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07TK OM English

07TK OM English

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Bicycle Owner’s Manual

Even if you have ridden a bike for years, it is
important for EVERY person to read Chapter 1
before you ride your new bicycle.
i
Meaning of special symbols and
lettering
IMPoRTANT: KEEP FoR FuTuRE REFERENcE
About this owner's Manual
This manual explains how to ride
your new bike safely.
Even if you have ridden a bicycle
for years, it is important for EVERY
person to read chapter 1 before
riding this bicycle!
Parents should explain Chapter
1 to a child or anyone else who
might not otherwise understand
this information.
This manual also shows how
to perform basic maintenance.
Some maintenance should only be
performed by your dealer, and the
manual indicates these tasks. If
you choose to perform these tasks,
you should purchase a detailed
repair manual from your dealer.
This manual includes a CD
(compact disc) with more compre-
hensive information. This CD can
be viewed by inserting it into your
home computer. If you do not have
a computer, take the CD to your
school, work, or public library and
view it there.
If your CD does not work, go to
the web address on the cover to
access the information on the web.
My bicycle model:
My serial number: Lock key #
My dealer:
My dealer's phone:
K
e
e
p

f
o
r

y
o
u
r

r
e
c
o
r
d
s
WARNING
In this manual, the WARNING sign
indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
cAuTIoN
In this manual, the CAUTION sign
indicates a hazardous situation
which, if not avoided, may result in
minor or moderate injury.
Register your bicycle
Bicycle registration is the only
record we have of who owns this
bike. If there is ever a need to
communicate with the owner,
such as providing updated safety
information, your registration is
crucial. There are two easy ways to
register your new bicycle:
• Click the Registration link
when viewing the CD supplied
with this manual
• Go to the web address on the
back cover of this manual and
follow the links.
The web site also provides a link
to updated safety information. If
you choose not to register, make
sure you check the web site often.
ii
Assembly of your new bicycle
Assembly and the first adjust-
ment of your bicycle take special
tools and skills, so this should only
be done by an authorized dealer.
If you have questions
There are many models, with
a variety of equipment, so
this manual may contain some
information that does not apply
to your bike. Some illustra-
tions may vary from the actual
bicycles.
If you have any questions after
reading the information in this
manual, consult your dealer. If
you have a question or problem
that your dealer can’t handle,
contact us:
Attn: Customer Service
801 W. Madison Street
Waterloo, Wisconsin 53594
920.478.4678
This manual conforms with these
standards:
ANSI Z535.4
CPSC CFR 1512
BS 6102 : Part 1: 1992
CEN 14764, 14765, 14766, 14872
iii
TAbLE oF coNTENTS
chapter 1- Guide to Safe on-and-
off Road operation
bicycle type and use classification
Child bike .................................. 1
Condition 1 ................................ 1
Condition 2 ................................ 1
Condition 3 ................................ 2
Condition 4 ................................ 2
Condition 5 ................................ 2
before a first ride
Make sure the bicycle fits ......... 3
Know how the bicycle performs 3
check the bike before every ride
Before every ride checklist ....... 4
Carbon fiber inspection ............. 7
Rules for safe riding
Know and observe local bicycle
riding laws ............................. 9
Watch for cars, pedestrians, and
other obstacles ....................... 9
Wear a helmet and proper cycling
clothes .................................... 9
Change your riding to be safe in
variable conditions................. 9
Riding instructions
Use your brakes carefully ....... 12
Use good shifting techniques . 12
Take care of your bike
Protect your bike when parking
or storing it ......................... 13
Carry repair items ................... 14
Only install and use approved
accessories ........................... 14
Keep the bike clean ................. 14
Avoid clamping the frame during
transportation or repair ...... 14
Protect your bicycle during
shipping ............................... 14
chapter 2: Maintenance
Maintenance schedule ............. 15
Recommended tools for proper
bicycle maintenance ............. 16
chapter 3: Adjustment 17
Handlebar ................................ 17
Stem ........................................ 17
Bar-ends .................................. 19
Saddle ...................................... 19
Headset .................................... 21
Crankset .................................. 21
Crank arms ............................. 21
Pedals ...................................... 21
Bottom bracket ........................ 21
Chain ....................................... 21
Cables ...................................... 22
Shifters .................................... 22
Front derailleur ....................... 22
Rear derailleur ........................ 23
Nexus 4, 7, or 8 speed systems 24
3 speed systems ...................... 24
Brake levers ............................ 25
Brakes ..................................... 27
Wheels ..................................... 29
Suspension components .......... 31
Accessories .............................. 31
Folding bike ............................ 32
Stem ........................................ 33
Seatpost ................................... 33
Bottom bracket ........................ 33
Pedals ...................................... 33
chapter 4: Lubrication
Derailleurs ............................... 34
Headset .................................... 34
Brakes and brake levers .......... 34
Wheels ..................................... 34
Suspension forks ..................... 34
Rear suspension ...................... 34
Control cables ......................... 34
For more information.............. 35
Limited warranty .................... 36

Riding a bicycle in a manner
beyond, or more severe than, its
intended use can cause the bicycle
or part of the bicycle to fail. The
following information explains
the type of riding intended for
different types of bikes. Read the
safety information in Chapter 1 for
further details.
child bike
These bikes
are designed for
children riding
where parental
supervision is
always required.
Riders shall avoid
areas used by
automobiles, as
well as inclines,
curs, stairs, or areas near drop-offs
or pools.
child bike types
• Maximum seat height of 680
mm; generally, bicycles with
16" or 20" wheels, and kids'
tricycles
• No quick-release wheel
fastening systems
• Weight limit: 80 lbs (36 kg)
condition 1
Bikes designed
for riding on a
paved surface
where the tires do
not lose ground
contact.
condition 1 bike
types
• Drop-type
handlebars including touring
bikes, but not cyclocross bikes
• Triathlon, time trial, or speed
bikes
• Tandems of any design
• Cruisers with wide, 26" tires
and swept-back handlebar
• Any bike that folds
• Weight limit: 275 lbs (125 kg);
Tandems: 550 lb (250 kg)
condition 2
Bikes designed
for riding
Condition 1,
plus smooth
gravel roads and
improved trails
with moderate
grades where the
tires do not lose
ground contact.
condition 2 bike types
• Hybrid bikes with 700c wheels,
tires wider than 28c, and flat
handlebars
• City bikes- specially-equipped
hybrids
• Cyclocross bikes- with drop-
type handlebars, knobby 700c
tires, and cantilever or disc
brakes
• Weight limit: 300 lbs (136 kg)
bIcYcLE TYPE AND uSE cLASSIFIcATIoN
Chapter : Guide to Safe On-and-Off Road Operation
WARNING
bicycles, or their parts, can be
broken or damaged by riding in a
manner more stressful than the
intended use of the bike. If the
bike is damaged, you could lose
control and fall. Do not ride beyond
the design limits of the bike. If
you are unsure of the limits of the
bike, consult your dealer.

condition 5
Bikes designed
for jumping,
hucking, high
speeds, or aggres-
sive riding on
rougher surfaces,
or landing on flat
surfaces.
However, this
type of riding
is extremely hazardous and puts
unpredictable forces on a bicycle
which may overload the frame,
fork, or parts. If you choose to ride
in Condition 5 terrain, you should
take appropriate safety precau-
tions such as more frequent bike
inspections and replacement of
equipment. You should also wear
comprehensive safety equipment
such as a full-face helmet, pads,
and body armor.
condition 5 bike types
• "Freeride" or "jumping" bikes
with heavy-duty frames, forks,
and components
• Weight limit: 300 lbs (136 kg)
condition 3
Bikes designed
for riding
Conditions 1 and
2, plus rough
trails, small
obstacles, and
smooth technical
areas, including
areas where
momentary loss of
tire contact with the ground may
occur. NOT jumping.
All mountain bikes without rear
suspension are Condition 3, and so
are some light-weight rear suspen-
sion models.
condition 3 bike types
• "Standard" or "cross-country"
mountain bikes with wide,
knobby 24, 26, or 29" tires
• May include short-travel rear
suspension (3"/75 mm or less)
• Weight limit: 300 lbs (136 kg)
condition 4
Bikes designed
for riding
Conditions 1, 2,
and 3, plus rough
technical areas,
moderately sized
obstacles, and
small jumps.
condition 4 bike
types
• "Heavy-duty" or "all-mountain"
mountain bikes with wide,
knobby 24, 26, or 29" tires
• May include medium-travel rear
suspension (4"/100 mm or more)
• Weight limit: 300 lbs (136 kg)
Chapter : Guide to Safe On-and-Off Road Operation

Learn the power of your brakes
The stopping power on bikes
varies according to the intended
use of the bike. If you would like
your bike to have more, or less,
stopping power, consult your
dealer about brake adjustments
or other brake options for your
bicycle.
Avoid toe-clip overlap
When riding
slowly, do not
pedal if the
handlebar is
turned. It may
be possible,
at very slow
speeds, when
the handlebar
is turned, for
your foot or toe-
clips to contact
the front wheel or fender (Figure
2). At normal riding speeds, the
handlebar does not turn enough
for this to occur.
Make sure the bicycle fits
Your dealer should fit you with
the proper size of bicycle.
There should
be at least 1” (25
mm) clearance
between the top
tube and the rider
when standing
over the bicycle
(Figure 1). For
mountain bikes,
2-3” (50-75 mm)
clearance is
recommended.
The seat and
handlebar may be
adjusted to offer
the best comfort and performance.
Before making these adjustments,
refer to Chapter 3.
Know how the bicycle performs
The features of your bicycle, if
misused, may cause you to lose
control of the bike. Before riding
fast or in more difficult conditions,
learn the function and performance
of all the mechanisms of your bike
by riding at slower speeds in a flat,
empty parking lot.
If you want your bicycle to
perform differently, or if you have
special needs that require different
parts for the safe operation of your
bike, consult your dealer.
bEFoRE A FIRST RIDE
Figure - Minimum stand-
over height
A = " (5 mm) for most
bicycles
-" (50-75 mm) for
mountain bicycles
A
Figure - Toe-clip overlap
WARNING
Mis-use of the braking system,
including over-use of the front
brake, can cause you to lose
control and fall. Avoid improper
braking by understanding and
practicing proper application of
your brakes as explained in this
manual.
WARNING
contact between your foot or toe-
clip and the front wheel or fender
can cause you to lose control and
fall. Avoid pedaling when turning
at slow speed.
Chapter : Guide to Safe On-and-Off Road Operation

Stop riding if you have frame
problems
Occasionally riders experience
problems with their frame or fork.
If a frame or fork has any problem,
do not ride the bicycle.
As an example, in very rare
cases, some riders may experi-
ence a “shimmy” or “harmonic
oscillation” or “frame vibration” at
certain speeds. If you are experi-
encing a shimmy, slow down
immediately. Take your bicycle
directly to a dealer for inspection
and repair.
Before every ride, inspect the
bike with the following check list.
If any part of the bicycle fails the
inspection, repair the bicycle by
following the information provided
by this manual, or take the bike to
your dealer for service. Never ride
a bike with a damaged part; have
it replaced.
This is not a comprehensive maintenance
program.
before every ride checklist
Wheels
 Tire inflation
brakes
Handlebar and stem
Seat and seatpost
Suspension adjustments
Lights and reflectors
Frame, fork, and components
check the wheels
Check that the wheels are straight.
Spin each wheel and watch the rim
as it passes through the brake pads
or the frame. If the rim wobbles
up and down or from side to side,
repair the wheel.
Check that the wheels are properly
attached. Bicycle wheels are attached
by several systems: threaded axle
nuts, a quick-release where a lever-
actuated wheel retention mechanism
Chapter : Guide to Safe On-and-Off Road Operation
WARNING
A shimmy, or steering wobble,
can cause you to lose control and
fall. If you experience a shimmy,
slow down immediately. Take your
bicycle to your dealer for inspec-
tion and repair.
cHEcK THE bIKE
bEFoRE EVERY RIDE
cAuTIoN
A bicycle that does not work properly
can cause you to lose control and fall.
Inspect the entire bicycle thoroughly
before every ride, and do not ride it
until any problem has been corrected
55
causes the brake pads to squeeze
the rim. When the brakes are not
applied, the brake pads should be 1
to 2 mm from the rim.
Squeeze each brake lever toward
the handlebar to make sure the
brake moves freely and stops the
bike. If the brake lever can be
pulled to the handlebar, the brake
is too loose. If the brake pads are
too close to the rim, the brake
is too tight. Brake pads should
be aligned with the rim surface
(Figure 5).
Disc brake- a hand lever
connected to the brake by a cable
or hydraulic hose squeezes a disc
mounted on the wheel hub.
Squeeze each brake lever toward
the handlebar to make sure the
brake moves freely and stops
Figure 5- Brake pad alignment
A- Brake pad aligned with rim surface
B- Pad and rim should be parallel
C- Direction of rim rotation
D- 0.5-.0 mm toe-in
A
B
C
D
(Figure 3) allows
the wheel to be
installed and
removed without
tools, or a thru-
axle where the
axle is threaded
through the ends
of the frame or
fork. For informa-
tion about adjust-
ment and closure
of the wheel attachment devices on
your bicycle, see
Chapter 3.
Test for proper
wheel attachment.
Pick up the bike
and sharply hit
the top of the tire
(Figure 4). The
wheel must not
come off, be loose,
or move from side
to side. Further
tests are provided in Chapter 3.
check the tire inflation
Inflate the tires to the air pressure
recommended on the tire sidewalls.
check the brakes
Follow the inspection instructions
for the type of brake on your bike:
Hand-rim brake- a hand lever
connected to the brake by a cable
Figure - Test for loose-
ness
Chapter : Guide to Safe On-and-Off Road Operation
WARNING
A wheel attachment device that is
not properly adjusted and closed
may allow the wheel to be loose
or come off unexpectedly, causing
you to lose control and fall. Make
sure the wheels are properly
attached before riding the bike.
WARNING
Never ride a bike if you are not
certain the brakes are working
properly, or you if suspect a
problem with the brake cables or
hydraulic hose. Malfunctioning
brakes can cause you to lose
control and fall. Inspect the brakes
thoroughly before every ride.
If your brakes are not working
properly, re-adjust them or take
the bike to your dealer for service.
Figure - Wheel quick-
release

the bike. If the brake lever can
be pulled to the handlebar, the
brake is too loose. The brake pads
should be 0.25-0.75 mm away from
the disc when the brakes are not
applied. If the pads are too close,
the brake is too tight, or mis-
aligned.
Internal hub brake- a hand lever
connected to the brake by a cable
activates a mechansim inside the
hub.
If it takes more than 5/8” (15
mm) of brake lever movement to
stop the bike, the brake is too
loose. If it takes less than 7 mm of
lever movement to stop the bike,
the brakes are too tight.
Coaster brake- the brake is
engaged by
pedaling
backwards.
When pedaling
backwards, the
brake should
engage with less
than 60 degrees
rotation (1/6
revolution).
The chain actuates the brake,
so make sure the chain cannot
come off. There should be between
1/4-1/2” (6-12 mm) total vertical
movement of the chain (Figure 6).
check the handlebar and stem
Make sure
the stem is in
alignment with
the front wheel.
Test the stem
connection to
the fork by
attempting to turn
the handlebar
from side to side
with the front
wheel locked
between your
knees (Figure 7).
Test the security of the handlebar
by attempting to rotate it in the
stem. It should not move or be
loose. Make sure that no cables are
stretched or pinched by rotating
the handlebar.
Check that the handlebar plugs
are properly inserted into both
ends of the handlebar (and bar-
ends).
check the seat and seatpost
Make sure the seat is secure by
attempting to turn the seat and
seatpost in the frame, and attempt
to move the front of the seat up
and down. It should not move or
be loose.
Figure - Checking chain
tension
Chapter : Guide to Safe On-and-Off Road Operation
Figure 7- Function testing
the handlebar and stem
cAuTIoN
Disc brakes and discs get very hot
during use and could burn skin. Also,
the disc edges may be sharp and
could cut skin. Avoid touching the
disc or disc brake when hot, or when
rotating.
cAuTIoN
Internal hub brakes get very hot
during use and could burn skin.
Avoid touching the hub or cooling
fins when hot.
77
large hole in the road or a sharp
bump such as a railroad track can
put large forces on your bike.
The manner in which you ride
will determine whether your bike
and its parts will last. If you ride
hard or aggressively, you should
replace the bike and/or its parts
more often than riders who ride
smoothly or cautiously. There are
many variables: weight, speed,
technique, terrain, maintenance,
riding environment (humidity,
salinity, temperature, etc.), and
the frame or part itself- so it
is impossible to give a precise
timetable for replacement. If you
aren't sure, ask your dealer. But as
a rule, it is better to err on the safe
side and replace the bike or parts
more frequently.
carbon fiber inspection procedures
Carbon fiber is among the
strongest materials used in bicycle
manufacture. However, carbon has
unique qualities, different from
metal parts, and must be inspected
carefully for damage.
Unlike metal parts, carbon
composite parts that have been
damaged may not bend, bulge,
check the suspension adjust-
ments
Make sure your suspension
components are adjusted to your
riding style, and that no suspen-
sion component can "bottom-out"
or be so compressed that there is
no further suspension travel or
movement remaining.
check the lights and reflectors
Make sure the lights are
functioning correctly and that any
batteries are charged. If the lights
use a dynamo, make sure it is
mounted correctly and all attach-
ment hardware is tight. Make
sure reflectors are clean and in
position.
check frame, fork, and
components
Carefully inspect your frame,
fork, and components for signs
of fatigue before and after each
ride. Regularly inspect your entire
bicycle for signs of fatigue stress:
• Dents
• Cracks
• Scratches
• Deformation
• Discoloration
• Unusual noises
Even if you perform regular
inspections, if you exceed the limit
of strength of your bicycle or a
given part, it may fail if overloaded.
After any high force load,
thoroughly inspect all the parts of
your bike. High force loads include
crashes, but you don't have to
crash to put a high force load on
your bike. For example, hitting a
Chapter : Guide to Safe On-and-Off Road Operation
WARNING
A damaged carbon fiber part can
fail suddenly. Inspect your carbon
fiber bicycle or parts for damage
frequently. If you have crashed
or impacted your bicycle, or
suspect a carbon part is damaged,
IMMEDIATELY SToP RIDING
YouR bIcYcLE. Take it to your
dealer for inspection, service,
and evaluation under the crash
replacement policy.

