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51 TREK ASSEMBLY MANUAL 27 April 2012
Special Assembly
To install the handlebar
1. Place the handlebar in the clamp of the stem and loosely insert the clamp bolt(s).
2. Gradually snug up (don’t yet fully tighten) alternating bolts, keeping the face plate
centered with even gaps above and below the plate. Also center the handlebar in
the stem.
3. Place the bike on the ground and adjust the position of the bar and controls. Align
the stem with the front wheel. For a quill stem, make sure the minimum insertion
mark is inside the steerer. Set the handlebar angle.
4. Tighten the stem expansion bolt.
5. Tighten the handlebar clamp bolts.
6. Set the position and angle of the levers.
7. Tighten the clamp bolts of the shifters and brake levers.
To adjust a threaded headset
1. Stand over the top tube of the bicycle with both feet on the ground.
2. Look, listen, and feel for looseness or tightness of the headset bearings. Apply the
front brake firmly while you rock the bicycle forward and backward. If the headset
or fork move side-to-side relative to the frame, the bearings are loose. Lift the front
wheel off the ground and slowly rotate the fork and handlebar to the right and left.
If there is any grinding noise, or stickiness or binding at any point in the rotation,
the bearings are too tight.
3. With a headset spanner, turn the threaded cup slightly to loosen or tighten the
headset bearing adjustment.
4. Hold the threaded cup and tighten the locknut.
5. After tightening the locknut, re-check the bearing adjustment. If necessary, re-
adjust the headset.
To adjust a direct-connect headset
1. Stand over the top tube of the bicycle with both feet on the ground.
2. Look, listen, and feel for looseness or tightness of the headset bearings.
Apply the front brake firmly while you rock the bicycle forward and backward. If the
headset or fork move side-to-side relative to the frame, the bearings are loose. Lift
the front wheel off the ground and slowly rotate the fork and handlebar to the right
and left. If there is any grinding noise, or stickiness or binding at any point in the
rotation, the bearings are too tight.
3. If the headset requires adjustment, loose the steerer clamp bolts.
4. To loosen or tighten the headset bearing adjustment, turn the bearing preload
adjustment bolt.
4. Tighten the steerer clamp bolts.
5. After tightening the steerer clamp bolts, re-check the bearing adjustment. If
necessary, re-adjust the headset.
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