bicycle manual

8/7/2019 Bicycle Manual

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Bicycle Owners ManualEven if you have ridden a bike for years, it is

important for EVERYperson to read Chapter 1before you ride your new bicycle.


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i

Meaning f speial symls andlettering

IMPoRTANT: KEEP FoR FuTuRE REFERENcE

At this owner's ManalThis manual explains how to ride

your new bike safely.

Even if y have ridden a iylefr years, it is imprtant fr EVERYpersn t read chapter 1 efreriding this iyle!

Parents should explain Chapter1 to a child or anyone else whomight not otherwise understandthis information.

This manual also shows how

to perform basic maintenance.Some maintenance should only beperformed by your dealer, and themanual indicates these tasks. Ifyou choose to perform these tasks,you should purchase a detailedrepair manual from your dealer.

This manual includes a CD(compact disc) with more compre-

hensive information. This CD canbe viewed by inserting it into yourhome computer. If you do not havea computer, take the CD to yourschool, work, or public library andview it there.

If your CD does not work, go tothe web address on the cover toaccess the information on the web.

My bicycle model:

My serial number: Lock key #

My dealer:

My dealer's phone:K

eep

foryou

rrec

ord

s

WARNINGIn this manal, the WARNING signindiates a hazards sitatinwhih, if nt avided, ld resltin death r seris injry.

cAuTIoNIn this manal, the CAUTION signindiates a hazards sitatinwhih, if nt avided, may reslt inminr r mderate injry.

Register yr iyleBicycle registration is the only

record we have of who owns thisbike. If there is ever a need tocommunicate with the owner,

such as providing updated safetyinformation, your registration iscrucial. There are two easy ways toregister your new bicycle:

Click the Registration linkwhen viewing the CD suppliedwith this manual

Go to the web address on theback cover of this manual andfollow the links.

The web site also provides a linkto updated safety information. Ifyou choose not to register, makesure you check the web site often.


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ii

Assemly f yr new iyle

Assembly and the first adjust-ment of your bicycle take specialtools and skills, so this should only

be done by an authorized dealer.

If y have qestins

There are many models, witha variety of equipment, sothis manual may contain someinformation that does not applyto your bike. Some illustra-tions may vary from the actualbicycles.

If you have any questions afterreading the information in thismanual, consult your dealer. Ifyou have a question or problemthat your dealer cant handle,contact us:

Attn: Customer Service

801 W. Madison Street

Waterloo, Wisconsin 53594

920.478.4678

This manual conforms with thesestandards:

ANSI Z535.4

CPSC CFR 1512

BS 6102 : Part 1: 1992

CEN 14764, 14765, 14766, 14872


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iii

TAbLE oF coNTENTS

chapter 1- Gide t Safe on-and-off Rad operatin

biyle type and se lassifiatin

Child bike .................................. 1Condition 1 ................................ 1Condition 2 ................................ 1Condition 3 ................................ 2Condition 4 ................................ 2Condition 5 ................................ 2

befre a first ride

Make sure the bicycle fits ......... 3Know how the bicycle performs 3

chek the ike efre every ride

Before every ride checklist ....... 4Carbon fiber inspection ............. 7

Rles fr safe riding

Know and observe local bicycleriding laws ............................. 9

Watch for cars, pedestrians, and

other obstacles ....................... 9Wear a helmet and proper cyclingclothes .................................... 9

Change your riding to be safe invariable conditions................. 9

Riding instrtins

Use your brakes carefully ....... 12Use good shifting techniques . 12

Take are f yr ikeProtect your bike when parkingor storing it ......................... 13

Carry repair items ................... 14Only install and use approved

accessories ........................... 14Keep the bike clean ................. 14Avoid clamping the frame during

transportation or repair ...... 14Protect your bicycle during

shipping ............................... 14

chapter 2: MaintenaneMaintenance schedule ............. 15Recommended tools for proper

bicycle maintenance ............. 16

chapter 3: Adjstment 17Handlebar ................................ 17Stem ........................................ 17Bar-ends .................................. 19Saddle ...................................... 19Headset .................................... 21Crankset .................................. 21Crank arms ............................. 21

Pedals ...................................... 21Bottom bracket ........................ 21Chain ....................................... 21Cables ...................................... 22Shifters .................................... 22Front derailleur ....................... 22Rear derailleur ........................ 23Nexus 4, 7, or 8 speed systems243 speed systems ...................... 24Brake levers ............................ 25

Brakes ..................................... 27Wheels ..................................... 29Suspension components .......... 31Accessories .............................. 31Folding bike ............................ 32Stem ........................................ 33Seatpost ................................... 33Bottom bracket ........................ 33Pedals ...................................... 33

chapter 4: LriatinDerailleurs ............................... 34Headset .................................... 34Brakes and brake levers .......... 34Wheels ..................................... 34Suspension forks ..................... 34Rear suspension ...................... 34Control cables ......................... 34

For more information.............. 35Limited warranty .................... 36


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Riding a bicycle in a mannerbeyond, or more severe than, itsintended use can cause the bicycleor part of the bicycle to fail. The

following information explainsthe type of riding intended fordifferent types of bikes. Read thesafety information in Chapter 1 forfurther details.

child ikeThese bikes

are designed for

children ridingwhere parentalsupervision isalways required.Riders shall avoidareas used byautomobiles, aswell as inclines,curs, stairs, or areas near drop-offsor pools.

child ike types

Maximum seat height of 680mm; generally, bicycles with16" or 20" wheels, and kids'tricycles

No quick-release wheelfastening systems

Weight limit: 80 lbs (36 kg)

cnditin 1Bikes designed

for riding on apaved surfacewhere the tires donot lose groundcontact.

cnditin 1 iketypes

Drop-typehandlebars including touringbikes, but not cyclocross bikes

Triathlon, time trial, or speedbikes

Tandems of any design

Cruisers with wide, 26" tiresand swept-back handlebar

Any bike that folds

Weight limit: 275 lbs (125 kg);Tandems: 550 lb (250 kg)


for ridingCondition 1,plus smoothgravel roads andimproved trailswith moderategrades where the

tires do not loseground contact.

cnditin 2 ike types

Hybrid bikes with 700c wheels,tires wider than 28c, and flathandlebars

City bikes- specially-equippedhybrids

Cyclocross bikeswith drop-

type handlebars, knobby 700ctires, and cantilever or discbrakes


bIcYcLE TYPE AND uSE cLASSIFIcATIoN

Chapter : Guide to Safe On-and-Off Road Operation

WARNINGbiyles, r their parts, an erken r damaged y riding in amanner mre stressfl than the

intended se f the ike. If theike is damaged, y ld lsentrl and fall. D nt ride eyndthe design limits f the ike. Ify are nsre f the limits f theike, nslt yr dealer.


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for jumping,hucking, high

speeds, or aggres-sive riding onrougher surfaces,or landing on flatsurfaces.

However, thistype of ridingis extremely hazardous and putsunpredictable forces on a bicycle

which may overload the frame,fork, or parts. If you choose to ridein Condition 5 terrain, you shouldtake appropriate safety precau-tions such as more frequent bikeinspections and replacement ofequipment. You should also wearcomprehensive safety equipmentsuch as a full-face helmet, pads,and body armor.

cnditin 5 ike types

"Freeride" or "jumping" bikeswith heavy-duty frames, forks,and components



for ridingConditions 1 and

2, plus roughtrails, smallobstacles, andsmooth technicalareas, includingareas wheremomentary loss oftire contact with the ground mayoccur. NOT jumping.

All mountain bikes without rearsuspension are Condition 3, and soare some light-weight rear suspen-sion models.

cnditin 3 ike types

"Standard" or "cross-country"mountain bikes with wide,knobby 24, 26, or 29" tires

May include short-travel rear

suspension (3"/75 mm or less) Weight limit: 300 lbs (136 kg)


for ridingConditions 1, 2,and 3, plus roughtechnical areas,

moderately sizedobstacles, andsmall jumps.

cnditin 4 iketypes

"Heavy-duty" or "all-mountain"mountain bikes with wide,knobby 24, 26, or 29" tires

May include medium-travel rearsuspension (4"/100 mm or more)




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Learn the pwer f yr rakes

The stopping power on bikesvaries according to the intendeduse of the bike. If you would like

your bike to have more, or less,stopping power, consult yourdealer about brake adjustmentsor other brake options for yourbicycle.

Avid te-lip verlap

When ridingslowly, do notpedal if the

handlebar isturned. It maybe possible,at very slowspeeds, whenthe handlebaris turned, foryour foot or toe-clips to contactthe front wheel or fender (Figure2). At normal riding speeds, thehandlebar does not turn enoughfor this to occur.

Make sre the iyle fitsYour dealer should fit you with

the proper size of bicycle.

