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ii TREK ASSEMBLY MANUAL 27 April 2012
Table of Contents
Removal of Bike from Box ............................................... 1
Put Frame in Repair Stand .............................................. 2
Wheels ............................................................................. 3
Clix™ Wheel Quick-release .......................................... 5
Handlebar ........................................................................ 7
ATB-style handlebar ..................................................... 7
Road-style handlebar ................................................... 9
Saddle ........................................................................... 12
Brakes ........................................................................... 13
V-type brakes ............................................................. 13
Hydraulic disc brakes ................................................. 15
Cable-actuated disc brakes ....................................... 16
Road bike brakes (sidepull, or caliper) ....................... 17
U-brakes ..................................................................... 19
Crankset and Bottom Bracket ....................................... 21
Pedals ............................................................................ 22
Rear Derailleur ............................................................... 23
Front Derailleur .............................................................. 25
Shifting .......................................................................... 27
Reectors ...................................................................... 29
Accessories ................................................................... 29
Function Check ............................................................. 30
Inspect, Clean, and Finish Up ....................................... 32
Basic Assembly
Suspension .................................................................... 33
Suspension seatpost .................................................. 33
Suspension forks or rear shocks ................................ 33
Coaster Brake ............................................................... 34
Chain Tension with Single Cog ...................................... 35
Adjusting chain tension .............................................. 35
Belt Drive ....................................................................... 36
Inter-M Roller Brakes ..................................................... 39
BMX Rotor ..................................................................... 40
Tandem Timing Chain .................................................... 41
Nexus 4, 7, or 8 Speed Shift System ............................ 42
Brake Hose and Ferrule for Internal Routing ................. 43
Three-speed Shift System ............................................. 44
Mid-line Brake Levers ................................................... 45
Dia-tech Brake Levers (on 520) ..................................... 45
Tubular Tires .................................................................. 46
TubeLess Ready (TLR) Tires .......................................... 48
Fork Installation ............................................................. 50
Special Assembly
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