MINOURA | WHEEL ASSEMBLY KIT | Owner`s manual | MINOURA WHEEL ASSEMBLY KIT Owner`s manual

2014 Speed Concept: Service Information
When we introduced the Trek Speed Concept bike in 2011, it was the fastest frameset
we had ever made. The 2014 version is even faster. It has shaped tubes, hidden front and
rear brakes, very thin-walled carbon tubes, and a new front-end design including a new
handlebar configuration.
Special Assembly Techniques Required
Because of the unique features of the Speed Concept, it requires assembly and adjustment
techniques that are different from other bikes that are explained in this manual. We have
also provided general maintenance information:
•
Carbon fiber care
•
Head bearings installation
•
Bottom bracket bearing installation for a variety of bottom bracket types
Please save these instructions for future reference. Also check www.trekbikes.com for
updates.
Some of the tasks in these instructions may have been done by the factory. We include the
instructions for these steps here for later reference when you need to perform service on
this bike.
Note: Instructions for the Shimano electronic Di2 shift system are in a separate document. See your dealer.
These instructions are written for an experienced mechanic. If you need further information,
refer 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 Manual. You should also read that manual as it contains important
use, safety, and maintenance information that also pertains to the assembly of this bicycle.
Note About Performing Mechanical Work On Bicycles
Many people think of bicycles as simple machines, almost toys. However, modern bicycles
use high-tech materials and designs that rely on correct maintenance and precision
workmanship. If any part on the bicycle is worn, corroded, rusted, loose, or damaged in
any other way, replace the part. If you do not have the correct tools or experience, do not
perform the tasks in this manual; take your bicycle to your dealer for service.
In some cases we provide several methods of checking the tightness or connection of parts.
The most preferable of these is always the one with the most precision. In other words,
correct mechanical work requires that all bolts be tightened with a torque wrench.
Incorrect mechanical work on your bicycle could lead to damage or premature breakage of a
part, which could cause you to fall and lead to serious injury or death.
© Copyright Trek Bicycle Corporation 2013
All Rights Reserved
Table of Contents
1. Working with Carbon Fiber Parts............................................................. 1
10. Front Brake................................................................................................24
To Install And Adjust The Front Brake..................................................25
2. Speed Concept General Information..................................................... 2
Changes From The Previous Version......................................................2
11. Rear Brake..................................................................................................28
Special Features And Assembly Information.......................................2
To Install And Adjust The Rear Brake.................................................. 29
Preparing And Tightening Fasteners....................................................... 3
For More Information................................................................................. 3
12. DuoTrap Computer Sensor................................................................... 32
To Install A DuoTrap Sensor....................................................................32
3. Sizing The Bike..............................................................................................3
13. Accessories............................................................................................... 33
4. Seatpost ....................................................................................................... 4
To Install A Draft Storage Box................................................................33
To Install The Seatpost...............................................................................5
To Install A Speed Box............................................................................. 34
To Adjust The Height Of The Saddle......................................................5
To Install A Bottle Cage............................................................................35
To Adjust The Angle (Tilt) Of The Saddle.............................................5
14. Crankset.................................................................................................... 37
5. Using A Repair Stand................................................................................. 6
To Install The Axle Shields.......................................................................37
To Attach The Workstand Clamp Adapter...........................................6
Pressing Crankset Bearings.................................................................... 38
SRAM GXP................................................................................................. 39
6. Fork................................................................................................................. 7
Shimano HollowTech............................................................................... 43
To Install The Bearings And Fork.............................................................8
Campagnolo UltraTorque....................................................................... 47
To Remove The Fork....................................................................................9
FSA MegaExo AL....................................................................................... 51
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
9. Derailleurs ................................................................................................. 22
To Install The Front Derailleur ...............................................................23
ii
TREK SERVICE INFORMATION
17 July 2013
Crankset Troubleshooting...................................................................... 54
1. Working with Carbon Fiber Parts
Carbon fiber parts are different from metal parts, so they require different treatment. This
section explains some of the specifics. Also see the Trek Bicycle Owner’s Manual.
Avoid Sharp Edges Or Excessive Pressure
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.
As carbon frames have gotten lighter and lighter, you can now feel movement in the tubes
when you squeeze them. This is normal and no reflection of the strength of the frame.
However, repeated compression of the sides of the tubes is not good for them, and could
eventually lead to frame damage. Do not squeeze the frame tubing with your fingers, and
especially never clamp the tubing in any mechanical device, including car racks.
Prepare Carbon Parts Before Installation
Carbon parts can be assembled either clean or with carbon prep:
•
To clean a carbon part, scrub both the part and its mating surface with rubbing alcohol
and a shop rag; clean until the rag shows no discoloration.
•
Alternately, we recommend applying one of the following special carbon prep products:
•
Fiber Grip™ carbon fiber 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
vibration work together to allow the carbon prep to move down the steerer into the headset
spacers. Carbon prep is somewhat abrasive and due to the slight motion involved with
the headset spacers, carbon prep can wear away steerer material, causing the fork to lose
strength.
With most carbon parts you should avoid grease. If grease is applied to a carbon part that
is clamped, the part may slip in the clamp, even at the recommended torque specification.
