, or coaster brakes, follow the
instructions To remove the rear wheel for that brake type in the
Brake Systems section.
68
Wheels
To remove a wheel
1. Shift to the smallest rear cog.
2. Open the brake by following the instructions
To open the brake, for your type of brakes, in
the Brakes section.
3. Open the wheel quick-release, or loosen the
axle nuts.
4. For a rear wheel, hold the derailleur cage with
your thumb (Figure 3.8.14), and unwind the
derailleur cage (Figure 3.8.15).
5. Slide the wheel out of the dropouts.
Figure 3.8.14 Thumb on rear
derailleur
To install a wheel
1. For a rear wheel, rotate the derailleur back,
while unwinding the derailleur cage with your
thumb (Figure 3.8.15). Place the chain on the
small cog.
2. Place the wheel in the frame or fork, making
sure that the axle is inserted all the way into
the dropouts.
3. Re-install and adjust the quick-release or
tighten the axle nuts as shown in the Wheels
section.
Figure 3.8.15 Thumb on rear
4. Close the brake.
derailleur
5. Test the brake to make sure it is properly
adjusted.
6. Spin the wheel to see that it is centered and the wheel turns
freely without rubbing.
Lubrication
Every year, re-grease wheel bearings. This requires special
tools and training, so should only be done by your Trek dealer.
Every year, lubricate wheel quick-release. Apply several
drops of Wrench Force® synthetic lube or a similar light oil
where the quick-release lever rotates in the quick-release
body.
Tubeless-compatible wheel system
Some Trek bikes are equipped with rims marked "Tubeless."
For more information on this system, see Tubeless
Compatible Wheel System on pages 74-78.
CHAPTER THREE
Inspection, Adjustment & Lubrication
69
REFLECTORS
Introduction
The reflectors on your bicycle illuminate when a light is
shone on them, directing some of the light back to the source.
In poor lighting conditions, if an oncoming vehicle has their
lights on, the reflectors may help the other vehicle see your
bike. Reflectors are an important part of your bicycle’s safety
equipment. Do not remove the reflectors from your bicycle.
Inspection
Every three months, make sure all the nuts and bolts
holding the front, rear, pedal, and wheel reflectors are tight.
Check that front and rear reflectors are oriented so their reflective surfaces are perpendicular to the ground, and that all
reflective surfaces are clean and in good condition. The front
reflector should point directly forward, and the rear should
point directly back. The rear reflector should be at least three
inches below the top of the seat.
Schraeder and Presta Valves
There are two styles of valves used on Trek
bicycles (Figure 3.8.16), which use different use
techniques for inflation:
• Schraeder valve- remove the valve cap, attach an
air pump with a Schraeder fitting, and inflate. Put
the cap back on, as the cap keeps dirt and debris
out of the valve.
• The Presta valve is also known as a French
valve. To inflate a Presta valve, remove the valve
cap, if present. Presta valves seal very tightly, and
Schraeder
Presta
require a lot of pressure to open them initially,
so after unscrewing the valve nut, depress the
Figure 3.8.16 Valve stem types
nut with your finger to open the valve. This
should let a little air out. Inflate using a Presta
valve fitting. After inflation, tighten the valve nut against
the valve stem until finger-tight. This provides the same
function as the valve cap on a Schraeder valve.
70
Wheels
BICYCLE TIRE INSTALLATION
These instructions are written for standard
wheel systems where the air inside the tire is
contained in an inner tube.
Follow these steps when repairing or replacing a
tube in the event of a flat tire, or when replacing a
worn tire.
To remove a wheel from the bike
1. Follow the instructions To open the brake, in
the Brake System section of this chapter.
2. Follow the instructions To remove a wheel, in
the Wheels section of this chapter.
Figure 3.8.17 Install the first
bead
To remove the tire from the wheel
Remove the tire from the rim with your hands,
or tire levers.
Do not use sharp objects such as a screwdriver to remove
the tire.
1. Deflate the tire completely.
2. Working your way all around the wheel, squeeze
the tire beads into the bottom of the rim well.
3. Starting opposite the valve, lift one tire bead up
and out of the rim.
4. Continue around the wheel lifting the bead out
until one bed is completely free (Figure 3.8.18).
5. Reach up into the tire and remove the inner
tube.
6. Remove the second tire bead from the rim.
Figure 3.8.18 Insert the tube
in the rim
To install a tire on the wheel
1. If you are repairing a tube leak, repair the
puncture on the tube with a tube patch, or
replace the tube.
2. Follow the Inspection procedures in the Wheels
section to check the rim and inside of the tire.
If you are replacing the tube or tire, make sure the new
tube or tire is the same size as the old one, or check with
your Gary Fisher dealer for compatibility of differing sizes.
The size can be found on the side of the tire.