There shouldbe at least 1 (25mm) clearancebetween the toptube and the riderwhen standingover the bicycle(Figure 1). Formountain bikes,2-3 (50-75 mm)

clearance isrecommended.

The seat andhandlebar may beadjusted to offerthe best comfort and performance.Before making these adjustments,refer to Chapter 3.

Knw hw the iyle perfrms

The features of your bicycle, ifmisused, may cause you to losecontrol of the bike. Before ridingfast or in more difficult conditions,learn the function and performanceof all the mechanisms of your bikeby riding at slower speeds in a flat,empty parking lot.

If you want your bicycle toperform differently, or if you havespecial needs that require differentparts for the safe operation of yourbike, consult your dealer.

bEFoRE A FIRST RIDE

Figure - Minimum stand-

over heightA = " (5 mm) for most

bicycles

-" (50-75 mm) for

mountain bicycles

A

Figure - Toe-clip overlap

WARNINGMis-se f the raking system,inlding ver-se f the frntrake, an ase y t lsentrl and fall. Avid imprperraking y nderstanding andpratiing prper appliatin fyr rakes as explained in thismanal.

WARNINGcntat etween yr ft r te-lip and the frnt wheel r fenderan ase y t lse ntrl andfall. Avid pedaling when trningat slw speed.



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Stp riding if y have frameprlems

Occasionally riders experienceproblems with their frame or fork.If a frame or fork has any problem,do not ride the bicycle.

As an example, in very rarecases, some riders may experi-ence a shimmy or harmonicoscillation or frame vibration atcertain speeds. If you are experi-encing a shimmy, slow downimmediately. Take your bicycle

directly to a dealer for inspectionand repair.

Before every ride, inspect thebike with the following check list.If any part of the bicycle fails theinspection, repair the bicycle by

following the information providedby this manual, or take the bike toyour dealer for service. Never ridea bike with a damaged part; haveit replaced.

This is not a comprehensive maintenance

program.

befre every ride heklist

Wheels

Tire inflatin

brakes

Handlear and stem

Seat and seatpst

Sspensin adjstments

Lights and refletrs

Frame, frk, and mpnents

chek the wheels

Check that the wheels are straight.Spin each wheel and watch the rimas it passes through the brake padsor the frame. If the rim wobblesup and down or from side to side,repair the wheel.

Check that the wheels are properly

attached. Bicycle wheels are attachedby several systems: threaded axlenuts, a quick-release where a lever-

actuated wheel retention mechanism


WARNINGA shimmy, r steering wle,an ase y t lse ntrl andfall. If y experiene a shimmy,slw dwn immediately. Take yriyle t yr dealer fr inspe-tin and repair.

cHEcK THE bIKEbEFoRE EVERY RIDE

cAuTIoNA iyle that des nt wrk prperlyan ase y t lse ntrl and fall.Inspet the entire iyle thrghlyefre every ride, and d nt ride itntil any prlem has een rreted


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55

causes the brake pads to squeeze

the rim. When the brakes are notapplied, the brake pads should be 1to 2 mm from the rim.

Squeeze each brake lever towardthe handlebar to make sure thebrake moves freely and stops thebike. If the brake lever can bepulled to the handlebar, the brakeis too loose. If the brake pads aretoo close to the rim, the brake

is too tight. Brake pads shouldbe aligned with the rim surface(Figure 5).

Disc brake- a hand leverconnected to the brake by a cableor hydraulic hose squeezes a discmounted on the wheel hub.

Squeeze each brake lever towardthe handlebar to make sure the

brake moves freely and stops

Figure 5- Brake pad alignment

A- Brake pad aligned with rim surfaceB- Pad and rim should be parallel

C- Direction of rim rotation

D- 0.5-.0 mm toe-in

A

B

C

D

(Figure 3) allowsthe wheel to beinstalled andremoved without

tools, or a thru-axle where theaxle is threadedthrough the endsof the frame orfork. For informa-tion about adjust-ment and closureof the wheel attachment devices onyour bicycle, seeChapter 3.

Test for properwheel attachment.Pick up the bikeand sharply hitthe top of the tire(Figure 4). Thewheel must notcome off, be loose,

or move from sideto side. Furthertests are provided in Chapter 3.

chek the tire inflatin

Inflate the tires to the air pressurerecommended on the tire sidewalls.

chek the rakes

Follow the inspection instructionsfor the type of brake on your bike:

Hand-rim brake- a hand leverconnected to the brake by a cable

Figure - Test for loose-

ness


WARNINGA wheel attahment devie that isnt prperly adjsted and lsedmay allw the wheel t e lser me ff nexpetedly, asingy t lse ntrl and fall. Makesre the wheels are prperlyattahed efre riding the ike.

WARNINGNever ride a ike if y are ntertain the rakes are wrking

prperly, r y if sspet aprlem with the rake ales rhydrali hse. Malfntiningrakes an ase y t lsentrl and fall. Inspet the rakesthrghly efre every ride.If yr rakes are nt wrkingprperly, re-adjst them r takethe ike t yr dealer fr servie.

Figure - Wheel quick-

release


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the bike. If the brake lever canbe pulled to the handlebar, thebrake is too loose. The brake padsshould be 0.25-0.75 mm away fromthe disc when the brakes are notapplied. If the pads are too close,the brake is too tight, or mis-aligned.

Internal hub brake- a hand leverconnected to the brake by a cableactivates a mechansim inside thehub.

If it takes more than 5/8 (15mm) of brake lever movement tostop the bike, the brake is tooloose. If it takes less than 7 mm oflever movement to stop the bike,the brakes are too tight.

Coaster brake- the brake isengaged bypedalingbackwards.When pedalingbackwards, thebrake shouldengage with lessthan 60 degreesrotation (1/6

revolution).

The chain actuates the brake,so make sure the chain cannotcome off. There should be between1/4-1/2 (6-12 mm) total vertical

movement of the chain (Figure 6).

chek the handlear and stem

Make surethe stem is inalignment withthe front wheel.Test the stemconnection to

the fork byattempting to turnthe handlebarfrom side to sidewith the frontwheel lockedbetween yourknees (Figure 7).Test the security of the handlebarby attempting to rotate it in the

stem. It should not move or beloose. Make sure that no cables arestretched or pinched by rotatingthe handlebar.

Check that the handlebar plugsare properly inserted into bothends of the handlebar (and bar-ends).

chek the seat and seatpst

Make sure the seat is secure byattempting to turn the seat andseatpost in the frame, and attemptto move the front of the seat upand down. It should not move orbe loose.

Figure - Checking chaintension


Figure 7- Function testing

the handlebar and stem

cAuTIoNDis rakes and diss get very htdring se and ld rn skin. Als,

the dis edges may e sharp andld t skin. Avid thing thedis r dis rake when ht, r whenrtating.

cAuTIoNInternal h rakes get very ht

dring se and ld rn skin.Avid thing the h r lingfins when ht.


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or deform; a damaged part mayappear to be normal to a cursoryglance. If you have any doubtsabout the integrity of a part, do

not ride the bicycle.Be very careful when handling

carbon fiber parts that aresuspected of damage. When acomposite part is damaged, thereis a possibility that individualfibers may be exposed. Carbonfibers are thinner than a humanhair, but quite stiff. If the point

of one of these fibers is pressedagainst your skin, it could pierceyour skin like a needle.

Inspeting arn fier mpsiteframe, frk, r parts

Use the following procedures toinspect carbon composite parts:

Check for scratches, gouges, orother surface problems.

Check the part for loss ofrigidity.

Check the part for delamina-tion.

Listen for unusual creaking orclicking noises.

These tests may not be conclusive.

The tests are difficult todescribe, so we provide a movie

of inspecting a composite part onthe owner's manual CD and on theowner's manual web site.

T hek a part fr srfaeprlems (visal test)

1. Clean the part thoroughly witha damp cloth.

2. Look closely for problems:

scratches

gouges

cracks

loose fibers (which will appear

like thin hairs) other surface flaws

T hek a part fr lss f rigidity(flex test)

Use the part in a normal manner(without actually riding) whilesomeone watches carefully forunexpected movement.

As an example, if you suspecta composite seatpost has beendamaged, sit gently on the saddlewhile someone watches to see ifthe seatpost flexes.

T hek a part fr delaminatin(tap test)

1. Clean the part thoroughly witha damp cloth.

2. With a coin, tap the part nearany possible damage and placeswhere the part is known tobe in good condition (or use asimilar part).

3. Listen carefully for variationsin sound, especially a hollowsound, "dead" tone, or anysound indicating that the partis not solid.



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Figure - Wear a bicycle

helmet

45

90

Figure - Angle for cross-ing tracks


If a car suddenly enters your lane,or someone unexpectedly opensthe door of a parked car, you couldbe involved in a serious accident.

Mount a horn or bell on yourbicycle, and use it to alert others ofyour approach.