or deform; a damaged part may
appear to be normal to a cursory
glance. If you have any doubts
about the integrity of a part, do
not ride the bicycle.
Be very careful when handling
carbon fiber parts that are
suspected of damage. When a
composite part is damaged, there
is a possibility that individual
fibers may be exposed. Carbon
fibers are thinner than a human
hair, but quite stiff. If the point
of one of these fibers is pressed
against your skin, it could pierce
your skin like a needle.
Inspecting carbon fiber composite
frame, fork, or parts
Use the following procedures to
inspect carbon composite parts:
• Check for scratches, gouges, or
other surface problems.
• Check the part for loss of
rigidity.
• Check the part for delamina-
tion.
• Listen for unusual creaking or
clicking noises.
These tests may not be conclusive.
The tests are difficult to
describe, so we provide a movie
of inspecting a composite part on
the owner's manual CD and on the
owner's manual web site.
To check a part for surface
problems (visual test)
1. Clean the part thoroughly with
a damp cloth.
2. Look closely for problems:
• scratches
• gouges
• cracks
• loose fibers (which will appear
like thin hairs)
• other surface flaws
To check a part for loss of rigidity
(flex test)
Use the part in a normal manner
(without actually riding) while
someone watches carefully for
unexpected movement.
As an example, if you suspect
a composite seatpost has been
damaged, sit gently on the saddle
while someone watches to see if
the seatpost flexes.
To check a part for delamination
(tap test)
1. Clean the part thoroughly with
a damp cloth.
2. With a coin, tap the part near
any possible damage and places
where the part is known to
be in good condition (or use a
similar part).
3. Listen carefully for variations
in sound, especially a hollow
sound, "dead" tone, or any
sound indicating that the part
is not solid.
Chapter : Guide to Safe On-and-Off Road Operation

Figure - Wear a bicycle
helmet
45
90
Figure - Angle for cross-
ing tracks
Chapter : Guide to Safe On-and-Off Road Operation
If a car suddenly enters your lane,
or someone unexpectedly opens
the door of a parked car, you could
be involved in a serious accident.
Mount a horn or bell on your
bicycle, and use it to alert others of
your approach.
Wear a helmet and proper
cycling clothes
Wear a helmet
that meets CPSC
or CE safety
testing standards
(Figure 9); it
may help prevent
injury.
Helmets should
be removed when
not riding the
bicycle. If the
helmet is caught,
stuck on, or stuck
between objects, the wearer could
choke.
Wear protective clothing including
helmet, eye protection, and gloves.
Avoid loose-fitting pants that could
get caught in the chain.
Also wear light, bright, and reflec-
tive clothing to make yourself more
visible, especially at night.
change your riding to be safe in
variable conditions
Ride carefully in wet weather
No brakes, whatever their
design, work as effectively in wet
weather as they do in dry. Even
properly aligned, lubricated,
and maintained brakes require
greater lever pressure and longer
Know and observe local bicycle
riding laws
Most state and local areas have
specific laws for cyclists, and you
should follow them. Local cycling
clubs or your state’s Department
of Transportation (or equivalent)
should be able to supply this
information to you. The require-
ments for items such as lights and
reflectors change between areas,
so check ahead.
These are a few of the more
important rules of riding:
• Use proper hand signals.
• Ride single file when riding
with other cyclists.
• Ride on the correct side of the
road; never go against traffic.
• Ride defensively; expect the
unexpected. A cyclist is hard to
see, and many drivers simply
are not trained to recognize
the rights and special consider-
ations of a bicycle rider.
Watch for cars, pedestrians, and
other obstacles
Watch for and avoid potholes,
drain grates, soft or low shoulders,
and other deviations which could
impact your wheels or cause them
to slip. When
crossing railroad
tracks or drain
grates, do so
carefully at a 90°
angle (Figure 8).
If you are not sure
of riding surface
conditions, walk
your bike.
RuLES FoR SAFE RIDING
0 0
stopping distances in wet weather.
Anticipate the extra distance it will
take to stop.
Wet weather causes reduced
traction. Use slower cornering
when traction is reduced, such
as when riding over wet leaves,
painted crosswalks, or manhole
covers.
When wet weather cools to below
freezing, traction is reduced even
further. In addition, brakes may
not work as well. Adjust your
riding speed accordingly, or use
other forms of transportation.
When riding in wet weather, a
dynamo (generator light) may not
work properly. Avoid riding in wet
weather when visibility is reduced.
Strong winds can make a bicycle
steer or turn unexpectedly. In
windy conditions, slow down or
use other forms of transportation.
be careful when riding in low light
conditions.
Your bicycle is equipped with a
full set of reflectors; keep them
clean and in position. As useful as
these reflectors are, they do not
help you see, nor do they help you
be seen unless light is directed on
them. Use a working headlight and
taillight when you ride in poorly
lighted or low visibility conditions.
The important thing is to see and
be seen. If you do any amount of
riding at dusk, at night, or in any
poorly lighted conditions, consult
your dealer to find appropriate
products to aid your vision and
make you more visible.
Do not use unsafe riding practices
Many cycling accidents could be
avoided by using common sense.
Here are a few examples:
• Do not ride ‘no hands’.
• Do not ride with loose objects
attached to the handlebar or
any other part of the bicycle.
• Do not ride while intoxicated or
while using medications which
might make you drowsy.
• Do not ‘ride double’.
continued next page
Chapter : Guide to Safe On-and-Off Road Operation
WARNING
A bicycle rider without proper
lighting and reflectors may not
have good vision and may not be
visible to others. use front and
rear bicycle lights and reflec-
tors when riding in poor visibility
conditions. Failure to do so will
increase your chances of being
involved in an accident in low light
conditions.
WARNING
The following riding practices
increase your risk of injury:
• Jumping your bicycle
• Performing bicycle stunts
• Severe off-road riding
• Downhill riding
• Any abnormal bike riding
Each of these practices increases
the stress on every part of
your bicycle. Frames or parts
under high stress may fatigue
prematurely, causing them to fail
and increasing the risk of injury to
the rider. To decrease your risk of
injury, avoid these riding practices.

• Use special care when off-road
riding. Ride only on the trails.
Avoid rocks, branches, or depres-
sions. When approaching a
descent, reduce speed, keep your
weight back and low, and use the
rear brake more than the front.
• Do not ride in an abusive
manner; ride within the Use
Classification for your type of
bicycle (see pages 1-2).
Bicycles are not indestructible.
As with anything mechanical,
every part of a bicycle has a
limited useful life due to wear,
stress, and fatigue. Fatigue refers
to a low-stress force that, when
repeated over a large number of
cycles, can cause a material to fail
or break. The length of the life of a
part varies according to its design,
materials, use, and maintenance.
Although lighter frames or parts
may, in some cases, have a longer
life than heavier ones, it should
be expected that light-weight,
high-performance bicycles and
parts require better care and more
frequent inspections.
Avoid riding too fast
Higher speeds create higher
risks and greater forces in the
event of a crash. At higher speeds,
it is more likely that wheels will
Chapter : Guide to Safe On-and-Off Road Operation
WARNING
Training wheels prevent the
normal inward lean of a bicycle
during a turn. If the bicycle is
turned too quickly, the bike may
tip over, resulting in an accident.
With training wheels, do not ride
fast or turn sharply.
slip, or that a small bump can
create a significant impact to your
frame or fork. Keep your bicycle
under control at all times. For
children, the limit of speed for safe
riding is much lower, so parents
should strictly enforce this rule.

RIDING INSTRucTIoNS
use your brakes carefully
Always keep a safe stopping
distance between you and other
vehicles or objects. Adjust stopping
distances and braking forces to suit
riding conditions.
If your bike has two hand brakes,
apply both brakes
at the same time.
Over-use, or mis-
use, of a front-
wheel brake, such
as using only the
front-wheel brake
in an emergency,
could cause the
rear wheel to lift
from the ground
which could cause
you to lose control (Figure 10).
Bicycles are normally manufac-
tured with the left brake lever
controlling the front-wheel brake.
To change so that the right lever
controls the front-wheel brake, see
Chapter 3.
Many models of modern brakes
are very powerful; they are designed
to stop a bike in wet or muddy
conditions. If you feel your brakes
are too powerful for your riding
needs, take your bike to your dealer
for adjustment or replacement of the
braking system.
use good shifting techniques
Shifting gears allows you to
choose the gear combination most
comfortable for riding conditions,
one that allows you to maintain a
constant rate of pedaling. Shifting
systems are of two types: derail-
leur (external) and internal.
Shifting a bike with a derailleur
The left-hand shifter controls
the front derailleur and the right-
hand shifter controls the rear
derailleur. Use only one shifter
at a time. Shift gears only when
the pedals and chain are moving
forward. When you shift, reduce
the force on the pedals to provide
quicker and smoother shifting,
to help avoid excessive chain
and gear wear, and to help avoid
bent chains, derailleurs, and
chainrings. Avoid shifting when
going over bumps; the chain may
not shift properly or may fall off.
With modern indexed shifting
systems, a movement of the shifter
from one position to the next (or
movement of the shifter to the
"shift" position) should promptly
move the chain from one gear to
the next. However, bikes equipped
STI road shifters and triple
chainrings may shift better, partic-
ularly when shifting from the
smallest chainring to the middle, if
you “hold” the lever for a moment
before letting go of the shifter.
Shifting a bike with internal gearing
Shifting with internal gearing
Chapter : Guide to Safe On-and-Off Road Operation
Figure 0- Overuse of the
front-wheel brake
WARNING
Applying sudden or excessive
stopping force with the front-
wheel brake may cause the rear
wheel to lift off the ground, or the
front wheel to slip out from under
you, which can cause you to lose
control and fall. Apply both brakes
at the same time, and shift your
weight backwards on the bike
while braking.

Protect your bike when parking
or storing it
Protect your bike from theft
Purchase and use a lock that
is effective against bolt cutters
and saws. Never leave your bike
unlocked while unattended.
Record and keep your serial number
Register your bicycle with your
local police department. Complete
our on-line warranty registration;
we will keep the serial number of
your bike on file. Also, write the
serial number in the front of this
manual, and keep the manual in a
safe place.
Park your bike safely
When not riding, keep your bike
in a place where it will be out of
the way, and make sure it cannot
fall over. Do not lay the bike on
its derailleurs, as you may bend
the rear derailleur or get dirt on
the drivetrain. Don’t let the bike
fall down, as this may cut the
handlebar grips, or tear the seat.
Incorrect use of bike racks may
bend your wheels.
Store your bike carefully
When not riding, keep your bike
where it will be protected from
rain, snow, sun, etc. Do not store
the bike near electric motors,
as ozone from motors destroys
rubber and paint. Rain or snow
may cause the metal on your
bicycle to corrode. Ultraviolet
radiation from the sun may fade
the paint, or crack any rubber or
plastic on the bicycle.
is best performed when coasting,
stopped, or back pedaling. If you
must shift while pedaling, reduce
your pressure on the pedals.
Excessive chain tension makes
shifting difficult.
Chapter : Guide to Safe On-and-Off Road Operation
TAKE cARE oF
YouR bIKE
Chapter : Guide to Safe On-and-Off Road Operation
Before storing your bike for an
extended period of time, clean
and lubricate it, and polish the
frame with frame polish. Hang
the bicycle off the ground with
the tires at approximately half
pressure. Before riding the bicycle
again, be certain it is in good
working order.
carry repair items
Carry a pump, spare inner tube,
patch kit, and appropriate tools to
keep your bicycle running in the
case of a flat tire of other common
mechanical problem. If you ride
at night, carry spare bulbs and
batteries for your lights.
only install and use approved
accessories
Not all accessories are compat-
ible or safe, so only add accessories
that are approved by the manufac-
turer. As an example, a child
carrier places weight high on the
bike, affecting the stability of the
vehicle. Although most of our bikes
can be fitted with a child carrier,
the rider must use extra caution
to compensate for the decreased
stability.
The list of incompatible parts is
too long for this manual. If you are
unsure whether a part is approved,
consult your dealer.
Keep the bike clean
If your frame or a component
is dirty, clean it with a soft,
damp cloth and bike cleaner or a
solution of dish soap and water.
Use of industrial solvents or
harsh chemicals for cleaning may
damage the paint.
Avoid clamping the frame during
transportation or repair
Never clamp the bike frame by its
finished or painted surfaces. This
type of clamp this may damage the
paint or even dent, crush, or break
the light-weight tubing used in
high-performance bicycle frames.
Protect your bicycle during
shipping
If you have to ship your bike,
make sure it is properly padded
and protected to avoid damage.
Ask your dealer about supplies
used to ship a new bike, such as a
fork block.
WARNING
Never modify your frameset
or parts in any way, including
sanding, drilling, filing, removing
redundant retention devices,
installing incompatible forks, or
by any other method. Improper
components or improper assembly
can place unknown stress on your
bike or components. An improperly
modified frame, fork, or component
can cause you to lose control and
fall. before adding or changing
any part of your bike, consult your
dealer.
NoTIcE
Clamping devices used by
work stands and car carriers
can damage the finish on a
bike or even crush the tubing.
When putting a bike in a repair
stand, clamp the seatpost. When
carrying a bike in a car carrier,
clamp the wheels and the fork
tips.
5 5
cHAPTER 2: MAINTENANcE
Maintenance schedule
This maintenance schedule is
based on normal usage. If you ride
your bike more than average, or in
rain, snow, or off-road conditions,
service your bicycle more often
than the schedule suggests. If any
part appears to be malfunctioning,
inspect and service it immediately,
or consult your dealer. If a part is
damaged, replace it before riding
the bicycle again.
After initial break-in, new
bikes should be checked for
stretched cables and other normal
conditions. Approximately two
months after purchasing your new
bike, have your dealer thoroughly
inspect the bicycle.
All bikes should be thoroughly
serviced once a year, even if they
have not been ridden much.
Every ride
Check the wheels ...................... 4
Check the tire inflation ............. 5
Check the brakes ....................... 5
Check the handlebar and stem . 6
Check the seat and seatpost ..... 6
Check the suspension adjust-
ments ..................................... 7
Check the lights and reflectors. 7
Check frame, fork, and
components ............................ 7
Weekly
Wipe off your bicycle with a damp
cloth ..................................... 14
Check for loose spokes ............ 29
Lubricate suspension forks ..... 34
Check suspension fork bolts ... 31
Check rear suspension bolts ... 18
Monthly
Check the attachment of the
handlebar and stem ............. 17
Check the attachment of the seat and seatpost 1 9
Check the chain ...................... 21
Check the chainguard (accesso-
ries) ...................................... 31
Inspect cables for wear ........... 22
Check the operation of shifters 22
Inspect derailleurs .................. 22
Lubricate derailleurs ............... 34
Check the internal shift system 24
Check headset bearing adjust-
ment ..................................... 21
Check brake pads .................... 27
Check brake bolts .................... 27
Check chain tension .................. 6
Inspect Trekking accessory bolts
31
Check wheel bearing adjustment
29
Check rims for wear ................ 29
Every 3 Months
Clean and polish finish ........... 13
Check the crankset and bottom
bracket ................................. 21
Lubricate brake levers ........... 34
Every year
Lubricate handlebar stem ....... 33
Lubricate seatpost ................... 33
Re-grease pedal threads and
bearings ............................... 21
Re-grease bottom bracket
bearings ............................... 33
Re-grease wheel bearings ....... 34
Re-grease headset bearings .... 34
Lubricate wheel quick-releases 34
Re-grease suspension forks .... 34
Chapter : Maintenance

Recommended tools for proper
bicycle maintenance
Torque wrench with lb•in or N•m
gradations
2, 4, 5, 6, 8 mm allen wrenches
9, 10, 15 mm open-end wrenches
15 mm box end wrench
Socket wrench, 14, 15, and 19
mm socket
T25 Torx wrench
No. 1 phillips head screwdriver
Bicycle tube patch kit, tire pump
with gauge, and tire levers
Special high pressure air pump
for rear shock or suspension
fork
Note: Not all bikes require all these tools
Chapter : Maintenance
7 7
This chapter lists instructions
for adjustment of the parts of a
bicycle. After any repair, inspect
the bike as explained in Chapter 1.
A Word About Torque Specifications
Torque is a measurement of
the tightness of a threaded
fastener such as a screw or bolt,
determined by using a torque
wrench. The torque specifica-
tions should be used to make
sure you do not over-tighten the
fasteners. Applying more than the
recommended torque to a fastener
does not provide extra holding
power, and may actually lead to
damage or failure of a part.
Always perform the simple
function tests listed in this chapter
to make sure a part is properly
tightened, whether or not the
part was tightened with a torque
wrench. If a part fails inspection at
the recommended torque, take the
bike to your dealer.
cHAPTER 3: ADJuSTMENT
Handlebar
To adjust the angle of the handlebar
1. Loosen the handlebar clamp
bolt(s) on the stem (Figures
11-12) just enough that the
handlebar can be rotated in the
stem.
2. Position the handlebar to the
desired angle, making sure it is
centered in the stem.
3. Tighten the handlebar clamp
bolt(s) according to stem type:
• Welded stems- 100-120 lb•in
(11.3-13.6 N•m).
• Forged stems- 150-180 lb•in
(17-20.3 N•m)
Stem
There are two types of stems:
• Direct-connect (Figure 11)
• Quill-type (Figure 12)
Adjusting the
handlebar height
on a direct-connect
stem affects the
headset bearing
adjustment.
This procedure
requires special
tools and training
so this should
only be done by
your dealer.
To align a direct-connect stem
1. Loosen the steerer clamp bolts
two to three turns.
2. Align the stem with the front
wheel.
3. Tighten the steerer clamp bolts
to 100-120 lb•in (11.3-13.6
N•m).
Figure - Direct-connect
stem
A- Handlebar clamp bolts
B- Steerer clamp bolts
B
A
Chapter : Adjustment
WARNING
A bicycle that malfunctions can
cause you to lose control and
fall. Inspect the entire bicycle
thoroughly before every ride, and
do not ride it until any problem
has been corrected.
WARNING
An improperly adjusted or
tightened handlebar, stem, or
bar-ends can cause you to lose
control and fall. Make sure the
stem, handlebar, and bar-ends are
positioned and tightened properly
before riding the bike.

