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TREK SERVICE INFORMATION August 2016

9. Derailleurs

At this point in the assembly, the cables should be in the housings that run through the
down tube. These instructions explain the correct routing through the bottom bracket cable
guide and to each of the derailleurs.

Figure 9.1. Speed Concept parts for shift cable routing

Part

Bottom bracket shift cable
guide

Kit 437032

Bolt

Front derailleur hanger

326957

Front derailleur spherical
washer (9 series only)

W319573

Front derailleur frame
grommet

Kit 437032

Rear dropout cable guide/
housing stop

Kit 437032

Rear derailleur hanger

W315464

Bolts W318604

Dropout cable guide/
housing stop

Bottom bracket shift cable guide

Front derailleur
frame grommet

Part

Torque Spec

(Nm)

Front derailleur
mounting bolt

Derailleur
manufacturer’s
recommendation

BB cable guide bolt

Tools and materials required

•

Derailleur cable and 4 mm housing

•

Derailleur housing ferrules

•

Housing cutters

•

Torque wrench

•

4 and 5 mm hex wrench

Содержание Speed Concept 2014

Страница 1: ...er to your bicycle owner s manual the instructions in a bicycle mechanic s handbook or consult your dealer These instructions are not intended to replace the information in the Trek Bicycle Owner s Ma...

Страница 2: ...To Remove The Fork 9 7 Cables Housings And Bar Assembly 11 To Install The Housings In The Frame 12 To Install Housings In The Mono Extension And Aerobar 14 8 Arm supports 19 To Install arm supports 20...

Страница 3: ...ber assembly gel from Finish Line Park Tool SAC 2 Supergrip Assembly Compound Tacx carbon assembly compound Note Do not apply carbon prep between the stem and a carbon fork steerer Gravity heat and vi...

Страница 4: ...corporate state of the art technology and design This may require special consideration or techniques during assembly use or maintenance Compatibility of parts Trek only recommends Bontrager parts for...

Страница 5: ...n too loose or too tight can cause a bolt or clamp to break When multiple fasteners attach a part gradually tighten alternating bolts in small increments Figure 2 1 do not completely tighten one and t...

Страница 6: ...required 4 mm hex wrench Torque wrench Park Polylube 1000 grease Part PN 9 Series seatpost 15 mm offset 275 mm 436173 335 mm 436174 50 mm offset 275 mm 436175 335 mm 436176 7 Series seatpost 17 mm of...

Страница 7: ...sertion mark is inside the frame 3 Tighten the bolts to 5 2 Nm To Adjust The Angle Tilt Of The Saddle 1 Loosen the saddle clamp bolt Figure 4 3 2 With your fingers rotate the tilt wheel The tilt wheel...

Страница 8: ...he adapter clamps only to the seatpost which must be installed first Figure 5 1 Madone clamp adapter Tools and materials required Workstand Workstand clamp adapter PN 403494 Adapters PN 416101 To Atta...

Страница 9: ...Fork Lock washer Part PN Steering axle XS W333838 S W333885 M W333838 L W333886 XL W333887 Stem Low near 436145 Low far 436146 Medium near 436147 Medium far 436148 High near 436149 High far 436150 Cov...

Страница 10: ...t bump the fork against the frame during insertion Figure 6 5 Steering lock bolt passes through lock washer and into steering axle 5 Tighten the steering axle to 2 Nm Figure 6 4 Check that the fork ro...

Страница 11: ...9 from the front brake Figure 6 8 Brake cover 1 Remove the two grommets and housing cover bolts and remove the brake cover Figure 6 8 Figure 6 7 Steering axle pinch bolt 7 Place the stem on top of th...

Страница 12: ...Steering axle pinch bolt Figure 6 13 Stem attachment bolts two 5 Loosen and remove the steering axle lock bolt and washer Figure 6 12 6 Note Support the fork after removing the stem its only attachme...

Страница 13: ...ing covers Part PN Top cradle W326496 Top cradle bolts 2 Kit 437027 Mono extension Ergo long 436141 Ergo short 436142 S bend 436144 Straight 436143 Pivot cradle W331631 Mono spacer 15 mm W3265000 25 m...

Страница 14: ...f the head tube 2 Slide the rear brake housing and both pieces of shift housing through the top tube housing window Figure 7 3 down the down tube and out of the window at the bottom bracket Figure 7 4...

Страница 15: ...on is in the brake yoke Figure 7 6 and slide the housing into the yoke 6 Run the rear brake cable backwards through the brake then into the yoke and housing This is to hold the housing in place while...