Figure 3.8.19 Inner tube
pinched between the tire and
the rim
3. Inflate the tube until it begins to take shape.
4. Place the tube in the tire.
5. Insert the tube valve stem through the hole in the rim.
CHAPTER THREE
Inspection, Adjustment & Lubrication
71
6. Starting at the valve stem, install the first bead
onto the rim (Figure 3.8.17).
7. Push the tire and tube over so the tube is inside
the rim (Figure 3.8.18).
8. Again starting at the valve stem, carefully push
the second bead into the rim using your hands.
Be careful not to pinch the tube between the rim and the
tire (Figure 3.8.19) when mounting the tire.
Figure 3.8.20 Inner tube contained by the tire and the rim
9. Push the base of the valve stem up into the tire,
so that it its not caught between the tire beads
and the rim.
10. Inflate the tire to about half pressure while
checking that the tire bead is properly seated in
the rim (Figure 3.8.20).
11. Deflate the tire again.
This will help avoid any pinching of the tube.
12. Inflate the tire to the pressure indicated on the
side of the tire.
To install the wheel on the bike
1. Follow the instructions To install a wheel, in the
Wheels section of this chapter.
2. Follow the instructions To close the brake, in the
Brake System section of this chapter.
72
Wheels
TRICYCLE TIRE INSTALLATION
These instructions are written for the Trek tricycle rear wheel
(Figure 3.8.21), where a split rim design holds a standard tire
and tube, and where the air inside the tire is contained in an
inner tube.
Follow these steps when repairing or replacing a tube in the
event of a flat tire, or when replacing a worn tire.
To repair a flat rear tire, it is not necessary to
remove the wheel from the axle.
To remove the tire from the wheel
1. Deflate the tire completely.
2. Loosen and remove all the rim bolts , and
separate the rim halves.
3. Remove the tire from the rim with your hands.
To install a tire on the wheel
1. If you are repairing a tube leak, repair the
Figure 3.8.21
puncture on the tube with a tube patch, or
replace the tube.
2. Follow the Inspection procedures in the Wheels section to
check the rim and inside of the tire.
3.
4.
5.
6.
Tricycle rim bolts
If you are replacing the tube or tire, make sure the new tube or tire is the
same size as the old one, or check with your Trek dealer for compatibility
of differing sizes. The size can be found on the side of the tire.
Inflate the tube until it begins to take shape.
Place the tube in the tire.
Insert the tube valve stem through the hole in the rim.
Bolt the rim halves together and tighten to 180-220 lb•in
(20.3-24.9 Nm)
Be careful not to pinch the tube or the tire between the rim halves when
mounting the tire.
7. Inflate the tire to about half pressure while checking that
the tire bead is properly seated in the rim.
8. Deflate the tire again.
This will help avoid any pinching of the tube.
9. Inflate the tire to the pressure indicated on the side of the tire.
CHAPTER THREE
Inspection, Adjustment & Lubrication
73
TUBELESS-COMPATIBLE WHEEL
SYSTEM
Some Trek bicycles are equipped with a Bontrager tubelesscompatible wheel system. This system can be used with
"Tubeless" tires, and also with standard tires when an inner
tube is used. The tubeless mode requires special parts:
• Tubeless tire
• Tubeless rim
• Tubeless rim strip
• Tubeless valve stem
On some models of bicycles, "Tubeless-compatible" wheelsets
are sold without these components installed.
A 'regular' tire fits the tubeless-compatible rim, but a regular
tire requires an inner tube since it does not have an impermeable layer to hold the air. This section explains other requirements of this system, and includes installation instructions.
WARNING
A standard tire will not hold air without an inner tube and it
could lose air suddenly causing you to lose control and fall.
Always use an inner tube with a standard tire.
Avoiding leaks with a tubeless tire
A properly mounted tubeless tire will ‘bleed’ air, up to 4 PSI
(0.25 ATM) per day. If a tubeless tire loses air faster than this,
check potential leakage sites. Dirt, sand, grime, or roughness
on any of the sealing surfaces may cause a tubeless tire to leak.
Check that the valve nut is tight, check for punctures, and
check all sealing surfaces:
• Tire to rim contact
• Tire to rim strip contact
• Valve stem to rim strip contact
• Rim strip to rim contact.
If a tubeless tire is punctured, a small hole (less than 3mm)
can be patched from the inside of the tire with a sticky glueless
patch. If the puncture hole is greater than 3mm, or the tire
casing is damaged with broken threads instead of merely
punctured, replace the tire. If the air is leaking from the rim
strip, install a new rim strip.
If the air leaks rapidly and you can't find the air source,
it may be difficult to inflate the tire enough to locate the
puncture. However, its easy to convert from tubeless to the use
of a standard inner tube.
74
Tubeless-compatible Wheel Systems
A tubeless tire must be complete sealed to the rim
Before a tubeless tire can be inflated, both beads
must make full contact with the rim strip at the
bottom of the rim well, all the way around the
rim. For this to happen, a tubeless tire must fit
more tightly on the rim than a conventional tire.