On the other hand, the bearing seats of the Speed Concept frameset do require grease, as
explained in these instructions.
Never Modify The Fork, Frame, Or Components
The parts of the Speed Concept frameset have been carefully designed to meet the strength
and function requirements of safe riding. Modifying these parts in any way could make the
bike unsafe. As an example, removing the redundant wheel retention tabs on fork tips could
make the fork less functional.
Not all parts and accessories are compatible or safe, so only add a part or accessory that
has the approval of the manufacturer. As examples, clamping any accessory on a carbon
fiber part can weaken or damage the part, and using incorrect brake pads on a carbon rim
can cause the rim to overheat and possibly delaminate. Any modification of a frame, fork, or
components means that the bike no longer meets our specifications and will therefore void
the bike’s warranty.
1
TREK SERVICE INFORMATION
17 July 2013
2. Speed Concept General Information
The Speed Concept design incorporates a number of special parts with special features.
This section gives a brief explanation of some of the features, their use and maintenance,
and general information about the bike.
Changes From The Previous Version
The 2014 Speed Concept looks similar to the previous version, but there are many changes.
These changes make ‘upgrading’ to the new design impossible. For example, due to a
larger-diameter steering axle and a 20 mm shorter head tube on every frame size, the new
fork is not compatible with the old frame. However, the benefits to the new design make the
changes entirely worthwhile. Here are some of the changes:
•
Two-bolt, rear-access seatpost clamp
•
Seatpost with two-bolt saddle clamp
•
Larger-diameter aluminum alloy steering axle with integrated bearing preload feature
•
Steering bumper to reduce possible damage under full fork rotation
•
‘Mono’ aero extension, with bottle mount on top of stem
•
New housing routing from bar to frame, with new cover
•
Carbon fiber dropouts on 9 Series
•
Carbon fiber front derailleur hanger
•
Mega seat-box option
Special Features And Assembly Information
The Speed Concept frame and parts incorporate 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 the Speed Concept
bike because with these parts the torque specifications and crush strength have been
evaluated by our engineering staff. Other parts might not meet our requirements, and
could lead to damage.
•
Carbon fiber construction- Carbon fiber composite is by weight the lightest, strongest
frame material available today. Please read about special care needed for carbon fiber
in your Trek bicycle owner’s manual.
•
Integrated fork design- The leading fork design provides the least wind drag of any
bicycle we have ever designed. With the carefully integrated head tube / fork interface,
hidden head bearings, and hidden brakes, the air flows smoothly across the frame.
However, this design limits the rotation of the fork; if you turn the aerobar too far the
fork will contact the frame, possibly damaging the paint. For 2014 we have added an
integrated fork bumper to reduce damage. However, care still needs to be taken.
•
Internal cable routing- To minimize wind drag, the cables and housing of the Speed
Concept are hidden to the maximum extent possible.
•
Seatpost for either time trial or triathlon- The seatpost can be rotated 180 degrees to
gain different positions. In addition, there are two lengths of seatposts and two offsets
available.
2
TREK SERVICE INFORMATION
17 July 2013
•
Hidden brakes- If you can’t see them, the wind can’t find them. The brakes are sensitive
to rim width, so a brake will require re-adjustment if the wheel is changed, because.
There are pad-width adjustment features built into the brakes.
•
Carbon rims- By weight, carbon is the strongest material used in bicycle construction.
It also allows greater flexibility in designing shapes, so Bontrager carbon rims are very
aero. Make sure you use brake pads that are compatible with the rim material.
Preparing And Tightening Fasteners
For each threaded fastener that does not use threadlocker, apply a light coat of grease to the
threads and shoulder of the bolt or screw. Then tighten correctly.
The correct torque is noted on or near most of the threaded fasteners on the Speed Concept
bike. The specification on the bike tells you the range of torque. Do not exceed it. However,
do not leave bolts loose. You should try to tighten a bolt to close to the listed value. Either
condition, 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 then start the other. If a clamp
uses a band (Figure 2.2), the gap at either end of he band should be the same. As the
bolts become snug, check the alignment of the parts. Then use a torque wrench for final
tightening. When the tightening is completed, all bolts of a given clamp must be tightened
to the same torque.
For More Information
1
4
Figure 2.1. Bolt tightening sequence
Trek dealers have access to the Trek Customer Service department for information about
the Speed Concept bikes and parts, so they can order any and all parts for the bikes through
standard channels.
You can find updates to this manual at this web address:
www.trekbikes.com/us/en/support/manuals
Figure 2.2. Gaps at either end of clamp band
3. Sizing The Bike
Before assembling the bike, make sure the frame is the correct size and, as much as
possible, that you have chosen the correct stem and spacer stack. There is information on
our website that explains how to do this. Visit our website:
www.trekbikes.com/us/en/support/manuals
3
TREK SERVICE INFORMATION
17 July 2013
3
2
4. Seatpost
Tools and materials required
This section explain how to install the seatpost, adjust the seatpost height, and how to tilt
the saddle.