To align or adjust a quill-type stem
To adjust the height of the adjustable-rise stem
in Figure 12, frst change the stem angle, which
gives access to the stem expander bolt.
1. Loosen the
stem expander
bolt two to
three turns.
2. Tap the top
of the stem
expander bolt
with a wood
or plastic-
faced mallet to
loosen the stem
wedge.
3. Adjust the
handlebar to
the desired
height, but
with the
minimum
insertion
line inside
the frame
(Figure 13). A
minimum of
2
3/4
” (70 mm)
of the stem
quill must
always remain
in the frame.
4. Tighten to
120 lb•in (13.6 N•m).
To change the angle of an adjust-
able-rise stem
1. Loosen the angle adjustment
bolt (Figure 12) until the stem
angle can be changed.
2. Position the stem to the desired
angle.
3. Tighten the angle adjusting
bolt to 150-170 lb•in (17-20.3
N•m).
To change the angle of a bontrager
adjustable-rise stem
1. Slide the
locking button
(Figure 14)
forward and
lift the quick-
release lever.
2. Position the
stem and
handlebar to
the desired
angle.
3. Close the
quick-release
lever.
Make sure the
lever is completely closed and the
locking button has returned to its
locked position.
To adjust the clamping force of the
quick-release lever of the bontrager
adjustable-rise stem
1. Open the quick-release lever.
2. Turn the tension adjusting
screw (Figure 14).
3. Check that at about halfway
through the lever throw there is
some resistance.
If the clamp force is too high or too low, re-
adjust the screw.
Chapter : Adjustment
WARNING
Never ride your bicycle with a quill
stem raised above the minimum
insertion mark. A quill stem that
is positioned too high can damage
the bike and can cause you to lose
control and fall. Make sure the
minimum insertion mark (Figure
13) is inside the frame.
Figure - Adjustable-rise
quill stem
A- Handlebar clamp
bolts
B- Stem expander bolt
C- Angle adjusting bolt
B
C
A
Figure - Minimum
insertion mark on quill
stem
A- This line must be
inside the bike frame
A
Figure - Bontrager
adjustable-rise stem
A- Tension adjusting
screw
B- Quick-release lever
C- Locking button
B
C
A

bar-ends
Bar-ends
(Figure 15) are
designed for
climbing only.
Ensure the bar-
ends face forward
and away from
you, but at an
angle not less
than 15° from
parallel to the
ground.
To adjust the angle of the bar-ends
1. Loosen the bar-end clamp
bolt(s) until they can be rotated
on the handlebar.
2. Position the bar-ends to the
desired angle.
3. Tighten the bar-end clamp bolt
to 85-125 lb•in (9.6-14.1 N•m)
Saddle
The correct adjustment of the
seat angle is largely a matter of
personal preference. With proper
adjustment, the right bike seat will
be reasonably comfortable even for
long rides.
To select the saddle angle, first
try riding with the top of the seat
parallel to the ground. For bikes
with rear suspension, try tilting
the seat nose down slightly so
that compression of the rear shock
under your body weight (sag)
results in a level seat.
The seat may also be moved
forward or backward along the
seatpost to increase comfort as
well as adjust the distance to the
handlebar.
Never engage the seatpost binder
with the seatpost out of the frame.
To adjust the angle of the seat
1. Loosen the
seat fixing bolt
(Figure 16)
just far enough
so the seat can
be tilted fore
and aft.
Some seatposts use
two bolts, where
angle adjustment is
done by loosening
one bolt and
tightening the other
bolt.
2. Place a
straight edge,
such as a
bubble level or
ruler, across
the top of the
seat to better
see the angle.
Figure - Seatpost parts
A- Seat fxing bolts
B- Seatpost
C- Seatpost binder bolt
A
B
C
Chapter : Adjustment
WARNING
Extended riding with a poorly
adjusted saddle or one that does
not properly support your pelvic
area can cause injury to your
nerves and blood vessels. If your
saddle causes pain or numbness,
re-adjust the saddle position.
If after adjustment your saddle
still causes pain or numbness,
consult your dealer about further
positioning or replacing the saddle
with one that better fits you.
Figure 5- Bar-ends
A- Bar-end clamp bolt
A
Figure 7- Bontrager
seatpost
A- Seat fxing bolt
A
0 0
3. Adjust the seat and re-tighten
the seat fixing bolt according
to the type of seatpost:
• Double bolts using a 5 mm
allen wrench- 80-125 lb•in (9.6-
14.1 N•m).
• Single bolt using a 13 or 14
mm open-end wrench- 180-220
lb•in (20.3-24.9 N•m).
• Single bolt using a 6 mm allen
wrench- 150-250 lb•in (17-28.3
N•m).
• Double bolts using a 4 mm
allen wrench- 45-60 lb•in (5-6.8
N•m).
To adjust the seat height of a
bicycle
1. Sit on the seat in riding
position without shoes, while
someone holds the bicycle up.
2. Position the crank arms so
they are
parallel to
the seat
tube.
3. Loosen the
seatpost
binder bolt,
or quick-
release.
4. Extend the
seatpost
until, with
your heel resting on the bottom
pedal, your extended leg is
straight (Figure 18).
When wearing your shoes there should be a
slight bend in your knee in a proper riding
position; with the ball of your foot on the pedal.
5. Make sure
the minimum
insertion
mark on
the seatpost
(Figure 19)
is not visible
above the
bike frame. A
minimum of
2
1/2”
(64 mm)
of seatpost
must remain
in the frame.
6. Close the seatpost quick-
release, or tighten the bolt to
85-125 lb•in (9.6-14.1 N•m)
To adjust the seat position of a
tricycle
1. Loosen and
remove the
clamp bolts
(Figure 20).
2. Move the
seat mast to
the desired
position.
3. Install and
tighten the
seat mast
clamp bolts to
85-125 lb•in
(9.6-14.1 N•m).
Chapter : Adjustment
Figure - Minimum
insertion mark on
seatpost
A- This line must be
inside the bike frame
A
WARNING
A seatpost that is positioned too
high can damage the bike and can
cause you to lose control and fall.
Make sure the minimum insertion
mark (Figure 19) is inside the frame.
Figure - Leg extension with
proper seat height
Figure 0- Tricycle seat
mast
A- Seat mast
B- Clamp bolts
A
B

crank arms
Some bicycles offer adjustable
crankarm length. To change the
crank length, remove the pedals
and install them into the second
set of holes. Tighten by following
the instructions for Pedals.
Pedals
To adjust the release force
on clipless pedals, refer to the
information on the CD supplied
with your bicycle, or consult your
dealer.
The left pedal is left-hand
threaded, while the right pedal
is right-hand (normal) threaded.
Tighten pedals into the crankarms
to 350-380 lb•in (40.2-42.9 N•m).
Adjustment of pedal bearings
requires special tools and
training. These services should
only be performed by your dealer.
bottom bracket
Adjustment of bottom bracket
bearings requires special tools
and training. These services
should only be performed by your
dealer.
chain
To adjust the chain tension on a
single speed bike
1. In small increments, loosen the
rear wheel axle nuts on alternate
sides of the wheel.
If you fully loosen one side before loosening the
other, you may cause the bearings to come out of
adjustment.
Headset
To check if the headset is loose or
tight
1. Apply the front brake firmly
while you rock the bicycle
forward and backward.
2. With the front wheel off the
ground, slowly rotate the fork
and handlebar to the right and
left.
If the headset bearings rock in
the frame or do not turn smoothly,
do not ride the bicycle; take the
bike to your dealer for service.
Adjustment of headset bearings
requires special tools and training.
These services should only be
performed by your dealer.
crankset
To check the bottom bracket
bearing adjustment
1. Lift the chain from the
chainrings.
2. Rotate the crank so that one of
the arms is parallel to the seat
tube.
3. Put one hand on the crank arm
and one hand on the seat tube,
and attempt to move the crank
arm laterally toward and away
from the seat tube.
4. Spin the cranks.
If the crank feels or sounds loose,
or if the motion stops abruptly or
you hear a grinding noise coming
from the bearings, the bearings
need to be adjusted or re-greased
by your dealer.
Chapter : Adjustment

3. Turn the low gear adjusting
screw (marked “L”) until the
inner chain guide of the derail-
leur is approximately 0.5 mm
from the chain.
4. Pull on the cable end, and
down-shift the left shift lever
several times so that it is in the
small-chainring position.
5. On the shifter or down tube,
turn the shift cable adjusting
barrel to its most clockwise
position.
6. Insert the cable in the groove
found next to the derailleur
cable clamp bolt, pull the cable
taut, andtighten the bolt:
• Front derailleur cable clamp
bolt- 44-60 lb•in (5.0-6.8 N•m).
To adjust the big chainring position
1. Shift the rear derailleur to the
smallest rear cog.
2. Turn the high-gear adjusting
screw (marked “H”) counter-
clockwise until it cannot
interfere with the motion of the
derailleur.
3. Hand-turn the cranks, and use
the shifter to carefully shift
the chain onto the outside
chainring.
4. Position the outer chain guide
of the front derailleur approxi-
mately 0.5 mm from the chain.
5. Re-tighten the high gear
adjusting screw until it meets
resistance.
If you have turned the screw too far, the front
derailleur will move toward the small chainring.
2. Slide the wheel to re-tension
the chain, and center the wheel
in the frame.
Some models have a chain tensioning device which
helps position the wheel.
3. Complete the wheel installa-
tion.
cables
Check the cables for kinks, rust,
broken strands, or frayed ends.
Also check the housing for loose
wire strands, bent ends, cuts, and
wear. If you suspect a problem
with a cable, do not ride the
bicycle; follow the instructions to
replace a cable (page 34), or have
your dealer service the bicycle.
Shifters
The position of the shifters can
be adjusted on the handlebar.
Follow the instructions for
adjusting the lever position on
pages 25-26.
Front derailleur
To adjust the small chainring
position
1. Shift the
chain onto the
smallest front
chainring and
the largest
rear cog.
2. Loosen the
front derail-
leur cable
clamp bolt
(Figure 21)
until the cable
is free.
Chapter : Adjustment
Figure - Front derail-
leur
A- Cable
B- Adjusting screws
C- Cable clamp bolt
A
B
C

6. Go through the various gear
combinations. Make sure the
chain does not fall off when you
shift, and the derailleur cage
does not rub on any part of the
crankset.
To adjust the middle gear position,
with three chainrings
1. Shift the chain onto the
largest front chainring and the
smallest rear cog.
2. Rotate the cable tension barrel-
adjuster (on the downtube, or
on the lever) counter-clockwise,
increasing cable tension to
align the inner derailleur cage
until it just touches the chain.
3. Go through the various gear
combinations to ensure the
chain smoothly lines up with all
the chainrings.
Note: some front shifters have a ‘tab’ feature:
slightly downshift the lever and the derailleur
will move in slightly, no longer touching the
chain.
Rear derailleur
To adjust the small cog position
1. Shift the chain onto the
smallest rear
cog and the
largest front
chainring.
2. Loosen the
cable clamp
bolt (Figure
22) until the
cable is free.
3. Stand behind the bicycle to see
that the smallest rear cog, the
chain, and the two derailleur
pulleys are in line.
4. If they are not aligned, turn
the high gear adjusting screw
(usually marked “H”,) until this
line is established.
5. While pulling on the cable, up-
shift until the shifter is in the
small cog position.
6. On the shifter or down tube,
turn the adjusting barrel
all the way clockwise. Turn
the adjusting barrel on the
rear derailleur all the way
clockwise, and then one turn
counter-clockwise.
7. Insert the cable into the clamp
bolt groove on the rear derail-
leur, pull the shift cable taut,
and tighten the cable clamp bolt
to 44-60 lb•in (5.0-6.8 N•m).
To adjust the large cog position
1. Turn the low gear adjusting
screw on the rear derailleur
(usually marked “L”) far enough
counter-clockwise that it will
not restrict the movement of
the derailleur.
2. Carefully shift the chain onto
the smallest front chainring
and the largest rear cog.
Do not over-shift the rear derailleur, or the
chain may wedge between the large cog and
the spokes.
3. Position the rear derailleur
pulleys in line with the largest
cog.
4. Turn the low gear adjusting
screw clockwise until it meets
resistance.
Chapter : Adjustment
Figure - Rear derailleur
A- Adjusting screws
B- Barrel adjuster
C- Cable clamp bolt
D- Cable
A
B
C D

If you have turned it too far, the derailleur will
move toward the outside of the bicycle.
5. Go through the various gear
combinations. Make sure the
chain does not fall off when you
shift.
To align the indexing system
1. Shift the chain onto the
largest front chainring and the
smallest rear cog.
2. Shift one click with the rear
shifter.
3. Check if the chain moves
smoothly to the next gear.
• If the chain makes excessive
noise or does not shift, turn
the barrel-adjuster counter-
clockwise in small increments
and check again for a smooth
shift.
• If instead, the chain moves to
the third smallest cog, turn the
barrel adjuster clockwise until
the derailleur pulleys align with
the second smallest cog.
4. Go through the gear combina-
tions to ensure the chain
smoothly lines up with all the
rear cogs.
If the derailleur cannot be
adjusted in this manner, the
derailleur hanger may be out of
alignment; take the bike to your
dealer for service.
Nexus 4, 7, or 8 speed systems
To adjust the rear shifting
1. Rotate the shifter to the 4th
gear position.
2. Align the indicator on the rear
hub pulley (Figure 23) with
the cog joint
bracket.
3. If the red
lines do not
line up, adjust
the gear cable
tension by
rotating the
barrel adjuster
until this
alignment is
achieved.
4. Shift to 1st
gear, then
back to 4th, and re-check the
adjustment.
3 speed systems
To adjust the rear shifting
1. Rotate the
shifter to
the 2nd gear
position.
2. Align the
indicator on
the bell crank
window with
the line on
the push rod
(Figure 24).
Chapter : Adjustment
Figure - Pulley and cog
joint bracket
A- Pulley
B- Cog joint bracket
C- Cable clamp bolt
B
A
C
Figure - Three-speed
bell crank
A- Bell crank window
A
5 5
brake levers
The brake
system allows
you to slow or
stop your bike, a
function critical
to your safety.
The brake
system is difficult
to adjust properly
without the proper
tools and training.
It is strongly
recommended
that adjustment of a brake be done
by your dealer. If you need more
specific information regarding your
brake system,
contact your
dealer.
To adjust the
position of a lever
1. Locate the
lever clamp
bolt (Figures
25-27).
2. Loosen the
clamp bolt 2-3
turns.
3. Position the
lever.
4. Tighten the
clamp bolt:
• Regular brake
levers- 53-69
lb•in (6.0-7.8
N•m).
• On mid-bar
levers (Figure
27)- 20-30
lb•in (2.3-3.3
N•m).
3. If the indicators do not line
up, adjust the gear cable
tension by rotating the barrel
adjuster until this alignment is
achieved.
4. Shift to 1st gear, then back to
2nd, and re-check the adjust-
ment.
Chapter : Adjustment
Figure 5- Lever clamp
bolt, road lever
A- Lever clamp bolt
A
Figure - Lever clamp
bolt, mountain lever
A- Lever clamp bolt
B- Reach adjustment
screw
C- Cable
D- Barrel adjuster
A
C
D
B
Figure 7- Mid-bar brake
lever
A- Lever clamp bolt
A

