Bontrager RACE X LITE BAR-ENDS User manual

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Race X Lite ™ Bar Ends • Part Number 263759

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Race X Lite ™ Bar Ends • Part Number 263759

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© Copyright Trek Bicycle Corporation 2005
All rights reserved

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BONTRAGER RACE X LITE BAR-ENDS
Owner’s Manual
Table of contents
Introduction ....................................................1-2
Bontrager Race X Lite bar-ends ..........................3-7
Inspecting bar-ends ......................................... 5
Adjusting bar-ends .........................................6-7
Lubricating bar-ends ........................................ 7
Installation instructions .....................................8-9
Carbon compatibility .....................................10-11
Carbon fiber composite inspection procedures ...12-16
Limited Warranty .........................................18-19

1
Introduction
Bontrager wheelsets and components are built to exceed
the demands of professionals. Pooling vast resources,
Bontrager is able to deliver cutting-edge performance
without sacrificing strength or durability.
Top level riders, including World Champions, compete on
the same product that you can purchase. Whether lead-
ing the pack into Paris or double-jumping in Vancouver,
Bontrager has you covered.
Thanks for buying Bontrager.
Please read all of the supplied instructions thoroughly
before using your Bontrager gear; the manual contains
important safety and maintenance information. Also visit
the website for important updates.

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If you do not understand the information in this manual,
or you have a question about your components or
wheelset that this manual does not cover, consult your
Bontrager dealer, or contact us.
Mailing address:
Bontrager Components & Wheelsets
Attn: Customer Service
801 W. Madison St.
Waterloo, Wisconsin 53594
Telephone:
In the United States, call 920.478.4678
Web or e-mail:
http://www.bontrager.com

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Bontrager Race X Lite bar-ends
These bar-ends (Figure 1) have ergonomic HCM carbon
extensions which increase comfort and control.
These high-performance bar-ends offer these features:
• High-compression molded carbon construction:
an incredibly strong structure also allowing for a
comfortable, ergonomic shape
• Forged 6061 alloy clamp: strong, light, and safe
for use on carbon handlebars
• Low weight: just 110 grams per pair
Figure 1: Bar-ends

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Bar-ends provide a secondary hand position on a
mountain-style handlebar. Bar-ends are designed for
climbing only. Be careful when riding with bar-ends in
brushy areas, or narrow trails. Never allow your bar-ends
to come in contact with objects which may cause you to
lose control of your bicycle.
If you crash your bike, remove the bar-ends and inspect
the bar-ends and the ends of the handlebar. Replace the
handlebar or bar-ends if there is any sign of damage.
Figure 2: Bar-end clamp bolt

5
Inspecting bar-ends
If you are unsure of the safety of your handlebar system,
do not ride the bicycle; take the bicycle to your dealer
for adjustments.
Once a month check your bar-ends. Push down on them
to make sure they cannot rotate on the handlebars.
If the bar-ends slip, follow the procedures in Adjusting
bar-ends.
Ensure the bar-ends face forward and away from you, at
an angle not less than 15° from parallel to the ground.
Check that all bolts are tight according to the torque
specifications:
• Bar-end clamp bolts (Figure 2): 40-60 lb•in
(4.5-6.8 Nm).
If your bicycle has any carbon fiber parts, also follow
the carbon fiber composite inspection procedures on
page 13.

6
WARNING
Improperly adjusted or tightened
bar-ends can cause you to lose control
and fall. Make sure the bar-ends are
positioned and tightened properly before
riding the bike.
Adjusting bar-ends
Bar-end position, the angle of the bar-ends to the
ground, is largely a matter of personal preference blend-
ing comfort, efficiency, and balance. Your hands should
be comfortable, and able to easily grasp the bar-ends
when either seated, or standing on the pedals.

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To adjust the angle of the bar-ends
1. Loosen the handlebar clamp bolt(s) just enough that
the bar-ends can be rotated on the handlebar.
2. Position the bar-ends to the desired angle.
3. Tighten as shown in Inspecting bar-ends.
If the bar-ends slip on the bar, remove the bar-ends,
clean the handlebar and bar-ends with rubbing alcohol,
and follow the inspection and adjustment procedures to
re-position the bar-ends.
Lubricating bar-ends
Once a year, lubricate the bar-end clamp bolts.

