Important: Keep for Future reference

About this Owner's Manual Your new This manual explains how to ride your Assembly and the first adjustment new bike safely, and how to maintain of your bicycle take special tools and your bicycle to keep it operating safely. skills, so this should only be done by Every person, prior to riding this an authorized dealer. bicycle, should read at least Chapter 1 of this manual. Parents should explain Meaning of special symbols and Chapter 1 to a child, or anyone else, lettering who might not otherwise understand this information. Warning Even if you have ridden a bicycle In this manual, the WARNING sign for years, it is important for EVERY indicates a potentially hazardous person to read Chapter 1 before riding situation which, if not avoided, could this bicycle! result in death or serious injury. This manual includes a CD (compact disc) with more comprehensive information. This CD can be viewed by Caution inserting it into your home computer. In this manual, the CAUTION sign If you do not have a computer, take indicates a potentially hazardous the CD to your school, work, or public situation or unsafe practice which, if library and view it there. In addition not avoided, may result in minor or to reading the extensive information moderate injury. on the CD, you should register your Bold letters indicate important text, bike on-line; the CD has links to the or points to note. registration site. If your CD does not Italicized letters indicate a reference work, go to the web address on the to another section within the manual. cover to access the information on the Web. There are many models, with a variety of equipment, so this manual may contain some information that does not apply to your bike. Some illustrations may vary from the actual . If you have any questions after reading the information in this manual, the CD, or web site, consult your dealer. If you have a question or problem that your dealer can’t handle, Register your bicycle on-line contact us: There are two easy ways to register your new bicycle: Attn Customer Service • Click the link when viewing the CD 801 W. Madison Street supplied with this manual Waterloo, Wisconsin 53594 • Go to the web address on the cover 920.478.4678 of this manual and follow the links

My bicycle model:

My serial number: Lock key #

My dealer:

My dealer's phone: Bicycle type and use classification

Road “Drop” or designed for handlebars, caliper small kids to be ridden brakes, and 700c or 650c only on sidewalks, and wheels with 20-25c tires. always under parental Condition 1 supervision. Touring Similar to a Mountain Wide tires, road bike, except with “flat” handlebars, and direct-pull brakes and direct pull or disc wider tires. Designed for brakes. For riding on self-contained touring. rougher surfaces. Front Condition 1 suspension, or light- weight full suspension Condition 3; Cross Similar to a road NOT Condition 4 bike, except wider tires and cantilever brakes. Freeride or "hucking" With a skilled rider Wide tires, “riser” in mind, designed for handlebars, double- riding off-pavement. crown, triple-clamp Condition 2 suspension forks, and disc brakes (only). Hybrid “Flat” handlebars For aggressive riding like a , but on rougher surfaces. 700c wheels like a road Compared to a standard mountain bike. Condition 2 bike, a freeride bike has a heavy-duty and reinforced frame. Condition 4 City bike A hybrid BMX BMX-style bikes equipped with accesso- with riser handlebar ries like fenders, rack. and 20-inch wheels.. Condition 1 Condition 3 Jumping BMX-style bikes with heavy-duty, Folding Hybrid features, reinforced frame and but with a hinged frame fork, and 48- wheels. Models and . Condition 1 TR30 and Vert 2 only. Condition 4 Conditions for Use Riding a bicycle in a manner other Tandem Built for two, than its intended use can cause the with either “drop” , or part of the bicycle, to fail. handlebars or “flat” Read the safety information in Chapter handlebars as on a 1 for further details. hybrid. Condition 1 Condition 1- riding on a paved surface where the tires do not lose Cruiser Wide, sweeping ground contact handlebars, wide saddle, Condition 2- includes Condition 1 and balloon tires. plus smooth gravel roads and smooth Condition 1 improved trails with moderate grades where the tires do not lose ground Juvenile Smaller bikes contact designed for kids but Condition 3- includes Conditions also fitting smaller 1 and 2 plus rough trails, rough adults. Includes BMX unpaved roads, and rough technical with coaster brake. areas with unimproved trails, where Condition 1 momentary loss of tire contact with the ground may occur. NOT jumping. Condition 4- Any riding in excess of Condition 3  Table of Contents Before a first ride