With a snug fitting tubeless tire, bare-handed
installation may be difficult. If you use tire levers
for installation or removal, avoid damaging the
rim or abrading the tire beads. If either surface
is roughened, air may bleed excessively from the
mounted tire.
If the tire beads are sealed on the rim strip,
air pressure will push the beads up to the rim
hooks, where they can seal tightly. You don't need
a compressor to do this; a good floor pump or an
air cartridge will work. Even a hand pump may
work, if nothing else is available.
Presta nut
Tubeless
valve nut
Figure 3.10.1 Tubeless valve
stem
To install a valve stem
Too
tight
1. Center the tubeless rim strip in the rim, and
align the valve holes of the rim strip and rim.
2. Align the slot on the head of the tubeless valve
with the rim (Figure 3.10.1), and press the
valve stem through the rim strip and the rim.
3. Thread the tubeless valve nut (Figure 3.10.1)
onto the valve, and tighten firmly by hand.
3.10.2 Starting the first
There should be no gap between the valve and Figure
bead at the valve
the rim strip.
4. Make sure the rim strip is smooth, even, and centered in the
rim well.
To install a tubeless tire.
It is recommended to lube the tire and rim with soapy water
to aid in tire installation and seating of the bead.
1. Starting opposite the valve, lay one tire bead into the center
of the rim well.
Note: If you start at the valve, the bead will lie on top of the valve, which
will take up some slack needed to lift the tire bead over the rim shoulder
(Figure 3.10.2).
2. Start opposite the valve again, and install the second tire
bead until there is about 10 inches (25cm) of bead left
outside the rim.
CHAPTER THREE
Inspection, Adjustment & Lubrication
75
3. Roll the tire, along with both beads, so the
second bead is at the bottom of the rim well
(Figure 3.10.3). This provides some slack in the
beads.
4. Finish installing the second bead.
To inflate a tubeless tire
Note: To help remove any gaps between the tire beads and rimstrip,
hold both beads, adjacent to the valve stem, up and out of the center
channel with your fingers.
Figure 3.10.3 Stacking the
beads
Bead lock
1. Begin to inflate the tire, filling it as rapidly as
possible to about 60PSI (4 ATM), until the tire
beads snap into the rim hooks (Figure 3.10.4).
Most tires have lines or marks running around
the casing, just above the bead. When the tire
is correctly installed, these lines are at an even
distance from the rim.
2. When the beads are correctly seated all around
the rim, inflate (or deflate) the tire to the desired
pressure.
Figure 3.10.4 Bead engagement
with the rim hook
WARNING
If a tubeless tire has insufficient air pressure it could lose
air suddenly causing you to lose control and fall. Always ride
with tubeless tires inflated to a minimum of 30PSI (2 ATM.)
To remove a tubeless tire
On tubeless-compatible rims the bottom of the
well is too narrow for both beads to rest fully
against the rim bottom at the same time, so the
tire must be rolled to "stack" the beads and get one
bead at the bottom.
1. Let all the air out of the tire.
Figure 3.10.5 Pushing the bead
with the thumbs
76
Tubeless-compatible Wheel System
2. With the wheel facing you, roll the tire up and
away from the rim with your thumbs (Figure
3.10.5) while you use your fingers to stack the
beads (Figure 3.10.3).
3. At the valve, pull the lower, slacker bead of the
tire up, out, and away from the rim (Figure
3.10.6).
4. Keep pulling the loosened bead up and out of
the rim, rolling and pushing the tire toward
the hub until the bead is completely off the rim.
5. Remove the other bead, starting at the valve.
To remove the valve stem
Figure 3.10.6 Second bead is
under the first to create slack
1. Remove the tubeless valve nut (Figure 3.10.1).
2. Thread the presta nut into the valve stem, and push the
stem out of the rim.
To install a tire and inner tube
With an inner tube, either a conventional or tubeless tire can
be used.
1. Make sure the rim strip is centered in the rim well and fully
covers all spoke holes.
2. Install the tire and tube in the normal manner.
To change to a tubeless tire
1. Remove the tire and inner tube.
2. Make sure the rim strip is centered in the rim
well and fully covers all spoke holes.
3. Follow the instructions To install a valve stem.
4. Follow the instructions To install a tubeless
tire and To inflate a tubeless tire.
To remove the rim strip
If the rim strip is to be used again, be careful
not to mar, tear, or stretch the valve hole.
1. Follow the instructions To remove a tubeless
tire and To remove the valve stem.
Figure 3.10.7 Lifting the rim
2. Insert a round-bladed screwdriver (or similar
strip
tool) through the valve hole in the rim strip, and
between the rim and rim strip (Figure 3.10.7).
3. Lift the rim strip with the screwdriver, and place a tire lever
underneath the rim strip.