• Hayes hydraulic levers- 25-35
lb•in (2.8-4 N•m)
To adjust the reach to the brake
lever (cable type)
With some brake levers, you can
change the reach, the distance from
the handlebar to the lever.
1. Locate the reach adjustment
screw (Figure 26) and turn.
To decrease the reach, turn the screw in
(clockwise). To increase the reach, turn the
screw out (counter-clockwise).
2. If needed after adjusting the
reach, re-adjust the brake pad
clearance.
To adjust the reach to the brake
lever (Hayes hydraulic type)
1. Locate the reach adjustment
screw between the lever and
the handlebar, near the lever
pivot.
2. To decrease the reach, turn
the screw in (clockwise). To
increase the reach, turn the
screw out (counter-clockwise).
To change which lever controls the
front brake (cable type)
See the Brakes section for brake adjustment
procedures.
1. Open the brake.
2. For a road bike, disconnect
the brake cable and completely
remove it from the lever.
• For a mountain bike, just
remove the leaded end of the
cable from the lever.
3. Install the cables into the
opposite levers.
4. Close the brakes.
5. Inspect the brakes as explained
in Chapter 1, and re-adjust as
necessary.
To change which lever controls the
front brake (Hayes hydraulic type)
Changing the levers with Shimano hydraulic
brakes requires special tools and training so
should only be done by your dealer.
1. Loosen and remove both lever
clamp bolts.
2. Remove the levers and re-
position according to your
preference.
3. Re-install the clamp bolts and
tighten to 25-35 lb•in (2.8-4
N•m).
Chapter : Adjustment
7 7
brakes
Once a month,
inspect brake
pads for wear.
If the grooves
in the braking
surface are less
than 2 mm deep,
or 1 mm deep for
direct-pull brakes,
replace the pads.
Replace disc
brake pads that
are thinner than
1.0 mm.
To adjust brake
pad clearance to
the rim
1. Turn the
barrel adjuster.
To increase the
pad clearance,
turn the barrel
adjuster in
(clockwise).
To reduce the
pad clearance,
turn the barrel
adjuster out
(counter-
clockwise).
For most direct-pull
(Figure 28), or
cantilever (Figure
30) systems the
barrel adjuster is on
the lever. For most
road caliper systems
(Figure 29) the
barrel adjuster is on
the brake itself.
2. If the brake pads cannot be
adjusted properly, loosen the
cable clamp bolt and re-attach
the cable.
To center a V-type, cantilever, or
road brake
1. Rotate the centering screw.
Turn in small increments and
check for centering.
2. If the brake has two centering
screws, adjust the overall spring
tension while centering the
brake.
To adjust the alignment of the
brake pads on a rim brake
1. Loosen the brake pad fixing
bolt.
2. Align the pads as shown on
page 5, and tighten the pad
fixing bolts:
• Road caliper- 40-60 lb•in (4.5-
6.8 N•m)
• Direct-pull or cantilever- 70-80
lb•in (7.9-9 N•m)
3. After adjusting the brakes, test
them by applying force to the
levers. Ensure the cable does
not slip, the pads close toward
the rim at right angles, and the
pads do not contact the tire.
To align a hydraulic disc brake
1. Loosen the brake mounting
bolts.
2. Apply the lever fully, and
gradually tighten the bolts to
100-110 lb•in (11.3-12.4 N•m).
Chapter : Adjustment
Figure 0- Cantilever
brake
A- Linkwire
B- Pad fxing bolt
C- Arm fxing bolt
D- Centering screw
A
D
C
B
Figure - Direct pull
brake
A- Cable clamp bolt
B- No contact
C- Pad fxing bolt
D- Centering screw
E- Arm fxing bolt
A
C
E
D
B
Figure - Caliper brake
A- Barrel adjuster
B- Centering screw
C- Pad fxing bolt
D- Brake relase lever
A B
C
D

To align a cable-actuated disc brake
There are several parts to this
procedure:
•To adjust right brake pad
clearance to the disc
1. Turn the fixed
pad adjuster
(Figure 31).
2. If the pads
cannot be
adjusted
properly in this
manner, follow
the instruc-
tions To adjust
left brake pad
clearance to the
disc, and re-set
the right pad.
• To adjust left brake pad clearance
to the disc
1. Turn the cable barrel adjuster.
To increase the pad clearance,
turn the barrel adjuster
in (clockwise). To reduce
the pad clearance, turn the
barrel adjuster out (counter-
clockwise).
2. If the pads cannot be adjusted
properly in this manner, loosen
the cable clamp bolt and re-
attach the cable. Tighten the
cable clamp bolt to 50-70 lb•in
(5.7-7.9 N•m).
3. After adjustment, turn the
locking nut clockwise to help
prevent rotation of the barrel
adjuster.
• To align the brake with the disc
1. Loosen the brake mounting
bolts.
Chapter : Adjustment
2. Slide a business card, or
similar thin object, between the
right brake pad and the disc.
3. Apply the lever fully, and
gradually tighten the bolts to
100-110 lb•in (11.3-12.4 N•m).
To remove disc brake pads
1. Remove the wheel.
2. With your fingers or thin-
tipped pliers, grasp the installa-
tion tang of the brake pad and
pull out.
To open the brake for wheel removal
• For most road calipers, lift the
brake release lever to the open
UP position. To close, simply
turn the lever to the Down
position.
• For Campagnolo levers, there is a
release button at the top of the
lever. Slightly depress the brake
lever, and push the button until
it is flush with the lever body.
Release the lever and the brake
will open.
To close, reverse the instruc-
tions.
• For cantilever brakes, release the
linkwire. With one hand, squeeze
the brake pads firmly against the
rim. With the other hand, pull the
leaded end of the linkwire from
the retaining fork on the brake
arm. Release the brake pads, and
the brake will open.
To close the brake, reverse the
instructions.
Figure - Disc brake
A- Mounting bolts
B- Fixed pad adjuster
C- Cable clamp bolt
C
A
B

Wheels
Inspect tires for wear and
damage. Make sure rims are
clean, and check for wear; if the
small indentations on the braking
surface disappear, replace the rim.
Make sure there are no loose,
damaged, or broken spokes. Check
that hub bearings are properly
adjusted. Make sure a rim strip
is in place and all spoke holes are
completely covered.
To adjust and install a quick-release
wheel
1. Move the
quick-release
lever to the
OPEN position
(Figure 32)
and set the
wheel so it
firmly touches
the inside of
the fork ends.
2. With the lever
about halfway
between
the OPEN
and CLOSE
positions,
tighten the adjusting nut
(Figure 33) until finger-tight.
• For direct-pull type brakes,
disconnect the pipe from the
link arm. With one hand,
squeeze the pads firmly against
the rim. With the other hand,
pull the pipe back from the link
arm, and lift the pipe. Once
disconnected, let go of the
brake pads and the brake will
open.
To close the brake, reverse the
instructions.
• For internal or drum brakes, to
remove the rear wheel, first
disconnect the shift and brake
cables.
-To disconnect the brake
cable, press the cable carrier
arm forward, and the cable
clamp bolt rearward, so the bolt
aligns with the larger diameter
hole in the carrier. Pull the
cable clamp bolt outward to
disengage it from the carrier.
Slide the brake cable stop
forward to remove it from the
brake arm. Undo brake strap
bolt.
-To disconnect the shift cable,
put the shifter in 1st gear. Pull
the cable housing out of the
shift cable housing stop. Rotate
the shift cable fixing bolt until
the washer flats align with the
slit in the cog joint bracket.
Remove the cable.
Chapter : Adjustment
OPEN
CLOSED
Figure - Lever positions
WARNING
brake pads remove material when
the brake is applied. If too much
material is removed, the rim may
become weak and fail suddenly,
causing a loss of control. Regularly
inspect your rims for wear and
replace them when they are worn.
Figure - Tighten nut
A- Adjusting nut
A
0 0
3. Place the lever in the palm of
your hand and throw the lever
as shown in
Figure 34 to
the CLOSE
position
(Figures 36-
37).
At the half-
closed position of
the lever, there
should be some
resistance.
• Do not tighten
the quick-
release wheel
retention
mechanism
by turning
the lever like
a wing nut
(Figure 35); it
will not result
in sufficient
force to hold
the wheel in
place.
5. If the lever
is moved to
the CLOSE
position with
little or no
resistance,
clamping
strength is
insufficient. Return the lever
to the OPEN position, tighten
the adjusting nut further, close
the lever, and again test for
resistance. For further informa-
tion on correct adjustment of
the quick-release tension, read
Figure 38.
6. Orient the quick-release
levers so they do not interfere
with any other bicycle part or
accessory part (such as rack or
fenders), and so obstacles in the
path of the bicycle cannot snag
the levers.
7. Test that you have properly
adjusted and closed the quick-
release. If the quick-release
fails any test, either repeat
these adjustment procedures,
including these tests, or take
your bicycle to your dealer for
service.
8. Test for proper quick-release
adjustment:
• Pick up the bike, and sharply
hit the top of the tire (Figure
39). The wheel
must not come
off, be loose,
or move from
side to side.
• Make sure the
quick-release
lever cannot be
rotated parallel
to the wheel
(Figure 40).
Chapter : Adjustment
Figure - Test for
looseness
Figure 0- Test for
rotation
Figure 7- Rear lever
position
If it requires more than 5 pounds (00 Newton) force to
completely close the quick-release lever, open the lever
and slightly loosen the quick-release adjusting nut.
If it requires less than pounds (5. Newton) force to
begin to open the lever from the fully closed position,
open the lever and slightly tighten the quick-release
adjusting nut.
Repeat the adjustment if necessary.
Figure - Actual measurements
O
PEN
O
P
E
N
O
P
E
N
O
P
E
N
Figure 5- Do not turn
lever
Figure - Front lever
position
Figure - Proper lever
throw

• When the quick-release is
properly tightened and clamped
by the lever in the closed
position, the clamping force is
adequate to cause metal-into-
metal engagement (embossing)
of the dropout surfaces.
• See Figure 38.
To install an axle-nut wheel
Some wheels are attached by
nuts threaded onto the axle. The
front wheel may require a toothed
washer to be placed between the
nut and fork tip. Some bicycles
also have pegs, tubular axle
extension.
1. Tighten the axle nuts:
• Tighten a regular front wheel
to 180-240 lb•in (20.3-27.1
N•m).
• Tighten a regular rear wheel to
240-300 lb•in (27.1-33.9 N•m).
2. Test to ensure that you have
properly tightened the axle-
nuts.
• Pick up the bike, and sharply
hit the top of the tire (Figure
39). The wheel must not come
off, be loose, or move from side
to side.
If the wheel attachment fails the
test, repeat these procedures,
including the tests, or take your
bicycle to your dealer for service.
To install a thru-axle wheel
1. Open the quick-release or
loosen the clamp bolts on both
fork ends.
2. With the wheel in place, slide
the axle into the fork tips.
3. Close the quick-releases, or
tighten the clamp bolts to 45-55
lb•in (5.1-6.2 N•m).
4. Test to ensure that you have
properly attached the thru-axle.
• Pick up the bike, and sharply
hit the top of the tire (Figure
39). The wheel must not come
off, be loose, or move from side
to side.
If the wheel attachment fails
the test, repeat these procedures,
including the tests, or take the
bicycle to your dealer for service.
Suspension components
Changing your suspension
settings affects handling and
braking characteristics. After
making a change, carefully test the
bike in a low traffic area until you
are familiar with its performance.
Sag is the compression of a
shock that occurs when the
rider sits on the bike in a normal
position. For an all-round ride, set
the forks at about 15% sag, and
a rear shock at about 25% sag.
Experiment with the adjustment
in small increments to find your
preference. If the suspension is
fully compressed, its movement
will stop abruptly and could cause
you to lose control. See the CD or
web site for more specific adjust-
ment and maintenance informa-
tion, or consult your dealer.
Accessories
Once a month, check any
accessories to make sure they
are properly attached. If any part
seems loose or misaligned, either
tighten the part or take the bike to
your dealer for service.
Chapter : Adjustment

To adjust training wheels
See other sections of this manual as needed.
1. Place the bike on a flat, smooth
surface, with the tires properly
inflated.
2. Loosen the rear axle nuts.
Follow the procedures in the
Wheels section.
3. Stand the bike up very
straight, and set a gap of
about 1/4“ (6 mm) between the
training wheels and the ground
on both sides of the bike. Make
sure the gap is the same on
both sides.
4. Adjust the chain tension and
re-tighten the axle nuts.
To install a light bulb
1. Locate the lens set-screw on
the back of either the taillight
or head light.
2. Remove the screw.
3. Rotate the lens 1/4 turn
clockwise and lift the lens
assembly off the bulb mount.
4. Unscrew the bulb.
Be careful not to crush the glass of the bulb.
Do not dislodge the wire in the base of the bulb
mount.
5. Screw a new bulb in until
finger tight.
6. Place the lens on the bulb
mount, rotate the lens 1/4 turn
counter-clockwise.
7. Install the lens set-screw.
Check that the new bulb works.
If it does not, check the wiring for
correct placement, and verify that
the new bulb is not damaged.
Folding bike
Some models of Trek bikes have
a large hinge in the middle to fold
the bike by following these steps:
To lower the saddle
1. Open the seatpost quick-
release and lower the saddle.
2. Close the quick-release to hold
the seatpost in position.
To fold the pedals
1. Push the end of the pedal
directly inward, toward the
crankset.
2. Fold the pedal over.
3. Repeat for the other pedal.
To fold the handlebar stem
1. Rotate the lever lock away
from the lower quick-release.
2. Hold the handlebar with the
cables out of the way to prevent
pinching, and open the lower
quick-release.
3. Fold the handlebar assembly to
its down position.
To fold the main frame
1. Open the latch lock.
2. Pull outwards, away from the
frame, on the end of the frame
latch until the latch opens.
3. While avoiding pinching
yourself or cables, fold the bike
in half.
To unfold the frame, reverse the
steps of the folding procedure.
Chapter : Adjustment
WARNING
Riding a folding bike with
movement at the lower stem quick-
release or main frame hinge could
cause you to lose control and fall. If
the folding frame moves at the stem
or frame hinge, take the bike to your
dealer for service.

This section explains the parts
that require lubrication, their
frequency, and brief instructions.
See your dealer for recommended
lubrications. If you need more
detailed information, see other
sections of this manual as needed,
or consult your dealer.
Re-greasing bearings requires
special tools and training, so
this should only be done by
your dealer. Some bearings are
permanently sealed and do not
require yearly re-greasing
Stem
Once a year lubricate the stem.
Note: Lubricating a direct-connect stem
requires adjustment of the headset bearings, so
should only be done by your dealer.
1. Remove the stem from the
frame.
2. Clean the stem and wipe any
old grease.
3. Apply a thin layer of grease
to the section of the quill that
will be inserted into the frame,
including the stem wedge.
4. Install the stem.
Seatpost
Once a year, lubricate the
seatpost. Choose the method for
your frame and seatpost material:
Aluminum seatpost in a metal
frame
1. Loosen the seatpost binder
bolt, or open the quick-release,
and remove the seatpost from
the frame.
2. Wipe any old grease off the
seatpost, and clean if necessary.
3. Apply a thin layer of grease to
the section of the seatpost that
will be inside the frame.
4. Insert the seatpost into the
frame.
5. Adjust the seat to the proper
height, align it, and tighten the
seatpost binder bolt.
carbon fiber seatpost, or carbon
fiber frame
1. Loosen the seatpost binder
bolt, or open the quick-release,
and remove the seatpost from
the frame.
2. Wipe the seatpost and inside
the seat tube with a soft cloth
and clean water.
3. Let the seeatpost dry, then
insert it into the frame.
4. Adjust the seat to the proper
height, align it, and tighten the
seatpost binder bolt.
bottom bracket
Once a year, have your dealer
re-grease the bottom bracket
bearings,
Pedals
Once a year, have your dealer re-
grease the pedal bearings.
Once a year re-grease the pedal
axles where they thread into the
crank arms.
Note: There are right and left pedals, usually
marked with a letter stamped on the end of the
pedal axle, or on the wrench fats.
1. Remove the pedals; turn the
right pedal spindle counter-
clockwise, but turn the left
clockwise.
cHAPTER 4: LubRIcATIoN
Chapter : Lubrication

2. Apply a this layer of grease
over all the threads.
3. Install the pedals on the proper
side; put the right pedal on the
right crank arm and the left
pedal on the left crank arm.
4. Tighten the pedals.
Derailleurs
Every month, lubricate all pivot
points on both the front and rear
derailleurs, including the derail-
leur pulleys on the rear derailleur,
with chain lube.
Headset
Once a year, have your dealer re-
grease the headset bearings.
brakes and brake levers
Every 3 months lubricate your
brake lever pivots and brake arm
fixing pivots with a light oil.
Wheels
Once a year, have your dealer re-
grease the wheel bearings.
Every year, lubricate wheel
quick-releases. Apply several
drops of synthetic lube or a
similar light oil where the quick-
release lever rotates in the quick-
release body.
Suspension forks
Once a month, apply a light oil to
the upper fork leg where the lower
leg slides on it. Wipe clean.
Rear suspension
No lubrication is required for
the shock or the pivot of your
full suspension bike. Avoid all
lubricants.
control cables
Lubricate cables whenever they
are installed.
To install a cable
Installing a cable in a cantilever brake requires
special tools and training, so should only be
done by your dealer.
1. Note the path of the old cable,
loosen the cable anchor bolt,
and remove the worn cable.
2. Grease the new cable and
reinstall, feeding it along the
same path as the old cable,
including through the cable
anchor bolt.
3. Make sure the leaded cable-end
is seated properly in the lever,
and the housing is properly
seated in the lever.
If needed when installing a cable in a brake,
re-adjust the brake.
4. Turn the adjusting barrel
clockwise so the threads on
the adjusting barrel are not
exposed.
For a shift cable, put the shifter in the position
with the least cable tension.
For a brake, hold the brake closed while you do
the next step.
5. Tighten the cable clamp bolt
to52-69 lb•in. (6-8 N•m).
6. Cut the cable so that no more
than 2” (51 mm) extends
beyond the anchor bolt.
7. Crimp a metal cap or place a
bit of solder on the end of the
cable to prevent fraying.
8. Follow the instructions for
adjustment.
Chapter : Lubrication
5 5
If you would like additional
information about your bicycle,
maintenance, or bicycling in
general, there are many resources
in your community.
First, talk to your bicycle dealer.
They have extensive experience
with bicycles and riding in your
community. With this background,
they can help you with your
individual questions and help
you find areas to enjoy your new
bicycle. In addition, most dealers
stock a variety of book about
cycling, including extensive repair
manuals.
Second, check your public
library. Most libraries have
extensive offerings of books
written by experts in the field
about riding, racing, bicycle safety,
bicycle maintenance, and more.
Third, go on-line. The best on-
line resource for your bike can
be found by viewing the CD that
accompanies this manual. Place
the CD in a computer, and you
will find much more information.
With internet access, you can link
direct from the CD to our company
web site. Links to some of the
companies that make the parts of
your bike are also provided. All of
this information and help is just a
click away.
FoR MoRE INFoRMATIoN
For more information

