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1 TREK ASSEMBLY MANUAL 27 April 2012
Basic Assembly
Removal of Bike from Box
Begin by taking the bike out of the box and making sure all the parts are included.
Tools Required
• Long, thin object like large screwdriver or pedal wrench
• Pen
Watch Out for Staples
Some boxes are glued, some are stapled, some are both. If the box is closed using
staples, be careful not to cut or scratch yourself as you open it. Also be careful when
removing a bike from a box; staples can damage the nish of the bike.
To Open the Box
1. Slip a long, thin tool under the top flap of the carton, and slide the tool for the
length of the box (Figure 1).
2. Fold back the top flaps of the box so it stays open.
3. Remove all the contents, pulling out any loose items first. Leave all the frame
protection on the bike. Place the other items on top of your workbench.
4. Place the frame and front wheel against your workbench so that they cannot be
knocked over.
5. Inspect the contents for completeness. Turn the box upside down to double check
that no nuts, bolts, etc. have fallen off and are hiding under the box flaps.
6. Record the data on the end of the box (Figure 2). Include the serial number and
manufacturing codes including date of manufacture. If there is a problem with the
bike, Quality Control will ask for this information.
Figure 1. Slide a thin tool under the box ap
Figure 2. Model data on end of bike box
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