Chapter 1: Guide to Safe On-and-Off Make sure the bicycle fits you Road Operation properly. Make sure the bicycle fits you properly.. ii Your dealer should Know how the bicycle performs...... ii fit you with the Check the bike before every ride...... 1-3 proper size of Check the wheels...... 1 bicycle. There Check the tire inflation...... 1 should be at least 1 inch Check the brakes...... 2 one inch (25mm) clearance between Check the handlebar and stem...... 2-3 the top tube and Check the seat and ...... 3 the rider when Check the suspension adjustments...... 3 standing over the Check the lights and reflectors...... 3 bicycle (Figure Figure 1 Minimum stand- over height: Rules for safe riding...... 3 1). For mountain 1" (25mm) for most Riding instructions...... 4-6 bikes, two to bicycles 2-3" (50-75mm) for three inches (50- mountain bicycles Chapter 2: Maintenance 75mm) clearance is Some maintenance and repair should recommended. only be performed by your dealer, as Some models have maximum weight indicated in this manual. limits: Maintenance schedule...... 7 Tricycle 80lbs. (36kg.) Recommended tools for proper bicycle The seat and handlebars may be maintenance...... 7 adjusted to offer the best comfort and Chapter 3: Adjustment performance. Before making these adjustments, refer to Chapter 2. A word about specifications...... 8 Handlebars...... 8 Know how the bicycle performs. Stem...... 8-9 The features of your bicycle, if Bar-ends...... 9 misused, may cause you to lose Saddle...... 9-11 control of the bike. Before riding fast Pedals...... 11 or in more difficult conditions, learn ...... 11 the function and performance of all the mechanisms of your bike by riding Crank arms...... 11 at slower speeds in a flat, empty ...... 11 parking lot. Chain...... 11 If you want your bicycle to perform Cables...... 11 differently, or if you have special needs Shifters...... 11 that require different parts for the safe Front ...... 11-12 operation of your bike, consult your Rear derailleur...... 12-13 dealer. As an example, the stopping Nexus 4, 7, or 8 speed systems...... 13 power on bikes varies according to the 3 speed systems...... 13 intended use of the bike. If you would like your bike to have more, or less, SRAM DualDrive system...... 13 stopping power, consult your dealer Brake levers...... 13-14 about brake adjustments or other Brakes...... 14-16 brake options for your bicycle. Wheels...... 16-18 Suspension components...... 18 Accessories...... 18 WARNING Mis-use of the braking system, Folding bike...... 18-19 including over-use of the front Chapter 4: Lubrication brake, can cause you to lose control ...... 19-20 and fall. Avoid improper braking by understanding and practicing Limited warranty proper application of your brakes as ...... 21 explained in this manual. ii When riding to your dealer for service. Never ride slowly, do not a bike with a damaged part; have it pedal if the replaced. This is not a comprehensive handlebar is maintenance program. turned. It may be possible, at very  Check the wheels. slow speeds when Check that the wheels are the handlebar is straight. Spin each wheel and watch turned, for your the rim as it passes through the brake foot or toe-clips to pads or the frame. If the rim wobbles, contact the front Figure 2- Toe-clip overlap up and down or from side to side, wheel or repair the wheel. (Figure 2). At normal riding speeds, Check that the wheels are properly the handlebar does not turn enough attached. Bicycle for this to occur. wheels are attached by several systems: WARNING threaded axle nuts, a quick- Contact between your foot or toe- release where a clip and the front wheel or fender lever-actuated can cause you to lose control and wheel retention fall. Avoid pedaling when turning at mechanism (Figure slow speed. 3) allows the wheel to be installed and In very rare cases, some riders may Figure 3- Wheel quick- removed without release experience a “shimmy” or “harmonic tools, or a through- oscillation” or “frame vibration” at axle where the axle certain speeds. If you are experiencing is threaded through a shimmy, slow down immediately. the ends of the Take your bicycle directly to a dealer frame or fork. For for inspection and repair. information about adjustment and WARNING closure of the wheel attachment devices A shimmy, or steering wobble, can on your bicycle, see cause you to lose control and fall. If Chapter 3. you experience a shimmy, slow down Figure 4- Test for loose- immediately. Take your bicycle to Test for proper ness wheel attachment. your dealer for inspection and repair. Pick up the bike, and sharply hit the top of the tire (Figure 4). The wheel must not come off, be loose, or move Check the bike from side to side. Further tests are before every ride provided in Chapter 3. Before every ride, inspect the bike with the following check list. If any WARNING part of the bicycle fails the inspection, A wheel attachment device that is repair the bicycle by following the not properly adjusted and closed information provided by us or take it may allow the wheel to be loose or come off unexpectedly, causing you to lose control and fall. Make sure Caution the wheels are properly attached A bicycle that does not work properly before riding the bike. can cause you to lose control and fall. Inspect the entire bicycle thoroughly  Check the tire inflation. before every ride, and do not ride it Inflate the tires to the air pressure until any problem has been corrected. recommended on the tire sidewalls.   Check the brakes brake pads should be 0.25 to 0.75mm Follow the inspection instructions away from the disc when the brakes for the type of brake on your bike: are not applied. If the pads are too close, the brake is too tight, or mis- aligned. WARNING Internal drum or roller brakes- a Never ride a bike if you are not hand lever operates a brake inside the certain the brakes are working hub. If it takes more than about 5/8 properly, or you if suspect a inch (15mm) of brake lever movement problem with the brake cables or to stop the bike, the brake is too loose. hydraulic hose. Malfunctioning If it takes less than 7mm of lever brakes can cause you to lose movement to stop the bike, the brakes control and fall. Inspect the brakes are too tight. thoroughly before every ride. If your brakes are not working properly, re- Caution adjust them or take the bike to your Internal hub brakes get very hot dealer for service. during use and could burn skin. Avoid touching the hub or cooling fins Hand-rim brakes- a brake lever, when hot. connected to the brake by a cable, causes the brake pads to squeeze the Coaster brakes- the brake is rim. When the brakes are not applied, engaged by pedaling backwards. When the brake pads should be 1 to 2mm pedaling backwards, the brake should from the rim. Squeeze each brake lever engage with less toward the handlebar to make sure than 60 degrees the brake moves freely and stops the rotation (1/6 bike. If the brake lever can be pulled to revolution). the handlebar, the brake is too loose. The chain If the brake pads are too close to the actuates the brake, rim, the brake is too tight. Brake pads so make sure the should be aligned with the rim surface chain cannot come (Figure 5). off. There should be between 1/4 and 1/2 Brake pad aligned Pad and rim Direction of rim rotation inches (6-12mm) with rim surface should be parallel total vertical Figure 6- Checking chain movement of the tension chain (Figure 6). 0.5-1.0mm toe-in  Check the handlebar and stem. Figure 5- Brake pad alignment Make sure the stem is in alignment with the front wheel. Test the stem Disc brakes- a hand lever connected connection to the fork by attempting to the brake squeezes a disc mounted to turn the handlebars from side on the wheel hub. to side with the front wheel locked Squeeze each brake lever toward between your the handlebar to make sure the brake knees (Figure 7). moves freely and stops the bike. If Test the security the brake lever can be pulled to the of the handlebars handlebar, the brake is too loose. The by attempting to rotate them in the Caution stem. Make sure Disc brakes and discs get very hot that no cables during use and could burn skin. Also, are stretched or the disc edges may be sharp and could pinched by rotating the handlebars. cut skin. Avoid touching the disc or Figure 7- Function test- Check that ing the handlebar and disc brake when hot, or when rotating. stem  the handlebar plugs are properly • Ride defensively; expect the inserted into both ends of the unexpected. A cyclist is hard to see, handlebars, and bar-ends. and many drivers simply are not Carefully inspect your handlebar trained to recognize the rights and and stem for signs of fatigue: special considerations of a bicycle scratches, cracks, dents, deforma- rider. tion, or discoloration. Watch for cars, pedestrians, and Check the seat and seatpost.  other obstacles. Make sure the seat is secure by attempting to turn the seat and Watch for, and avoid, potholes, drain seatpost in the frame, and attempt grates, soft or low shoulders, and to move the front of the seat up and other deviations which could impact down. It should not move or be loose. your wheels or cause them to slip. When crossing railroad tracks or  Check the suspension adjust- drain grates, do so ments. carefully at a 90° Make sure your suspension angle (Figure 8). 90 components are adjusted to your If you are not sure riding style, and that no suspension of riding surface component can "bottom-out", or be so conditions, walk compressed that there is no further your bike. 45 suspension travel or movement If a car suddenly remaining. enters your lane, or  someone unexpect-  Check the lights and reflectors. edly opens the door Figure 8- Angle for Make sure the lights are functioning of a parked car, you crossing tracks correctly and that any batteries are could be involved charged. If the lights use a dynamo, in a serious accident. Mount a horn or make sure it is mounted correctly bell on your bicycle, and use it to alert and all attachment hardware is tight. others of your presence. Make sure reflectors are clean and in Wear a helmet and proper position. clothes. Wear a helmet that Rules for safe meets CPSC or riding CE safety testing standards (Figure Know and observe local bicycle 9); it may help prevent injury. riding laws. Helmets should Most state and local areas have be removed when specific laws for cyclists, and you not riding the should follow them. Local cycling bicycle because clubs or your state’s Department of if the helmet is Figure 9- Wear a bicycle Transportation (or equivalent) should caught, stuck on, helmet be able to supply this information to or stuck between you. The requirements for items like objects, the wearer could choke. lights and reflectors change between Wear protective clothing including areas, so check ahead. helmet, eye protection, and gloves. These are a few of the more Avoid loose-fitting pants that could get important rules of riding: caught in the chain. • Use proper . Also wear light, bright, and reflective • Ride single file when riding with clothing, especially at night, to make other cyclists. yourself more visible. • Ride on the correct side of the road; never go against traffic.  Riding instructions

