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50 TREK ASSEMBLY MANUAL 27 April 2012
Special Assembly
Fork Installation
On certain of the larger size bicycles, forks may ship not installed to the frames.
Forks will ship packed within the same box as the bike. These changes have been
made in order to avoid UPS shipping surcharges for over-sized bicycle boxes.
Headset fork crown race and head tube cups will be pre-installed in all models. All
other headset parts (bearings, top caps, spacers, etc.) will be packed with the stem
in the not installed parts (NIP) box. Before installing parts, they should be lubricated
to ease assembly and prevent corrosion.
To prepare the bicycle
1. Follow normal procedures to un-box the bike.
2. Place the bike in a repair stand.
3. Go to the section in the instructions for the type of headset on the bicycle you are
assembling.
To install the fork
1. Check that the crown race is properly installed on the fork crown, and the headset
cups are properly pressed into the head tube.
2. Slide the fork steerer tube up through the head tube.
3. For a threaded headset:
Apply a light grease to the threads at the top of the steerer. Engage the threads of
the steerer with the threaded cup and turn by hand until snug against the bearings.
Install the toothed washer onto the steerer. Engage the threads of the steerer with
the locknut and turn by hand until snug against the threaded cup and toothed
washer. Don’t completely tighten the headset locknut yet. Final adjustment and
tightening will be done with the bike on the oor with the handlebar assembly
completed.
• For a direct-connect headset:
Apply a light grease to the threaded pieces, including the bearing adjustment
screw. Slide the upper headset bearing compression washer, and bearing cover
over the steerer. Lubricate the steerer (see pages 69-70). Place at least one spacer
above the bearing cover and install the stem, partially tightening the steerer
clamp bolts. Place any remaining spacers above the stem (a minimum of one
spacer above the stem with a carbon steerer) and attach the top cap and bearing
adjustment screw.
To install a quill stem
1. Apply a light grease to the threads and bearing surfaces of all clamp bolts of the
stem and expander bolt, and the outside of the quill.
3. Place the stem in the steerer.
4. Partially tighten the stem expander bolt.
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