Wear a helmet and prperyling lthesWear a helmet

that meets CPSCor CE safety

testing standards(Figure 9); itmay help preventinjury.

Helmets shouldbe removed whennot riding thebicycle. If thehelmet is caught,stuck on, or stuck

between objects, the wearer couldchoke.

Wear protective clothing includinghelmet, eye protection, and gloves.Avoid loose-fitting pants that couldget caught in the chain.

Also wear light, bright, and reflec-tive clothing to make yourself morevisible, especially at night.

change yr riding t e safe invariale nditins

Ride areflly in wet weather

No brakes, whatever theirdesign, work as effectively in wetweather as they do in dry. Evenproperly aligned, lubricated,and maintained brakes require

greater lever pressure and longer

Knw and serve lal iyleriding lawsMost state and local areas have

specific laws for cyclists, and youshould follow them. Local cyclingclubs or your states Departmentof Transportation (or equivalent)should be able to supply thisinformation to you. The require-ments for items such as lights andreflectors change between areas,so check ahead.

These are a few of the more

important rules of riding: Use proper hand signals.

Ride single file when ridingwith other cyclists.

Ride on the correct side of theroad; never go against traffic.

Ride defensively; expect theunexpected. A cyclist is hard tosee, and many drivers simply

are not trained to recognizethe rights and special consider-ations of a bicycle rider.

Wath fr ars, pedestrians, andther stalesWatch for and avoid potholes,

drain grates, soft or low shoulders,and other deviations which couldimpact your wheels or cause themto slip. Whencrossing railroadtracks or draingrates, do socarefully at a 90angle (Figure 8).If you are not sureof riding surfaceconditions, walk

your bike.

RuLES FoR SAFE RIDING


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00

stopping distances in wet weather.Anticipate the extra distance it willtake to stop.

Wet weather causes reduced

traction. Use slower corneringwhen traction is reduced, suchas when riding over wet leaves,painted crosswalks, or manholecovers.

When wet weather cools to belowfreezing, traction is reduced evenfurther. In addition, brakes maynot work as well. Adjust your

riding speed accordingly, or useother forms of transportation.

When riding in wet weather, adynamo (generator light) may notwork properly. Avoid riding in wetweather when visibility is reduced.

Strong winds can make a bicyclesteer or turn unexpectedly. Inwindy conditions, slow down oruse other forms of transportation.

be arefl when riding in lw lightnditins.

Your bicycle is equipped with afull set of reflectors; keep themclean and in position. As useful asthese reflectors are, they do nothelp you see, nor do they help yoube seen unless light is directed onthem. Use a working headlight and

taillight when you ride in poorlylighted or low visibility conditions.The important thing is to see andbe seen. If you do any amount of

riding at dusk, at night, or in anypoorly lighted conditions, consultyour dealer to find appropriateproducts to aid your vision andmake you more visible.

D nt se nsafe riding praties

Many cycling accidents could beavoided by using common sense.Here are a few examples:

Do not ride no hands.

Do not ride with loose objectsattached to the handlebar orany other part of the bicycle.

Do not ride while intoxicated orwhile using medications whichmight make you drowsy.

Do not ride double.

continued next page


WARNINGA iyle rider witht prperlighting and refletrs may nthave gd visin and may nt evisile t thers. use frnt andrear iyle lights and refle-trs when riding in pr visiilitynditins. Failre t d s willinrease yr hanes f eing

invlved in an aident in lw lightnditins.

WARNINGThe fllwing riding pratiesinrease yr risk f injry:

Jmping yr iyle Perfrming iyle stnts Severe ff-rad riding Dwnhill riding Any anrmal ike riding

Eah f these praties inreasesthe stress n every part fyr iyle. Frames r partsnder high stress may fatigeprematrely, asing them t failand inreasing the risk f injry t

the rider. T derease yr risk finjry, avid these riding praties.


15/41

Use special care when off-roadriding. Ride only on the trails.Avoid rocks, branches, or depres-sions. When approaching a

descent, reduce speed, keep yourweight back and low, and use therear brake more than the front.

Do not ride in an abusivemanner; ride within the UseClassification for your type ofbicycle (see pages 1-2).

Bicycles are not indestructible.As with anything mechanical,

every part of a bicycle has alimited useful life due to wear,stress, and fatigue. Fatigue refersto a low-stress force that, whenrepeated over a large number ofcycles, can cause a material to failor break. The length of the life of apart varies according to its design,materials, use, and maintenance.Although lighter frames or parts

may, in some cases, have a longerlife than heavier ones, it shouldbe expected that light-weight,high-performance bicycles andparts require better care and morefrequent inspections.

Avid riding t fast

Higher speeds create higherrisks and greater forces in theevent of a crash. At higher speeds,it is more likely that wheels will


WARNINGTraining wheels prevent thenrmal inward lean f a iyledring a trn. If the iyle istrned t qikly, the ike maytip ver, reslting in an aident.

With training wheels, d nt ridefast r trn sharply.

slip, or that a small bump cancreate a significant impact to yourframe or fork. Keep your bicycleunder control at all times. For

children, the limit of speed for saferiding is much lower, so parentsshould strictly enforce this rule.


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RIDING INSTRucTIoNS

use yr rakes arefllyAlways keep a safe stopping

distance between you and othervehicles or objects. Adjust stoppingdistances and braking forces to suitriding conditions.

If your bike has two hand brakes,apply both brakesat the same time.Over-use, or mis-use, of a front-wheel brake, suchas using only the

front-wheel brakein an emergency,could cause therear wheel to liftfrom the groundwhich could causeyou to lose control (Figure 10).

Bicycles are normally manufac-tured with the left brake levercontrolling the front-wheel brake.

To change so that the right levercontrols the front-wheel brake, seeChapter 3.

Many models of modern brakesare very powerful; they are designedto stop a bike in wet or muddyconditions. If you feel your brakesare too powerful for your ridingneeds, take your bike to your dealer

for adjustment or replacement of thebraking system.

use gd shifting tehniqesShifting gears allows you to

choose the gear combination mostcomfortable for riding conditions,one that allows you to maintain aconstant rate of pedaling. Shiftingsystems are of two types: derail-leur (external) and internal.

Shifting a ike with a derailler

The left-hand shifter controlsthe front derailleur and the right-hand shifter controls the rearderailleur. Use only one shifterat a time. Shift gears only whenthe pedals and chain are movingforward. When you shift, reducethe force on the pedals to providequicker and smoother shifting,to help avoid excessive chain

and gear wear, and to help avoidbent chains, derailleurs, andchainrings. Avoid shifting whengoing over bumps; the chain maynot shift properly or may fall off.

With modern indexed shiftingsystems, a movement of the shifterfrom one position to the next (ormovement of the shifter to the"shift" position) should promptly

move the chain from one gear tothe next. However, bikes equippedSTI road shifters and triplechainrings may shift better, partic-ularly when shifting from thesmallest chainring to the middle, ifyou hold the lever for a momentbefore letting go of the shifter.

Shifting a ike with internal gearing

Shifting with internal gearing


Figure 0- Overuse of the

front-wheel brake

WARNINGApplying sdden r exessivestpping fre with the frnt-wheel rake may ase the rearwheel t lift ff the grnd, r thefrnt wheel t slip t frm ndery, whih an ase y t lsentrl and fall. Apply th rakesat the same time, and shift yr

weight akwards n the ikewhile raking.


17/41

Prtet yr ike when parkingr string it

Prtet yr ike frm theft

Purchase and use a lock thatis effective against bolt cuttersand saws. Never leave your bikeunlocked while unattended.

Rerd and keep yr serial nmer

Register your bicycle with yourlocal police department. Completeour on-line warranty registration;

we will keep the serial number ofyour bike on file. Also, write theserial number in the front of thismanual, and keep the manual in asafe place.

Park yr ike safely

When not riding, keep your bikein a place where it will be out ofthe way, and make sure it cannot

fall over. Do not lay the bike onits derailleurs, as you may bendthe rear derailleur or get dirt onthe drivetrain. Dont let the bikefall down, as this may cut thehandlebar grips, or tear the seat.Incorrect use of bike racks maybend your wheels.

Stre yr ike areflly

When not riding, keep your bikewhere it will be protected fromrain, snow, sun, etc. Do not storethe bike near electric motors,as ozone from motors destroysrubber and paint. Rain or snowmay cause the metal on yourbicycle to corrode. Ultravioletradiation from the sun may fadethe paint, or crack any rubber orplastic on the bicycle.

is best performed when coasting,stopped, or back pedaling. If youmust shift while pedaling, reduceyour pressure on the pedals.

Excessive chain tension makesshifting difficult.