Use your brakes carefully. controls the rear derailleur. Use only Always keep a safe stopping distance one at a time. Shift only between you and other vehicles or when the pedals and chain are moving objects. Adjust stopping distances and forward. When you shift, reduce the braking forces to suit riding conditions. force on the pedals to provide quicker and smoother shifting, to help avoid If your bike has two hand brakes, excessive chain and wear, and to apply both brakes at the same time. help avoid bent chains, , and Over-use, or mis-use, of a front-wheel chainrings. Avoid shifting when going brake, such as using only the front- over bumps; the chain may not shift wheel brake in an emergency, could properly, or may fall off. cause the rear wheel to lift from the ground which could With modern indexed shifting cause you to lose systems, a movement of the shifter control (Figure 10). from one position to the next (or movement of the shifter to the "shift" Bicycles are position) should promptly move the normally manufac- chain from one gear to the next. tured with the left However, bikes equipped STI road brake lever control- shifters and triple chainrings may shift ling the front-wheel better, particularly when shifting from brake. To change so the smallest chainring to the middle, that the right lever if you “hold” the lever for a moment controls the front- Figure 10- Overuse of the before letting go of the shifter. wheel brake, see front-wheel brake Chapter 3. Shifting a bike with internal gearing is best performed when Many models of modern brakes are coasting, stopped, or back pedaling. If very powerful; they are designed to stop you must shift while pedaling, reduce a bike in wet or muddy conditions. If your pressure on the pedals. Excessive you feel your brakes are too powerful for chain tension makes shifting difficult. your riding needs, take your bike to your dealer for adjustment, or replacement of Change your riding to be safe in bad the braking system. weather conditions. No brakes, whatever their design, WARNING work as effectively in wet weather as they do in dry. Even properly aligned, Applying sudden or excessive stopping lubricated, and maintained brakes force with the front-wheel brake may require greater lever pressure and cause the rear wheel to lift off the longer stopping distances in wet ground, or the front wheel to slip out weather. Anticipate the extra distance from under you, which can cause you it will take to stop. to lose control and fall. Apply both Wet weather causes reduced brakes at the same time, and shift traction. Use slower cornering when your weight backwards on the bike traction is reduced, like when riding while braking. over wet leaves, painted crosswalks, or manhole covers. Use good shifting techniques. When wet weather cools to below freezing, traction is reduced even Shifting gears allows you to choose further. In addition, brakes may not the gear combination most comfort- work as well. Adjust your riding speed able for riding conditions, one that accordingly, or use other forms of allows you to maintain a constant rate transportation. of pedaling. Shifting systems are of two types: derailleur (external) and Strong winds can make a bicycle internal. steer or turn unexpectedly. In windy conditions, slow down or use other Shifting a bike with a derailleur- forms of transportation. the left-hand shifter controls the front derailleur and the right-hand shifter When riding in wet weather, a

 dynamo (generator light) may not • Do not ride in an abusive manner; work properly. Avoid riding in wet ride within the Use Classification weather when visibility is reduced. for your type of bicycle (see page i). Bicycles are not indestructible. Be careful when riding in low light As with anything mechanical, every conditions. part of a bicycle has a limited useful Your bicycle is equipped with a full life due to wear, stress, and fatigue. set of reflectors; keep them clean and Fatigue refers to a low-stress force in position. As useful as these reflec- that, when repeated over a large tors are, they do not help you see, nor number of cycles, can cause a do they help you be seen unless light material to fail or break. The length is directed on them. Use a working of the life of a part varies according headlight and tail light when you to its design, materials, use, and ride in poorly lighted or low visibility maintenance. Although lighter conditions. The important thing is to frames or parts may, in some cases, see and be seen. If you do any amount have a longer life than heavier ones, of riding at dusk, at night, or in any it should be expected that light poorly lighted conditions, consult weight, high performance bicycles your dealer to find appropriate and parts require better care and products to aid your vision and make more frequent inspections. you more visible. Regularly inspect your entire bicycle for signs of fatigue stress: • Dents WARNING • Cracks A bicycle rider without proper • Scratches lighting and reflectors may not have good vision, and may not be • Deformation visible to others, which can cause a • Discoloration collision resulting in severe injury Carefully inspect your frame and or death. Use front and rear bicycle components for signs of fatigue before lights and reflectors when riding in and after each ride. Go to the web poor visibility conditions. Failure to address on the cover to find special do so will increase your chances of instructions on how to inspect carbon being involved in an accident in low fiber parts. light conditions. Even if you perform regular inspec- tions, if you exceed the limit of Do not use unsafe riding practices. strength of your bicycle or a given Many cycling accidents could be part, it will fail. avoided by using common sense. Here are a few examples: WARNING • Do not ride ‘no hands’. The following riding practices • Do not ride with loose objects increase your risk of injury: attached to the handlebars, or any • Jumping your bicycle other part of the bicycle. • Performing bicycle stunts • Do not ride while intoxicated, or • Severe off-road riding while using medications which • Downhill riding might make you drowsy. • Any abnormal bike riding Each of these practices increases • Do not ‘ride double’. the stress on every part of your • Use special care when off-road bicycle. Frames or parts under high riding. Ride only on the trails. stress may fatigue prematurely, Avoid rocks, branches, or depres- causing them to fail and increasing sions. When approaching a descent, the risk of injury to the rider. To reduce speed, keep your weight back decrease your risk of injury, avoid and low, and use the rear brake more these riding practices. than the front.  Protect your bike when parking or approved by the manufacturer. As an storing it. example, a child carrier places weight high on the bike, affecting the stability Protect your bike from theft. of the vehicle. Although any of our Purchase and use a lock that is bikes can be fitted with a child carrier, effective against bolt cutters and saws. the rider must use extra caution to Never leave your bike unlocked while compensate for the decreased stability. unattended. If you are unsure whether a part is Register your bicycle with your approved, consult your dealer. local police department. Complete our on-line warranty registration; we will keep the serial number of your bike on WARNING file. Also, keep a record of the serial Never modify your frameset or number in a safe place. parts in any way, including sanding, Park your bike safely in a place drilling, filing, removing redundant where it will be out of the way, and retention devices, installing make sure it cannot fall over. Do not incompatible forks, or by any other lay the bike on its derailleurs, as you method. Improper components may bend the rear derailleur or get or improper assembly can place dirt on the drivetrain. Don’t let the unknown stress on your bike or bike fall down, as this may cut the components. An improperly modified handlebar grips, or tear the seat. frame, fork, or component can cause Incorrect use of bike racks may bend you to lose control and fall. Before your wheels. adding or changing any part of your Store your bike carefully where it bike, consult your dealer. will be protected from rain, snow, sun, etc. when not riding. Rain or snow Keep the bike clean may cause the metal on your bicycle to corrode. Ultraviolet radiation from the If your frame or a component is dirty, clean it with a soft, damp cloth sun may fade the paint, or crack any ® rubber or on the bicycle. and Wrench Force bike cleaner or a Before storing your bike for an similar product. Do not use solvents extended period of time, clean and or harsh chemicals. Use of industrial lubricate it, and polish the frame solvents for cleaning may damage the with Wrench Force® frame polish paint. or a similar frame protectant. Hang Use care when holding the bike the bicycle off the ground with the during transportation or repair tires at approximately half pressure. Do not store the bike near electric Never clamp the bike frame by its motors, as ozone from motors finished or painted surfaces, because destroys rubber and paint. Before this may damage the paint or even riding the bicycle again, be certain it dent, crush, or break the lightweight is in good working order. tubing used in high-performance bicycle frames. When holding the Carry repair items. bicycle for repairs, clamp the seatpost. Carry a pump, spare inner tube, patch When holding the bicycle for transpor- kit, and appropriate tools to keep tation on a motor vehicle, clamp the your bicycle running in the case of a bicycle by the wheels and fork tips. flat tire of other common mechanical problem. If you ride at night, carry Caution spare bulbs or batteries for your Clamping devices used by work lights. stands and car carriers can damage Only install and use approved the finish on a bike or even crush accessories. the tubing. When putting a bike in a repair stand, clamp the seatpost. Not all accessories are compatible or When carrying a bike in a car carrier, safe, so only add accessories that are clamp the wheels and the fork tips.  Chapter 2: Maintenance

