Trek Belleville fork handlebar assembly?
 

Hello,
I recently received a brand new Trek Belleville not assembled.
It was a gift and i figured since i have put a few bikes together, i could figure it out.
No assembly manual was included and the Trek pamphlet is worthless... plus the CD in the manual is cracked and won't play.
With only photos on the internet to go by...
(like these http://www.biketinker.com/2011/fine-...ek-belleville/)
The only part i am having trouble with is the forks and handlebars.

The fork has a long neck in which the one piece handlebar/stem clamps to it. They are then secured by a cap with a screw through it.

When i tighten everything, i can't turn/steer the bike. When i loosen things up to steer, there is up and down play between the fork/bars inside the neck.

Has anybody ever assembled one of these bikes before?
Any tips or suggestions?
maybe i am missing a piece that secures the forks to the frame before the handlebars are secured to the fork?

TIA.
-Josh

After an hour of beating myself up and resorting to posting on the forum, I may have figured it out. there was a plastic collar that fit beneath the silver collar in this photo. It seemed to act as a spacer thus letting the silver collar create tension on the inner plastic collar which makes contact with the inner neck bearing. I am baffled that such a cheap plastic collar has such an important function.... but... i tightened everything pretty good and the bike steers as a bike should.

If i am wrong, please correct me. Otherwise, hopefully this post will serve as some help for somebody else trying to figure this bike out.

Next step... figuring out the lighting/electrical....

That setup works like other run-of-the-mill threadless headsets. You're probably missing the wedge ring that centers the fork in the upper bearing. In this representative picture, it would be part #8:

http://www.sicklines.com/news-images...0_headset3.jpg

yep. That was the ring i was leaving out. Thanks.

So you got a grey market bike, eh. ?

No... it is legit. My job works with Trek as a sponsor.... i had the option of waiting a few weeks to have it assembled or getting it now. I was impatient and I like putting things together.

your figure out the wiring yet?

Didn't figure out the wiring yet. it was getting late and the wife was asking when i would leave the garage....
It seems simple but i think i am missing the connector plug to connect the wiring to the generator hub.
Trek did an amazing packing job... but nothing was labeled or organized into boxes that would make sense....

Is polarity an issue? I didn't look yet for signs of a '+' or '-'.

I went to attach my pedals and i think they are total garbage. They hardly spin on their own. It is as if the bearings are shot. And they are brand new. I'm going to see if i have an old set lying around or perhaps a trip to the local bike shop is in my near future.

If there isn't a chunky feeling to the action as the pedals spin they should be fine. If there is go to your LBS. I work for a Trek dealer and they (perhaps others?) use a low quality medium-weight grease, and hardly any of it for that matter, on most bearing assemblies. Good luck with the wiring.

They are very chunky feeling. A flick of the wrist on the pedal results in hardly any free play or full rotation/spin. I'll look for replacements soon. I have a broken pushrod issue on an internal 3 speed shimano hub (different bike) that warrants a bike shop visit in my near future.
Thanks for your reply. Glad to know that true bike pros are on this forum.