Страница 16: ...xtend 3 to 4 75 100 mm past both ends of the bar You will re size the housing later 2 Slide the pivot cradle into position between the mono extension and the mono spacer Figure 7 9 3 Insert the T nuts...

Страница 17: ...e an extra 25 mm of housing protruding out of the t slot Note The high far stem requires that the front brake housing exit the rear of the aerobar in a manner similar to the rear brake housing Figure...

Страница 18: ...able through the lever and aerobar housing Figure 7 17 Ferrule in sideways position 10 Dry fit the aerobar to the stem Place the ferrule in the stem Make sure the tabs on the ferrule engage the cut ou...

Страница 19: ...nect the shift housing from the mono extension to the shift housing from the frame The rear brake housing should be in the middle Figure 7 20 Insert the shift housings into the double ferrules Make su...

Страница 20: ...bike but lean inward nearer the top of the bar 17 Secure the stem cover with the two side attachment bolts Figure 7 22 Figure 7 23 Side attachment bolts go in at an angle Figure 7 24 Tightening shift...

Страница 21: ...d wing W326497 Bolt Kit 437027 Dog bone washer Kit 437027 Spacer 5 mm W327606 Figure 8 1 Arm supports Mono extension one of four choices Arm pads Arm pad holder Pad wing Dog bone washer Spacer Part To...

Страница 22: ...ighten the bolts to 6 8 Nm and then tighten the set screw Figure 8 3 until it makes contact with the mono spacer 3 Attach the Pad wing to the mono extension Figure 8 4 Tighten to 4 5 2 Nm Note Use any...

Страница 23: ...21 TREK SERVICE INFORMATION August 2016 Figure 8 6 Arm pad 5 Attach the arm pads to the holders by their hook and loop fasteners Figure 8 6...

Страница 24: ...t Front derailleur hanger 326957 Front derailleur spherical washer 9 series only W319573 Front derailleur frame grommet Kit 437032 Rear dropout cable guide housing stop Kit 437032 Rear derailleur hang...

Страница 25: ...not use the washer from the derailleur manufacturer The Speed Concept spherical washer which is identical to the one used on the 2013 Madone is PN 319576 2 Orient the seat tube grommet Figure 9 3 and...

Страница 26: ...after installing the aerobar Part PN Wedge W546698 Brake W326964 Pads by rim type aluminum rim Your choice carbon rim 431461 Pad carriers pair 433749 Cover x small W326645 small W328662 medium W32664...

Страница 27: ...Figure 10 3 Tighten the brake bolts 2 Install both brake arms onto the fork Figure 10 3 Tighten to 6 8 Nm 3 Place the wedge in the home position between the rollers Figure 10 4 Figure 10 4 Wedge in ho...

Страница 28: ...the cable If desired solder the end Or install a cable crimp then bend it forward Figure 10 7 Length of cable after cutting 7 Insert the correct brake pads and set the pad spacers Figure 10 8 and see...

Страница 29: ...of the cover Figure 10 11 then place the cover over the brake and install the cover bolts Tighten to 3 Nm Figure 10 12 Brake cover grommets Figure 10 13 Centering screw inside front brake cover 11 In...

Страница 30: ...ear brake Noodle Wedge Cover 10 mm cover attachment bolts 2 Part PN Wedge W546699 Brake W325747 Pads by rim type aluminum rim Your choice carbon rim 431461 Noodle included with brake N A Cover UCI leg...

Страница 31: ...l finger tight 4 Without changing the wedge location on the cable remove the wedge from the rollers Move the wedge up the cable about 1 mm to compensate for cable stretch Hold the top and bottom surfa...

Страница 32: ...centering screws center the brake To make the brake easier to adjust after the crankset is installed the centering screws are both accessed from the non drive side of the bike Figure 10 8 Figure 11 6...

Страница 33: ...alled and without Figure 11 11 Attaching the rear brake cover with two 10 mm bolts 10 Install the two rear 10 mm brake cover attachment bolts Figure 11 11 Tighten to 3 Nm Figure 11 10 Attaching the re...

Страница 34: ...A DuoTrap Sensor 1 On the chainstay locate the DuoTrap cover Remove the rubber plug that covers the attachment bolt Figure 12 2 Remove the bolt and the cover plate 2 Slide the cylindrical part of the...

Страница 35: ...2 3 Nm Part PN Draft Storage Box 433746 Part Torque Spec Nm Attachment bolt 2 3 To Install A Draft Storage Box This box is placed out of the wind behind the seat tube Figure 13 1 The box slides down...

