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Trek 2012 Manual

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8 TREK ASSEMBLY MANUAL 27 April 2012
Basic Assembly
Figure 16. Check for contact between the controls and the
top tube
Figure 17. Adjustable-rise stem
To position and tighten the handlebar assembly
1. Place the bike on the ground and adjust the position of the bar and controls.
Align the stem with the front wheel. Make sure the minimum insertion mark is inside
the steerer. Set the handlebar angle.
2. Tighten the stem expansion bolt or steerer clamp bolt(s).
3. Tighten the handlebar clamp bolts.
4. Set the position and angle of the levers. The brake levers should be in line with
the rider’s forearms during braking. Adjust the side to side placement of the levers,
leaving more room for big hands on big bikes. Ensure that the shift and brake levers
do not interfere with each other.
5. Tighten the clamp bolts of the shifters and brake levers.
6. Adjust the angle of the bar-ends.
7. Tighten the bar-end clamp bolts.
8. Install the handlebar reflector. Position it so that it points straight ahead and is
vertical.
9. Place the bike back into the work stand and check that the bar-ends or other
controls do not contact the frame when the handlebar is turned fully to the side
(Figure 16).
• If the frame needs protection, check with your manager regarding padding or other
solutions.
To install an adjustable-rise stem
Some ATBs and hybrids are equipped with a stem with an adjustable extension tube
angle (Figure 17).
1. Loosen the angle adjustment bolt (Figure 18) several turns until the teeth of the
locking mechanism are disengaged.
2. Lay the extension down to its lowest angle to reveal the expander bolt (Figure 19).
3. Position and tighten the handlebar assembly.
4. Set the stem angle and tighten the angle adjustment bolt. A normal hybrid riding
position places the hands 4-6 inches (10-15cm) higher than the top of the saddle,
so a 30 or 40 degree angle usually works best. In any case, the housing should be
long enough to allow the stem to be at its maximum height with the stem angle at
its highest position.
Figure 18. Angle adjustment bolt
Figure 19. Stem expander bolt
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