CHAPTER THREE
Inspection, Adjustment & Lubrication
77
Rim strip direction
4. With the tire lever, lift and roll the rim strip
over the opposite rim hook (Figure 3.10.8).
5. Continue to roll the rim strip up and out of the
rim as you work your way fully around the rim.
To install the rim strip
Tire lever
Figure 3.10.8 Rolling the rim
strip
There are two styles of tubeless rim strips; one
for symmetric rims, and one for asymmetric rims
where the spoke bed is not centered in the rim.
Make sure you are installing the correct type of
strip for your rim, and that if you are installing
an asymmetric rim strip, that you have correctly
oriented it with the rim.
Make sure the rim strip is in good condition, with
no tears, holes, or deformed areas near the valve
hole or along its edges.
1. Align the valve hole in the rim with the valve
hole in the and rim strip.
2. Place the tubeless valve stem through the rim
strip valve hole, and then the rim.
Note: the ‘U’ shape of the rim strip should face the same
direction as the ‘U’ shape of the rim well (Figure 3.10.9).
Figure 3.10.9 Mating the rim
strip to the rim
78
3. Work the rim strip into the rim, moving away
from the valve stem in both directions until
six to ten inches (15 to 25cm) rim strip remain
outside the rim.
4. With your fingers, lift and slightly stretch the
rim strip so that it can be laid flat in the rim
well.
5. Follow the appropriate installation procedures to
install a tire.
Tubeless-compatible Wheel System
SUSPENSION SYSTEMS: FORKS
A suspension fork, like a shock absorber, allows
the front wheel to move over bumps with less
vertical motion transmitted to the bike or rider.
Suspension forks require regular lubrication to
work smoothly and to provide long seal life. Read
the Suspension Fork Owner's Manual you received
with your bike. If you did not receive a fork manual,
get one from your dealer, contact us and we’ll send
you one, or download one from an internet site:
www.rockshox.com
www.answerproducts.com (for Manitou forks)
www.marzocchi.com
The following information is only meant to
supplement the fork manufacturer’s manual.
Preload adjusters
Tire
clearance
Figure 3.11.1 Suspension fork tire
clearance
Inspection
Before every ride, ensure that the suspension
fork is operating properly. Do not ride with less
than the minimum clearances between the top of
the tire and the bottom of the fork crown (Figure
3.11.1), listed in the Suspension Fork Owner’s
Manual supplied with your suspension fork.
Damping
adjuster
Adjustment
The softness of the suspension fork spring,
Figure 3.11.2 Damping adjuster
also called the preload, may be adjustable.
Damping, the control of the speed of the spring, may also
be adjustable (Figure 3.11.2). Follow the instructions in the
Suspension Fork Owner’s Manual supplied with your suspension fork.
Changing your suspension will affect handling and braking
characteristics. After making a change, carefully test the bike in a
low traffic area until you are familiar with its performance.
Lubrication
Follow the Lubrication and Maintenance instructions in the
Suspension Fork Owner’s Manual supplied with your suspension fork.
WARNING
An improperly adjusted or tightened suspension fork can
cause you to lose control and fall. Make sure the suspension
bolts are tightened properly, and the minimum tire clearance
is correct, before riding the bike.
CHAPTER THREE
Inspection, Adjustment & Lubrication
79
SUSPENSION SYSTEMS: REAR SHOCKS
Rear suspension allows the rear wheel to move over bumps
with less vertical motion transmitted to the bike or rider. If
your bicycle is equipped with rear suspension, ensure that it
is operating properly before every ride. Read the Rear Shock
Owner's Manual you received with your bike. If you did not
receive a shock manual, get one from your dealer, contact us and
we’ll send you one, or download one from an internet site:
www.rockshox.com
www.foxshocks.com
The following information is only meant to supplement the
shock manufacturer’s manual.
Read the general information in Suspension pointers- all
systems as well as the specific information for your type of rear
suspension, covered on the following pages.
Rear suspension pointers- all systems
To get the best performance from your rear suspension
system, maintain its parts well
• Mainframe
• Swingarm
• Bearings
• Attachment hardware
• Rear shock
To work properly, all attachment hardware must be correctly
tightened, and the rear shock must be adjusted to your weight,
your riding style, and the terrain you are riding on.
Keep your suspension components clean. Dirt, mud, and
other contaminants can work into the suspension components,
causing premature wear or excess friction. To clean your
suspension system, use a soft cloth, a brush with soft bristles,
and a solution of soapy water. Rinse with clean water. Do not
use solvents or chemical cleaners, as they can remove the
lubrication from the bearings or rear shock.
Changing your suspension settings will affect handling and
braking characteristics. After making a change, carefully test
the bike in a low traffic area until you are familiar with its
performance.
Lubrication- all systems
No lubrication is required for the shock or the pivot of your
Trek full suspension bike. Avoid all lubricants as they may
damage the cartridge or composite bearings. For best results
and long life, simply wash the shock and pivot area with a
solution of soap and water, or just water.