TAKE cARE oFYouR bIKE


18/41


Before storing your bike for anextended period of time, cleanand lubricate it, and polish theframe with frame polish. Hang

the bicycle off the ground withthe tires at approximately halfpressure. Before riding the bicycleagain, be certain it is in goodworking order.

carry repair itemsCarry a pump, spare inner tube,

patch kit, and appropriate tools to

keep your bicycle running in thecase of a flat tire of other commonmechanical problem. If you rideat night, carry spare bulbs andbatteries for your lights.

only install and se apprvedaessriesNot all accessories are compat-

ible or safe, so only add accessories

that are approved by the manufac-turer. As an example, a childcarrier places weight high on thebike, affecting the stability of thevehicle. Although most of our bikescan be fitted with a child carrier,

the rider must use extra cautionto compensate for the decreasedstability.

The list of incompatible parts is

too long for this manual. If you areunsure whether a part is approved,consult your dealer.

Keep the ike leanIf your frame or a component

is dirty, clean it with a soft,damp cloth and bike cleaner or asolution of dish soap and water.

Use of industrial solvents orharsh chemicals for cleaning maydamage the paint.

Avid lamping the frame dringtransprtatin r repairNever clamp the bike frame by its

finished or painted surfaces. Thistype of clamp this may damage thepaint or even dent, crush, or break

the light-weight tubing used inhigh-performance bicycle frames.

Prtet yr iyle dringshippingIf you have to ship your bike,

make sure it is properly paddedand protected to avoid damage.Ask your dealer about suppliesused to ship a new bike, such as afork block.

WARNINGNever mdify yr framesetr parts in any way, inldingsanding, drilling, filing, remvingredndant retentin devies,installing inmpatile frks, ry any ther methd. Imprpermpnents r imprper assemlyan plae nknwn stress n yrike r mpnents. An imprperlymdified frame, frk, r mpnentan ase y t lse ntrl andfall. befre adding r hanging

any part f yr ike, nslt yrdealer.

NoTIcEClamping devices used by

work stands and car carrierscan damage the finish on abike or even crush the tubing.When putting a bike in a repair

stand, clamp the seatpost. Whencarrying a bike in a car carrier,clamp the wheels and the forktips.


19/41

55

cHAPTER 2: MAINTENANcE

Maintenane shedleThis maintenance schedule is

based on normal usage. If you rideyour bike more than average, or inrain, snow, or off-road conditions,service your bicycle more oftenthan the schedule suggests. If anypart appears to be malfunctioning,inspect and service it immediately,or consult your dealer. If a part isdamaged, replace it before ridingthe bicycle again.

After initial break-in, new

bikes should be checked forstretched cables and other normalconditions. Approximately twomonths after purchasing your newbike, have your dealer thoroughlyinspect the bicycle.

All bikes should be thoroughlyserviced once a year, even if theyhave not been ridden much.

Every rideCheck the wheels ...................... 4Check the tire inflation ............. 5Check the brakes ....................... 5Check the handlebar and stem . 6Check the seat and seatpost ..... 6Check the suspension adjust-

ments ..................................... 7Check the lights and reflectors. 7Check frame, fork, and

components ............................ 7

Weekly

Wipe off your bicycle with a dampcloth ..................................... 14

Check for loose spokes ............ 29Lubricate suspension forks ..... 34Check suspension fork bolts ... 31Check rear suspension bolts ... 18

Mnthly

Check the attachment of thehandlebar and stem ............. 17

Check the attachment of the seat and sea9Check the chain ...................... 21Check the chainguard (accesso-

ries) ...................................... 31Inspect cables for wear ........... 22Check the operation of shifters22Inspect derailleurs .................. 22Lubricate derailleurs ............... 34Check the internal shift system24Check headset bearing adjust-

ment ..................................... 21Check brake pads .................... 27Check brake bolts .................... 27Check chain tension .................. 6Inspect Trekking accessory bolts

31Check wheel bearing adjustment

29Check rims for wear ................ 29

Every 3 MnthsClean and polish finish ........... 13Check the crankset and bottom

bracket ................................. 21Lubricate brake levers ........... 34

Every year

Lubricate handlebar stem ....... 33Lubricate seatpost ................... 33Re-grease pedal threads and

bearings ............................... 21Re-grease bottom bracket

bearings ............................... 33Re-grease wheel bearings ....... 34Re-grease headset bearings .... 34Lubricate wheel quick-releases 34Re-grease suspension forks .... 34

Chapter : Maintenance


20/41

Remmended tls fr prperiyle maintenaneTorque wrench with lbin 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 19mm socket

T25 Torx wrench

No. 1 phillips head screwdriver

Bicycle tube patch kit, tire pump

with gauge, and tire leversSpecial high pressure air pump

for rear shock or suspensionfork

Note: Not all bikes require all these tools

Chapter : Maintenance


21/41

77

This chapter lists instructionsfor adjustment of the parts of abicycle. After any repair, inspectthe bike as explained in Chapter 1.

A Wrd At Trqe Speifiatins

Torque is a measurement ofthe tightness of a threadedfastener such as a screw or bolt,determined by using a torquewrench. The torque specifica-tions should be used to makesure you do not over-tighten thefasteners. Applying more than therecommended torque to a fastenerdoes not provide extra holding

power, and may actually lead todamage or failure of a part.

Always perform the simplefunction tests listed in this chapterto make sure a part is properlytightened, whether or not thepart was tightened with a torquewrench. If a part fails inspection atthe recommended torque, take thebike to your dealer.

cHAPTER 3: ADJuSTMENT

Handlear

T adjst the angle f the handlear

1. Loosen the handlebar clamp

bolt(s) on the stem (Figures11-12) just enough that thehandlebar can be rotated in thestem.

2. Position the handlebar to thedesired angle, making sure it iscentered in the stem.

3. Tighten the handlebar clampbolt(s) according to stem type:

Welded stems- 100-120 lbin(11.3-13.6 Nm).

Forged stems- 150-180 lbin(17-20.3 Nm)

StemThere are two types of stems:

Direct-connect (Figure 11)

Quill-type (Figure 12)

Adjusting thehandlebar heighton a direct-connectstem affects theheadset bearingadjustment.This procedurerequires specialtools and training

so this shouldonly be done byyour dealer.

T align a diret-nnet stem

1. Loosen the steerer clamp boltstwo to three turns.

2. Align the stem with the frontwheel.

3. Tighten the steerer clamp boltsto 100-120 lbin (11.3-13.6Nm).

Figure - Direct-connect

stemA- Handlebar clamp bolts

B- Steerer clamp bolts

B

A

Chapter : Adjustment

WARNINGA iyle that malfntins anase y t lse ntrl andfall. Inspet the entire iylethrghly efre every ride, andd nt ride it ntil any prlemhas een rreted.

WARNINGAn imprperly adjsted rtightened handlear, stem, rar-ends an ase y t lsentrl and fall. Make sre thestem, handlear, and ar-ends are

psitined and tightened prperlyefre riding the ike.


22/41

T align r adjst a qill-type stemTo adjust the height of the adjustable-rise stem

in Figure 12, rst change the stem angle, which

gives access to the stem expander bolt.

1. Loosen thestem expanderbolt two tothree turns.

2. Tap the topof the stemexpander boltwith a woodor plastic-faced mallet to

loosen the stemwedge.

3. Adjust thehandlebar tothe desiredheight, butwith theminimuminsertion

line insidethe frame(Figure 13). Aminimum of23/4 (70 mm)of the stemquill mustalways remainin the frame.

4. Tighten to

120 lbin (13.6 Nm).

T hange the angle f an adjst-ale-rise stem

1. Loosen the angle adjustmentbolt (Figure 12) until the stem

angle can be changed.

2. Position the stem to the desiredangle.

3. Tighten the angle adjustingbolt to 150-170 lbin (17-20.3Nm).

T hange the angle f a bntrageradjstale-rise stem

1. Slide thelocking button(Figure 14)forward andlift the quick-release lever.

2. Position thestem andhandlebar tothe desiredangle.

3. Close thequick-releaselever.

Make sure thelever is completely closed and thelocking button has returned to itslocked position.

T adjst the lamping fre f theqik-release lever f the bntrageradjstale-rise stem

1. Open the quick-release lever.

2. Turn the tension adjustingscrew (Figure 14).

3. Check that at about halfwaythrough the lever throw there issome resistance.

If the clamp force is too high or too low, re-adjust the screw.


WARNINGNever ride yr iyle with a qillstem raised ave the minimminsertin mark. A qill stem thatis psitined t high an damagethe ike and an ase y t lsentrl and fall. Make sre the

minimm insertin mark (Figre13) is inside the frame.

Figure - Adjustable-rise

quill stem

A- Handlebar clamp

bolts

B- Stem expander bolt

C- Angle adjusting bolt

B

C

A

Figure - Minimum

insertion mark on quill

stem

A- This line must be

inside the bike frame

A

Figure - Bontrageradjustable-rise stem

A- Tension adjusting

screw

B- Quick-release lever

C- Locking button

B

C

A


23/41

bar-endsBar-ends

(Figure 15) aredesigned forclimbing only.Ensure the bar-ends face forwardand away fromyou, but at anangle not lessthan 15 fromparallel to theground.