All Trek bikes are sold exclusively
through our network of Authorized
Dealers who we entrust with profes-
sional assembly and service of your
bicycle.
Trek Bicycle Corporation warrants
each new Trek frame, rigid fork, or
original component part of the bicycle
against defects in workmanship and
materials:
For the lifetime of the original
owner-
• The bicycle frame, except the fork
and the Session model
For five years-
• Rigid forks
• All Bontrager components and
accessories, except consumables
such as tires and inner tubes.
For three years-
• The Session model frame
For one year-
• Paint and decals
• All original parts, excluding
suspension forks, and rear shock
absorbers
• All original parts, excluding
Shimano parts, suspension forks,
and rear shock absorbers
• All Shimano parts, suspension
forks, and rear shock absorbers
shall be covered by the stated
warranty of the original manufac-
turer.
This warranty does not cover-
• Normal wear and tear
• Improper assembly
• Improper follow-up maintenance
• Installation of parts or accesso-
ries not originally intended for, or
compatible with, the bicycle as sold
• Damage or failure due to accident,
misuse, abuse, or neglect
• Labor charges for part replacement
or changeover
This warranty is void in its entirety
by any modification of the frame, fork,
or components.
This warranty is expressly limited
to the repair or replacement of a
defective item and is the sole remedy
of the warranty. This warranty extends
from the date of purchase, applies
only to the original owner, and is not
transferable. Trek Bicycle Corporation
is not responsible for incidental or
consequential damages. Some states do
not allow the exclusion of incidental or
consequential damages, so the above
exclusion may not apply to you.
Claims under this warranty must
be made through an authorized Trek
dealer. Proof of purchase is required.
The subject item must be registered
with Trek Bicycle Corporation, either
through on-line registration or by the
receipt of a warranty registration card
by Trek Bicycle Corporation, before a
warranty claim may be processed.
Warranty duration and detail may
differ by frame type and/or by country.
This warranty gives the consumer
specific legal rights, and those rights
may vary from place to place. This
warranty does not affect the statutory
rights of the consumer.
carbon crash replacement policy
Assessing any damage done to a
carbon fiber part requires more experi-
ence than is needed to inspect metal
parts. If you crash or impact your
bike and the force of the impact is
absorbed by a carbon part, we strongly
encourage you to replace the part, even
if there are no indications of damage.
If such a crash or impact occurs,
Trek offers a crash replacement
program for carbon parts, substantially
reducing any replacement cost. To take
advantage of this program, contact us
using the information listed above and
ask for the Warranty department.
LIMITED WARRANTY
Limited warranty
© 2006 Trek Bicycle Corporation
All rights reserved.
The Trek Logo is a registered trademark of Trek Bicycle Corporation.
Part # 278709
Customer Service
920-478-4678
www.trekbikes.com
801 West Madison Street
Waterloo, Wisconsin 53594 USA
An english version of this manual is on the CD. If you do not have access to a com-
puter and would like a printed version, contact us at the address on this page.
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à un ordinateur et si vous souhaitez obtenir une version papier, contactez-nous
à l’adresse qui fgure sur la page.
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schen, wenden Sie sich an uns unter der hier angegebenen Adresse.
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IMPoRTANT: KEEP FoR FuTuRE REFERENcE
This manual explains how to ride your new bike safely. Even if you have ridden a bicycle for years, it is important for EVERY person to read chapter 1 before riding this bicycle! Parents should explain Chapter 1 to a child or anyone else who might not otherwise understand this information. This manual also shows how to perform basic maintenance. Some maintenance should only be performed by your dealer, and the manual indicates these tasks. If you choose to perform these tasks, you should purchase a detailed repair manual from your dealer. This manual includes a CD (compact disc) with more comprehensive information. This CD can be viewed by inserting it into your home computer. If you do not have a computer, take the CD to your school, work, or public library and view it there. If your CD does not work, go to the web address on the cover to access the information on the web.

About this owner's Manual

Meaning of special symbols and lettering In this manual, the WARNING sign indicates a hazardous situation which, if not avoided, could result in death or serious injury.

WARNING

In this manual, the CAUTION sign indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

cAuTIoN

Bicycle registration is the only record we have of who owns this bike. If there is ever a need to communicate with the owner, such as providing updated safety information, your registration is crucial. There are two easy ways to register your new bicycle: • Click the Registration link when viewing the CD supplied with this manual • Go to the web address on the back cover of this manual and follow the links. The web site also provides a link to updated safety information. If you choose not to register, make sure you check the web site often.

Register your bicycle

Keep for your records

My bicycle model: My serial number: My dealer: My dealer's phone: i Lock key #

Assembly of your new bicycle Assembly and the first adjustment of your bicycle take special tools and skills, so this should only be done by an authorized dealer. If you have questions There are many models, with a variety of equipment, so this manual may contain some information that does not apply to your bike. Some illustrations may vary from the actual bicycles. If you have any questions after reading the information in this manual, consult your dealer. If you have a question or problem that your dealer can’t handle, contact us: Attn: Customer Service 801 W. Madison Street Waterloo, Wisconsin 53594 920.478.4678

This manual conforms with these standards: ANSI Z535.4 CPSC CFR 1512 BS 6102 : Part 1: 1992 CEN 14764, 14765, 14766, 14872

ii

TAbLE oF coNTENTS
chapter 1- Guide to Safe on-and- chapter 2: Maintenance Maintenance schedule ............. 15 off Road operation
bicycle type and use classification Child bike .................................. 1 Condition 1................................ 1 Condition 2................................ 1 Condition 3................................ 2 Condition 4................................ 2 Condition 5................................ 2 before a first ride Make sure the bicycle fits ......... 3 Know how the bicycle performs 3 check the bike before every ride Before every ride checklist ....... 4 Carbon fiber inspection............. 7 Rules for safe riding Know and observe local bicycle riding laws ............................. 9 Watch for cars, pedestrians, and other obstacles ....................... 9 Wear a helmet and proper cycling clothes .................................... 9 Change your riding to be safe in variable conditions................. 9 Riding instructions Use your brakes carefully ....... 12 Use good shifting techniques . 12 Take care of your bike Protect your bike when parking or storing it ......................... 13 Carry repair items ................... 14 Only install and use approved accessories ........................... 14 Keep the bike clean ................. 14 Avoid clamping the frame during transportation or repair ...... 14 Protect your bicycle during shipping ............................... 14 Recommended tools for proper bicycle maintenance............. 16 Handlebar ................................ 17 Stem ........................................ 17 Bar-ends .................................. 19 Saddle ...................................... 19 Headset.................................... 21 Crankset .................................. 21 Crank arms ............................. 21 Pedals ...................................... 21 Bottom bracket........................ 21 Chain ....................................... 21 Cables ...................................... 22 Shifters .................................... 22 Front derailleur....................... 22 Rear derailleur ........................ 23 Nexus 4, 7, or 8 speed systems24 3 speed systems ...................... 24 Brake levers ............................ 25 Brakes ..................................... 27 Wheels ..................................... 29 Suspension components.......... 31 Accessories .............................. 31 Folding bike ............................ 32 Stem ........................................ 33 Seatpost ................................... 33 Bottom bracket........................ 33 Pedals ...................................... 33 Derailleurs ............................... 34 Headset.................................... 34 Brakes and brake levers.......... 34 Wheels ..................................... 34 Suspension forks ..................... 34 Rear suspension ...................... 34 Control cables ......................... 34 For more information.............. 35 Limited warranty .................... 36

chapter 3: Adjustment

17

chapter 4: Lubrication

iii

Bikes designed for riding on a paved surface where the tires do not lose ground contact. bicycles with • Hybrid bikes with 700c wheels. knobby 700c tires. time trial. Tandems: 550 lb (250 kg) condition 1 WARNING These bikes are designed for children riding condition 2 where parental Bikes designed supervision is for riding always required. Riders shall avoid plus smooth areas used by gravel roads and automobiles. tires do not lose ground contact. consult your dealer. or speed bikes • Tandems of any design • Cruisers with wide. but not cyclocross bikes • Triathlon. generally. you could lose control and fall. Read the safety information in Chapter 1 for further details. bicycles. and cantilever or disc brakes • Weight limit: 300 lbs (136 kg) child bike  Chapter : Guide to Safe On-and-Off Road Operation . stairs. with moderate curs. can be broken or damaged by riding in a manner more stressful than the intended use of the bike. 26" tires and swept-back handlebar • Any bike that folds • Weight limit: 275 lbs (125 kg). and kids' tires wider than 28c. child bike types • Maximum seat height of 680 condition 2 bike types mm.with droptype handlebars.bIcYcLE TYPE AND uSE cLASSIFIcATIoN Riding a bicycle in a manner beyond. Do not ride beyond the design limits of the bike. or areas near drop-offs grades where the or pools. 16" or 20" wheels. its intended use can cause the bicycle or part of the bicycle to fail. If you are unsure of the limits of the bike. condition 1 bike types • Drop-type handlebars including touring bikes.specially-equipped fastening systems hybrids • Weight limit: 80 lbs (36 kg) • Cyclocross bikes. or their parts. If the bike is damaged. as improved trails well as inclines. and flat tricycles handlebars • No quick-release wheel • City bikes. or more severe than. Condition 1. The following information explains the type of riding intended for different types of bikes.

fork. 2. and small jumps. 26. and smooth technical areas. moderately sized obstacles. If you choose to ride in Condition 5 terrain. or 29" tires • May include short-travel rear suspension (3"/75 mm or less) • Weight limit: 300 lbs (136 kg) condition 3 Bikes designed for jumping. high speeds. or parts. you should take appropriate safety precautions such as more frequent bike inspections and replacement of equipment. and components • Weight limit: 300 lbs (136 kg) condition 5 Bikes designed for riding Conditions 1. condition 3 bike types • "Standard" or "cross-country" mountain bikes with wide. and body armor. You should also wear comprehensive safety equipment such as a full-face helmet.Bikes designed for riding Conditions 1 and 2. or aggressive riding on rougher surfaces. and so are some light-weight rear suspension models. knobby 24. condition 4 bike types • "Heavy-duty" or "all-mountain" mountain bikes with wide. including areas where momentary loss of tire contact with the ground may occur. or landing on flat surfaces. small obstacles. 26. hucking. However. this type of riding is extremely hazardous and puts unpredictable forces on a bicycle which may overload the frame. condition 5 bike types • "Freeride" or "jumping" bikes with heavy-duty frames. NOT jumping. knobby 24. forks. plus rough trails. plus rough technical areas. All mountain bikes without rear suspension are Condition 3. or 29" tires • May include medium-travel rear suspension (4"/100 mm or more) • Weight limit: 300 lbs (136 kg) condition 4 Chapter : Guide to Safe On-and-Off Road Operation  . pads. and 3.

including over-use of the front brake. or if you have special needs that require different parts for the safe operation of your bike. can cause you to lose control and fall. do not pedal if the handlebar is turned. Before making these adjustments. may cause you to lose control of the bike. when the handlebar is turned. WARNING Know how the bicycle performs WARNING  Chapter : Guide to Safe On-and-Off Road Operation . the handlebar does not turn enough for this to occur. at very slow speeds. Avoid pedaling when turning at slow speed. refer to Chapter 3. Mis-use of the braking system. bicycles The seat and -" (50-75 mm) for handlebar may be mountain bicycles adjusted to offer the best comfort and performance. if misused. empty parking lot. or less. There should be at least 1” (25 mm) clearance between the top tube and the rider A when standing over the bicycle (Figure 1). stopping power. It may be possible. consult your dealer.Minimum standclearance is over height A = " (5 mm) for most recommended. If you would like your bike to have more. for Figure . consult your dealer about brake adjustments or other brake options for your bicycle.bEFoRE A FIRST RIDE Your dealer should fit you with the proper size of bicycle. contact between your foot or toeclip and the front wheel or fender can cause you to lose control and fall. At normal riding speeds. Avoid toe-clip overlap When riding slowly. 2-3” (50-75 mm) Figure . Make sure the bicycle fits Learn the power of your brakes The stopping power on bikes varies according to the intended use of the bike.Toe-clip overlap your foot or toeclips to contact the front wheel or fender (Figure 2). learn the function and performance of all the mechanisms of your bike by riding at slower speeds in a flat. Before riding fast or in more difficult conditions. Avoid improper braking by understanding and practicing proper application of your brakes as explained in this manual. The features of your bicycle. For mountain bikes. If you want your bicycle to perform differently.

do not ride the bicycle. Check that the wheels are straight. or take the bike to your dealer for service. repair the wheel. If you are experiencing a shimmy. can cause you to lose control and fall. If you experience a shimmy. If a frame or fork has any problem. or steering wobble. cAuTIoN Check that the wheels are properly attached.cHEcK THE bIKE bEFoRE EVERY RIDE Stop riding if you have frame problems Occasionally riders experience problems with their frame or fork. inspect the bike with the following check list. in very rare cases. before every ride checklist WARNING  Wheels  Tire inflation  brakes  Handlebar and stem  Seat and seatpost  Suspension adjustments  Lights and reflectors  Frame. As an example. Take your bicycle directly to a dealer for inspection and repair. A shimmy. and components A bicycle that does not work properly can cause you to lose control and fall. Bicycle wheels are attached by several systems: threaded axle nuts. Before every ride. If the rim wobbles up and down or from side to side. If any part of the bicycle fails the inspection. fork. repair the bicycle by following the information provided by this manual. have it replaced. Take your bicycle to your dealer for inspection and repair. This is not a comprehensive maintenance program. and do not ride it until any problem has been corrected check the wheels Spin each wheel and watch the rim as it passes through the brake pads or the frame. slow down immediately. a quick-release where a leveractuated wheel retention mechanism Chapter : Guide to Safe On-and-Off Road Operation  . Inspect the entire bicycle thoroughly before every ride. Never ride a bike with a damaged part. some riders may experience a “shimmy” or “harmonic oscillation” or “frame vibration” at certain speeds. slow down immediately.

a hand lever connected to the brake by a cable or hydraulic hose squeezes a disc check the brakes mounted on the wheel hub.a hand lever brake moves freely and stops connected to the brake by a cable 5 Chapter : Guide to Safe On-and-Off Road Operation .Test for looseor move from side ness to side. or you if suspect a problem with the brake cables or hydraulic hose. Make sure the wheels are properly attached before riding the bike. the brake is too tight. be loose.(Figure 3) allows the wheel to be installed and removed without tools. Never ride a bike if you are not certain the brakes are working properly.Wheel quickrelease tion about adjustment and closure of the wheel attachment devices on your bicycle. check the tire inflation Inflate the tires to the air pressure recommended on the tire sidewalls. Pick up the bike and sharply hit the top of the tire (Figure 4). Further tests are provided in Chapter 3. Test for proper wheel attachment. the brake is too loose.Direction of rim rotation D. or a thruaxle where the axle is threaded through the ends of the frame or fork. If your brakes are not working properly.Brake pad aligned with rim surface B. see Chapter 3.Brake pad alignment A. B C A Figure 5.Pad and rim should be parallel C. Follow the inspection instructions Squeeze each brake lever toward for the type of brake on your bike: the handlebar to make sure the Hand-rim brake. causing you to lose control and fall. If the brake lever can be pulled to the handlebar.0 mm toe-in D WARNING WARNING Disc brake. A wheel attachment device that is not properly adjusted and closed may allow the wheel to be loose or come off unexpectedly. For informa. re-adjust them or take the bike to your dealer for service. Malfunctioning brakes can cause you to lose control and fall. Brake pads should be aligned with the rim surface (Figure 5). Squeeze each brake lever toward the handlebar to make sure the brake moves freely and stops the bike.Figure . The wheel must not come off. the brake pads should be 1 to 2 mm from the rim. causes the brake pads to squeeze the rim.5-. Inspect the brakes thoroughly before every ride. If the brake pads are too close to the rim.0. When the brakes are not applied. Figure .

75 mm away from Test the stem the disc when the brakes are not connection to applied. Chapter : Guide to Safe On-and-Off Road Operation  . between your knees (Figure 7). Also. If it takes less than 7 mm of ends of the handlebar (and barends). or when rotating. It should not move or be Avoid touching the hub or cooling loose.check the handlebar and stem Make sure the bike. the disc edges may be sharp and could cut skin. Make sure that no cables are fins when hot. the fork by the brake is too tight. If the brake lever can the stem is in be pulled to the handlebar. stretched or pinched by rotating the handlebar. the brake is too loose. the alignment with brake is too loose. stem. cAuTIoN The chain actuates the brake. If the pads are too close. Avoid touching the disc or disc brake when hot. check the seat and seatpost Coaster brake. brake should engage with less than 60 degrees rotation (1/6 revolution). and attempt backwards. It should not move or backwards. or misattempting to turn aligned. Figure . If it takes more than 5/8” (15 Check that the handlebar plugs mm) of brake lever movement to are properly inserted into both stop the bike. should be 0. There should be between 1/4-1/2” (6-12 mm) total vertical movement of the chain (Figure 6). the brakes are too tight.25-0. so make sure the chain cannot come off.a hand lever from side to side connected to the brake by a cable with the front Figure 7. the handlebar Internal hub brake.the brake is Make sure the seat is secure by engaged by attempting to turn the seat and pedaling seatpost in the frame. cAuTIoN Test the security of the handlebar Internal hub brakes get very hot by attempting to rotate it in the during use and could burn skin.Function testing the handlebar and stem activates a mechansim inside the wheel locked hub.Checking chain tension Disc brakes and discs get very hot during use and could burn skin. The brake pads the front wheel. the be loose. to move the front of the seat up When pedaling and down. lever movement to stop the bike.

check the suspension adjustments Make sure your suspension components are adjusted to your riding style. speed. and components for signs of fatigue before and after each ride. thoroughly inspect all the parts of your bike. carbon fiber inspection procedures WARNING 7 Chapter : Guide to Safe On-and-Off Road Operation . and must be inspected carefully for damage. High force loads include crashes. Regularly inspect your entire bicycle for signs of fatigue stress: • Dents • Cracks • Scratches • Deformation • Discoloration • Unusual noises Even if you perform regular inspections. For example. carbon composite parts that have been damaged may not bend. Take it to your dealer for inspection. it may fail if overloaded. make sure it is mounted correctly and all attachment hardware is tight. technique. temperature. and components Carefully inspect your frame. etc. If you ride hard or aggressively. different from metal parts. Unlike metal parts. But as a rule. or suspect a carbon part is damaged. maintenance. and evaluation under the crash replacement policy. it is better to err on the safe side and replace the bike or parts more frequently. you should replace the bike and/or its parts more often than riders who ride smoothly or cautiously.). There are many variables: weight. but you don't have to crash to put a high force load on your bike. If the lights use a dynamo. and the frame or part itself. salinity. riding environment (humidity. terrain. carbon has unique qualities. IMMEDIATELY SToP RIDING YouR bIcYcLE. Inspect your carbon fiber bicycle or parts for damage frequently. service. The manner in which you ride will determine whether your bike and its parts will last. Make sure reflectors are clean and in position. bulge. A damaged carbon fiber part can fail suddenly. fork. If you have crashed or impacted your bicycle. However. fork. Carbon fiber is among the strongest materials used in bicycle manufacture. and that no suspension component can "bottom-out" or be so compressed that there is no further suspension travel or movement remaining. if you exceed the limit of strength of your bicycle or a given part. check frame. If you aren't sure. hitting a large hole in the road or a sharp bump such as a railroad track can put large forces on your bike. After any high force load. ask your dealer. check the lights and reflectors Make sure the lights are functioning correctly and that any batteries are charged.so it is impossible to give a precise timetable for replacement.