•
4 mm hex wrench
•
Torque wrench
•
Park Polylube 1000 grease
The 2014 Speed Concept seatpost has an aerodynamic shape (Figure 4.1), but it can be
turned or reversed in the frame to allow for a wide variety of seating positions. It is also
available in two offsets and two lengths.
Part
PN
9 Series seatpost
Seatpost
15 mm offset, 275 mm
436173
335 mm
436174
50 mm offset, 275 mm
436175
335 mm
436176
7 Series seatpost
Seatpost clamp
17 mm offset, 276 mm
327450
350 mm
327671
Saddle clamp bolt
T-nut
Thumb wheel
Bolt
Top plate, carbon
Bottom plate, carbon
Kit 437030
Spring
Set screw
Seatpost clamp bolts
Teflon washer
Washer
Di2 bracket
W332400
Seatpost clamp and bolts
439012
Part
Torque Spec
(Nm)
Figure 4.1. Exploded diagram of Speed Concept frame and seatpost
4
TREK SERVICE INFORMATION
17 July 2013
Seatpost clamp bolts
5.2
Saddle clamp bolt
5-7
To Install The Seatpost
1. Grease the threads of the seatpost clamp bolts (Figure 4.2).
2. Insert the seatpost and tighten the seatpost clamp bolts to 5.2 Nm.
The seatpost can be inserted dry, or for more grip insert it with carbon prep on the
portion of the post that is inside the frame.
Seatpost
clamp bolts
Figure 4.2. Seatpost clamp bolts on the back of the seat
tube
To Adjust The Height Of The Saddle
1. Loosen the seatpost clamp bolts (Figure 4.3).
2. Slide the post up or down as necessary.
Make sure the minimum insertion 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 acts like a nut instead of a bolt, so it will seem like it is left-hand threaded.
Note: When you tighten the saddle clamp bolt, the saddle angle will change about 3°. To
compensate for this change, turn the tilt wheel one full turn (the direction you turn the
wheel depends on the orientation of the seatpost in the frame) to lower the saddle on the
end at the tilt wheel. When you tighten the bolt, the saddle will flatten out and those 3°
will be erased.
3. Tighten the saddle clamp bolt to 5-7 Nm.
Note: If the tilt is wrong, repeat steps 1 through 3. Do not under- or overtighten the saddle
clamp bolt to achieve the correct tilt.
5
TREK SERVICE INFORMATION
17 July 2013
Tilt wheel
Saddle clamp
bolt
Figure 4.3. Tilt wheel and saddle clamp bolt of saddle
angle adjustment mechanism
5. Using A Repair Stand
This section explains how to correctly put the Speed Concept in a work stand.
Do not clamp the frame. The only accepted or recommended method for holding the Speed
Concept is to use the special workstand clamp adapter designed specifically to clamp the
seatpost (Figure 5.1). The adapter clamps only to the seatpost, which must be installed first.
Tools and materials required
•
Workstand
•
Workstand clamp adapter,
PN 403494
•
Adapters, PN 416101
To Attach The Workstand Clamp Adapter
1.
Open the clamp adapter (Figure 5.1).
2.
Insert the elliptical adapters (Figure 5.2).
3.
Wrap the adapter around the seatpost.
If needed, raise the seatpost to provide room for the adapter to clamp.
4. Insert the base of the clamp adapter into the workstand.
Figure 5.1. Madone clamp adapter
Figure 5.2. Elliptical seatpost adapters for Madone clamp
6
TREK SERVICE INFORMATION
17 July 2013
6. Fork
Tools and materials required
This section explains how to install the integrated fork on the 2014 Speed Concept,
including installing the head bearings (the Speed Concept uses integrated head bearings
instead of a conventional headset). After that information, there are instructions for
removing the fork.
•
Bicycle grease
•
Torque wrench
•
4, 5, and 8 mm hex wrench
Figure 6.1 shows the parts of the fork assembly.
If the fork is already in the bike, you can go to the next section, Cables, Housings,
and Bar Assembly.
Part
PN
Steering axle
XS
W333838
S W333885
Steering axle
M W333838
Stem attachment bolts
L W333886
XL W333887
Stem
Steering axle
pinch bolt
Stem
Low near
436145
Low far
436146
Medium near 436147
Upper head bearing
Medium far 436148
High near 436149
Lower head bearing
High far
327797
Stem attachment
bolts (2)
Kit 437027
Steering axle pinch
bolt
Kit 437027
Fork
Lock washer
Steering lock bolt
Figure 6.1. Fork attachment exploded diagram
436150
Cover bolt
Nut Kit 437027
Upper head bearing
W276442
Lower head bearing
428420
Steering lock bolt
Kit 437032
Lock washer
Kit 437032
Fork bumper
Steel QR
Kit 437032
Front
W327469
Rear W327470
Titanium QR
Front
W329030
Rear W329031
Part
7
TREK SERVICE INFORMATION
17 July 2013
Torque Spec
(Nm)
Steering axle
2
Steering axle lock bolt
6
Stem-to-fork bolts
10
Steering axle pinch bolt
5.2
To Install The Bearings And Fork
1.
Apply a light coat of grease to the bearing contact surfaces of the frame and fork, and
steering axle.
2.