T adjst the angle f the ar-ends

1. Loosen the bar-end clampbolt(s) until they can be rotatedon the handlebar.

2. Position the bar-ends to thedesired angle.

3. Tighten the bar-end clamp boltto 85-125 lbin (9.6-14.1 Nm)

SaddleThe correct adjustment of the

seat angle is largely a matter ofpersonal preference. With properadjustment, the right bike seat willbe reasonably comfortable even forlong rides.

To select the saddle angle, firsttry riding with the top of the seat

parallel to the ground. For bikeswith rear suspension, try tiltingthe seat nose down slightly sothat compression of the rear shockunder your body weight (sag)results in a level seat.

The seat may also be movedforward or backward along theseatpost to increase comfort aswell as adjust the distance to thehandlebar.

Never engage the seatpost binderwith the seatpost out of the frame.

T adjst the angle f the seat

1. Loosen theseat fixing bolt(Figure 16)just far enoughso the seat canbe 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 astraight edge,such as a

bubble level orruler, acrossthe top of theseat to bettersee the angle.

Figure - Seatpost parts

A- Seat xing bolts

B- Seatpost

C- Seatpost binder bolt

A

B

C


WARNINGExtended riding with a prlyadjsted saddle r ne that des

nt prperly spprt yr pelviarea an ase injry t yrnerves and ld vessels. If yrsaddle ases pain r nmness,re-adjst the saddle psitin.If after adjstment yr saddlestill ases pain r nmness,nslt yr dealer at frtherpsitining r replaing the saddlewith ne that etter fits y.

Figure 5- Bar-ends

A- Bar-end clamp bolt

A

Figure 7- Bontrager

seatpost

A- Seat xing bolt

A


24/41

00

3. Adjust the seat and re-tightenthe seat fixing bolt accordingto the type of seatpost:

Double bolts using a 5 mmallen wrench- 80-125 lbin (9.6-14.1 Nm).

Single bolt using a 13 or 14mm open-end wrench- 180-220lbin (20.3-24.9 Nm).

Single bolt using a 6 mm allenwrench- 150-250 lbin (17-28.3Nm).

Double bolts using a 4 mmallen wrench- 45-60 lbin (5-6.8Nm).

T adjst the seat height f aiyle

1. Sit on the seat in ridingposition without shoes, whilesomeone holds the bicycle up.

2. Position the crank arms so

they areparallel tothe seattube.

3. Loosen theseatpostbinder bolt,or quick-release.

4. Extend theseatpostuntil, withyour heel resting on the bottompedal, your extended leg isstraight (Figure 18).

When wearing your shoes there should be a

slight bend in your knee in a proper riding

position; with the ball of your foot on the pedal.

5. Make surethe minimuminsertionmark on

the seatpost(Figure 19)is not visibleabove thebike frame. Aminimum of21/2 (64 mm)of seatpostmust remainin the frame.

6. Close the seatpost quick-release, or tighten the bolt to85-125 lbin (9.6-14.1 Nm)

T adjst the seat psitin f atriyle

1. Loosen andremove theclamp bolts(Figure 20).

2. Move theseat mast tothe desiredposition.

3. Install andtighten theseat mastclamp bolts to85-125 lbin(9.6-14.1 Nm).


Figure - Minimum

insertion mark on

seatpost

A- This line must be

inside the bike frame

A

WARNINGA seatpst that is psitined thigh an damage the ike and anase y t lse ntrl and fall.

Make sre the minimm insertinmark (Figre 19) is inside the frame.

Figure - Leg extension with

proper seat height

Figure 0- Tricycle seat

mast

A- Seat mast

B- Clamp bolts

A

B


25/41

crank armsSome bicycles offer adjustable

crankarm length. To change thecrank length, remove the pedalsand install them into the secondset of holes. Tighten by followingthe instructions for Pedals.

PedalsTo adjust the release force

on clipless pedals, refer to theinformation on the CD suppliedwith your bicycle, or consult your

dealer.The left pedal is left-hand

threaded, while the right pedalis right-hand (normal) threaded.Tighten pedals into the crankarmsto 350-380 lbin (40.2-42.9 Nm).

Adjustment of pedal bearingsrequires special tools andtraining. These services shouldonly be performed by your dealer.

bttm raketAdjustment of bottom bracket

bearings requires special toolsand training. These servicesshould only be performed by yourdealer.

chain

T adjst the hain tensin n asingle speed ike

1. In small increments, loosen therear wheel axle nuts on alternatesides of the wheel.

If you fully loosen one side before loosening the

other, you may cause the bearings to come out of

adjustment.

Headset

T hek if the headset is lse rtight

1. Apply the front brake firmlywhile you rock the bicycleforward and backward.

2. With the front wheel off theground, slowly rotate the forkand handlebar to the right andleft.

If the headset bearings rock inthe frame or do not turn smoothly,

do not ride the bicycle; take thebike to your dealer for service.

Adjustment of headset bearingsrequires special tools and training.These services should only beperformed by your dealer.

crankset

T hek the ttm raketearing adjstment

1. Lift the chain from thechainrings.

2. Rotate the crank so that one ofthe arms is parallel to the seattube.

3. Put one hand on the crank armand one hand on the seat tube,and attempt to move the crank

arm laterally toward and awayfrom the seat tube.

4. Spin the cranks.

If the crank feels or sounds loose,or if the motion stops abruptly oryou hear a grinding noise comingfrom the bearings, the bearingsneed to be adjusted or re-greasedby your dealer.



26/41

3. Turn the low gear adjustingscrew (marked L) until theinner chain guide of the derail-leur is approximately 0.5 mm

from the chain.4. Pull on the cable end, and

down-shift the left shift leverseveral times so that it is in thesmall-chainring position.

5. On the shifter or down tube,turn the shift cable adjustingbarrel to its most clockwiseposition.

6. Insert the cable in the groovefound next to the derailleurcable clamp bolt, pull the cabletaut, andtighten the bolt:

Front derailleur cable clampbolt- 44-60 lbin (5.0-6.8 Nm).

T adjst the ig hainring psitin

1. Shift the rear derailleur to the

smallest rear cog.2. Turn the high-gear adjusting

screw (marked H) counter-clockwise until it cannotinterfere with the motion of thederailleur.

3. Hand-turn the cranks, and usethe shifter to carefully shiftthe chain onto the outsidechainring.

4. Position the outer chain guideof the front derailleur approxi-mately 0.5 mm from the chain.

5. Re-tighten the high gearadjusting screw until it meetsresistance.

If you have turned the screw too far, the front

derailleur will move toward the small chainring.

2. Slide the wheel to re-tensionthe chain, and center the wheelin the frame.

Some models have a chain tensioning device which

helps position the wheel.

3. Complete the wheel installa-tion.

calesCheck the cables for kinks, rust,

broken strands, or frayed ends.Also check the housing for loosewire strands, bent ends, cuts, and

wear. If you suspect a problemwith a cable, do not ride thebicycle; follow the instructions toreplace a cable (page 34), or haveyour dealer service the bicycle.

ShiftersThe position of the shifters can

be adjusted on the handlebar.Follow the instructions for

adjusting the lever position onpages 25-26.

Frnt derailler

T adjst the small hainringpsitin

1. Shift thechain onto the

smallest frontchainring andthe largestrear cog.

2. Loosen thefront derail-leur cableclamp bolt(Figure 21)until the cable

is free.


Figure - Front derail-

leur

A- Cable

B- Adjusting screwsC- Cable clamp bolt

A

B

C


27/41

6. Go through the various gearcombinations. Make sure thechain does not fall off when youshift, and the derailleur cage

does not rub on any part of thecrankset.

T adjst the middle gear psitin,with three hainrings

1. Shift the chain onto thelargest front chainring and thesmallest rear cog.

2. Rotate the cable tension barrel-

adjuster (on the downtube, oron the lever) counter-clockwise,increasing cable tension toalign the inner derailleur cageuntil it just touches the chain.

3. Go through the various gearcombinations to ensure thechain smoothly lines up with allthe chainrings.

Note: some front shifters have a tab feature:

slightly downshift the lever and the derailleur

will move in slightly, no longer touching the

chain.

Rear derailler

T adjst the small g psitin

1. Shift the chain onto thesmallest rearcog and the

largest frontchainring.

2. Loosen thecable clampbolt (Figure22) until thecable is free.

3. Stand behind the bicycle to seethat the smallest rear cog, thechain, and the two derailleurpulleys are in line.

4. If they are not aligned, turnthe high gear adjusting screw(usually marked H,) until thisline is established.

5. While pulling on the cable, up-shift until the shifter is in thesmall cog position.

6. On the shifter or down tube,turn the adjusting barrel

all the way clockwise. Turnthe adjusting barrel on therear derailleur all the wayclockwise, and then one turncounter-clockwise.

