Trek Madone 2016 Assembly Manual
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Trek Madone 2016 Assembly Manual

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2 0 1 6
M A D O N E
A S S E M B L Y
M A N U A L

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Summary of Contents for Trek Madone 2016

  • Page 1 2 0 1 6 M A D O N E A S S E M B L Y M A N U A L...
  • Page 3 Trek Factory Racing team. sophisticated instruments—along with opinionated feedback from our most demanding test riders, the Hundreds of people had a hand in making the 2016 Trek Factory Racing team.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction 7. Installing Di2 wires in the handlebar Installing the front derailleur Di2 wire 1. Installing housings in the handlebar Installing the rear derailleur Di2 wire Installing the front derailleur housing Installing the rear derailleur housing 8. Installing the Control Center (Di2) Installing the rear brake housing Installing the Di2 junction box Charging the battery Installing the front brake housing Installing the rear brake guide cable...

  • Page 6: Introduction

    Congratulations. If you’re reading this assembly manual, odds are you’re about to lay hands on the most advanced road bicycle Trek has ever made. The all-new Madone represents a complete redefinition of the road bike ideal. Unburdened by convention, Trek engineers chased a new vision—a bike that would not only set a new...

  • Page 7: Installing Housings In The Handlebar

    INSTALLING HOUSINGS IN THE HANDLEBAR The 2016 Madone has a completely new handlebar with internal cabling. Refer to precut/pre-installed housing lengths in table Installing the front derailleur below according to frame size. housing in the handlebar Mechanical build housing lengths for 2016 madone TOOLS AND MATERIALS REQUIRED Total cable length recommendations •...
  • Page 8 INSTALLING HOUSINGS IN THE HANDLEBAR On the bottom of the stem, identify the correct hole for Push the installation cable through the bottom of the the front derailleur (FD). stem toward the lever exit hole. LEVER EXIT HOLE BOTTOM OF STEM Installation sequence of the four housings.

  • Page 9: Installing The Rear Derailleur Housing

    INSTALLING HOUSINGS IN THE HANDLEBAR Remove the installation cable from the housing. NOTE The rear brake housing must be behind the rear 60mm derailleur housing as the housings exit the shared stem hole. (See tip below.) Installing the rear derailleur housing in the handlebar Repeat the same steps as performed for front derailleur, but use the hole marked RDC.

  • Page 10: Installing The Front Brake Housing

    INSTALLING HOUSINGS IN THE HANDLEBAR Installing the front brake Installing the rear brake housing in the handlebar guide cable Repeat the same steps as performed for the TOOLS AND MATERIALS REQUIRED front derailleur, but use the hole marked FBC. • Spare cable (1) •...

  • Page 11: Installing Levers On The Handlebar

    INSTALLING LEVERS ON THE HANDLEBAR Place end caps onto the lever end of Installing the levers and cables the derailleur housings. TOOLS AND MATERIALS REQUIRED NOTE • Brake cables (2) • Levers (2) Ensure that the brake housing is on top of the •...

  • Page 12: Installing The Rear Brake Housing

    INSTALLING THE REAR BRAKE HOUSING Pull the rear brake cable halfway Installing the rear brake housing out of the lever. TOOLS AND MATERIALS REQUIRED • Frame • Handlebar (with levers installed) • Electrical tape • Non-drive side • Foam sleeve REAR BRAKE bearing top cap CABLE...

  • Page 13: Installing The Fork And The Handlebar

    INSTALLING THE FORK AND HANDLEBAR TOOLS AND MATERIALS REQUIRED • Frame • Compression Ring • Non-drive side bearing top cap • Tape • Upper headset bearing • Drive side bearing top cap • Fork • Lower headset bearing • Shaped spacers •...

  • Page 14: Installing The Fork

    INSTALLING THE FORK AND HANDLEBAR IF YOU DO NOT NEED TO CUT THE FORK, Installing the fork GO TO STEP 3. While you guide the housings to the correct sides Cutting the fork ( Steps 2.1–2.4 ) of the steerer (see Steerer diagram), pass the fork through the head tube, upper bearing, compression ring, spacers, and the stem.
  • Page 15 INSTALLING THE FORK AND HANDLEBAR The two detents in the bottom of the stem align Installing the fork (continued) with the shaped spacers. Slide the upper bearing into the head tube, then slide the compression ring into place. COMPRESSION RING UPPER HEADSET BEARING BOTTOM OF...
  • Page 16 INSTALLING THE FORK AND HANDLEBAR Align the top caps and shaped spacers as you slide Install the stem top cap and preload the stem down. As you lower the stem onto the the headset bearings with a max torque of 4Nm. frame, the foam sleeve and rear brake cable should slide into the top tube.

  • Page 17: Installing The Front Brake

    INSTALLING THE FRONT BRAKE Install clear plastic Installing the front brake cable sleeve over the brake and front brake arms cable housing, then an end cap with TOOLS AND MATERIALS REQUIRED integrated liner. • Housing stop • Torx T10 for wedge set screws •...

  • Page 18: Adjusting The Front Brake

    INSTALLING THE FRONT BRAKE Install and tighten the M6 countersunk bolt. Install the brake wedge in the rollers of the brake arms. Make sure the wedge is aligned properly, behind the small black washers. ROLLERS BLACK WASHERS Install the front brake arms and tighten. While you pull the cable tight, use a marker to draw a line on the brake cable at both the top and bottom edges of the brake wedge.

