Bontrager Aerobar Race Lite User manual

Part Number 284206

Race X Lite
Aerobar Owner's Manual
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

Please read this instruction manual thoroughly before using
your new aerobar; it contains important safety and maintenance
information. Also check our web site for further information or
updates. If you do not understand the information, or you have
a question about your aerobar that this manual does not cover,
consult your Bontrager dealer. If you have a question or problem
that your Bontrager dealer can’t handle, contact us at:
Bontrager Components 920.478.4678
Attn: Customer Service http://www.bontrager.com
801 W. Madison Street
Waterloo, Wisconsin 53594

Conditions for use.................................................................. 1
Safe use .................................................................................. 2
Inspect the aerobar before every ride................................. 2
Test ride the aerobar before your rst ride......................... 5
Only install and use approved accessories......................... 5
Maintenance........................................................................... 6
Adjust the position ............................................................. 6
Keep all fasteners tight....................................................... 6
Remove the arm pads before transporting on a car ........... 7
Installation.............................................................................. 8
Bontrager limited warranty.................................................. 14
Carbon crash replacement policy..................................... 15



Many bicycle parts are intended to be used in a specic type or
condition of riding. It is unsafe to use a bicycle or part in a condition
higher than the condition for which it is intended, as listed below:




For riding on pavement only
Riding on a paved
surface where the
tires do not lose
ground contact
All Bontrager
aerobars
For more information about Use Conditions, visit our web site at
http://www.bontrager.com.









The following information is very important for your safety.
WARNING! Failure to follow the safety
information in this manual may
result in failure of the aerobar
resulting in serious personal
injury or death.

Before every ride, complete the following check list to inspect
the aerobar and its connected parts: the handlebar, stem, and fork.
If any part of the bicycle fails the inspection, repair the bicycle by
following the information provided in this manual or take the bicycle
to your dealer for service. Never
ride a bicycle with a damaged part;
replace the part.


Make sure the stem is aligned with
the front wheel. Test the stem con-
nection to the fork by attempting to
turn the handlebar from side to side
with the front wheel locked between
your knees (Figure 1). Test the secu-
rity of the handlebar by attempting
to rotate it in the stem. It should not
move or be loose. Make sure that no Figure - Function testing
the handlebar and stem


cables are stretched or pinched by rotating the handlebar.
Check that the aerobar cannot rotate around the handlebar. Check
that the handlebar plugs are properly inserted into both ends of the
aerobar. If your bicycle fails a test, see the Maintenance section or
take the bicycle to your dealer for service.

Before and after each ride, carefully inspect your aerobar for
signs of impact or fatigue stress:
• Dents • Cracks
• Scratches • Deformation
• Discoloration • Noise
Even if you perform regular inspections, if you exceed the limit
of strength of a given part, it may fail if overloaded. After any high
force load, thoroughly inspect all the parts of your bicycle. High












force loads include crashes, but you don't have to crash to put a high
force load on your bicycle. For example, hitting a large hole in the
road or a sharp bump such as a railroad track can put large forces on
your bicycle.
The manner in which you ride will determine whether your bicycle
and its parts will last. If you ride hard or aggressively, you should
replace the bicycle and/or its parts more often than riders who ride
smoothly or cautiously. When evaluating your use of the bike or
part, 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. But as a rule, it is better to err on the safe
side and replace the bicycle or parts more frequently. If you aren't
sure, ask your dealer.

Carbon ber is among the strongest materials used in bicycle
manufacture. However, carbon ber has unique qualities, different
from metal parts, and must be inspected carefully for damage.

Unlike metal parts, carbon ber parts that have been damaged may
not bend, bulge, or deform; a damaged part may appear to be normal
to a cursory glance. Use the following procedures to inspect carbon
ber parts (These tests may not be conclusive):
• Check for scratches, gouges, or other surface problems.
• Check the part for loss of rigidity.
• Check the part for delamination.
• Listen for unusual creaking or clicking noises.
The tests are difcult to describe, so we provide a movie of


inspecting a carbon ber part in the owner's manual section of the
Bontrager web site as an aid to describing the tests. If you have any
doubts about the integrity of a part, do not ride the bicycle.

Be extra careful when using aerobars for the rst time. Riding with
aerobars requires a position that may be new or different, and the
bicycle may steer or handle differently. Practice using these aerobars
in a low trafc area to become accustomed to any changes in the
steering or handling characteristics.
Also, look forward when riding. Do not look down at the ground.