Maintenance schedule Check chain tension...... 2, 11 This maintenance schedule is based Inspect Trekking accessory bolts..... 18-19 on normal usage. If you ride your bike Check wheel bearing adjustment...... 16 more than average, or in rain, snow, Check rims for wear...... 16 or off-road conditions, service your bicycle more often than the schedule Every 3 Months suggests. If any part appears to be Clean and polish finish...... 16 malfunctioning, inspect and service it Check the and bottom bracket 11 immediately, or consult your dealer. Lubricate brake levers ...... 20 If a part is damaged, replace it before riding the bicycle again. Every year After initial break-in, new bikes Lubricate handlebar stem...... 19 should be checked for stretched cables Lubricate seatpost...... 19 and other normal conditions. About Re-grease pedal threads and bearings.. 19 two months after purchasing your Re-grease bottom bracket bearings...... 19 new bike, have your dealer thoroughly Re-grease wheel bearings...... 19-20 inspect the bicycle. Re-grease headset bearings...... 19 All bikes should be thoroughly Lubricate wheel quick-releases...... 19-20 serviced once a year, even if they have not been ridden much. Have the bike Re-grease suspension forks...... 20 completely serviced every year. Every ride Check the wheels...... 1 Check the tire inflation...... 1 Check the brakes...... 2 Check the handlebar and stem...... 2-3 Check the seat and seatpost...... 3 Recommended tools for proper Check the suspension adjustments...... 3 bicycle maintenance: Check the lights and reflectors...... 3 Torque wrench with lb•in or Nm gradations Weekly 2, 4, 5, 6, 8mm allen wrenches Wipe off your bicycle with a damp cloth 6 Check for loose ...... 16 9, 10, 15mm open-end wrenches Lubricate suspension forks...... 20 15mm box end wrench Check suspension fork bolts...... 18 Socket wrench, 14, 15, and 19mm Check rear suspension bolts...... 18 socket T25 Torx wrench Monthly No. 1 phillips head screwdriver Check the attachment of the handlebar and stem...... 2-3, 8-9 Bicycle tube patch kit Check the attachment of the seat and pump with gauge seatpost...... 3, 9-11 Tire levers Check the chain...... 11 Wrench Force® synthetic chain lube Check the chainguard (accessories)...... 18 or similar lubricant Inspect cables for wear...... 11 Wrench Force® synthetic grease or Check the operation of shifters.. 11, 12-13 similar bicycle grease Inspect derailleurs...... 11-13 Wrench Force® frame polish or Lubricate derailleurs...... 20 similar frame protectant Check the internal shift system...... 13 Special high pressure air pump for Check headset bearing adjustment...... 11 rear shock or suspension fork Check brake pads...... 14 Check brake bolts...... 14-16 Note: Not all bikes require all these tools Inspect a rotor for proper function...... 16

 Chapter 3: Adjustment

This chapter lists instructions for • On forged stems to 150-180 lb•in adjustment of the parts of a bicycle. (17-20.3 Nm) After any repair, inspect the bike as • On 4-bolt BMX stems to 80-100 explained in Chapter 1. lb•in (9-11.3 Nm). WARNING Stem A bicycle that malfunctions can To align a direct-connect stem with cause you to lose control and fall. Inspect the entire bicycle thoroughly the front wheel before every ride, and do not ride 1. Loosen the Handlebar clamp bolts it until any problem has been steerer clamp corrected. bolts two to three turns. A Word About Torque Specifications 2. Align the stem with the front Torque is a measurement of the wheel. tightness of a threaded fastener such 3. Tighten the Steerer clamp bolts as a screw or bolt, determined by Figure 11- Direct-connect using a torque wrench. The torque steerer clamp stem specifications should be used to make bolts on sure you do not over-tighten the mountain and fasteners. Applying more than the road bikes to 100-120 lb•in (11.3- recommended torque to a fastener 13.6 Nm). does not provide extra holding power, • On BMX bikes, tighten to 145 lb•in and may actually lead to damage or (16.4 Nm) . failure of a part. Always perform the simple function To align a quill-type stem with tests listed in this chapter to make the front wheel, or to change the sure a part is properly tightened, handlebar height whether or not the part was tightened Handlebar clamp Adjusting the bolts with a torque wrench. handlebar height Stem on a direct-connect expander Handlebars stem (Figure 11) bolt To adjust the angle of the handle- affects the headset bearing adjustment. bars This procedure 1. Loosen the handlebar clamp bolt(s) requires special Angle on the stem (Figures 11-12) just tools and training adjusting enough that the handlebars can be so this should only bolt Figure 12- Adjustable-rise rotated in the stem. be done by your quill stem 2. Position the handlebars to the dealer. desired angle, making sure they are To adjust the centered in the stem. height of the 3. Tighten the handlebar clamp bolt(s) adjustable-rise on welded stems to 100-120 lb•in stem in Figure 12, (11.3-13.6 Nm). first change the stem angle, which gives access to This line WARNING the stem expander must be inside An improperly adjusted or tightened bolt. the bike handlebar, stem, or bar-ends can 1. Loosen the stem frame cause you to lose control and fall. expander bolt Figure 13- Minimum two to three insertion mark on quill Make sure the stem, handlebar, stem and bar-ends are positioned and turns. tightened properly before riding the bike.