80
Suspension Systems
Fuel
This system connects the swingarm to the
mainframe with a short rocker linkage (Figure 3.12.1).
Linkage bolts
Air
valve
Inspection
After every 10 hours of use inspect the
shock mounting bolts and the pivot bolts for
tightness. Remove the nut from the bolt or axle,
clean the threads thoroughly, and apply a threadlocking compound (Loctite 242 is excellent).
Tighten the bolts to these torques:
Rocker
bolts
Shock
mounts
Pivot
• Shock mounting bolts 133-164 lb•in (15.0-18.5 Nm).
• Pivot axle bolts
95-115 lb•in (10.7-13.0 Nm).
• Rocker bridge bolts
50-75 lb•in (5.7-8.5 Nm).
Figure 3.12.1 Fuel suspension
parts
Once a month check for bearing wear. Place one hand on
top of the rear tire, and grasp the seatpost with the other. Try
to move the rear wheel from side to side, and the seatpost up
and down. If you feel any looseness, take the bike to your Trek
dealer for service.
Suspension adjustment
LBS
100
110
120
130
140
150
160
170
PSI
67
74
81
87
94
101
107
114
CHAPTER THREE
KG ATM
45 4.6
50 5.1
55 5.5
60 6.0
65 6.6
70 7.3
75 7.8
80 8.2
LBS
180
190
200
210
220
230
240
PSI
121
127
134
141
147
154
161
pre
ssu
re
Air
yw
eig
ht
Bo
d
Bo
dy
we
igh
t
Air
pre
ssu
re
pre
ssu
re
Air
yw
eig
ht
Bo
d
re
pre
ssu
Air
Bo
d
yw
eig
ht
Your shock owner's manual tells you how to adjust the rear
shock for most bike designs. This information makes tuning
suggestions specifically for the Fuel.
For an all-round ride, set the forks for about 15% sag
(12mm), and the rear shock at about 25% sag (9mm) sag. If
your riding is slower or more technical, you may want slightly
more sag. If you ride really fast, or on smoother terrain, you
may like less. Find the correct pressures for the starting sag
in the chart below, then try increments of 5 to 10PSI (0.25
to 0.5ATM). If the shock has damping adjustment, set it at 2
clicks in from full fast.
KG ATM
85 8.7
90
9.1
95 9.7
100 10.2
105 10.6
110
11.1
Inspection, Adjustment & Lubrication
81
Liquid
This suspension system connects the swingarm to the
mainframe with a long rocker linkage (Figure 3.12.2).
Air
valve
Inspection
Linkage
bolts
After every 10 hours of use inspect the shock
mounting bolts and the pivot bolts for tightness.
Remove the nut from the bolt or axle, clean the
threads thoroughly, and apply a thread-locking
compound (Loctite 242 is excellent). Tighten the
bolts to these torques:
Shock
mount
Pivot
• Shock mounting bolts: 125-200 lb•in (14.1-22.6 Nm)
• Pivot bolts: 125-200 lb•in (14.1-22.6 Nm)
• Linkage bolts: 125-200 lb•in (14.1-22.6 Nm).
Figure 3.12.2 Liquid suspension parts
Once a month check for bearing wear. Place one hand on
top of the rear tire, and grasp the seatpost with the other. Try
to move the rear wheel from side to side, and the seatpost up
and down. If you feel any looseness, take the bike to your Trek
dealer for service.
Adjustment
82
Suspension Systems
PSI
170
180
190
200
210
220
230
pre
ssu
re
Air
yw
eig
ht
LBS
170
180
190
200
210
220
230
Bo
d
Bo
dy
we
igh
t
Air
pre
ssu
re
KG
45
50
55
60
65
70
75
pre
ssu
re
ATM
6.8
7.6
8.3
9.1
9.9
10.6
11.4
yw
eig
ht
Bo
d
re
pre
ssu
PSI
100
110
120
130
140
150
160
Air
LBS
100
110
120
130
140
150
160
Air
Bo
d
yw
eig
ht
Your shock owner's manual tells you how to adjust the rear
shock for most bike designs. This information makes tuning
suggestions specifically for the Liquid.
For an all-round ride, set the forks for about 15% sag
(19mm), and the rear shock at about 1/8 inch (12mm) sag. If
your riding is slower or more technical, you may want slightly
more sag. If you ride really fast, or on smoother terrain, you
may like less. Find the correct pressures for the starting sag
in the chart below, then try increments of 5 to 10PSI (0.25
to 0.5ATM). If the shock has damping adjustment, set it at 2
clicks in from full fast.
KG ATM
80 12.1
85 12.9
90 13.7
95 14.4
100 15.2
105 15.9
110 16.7
Y
On the Y bike, the swingarm is attached directly
to the shock and main frame, and the crankset
is on the swingarm.