Not all accessories are compatible or safe, so only add accessories
that are approved by the manufacturer. As an example, the clamp
design on some parts applies a powerful but uneven force, which











can crush or damage the part to which it clamps. If you are unsure
whether a part is approved, consult your dealer.



This section explains the possible adjustments to the position of
your aerobar and the maintenance that you should regularly perform.

The Race X Lite aerobar offers several adjustments to provide
an increase in comfort or aerodynamics. For instructions on how to
perform these adjustments, read the Installation section.
Extension tube length- the distance from the handlebar to the
ends of the extension tubes. Slide the extension tubes forward or
backward in the extension tube clamps. Leave at least 15 mm of
extension tube exposed behind the clamp.
Extension tube angle- the angle of the aerobar. Rotate the handle-
bar clamp on the handlebar.
Arm width- the width of the arm rests. Move the arm rests on the
arm rest adjusters, or move the handlebar clamps on the handlebar.
Arm pad position- the position of the arm rests relative to the
front of the bike. Move the am rests forward or backwards on the
width adjusters. Choose from one of four possible positions.
Arm pad angle- the angle of the arm rests. Rotate the brackets on
the extension tubes.

Follow these maintenance suggestions to keep your aerobar
in correct condition.



Check that all the fasteners (screws or bolts) on your aerobar
are tightened correctly:
• Handlebar clamp bolts: 100 lb•in (11.3 N•m)
• Extension tube pinch bolts: 60 lb•in (6.7 N•m)
• Width adjusters attachment bolts: 60 lb•in (6.7 N•m)
• Arm pad holder screws: 30 lb•in (3.4 N•m)

All fasteners must be tightened to Bontrager (or the bicycle
manufacturer's) specications. A threaded fastener that is too loose
can result in a part coming loose. The torque specications should be
used to make sure you do not over-tighten a fastener. 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.
If a part that is tightened to the correct torque is still loose, take the
bicycle to your dealer for service.
During production, threaded areas of all fasteners have been pre-
treated with a special blue thread-locking compound. This special
compound is easy to detect. If you cannot detect this thread locking
compound or if you have cleaned it off through normal maintenance,
re-apply a suitable blue thread-locking compound such as Loctite®
242 before assembly.
Do not grease the handlebar clamping area. This may cause the
aerobar to slip while riding.


When carrying your bicycle on a roof rack, remove the arm pads.


Figure  Race X Lite aerobar parts
A
G
D
H
B
G
K
J
M
L
E
F
I
N
C

0

 
A Extension tube 
B Bolt, extension tube pinch 
C Nut, handlebar clamp 
D Bracket, upper handlebar clamp 
E Shim, upper 
F Shim, lower 
G Bracket, lower handlebar clamp 
H Bolt, handlebar clamp, M x  
I Arm pad, right 
Arm pad, left (not shown) 
J Screw, arm pad holder 
K Arm pad holder, right 
Arm pad holder, left (not shown) 
L Pad width adjuster 
M Bolt, width adjuster pinch 
N Cable guide plug 



Incorrect installation of the aerobar could cause you to lose control
and fall from your bicycle. If you are not familiar with the installa-
tion of aerobars, have your dealer install them.
Before installing your aerobar, read the Safety information.
Note to Dealers: If you install this product
for the consumer, please provide him or her
with this owner’s manual after installation
of the aerobar.

Some lightweight aluminum or carbon ber handlebars are
not compatible with aerobar assemblies; refer to the handlebar
manufacturer's installation instructions.
This aerobar is designed to t handlebars with either a 26.0 mm or
31.8 mm stem clamp diameter using the following parts:
• For a 26.0 mm handlebar, use the four shims (two each, E
and F, Figure 2) included with this aerobar assembly.
• For a 31.8 mm handlebar, no shims are required.

• 3, 4, and 5 mm allen wrenches
• Torque wrench

The following letter references (A, B, C, etc.) are for Figure 2.
1. Determine the desired aerobar width.
If needed, unwrap the top section of
handlebar tape to attain the desired width.


