June 28, 2010

Modern bicycles use high-tech materials and designs that rely on correct maintenance, precision workmanship, and compatibility of the parts. Mechanics must continue to learn the new procedures and requirements of these new bicycles. Incorrect mechanical work on a bicycle could lead to damage or breakage of a part, which could lead to a crash.

This bulletin includes information from an August 2009 Bontrager service bulletin, the Trek and Fisher bicycle owner’s manuals, 2010 Madone and Cronus assembly manuals, and new information.  Also attached below is the Trek CarbonCare Consumer Letter.  Dealers may want to share this information with customers to educate them on providing proper care for their carbon 2010 6 series bikes.

Caring for the Carbon Steer Tube on Your Fork

The steer tube is a tube that extends from the fork crown and is hidden as it passes through the headtube, headset, spacers, and stem. It effectively connects the fork legs with the stem and handlebars used to steer your bike.

A bike’s fork is loaded heavily when ridden. The front wheel pushes up on the fork legs as it passes over bumps in the road, and a rider’s weight on the handlebar is magnifi ed by the leverage that results from the distance separating a rider’s hands and the steer tube. To allow the fork to absorb these forces, the correct headset spacer and stem confi guration is critical.

Moving spacers or changing stems requires that the headset bearing preload be re-adjusted. Because correct headset adjustment is critical to your safety and the longevity of the frame and bearings, we recommend that only an Authorized Trek Retailer alter the headset spacer and stem assembly. Trek is providing the following information so that you can understand the work your local Trek Retailer may be performing.

Below the stem on all steerers
Always place at least one 5mm spacer below the stem. This spacer rests on top of the bearing cover, which also must be at least 5mm in height. Alternately, do not place a spacer group that exceeds 40mm in height collectively underneath the stem. With a carbon steer tube, always place at least one 5mm spacer above the stem and below the top cap.

Above the stem on carbon fiber steerers
With a carbon steerer, always place at least one 5mm spacer above the stem. A stem placed right at the top of the steerer can put too much force on the unsupported cut edge of the steerer, possibly crushing the steerer.

Do Not Over-Tighten The Stem Bolts

The steer tube clamp bolts of a stem are designed to keep the stem securely affixed to the steer tube through any riding condition. Consequently, they are very powerful. Although tightening them more may seem like a good precaution, over-tightening a stem’s steer-clamp bolts can crush the steer tube. Crushing the steer tube can damage the headset, the frame, and can cause the steer tube to break. Always use a torque wrench when tightening clamp bolts securing a carbon fiber part, and follow the manufacturer’s recommendations. With a Bontrager carbon steer tube, never tighten the stem’s clamp bolts to more than 55 lb•in (6 Nm).

When properly torquing a stem onto a steer tube, gradually tighten each steer tube clamp bolt, alternating back and forth in small increments, until both bolts are at the correct torque. Do not tighten one bolt all the way before tightening the other, and do not leave the bolts at unequal torque values.

Use Only An Approved Bontrager Stem
Some stems utilize designs that are not compatible with carbon steer tubes. Installing an incompatible stem can create a load point that can damage a steer tube, which may lead to a steer tube failure. Trek strongly recommends using a Bontrager stem with your fork. Bontrager stems have been designed and tested to be compatible with both aluminum and carbon steer tubes found on Bontrager forks. Installing another brand of stem could cause damage to the steer tube and will void the warranty of the fork.

Do Not Use A Star-Fangled Nut
Threadless headset systems use two different methods to adjust bearing preload; compression nut assemblies and star-fangled nuts. With a carbon steer tube, do not use a star-fangled nut; use only the compression nut assembly supplied with the fork. A star-fangled nut can score or cut carbon fi bers, which can weaken and damage the steer tube.

Check Your Fork Before Every Ride
As explained in your owner’s manual, you should check the fork’s safety before every ride. Look for signs of fatigue and stress and feel for play. A hard impact or crash can cause stress or damage to the fork. Do not ride a fork that you suspect has been damaged; take the bike to your dealer for a thorough inspection.

June 15, 2010

DEALER SAFETY RECALL NOTICE
Recall of Thule Domestique Bicycle Carrier, Model 513

Dear Thule Dealer,

Thule, Inc. has decided that a defect which relates to motor vehicle safety exists in certain Domestique Bicycle Carriers, Model 513, sold between April and May 2010. Thule requests that you stop using this rack immediately.

During installation or use of the Domestique Bicycle Carrier, the rear fork head boss (area inside hole where bolt is placed - see diagram) may fail. If the rear fork head boss fails, the fork head may become loose resulting in the instability of the front end of the Domestique bicycle carrier and any attached bicycle. This instability may cause
both the Domestique Bicycle Carrier and attached bicycle to break free and/or separate from the vehicle, which could cause a vehicle crash or injure nearby pedestrians.

In order to remedy this situation, please call your Thule Dealer Services Representative at (800) 848-5322 to receive an RA # and Thule will issue you an exchange, refund or credit - whichever you prefer. Replacement Domestique bicycle carriers will be available in the coming weeks and will be distinguished from the current defect Domestique by a visibly marked with an “OK” neon green label on the product label on the outside of the carton (see photo below) and May 18, 2010 or later “production date code” embossed on the inside of the fork head.

To aid us in reaching as many consumers as possible, Thule requests that you provide us with contact information (name and address) of any customers to whom you have sold the product(s) covered by this recall. Should a consumer come in with a complaint about this product, please direct them to our consumer service toll-free line at 1- 800-238-2388 and advise them to stop using the product immediately. Once we make contact with the consumers we will provide them with a Domestique Recall Kit, #7521157001, which includes a replacement fork head, tool and replacement instructions or a replacement Domestique bicycle carrier.

Finally, in order to keep you fully informed as to how we are proceeding with this voluntary recall, we have also included a copy of the retail Point of Sale poster concerning the recall that we request that you display in your stores. We request that you make as many copies of the Point of Sale poster as may be needed, and that you arrange immediately for display of these posters at all of your retail locations. Copies of our press release, instruction sheet from the Recall Kit and consumer notification letter can be found at www.thule.com.

Please note that Thule, Inc. is required to advise you that it is a violation of federal law for you to sell or lease any item covered by this notification until the defect identified herein has been remedied.

We thank you for your cooperation and understanding. We highly value you as a trusted partner and want to maintain the confidence you and your customers have shown in our entire line of car rack systems.

Sincerely,

Noel Roberts
Director of Quality
Thule, Inc.