If you have any doubts about the integrity of a part. When a composite part is damaged. especially a hollow sound. a damaged part may appear to be normal to a cursory glance. Be very careful when handling carbon fiber parts that are suspected of damage. Chapter : Guide to Safe On-and-Off Road Operation  . or any sound indicating that the part is not solid. 2. • Check the part for loss of rigidity. 3. If the point of one of these fibers is pressed against your skin. As an example. or parts Use the following procedures to inspect carbon composite parts: • Check for scratches. so we provide a movie of inspecting a composite part on the owner's manual CD and on the owner's manual web site. To check a part for delamination (tap test) 1. gouges. tap the part near any possible damage and places where the part is known to be in good condition (or use a similar part). if you suspect a composite seatpost has been damaged. Clean the part thoroughly with a damp cloth. there is a possibility that individual fibers may be exposed. To check a part for surface problems (visual test) 1. Inspecting carbon fiber composite frame. it could pierce your skin like a needle. do not ride the bicycle. • gouges • cracks • loose fibers (which will appear like thin hairs) • other surface flaws To check a part for loss of rigidity (flex test) Use the part in a normal manner (without actually riding) while someone watches carefully for unexpected movement. The tests are difficult to describe. 2. fork. Carbon fibers are thinner than a human hair.or deform. Clean the part thoroughly with a damp cloth. or other surface problems. • Check the part for delamination. Listen carefully for variations in sound. • Listen for unusual creaking or clicking noises. but quite stiff. Look closely for problems: • scratches These tests may not be conclusive. With a coin. "dead" tone. sit gently on the saddle while someone watches to see if the seatpost flexes.

If the helmet helmet is caught.Wear a bicycle bicycle. Local cycling clubs or your state’s Department of Transportation (or equivalent) should be able to supply this information to you. do so Ride carefully in wet weather carefully at a 90° No brakes. and gloves. Mount a horn or bell on your bicycle. • Ride defensively. bright. Most state and local areas have specific laws for cyclists. and reflecWatch for and avoid potholes. tive clothing to make yourself more visible. whatever their angle (Figure 8). Helmets should be removed when not riding the Figure . eye protection. and you should follow them. stuck on.Angle for cross. The requirements for items such as lights and reflectors change between areas. walk and maintained brakes require your bike. work as effectively in wet 45 If you are not sure weather as they do in dry. Even of riding surface properly aligned. you could be involved in a serious accident. drain grates. and other deviations which could impact your wheels or cause them to slip. These are a few of the more important rules of riding: • Use proper hand signals. it may help prevent injury.greater lever pressure and longer ing tracks Wear a helmet and proper cycling clothes  Chapter : Guide to Safe On-and-Off Road Operation . Watch for cars. especially at night. Figure . When change your riding to be safe in crossing railroad variable conditions 90 tracks or drain grates. • Ride on the correct side of the road. and Avoid loose-fitting pants that could get caught in the chain. A cyclist is hard to see. lubricated. pedestrians. • Ride single file when riding with other cyclists. never go against traffic. or someone unexpectedly opens the door of a parked car. conditions. so check ahead. and use it to alert others of your approach. design. soft or low shoulders.RuLES FoR SAFE RIDING Know and observe local bicycle riding laws If a car suddenly enters your lane. Wear protective clothing including helmet. the wearer could choke. expect the unexpected. other obstacles Also wear light. or stuck between objects. Wear a helmet that meets CPSC or CE safety testing standards (Figure 9). and many drivers simply are not trained to recognize the rights and special considerations of a bicycle rider.

or use other forms of transportation. Failure to do so will increase your chances of being involved in an accident in low light conditions. nor do they help you be seen unless light is directed on them. • Do not ride with loose objects attached to the handlebar or any other part of the bicycle. at night. or manhole covers. be careful when riding in low light conditions. such as when riding over wet leaves. Use a working headlight and A bicycle rider without proper lighting and reflectors may not have good vision and may not be visible to others. Do not use unsafe riding practices Many cycling accidents could be avoided by using common sense. continued next page WARNING The following riding practices increase your risk of injury: • Jumping your bicycle • Performing bicycle stunts • Severe off-road riding • Downhill riding • Any abnormal bike riding Each of these practices increases the stress on every part of your bicycle. causing them to fail and increasing the risk of injury to the rider. painted crosswalks. • Do not ‘ride double’. traction is reduced even further. use front and rear bicycle lights and reflectors when riding in poor visibility conditions. As useful as these reflectors are. consult your dealer to find appropriate products to aid your vision and make you more visible. When wet weather cools to below freezing. WARNING Chapter : Guide to Safe On-and-Off Road Operation 0 . • Do not ride while intoxicated or while using medications which might make you drowsy. a dynamo (generator light) may not work properly. The important thing is to see and be seen. Here are a few examples: • Do not ride ‘no hands’. brakes may not work as well. If you do any amount of riding at dusk. taillight when you ride in poorly lighted or low visibility conditions. Avoid riding in wet weather when visibility is reduced. Frames or parts under high stress may fatigue prematurely. avoid these riding practices. When riding in wet weather. In windy conditions. slow down or use other forms of transportation. keep them clean and in position. Wet weather causes reduced traction. Anticipate the extra distance it will take to stop. or in any poorly lighted conditions. Your bicycle is equipped with a full set of reflectors. To decrease your risk of injury.stopping distances in wet weather. In addition. Adjust your riding speed accordingly. they do not help you see. Strong winds can make a bicycle steer or turn unexpectedly. Use slower cornering when traction is reduced.

Keep your bicycle under control at all times. As with anything mechanical. WARNING  Chapter : Guide to Safe On-and-Off Road Operation . it should be expected that light-weight. the bike may tip over. can cause a material to fail or break. high-performance bicycles and parts require better care and more frequent inspections.• Use special care when off-road riding. or depressions. With training wheels. and use the rear brake more than the front. so parents should strictly enforce this rule. have a longer life than heavier ones. in some cases. reduce speed. Bicycles are not indestructible. and fatigue. Although lighter frames or parts may. stress. it is more likely that wheels will slip. do not ride fast or turn sharply. Training wheels prevent the normal inward lean of a bicycle during a turn. When approaching a descent. use. Avoid riding too fast Higher speeds create higher risks and greater forces in the event of a crash. and maintenance. ride within the Use Classification for your type of bicycle (see pages 1-2). • Do not ride in an abusive manner. At higher speeds. If the bicycle is turned too quickly. every part of a bicycle has a limited useful life due to wear. Fatigue refers to a low-stress force that. keep your weight back and low. materials. or that a small bump can create a significant impact to your frame or fork. Ride only on the trails. resulting in an accident. Avoid rocks. branches. For children. when repeated over a large number of cycles. The length of the life of a part varies according to its design. the limit of speed for safe riding is much lower.

of a frontwheel brake. However. Use only one shifter at a time. take your bike to your dealer use your brakes carefully for adjustment or replacement of the braking system. WARNING Chapter : Guide to Safe On-and-Off Road Operation  . the chain may not shift properly or may fall off. Shifting gears allows you to choose the gear combination most comfortable for riding conditions. bikes equipped STI road shifters and triple chainrings may shift better. apply both brakes at the same time. and shift your weight backwards on the bike while braking. Shift gears only when the pedals and chain are moving forward. If your bike has two hand brakes. see Chapter 3. if you “hold” the lever for a moment before letting go of the shifter. With modern indexed shifting systems. which can cause you to lose control and fall. Adjust stopping distances and braking forces to suit riding conditions. to help avoid excessive chain and gear wear. such as using only the front-wheel brake in an emergency. Shifting a bike with a derailleur The left-hand shifter controls the front derailleur and the righthand shifter controls the rear derailleur. Many models of modern brakes are very powerful.RIDING INSTRucTIoNS Always keep a safe stopping distance between you and other vehicles or objects. reduce the force on the pedals to provide quicker and smoother shifting. Avoid shifting when going over bumps. and to help avoid bent chains. or misuse. If you feel your brakes are too powerful for your riding needs. particularly when shifting from the smallest chainring to the middle. they are designed to stop a bike in wet or muddy conditions. and chainrings. or the front wheel to slip out from under you. derailleurs.Overuse of the front-wheel brake from the ground which could cause you to lose control (Figure 10). Bicycles are normally manufactured with the left brake lever controlling the front-wheel brake. When you shift. Shifting a bike with internal gearing Shifting with internal gearing use good shifting techniques Applying sudden or excessive stopping force with the frontwheel brake may cause the rear wheel to lift off the ground. could cause the rear wheel to lift Figure 0. a movement of the shifter from one position to the next (or movement of the shifter to the "shift" position) should promptly move the chain from one gear to the next. Shifting systems are of two types: derailleur (external) and internal. one that allows you to maintain a constant rate of pedaling. Apply both brakes at the same time. Over-use. To change so that the right lever controls the front-wheel brake.

Rain or snow may cause the metal on your bicycle to corrode. keep your bike where it will be protected from rain. Ultraviolet radiation from the sun may fade the paint. or crack any rubber or plastic on the bicycle. sun. and make sure it cannot fall over. Incorrect use of bike racks may bend your wheels. Record and keep your serial number Register your bicycle with your local police department. stopped. Store your bike carefully When not riding. Do not lay the bike on its derailleurs. we will keep the serial number of your bike on file. Do not store the bike near electric motors. as this may cut the handlebar grips. If you must shift while pedaling. as ozone from motors destroys rubber and paint. keep your bike in a place where it will be out of the way. etc. as you may bend the rear derailleur or get dirt on the drivetrain. Excessive chain tension makes shifting difficult. Don’t let the bike fall down. write the serial number in the front of this manual. or tear the seat.  Chapter : Guide to Safe On-and-Off Road Operation . reduce your pressure on the pedals. Park your bike safely When not riding. snow. and keep the manual in a safe place. Protect your bike when parking or storing it Protect your bike from theft Purchase and use a lock that is effective against bolt cutters and saws. or back pedaling. Never leave your bike unlocked while unattended. Complete our on-line warranty registration. Also.TAKE cARE oF YouR bIKE is best performed when coasting.

be certain it is in good working order. removing carrying a bike in a car carrier. or tips. If you ride at night. filing. a child high-performance bicycle frames. and polish the frame with frame polish. or break that are approved by the manufac. such as a dealer. only install and use approved accessories Avoid clamping the frame during transportation or repair Chapter : Guide to Safe On-and-Off Road Operation  . spare inner tube. fork. Although most of our bikes Clamping devices used by can be fitted with a child carrier. carrier places weight high on the bike. redundant retention devices. This Not all accessories are compattype of clamp this may damage the ible or safe. Use of industrial solvents or harsh chemicals for cleaning may damage the paint. Before riding the bicycle again. before adding or changing any part of your bike. When putting a bike in a repair Never modify your frameset or parts in any way. clean and lubricate it. drilling. clamp the seatpost. crush. Improper components or improper assembly Protect your bicycle during can place unknown stress on your shipping bike or components. or component make sure it is properly padded can cause you to lose control and and protected to avoid damage. fall. so only add accessories paint or even dent. Keep the bike clean carry repair items Never clamp the bike frame by its finished or painted surfaces. Hang the bicycle off the ground with the tires at approximately half pressure. clamp the wheels and the fork installing incompatible forks. carry spare bulbs and batteries for your lights. patch kit. including stand.the light-weight tubing used in turer. The list of incompatible parts is too long for this manual. the rider must use extra caution to compensate for the decreased stability. clean it with a soft. damp cloth and bike cleaner or a solution of dish soap and water. work stands and car carriers can damage the finish on a WARNING bike or even crush the tubing. consult your Ask your dealer about supplies used to ship a new bike. If you are unsure whether a part is approved. When sanding. An improperly If you have to ship your bike. affecting the stability of the NoTIcE vehicle. Carry a pump. modified frame.Before storing your bike for an extended period of time. consult your dealer. and appropriate tools to keep your bicycle running in the case of a flat tire of other common mechanical problem. by any other method. fork block. If your frame or a component is dirty. As an example.

........... 33 Lubricate seatpost . snow.....cHAPTER 2: MAINTENANcE This maintenance schedule is based on normal usage.. All bikes should be thoroughly serviced once a year......... have your dealer thoroughly inspect the bicycle................... service your bicycle more often than the schedule suggests.................. 6 Check the suspension adjustments ................... even if they have not been ridden much.............................. 21 Check brake pads .......... 31 Inspect cables for wear ....................... 34 Check suspension fork bolts .......... 7 Check frame................. 34 Every year Lubricate handlebar stem ............... If any part appears to be malfunctioning... If you ride your bike more than average... 13 Check the crankset and bottom bracket .................................. 21 Re-grease bottom bracket bearings . 18 Maintenance schedule Monthly Check the attachment of the handlebar and stem ........... 33 Re-grease pedal threads and bearings ... After initial break-in..... If a part is damaged............... 22 Check the operation of shifters22 Inspect derailleurs ................... 21 Lubricate brake levers ...... 34 Lubricate wheel quick-releases34 Re-grease suspension forks ............... 27 Check chain tension ............. or consult your dealer. or off-road conditions................ Approximately two months after purchasing your new bike..... 29 Lubricate suspension forks ........... inspect and service it immediately...... and components .... Every ride Check the wheels ......... 21 Check the chainguard (accessories) .................... replace it before riding the bicycle again............. 22 Lubricate derailleurs .............. 29 Every 3 Months Clean and polish finish ....................................... new bikes should be checked for stretched cables and other normal conditions..... 4 Check the tire inflation ... 5 Check the brakes........... 6 Check the seat and seatpost .. 27 Check brake bolts........... 17 Check the attachment of the seat9 and seat Check the chain .................. fork.............. 31 Check rear suspension bolts ......... 14 Check for loose spokes .......... 34 Re-grease headset bearings ........ or in rain.......... 7 Weekly Wipe off your bicycle with a damp cloth ..... 34 5 Chapter : Maintenance . 7 Check the lights and reflectors.......... 33 Re-grease wheel bearings ........... 34 Check the internal shift system24 Check headset bearing adjustment .... 5 Check the handlebar and stem . 6 Inspect Trekking accessory bolts 31 Check wheel bearing adjustment 29 Check rims for wear........

Recommended tools for proper bicycle maintenance Torque wrench with lb•in or N•m gradations 2. 8 mm allen wrenches 9. and tire levers Special high pressure air pump for rear shock or suspension fork Note: Not all bikes require all these tools Chapter : Maintenance  . 15 mm open-end wrenches 15 mm box end wrench Socket wrench. tire pump with gauge. 5. 14. 1 phillips head screwdriver Bicycle tube patch kit. 15. and 19 mm socket T25 Torx wrench No. 4. 6. 10.

After any repair. Position the handlebar to the desired angle. The torque specifications should be used to make sure you do not over-tighten the fasteners. Loosen the handlebar clamp bolt(s) on the stem (Figures 11-12) just enough that the handlebar can be rotated in the stem.6 N•m). 3. A Word About Torque Specifications Torque is a measurement of the tightness of a threaded fastener such as a screw or bolt.150-180 lb•in (17-20.100-120 lb•in (11. Inspect the entire bicycle thoroughly before every ride.3-13. Stem An improperly adjusted or tightened handlebar. Tighten the steerer clamp bolts to 100-120 lb•in (11.Steerer clamp bolts your dealer. handlebar. To align a direct-connect stem 1. • Forged stems. and bar-ends are positioned and tightened properly before riding the bike. and may actually lead to damage or failure of a part.Handlebar clamp bolts only be done by B. 2.Direct-connect stem so this should A. 3. If a part fails inspection at the recommended torque. take the bike to your dealer. Make sure the stem. This procedure requires special B tools and training Figure . Loosen the steerer clamp bolts two to three turns. Handlebar To adjust the angle of the handlebar 1. or bar-ends can cause you to lose control and fall. WARNING 7 Chapter : Adjustment . Tighten the handlebar clamp bolt(s) according to stem type: • Welded stems. Always perform the simple function tests listed in this chapter to make sure a part is properly tightened. Applying more than the recommended torque to a fastener does not provide extra holding power. inspect the bike as explained in Chapter 1. and do not ride it until any problem has been corrected. whether or not the part was tightened with a torque wrench.6 N•m).3 N•m) WARNING There are two types of stems: • Direct-connect (Figure 11) • Quill-type (Figure 12) Adjusting the A handlebar height on a direct-connect stem affects the headset bearing adjustment. stem. determined by using a torque wrench. 2. A bicycle that malfunctions can cause you to lose control and fall. making sure it is centered in the stem.cHAPTER 3: ADJuSTMENT This chapter lists instructions for adjustment of the parts of a bicycle. Align the stem with the front wheel.3-13.

