Manual Trek 2012 (page 48 of 77) (English)

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45 TREK ASSEMBLY MANUAL 27 April 2012

Special Assembly

Mid-line Brake Levers

Some bikes with drop bars have a secondary brake lever, also called a mid-line

brake lever (Figure 82).

To install mid-line brake levers

1. Place the mid-line and ‘standard’ levers to the desired positions on the bar.

2. Cut and place the brake housing between the ‘standard’ lever and the mid-line

lever. Make sure the housing enters the mid-line lever in a straight line.

3. Set the reach adjustment on the mid-line brake lever.

4. Install the brake cable and adjust the brake.

5. Check the function of the levers:

• The mid-line lever cannot contact the bar when it is squeezed during hard

braking.

• The standard lever works properly.

6. If the levers fail either test, readjust the brake or change the reach on the mid-line

lever.

Dia-tech Brake Levers (on 520)

The Trek 520 uses a special drop-bar brake lever that is compatible with V-type

brakes. This brake lever requires additional assembly.

To install Dia-Tech brake levers

1. Install the levers on the handlebars, with the housing exit holes in the top of the

levers on the inside of the handlebar, nearest the stem (Figure 83).

2. Loosen the cable cover screw that holds the leaded end of the cable, found in the

front of the lever (Figure 83).

3. Insert the cable from the front of the lever, set the leaded end in the lever, and

tighten the cover screw.

4. Slide the pipe down the cable (Figure 84) and into the lever body (Figure 85).

5. Install the cables and housing, and adjust the brakes, following the normal

procedure.

Figure 82. Mid-line brake lever

Figure 83. Cable end and cover

Figure 84. Sliding pipe down cable

Figure 85. Pipe installed in lever

Cable

cover

screw

Housing

exit hole

Pipe

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