With your hands, align the upper bearing and press it into the frame (Figure 6.2).
Figure 6.2. Upper head bearing pressed into frame
3.
Align the lower bearing with the fork crown (Figure 6.3).
4. Apply a light coat of grease to the external threads of the steering axle and insert it
into the fork: hold the lower bearing and fork against the bottom of the head tube while
you pass the steering axle through the upper bearing, then the lower bearing, and then
thread the steering axle into the fork.
Figure 6.3. Lower head bearing on fork crown
Note: Be careful not to mar the paint; don’t bump the fork against the frame during
insertion.
Figure 6.4. Steering axle passes through both bearings,
then threads into fork crown
5.
Tighten the steering axle to 2 Nm (Figure 6.4).
Check that the fork rotates freely without any end play. Adjust with the steering axle
tension as necessary.
6. From under the fork crown, place the lock washer over the steering axle and thread the
steering axle lock bolt into the bottom of the steering axle (Figure 6.5). With an 8 mm
hex wrench, hold the top of the steering axle to prevent spinning while you tighten the
steering axle lock bolt to 6 Nm..
The steering lock bolt centers the steering axle, and when tightened locks the head
bearings adjustment.
Figure 6.5. Steering lock bolt passes through lock washer
and into steering axle
8
TREK SERVICE INFORMATION
17 July 2013
7.
Place the stem on top of the fork with the steering axle in the stem clamp. Insert the
two stem-to-fork attachment bolts (Figure 6.6) through the stem and thread them into
the top of the fork. Tighten to 10 Nm.
Figure 6.6. Stem-to-fork attachment bolts (two)
8. Tighten the steering axle pinch bolt (Figure 6.7) to 5.2 Nm.
Figure 6.7. Steering axle pinch bolt
To Remove The Fork
Although you can replace the fork with the derailleur cables and rear brake cable connected,
you may find this procedure easier with them disconnected. These instructions explain the
steps with the cables connected.
1. Remove the two grommets and housing cover bolts, and remove the brake cover (Figure
6.8).
Figure 6.8. Brake cover
2. Squeeze the pads together and disconnect the brake wedge (Figure 6.9) from the front
brake.
Figure 6.9. Squeeze the lower arms to remove the wedge
9
TREK SERVICE INFORMATION
17 July 2013
3. Loosen and remove the three aerobar attachment bolts (Figure 6.10), and remove the
aerobar/mono-extension assembly.
Note: To simply remove the fork, you can skip this step and leave the mono-extension
assembly attached to the aerobar.
Figure 6.10. Aerobar attachment bolts (three)
4. Loosen the steering axle pinch bolt (Figure 6.11).
Figure 6.11. Steering axle pinch bolt
5. Loosen and remove the steering axle lock bolt and washer (Figure 6.12).
Figure 6.12. Steering axle and steering axle lock bolt
6. Note: Support the fork after removing the stem; its only attachment will be the lower
bearing.
Loosen and remove the two stem attachment bolts (Figure 6.13), and remove the stem.
7. Note: The fork will detach when the steering axle is removed.
While you support the fork, loosen and remove the steering axle.
Figure 6.13. Stem attachment bolts (two)
10
TREK SERVICE INFORMATION
17 July 2013
7. Cables, Housings, And Bar Assembly
This section explains how to install housings in the aerobar, mono-extension, and frame;
and how to assemble the bar. Figure 7.1 shows an exploded view of the bar assembly.
Tools and materials required
•
Torque wrench
•
3 and 4 mm hex wrench
If you are assembling a new bike, don’t be confused by the backwards cables in the housing;
those cables are just there to hold the housing in place during shipping.
If you are replacing cables or housing, you must remove the aerobar before proceeding.
Top cradle and
bolts (2)
Mono-extension
(4 options)
Part
PN
Top cradle
W326496
Top cradle bolts (2)
Kit 437027
Mono-extension
Ergo long 436141
Ergo short 436142
S-bend 436144
Pivot cradle
Mono-spacer (4 choices)
Straight 436143
Aerobar
Pivot cradle
W331631
Mono-spacer
15 mm
T-nuts for top
cradle bolts (2)
W3265000
25 mm W326501
35 mm W326502
45 mm W326503
Stem cover
Stem (6 choices with matching covers)
Cover bolt
T-nuts (2)
Kit 437027
Front brake ferrule
W327798
Aerobar:
UCI
W326797
non-UCI W326796
Aerobar attachment
bolts (3)
Steering axle pinch
bolt
Figure 7.1. Exploded assembly of stem, aerobar, and mono-extension
Aerobar to stem
attachment bolt, front
Kit 437027
Rear Kit 437027
Bottom bracket cable
guide w/bolt
Kit 437032
Stem Cover
W326769
Low near
Low far
W326770
Medium near W326771
Medium far W326772
High near W326773
High far
W326774
Part
Bottom bracket
cable guide
BB cable guide bolt
Figure 7.2. Exploded assembly of frame and bottom bracket cable guide
11
TREK SERVICE INFORMATION
17 July 2013
Torque Spec
(Nm)
BB cable guide bolt
3
Brake attachment bolts
6.8
Stem cover bolts
2
Steering axle pinch bolt
5.2
Aerobar attachment
bolts
6-8
Top cradle bolts
6-8
To Install The Housings In The Frame
If the housings are already in place in the frame, go to To install housings in the monoextension and aerobar, on page 14.