Страница 36: ...attaches to the frame with two mounting bolts 1 Align the Speed Box with the threaded holes on the top tube Figure 13 4 2 Insert two M5 bolts though the Speed Box and into the threaded holes in the t...

Страница 37: ...t two bolts through the cage mount and into the mono extension Figure 13 6 Tighten to 5 2 Nm Figure 13 6 The cage mount attaches to the mono extension Figure 13 7 The cage can be attached at a choice...

Страница 38: ...od to install a computer Computers with a rigid band clamp such as the SRM will require the spacer Figure 13 8 Computers with a more flexible mount can attach directly to the bottle cage Figure 13 9 F...

Страница 39: ...ieve the correct assembly and adjustment Figure 14 2 Inserting one half of the axle shield into frame Figure 14 1 Applying grease to the axle shield Figure 14 3 Release tab 2 Place the male axle shiel...

Страница 40: ...ss the bearing into the frame by hand as far as possible 4 With the cup guide on the bearing side Figure 14 5 slide the bearing press through the bearing and frame 5 Center the guide in the bearing 6...

Страница 41: ...structions available at http www sram com _media techdocs 2005_gxp 05 r5 e pdf Tools And Materials Required Crankset and bottom bracket 8 mm hex wrench Bearing installation tool PN 404694 Rock N Roll...

Страница 42: ...aring onto the installation tool Either side of the drive side bearing is the right side The non drive bearing on GXP systems has a lip Figure 14 8 Install the bearing so that the lip faces in 3 Press...

Страница 43: ...ve Side Crankarm 1 Apply a light coat of grease to the inside of the metal bearing seal 2 With the grease side toward the bearing slide the bearing seal onto the axle Figure 14 14 3 Follow the TruVati...

Страница 44: ...non drive end 2 Gently rock the axle while you pull the axle out Inspecting The Bottom Bracket Every 3 months check the bottom bracket adjustment To Check The Bottom Bracket Bearing Adjustment 1 Lift...

Страница 45: ...tp techdocs Shimano com media techdocs content cycle SI Dura Ace FC 7800 7803 SI_1F30H_En_v1_m56577569830605111 pdf Tools and materials required 1 Crankset and bottom bracket 2 Shimano FC16 crank arm...

Страница 46: ...aring into the drive side of the bottom bracket shell Figure 14 17 4 Repeat steps 1 3 for the other bearing on the non drive side To Install The Drive Side Crankarm When handling the seals avoid bendi...

Страница 47: ...light coat of grease to the inside of the other bearing seal 2 With the grease side toward the bearing slide the bearing seal onto the axle Figure 14 22 3 Align the non drive crank arm with the groove...

Страница 48: ...non drive end 2 2 Gently rock the axle while you pull the axle out Inspecting The Bottom Bracket 1 Every 3 months check the bottom bracket adjustment To Check The Bottom Bracket Bearing Adjustment 1 L...

Страница 49: ...e bearings into the frame If the bearing fit is too tight make sure the seal seats are clean and free of debris Tools And Materials Required To complete the installation you will need the Campagnolo i...

Страница 50: ...ocTite Primer to the outer step of the bearings cups and the outer shoulder of the bottom bracket shell Figure 14 26 Allow the primer to evaporate completely 3 Apply LocTite 638 to the faced of the se...

Страница 51: ...9 Greasing the bearing cups Figure 14 30 Inserting the Wave washer after the washer on the non drive side 4 Slide the non drive side axle through the seal seat and bottom bracket shell Figure 14 31 To...

Страница 52: ...ings are pressed onto one of the halves of the bottom bracket axle To remove the bearings follow the Campagnolo service instructions Inspecting The Bottom Bracket Every 3 months check the bottom brack...

Страница 53: ...to tap them with a soft faced mallet However Do not use a hammer to install the bearings into the frame If the bearing fit is too tight make sure the bearings are clean and free of debris Tools And Ma...

Страница 54: ...he bearings 2 With the plastic bearing shield facing out press one bearing into the drive side of the bottom bracket shell Figure 14 35 3 Repeat Steps 1 2 for the other bearing on the non drive side T...

Страница 55: ...by hand you may use the following method to remove them 1 Slide the crank axle into the bearing so that the bearing is over the non drive side of the axle about 1 inch 25 mm from the non drive end 2 G...

Страница 56: ...s been tightened to the torque specifications see page 38 Most issues with play in GXP crankarms are resolved when the arms are properly tightened If this does not solve the issue add a 0 5 mm washer...

Страница 57: ...al 0 3 mm thick to the seal around the inner diameter This will move the outer edge of the seal away from the bearing Bearing not seated properly The axle shield might not be seated completely in the...

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