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32 TREK ASSEMBLY MANUAL 27 April 2012
Basic Assembly
Inspect, Clean, and Finish Up
After the bike is completely assembled, test the bike to make sure all work
was performed properly, and then record that the bicycle was assembled and
inspected. Finally, move the bike from the assembly area. Some stores have
another mechanic inspect the bike, and record that inspection, before the bike is
moved to the sales oor.
To test ride the bike
1. Take the bike for a test ride. Attempt to mimic the behavior of a rider handling the
bike roughly.
2. Check both brakes. Make sure they stop and do not squeal.
3. Check the shifting in all gear combinations.
4. Check the wheels. Ride over rough surfaces, and bounce both front and rear
wheels.
5. Check the suspension. Ride over terrain that will activate the suspension.
6. Check the controls for position and comfort.
To re-check the assembly
Retest the bike by following the procedures in the function check on pages 30-31.
Repair or re-adjust any parts that do not pass the test.
1. Repeat the test ride and function check of the bike.
2. Repeat until the bike passes both steps.
To clean the bike
1. Place the bike in the work stand.
2. With a soft cloth and frame polish, wipe the frame and parts to remove all dust,
dirt, or fingerprints.
3. With the bike on the floor, adjust the saddle to an appropriate height, align it, and
tighten the seatpost clamp.
To complete the paperwork
1. Fill out inventory tags and bicycle assembly checklist.
2. Sign your work.
3. Move the completed bike to the assembly inspection area.
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