7. Insert the cable into the clampbolt groove on the rear derail-leur, pull the shift cable taut,and tighten the cable clamp bolt

to 44-60 lbin (5.0-6.8 Nm).

T adjst the large g psitin

1. Turn the low gear adjustingscrew on the rear derailleur(usually marked L) far enoughcounter-clockwise that it willnot restrict the movement ofthe derailleur.

2. Carefully shift the chain onto

the smallest front chainringand 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 derailleurpulleys in line with the largestcog.

4. Turn the low gear adjustingscrew clockwise until it meetsresistance.


Figure - Rear derailleur

A- Adjusting screws

B- Barrel adjuster

C- Cable clamp boltD- Cable

A

B

C D


28/41

If you have turned it too far, the derailleur will

move toward the outside of the bicycle.

5. Go through the various gearcombinations. Make sure the

chain does not fall off when youshift.

T align the indexing system

1. Shift the chain onto thelargest front chainring and thesmallest rear cog.

2. Shift one click with the rearshifter.

3. Check if the chain movessmoothly to the next gear.

If the chain makes excessivenoise or does not shift, turnthe barrel-adjuster counter-clockwise in small incrementsand check again for a smoothshift.

If instead, the chain moves tothe third smallest cog, turn thebarrel adjuster clockwise untilthe derailleur pulleys align withthe second smallest cog.

4. Go through the gear combina-tions to ensure the chainsmoothly lines up with all therear cogs.

If the derailleur cannot beadjusted in this manner, the

derailleur hanger may be out ofalignment; take the bike to yourdealer for service.

Nexs 4, 7, r 8 speed systems

T adjst the rear shifting

1. Rotate the shifter to the 4th

gear position.

2. Align the indicator on the rearhub pulley (Figure 23) withthe cog jointbracket.

3. If the redlines do notline up, adjustthe gear cable

tension byrotating thebarrel adjusteruntil thisalignment isachieved.

4. Shift to 1stgear, thenback to 4th, and re-check theadjustment.

3 speed systems

T adjst the rear shifting

1. Rotate theshifter tothe 2nd gearposition.

2. Align the

indicator onthe bell crankwindow withthe line onthe push rod(Figure 24).


Figure - Pulley and cog

joint bracket

A- Pulley

B- Cog joint bracket

C- Cable clamp bolt

BA

C

Figure - Three-speed

bell crank

A- Bell crank window

A


29/41

55

brake leversThe brake

system allowsyou to slow orstop your bike, afunction criticalto your safety.

The brakesystem is difficultto adjust properlywithout the propertools and training.It is strongly

recommendedthat adjustment of a brake be doneby your dealer. If you need morespecific information regarding yourbrake system,contact yourdealer.

T adjst thepsitin f a lever

1. Locate thelever clampbolt (Figures25-27).

2. Loosen theclamp bolt 2-3turns.

3. Position thelever.

4. Tighten theclamp bolt:

Regular brakelevers- 53-69lbin (6.0-7.8Nm).

On mid-barlevers (Figure27)- 20-30

lbin (2.3-3.3Nm).

3. If the indicators do not lineup, adjust the gear cabletension by rotating the barreladjuster until this alignment is

achieved.4. Shift to 1st gear, then back to

2nd, and re-check the adjust-ment.


Figure 5- Lever clamp

bolt, road lever

A- Lever clamp bolt

A

Figure - Lever clamp

bolt, mountain lever

A- Lever clamp bolt

B- Reach adjustment

screw

C- Cable

D- Barrel adjuster

A

C

D

B

Figure 7- Mid-bar brake

leverA- Lever clamp bolt

A


30/41

Hayes hydraulic levers- 25-35lbin (2.8-4 Nm)

T adjst the reah t the rake

lever (ale type)With some brake levers, you can

change the reach, the distance fromthe handlebar to the lever.

1. Locate the reach adjustmentscrew (Figure 26) and turn.

To decrease the reach, turn the screw in

(clockwise). To increase the reach, turn the

screw out (counter-clockwise).

2. If needed after adjusting thereach, re-adjust the brake padclearance.

T adjst the reah t the rakelever (Hayes hydrali type)

1. Locate the reach adjustmentscrew between the lever andthe handlebar, near the leverpivot.

2. To decrease the reach, turnthe screw in (clockwise). Toincrease the reach, turn thescrew out (counter-clockwise).

T hange whih lever ntrls thefrnt rake (ale type)

See the Brakes section for brake adjustment

procedures.

1. Open the brake.

2. For a road bike, disconnectthe brake cable and completelyremove it from the lever.

For a mountain bike, justremove the leaded end of thecable from the lever.

3. Install the cables into theopposite levers.

4. Close the brakes.

5. Inspect the brakes as explainedin Chapter 1, and re-adjust asnecessary.

T hange whih lever ntrls thefrnt rake (Hayes hydrali type)

Changing the levers with Shimano hydraulic

brakes requires special tools and training so

should only be done by your dealer.

1. Loosen and remove both leverclamp bolts.

2. Remove the levers and re-position according to yourpreference.

3. Re-install the clamp bolts andtighten to 25-35 lbin (2.8-4Nm).



31/41

77

brakesOnce a month,

inspect brakepads for wear.If the groovesin the brakingsurface are lessthan 2 mm deep,or 1 mm deep fordirect-pull brakes,replace the pads.Replace discbrake pads that

are thinner than1.0 mm.

T adjst rakepad learane tthe rim

1. Turn thebarrel adjuster.To increase thepad clearance,

turn the barreladjuster in(clockwise).To reduce thepad clearance,turn the barreladjuster out(counter-clockwise).

For most direct-pull

(Figure 28), orcantilever (Figure

30) systems the

barrel adjuster is on

the lever. For most

road caliper systems

(Figure 29) the

barrel adjuster is on

the brake itself.

2. If the brake pads cannot beadjusted properly, loosen thecable clamp bolt and re-attachthe cable.

T enter a V-type, antilever, rrad rake

1. Rotate the centering screw.Turn in small increments andcheck for centering.

2. If the brake has two centeringscrews, adjust the overall springtension while centering the

brake.

T adjst the alignment f therake pads n a rim rake

1. Loosen the brake pad fixingbolt.

2. Align the pads as shown onpage 5, and tighten the padfixing bolts:

Road caliper- 40-60 lbin (4.5-6.8 Nm)

Direct-pull or cantilever- 70-80lbin (7.9-9 Nm)

3. After adjusting the brakes, testthem by applying force to thelevers. Ensure the cable doesnot slip, the pads close towardthe rim at right angles, and thepads do not contact the tire.

T align a hydrali dis rake

1. Loosen the brake mountingbolts.

2. Apply the lever fully, andgradually tighten the bolts to100-110 lbin (11.3-12.4 Nm).


Figure 0- Cantilever

brake

A- Linkwire

B- Pad xing bolt

C- Arm xing bolt

D- Centering screw

A

DC

B

Figure - Direct pull

brake

A- Cable clamp bolt

B- No contact

C- Pad xing boltD- Centering screw

E- Arm xing bolt

A

C

E

D

B

Figure - Caliper brake

A- Barrel adjuster

B- Centering screw

C- Pad xing bolt

D- Brake relase lever

A B

C

D


32/41

T align a ale-atated dis rake

There are several parts to thisprocedure:

To adjust right brake pad

clearance to the disc

1. Turn the fixedpad adjuster(Figure 31).

2. If the padscannot beadjustedproperly in thismanner, follow

the instruc-tions To adjustleft brake padclearance to thedisc, and re-setthe 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 adjusterin (clockwise). To reducethe pad clearance, turn thebarrel adjuster out (counter-clockwise).

2. If the pads cannot be adjustedproperly in this manner, loosenthe cable clamp bolt and re-attach the cable. Tighten the

cable clamp bolt to 50-70 lbin(5.7-7.9 Nm).

3. After adjustment, turn thelocking nut clockwise to helpprevent rotation of the barreladjuster.

To align the brake with the disc

1. Loosen the brake mountingbolts.


2. Slide a business card, orsimilar thin object, between theright brake pad and the disc.

3. Apply the lever fully, andgradually tighten the bolts to100-110 lbin (11.3-12.4 Nm).

T remve dis rake pads

1. Remove the wheel.

2. With your fingers or thin-tipped pliers, grasp the installa-tion tang of the brake pad andpull out.

T pen the rake fr wheel remval

For most road calipers, lift thebrake release lever to the openUP position. To close, simplyturn the lever to the Downposition.

For Campagnolo levers, there is arelease button at the top of the

lever. Slightly depress the brakelever, and push the button untilit is flush with the lever body.Release the lever and the brakewill open.

To close, reverse the instruc-tions.