Preload
adjusting
nut
Inspection
After every 10 hours of use inspect the
shock mounting bolts and the pivot bolts for
tightness. Remove the nut from the bolt or axle,
clean the threads thoroughly, and apply a threadlocking compound (Loctite 242 is excellent).
Tighten the bolts to these torques:
• Shock mounting bolts: 61-75 lb•in (6.9-8.5 Nm)
• Pivot bolts: 100-110 lb•in (11.3-12.4 Nm).
• Linkage attachment bolts: 15-20 lb•in (1.7-2.2 Nm).
Figure 3.12.3 Coil/over rear
shock
Once a month check for bearing wear. Place one hand on
top of the rear tire, and grasp the seatpost with the other. Try
to move the rear wheel from side to side, and the seatpost up
and down. If you feel any looseness, take the bike to your Trek
dealer for service.
Adjustment
To increase the preload (decrease the sag) on coil/over
shocks (Figure 3.12.3), rotate the adjustment nut to compress
the spring. To make the suspension softer, rotate the nut to
lengthen the spring. If the spring on your shock does not
offer the desired range of adjustment, replacement springs are
available with different spring rates. See your Trek dealer.
When adjusting the seat height on your Trek Y bike, do
not lower the bottom of the seat post to any position closer
than 1.5" (38 mm) to the top of the swingarm. Allowing the
swingarm to contact the seat post could damage your bicycle.
CHAPTER THREE
Inspection, Adjustment & Lubrication
83
Diesel
With this suspension design, the swingarm is attached to the
mainframe and a long rocker linkage
Inspection
After every 10 hours of use inspect the shock mounting
bolts and the pivot bolts for tightness. Remove the nut from the
bolt or axle, clean the threads thoroughly, and apply a threadlocking compound (Loctite 242 is excellent). Tighten the bolts
to these torques:
• Shock mounting bolts: 125-200 lb•in (14.1-22.6 Nm)
• Pivot bolts: 125-200 lb•in (14.1-22.6 Nm)
• Linkage bolts: 125-200 lb•in (14.1-22.6 Nm).
Once a month check for bearing wear. Place one hand on
top of the rear tire, and grasp the seatpost with the other. Try
to move the rear wheel from side to side, and the seatpost up
and down. If you feel any looseness, take the bike to your Trek
dealer for service.
Adjustment
To get the most from your new Diesel, the suspension must
be set up correctly. As a starting point we recommend setting
the forks for about 15% sag (20-30mm), and the rear shock
at about 25% sag (17mm, measured on the shock). This will
provide a good, all-round ride. If your riding is slower or more
technical, you may want a softer setup. If you ride really fast, or
on smoother terrain, you may like the Diesel set up a bit firmer.
Set the damping adjustment according to your anticipated
speed, with more damping as the speed increases.
84
Suspension Systems
CARE OF YOUR FRAME OR FORK
Trek bicycle frames are constructed from a variety of high
performance materials. For safe operation, and long life, take
care of your bike frame by following these instructions.
Inspection
Before every ride carefully inspect your frameset (frame
and fork) for signs of fatigue. Scratches, cracks, dents,
deformation, or discoloration are signs of stress-caused fatigue.
If any part shows signs of damage or fatigue, replace the part
before riding the bicycle.
Frame information- all frames
Trek framesets use three sizes of seat lugs designed to accept
seat posts with 27.12 to 27.20 mm, 29.12 to 29.2 mm, or 31.45
to 31.60 mm outer diameter. According to the specifications for
your frame, the seatpost should be measured for conformity to
this tolerance prior to installation.
For aluminum or steel frames, lubricate the seatpost to
prevent seizing in the frame. Do not lubricate a seatpost in an
OCLV frame; inside the seat lug of OCLV carbon frames, a thin
layer of fiberglass acts as an insulator to prevent corrosion.
The aluminum or OCLV carbon fiber composite parts of your
bicycle, both frame tubes and parts like rockers or dropouts,
are not as ductile as steel. Attempting to make adjustments to
an aluminum or OCLV part by bending or twisting it poses a
risk of breaking it. Readjustment of aluminum or OCLV frame
alignment is not recommended.
Tolerances for press fits and thread fits are critical. Pressing
a part which is too large, or misaligned, may break the frame
or part. Over-torquing a threaded fastener may ruin the
threads or break the part. Be sure bottom bracket and rear
derailleur threads are clean and well greased before insertion.
Start threads by hand, not with a wrench. Torque specifications
for bottom bracket cup threads is 430-610 lb•in (48.6-68.9
Nm). Torque specifications for rear derailleur threads is 70-85
WARNING
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. An
improperly modified frame, fork, or component can cause you
to lose control and fall.
CHAPTER THREE
Inspection, Adjustment & Lubrication
85
Chainstay
guard
24 mm
Figure 3.13.1 Chainstay guard
Chainkeeper
Figure 3.13.2 Chainkeeper
lb•in (7.9-9.6 Nm).
