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23 TREK ASSEMBLY MANUAL 27 April 2012
Basic Assembly
Rear Derailleur
A properly installed derailleur system shifts smoothly from gear to gear, and the chain
never falls o. Also, a properly adjusted derailleur system is quiet.
Some shift housing sets on mountain bikes or hybrids include a rubber housing boot
(Figure 52), a sealing device. To work properly, the boot must be mated to a special
tubular extension of the housing end cap on the last piece of housing.
Tools required
• Small phillips-head screwdriver
• 5mm allen wrench, or 9mm or 10mm end wrench
• Sharp probe (dental pick, sharpened spoke, etc.)
• SIS-type housing cutters
• Pliers, or crimping tool
To install the rear derailleur cable
1. Shift the chain to the small chainring and small rear cog.
2. Check the length of the shift housing. Leave enough housing for a longer stem, if
needed.
3. Open the end of the housing liner with a sharp probe to eliminate cable friction.
4. Lubricate the rear derailleur cable with a light grease or heavy oil.
• With sealed housing, remove the sealed end caps before lubricating the cable, then
replace end caps. Otherwise, little of the lube will actually get into the housing.
5. Pass the cable through the housings, cable donuts, and housing stops.
Figure 51. Rear derailleur
Figure 52. Boot on special housing end cap
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