For cantilever brakes, release thelinkwire. With one hand, squeezethe brake pads firmly against the

rim. With the other hand, pull theleaded end of the linkwire fromthe retaining fork on the brakearm. Release the brake pads, andthe brake will open.

To close the brake, reverse theinstructions.

Figure - Disc brake

A- Mounting bolts

B- Fixed pad adjuster

C- Cable clamp bolt

C

A

B


33/41

WheelsInspect tires for wear and

damage. Make sure rims areclean, and check for wear; if the

small indentations on the brakingsurface disappear, replace the rim.

Make sure there are no loose,damaged, or broken spokes. Checkthat hub bearings are properlyadjusted. Make sure a rim stripis in place and all spoke holes arecompletely covered.

T adjst and install a qik-release

wheel1. Move the

quick-releaselever to theOPEN position(Figure 32)and set thewheel so itfirmly touchesthe inside of

the fork ends.2. With the lever

about halfwaybetweenthe OPENand CLOSEpositions,tighten the adjusting nut(Figure 33) until finger-tight.

For direct-pull type brakes,disconnect the pipe from thelink arm. With one hand,squeeze the pads firmly against

the rim. With the other hand,pull the pipe back from the linkarm, and lift the pipe. Oncedisconnected, let go of thebrake pads and the brake willopen.

To close the brake, reverse theinstructions.

For internal or drum brakes, to

remove the rear wheel, firstdisconnect the shift and brakecables.

-To disconnect the brakecable, press the cable carrierarm forward, and the cableclamp bolt rearward, so the boltaligns with the larger diameterhole in the carrier. Pull thecable clamp bolt outward todisengage it from the carrier.Slide the brake cable stopforward to remove it from thebrake arm. Undo brake strapbolt.

-To disconnect the shift cable,put the shifter in 1st gear. Pullthe cable housing out of theshift cable housing stop. Rotate

the shift cable fixing bolt untilthe washer flats align with theslit in the cog joint bracket.Remove the cable.


OPEN

CLOSED

Figure - Lever positions

WARNINGbrake pads remve material whenthe rake is applied. If t mhmaterial is remved, the rim mayeme weak and fail sddenly,asing a lss f ntrl. Reglarlyinspet yr rims fr wear and

replae them when they are wrn.

Figure - Tighten nut

A- Adjusting nut

A


34/41

00

3. Place the lever in the palm ofyour hand and throw the leveras shown inFigure 34 to

the CLOSEposition(Figures 36-37).

At the half-closed position ofthe lever, thereshould be someresistance.

Do not tightenthe quick-release wheelretentionmechanismby turningthe lever likea wing nut(Figure 35); itwill not result

in sufficientforce to holdthe wheel inplace.

5. If the leveris moved tothe CLOSEposition withlittle or noresistance,clampingstrength isinsufficient. Return the leverto the OPEN position, tightenthe adjusting nut further, closethe lever, and again test forresistance. For further informa-tion on correct adjustment ofthe quick-release tension, read

Figure 38.

6. Orient the quick-releaselevers so they do not interferewith any other bicycle part oraccessory part (such as rack orfenders), and so obstacles in thepath of the bicycle cannot snag

the levers.7. Test that you have properly

adjusted and closed the quick-release. If the quick-releasefails any test, either repeatthese adjustment procedures,including these tests, or takeyour bicycle to your dealer forservice.

8. Test for proper quick-release

adjustment:

Pick up the bike, and sharplyhit the top of the tire (Figure39). The wheelmust not comeoff, be loose,or move fromside to side.

Make sure the

quick-releaselever cannot berotated parallelto the wheel(Figure 40).


Figure - Test for

looseness

Figure 0- Test forrotation

Figure 7- Rear lever

position

If it requires more than 5 pounds (00 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 pounds (5. Newton) force to

begin to open the lever from the fully closed position,

open the lever and slightly tighten the quick-releaseadjusting nut.

Repeat the adjustment if necessary.

Figure - Actual measurements

OPEN

OPEN

OPEN

OPEN

Figure 5- Do not turn

lever

Figure - Front lever

position

Figure - Proper lever

throw


35/41

When the quick-release isproperly tightened and clampedby the lever in the closedposition, the clamping force is

adequate to cause metal-into-metal engagement (embossing)of the dropout surfaces.

See Figure 38.

T install an axle-nt wheel

Some wheels are attached bynuts threaded onto the axle. Thefront wheel may require a toothed

washer to be placed between thenut and fork tip. Some bicyclesalso have pegs, tubular axleextension.

1. Tighten the axle nuts:

Tighten a regular front wheelto 180-240 lbin (20.3-27.1Nm).

Tighten a regular rear wheel to240-300 lbin (27.1-33.9 Nm).

2. Test to ensure that you haveproperly tightened the axle-nuts.

Pick up the bike, and sharplyhit the top of the tire (Figure39). The wheel must not comeoff, be loose, or move from sideto side.

If the wheel attachment fails thetest, repeat these procedures,including the tests, or take yourbicycle to your dealer for service.

T install a thr-axle wheel

1. Open the quick-release orloosen the clamp bolts on bothfork ends.

2. With the wheel in place, slide

the axle into the fork tips.

3. Close the quick-releases, ortighten the clamp bolts to 45-55lbin (5.1-6.2 Nm).

4. Test to ensure that you haveproperly attached the thru-axle.

Pick up the bike, and sharplyhit the top of the tire (Figure39). The wheel must not comeoff, be loose, or move from sideto side.

If the wheel attachment failsthe test, repeat these procedures,including the tests, or take the

bicycle to your dealer for service.

Sspensin mpnentsChanging your suspension

settings affects handling andbraking characteristics. Aftermaking a change, carefully test thebike in a low traffic area until youare familiar with its performance.

Sag is the compression of ashock that occurs when therider sits on the bike in a normalposition. For an all-round ride, setthe forks at about 15% sag, anda rear shock at about 25% sag.Experiment with the adjustmentin small increments to find yourpreference. If the suspension isfully compressed, its movement

will stop abruptly and could causeyou to lose control. See the CD orweb site for more specific adjust-ment and maintenance informa-tion, or consult your dealer.

AessriesOnce a month, check any

accessories to make sure theyare properly attached. If any partseems loose or misaligned, eithertighten the part or take the bike toyour dealer for service.



36/41

T adjst training wheelsSee other sections of this manual as needed.

1. Place the bike on a flat, smoothsurface, with the tires properly

inflated.2. Loosen the rear axle nuts.

Follow the procedures in theWheelssection.

3. Stand the bike up verystraight, and set a gap ofabout 1/4 (6 mm) between thetraining wheels and the groundon both sides of the bike. Make

sure the gap is the same onboth sides.

4. Adjust the chain tension andre-tighten the axle nuts.

T install a light l

1. Locate the lens set-screw onthe back of either the taillightor head light.

2. Remove the screw.3. Rotate the lens 1/4 turn

clockwise and lift the lensassembly off the bulb mount.

4. Unscrew the bulb.

Be careful not to crush the glass of the bulb.

Do not dislodge the wire in the base of the bulb

mount.

5. Screw a new bulb in untilfinger tight.

6. Place the lens on the bulbmount, rotate the lens 1/4 turncounter-clockwise.

7. Install the lens set-screw.

Check that the new bulb works.If it does not, check the wiring forcorrect placement, and verify thatthe new bulb is not damaged.

Flding ikeSome models of Trek bikes have

a large hinge in the middle to foldthe bike by following these steps:

T lwer the saddle

1. Open the seatpost quick-release and lower the saddle.

2. Close the quick-release to holdthe seatpost in position.

T fld the pedals

1. Push the end of the pedal

directly inward, toward thecrankset.

2. Fold the pedal over.

3. Repeat for the other pedal.

T fld the handlear stem

1. Rotate the lever lock awayfrom the lower quick-release.

2. Hold the handlebar with the

cables out of the way to preventpinching, and open the lowerquick-release.

3. Fold the handlebar assembly toits down position.

T fld the main frame

1. Open the latch lock.

2. Pull outwards, away from the

frame, on the end of the framelatch until the latch opens.

3. While avoiding pinchingyourself or cables, fold the bikein half.

To unfold the frame, reverse thesteps of the folding procedure.


WARNING

Riding a flding ike withmvement at the lwer stem qik-release r main frame hinge ldase y t lse ntrl and fall. Ifthe flding frame mves at the stemr frame hinge, take the ike t yrdealer fr servie.


37/41

This section explains the partsthat require lubrication, theirfrequency, and brief instructions.See your dealer for recommended

lubrications. If you need moredetailed information, see othersections of this manual as needed,or consult your dealer.

Re-greasing bearings requiresspecial tools and training, sothis should only be done byyour dealer. Some bearings arepermanently sealed and do not

require yearly re-greasing

StemOnce a year lubricate the stem.