1. To differentiate it from the rear housing, mark each end of the front derailleur shift
housing with a piece of tape.
Note: Only 4 mm housing will fit into the derailleur housing stops. To determine the length
of housings, use the previous pieces as a guide, or install new 1500 mm pieces that you will
re-size later.
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 7.3. Shift housing extending out of the head tube
3. Install ferrules on the shift housings and slide them into the bottom bracket cable guide
(Figure 7.4). Attach the guide with the BB cable guide bolt and tighten to 3 Nm.
Figure 7.4. Bottom bracket cable guide on shift housing
4. Put the brake housing in the middle of the shift housings at the head tube (Figure 7.5)
and at the bottom bracket between the two derailleur housing stops.
Note: To determine the length of housing, use the previous piece as a guide, or install a
new 700 mm piece that you will re-size later.
Figure 7.5. Brake housing along with shift housing
12
TREK SERVICE INFORMATION
17 July 2013
5. Install a ferrule on the brake housing. Make sure the guide tube, a short plastic tunnel
that reduces cable friction, is in the brake yoke (Figure 7.6), and slide the housing into
the yoke.
Brake yoke
Bottom bracket cable guide
Figure 7.6. Brake yoke with housing connected
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 you proceed with the next steps.
7. Attach the brake with the two brake attachment bolts (Figure 7.7). Tighten the bolts to
6.8 Nm.
Figure 7.7. Attaching the rear brake
13
TREK SERVICE INFORMATION
17 July 2013
To Install Housings In The Mono-Extension
And Aerobar
1. Starting from the front (shifter) end of the mono-extension, slide the shift housing
pieces through (Figure 7.8). Then align the housings with the holes in the mono-spacer,
and slide the mono-spacer into place under the mono-extension.
Note: Only 4 mm housing will fit the housing connectors. To determine the length of
housings, use the previous pieces as a guide, or install new pieces that extend 3 to 4” (75100 mm) past both ends of the bar. You will re-size the housing later.
Figure 7.8. Shift housing routed through mono-extension
and mono-spacer
2. Slide the pivot cradle into position between the mono-extension and the mono-spacer
(Figure 7.9).
Mono-extension
Pivot cradle
Mono-spacer
Figure 7.9. Pivot cradle between mono-extension and
mono-spacer
3. Insert the T-nuts into the underside of the mono-spacer (Figure 7.10).
T-nuts
Figure 7.10. Underside of mono-spacer
4. From the top of the mono-extension, insert the mono-extension attachment bolts
(Figure 7.11) through the mono-extension, pivot cradle, and into the mono-spacer
T-nuts.
These bolts control the tilt of the mono-extension, so for now only tighten until
finger-tight. Back out the set screw so that it is not touching.
Set screw
Mono-extension
attachment bolt
Figure 7.11. Mono-extension bolts allow fore/aft
adjustment and control tilt of bar. Set screw prevents
movement after adjustment.
14
TREK SERVICE INFORMATION
17 July 2013
5. From the rear of the aerobar, slide the rear brake housing through the aerobar (Figure
7.12) out to the lever.
Note: Place a cable into the housing before inserting the housing; the rounded cable end
will slide through the bar more easily than the raw housing end.
Figure 7.12. Rear brake housing routed out of aerobar
(top view of aerobar)
6. Slide the front brake housing through the ‘t-slot’ of the aerobar (Figure 7.13). Leave 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 7.12). For all other stems, the rear brake
housing will exit the “t-slot” as shown in Figure 7.13.
T-slot
Figure 7.13. T-slot and housing routes through aerobar
(bottom view of aerobar)
7. Install the brake levers (Figure 7.14). Tighten to the manufacturer’s recommendation.
Figure 7.14. Installing brake lever
8. Attach the front brake ferrule (Figure 7.15).
Figure 7.15. Front brake ferrule
15
TREK SERVICE INFORMATION
17 July 2013
9. Make sure the guide tube, a plastic sleeve that reduces cable friction (Figure 7.16), is in
place inside the brake ferrule. Install the front brake cable. This will hold the ferrule in
place during the next step.
Figure 7.16. Ferrule and guide tube
10. Dry-fit the aerobar to the stem.
Place the ferrule in the stem . Make sure the tabs on the ferrule engage the cut-out in
the stem.
Note: With the low near, medium near, and high near stems, the housing comes in from the
side so the ferrule must be oriented sideways (Figure 7.17).
With all far stems, the ferrule aligns with the centerline of the stem (Figure 7.18).
Figure 7.17. Ferrule in sideways position
Figure 7.18. Installing the aerobar, ferrule in long
position
11. Adjust the length of the front brake housing as needed.
12. Install the front brake cable through the lever and aerobar housing.
16
TREK SERVICE INFORMATION
17 July 2013
13. Install the mono-extension assembly (mono-extension, pivot cradle, and mono-spacer)
on the aerobar.