If the clamp force is too high or too low.6 N•m). B 2. Make sure the lever is completely closed and the locking button has returned to its locked position. Tighten the angle adjusting bolt to 150-170 lb•in (17-20. 3. Slide the B locking button A (Figure 14) forward and lift the quickrelease lever. A. 3. A minimum of 23/4” (70 mm) of the stem Figure .Minimum insertion mark on quill quill must always remain A-stem line must be This in the frame. To adjust the clamping force of the quick-release lever of the bontrager adjustable-rise stem 1. which gives access to the stem expander bolt. Turn the tension adjusting screw (Figure 14). Loosen the angle adjustment bolt (Figure 12) until the stem angle can be changed. WARNING Chapter : Adjustment  .Stem expander bolt 3.To align or adjust a quill-type stem 1. Make sure the minimum insertion mark (Figure 13) is inside the frame. Tighten to 120 lb•in (13.Quick-release lever quick-release C. 2. but with the minimum insertion line inside the frame A (Figure 13). A quill stem that is positioned too high can damage the bike and can cause you to lose control and fall. first change the stem angle. Adjust the C. readjust the screw. 2. Check that at about halfway through the lever throw there is some resistance. Position the stem to the desired angle.Tension adjusting 3. Open the quick-release lever.Angle adjusting bolt handlebar to the desired height. Tap the top of the stem expander bolt with a wood C or plasticfaced mallet to Figure .3 N•m).Bontrager adjustable-rise stem angle. Close the screw B.Locking button lever. To change the angle of an adjustable-rise stem 1. Never ride your bicycle with a quill stem raised above the minimum insertion mark. Loosen the stem expander A bolt two to three turns.Handlebar clamp wedge. 2.Adjustable-rise loosen the stem quill stem A. inside the bike frame 4. Position the C stem and handlebar to the desired Figure . bolts B. To adjust the height of the adjustable-rise stem in Figure 12. To change the angle of a bontrager adjustable-rise stem 1.

Bontrager seatpost A. For bikes with rear suspension.Seat fixing bolt  Chapter : Adjustment . WARNING Never engage the seatpost binder To adjust the angle of the bar-ends with the seatpost out of the frame. Tighten the bar-end clamp bolt so the seat can to 85-125 lb•in (9. Loosen the on the handlebar. the right bike seat will be reasonably comfortable even for long rides. If your saddle causes pain or numbness. Saddle 2. Some seatposts use two bolts.Seatpost parts A. try tilting the seat nose down slightly so that compression of the rear shock under your body weight (sag) results in a level seat.Bar-end clamp bolt Extended riding with a poorly adjusted saddle or one that does not properly support your pelvic area can cause injury to your nerves and blood vessels.Seat fixing bolts B. Loosen the bar-end clamp bolt(s) until they can be rotated To adjust the angle of the seat 1. With proper adjustment. across the top of the seat to better see the angle. re-adjust the saddle position. To select the saddle angle. The seat may also be moved forward or backward along the seatpost to increase comfort as well as adjust the distance to the handlebar.1 N•m) A be tilted fore and aft. Place a straight edge.Seatpost binder bolt A Figure 7. consult your dealer about further positioning or replacing the saddle with one that better fits you. The correct adjustment of the seat angle is largely a matter of personal preference. but at an angle not less than 15° from parallel to the ground. seat fixing bolt 2. just far enough 3.6-14. B C Figure .Bar-ends (Figure 15) are designed for climbing only. 1.Seatpost C. such as a bubble level or ruler. Position the bar-ends to the (Figure 16) desired angle.Bar-ends A. If after adjustment your saddle still causes pain or numbness. bar-ends A Figure 5. first try riding with the top of the seat parallel to the ground. Ensure the barends face forward and away from you. where angle adjustment is done by loosening one bolt and tightening the other bolt.

3-24.Tricycle seat mast tighten the A. 3.Seat mast seat mast B. Sit on the seat in riding position without shoes. your extended leg is straight (Figure 18). 5.80-125 lb•in (9. 6. WARNING Chapter : Adjustment 0 . with your heel resting on the bottom pedal.1 N•m) A seatpost that is positioned too high can damage the bike and can cause you to lose control and fall.1 N•m). or quickrelease. or tighten the bolt to 85-125 lb•in (9. Close the seatpost quickrelease. Adjust the seat and re-tighten the seat fixing bolt according to the type of seatpost: • Double bolts using a 5 mm allen wrench. while someone holds the bicycle up.45-60 lb•in (5-6. Position the crank arms so they are parallel to the seat tube.6-14. To adjust the seat height of a bicycle 1.614.Leg extension with proper seat height seatpost until. Make sure the minimum insertion mark on the seatpost (Figure 19) A is not visible above the bike frame. Install and Figure 0.1 N•m). • Double bolts using a 4 mm allen wrench. 4. To adjust the seat position of a tricycle 1.3 N•m).150-250 lb•in (17-28. Make sure the minimum insertion mark (Figure 19) is inside the frame.8 N•m). with the ball of your foot on the pedal.6-14. Loosen the seatpost binder bolt. Move the seat mast to the desired B position.9 N•m). • Single bolt using a 6 mm allen wrench. 2. A Figure .180-220 lb•in (20.Minimum minimum of insertion mark on 21/2” (64 mm) seatpost A.Clamp bolts clamp bolts to 85-125 lb•in (9.3. When wearing your shoes there should be a slight bend in your knee in a proper riding position. • Single bolt using a 13 or 14 mm open-end wrench. Extend the Figure . Loosen and remove the clamp bolts A (Figure 20).This line must be of seatpost inside the bike frame must remain in the frame. 3. 2.

remove the pedals and install them into the second set of holes. Adjustment of headset bearings requires special tools and training. 2. These services should only be performed by your dealer. 2. bottom bracket chain To adjust the chain tension on a single speed bike 1. refer to the information on the CD supplied with your bicycle. loosen the rear wheel axle nuts on alternate sides of the wheel. Some bicycles offer adjustable crankarm length. Tighten by following the instructions for Pedals. while the right pedal is right-hand (normal) threaded. 4. Apply the front brake firmly while you rock the bicycle forward and backward. slowly rotate the fork and handlebar to the right and left. These services should only be performed by your dealer. In small increments. To adjust the release force on clipless pedals. or if the motion stops abruptly or you hear a grinding noise coming from the bearings. If the crank feels or sounds loose. Lift the chain from the chainrings. Tighten pedals into the crankarms to 350-380 lb•in (40. Rotate the crank so that one of the arms is parallel to the seat tube. Adjustment of pedal bearings requires special tools and training. take the bike to your dealer for service. These services should only be performed by your dealer. With the front wheel off the ground. The left pedal is left-hand threaded. Adjustment of bottom bracket bearings requires special tools and training. you may cause the bearings to come out of adjustment.Headset To check if the headset is loose or tight 1. Spin the cranks.9 N•m).  Chapter : Adjustment . Put one hand on the crank arm and one hand on the seat tube. or consult your dealer. 3. To change the crank length. do not ride the bicycle.2-42. If the headset bearings rock in the frame or do not turn smoothly. and attempt to move the crank arm laterally toward and away from the seat tube. If you fully loosen one side before loosening the other. crank arms Pedals crankset To check the bottom bracket bearing adjustment 1. the bearings need to be adjusted or re-greased by your dealer.

and use the shifter to carefully shift the chain onto the outside chainring. Shift the rear derailleur to the smallest rear cog. or frayed ends. If you suspect a problem with a cable. Also check the housing for loose wire strands. Follow the instructions for adjusting the lever position on pages 25-26. Slide the wheel to re-tension the chain. Some models have a chain tensioning device which helps position the wheel. bent ends. 3. Front derailleur To adjust the small chainring position 1. broken strands.2.44-60 lb•in (5. Loosen the front derailleur cable clamp bolt Figure . Hand-turn the cranks. and wear.Adjusting screws is free. turn the shift cable adjusting barrel to its most clockwise position. On the shifter or down tube. 2. cables Shifters 3. 5. and down-shift the left shift lever several times so that it is in the small-chainring position. follow the instructions to replace a cable (page 34). 3. Check the cables for kinks. and center the wheel in the frame. Turn the low gear adjusting screw (marked “L until the ”) inner chain guide of the derailleur is approximately 0. Chapter : Adjustment  .Cable B. 6. 5. C 2. Turn the high-gear adjusting screw (marked “H”) counterclockwise until it cannot interfere with the motion of the derailleur. Position the outer chain guide of the front derailleur approximately 0. andtighten the bolt: • Front derailleur cable clamp bolt. cuts.5 mm from the chain. the front derailleur will move toward the small chainring.5 mm from the chain. 4. The position of the shifters can be adjusted on the handlebar. rust. pull the cable taut. Complete the wheel installation.0-6. C.Front derail(Figure 21) leur until the cable A. do not ride the bicycle. Re-tighten the high gear adjusting screw until it meets resistance.Cable clamp bolt If you have turned the screw too far. or have your dealer service the bicycle. 4. Shift the chain onto the A B smallest front chainring and the largest rear cog. Insert the cable in the groove found next to the derailleur cable clamp bolt. Pull on the cable end.8 N•m). To adjust the big chainring position 1.

Turn the adjusting barrel on the rear derailleur all the way clockwise.8 N•m). 7.Barrel adjuster C. If they are not aligned. Loosen the B cable clamp bolt (Figure 22) until the C cable is free.Cable clamp bolt D. Shift the chain onto the smallest rear cog and the largest front A chainring. Go through the various gear combinations to ensure the chain smoothly lines up with all the chainrings. Go through the various gear combinations. 2. turn the high gear adjusting screw (usually marked “H”. D Figure . increasing cable tension to align the inner derailleur cage until it just touches the chain. 6. and the derailleur cage does not rub on any part of the crankset. 3. Insert the cable into the clamp bolt groove on the rear derailleur. Position the rear derailleur pulleys in line with the largest cog. While pulling on the cable. To adjust the middle gear position. 3. or the chain may wedge between the large cog and the spokes. Carefully shift the chain onto the smallest front chainring and the largest rear cog. and then one turn counter-clockwise. 2. or on the lever) counter-clockwise. Rotate the cable tension barreladjuster (on the downtube. To adjust the large cog position 1.) until this line is established. 4.  Chapter : Adjustment .Rear derailleur A.Cable 3.6. Make sure the chain does not fall off when you shift. pull the shift cable taut. 2. and the two derailleur pulleys are in line.0-6. 5. and tighten the cable clamp bolt to 44-60 lb•in (5. 4. with three chainrings 1. Shift the chain onto the largest front chainring and the smallest rear cog. no longer touching the chain. the chain. On the shifter or down tube. Turn the low gear adjusting screw on the rear derailleur (usually marked “L far enough ”) counter-clockwise that it will not restrict the movement of the derailleur. Do not over-shift the rear derailleur. Note: some front shifters have a ‘tab’ feature: slightly downshift the lever and the derailleur will move in slightly. turn the adjusting barrel all the way clockwise.Adjusting screws B. Turn the low gear adjusting screw clockwise until it meets resistance. Stand behind the bicycle to see that the smallest rear cog. upshift until the shifter is in the small cog position. Rear derailleur To adjust the small cog position 1.

Shift one click with the rear shifter. 3. bell crank A. If the red lines do not line up. Shift to 1st gear. If you have turned it too far. adjust the gear cable tension by rotating the C barrel adjuster until this Figure . 7.Bell crank window Chapter : Adjustment  . Align the derailleur hanger may be out of indicator on alignment. Make sure the chain does not fall off when you shift.5. turn the barrel-adjuster counterclockwise in small increments and check again for a smooth shift. take the bike to your the bell crank dealer for service. the derailleur will move toward the outside of the bicycle. B.Pulley achieved. then back to 4th. window with the line on the push rod Figure . turn the barrel adjuster clockwise until the derailleur pulleys align with 3 speed systems the second smallest cog.Pulley and cog joint bracket alignment is A. Nexus 4. 2.Cable clamp bolt 4.Cog joint bracket C. Rotate the shifter to the 4th gear position. Go through the gear combinaTo adjust the rear shifting tions to ensure the chain 1. 3. Rotate the smoothly lines up with all the shifter to rear cogs. • If instead. 2. and re-check the adjustment. Shift the chain onto the largest front chainring and the smallest rear cog. Align the indicator on the rear hub pulley (Figure 23) with the cog joint A B bracket.Three-speed (Figure 24). • If the chain makes excessive noise or does not shift. Go through the various gear combinations. the 2. Check if the chain moves smoothly to the next gear. or 8 speed systems To adjust the rear shifting 1. If the derailleur cannot be adjusted in this manner. the chain moves to the third smallest cog. To align the indexing system 1. the 2nd gear A position. 4.

0-7. Loosen the clamp bolt 2-3 turns.Cable D.Reach adjustment screw C. If the indicators do not line up. 3. 2. brake levers B C D Figure . To adjust the position of a lever 1.53-69 lb•in (6. The brake A system is difficult to adjust properly without the proper Figure 5. Tighten the clamp bolt: • Regular brake levers. • On mid-bar levers (Figure 27).20-30 lb•in (2.Lever clamp bolt It is strongly recommended that adjustment of a brake be done by your dealer.Barrel adjuster A Figure 7. Position the lever.Lever clamp bolt. then back to 2nd. 4. adjust the gear cable tension by rotating the barrel adjuster until this alignment is achieved.3 N•m). The brake system allows you to slow or stop your bike. and re-check the adjustment. Shift to 1st gear. bolt. Locate the lever clamp bolt (Figures 25-27).3-3. If you need more specific information regarding your brake system. road lever A. contact your A dealer.Lever clamp tools and training. 4.Mid-bar brake lever A.Lever clamp bolt 5 Chapter : Adjustment . mountain lever A.3. a function critical to your safety.8 N•m).Lever clamp bolt B.

turn the screw in (clockwise). Loosen and remove both lever clamp bolts. 2. 5. To change which lever controls the front brake (Hayes hydraulic type) Changing the levers with Shimano hydraulic brakes requires special tools and training so should only be done by your dealer. 3. re-adjust the brake pad clearance. and re-adjust as necessary. just remove the leaded end of the cable from the lever. the distance from the handlebar to the lever. Re-install the clamp bolts and tighten to 25-35 lb•in (2. near the lever pivot.8-4 N•m) To adjust the reach to the brake lever (cable type) With some brake levers. you can change the reach. Remove the levers and reposition according to your preference. disconnect the brake cable and completely remove it from the lever.• Hayes hydraulic levers. turn the screw out (counter-clockwise). Inspect the brakes as explained in Chapter 1. 1. To decrease the reach. • For a mountain bike. To increase the reach. Chapter : Adjustment  . To increase the reach. turn the screw in (clockwise). To change which lever controls the front brake (cable type) 1.25-35 lb•in (2.8-4 N•m). To decrease the reach. Install the cables into the opposite levers. For a road bike. Close the brakes. 2. turn the screw out (counter-clockwise). Locate the reach adjustment screw (Figure 26) and turn. 1. 4. Locate the reach adjustment screw between the lever and the handlebar. To adjust the reach to the brake lever (Hayes hydraulic type) 1. See the Brakes section for brake adjustment procedures. 3. Open the brake. 2. 2. If needed after adjusting the reach.

cantilever. 2.Pad fixing bolt D.Centering screw C. For most direct-pull (Figure 28).Centering screw E. Ensure the cable does not slip.9-9 N•m) 3.No contact C.Cantilever brake A. turn the barrel adjuster out (counterclockwise).3-12. To center a V-type.40-60 lb•in (4. If the brake pads cannot be adjusted properly. turn the barrel adjuster in (clockwise). and tighten the pad fixing bolts: • Road caliper. To align a hydraulic disc brake 1. If the brake has two centering screws. Turn in small increments and check for centering.Centering screw 7 Chapter : Adjustment . Loosen the brake mounting bolts. Loosen the brake pad fixing bolt.Once a month. After adjusting the brakes.Pad fixing bolt D. brakes A 2. and the pads do not contact the tire. B C D E Figure . 2. Rotate the centering screw. To adjust brake pad clearance to the rim 1.Linkwire B. If the grooves in the braking surface are less than 2 mm deep.70-80 lb•in (7. inspect brake pads for wear.56.Arm fixing bolt D. replace the pads. and gradually tighten the bolts to 100-110 lb•in (11. Apply the lever fully. or cantilever (Figure 30) systems the barrel adjuster is on the lever. To adjust the alignment of the brake pads on a rim brake 1. Turn the barrel adjuster.Cable clamp bolt B.4 N•m).8 N•m) • Direct-pull or cantilever. loosen the cable clamp bolt and re-attach the cable. Replace disc brake pads that are thinner than 1.Caliper brake A.Pad fixing bolt C. or 1 mm deep for direct-pull brakes. test them by applying force to the levers. To reduce the pad clearance. or road brake 1. Align the pads as shown on page 5. To increase the pad clearance. the pads close toward the rim at right angles.Direct pull brake A.0 mm. For most road caliper systems (Figure 29) the barrel adjuster is on the brake itself. adjust the overall spring tension while centering the brake.Arm fixing bolt A B D C Figure .Barrel adjuster B. 2.Brake relase lever A B C D Figure 0.

or similar thin object.7-7. 2. To remove disc brake pads 1. and re-set the right pad. If the pads cannot be adjusted properly in this manner. B C Figure . 2. release the linkwire. and the brake will open. To reduce the pad clearance. and gradually tighten the bolts to 100-110 lb•in (11. Chapter : Adjustment  . grasp the installation tang of the brake pad and pull out. squeeze the brake pads firmly against the rim. reverse the instructions. A 2. Release the lever and the brake will open. To close. follow the instructions To adjust left brake pad clearance to the disc. To open the brake for wheel removal • For most road calipers. there is a release button at the top of the lever.Disc brake A. With the other hand. Loosen the brake mounting bolts. 3. Tighten the cable clamp bolt to 50-70 lb•in (5. With one hand. Remove the wheel. pull the leaded end of the linkwire from the retaining fork on the brake arm. turn the barrel adjuster out (counterclockwise). and push the button until it is flush with the lever body. between the right brake pad and the disc.Fixed pad adjuster C. • For Campagnolo levers. Release the brake pads. simply turn the lever to the Down position. To increase the pad clearance. If the pads cannot be adjusted properly in this manner. After adjustment. With your fingers or thintipped pliers.Cable clamp bolt • To adjust left brake pad clearance to the disc 1. To close the brake. • To align the brake with the disc 1.9 N•m). Turn the cable barrel adjuster.3-12. reverse the instructions. Turn the fixed pad adjuster (Figure 31). To close. 2. Slightly depress the brake lever. loosen the cable clamp bolt and reattach the cable. • For cantilever brakes.4 N•m).Mounting bolts B.To align a cable-actuated disc brake There are several parts to this procedure: •To adjust right brake pad clearance to the disc 1. turn the barrel adjuster in (clockwise). turn the locking nut clockwise to help prevent rotation of the barrel adjuster. lift the brake release lever to the open UP position. 3. Slide a business card. Apply the lever fully.