2. Attach the upper brackets (D) and lower brackets (G) to the
handlebar. Insert two handlebar clamp bolts (H) through
each upper bracket and lower bracket, and into the nuts
(C), which t into the upper bracket.
For a 26.0 mm handlebar, use the shims (E
and F) listed above. Locate and place the
dimple on the shim into the recess of the
bracket. If the dimple is in the recess, it will
prevent each shim from rotating.
3. Tighten the handlebar clamp bolts (H) to 100 lb•in (11.3
N•m).
4. Slide the left and right extension tubes (A) through the
upper brackets (D) and adjust the position of the exten-
sion tubes to the desired length and rotational angle.
Leave a minimum of 15 mm of extension
tube exposed behind the clamp of the upper
bracket.
5. Insert the extension tube pinch bolts (B) and tighten to 60
lb•in (6.7 N•m).
Do not overtighten bolts, as this may
damage the carbon tube.
6. Slide the left pad width adjuster (L) and right pad width
adjuster (L) onto the extension tubes.
7. Insert the width adjuster pinch bolts (M).
8. Adjust the angle of the width adjusters. Rotate the bracket
to the desired angle, and tighten the pinch bolts to 60
lb•in (6.7 N•m)
Note that extreme angle adjustment might
limit the ability of the arm pad holders to
align correctly.



The width of the arm pad holders can be customized to suit your
body type and riding style.
1. Insert two arm pad holder screws (J) through the desired
holes of the left and right arm pad holders (K) and into
the pad width adjusters (L).
2. Tighten each arm pad holder screw to 30 lb•in (3.4 N•m).
Two screws are required per side to prevent
the arm pad holders from spinning on the
arm width adjusters.
3. Repeat on the second arm pad holder.
4. Place the arm pads on the hook-and-loop fasteners of the
arm pad holders.

If you wish to install bar end shift levers into the tip of the Race
X Lite® extension tubes (A), slide the control cables and housing
through the cable guide plug (N). Do not drill or cut the extension
tubes. Tighten the shift lever mounting bolt until the shift lever is
rmly in place.
Do not over tighten the shift lever mounting
bolt as this may damage the carbon
extension tube. Do not exceed 45 lb•in (5
N•m).

Re-check all fasteners for tightness after the rst use of the aerobar
and periodically thereafter to insure secure attachment of the aerobar.




Bontrager warrants each new Bontrager component or wheelset
against defects in workmanship and materials:

• All Bontrager components and accessories, except consum-
ables such as tires and inner tubes.

• Bontrager consumables such as tires and inner tubes.

• Normal wear and tear
• Improper assembly
• Improper follow-up maintenance
• Installation of parts or accessories not originally intended
for or compatible with the Bontrager components or
wheelsets 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 modication of the
wheelset 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. Bontrager 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
Bontrager dealer. Proof of purchase is required.
This warranty gives the consumer specic legal rights, and those
rights may vary from place to place. This warranty does not affect the
statutory rights of the consumer.

Assessing any damage done to a carbon ber part requires more
experience than is needed to inspect metal parts. If you crash or
impact your bicycle 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, Bontrager 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 in the front of this manual and ask for the
Warranty department.

Español i



Lea detenidamente este manual de instrucciones antes de empezar
a utilizar el manillar aerodinámico; contiene información importante
de mantenimiento y seguridad. Consulte también nuestra página web
para obtener más información o actualizaciones. Si tiene dudas o pre-
guntas sobre el manillar aerodinámico que no pueda resolver con esta
documentación, consulte con su distribuidor de Bontrager. Si tiene
alguna duda o algún problema que su distribuidor de Bontrager no
pueda solucionar, póngase en contacto con nosotros en la dirección:
Bontrager Components 920.478.4678
Attn: Customer Service http://www.bontrager.com
801 W. Madison Street
Waterloo, Wisconsin 53594

Condiciones de uso ................................................................ 1
Uso seguro ............................................................................. 2
Inspección del manillar aerodinámico antes de cada uso... 2
Conducción de prueba con el manillar aerodinámico antes del
primer uso............................................................................... 5
Uso e instalación exclusiva de accesorios aprobados ........ 5
Mantenimiento ....................................................................... 6
Sujeción de los elementos de jación ................................ 6
Instalación.............................................................................. 8
Garantía limitada de Bontrager............................................ 14
Política de sustitución de piezas de carbono por accidente15

 Español

Muchas piezas de bicicleta están diseñadas para su uso en
condiciones o tipos de ciclismo especícos. Es peligroso utilizar una
bicicleta o una pieza en condiciones más extremas a las indicadas en
la lista siguiente:
 

For riding on pavement only
Conducción en una
supercie pavi-
mentada donde las
cubiertas no pierden
el contacto con el
terreno
Todos los
manillares
aerodinámicos
Bontrager
Para obtener más información sobre las condiciones de uso, visite
nuestra página web en la dirección
http://www.bontrager.com.