With the aerobar in place on the stem, pass the front attachment bolt up through the
stem, the bar, then into the mono-extension assembly (Figure 7.19). Tighten until finger
tight.
Figure 7.19. Tightening front attachment bolt
14. Connect the cables (Figure 7.20) and assemble the aerobar and stem.
Place the ferrule in the stem again. With a double ferrule, connect the rear brake housing
from the aerobar to the frame housing while you slide the rear brake cable through.
Figure 7.20. Housing window in the top tube
15. Connect 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 sure to connect front to front.
To allow space to close the stem cover, push the double ferrules as far as possible
forward or back in the stem, and make sure they are not in contact with the steering axle
or steering axle pinch band.
16. Loosen the front bolt five to six turns to allow the back of the mono-extension assembly
to tilt. This tilt provides clearance for the stem cover to drop into the rear cutout of the
aerobar (Figure 7.21).
Figure 7.21. Spreading the stem cover
17
TREK SERVICE INFORMATION
17 July 2013
17. Secure the stem cover with the two side attachment bolts (Figure 7.22).
Figure 7.22. Housing cover on stem
18. Re-insert the front aerobar attachment bolt and then the two bolts on the side of the
stem (Figure 7.23), and tighten all three bolts to 6-8 Nm.
Note: The side bolts are not on the centerline of the bike, but “lean” inward nearer the top
of the bar.
Figure 7.23. Side attachment bolts go in at an angle
19. If needed, cut to length the shift housings from the mono-extension to the shifters.
20.Install the shifters (Figure 7.24) and cables. Tighten the shifters to the manufacturer’s
recommendation.
Figure 7.24. Tightening shift lever body
18
TREK SERVICE INFORMATION
17 July 2013
8. Arm supports
Tools and materials required
With the aerobars and stem connected to the bike, you are ready to install the arm
supports.
Arm pads
Arm pad
holder bolts
Pad wing
holder bolts
Dog-bone washer
•
2.5 and 3 mm hex wrench
•
Torque wrench
Part
PN
Arm pads, pair
437028
Arm pad holders, pair
437029
Pad wing
W326497
Bolt Kit 437027
Dog-bone washer
Kit 437027
Spacer, 5 mm
W327606
Part
Arm pad holder
Pad wing
Mono-extension
(one of four choices)
Spacer
Figure 8.1. Arm supports
19
TREK SERVICE INFORMATION
17 July 2013
Torque Spec
(Nm)
Top cradle bolts
6-8
Tilt set screw
2
Pad wing bolts
4-5.2
Arm pad holder bolts
2
To Install arm supports
1. Make any final adjustments to the fore/aft position and/or tilt of the of the mono
extension (Figure 8.2).
Do not bottom-out the set screw on the top cradle.
Figure 8.2. Adjusting the tilt and reach of the monoextension assembly
2. After the position is set, tighten the bolts to 6-8 Nm and then tighten the set screw
(Figure 8.3) until it makes contact with the mono-spacer.
Figure 8.3. Tightening the set screw
3. Attach the Pad wing to the mono-extension (Figure 8.4). Tighten to 4-5.2 Nm.
Note: Use any of the attachment points provided. To provide even more positions, the Pad
wing can be installed facing either direction.
Figure 8.4. Attaching Pad wing to mono-extension
4. Using two bolts and a dog-bone washer for each, attach the arm pad holders (Figure
8.5) in one of the many available positions. Tighten to 2 Nm.
Figure 8.5. Installing arm pad holder with dog-bone
washer and two bolts
20
TREK SERVICE INFORMATION
17 July 2013
5. Attach the arm pads to the holders by their hook-and-loop fasteners (Figure 8.6).
Figure 8.6 Arm pad
21
TREK SERVICE INFORMATION
17 July 2013
9. Derailleurs
Tools and materials required
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.
•
Derailleur cable and 4 mm housing
•
Derailleur housing ferrules
•
Housing cutters
•
Torque wrench
•
4 and 5 mm hex wrench
Part
PN
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
Front derailleur
frame grommet
Part
Dropout cable guide/
housing stop
Bottom bracket shift cable guide
Figure 9.1. Speed Concept parts for shift cable routing
22
TREK SERVICE INFORMATION
17 July 2013
Torque Spec
(Nm)
Front derailleur
mounting bolt
Derailleur
manufacturer’s
recommendation
BB cable guide bolt
3
To Install The Front Derailleur
1.
Install the front derailleur with the special spherical washer (Figure 9.2) and tighten to
the manufacturer’s specifications.
Note: The 2014 Speed Concept frame uses an integrated carbon fiber front hanger. This
hanger requires a special spherical washer to allow you to adjust the position of the
derailleur. Do 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.
Figure 9.2. Spherical washer for carbon hanger (required)
2.
Orient the seat tube grommet (Figure 9.3) and then snap the grommet into the frame
hole in the seat tube (Figure 9.4).
Drive side
Figure 9.3. Correct orientation of seat tube grommet
3.
Attach the cable to the derailleur and adjust as normal.
Figure 9.4. Seat tube grommet on cable liner to front
derailleur
To Install The Rear Derailleur
1.