2. OPEN CLOSED Wheels WARNING  Chapter : Adjustment . the rim may become weak and fail suddenly. To close the brake.Adjusting nut positions. Slide the brake cable stop forward to remove it from the brake arm. Make sure there are no loose. or broken spokes. Once disconnected. Inspect tires for wear and damage. -To disconnect the brake cable. With the other hand. and the cable clamp bolt rearward. first disconnect the shift and brake cables. to remove the rear wheel. causing a loss of control. disconnect the pipe from the link arm. and check for wear. If too much material is removed. squeeze the pads firmly against the rim. reverse the instructions. Make sure a rim strip is in place and all spoke holes are completely covered. put the shifter in 1st gear. Make sure rims are clean. Pull the cable clamp bolt outward to disengage it from the carrier. replace the rim. pull the pipe back from the link arm. To adjust and install a quick-release wheel 1. With one hand. brake pads remove material when the brake is applied.Tighten nut and CLOSE A. damaged. Check that hub bearings are properly adjusted. • For internal or drum brakes. Remove the cable. Regularly inspect your rims for wear and replace them when they are worn. press the cable carrier arm forward. Pull the cable housing out of the shift cable housing stop. Move the quick-release lever to the OPEN position (Figure 32) and set the Figure . Undo brake strap bolt. and lift the pipe. Rotate the shift cable fixing bolt until the washer flats align with the slit in the cog joint bracket.Lever positions wheel so it firmly touches A the inside of the fork ends.• For direct-pull type brakes. let go of the brake pads and the brake will open. With the lever about halfway between the OPEN Figure . so the bolt aligns with the larger diameter hole in the carrier. tighten the adjusting nut (Figure 33) until finger-tight. if the small indentations on the braking surface disappear. -To disconnect the shift cable.

be loose.Proper lever closed position of throw the lever. tighten the adjusting nut further. close the lever. If it requires less than  pounds (5. If the quick-release fails any test. including these tests. 5. or move from side to side.Test for rotated parallel looseness to the wheel (Figure 40). and so obstacles in the path of the bicycle cannot snag the levers. • Do not tighten the quickrelease wheel retention Figure 5. there should be some resistance. EN OP Chapter : Adjustment E OP N E OP N Figure 0. either repeat these adjustment procedures. At the halfFigure . or take your bicycle to your dealer for service.3. Figure 7. and sharply hit the top of the tire (Figure 39). Figure . open the lever and slightly tighten the quick-release adjusting nut.Test for rotation 0 . For further information on correct adjustment of the quick-release tension. N OPE If it requires more than 5 pounds (00 Newton) force to completely close the quick-release lever. 7. Newton) force to begin to open the lever from the fully closed position. open the lever and slightly loosen the quick-release adjusting nut. 8.Rear lever clamping position strength is insufficient. Place the lever in the palm of your hand and throw the lever as shown in Figure 34 to the CLOSE position (Figures 3637). Test for proper quick-release adjustment: • Pick up the bike.Actual measurements 6. and again test for resistance. • Make sure the quick-release lever cannot be Figure . Orient the quick-release levers so they do not interfere with any other bicycle part or accessory part (such as rack or fenders). it will not result in sufficient force to hold Figure . read Figure 38. The wheel must not come off. Repeat the adjustment if necessary. Return the lever to the OPEN position.Front lever the wheel in position place.Do not turn mechanism lever by turning the lever like a wing nut (Figure 35). If the lever is moved to the CLOSE position with little or no resistance. Test that you have properly adjusted and closed the quickrelease.

Experiment with the adjustment in small increments to find your preference. To install an axle-nut wheel Some wheels are attached by nuts threaded onto the axle. or consult your dealer. Some bicycles also have pegs. 4. slide the axle into the fork tips. the clamping force is adequate to cause metal-intometal engagement (embossing) of the dropout surfaces. The wheel must not come off. After making a change.2 N•m). Open the quick-release or loosen the clamp bolts on both fork ends.1-33. or move from side to side. and sharply hit the top of the tire (Figure 39).1 N•m). Once a month. or take the bicycle to your dealer for service. or tighten the clamp bolts to 45-55 lb•in (5. The wheel must not come off. 2.3-27. If the wheel attachment fails the test. The front wheel may require a toothed washer to be placed between the nut and fork tip. For an all-round ride. If the suspension is fully compressed. Tighten the axle nuts: • Tighten a regular front wheel to 180-240 lb•in (20. With the wheel in place. Suspension components Accessories  Chapter : Adjustment . Test to ensure that you have properly tightened the axlenuts. repeat these procedures. be loose. 1. If the wheel attachment fails the test. • Tighten a regular rear wheel to 240-300 lb•in (27. 3. be loose. and a rear shock at about 25% sag. If any part seems loose or misaligned.9 N•m).• When the quick-release is properly tightened and clamped by the lever in the closed position. including the tests. Changing your suspension settings affects handling and braking characteristics. carefully test the bike in a low traffic area until you are familiar with its performance. Sag is the compression of a shock that occurs when the rider sits on the bike in a normal position. repeat these procedures. tubular axle extension. 2. and sharply hit the top of the tire (Figure 39).1-6. or move from side to side. set the forks at about 15% sag. Test to ensure that you have properly attached the thru-axle. • See Figure 38. Close the quick-releases. including the tests. See the CD or web site for more specific adjustment and maintenance information. either tighten the part or take the bike to your dealer for service. To install a thru-axle wheel 1. its movement will stop abruptly and could cause you to lose control. or take your bicycle to your dealer for service. check any accessories to make sure they are properly attached. • Pick up the bike. • Pick up the bike.

3. Fold the pedal over. toward the crankset. 6. Push the end of the pedal directly inward. on the end of the frame latch until the latch opens. take the bike to your dealer for service. 7. Close the quick-release to hold the seatpost in position. Repeat for the other pedal. To fold the main frame 1. 3. Hold the handlebar with the cables out of the way to prevent pinching. 2. Some models of Trek bikes have a large hinge in the middle to fold the bike by following these steps: To lower the saddle 1. Install the lens set-screw. Rotate the lens 1/4 turn clockwise and lift the lens assembly off the bulb mount. rotate the lens 1/4 turn counter-clockwise. Stand the bike up very straight. 4. Fold the handlebar assembly to its down position. with the tires properly inflated. and verify that the new bulb is not damaged. 2. Locate the lens set-screw on the back of either the taillight or head light. Riding a folding bike with movement at the lower stem quickrelease or main frame hinge could cause you to lose control and fall. Follow the procedures in the Wheels section.To adjust training wheels 1. Remove the screw. Adjust the chain tension and re-tighten the axle nuts. fold the bike in half. and set a gap of about 1/4“ (6 mm) between the training wheels and the ground on both sides of the bike. Unscrew the bulb. 2. 2. 2. Place the lens on the bulb mount. Rotate the lever lock away from the lower quick-release. If it does not. While avoiding pinching yourself or cables. Check that the new bulb works. WARNING Chapter : Adjustment  . 2. check the wiring for correct placement. Pull outwards. To install a light bulb 1. and open the lower quick-release. If the folding frame moves at the stem or frame hinge. 3. Screw a new bulb in until finger tight. Place the bike on a flat. 3. To fold the pedals 1. Loosen the rear axle nuts. reverse the steps of the folding procedure. To unfold the frame. smooth surface. Make sure the gap is the same on both sides. Do not dislodge the wire in the base of the bulb mount. Be careful not to crush the glass of the bulb. See other sections of this manual as needed. To fold the handlebar stem 1. Open the latch lock. Folding bike 5. 4. Open the seatpost quickrelease and lower the saddle. away from the frame. 3.

Apply a thin layer of grease to the section of the quill that will be inserted into the frame. or open the quick-release. carbon fiber seatpost. If you need more detailed information. Insert the seatpost into the frame. have your dealer regrease the pedal bearings. including the stem wedge. Apply a thin layer of grease to the section of the seatpost that will be inside the frame. Stem Once a year lubricate the stem. Note: Lubricating a direct-connect stem requires adjustment of the headset bearings. Wipe the seatpost and inside the seat tube with a soft cloth and clean water. and brief instructions. 3.  Chapter : Lubrication . but turn the left clockwise. 5. have your dealer re-grease the bottom bracket bearings. turn the right pedal spindle counterclockwise. or carbon fiber frame 1. or on the wrench flats. Loosen the seatpost binder bolt. so this should only be done by your dealer. 2. Remove the stem from the frame. Once a year re-grease the pedal axles where they thread into the crank arms. Wipe any old grease off the seatpost. align it. Adjust the seat to the proper height. 4. 4. Let the seeatpost dry. and tighten the seatpost binder bolt. bottom bracket Once a year. see other sections of this manual as needed. Re-greasing bearings requires special tools and training. Once a year. and tighten the seatpost binder bolt. 2. Adjust the seat to the proper height. or consult your dealer. usually marked with a letter stamped on the end of the pedal axle. so should only be done by your dealer. 4. lubricate the seatpost. and remove the seatpost from the frame. and remove the seatpost from the frame. their frequency. Install the stem. and clean if necessary. See your dealer for recommended lubrications. 2. Some bearings are permanently sealed and do not require yearly re-greasing 3. Loosen the seatpost binder bolt. Seatpost Pedals 1. 3. Clean the stem and wipe any old grease. align it. Remove the pedals. Once a year. Choose the method for your frame and seatpost material: Aluminum seatpost in a metal frame 1. then insert it into the frame. Note: There are right and left pedals. 1. or open the quick-release.cHAPTER 4: LubRIcATIoN This section explains the parts that require lubrication.

re-adjust the brake. Apply a this layer of grease over all the threads. have your dealer regrease the wheel bearings. including through the cable anchor bolt. Every 3 months lubricate your brake lever pivots and brake arm fixing pivots with a light oil. loosen the cable anchor bolt. and remove the worn cable. Tighten the pedals. and the housing is properly seated in the lever. For a brake. Wheels Suspension forks 5. Derailleurs Headset brakes and brake levers 1. Cut the cable so that no more than 2” (51 mm) extends beyond the anchor bolt. Avoid all lubricants. Every year. Crimp a metal cap or place a bit of solder on the end of the cable to prevent fraying. with chain lube.2. Note the path of the old cable. (6-8 N•m). 2. lubricate wheel quick-releases. Once a year. 7. have your dealer regrease the headset bearings. put the right pedal on the right crank arm and the left pedal on the left crank arm. Once a month. Install the pedals on the proper side. so should only be done by your dealer. Make sure the leaded cable-end is seated properly in the lever. Once a year. Follow the instructions for adjustment. including the derailleur pulleys on the rear derailleur. No lubrication is required for the shock or the pivot of your full suspension bike. Rear suspension Chapter : Lubrication  . Grease the new cable and reinstall. Wipe clean. 3. control cables Every month. feeding it along the same path as the old cable. Lubricate cables whenever they are installed. 8. For a shift cable. If needed when installing a cable in a brake. put the shifter in the position with the least cable tension. lubricate all pivot points on both the front and rear derailleurs. Tighten the cable clamp bolt to52-69 lb•in. Apply several drops of synthetic lube or a similar light oil where the quickrelease lever rotates in the quickrelease body. hold the brake closed while you do the next step. 6. 4. 3. To install a cable Installing a cable in a cantilever brake requires special tools and training. apply a light oil to the upper fork leg where the lower leg slides on it. Turn the adjusting barrel clockwise so the threads on the adjusting barrel are not exposed. 4.

Most libraries have extensive offerings of books written by experts in the field about riding. Links to some of the companies that make the parts of your bike are also provided. there are many resources in your community. They have extensive experience with bicycles and riding in your community. and you will find much more information. bicycle maintenance. including extensive repair manuals. With this background. check your public library. Second. you can link direct from the CD to our company web site. First. With internet access. they can help you with your individual questions and help you find areas to enjoy your new bicycle. or bicycling in general. Place the CD in a computer. The best online resource for your bike can be found by viewing the CD that accompanies this manual. go on-line.FoR MoRE INFoRMATIoN If you would like additional information about your bicycle. Third. maintenance. most dealers stock a variety of book about cycling. bicycle safety. All of this information and help is just a click away. In addition. talk to your bicycle dealer. racing. 5 For more information . and more.

suspension forks. Claims under this warranty must be made through an authorized Trek dealer. misuse. For the lifetime of the original owner• The bicycle frame. excluding suspension forks. even if there are no indications of damage. excluding Shimano parts. This warranty is expressly limited to the repair or replacement of a defective item and is the sole remedy of the warranty. This warranty does not cover- Limited warranty  . substantially reducing any replacement cost. Trek Bicycle Corporation is not responsible for incidental or consequential damages. This warranty extends from the date of purchase. applies only to the original owner. before a warranty claim may be processed. This warranty does not affect the statutory rights of the consumer. or compatible with.LIMITED WARRANTY All Trek bikes are sold exclusively through our network of Authorized Dealers who we entrust with professional assembly and service of your bicycle. abuse. so the above exclusion may not apply to you. Some states do not allow the exclusion of incidental or consequential damages. suspension forks. rigid fork. we strongly encourage you to replace the part. Warranty duration and detail may differ by frame type and/or by country. or neglect • Labor charges for part replacement or changeover For three yearsFor one year- carbon crash replacement policy Assessing any damage done to a carbon fiber part requires more experience than is needed to inspect metal parts. and is not transferable. If such a crash or impact occurs. The subject item must be registered with Trek Bicycle Corporation. either through on-line registration or by the receipt of a warranty registration card by Trek Bicycle Corporation. the bicycle as sold • Damage or failure due to accident. Trek offers a crash replacement program for carbon parts. • The Session model frame • Paint and decals • All original parts. If you crash or impact your bike and the force of the impact is absorbed by a carbon part. and rear shock absorbers shall be covered by the stated warranty of the original manufacturer. Trek Bicycle Corporation warrants each new Trek frame. and rear shock absorbers • All Shimano parts. or original component part of the bicycle against defects in workmanship and materials: This warranty is void in its entirety by any modification of the frame. except consumables such as tires and inner tubes. or components. To take advantage of this program. and rear shock absorbers • All original parts. • • • • Normal wear and tear Improper assembly Improper follow-up maintenance Installation of parts or accessories not originally intended for. Proof of purchase is required. and those rights may vary from place to place. except the fork and the Session model For five years- • Rigid forks • All Bontrager components and accessories. contact us using the information listed above and ask for the Warranty department. This warranty gives the consumer specific legal rights. fork.

Si no tiene acceso a un ordenador y desea obtener una versión impresa.com 801 West Madison Street Waterloo. póngase en contacto con nosotros mediante la dirección indicada en esta página. The Trek Logo is a registered trademark of Trek Bicycle Corporation.Customer Service 920-478-4678 www. kun je schrijven naar het adres op deze pagina. contactez-nous à l’adresse qui figure sur la page. If you do not have access to a computer and would like a printed version. contacte-nos na morada nesta página. En version af denne manual findes på cd’en. Si vous n’avez pas accès à un ordinateur et si vous souhaitez obtenir une version papier. Uma versão deste manual encontra-se no CD. Part # 278709 . Eine deutsche Version dieses Handbuchs finden Sie auf der CD. Een Nederlandstalige versie van deze handleiding vind je op de cd. Wenn Sie keinen Computer zur Verfügung haben und eine Druckversion des Handbuchs wünschen. Una versione italiana del presente manuale è riportata sul CD.trekbikes. Wisconsin 53594 USA EN FR An english version of this manual is on the CD. wenden Sie sich an uns unter der hier angegebenen Adresse. Una versión español de este manual se encuentra en el CD. Se non è possibile accedere a un computer ed è pertanto necessaria una copia cartacea. Als je geen toegang hebt tot een computer en een gedrukte handleiding wilt ontvangen. Hvis du ikke har adgang til en computer og gerne vil have en trykt version. Une version française de ce manuel se trouve sur le CD. Se não tem acesso a um computador e gostava de ter uma versão impressa. 本マニュアルのバージョンはCDに収録されています。コンピュータへアクセ スできず、印刷物をご希望の場合は、このページにある住所までご連絡くださ い。 本手册的第 版位于 CD。如果您无法访问计算机,并想要打印版本,请通过本 页上的地 DE ES IT NL DA PT JA ZL © 2006 Trek Bicycle Corporation All rights reserved. contact us at the address on this page. kan du kontakte os på adressen på denne side. siete pregati di contattarci ai recapiti sopraelencati.

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