 2. Tap the top of the stem expander bolt To adjust the clamping force of the with a wood or plastic-faced mallet to quick-release lever of the Bontrager loosen the stem wedge. adjustable-rise stem 3. Adjust the handlebars to the 1. Open the quick-release lever. desired height, but with the minimum insertion line inside the 2. Turn the release adjusting nut frame (Figure 13). A minimum of (Figure 14). 23/4 inches (70mm) of the stem quill The nut uses standard threading: must always remain in the frame. clockwise to tighten, counter- 4. Tighten to 175-260 lb•in (19.8-29.4 clockwise to loosen. Nm). 3. Check that at about halfway through the lever throw there is some resistance. If the clamp force is too high or too WARNING low, readjust the nut. Never ride your bicycle with a quill stem raised above the minimum 4. Follow the procedures in Inspection insertion mark. A quill stem that to make sure the handlebars are is positioned too high can damage clamped with adequate force. the bike and can cause you to lose control and fall. Make sure the Bar-ends minimum insertion mark (Figure 13) Bar-ends (Figure is inside the frame. 15) are designed for climbing only. Ensure the bar-ends To change the angle of an adjustable- face forward and rise stem away from you. 1. Loosen the (Figure 12) until the To adjust the angle stem can be rotated. of the bar-ends 2. Position the stem to the desired Bar-end 1. Loosen the bar- clamp bolt angle. end clamp bolt(s) Figure 15- Bar-ends 3. Tighten the angle adjusting bolt to until they can be 150-170 lb•in (17-20.3 Nm). rotated on the handlebar. To change the angle of a Bontrager 2. Position the bar-ends to the desired adjustable-rise stem angle, but an angle not less than 15° 1. Pull out the from parallel to the ground Release adjusting nut locking button 3. Tighten the bar-end clamp bolt to (Figure 14). 85-125 lb•in (9.6-14.1 Nm) 2. Pull the quick- release lever Saddle (Figure 14) Quick- The correct adjustment of the seat down. release lever angle is largely a matter of personal 3. Position the preference; first try riding with the top stem to the Locking button of the seat parallel to the ground. For desired angle. bikes with rear suspension, try tilting 4. Pull out the Figure 14- Bontrager the seat nose down slightly so that adjustable-rise stem locking button compression of the rear shock under again, and close your body weight (sag) results in a flat the quick-release lever. seat. Make sure the lever is completely The seat may also be moved forward closed and the locking button has or backward along the seatpost to returned to its locked position. increase comfort as well as adjust the distance to the handlebars. With proper adjustment, the right  bike seat will be reasonably comfort- • With double bolts using a 4mm able even for long rides. allen wrench, tighten to 45-60 lb•in (5-6.8 Nm). WARNING To adjust the seat height of a Extended riding with a poorly bicycle adjusted saddle, or one that does Never engage not properly support your pelvic the seatpost area, can cause short-term or long- binder with the term injury to your nerves and blood seatpost out of vessels. If your saddle causes pain the frame. or numbness, re-adjust the saddle 1. Sit on the position. If after adjustment your seat in riding saddle still causes pain or numbness, position consult your dealer about further without positioning or replacing the saddle shoes, while Figure 18- Leg extension with with one that fits you better. someone proper seat height holds the To adjust the angle of the seat bicycle up. 2. Position the 1. Loosen the crank arms so seat fixing bolt they are parallel (Figure 16) just This line to the seat tube. must be far enough so inside the the seat can be Seat 3. Loosen the bike frame tilted fore and fixing seatpost binder bolts aft. bolt, or quick- Seatpost release. Some use Figure 19- Minimum 4. Extend the insertion mark on two bolts, where Seatpost seatpost binder bolt seatpost until, angle adjustment is with your heel done by loosening Figure 16- Seatpost parts resting on the bottom pedal (Figure one bolt and 18), your extended leg is straight. tightening the other bolt. When wearing your shoes there 2. Place a straight should be a slight bend in your knee edge, such as a in a proper riding position; with the bubble level or ball of your foot on the pedal. ruler, across the Seat 5. Make sure the minimum insertion fixing top of the seat bolt mark on the seatpost (Figure 19) is to better see the not visible above the bike frame. A angle. minimum of 2 1/2 inches (64mm) of 3. Adjust the seat seatpost must remain in the frame. Figure 17- Bontrager and re-tighten seatpost 6. Close the seatpost quick-release, the seat fixing or tighten the bolt to 85-125 lb•in bolt. With double (9.6-14.1 Nm) bolts using a 5mm allen wrench tighten to 80-125 lb•in (9.6-14.1 Nm). WARNING • With a bolt using a 13 or 14mm A seatpost that is positioned too open-end wrench, tighten to 180- high can damage the bike and can 220 lb•in (20.3-24.9 Nm). cause you to lose control and fall. Make sure the minimum insertion • With a single bolt using a 6mm mark (Figure 19) is inside the frame. allen wrench, tighten to 150-250 lb•in (17-28.3 Nm).

10 To adjust the Bottom bracket seat position of a Adjustment of bottom bracket tricycle bearings requires special tools and 1. Loosen and Seat mast training. These services should only remove the be performed by your dealer. clamp bolts (Figure 20). Chain

2. Move the seat Clamp bolts To adjust the chain tension on a mast to the single speed bike desired position. Figure 20- Tricycle seat mast 1. Gradually loosen the rear wheel axle 3. Install and nuts on alternate sides of the wheel. tighten the seat mast clamp bolts to 85-125 lb•in 2. Slide the wheel to re-tension the (9.6-14.1 Nm). chain, and center the wheel in the frame. Headset Some models have a chain tensioning device which helps position the wheel. To check if the headset is loose or 3. Complete the wheel installation. tight 1. Apply the front brake firmly while Cables you rock the bicycle forward and Check the cables for kinks, rust, backward. broken strands, or frayed ends. Also 2. With the front wheel off the ground, check the housing for loose wire slowly rotate the fork and handle- strands, bent ends, cuts, and wear. If bars to the right and left. you suspect a problem with a cable, do not ride the bicycle; follow the instruc- If the headset bearings rock in the tions to replace a cable, or have your frame, or do not turn smoothly, do not dealer service the bicycle. ride the bicycle; take the bike to your dealer for service. Shifters Adjustment of headset bearings The position of the shifters can be requires special tools and training. adjusted on the handlebars. Follow the These services should only be instructions for adjusting the lever performed by your dealer. position on page 14. Pedals Front derailleur To adjust the release force on clipless pedals, refer to the information on To adjust the low the CD supplied with your bicycle, or gear position Cable Adjusting screws consult your dealer. 1. Shift the chain Tighten pedals into the crankarms onto the smallest to 350-380 lb•in (40.2-42.9 Nm). front chainring Cable Adjustment of pedal bearings and the largest clamp requires special tools and training. cassette cog. bolt These services should only be 2. Loosen the front performed by your dealer. derailleur cable Crank arms clamp bolt (Figure 21) until the cable Figure 21- Front derail- Some bicycles offer adjustable is free. leur crankarm length. To change the crank 3. Turn the low length, remove the pedals and install gear adjusting screw (marked “L”) them into the second set of holes. until the inner chain guide of the Tighten by following the instructions derailleur is approximately 0.5mm for Pedals. from the chain.

