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55 TREK ASSEMBLY MANUAL 27 April 2012
Supporting Information
Frame Alignment
This section explains the theory behind frame alignment and provides a step-by-step
procedure for checking alignment in your store.
Frame alignment theory
A well-built bicycle is “in alignment.” That is, the frame places the parts of the bicycle
relative to an imaginary plane that bisects the centerline of the bicycle. However,
a slight variance from “perfect” is allowed, a variance referred to by engineers as
“tolerance.”
Positioning of components
For the bicycle to ride well, and the parts to function their best, the frame tubes
and components must be aligned to the frame centerline plane. The rims should be
centered on the plane, which automatically means the hub axles are perpendicular
to the plane. The head tube should lay on the plane, and if both the head tube and
front wheel lay on the centerline plane, the fork is in alignment. The chainrings should
be on a separate but parallel plane, making the bottom bracket perpendicular to the
centerline plane. If all the bicycle’s components are oriented correctly to the main
centerline plane, the bicycle is in alignment.
Tolerance
Tolerance is specied by the engineer of a product. It is the acceptable variation from
the engineer’s drawing, and is designed to allow products to t together within a
normal manufacturing range. For example, if you were specifying the cut-length of a
roll of handlebar tape that you knew was 6” longer than required, you could specify a
tolerance of +/. 5” without ever shorting anyone. On the other hand, if you designed
the tape to be cut with only 1” of extra material, your tolerance would have to be
+/. 1” to avoid problems. The dimensions are dierent on a bicycle frame, but the
concept is the same.
Tolerances are specied according to how important or sensitive the part or structure
is to variance, and engineering drawings usually have tolerances called out for every
dimension. Tolerances have two uses; they provide a “blueprint” for manufacturing,
and they provide a “yardstick” for quality control.
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