From the bottom bracket cable guide, run the rear derailleur cable through the
chainstay and out the exit hole at the dropout.
2.
Install the dropout housing stop in the dropout exit hole (Figure 9.5).
3.
Measure and cut the rear derailleur housing. Install ferrules on both ends.
4. Install the housing, connect the cable to the derailleur, and adjust the derailleur as
normal.
Figure 9.5. Rear derailleur cable passing through the
dropout housing stop
23
TREK SERVICE INFORMATION
17 July 2013
10. Front Brake
Tools and materials required
The front brake (Figure 10.1) is hidden from the wind and from your eyes. But when correctly
assembled and adjusted, they work very well. The Speed Concept brakes use wedge/roller
actuation, so cable tension is critical.
Before starting this procedure, the front brake cable and housing should be in place after
installing the aerobar.
Brake arm
with roller
•
2, 2.5, and 4 mm hex wrench
•
10 mm socket
•
Torque wrench
•
Pliers or adjustable wrench
•
Cable cutters
Part
PN
Wedge
W331783
Brake
W326964
Pads by rim type
• aluminum rim
Wedge
Cover
Your choice
• carbon rim
431461
Pad carriers, pair
433749
Cover, white x-small
W315982
small W315983
medium W315982
large W315984
x-large W315985
Cover, black x-small
W306643
small W306641
medium W306643
Cover
attachment
bolts
Pads
large W306640
Pad carrier
x-large W306642
Grommets
Cover attachment
bolts (2)
Kit 437032
Grommets (2)
Kit 437032
Figure 10.1. Exploded view of front brake
Part
24
TREK SERVICE INFORMATION
17 July 2013
Torque Spec
(Nm)
Mounting bolts
6-8
Cable clamp
4-5
Pad carrier
6-8
Cover attachment bolts
3
To Install And Adjust The Front Brake
1.
Make sure the E-clip is in the groove on the brake bolt (Figure 10.2)
Figure 10.2. E-clip on brake bolt
2.
Install both brake arms onto the fork (Figure 10.3). Tighten to 6-8 Nm.
Figure 10.3. Tighten the brake bolts
3.
Place the wedge in the “home” position between the rollers (Figure 10.4).
Figure 10.4. Wedge in “home” position between rollers
4. Loosen the cable clamp nut and slide the cable through the wedge (Figure 10.5).
Tighten the cable clamp nut until finger-tight.
Figure 10.5. Cable in wedge
25
TREK SERVICE INFORMATION
17 July 2013
5.
Avoid moving the wedge on the cable. Remove the wedge from the brake. Hold the
wedge by its lower corners while you tighten the cable clamp nut to 4-5 Nm
(Figure 10.6).
Figure 10.6. Tightening the cable clamp nut
6. Cut the brake cable to length. It should not protrude past the spring (Figure 10.7).
Finish the end of the cable so that it will not interfere with the brake return spring.
If you choose to only cut the cable and not dress the end, the extended tunnel of the
wedge prevents immediate fraying of 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 Table 5
below). There should be 1.5 mm between each pad and the rim when the brake is not
engaged.
Make sure the pad carriers are oriented correctly so that the pads do no slide out when
the brake is applied.
Table 5. Brake pad spacing between NEW pads and brake arms
Rim width (mm)
Spacer
placement
19-23
1 x 1 mm inside
24-28
2 x 1 mm outside
Figure 10.8. Insert spacers
8. Align the brake pads (Figure 10.9). Tighten the pad carrier nuts to 6-8 Nm.
Figure 10.9. Brake pad alignment: carrier aligned with
rim, pad face parallel to rim face, slight toe-in
26
TREK SERVICE INFORMATION
17 July 2013
9.
With the centering screws, center the brake (Figure 10.10).
Figure 10.10 Center the brake over the rim
10. Engage the top tab of the cover (Figure 10.11), then place the cover over the brake and
install the cover bolts. Tighten to 3 Nm.
Fork
Tab
Brake cover
Attachment
bolts
Figure 10.11. Attachment points of front brake cover
11. Install the grommets over the cover attachment bolts (Figure 10.12).
Figure 10.12. Brake cover grommets
If needed, you can re-center the brake through the cover (Figure 10.13).
Figure 10.13. Centering screw inside front brake cover
27
TREK SERVICE INFORMATION
17 July 2013
11. Rear Brake
Tools and materials required
The rear brake (Figure 11.1) is inside a cover, under the bottom bracket. There are two covers
from which to choose.
The rear brake uses a wedge/roller actuation, so cable tension is critical.
Before installing the rear brake, the aerobar should be installed with the rear brake cable and
housing in place. The bottom bracket cable guide should also be in place.