Note: Lubricating a direct-connect stem

requires adjustment of the headset bearings, so

should only be done by your dealer.

1. Remove the stem from theframe.

2. Clean the stem and wipe any

old grease.3. Apply a thin layer of grease

to the section of the quill thatwill be inserted into the frame,including the stem wedge.

4. Install the stem.

SeatpstOnce a year, lubricate the

seatpost. Choose the method foryour frame and seatpost material:

Alminm seatpst in a metalframe

1. Loosen the seatpost binderbolt, or open the quick-release,and remove the seatpost fromthe frame.

2. Wipe any old grease off theseatpost, and clean if necessary.

3. Apply a thin layer of grease tothe section of the seatpost thatwill be inside the frame.

4. Insert the seatpost into theframe.

5. Adjust the seat to the properheight, align it, and tighten theseatpost binder bolt.

carn fier seatpst, r arnfier frame

1. Loosen the seatpost binderbolt, or open the quick-release,

and remove the seatpost fromthe frame.

2. Wipe the seatpost and insidethe seat tube with a soft clothand clean water.

3. Let the seeatpost dry, theninsert it into the frame.

4. Adjust the seat to the properheight, align it, and tighten the

seatpost binder bolt.

bttm raketOnce a year, have your dealer

re-grease the bottom bracketbearings,

PedalsOnce a year, have your dealer re-

grease the pedal bearings.Once a year re-grease the pedal

axles where they thread into thecrank arms.

Note: There are right and left pedals, usually

marked with a letter stamped on the end of the

pedal axle, or on the wrench ats.

1. Remove the pedals; turn theright pedal spindle counter-clockwise, but turn the left

clockwise.

cHAPTER 4: LubRIcATIoN

Chapter : Lubrication


38/41

2. Apply a this layer of greaseover all the threads.

3. Install the pedals on the properside; put the right pedal on theright crank arm and the leftpedal on the left crank arm.

4. Tighten the pedals.

DeraillersEvery month, lubricate all pivot

points on both the front and rearderailleurs, including the derail-leur pulleys on the rear derailleur,

with chain lube.

HeadsetOnce a year, have your dealer re-

grease the headset bearings.

brakes and rake leversEvery 3 months lubricate your

brake lever pivots and brake arm

fixing pivots with a light oil.

WheelsOnce a year, have your dealer re-

grease the wheel bearings.

Every year, lubricate wheelquick-releases. Apply severaldrops of synthetic lube or asimilar light oil where the quick-release lever rotates in the quick-release body.

Sspensin frksOnce a month, apply a light oil to

the upper fork leg where the lowerleg slides on it. Wipe clean.

Rear sspensinNo lubrication is required for

the shock or the pivot of yourfull suspension bike. Avoid alllubricants.

cntrl alesLubricate cables whenever they

are installed.

T install a aleInstalling a cable in a cantilever brake requires

special tools and training, so should only be

done by your dealer.

1. Note the path of the old cable,loosen the cable anchor bolt,and remove the worn cable.

2. Grease the new cable andreinstall, feeding it along thesame path as the old cable,including through the cableanchor bolt.

3. Make sure the leaded cable-endis seated properly in the lever,and the housing is properlyseated in the lever.

If needed when installing a cable in a brake,

re-adjust the brake.

4. Turn the adjusting barrel

clockwise so the threads onthe adjusting barrel are notexposed.

For a shift cable, put the shifter in the position

with the least cable tension.

For a brake, hold the brake closed while you do

the next step.

5. Tighten the cable clamp boltto52-69 lbin. (6-8 Nm).

6. Cut the cable so that no more

than 2 (51 mm) extendsbeyond the anchor bolt.

7. Crimp a metal cap or place abit of solder on the end of thecable to prevent fraying.

8. Follow the instructions foradjustment.

Chapter : Lubrication


39/41

55

If you would like additionalinformation about your bicycle,maintenance, or bicycling ingeneral, there are many resources

in your community.First, talk to your bicycle dealer.

They have extensive experiencewith bicycles and riding in yourcommunity. With this background,they can help you with yourindividual questions and helpyou find areas to enjoy your newbicycle. In addition, most dealers

stock a variety of book aboutcycling, including extensive repairmanuals.

Second, check your publiclibrary. Most libraries haveextensive offerings of bookswritten by experts in the fieldabout riding, racing, bicycle safety,bicycle maintenance, and more.

Third, go on-line. The best on-

line resource for your bike canbe found by viewing the CD thataccompanies this manual. Placethe CD in a computer, and youwill find much more information.With internet access, you can linkdirect from the CD to our companyweb site. Links to some of thecompanies that make the parts ofyour bike are also provided. All of

this information and help is just aclick away.

FoR MoRE INFoRMATIoN

For more information


40/41

All Trek bikes are sold exclusivelythrough our network of AuthorizedDealers who we entrust with profes-sional assembly and service of your

bicycle.Trek Bicycle Corporation warrants

each new Trek frame, rigid fork, ororiginal component part of the bicycleagainst defects in workmanship andmaterials:

Fr the lifetime f the riginalwner- The bicycle frame, except the fork

and the Session model

Fr five years- Rigid forks

All Bontrager components andaccessories, except consumablessuch as tires and inner tubes.

Fr three years- The Session model frame

Fr ne year- Paint and decals

All original parts, excluding

suspension forks, and rear shockabsorbers

All original parts, excludingShimano parts, suspension forks,and rear shock absorbers

All Shimano parts, suspensionforks, and rear shock absorbersshall be covered by the statedwarranty of the original manufac-turer.

This warranty des nt ver- Normal wear and tear

Improper assembly

Improper follow-up maintenance

Installation of parts or accesso-ries not originally intended for, orcompatible with, the bicycle as sold

Damage or failure due to accident,misuse, abuse, or neglect

Labor charges for part replacement

or changeover

This warranty is void in its entiretyby any modification of the frame, fork,or components.

This warranty is expressly limited

to the repair or replacement of adefective item and is the sole remedyof the warranty. This warranty extendsfrom the date of purchase, appliesonly to the original owner, and is nottransferable. Trek Bicycle Corporationis not responsible for incidental orconsequential damages. Some states donot allow the exclusion of incidental orconsequential damages, so the aboveexclusion may not apply to you.

Claims under this warranty mustbe made through an authorized Trekdealer. Proof of purchase is required.The subject item must be registeredwith Trek Bicycle Corporation, eitherthrough on-line registration or by thereceipt of a warranty registration cardby Trek Bicycle Corporation, before awarranty claim may be processed.

Warranty duration and detail maydiffer by frame type and/or by country.

This warranty gives the consumerspecific legal rights, and those rightsmay vary from place to place. Thiswarranty does not affect the statutoryrights of the consumer.

carn rash replaement pliyAssessing any damage done to a

carbon fiber part requires more experi-ence than is needed to inspect metalparts. If you crash or impact yourbike and the force of the impact isabsorbed by a carbon part, we stronglyencourage you to replace the part, evenif there are no indications of damage.

If such a crash or impact occurs,Trek offers a crash replacementprogram for carbon parts, substantiallyreducing any replacement cost. To takeadvantage of this program, contact ususing the information listed above and

ask for the Warranty department.

LIMITED WARRANTY

Limited warranty


41/41

2006 Trek Bicycle Corporation

ll ht d

Customer Service

920-478-4678www.trekbikes.com

801 West Madison Street

Waterloo, Wisconsin 53594 USA

An english version of this manual is on the CD. If you do not have access to a com-puter and would like a printed version, contact us at the address on this page.

Une version franaise de ce manuel se trouve sur le CD. Si vous navez pas accs un ordinateur et si vous souhaitez obtenir une version papier, contactez-nous

ladresse qui gure sur la page.

Eine deutsche Version dieses Handbuchs nden Sie auf der CD. Wenn Sie keinenComputer zur Verfgung haben und eine Druckversion des Handbuchs wn-schen, wenden Sie sich an uns unter der hier angegebenen Adresse.

Una versin espaol de este manual se encuentra en el CD. Si no tiene acceso aun ordenador y desea obtener una versin impresa, pngase en contacto connosotros mediante la direccin indicada en esta pgina.

Una versione italiana del presente manuale riportata sul CD. Se non possibileaccedere a un computer ed pertanto necessaria una copia cartacea, sietepregati di contattarci ai recapiti sopraelencati.

Een Nederlandstalige versie van deze handleiding vind je op de cd. Als je geentoegang hebt tot een computer en een gedrukte handleiding wilt ontvangen,kun je schrijven naar het adres op deze pagina.

En version af denne manual ndes p cden. Hvis du ikke har adgang til encomputer og gerne vil have en trykt version, kan du kontakte os p adressen

p denne side.

Uma verso deste manual encontra-se no CD. Se no tem acesso a um computadore gostava de ter uma verso impressa, contacte-nos na morada nesta pgina.

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