When cleaning frame parts, do not use solvents
or harsh chemicals. Remove road film with a soft
rag and a mild detergent and water solution. Use
of industrial solvents for cleaning or paint removal
may damage the paint.
Removing paint from any frameset requires
special techniques and great care. Harsh abrasives
will remove frame material, possibly weakening the
bicycle. See your Trek dealer for more information.
Excessive heat, such as that used in powder
coating, or any open flame, may damage the
adhesive which joins the frame parts. Do not
exceed 180º F. (82º C.) exposure to your frame.
Modifying the frame in any way will void the
warranty and may be unsafe.
Changing the forks on your bicycle could alter
the steering of the bicycle, or create undesirable
stress loads on the frame. Suspension forks may
add stress to a bike frame. Never add a suspension fork to a road bike, or change style and/or
length of forks. If you must replace the fork on any
bike, check with your dealer or the Trek Bicycles
technical service department to ensure that the
new forks are compatible with the frame.
Special OCLV road frame and fork requirements
Trek OCLV road frames must always be fitted with a chainstay
guard (Figure 3.13.1) and a chainkeeper (Figure 3.13.2) to
protect against damage in case of chainsuck or overshifting
past the inner chainring. Make sure the chainkeeper and
chainstay guard pieces are installed correctly and maintained
in good condition at all times. Should they become dislodged or
damaged, see your Trek dealer to have new ones installed right
away.
Bontrager carbon composite forks are not compatible with
any mechanism which clamps around the fork blade, with the
exception of bicycle computer sensors. Do not use mechanical
fasteners to attach any other parts to this fork. If you are
unsure of what items can be attached to this fork, consult your
Bontrager dealer.
Special frame features
Some Trek bikes feature an Accessory Port (Figure 3.13.3), an
86
Care of Your Frame or Fork
unique attachment point which allows you to use
custom accessories. Among these accessories are
trailers, racks, and more. See your Trek dealer
for details.
Universal
attachment
Frame Repair
Most types of frame damage may be repaired at
the Trek factory. You must send your frame back
to Trek through an authorized Trek dealer.
Figure 3.13.3 Accessory port
CHAPTER THREE
Inspection, Adjustment & Lubrication
87
FOLDING BIKE INSTRUCTIONS
Some models of Trek bikes have a large
hinge in the middle (Figure 3.14.1) that
allows folding of the bike for storage or
transportation. These instructions explain
how to fold and unfold a folding bike.
Hinge and clasp
Avoid pinching in folding mechanisms
Figure 3.14.1 Folding bicycle in riding mode
When operating folding mechanisms,
keep fingers and other body parts out
from items which are folded. Also keep
cables and housing from being pinched,
as this can damage the cables.
CAUTION
Pinching yourself between folding parts can cause serious injury.
Keep fingers out of folding mechanisms.
Inspection
Upper
quickrelease
Lower
quickrelease
Figure 3.14.2 Folding stem upper
and lower quick-releases
Before every ride, make sure the frame latch,
lower stem quick-release, and other quick-release
mechanisms are properly adjusted and closed.
Check that the frame latch is closed and the frame
has become a rigid structure by attempting to
move the center of the frame laterally, from side to
side. If there is any motion, take your bike to your
dealer for service.
Folding and unfolding the bike
Folding is done without tools, and takes only a
minute. Before starting, make sure you are familiar
with the proper operation of a quick-release. Pages
6 and 7 explain this procedure for operating the
quick-release for wheels, a similar mechanism.
To lower the saddle
Lever lock
(unlocked)
1. Open the seatpost quick-release and lower the
saddle to its lowest position.
2. Close the quick-release to hold the seatpost in
position (the seat makes an excellent handle).
To fold the pedals
Figure 3.14.3 Opening the lower
quick-release
88
Folding bike
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 (3.14.3)
away from the lower quickrelease.
3. While holding the handlebar
to prevent pinching, hold the
cables out of the way, and
open the lower quick-release
(Figure 3.14.3).
4. Fold the handlebar assembly
to its down position (Figure
3.14.4).
Figure 3.14.4 Pedals folded, saddle lowered, and handlebar
stem folded.
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 latch opens.
3. While avoiding pinching yourself or cables, fold the bike in
half (Figure 3.14.5).
To unfold the frame
1. Reverse the steps of the folding procedure.
Adjustment
After unfolding the bike, if the frame or the stem is not rigid,
the frame latch or lower stem quickrelease may need adjustment. If there
is any motion at a latched and locked
frame hinge or stem, take your bike to
your dealer for service.
WARNING
Riding a folding bike with
movement at the lower stem quickrelease 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 Trek dealer for service.
Figure 3.14.5 Folded bike
CHAPTER THREE
Inspection, Adjustment & Lubrication
89
TREKKING ACCESSORIES-
Lights, rack, fenders, and bell
Introduction
ON
To enhance their capacity for commuting,
trekking bicycles are equipped with a selection
of accessories which may include a generator
light set (Figure 3.15.1) for improved visibility,
fenders to keep the bike and rider drier, a rack
to carry belongings, or a bell to sound warnings
or greetings. All accessories must be properly
maintained for best service.