11 4. Pull on the cable end, and down- Note: some front shifters have a ‘tab’ shift the left shift lever several feature: slightly downshift the lever, times so it is in the small-chainring and the derailleur moves in slightly, no position. longer touching the chain. 5. Turn the shift cable adjusting barrel to its most clockwise Rear derailleur position. To adjust the high gear position 6. Insert the cable in the groove 1. Shift the chain found next to the derailleur cable onto the smallest clamp bolt, pull the cable taut, and rear cog and Adjusting clamp the cable: the largest front screws • Front derailleur cable clamp bolt to chainring. Barrel 44-60 lb•in (5.0-6.8 Nm). 2. Loosen the adjuster To adjust the high gear position cable clamp bolt Figure 22) until Cable 1. Shift the rear derailleur to the the cable is free. clamp smallest rear cog. bolt Cable 3. Stand behind 2. Turn the high-gear adjusting the bicycle to see Figure 22- Rear derail- screw (marked “H”) counter- that the smallest leur clockwise until it cannot interfere rear cog, the with the motion of the derailleur. chain, and the two derailleur 3. Hand-turn the cranks, and use the pulleys are in line. shifter to carefully shift the chain 4. If they are not aligned, turn the onto the outside chainring. high gear adjusting screw (usually 4. Position the outer chain guide of marked “H”,) until this line is the front derailleur approximately established. 0.5mm from the chain. 5. While pulling on the cable, up-shift 5. Re-tighten the high gear adjusting until the shifter is in the small cog screw until it meets resistance. position. If you have turned the screw too 6. Turn the adjusting barrel on the far, the front derailleur will move shifter, or down tube, all the way toward the small chainring. clockwise. Turn the adjusting Go through the various gear barrel on the rear derailleur all the combinations. Make sure the chain way clockwise, and then one turn does not fall off when you shift, and counter-clockwise. the derailleur cage does not rub on 7. Insert the cable into the clamp bolt any part of the crankset. groove on the rear derailleur, pull To adjust the middle gear position, the shift cable taut, and tighten the with three chainrings cable clamp bolt to 44-60 lb•in (5.0- 6.8 Nm). 1. Shift the chain onto the largest front chainring and the smallest To adjust the low gear position rear cog. 1. Turn the low gear adjusting screw 2. Rotate the cable tension barrel- on the rear derailleur (usually adjuster (on the downtube, or on the marked “L”) far enough counter- lever) counter-clockwise increasing clockwise so that it will not restrict cable tension to align the inner derail- the movement of the derailleur. leur cage until it just touches the 2. Carefully shift the chain onto the chain. smallest front chainring and the Go through the various gear largest rear cog. Do not over-shift combinations to ensure the chain the rear derailleur, or the chain may smoothly lines up with all the wedge between the large cog and chainrings. the spokes. 3. Position the rear derailleur pulleys in line with the largest cog. 12 4. Turn the low gear adjusting screw 3 speed systems clockwise until it meets resistance. If you have turned it too far, the To adjust the rear shifting derailleur will move toward the 1. Rotate the outside of the bicycle. shifter to 5. Go through the various gear the 2nd gear Bell combinations. Make sure the chain position. crank window does not fall off when you shift. 2. Align the indicator on To align the indexing system the bell crank 1. Shift the chain onto the largest window with the front chainring and the smallest line on the push rear cog. rod (Figure 24). 2. Shift one click with the rear 3. If the lines do Figure 24- Three-speed shifter. not line up, bell crank 3. Check if the chain moves smoothly adjust the gear to the next gear. cable tension by 4. If the chain makes excessive noise rotating the barrel adjuster until or does not shift, turn the barrel- this alignment is achieved. adjuster counter-clockwise in small 4. Shift to 1st gear, then back to 2nd, increments and check again for a and re-check the adjustment. smooth shift. If instead, the chain moves to the SRAM DualDrive system third smallest cog, turn the barrel To adjust the rear hub shifting adjuster clockwise until the derailleur pulleys align with the second smallest 1. Place the shifter Barrel adjuster cog. Go through the gear combina- in the Standard tions to ensure the chain smoothly mode. lines up with all the rear cogs. 2. Align the If the derailleur cannot be adjusted in indicator on the this manner, the derailleur hanger may Clickbox window by rotating the be out of alignment; take the bike to Indicator your dealer for service. barrel adjuster window (Figure 25). Nexus 4, 7, or 8 speed systems 4. Shift to Uphill mode, then back Figure 25- Clickbox (on To adjust the rear shifting rear hub) to Standard 1. Rotate the Cog joint mode, and re- shifter to the 4th bracket check the adjustment. gear position. 2. Align the Brake levers indicator on the The brake system allows you to slow rear hub pulley or stop your bike, a function critical to (Figure 23) with your safety. the cog joint The brake system is difficult to adjust bracket. properly without the proper tools and Cable clamp bolt 3. If the red lines training. It is strongly recommended do not line up, Figure 23- Pulley and cog joint bracket that adjustment of a brake be done by adjust the gear your dealer. If you need more specific cable tension by information regarding your brake rotating the barrel adjuster until system, contact your dealer. this alignment is achieved. 4. Shift to 1st gear, then back to To adjust the position of a lever 4th, and re-check the adjustment. 1. Locate the lever clamp bolt (Figures 26-28).

13 2. Loosen the 1. Open the brake. clamp bolt 2-3 2. For a road bike, disconnect the turns. brake cable and completely remove 3. Position the it from the lever. lever. • For a mountain bike, just remove 4. Tighten the the leaded end of the cable from the clamp bolt on lever. Lever regular brake clamp 3. Install the cables into the opposite levers to 53-69 bolt levers. lb•in (6.0-7.8 4. Close the brakes. Nm). Figure 26- Lever clamp bolt, road lever 5. Inspect the brakes as explained • On mid-bar in Chapter 1, and re-adjust as levers (Figure Lever clamp bolt necessary. 28) to 20-30 lb•in (2.3-3.3 To change which lever controls the Nm). front brake (hydraulic type) • On Hayes Reach adjustment 1. For a Hayes brake, loosen and hydraulic levers screw remove both clamp bolts. to 25-35 lb•in Cable (2.8-4 Nm) Changing the levers with Barrel hydraulic brakes requires special tools To adjust the reach adjuster Figure 27- Lever clamp and training so should only be done by to the brake lever bolt, mountain lever your dealer. (cable type) 2. Remove the levers and re-position according to your preference. With some brake levers, you can 3. Re-install the clamp bolts and change the reach, tighten to 25-35 lb•in (2.8-4 Nm). the distance from the handlebar to the Brakes lever. Inspect brake pads for wear. If the 1. Locate the reach Lever grooves in the braking surface are clamp adjustment screw bolt less than 2mm deep, or 1mm deep and turn. for direct-pull brakes, replace the Figure 28- Mid-bar brake pads. Replace disc brake pads that are To increase lever thinner than 1.0mm. the reach, turn the screw in To adjust brake pad clearance to the (clockwise). To reduce the reach, turn rim the screw out (counter-clockwise). 2. If needed after adjusting the reach, 1. Turn the barrel adjuster. To re-adjust the brake pad clearance. increase the pad clearance, turn the barrel adjuster in (clockwise). To adjust the reach to the brake To reduce the pad clearance, turn lever (hydraulic type) the barrel adjuster out (counter- clockwise). 1. Locate the reach adjustment screw between the lever and the For most direct-pull (Figure 29), handlebar, near the lever pivot. cantilever (Figure 31), or U-brake 2. To increase the reach, turn the (Figure 32) systems the barrel adjuster screw in (clockwise). To reduce the is on the lever. For most road caliper reach, turn the screw out (counter- systems (Figure 30) the barrel adjuster is on the brake itself. clockwise). 2. If the brake pads cannot be To change which lever controls the adjusted properly, loosen the cable front brake (cable type) clamp bolt and re-attach the cable. See the Brakes section for brake To center a V-type, cantilever, or adjustment procedures. road brake 14 1. Rotate the centering screw. Turn in To align a cable-actuated disc brake small increments There are several and check for Cable clamp bolt parts to this Mounting centering. procedure: bolts 2. If the brake has •To adjust right two centering brake pad No contact screws, adjust Pad clearance to the overall spring fixing Centering the disc tension while bolt screw 1. Turn the fixed centering the Arm pad adjuster brake. fixing bolt (Figure 33). To Cable clamp bolt increase the To center a U- Figure 29- Direct pull Figure 33- Disc brake brake pad clearance, turn the barrel 1. Hold the 13mm Barrel Centering adjuster screw adjuster in (clockwise). To reduce centering nut the pad clearance, turn the barrel with a wrench. adjuster out (counter-clockwise). 2. Loosen the arm 2. If the pads cannot be adjusted fixing bolt with properly in this manner, follow the a 5mm allen instructions wrench. To adjust left brake pad clearance to the disc, and re-set the 3. Rotate the Pad right pad centering nut. fixing . bolt • To adjust left brake pad clearance 4. Re-tighten the Figure 30- Caliper brake to the disc bolt. Linkwire 1. Turn the cable barrel adjuster. To To adjust the increase the pad clearance, turn alignment of the the barrel adjuster in (clockwise). brake pads on To reduce the pad clearance, turn caliper-type brake the barrel adjuster out (counter- clockwise). 1. Loosen the Pad 2. If the pads cannot be adjusted brake pad fixing fixing bolt. bolt properly in this manner, loosen the Centering cable clamp bolt and re-attach the Arm fixing bolt 2. Follow the screw cable as explained in procedures Figure 31- Cantilever To install a brake page 19, but without removing in cable, Inspection the cable to align and Cable Centering nut . carrier Arm tighten the brake fixing 3. After adjustment, turn the locking pads. bolt nut clockwise to help prevent 3. After adjusting rotation of the barrel adjuster. the brakes, test • To align the brake with the disc them by applying 1. Loosen the brake mounting bolts. force to the 2. Slide a business card, or similar levers. Ensure thin object, between the right brake Linkwire Pad fixing bolt the cable does pad and the disc. not slip, the pads Figure 32- U brake close toward the 3. Apply the lever fully, and gradually rim at right angles, and the pads do tighten each mounting bolt as not contact the tire. specified in Inspection. To align a hydraulic disc brake To remove disc brake pads 1. Loosen the brake mounting bolts. 1. Remove the wheel. 2. Apply the lever fully, and gradually 2. With your fingers, or thin-tipped tighten the bolts to: pliers, grasp the installation tang of 100-110 lb•in (11.3-12.4 Nm) the brake pad and pull out. 15 To adjust a rotor • For direct-pull type brakes, A rotor (Figure 34) allows the rear disconnect the pipe from the link brake cable to bypass the headset so arm. With one hand, squeeze the the handlebars can be rotated a full pads firmly against the rim. With 360 degrees. the other hand, pull the pipe back from the link arm, and lift the pipe. 1. Ensure that both lower barrel Once disconnected, let go of the adjusters are flush with (do not brake pads and the brake will open. show above) the lower cable stop, and the bearing unit is resting on To close the brake, reverse the the lower cable stop. instructions. The rear brake adjustment must be • For internal or drum brakes, to made with the bearing unit in this remove the rear wheel, first discon- position. The bearing unit should be nect the shift and brake cables. parallel to the upper and lower cable -To disconnect the brake cable, stops. press the cable carrier arm forward, 2. If it is tilted, and the cable clamp bolt rearward, there is slack in so the bolt aligns with the larger one of the cables. diameter hole in the carrier. Pull Pull each cable Rotor the cable clamp bolt outward to end, one at a disengage it from the carrier. Slide time to see which the brake cable stop forward to cable has slack at remove it from the brake arm. Undo the bearing unit. brake strap bolt. 3. Remove the -To disconnect the shift cable, slack through the put the shifter in 1st gear. Pull the barrel adjuster. Figure 34- Rotor cable housing out of the shift cable 4. When even housing stop. Rotate the shift cable pull is achieved, tighten all barrel fixing bolt until the washer flats adjuster locknuts. align with the slit in the cog joint bracket. Remove the cable. To open the brake for wheel removal • For most road calipers, lift the Wheels brake release lever to the open UP Inspect tires for wear and damage. position. To close, simply turn the Make sure rims are clean, and check lever to the Down position. for wear; if the small indentations • For levers, slightly on the braking surface disappear, depress the brake lever, and push replace the rim. Make sure there the button until it is flush with the are no loose, damaged, or broken lever body. Release the lever and spokes. Check that hub bearings are the brake will open. properly adjusted. Make sure a rim To close, reverse the instructions. strip is in place and all spoke holes are completely covered. • For cantilever brakes and U-brakes, release the linkwire. With one hand, To adjust and install a quick-release squeeze the brake pads firmly against wheel the rim. With the other hand, pull 1. Move the quick-release lever to the the leaded end of the linkwire from OPEN position the retaining fork on the brake arm. (Figure 39) and OPEN Release the brake pads, and the brake set the wheel will open. so it firmly To close the brake, reverse the touches the instructions. inside of the fork ends. CLOSED Figure 39- Lever posi- tions