  • Page 19: Installing The Vector Wings And Brake Cover

    INSTALLING THE FRONT BRAKE Slide the wedge down to align the bottom of the pre-load Use the appropriate centering bolt to make final slot with the top line. While you hold the wedge flat with centering adjustment (ex: tightening the drive side a 9mm wrench, tighten the cable clamp screws with a centering bolt will pull the drive side pad away T10 Torx wrench.

  • Page 20: Installing The Rear Brake

    INSTALLING THE REAR BRAKE TOOLS AND MATERIALS REQUIRED • M46 countersunk bolt for • Torx T10 for wedge Install the end cap housing stop set screws with integrated liner. • Ferrule with integrated liner • 9mm wrench • RB brake wedge •...

  • Page 21: Installing The Control Center (Mechanical)

    INSTALLING THE CONTROL CENTER (MECHANICAL) TOOLS AND MATERIALS REQUIRED With the handlebar straight, align the rear derailleur housing with the rear of the down tube • Mechanical Control Center • Cable cutter cutout. Align your mark on the housing with the •...
  • Page 22 INSTALLING THE CONTROL CENTER (MECHANICAL) Pass the front derailleur cable through the Use tape to hold the bottom bracket cable guide in threaded bolt in the junction box, and fully seat the place while you slide the cables from the bottom housing end in the end of the barrel adjuster bolt.
  • Page 23 INSTALLING THE CONTROL CENTER (MECHANICAL) Install the junction box and the cover, then tighten the attachment bolts. Rotate the adjustment knob toward the non-drive side, threading the adjustment bolt in until it stops turning. NOTE To fine-tune the front derailleur by moving the derailleur outward, rotate the adjustment knob toward the drive side.

  • Page 24: Installing Di2 Wires In The Handlebar

    INSTALLING THE Di2 WIRES IN THE HANDLEBAR TOOLS AND MATERIALS REQUIRED 2016 Madone: internal cable routing • Installation cable (1) • Brake housings (2) Electronic build housing and wire lengths • Handlebar • Hook tool Frame Recommended cable housing and wire length in mm •...

  • Page 25: Installing The Rear Derailleur Di2 Wire

    INSTALLING Di2 CABLE IN THE HANDLEBAR Push the installation cable through the bottom of the Installing the rear derailleur stem toward the lever exit hole. Di2 wire in the handlebar LEVER EXIT HOLE Repeat the same steps as performed for front derailleur, but use the hole marked RDC.

  • Page 26: Installing The Control Center (Di2)

    INSTALLING THE CONTROL CENTER (Di2) TOOLS AND MATERIALS REQUIRED As you insert the rear of the junction box cover into the downtube window, push any excess wire • Di2 Control Center into the frame. Installing the Di2 junction box Before you start, there should be four wires hanging out of the downtube window.

  • Page 27: Charging The Battery

    INSTALLING THE CONTROL CENTER (Di2) Connect all the wires to the junction box. Note that any wire can be connected to any connector. Trimming the derailleurs Hold the trim button down. You do not need to With the two screws, attach the outer cage to open the junction box.

  • Page 28: Installing The Chain Keeper

    INSTALLING THE CHAIN KEEPER TOOLS AND MATERIALS REQUIRED • Hex bolt • Chain keeper • Chain keeper washer Pass the bolt through the washer, and then the chain keeper. Thread the bolt into the frame, and tighten until finger tight. IMPORTANT Do not adjust the chain keeper yet.

  • Page 29: Installing And Adjusting The Seatpost

    INSTALLING AND ADJUSTING THE SEATPOST TOOLS AND MATERIALS REQUIRED Pass the seatpost into the seat tube. • Seatpost • Upper seal • Seatpost clamp & bolts • Lower seal Slide the upper seal onto the seatpost. NOTE The upper seal will slide more easily if held perpendicular to the seatpost.

  • Page 30: Making Basic Fit Adjustments

    MAKING BASIC FIT ADJUSTMENTS We recommend that you go through a formal fitting To adjust the fore/aft position of the saddle, procedure at your Trek retailer before making any loosen the side rail clamp bolt, slide the saddle, changes to the bike fit.

  • Page 31: Attaching The Light Or Reflector

    ATTACHING THE LIGHT OR REFLECTOR TOOLS AND MATERIALS REQUIRED Attaching the front mount • Light or reflector bracket • Light or reflector Remove set screw from the handlebar. Attaching the rear bracket and reflector or light Slide the light mounting bracket (or reflector bracket) onto the seat post clamp.

  • Page 32: Traveling With Your Madone

    TRAVELING WITH YOUR MADONE TOOLS AND MATERIALS SUGGESTED Slide the fork back up. You may want to wrap a rubber band or zip tie around the steerer • Shipping container • Rubber bands just above the compression ring to hold the •...

  • Page 33: Fit Measurements

    FIT MEASUREMENTS Saddle X Saddle setback Saddle tilt Handlebar X Saddle to bar drop Saddle Y Saddle height (BB to top center of saddle) Handlebar Y BIKE MEASUREMENTS (CM) Saddle height Stem length/angle Saddle model Handlebar width Saddle size Handlebar model Saddle tilt Headset spacer height Saddle setback...

  • Page 34: Service Information

    SERVICE INFORMATION Madone 9 Series Seat Tube Water Bottle Screws The Madone 9 series IsoSpeed technology utilizes an internal seat tube that was engineered to move during normal riding conditions. To prevent water bottle screws from inhibiting this movement, the threaded water bottle mounting holes are designed with a depth stop, meaning the hole has a bottom.
  • Page 35 SERVICE NOTES date miles/km...
  • Page 36 SERVICE NOTES date miles/km...
  • Page 38 PN 530390...

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