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Installation instructions
These instructions explain the steps to install new
Bontrager bar-ends. The correct installation of bar-ends
is critical to the rider’s safety, so this work should be
performed only by an experienced mechanic. If you are
not sure of your ability to correctly install these bar-ends,
have them installed by your Bontrager dealer.
Check all parts for compatibility and condition before
installing
The bar-ends interface the handlebar and grips. These
parts must be compatible and the correct diameters for
the bar-ends to function correctly. If you are not sure if
these bar-ends are compatible with your bicycle, consult
your dealer.
Make sure the handlebar is in good condition before
installing bar-ends. Look for any dents, bending, or other
deformation. Bar-ends can increase the force placed on a
handlebar, and could cause it to fail.

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If any component is made of carbon fiber composite,
make sure the connecting parts are carbon-compatible
(see page 11).
To install bar-ends
1. Make room on the handlebar for the bar-ends.
Remove the grips, slide the controls, and reinstall the
grips. If necessary, install new grips with open ends.
2. Remove any oil, grease, or dirt from the handlebar.
For carbon bars, clean with rubbing alcohol and a shop
rag; clean until the rag shows no discoloration.
3. Slide the bar-ends onto the handlebar and set the
angle position.
4. Install handlebar plugs.
5. Follow the inspection procedures and tighten the
handlebar clamp bolts.

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Carbon compatibility
Carbon fiber composite can be damaged by sharp edges
or clamping mechanisms which cause a point load, or
a high pressure area. Before installing any carbon fiber
part, or attaching any component to an existing carbon
fiber part, follow these procedures to make sure the
parts or components are carbon-compatible.
If the part is used, also make sure the part is in good
condition by following the carbon fiber composite
inspection procedures.
These procedures apply to any part interfacing a carbon
part. As an example, a carbon handlebar interfaces the
stem, brake levers, shift levers, and possibly bar-ends.
All of the clamps of these parts should be inspected for
carbon compatibility. If any part fails the inspection,
either fix the problem or replace the part.
Clamp style inspection
Make sure the clamp is carbon-friendly. The clamp must

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draw together smoothly, and not pinch. The clamp bolt
must be perpendicular to the radius of the clamped item,
and should be as close to the surface of the clamped
item as possible (Figure 3).
Surface inspection of clamping parts
Visually inspect the edges and surfaces of the interfacing
parts for burrs or deformation that might mar the
carbon part.
With your finger, again check the part. Any roughness
or sharp edges could
mar the carbon part.
Figure 3: Clamp bolt perpendicular
to radius

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WARNING
A damaged carbon fiber part can fail
suddenly, causing serious injury or death.
Inspect a carbon fiber bicycle, or parts,
for damage frequently. If you suspect
a carbon fiber part is damaged, replace
the part before riding or take the bike to
your dealer for service.
Carbon fiber composite inspection proce-
dures
Carbon fiber is among the strongest materials used in
bicycle manufacture. However, carbon has unique quali-
ties, different from metal parts, and must be inspected
carefully for damage.
Inspecting carbon fiber composite parts
Unlike metal parts, carbon composite parts that have
been damaged may not bend, bulge or deform; a dam-
aged part may appear to be normal to a cursory glance.

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After any high force load, like a crash, or other impact
to your bicycle, thoroughly inspect all the parts of your
bike, and 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 delamination.
These tests may not be conclusive. The following tests
are difficult to describe, so 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.

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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
If the part has any problems, do not ride the bike.
Take the bike to your dealer for replacement or further
inspection.

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To check a part for loss of rigidity (flex test)
Use the part in a normal manner (without actually rid-
ing) 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.
If the helper sees the part flex unexpectedly, or if the
part feels less rigid than it should be, do not ride the
bike. Take the bike to your dealer for replacement or
further inspection.