16 2. With the lever 7. Test that you have properly about halfway adjusted and closed the quick- between the release. If the quick-release fails any OPEN position test, either repeat these adjustment and the CLOSED procedures, including these tests, position, tighten or take your bicycle to your dealer the quick-release for service. adjusting nut Figure 40- Tighten nut If it requires more than 45 pounds (200 Newton) force to (Figure 40) until completely close the quick-release lever, open the lever and finger-tight. slightly loosen the quick-release adjusting nut. D If it requires less than 12 pounds (53.4 Newton) force to E S O begin to open the lever from the fully closed position, open 3. Place the lever L C the lever and slightly tighten the quick-release adjusting in the palm of nut. your hand and Repeat the adjustment if necessary.

EN Figure 45- Actual measurements throw the lever OP as shown in 8. Test for proper quick-release Figure 41 to Figure 41- Proper lever adjustment the CLOSED throw position (Figures • Pick up the bike, O P E and sharply hit 43-44). At the N

the top of the

O

half-closed P E

N tire (Figure 46). EN position of the OP lever, there The wheel must

not come off, be

should be some N E P resistance. O loose, or move Figure 46- Test for from side to side. looseness • Do not tighten Figure 42- Do not turn the quick-release lever • Make sure the wheel retention quick-release mechanism by lever cannot be turning the lever rotated parallel to like a wing nut the wheel (Figure (Figure 42); it 47). will not result in • When the sufficient force to quick-release Figure 47- Test for rotation hold the wheel in Figure 43- Front lever is properly position place. tightened, and clamped by the lever 5. If the lever is in the closed position, the clamping moved to the force is adequate to cause metal- CLOSED position into-metal engagement (embossing) with little or of the dropout surfaces. no resistance, • See Figure 45. clamping strength is To install an axle-nut wheel Figure 44- Rear lever Some wheels are attached by insufficient. position Return the lever tightening nuts threaded onto the to the OPEN position, tighten the axle. The front wheel may require a quick-release adjusting nut further toothed washer to be placed between and close the lever, and again test the nut and fork tip. Some bicycles for resistance. For further informa- also have pegs, tubular axle extension. tion on correct adjustment of the 1. Tighten the axle nuts: quick-release tension, read Figure • Tighten a regular front wheel to 45. 180-240 lb•in (20.3-27.1 Nm). 6. Orient the quick-release levers so • Tighten a regular rear wheel to they do not interfere with any other 240-300 lb•in (27.1-33.9 Nm). bicycle part or accessory part (such • For a front wheel with pegs, as rack or fenders), and so obstacles tighten to 220-240 lb•in (24.9-27 in the path of the bicycle cannot Nm). snag the levers. 17 • For a rear wheel with pegs, tighten Accessories to 350 lb•in (40 Nm). There are a wide variety of accesso- 2. Test to ensure that you have ries installed on bicycles. Once a properly tightened the axle-nuts. month, check any accessories to make • Pick up the bike, and sharply hit sure they are properly attached. If any the top of the tire (Figure 46). The part seems loose or misaligned, either wheel must not come off, be loose, tighten the part or take the bike to or move from side to side. your dealer for service. If the wheel attachment fails the test, To adjust repeat these procedures, including the tests, or take your bicycle to your See other sections of this manual as dealer for service. needed. 1. Place the bike on a flat, smooth To install a thru-axle wheel surface, with the tires properly 1. Open the quick-release or loosen inflated. the clamp bolts on both fork ends. 2. Loosen the rear axle nuts. Follow 2. With the wheel in place, slide the the procedures in the Wheels axle into the fork tips. section. 3. Close the quick-releases, or tighten 3. Stand the bike up very straight, the clamp bolts to 45-55 lb•in (5.1- and set a gap of about 1/4 inch 6.2 Nm). (6mm) between the training wheels and the ground on both sides of the 4. Test to ensure that you have bike. Make sure the gap is the same properly attached the thru-axle. on both sides. • Pick up the bike, and sharply hit 4. Adjust the chain tension and re- the top of the tire (Figure 46). The tighten the axle nuts. wheel must not come off, be loose, or move from side to side. To install a light bulb If the wheel attachment fails the test, 1. Locate the lens set-screw on the repeat these procedures, including the back of either the taillight or head tests, or take the bicycle to your dealer light. for service. 2. Remove the screw. Suspension components 3. Rotate the lens 1/4 turn clockwise Changing your suspension settings and lift the lens assembly off the affects handling and braking charac- bulb mount. teristics. After making a change, 4. Unscrew the bulb. carefully test the bike in a low traffic Be careful not to crush the glass of the area until you are familiar with its bulb. Do not dislodge the wire in the performance. base of the bulb mount. For an all-round ride, set the forks 4. Screw a new bulb in until finger for about 15% sag, and a rear shock tight. at about 25% sag. Experiment with 5. Place the lens on the bulb mount, the adjustment in small increments to rotate the lens 1/4 turn counter- find your preference. If the suspension clockwise. is fully compressed, its movement will 6. Install the lens set-screw. stop abruptly and could cause you to lose control. See the CD or web site for Check that the new bulb works. If it more specific adjustment and mainte- does not, check the wiring for correct nance information, or consult your placement, and verify that the new dealer. bulb is not damaged.