Figure 3.15.1 Generator headlight
Inspection
Once a month check to ensure the following nuts
and bolts are tight:
Fender adjusting nuts: 30-40 lb•in (3.5-4.5 Nm).
Fender and rack bolts: 50-60 lb•in (5.7-6.8 Nm).
If your bike is equipped with other accessories they should
also be inspected monthly.
Lights
The lights on your Trekking bike have been designed and
installed on your bike for extra safety in conditions with poor
visibility resulting from either fog or dark. These lights are
powered by a generator so no batteries are required. However,
for your lights to provide light the generator must be properly
installed, adjusted, and engaged in the ON position, with your
bicycle rolling with enough speed to illuminate the light bulbs,
usually about 3-4 miles per hour.
WARNING
When the bike is not moving, the generator will not provide
the power needed to illuminate the light bulbs of the lights,
causing you to be less visible to other traffic. Use a back-up
battery light source, or only stop in brightly lit areas where
you are out of the traffic flow.
To turn on your generator and thus your lights, press down
on the generator body as shown in Figure 92. This will engage
the generator and the lights will come on as soon as your bike
is rolling. You should visually check that both the headlight
and taillight are illuminated as you start to ride. To turn off
your lights, rotate the generator body away from its contact
with the tire until you hear a click. If you have done this
correctly, the generator should stay in the OFF position.
90
Trekking Accessories
Check your lights. For best results, the lights should be
carefully aimed to provide the best blend of brightness and
distance for your style of riding, as well as the best location in
front of your bike (generally centered directly in front of the
bike). The lenses of the lights should be kept clean. Remember
that your field of vision may be diminished when riding at
night, even with the headlight on. You should adapt your riding
speed for safety. Also remember that although you have your
lights on, you will be less visible than during daytime riding.
Always ride defensively!
In addition to aiming the lights on your bike and keeping
the lenses clean for maximum illumination, you may have to
replace the light bulbs occasionally. It is recommended that you
do this every six months because no warning will precede the
burning out of a light bulb. By replacing the bulbs periodically
you will reduce the risk of a bulb burning out during use of the
light which would leave you without a functioning light.
The wiring on your trekking bike lighting system may be
partially enclosed inside the frameset to protect the wires.
Avoid pulling, tearing, or cutting these wires, as damaging the
wires will cause the light to cease to function.
Installation
The correct bulbs can be purchased from your
Trek dealer. The bulb has its volts and wattage listed
on its base. The most commonly used bulbs are:
• Headlight- 6V 2.4w
• Taillight- 6V 0.6w
To install a light bulb
1. Locate the lens set-screw on the back of either
Figure 3.15.2 Replacing the
the taillight or head light (Figure 3.15.2).
2. Remove the screw with a Phillips screwdriver. light bulb
3. Rotate the lens 1/4 turn clockwise and lift the lens assembly
off the bulb mount.
You may then unscrew the bulb, being careful not to crush the glass of
the bulb.
4. Being careful not to dislodge the wire in the base of the
bulb mount, 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 with a Phillips screwdriver.
Check to make sure the new bulb works. If it does not, check
the wiring for correct placement. If the light still does not
work, verify that the new bulb is not damaged.
CHAPTER THREE
Inspection, Adjustment & Lubrication
91
TREK BICYCLE CORPORATION
LIMITED WARRANTY
Trek Bicycle Corporation warrants each new Trek bicycle
frame and rigid fork against defects in workmanship and
materials for the lifetime of the original owner. Trek Bicycle
Corporation likewise warrants all original parts, excluding
suspension forks and rear shock absorbers, for a period of
one year from the date of purchase. Suspension forks and rear
shock absorbers shall be covered by the stated warranty of
their original manufacturers. Paint and decals are warranted
for one year. This warranty is expressly limited to the repair or
replacement of a defective frame, fork, or defective part and is
the sole remedy of the warranty. This warranty applies only to
the original owner and is not transferable.
Claims under this warranty must be made through an
authorized Trek dealer. Proof of purchase is required. A
warranty registration card must be completed and received
by Trek Bicycle Corporation before a warranty claim may be
processed.
The warranty does not cover normal wear and tear, improper
assembly or follow-up maintenance, or installation of parts
or accessories not originally intended or compatible with the
bicycle as sold.
The warranty does not apply to damage or failure due
to accident, misuse, abuse, or neglect. Modification of the
frame or components shall void this warranty.
Trek Bicycle Corporation shall not be 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. Labor charges for parts
changeovers are not covered by the warranty.
This warranty gives the consumer specific legal rights, and
those rights may vary from place to place. This warranty
does not effect the statutory rights of the consumer.
92
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