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25 TREK ASSEMBLY MANUAL 27 April 2012
Basic Assembly
Front Derailleur
To perform properly, the front derailleur must be aligned with the chainrings, spaced
correctly above the chainrings, and have the limiting screws adjusted so that the
chain is not allowed to fall o the inner or outer chainrings.
In addition, the front shifter must position the front derailleur so that the chain runs
smoothly without rubbing in any desired gear combination.
Tools required
• 5mm allen wrench
• Small phillips-head screwdriver
• Sharp probe (dental pick, sharpened spoke, etc.)
• SIS-type housing cutters
• Pliers, or crimping tool
To align the front derailleur
1. Loosen the front derailleur attachment bolt.
2. Partially shift the front derailleur with your hand to check the derailleur alignment.
There should be 1-3mm of clearance between the bottom of the outer cage plate
and the top of any teeth on the large chainring.
3. Align the outer cage plate of the front derailleur to be parallel with the outer
chainring. As you tighten the derailleur clamp bolt, the derailleur will tend to rotate
on the seat tube. You can use this to fine-tune the alignment by applying a twisting
force to the derailleur as you tighten the clamp bolt.
4. Check that the inner cage plate does not touch the middle chainring.
To install the derailleur cable
1. Check the length of the shift housing. Leave enough length for a longer stem, in
case the customer needs one.
2. Lubricate the front 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.
3. Rotate the cable barrel adjuster fully into it’s stop. The barrel adjuster is either at
the shifter or cable stop.
4. Shift the shifter to low gear.
5. Seat all the housings in their stops.
6. Pass the cable through the housings, cable donuts, and housing stops.
Figure 56. Front derailleur
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