18 Chapter 4: Lubrication

Folding bike This section explains the parts that Some models of Trek bikes have a require lubrication, their frequency, large hinge in the middle to fold the and brief instructions. See your dealer bike by following these steps: for recommended lubrications. If you need more detailed information, To lower the saddle see other sections of this manual as 1. Open the seatpost quick-release needed, or consult your dealer. and lower the saddle. Re-greasing bearings requires 2. Close the quick-release to hold the special tools and training, so this seatpost in position. should only be done by your dealer. Some bearings are permanently sealed To fold the pedals and do not require yearly re-greasing 1. Push the end of the pedal directly inward, toward the crankset. Stem Once a year lubricate the stem. 2. Fold the pedal over. Note: Lubricating a direct-connect 3. Repeat for the other pedal. stem requires adjustment of the To fold the handlebar stem headset bearings, so should only be 1. Rotate the lever lock away from done by your dealer. 1. Remove the stem from the frame. the lower quick-release. 2. Wipe any old grease off the stem, 3. Hold the handlebar with the cables and clean it. out of the way to prevent pinching, and open the lower quick-release. 3. Apply a thin layer of grease to the section of the quill that will be 4. Fold the handlebar assembly to its inserted into the frame, including down position. the stem wedge. To fold the main frame 4. Install the stem. 1. Open the latch lock. 2. Pull outwards, away from the Seatpost frame, on the end of the frame latch Once a year, lubricate the seatpost until the latch opens. (except for a bike with a carbon fiber seat tube, where no lubrication is 3. While avoiding pinching yourself recommended). or cables, fold the bike in half. 1. Loosen the seatpost binder bolt, or To unfold the frame, reverse the open the quick-release, and remove steps of the folding procedure. the seatpost from the frame. 2. Wipe any old grease off the WARNING seatpost, and clean if necessary. Riding a folding bike with movement 3. Apply a thin layer of grease to the at the lower stem quick-release or section of the seatpost that will be main frame hinge could cause you inside the frame. to lose control and fall. If the folding 4. Insert the seatpost into the frame. frame moves at the stem or frame 5. Adjust the seat to the proper hinge, take the bike to your dealer for height, align it, and tighten the service. seatpost binder bolt. Bottom bracket Once a year re-grease the bottom bracket bearings, Pedals Once a year re-grease the pedal bearings. Once a year re-grease the pedal axles 19 where they thread into the crank arms. Control cables Note: There are right and left pedals, Lubricate cables whenever they are usually marked with a letter stamped installed. on the end of the pedal axle, or on the wrench flats. To install a cable 1. Remove the pedals; turn the right Installing a cable in a cantilever brake pedal spindle counter-clockwise, but requires special tools and training, so turn the left clockwise. should only be done by your dealer. 2. Apply a this layer of grease over all 1. Note the path of the old cable, and the threads. loosen the cable anchor bolt and 3. Install the pedals on the proper remove the worn cable. side; put the right pedal on the right 2. Grease the new cable and reinstall, crank arm and the left pedal on the feeding it along the same path as left crank arm. the old cable, including through the 4. Tighten the pedals. cable anchor bolt. 3. Make sure the leaded cable-end is Derailleurs seated properly in the lever, and the Every month, lubricate all pivot points housing is properly seated in the on both the front and rear derailleurs, lever. including the derailleur pulleys on the If needed when installing a cable in a rear derailleur, with chain lube. brake, readjust the brake. 4. Turn the adjusting barrel clockwise Headset so the threads on the adjusting Once a year re-grease the headset barrel are not exposed. bearings. For a shift cable, put the shifter in the position with the least cable tension. Brakes and Brake Levers For a brake, hold the brake closed Every 3 months lubricate your brake while you do the next step. lever pivots and brake arm fixing 5. Tighten the cable clamp bolt: pivots with a light oil. 52-69 lb•in. (6-8 Nm) 6. Cut the cable so that no more than Wheels 2 inches (51mm) extends beyond the Once a year re-grease the wheel anchor bolt. bearings. 7. Crimp a metal cap or place a bit Every year, lubricate wheel quick- of solder on the end of the cable to release. Apply several drops of prevent fraying. ® Wrench Force synthetic lube or a 8. Follow the instructions for adjust- similar light oil where the quick- ment. release lever rotates in the quick- release body. Suspension forks Once a month, apply a light oil to the upper fork leg where the lower leg slides on it. Wipe clean. Rear suspension No lubrication is required for the shock or the pivot of your full suspen- sion bike. Avoid all lubricants.

20 Limited Warranty

For more information (Trek) warrants each new frame, rigid fork, If you would like additional informa- or original component part of the tion about your bicycle, or bicycling in bicycle against defects in workman- general, there are many resources in ship and materials: your community. For the lifetime of the original First, talk to your bicycle dealer. owner- They have extensive experience with bicycles and riding in your community. • The or rigid fork With this background, they can help For one year- you with your individual questions • Paint and decals and help you find areas to enjoy your • All original parts, excluding suspen- new bicycle. In addition, most dealers sion forks and rear shock absorbers stock a variety of book about cycling, • Suspension forks and rear shock including extensive repair manuals. absorbers shall be covered by the Second, check your public library. stated warranty of the original Most libraries have extensive offerings manufacturer. of books written by experts in the field This warranty does not cover- about riding, racing, , bicycle maintenance, and more. • Normal wear and tear Third, go on-line. The best on-line • Improper assembly resource for your bike can be found by • Improper follow-up maintenance viewing the CD that accompanies this • Installation of parts or accesso- manual. Place the CD in a computer, ries not originally intended for, or and you will find much more informa- compatible with, the bicycle as sold tion. With internet access, you • Damage or failure due to accident, can link direct from the CD to our misuse, abuse, or neglect company web site. Links to some of the companies that make the parts of • Labor charges for part replacement your bike are also provided. All of this or changeover information and help is just a click This warranty is void in its entirety away. by any modification of the frame, fork, or components. This warranty is expressly limited to the repair or replacement of a defective item and is the sole remedy of the warranty. This warranty extends from the date of purchase, applies only to the original owner, and is not transferable. Trek is not respon- sible for incidental or consequential damages. Some states do not allow the exclusion of incidental or consequen- tial damages, so the above exclusion may not apply to you. Claims under this warranty must be made through an authorized dealer. Proof of purchase is required. The subject item must be registered with Trek, either through on-line registra- tion or by the receipt of a warranty registration card by Trek, before a warranty claim may be processed. This warranty gives the consumer specific legal rights, and those rights may vary from place to place. This warranty does not affect the statutory rights of the consumer. 21