Warning about Mechanical work

Read this information carefully before doing any work on your bicycle.

performing mechanical work on bicycles

Many people think of bicycles as simple machines, almost toys. However, modern bicycles use high-tech materials and designs that rely on correct maintenance and precision workmanship. This manual shows you how to do basic maintenance. Some tasks should only be done by your dealer, and this manual identifies them. If you do not have the correct tools or experience, do not perform the tasks in this manual; take your bicycle to your dealer for service.

In some cases we provide several methods of checking torque. The preferable method is always the one with the most precision.

Warning—Incorrect mechanical work on your bicycle could lead to damage or premature breakage of a part, which could cause you to fall.

Assembling your bicycle

Trek sells complete bicycles and framesets. A complete bicycle is equipped with all the parts, as shown in the catalog. A frameset is a collection of most or all of these parts: frame, fork, and headset.

If you purchased a complete bicycle, each and every part of your new bicycle has been carefully chosen and approved by our engineering department. Special tools and skills are necessary for the assembly and the first adjustment of your bicycle. Only your dealer should do this.

If you purchased a frameset, you take on the responsibility of choosing parts that are safe and compatible. The safety of the parts, and especially how those parts attach and interface with other parts of the bicycle, is not something that is always apparent. Unsafe parts can cause damage leading to loss of control and injury. Consult your dealer before assembling the frameset into a bicycle. Make sure all the parts you have chosen are compatible and that you have the correct tools and skills to complete the assembly in a safe manner.

Making Changes

Modifying the parts of your bicycle in any way can make your bicycle unsafe. Modifying means altering existing parts, adding parts or accessories, or exchanging for non-original parts. Some modifications are acceptable, and those are mentioned in this manual. In addition, your Trek dealer may be aware of other acceptable modifications. Any other modification of your frame, fork, or components means that your bicycle no longer meets our specifications and will therefore void the bicycle’s warranty. There are too many modifications to list them all, but here are a few examples:

· Removing paint with poor stripping techniques can weaken the frame because some bicycle frames have special surface treatments which add strength.

· Removing the redundant wheel retention tabs on fork tips could make your bicycle less functional.

· Removing all the spacers from under a direct-connect stem (or from above the stem with a carbon fiber steerer) puts unusual forces on the fork.

· Installing a part with an incorrect design, such an incorrect steerer clamp of a stem, can create a 'point load' that crushes the part to which it clamps.

· Incorrectly attaching or clamping anything to a bicycle or part, such as clamping aerobars onto a handlebar or attaching a trainer or exercise stand to a bicycle. Incorrect attachment can weaken the structure, especially with a part made of carbon fiber.

· Installing a motor or other drive system.

· Changing the forks on your bicycle could alter the steering of the bicycle.

Warning—An improperly assembled or modified bicycle—including the frame, fork, or any component—can break or cause another part to break, and so cause you to lose control and fall. Never modify your frameset or parts in any way, including these methods:
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Sanding
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Drilling
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Filing
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Removing redundant retention devices
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Installing non-approved parts or accessories
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Installing incompatible forks
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Any other method

Making changes to the frame or fork

Modifying the frame in any way will void the warranty and may be unsafe. The aluminum or carbon fiber composite parts of  the frame tubes and frame parts are not as ductile as steel. Attempting to make adjustments to an aluminum or carbon fiber part by bending or twisting can break the part. Removing paint from any frameset requires special techniques and great care. Harsh abrasives can remove frame material, possibly weakening the bicycle.

Adding accessories

To make your bicycle more personally useful, you may choose to add accessories such as fenders, a rack, etc. Not all accessories are compatible or safe, and the list is too long for this manual. If you are unsure if an accessory is appropriate, compatible, or safe, consult your Trek dealer. Read any instructions that are supplied with those accessories before installing them or having them installed, and read them again before riding your bicycle.

This is not a complete repair manual

This owner's manual is not intended to function as a complete bicycle repair manual. For suggestions on how to find more detailed repair information, see Books, schools, and links.