Centering
screws
Noodle
•
2, 2.5, and 4 mm hex wrench
•
10 mm socket
•
Torque wrench
•
Pliers or adjustable wrench
•
Cable cutters
Part
PN
Wedge
W331781
Brake
W325747
Pads by rim type
aluminum rim
carbon rim
Noodle (included with
brake)
Cover
Wedge
UCI legal
Di2 threaded insert
Speed Fin
Cover attachment
bolts 10 mm (2)
20 mm
Pad carriers , pair
10 mm cover
attachment
bolts (2)
20 mm cover
attachment
bolt (1)
Cover
Figure 11.1. Exploded diagram of rear brake
28
TREK SERVICE INFORMATION
14 February 2013
Your choice
431461
N/A
W327327
W326750
Kit 437032
Kit 437032
433749
Part
Torque Spec
(Nm)
Mounting bolts
6-8
Cable clamp bolt
4-5
Pad carrier nuts
6-8
Cover attachment bolt,
front
2
Cover attachment bolts,
rear
3
To Install And Adjust The Rear Brake
1.
If needed, remove the brake cover (Figure 11.2).
Figure 11.2. Cover attached with three bolts
2.
If needed, roughly center the brake. Loosen the two bracket attachment bolts (Figure
11.3), center the brake, and retighten the bolts to 6-8 Nm.
Figure 11.3. Brake attached by two bolts
3.
Place the wedge in the “home” position between the rollers (Figure 11.4). Loosen the
cable clamp nut and slide the cable through the wedge. Tighten the cable clamp bolt
until finger tight.
Figure 11.4. Wedge in rollers
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 surfaces of the wedge with a pliers or an adjustable wrench while you
tighten the nut (Figure 11.5). Tighten to 4-5 Nm.
Note: Do not leave the wedge in the brake while you tighten the nut; this will break the
delrin guide on the back of the wedge.
Re-install the wedge.
Do not cut the cable yet. Tuck the cable out of the way.
Figure 11.5. Holding the wedge while tightening the
cable clamp nut
29
TREK SERVICE INFORMATION
17 July 2013
5.
Insert the correct brake pads and set the pad spacers (Figure 11.6, and see Table 6
below). There should be 2 mm between each pad and the rim when the brake is not
engaged
Make sure the pad carriers are oriented correctly so that the pads do no slide out when
the brake is applied.
Table 6. Brake pad spacing between NEW pads and brake arms
Rim width
(mm)
Spacer
placement
19-23
1 x 1 mm inside
24-28
2 x 1 mm outside
Figure 11.6. Changing spacers
6. Align the brake pads (Figure 11.7). Tighten the pad carrier nuts to 6-8 Nm.
Figure 11.7. Brake pad alignment: carrier aligned with
rim, pad face parallel to rim face, slight toe-in
7.
With the left and right 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 11.8. Centering the left and right brake pads.
8. Size and cut the cable (Figure 11.9).
Finish the end of the cable so that it will not interfere with the brake return spring.
If you choose to only cut the cable and not dress the end, the extended tunnel of the
wedge prevents immediate fraying of the cable.
If desired, solder the end. Or install a cable crimp, then bend it downward.
Figure 11.9. Cut cable should not extend past spring.
30
TREK SERVICE INFORMATION
17 July 2013
9.
Install the front (20 mm) brake cover attachment bolt (Figure 11.10). Tighten to 2 Nm.
Figure 11.10. Attaching the rear brake cover with front
20 mm bolt
10. Install the two rear (10 mm) brake cover attachment bolts (Figure 11.11).
Tighten to 3 Nm.
Figure 11.11. Attaching the rear brake cover with two 10
mm bolts
If needed, you can re-center the brake through the window of the cover (Figure 11.12). Both
centering screws are accessible through this window.
Figure 11.12. Centering the rear brake with cover
installed, and without.
31
TREK SERVICE INFORMATION
17 July 2013
12. DuoTrap Computer Sensor
Tools and materials required
•
Phillips-head screwdriver
The 2014 Speed Concept frame includes a special pocket on the left chainstay for the
Bontrager DuoTrap sensor, which combines speed and cadence sensing in a single, wireless
unit (Figure 12.1).
Part
PN
DuoTrap sensor
426618
Rubber plug
296415
Cover /plug
411777
Part
Attachment bolt
Torque Spec
(Nm)
0.6-0.8
Figure 12.1. DuoTrap sensor
To Install 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.
Rubber plug
Figure 12.2. Location of attachment bolt
2.
Slide the cylindrical part of the sensor through the chainstay (Figure 12.3) until the
sensor sits flush with the surface of the chainstay.
3.
Install the attachment bolt and tighten to 0.6-0.8 Nm.
4. Place the rubber plug over the attachment bolt.
Figure 12.3. Sliding the speed cylinder of a DuoTrap
sensor through the chainstay
32
TREK SERVICE INFORMATION
17 July 2013
13. Accessories
Tools and materials required
•
4 mm hex wrench
•
Torque wrench
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
onto a removable track that attaches to the frame with two mounting bolts.
Part
PN
Draft Storage Box
433746
Part
Attachment bolt
Torque Spec
(Nm)
2-3
Figure 13.1. Draft Storage Box
1.
Place the track so that the spring-loaded button is at the bottom and on the non-drive side
of the bike. Insert two bolts through the track (Figure 13.2) and tighten to 2-3 Nm.
Figure 13.2. Attaching the track to the rear of the seat
tube. Note orientation of spring-loaded button.
2.
Align the draft box on the top of the track and slide it down the track (Figure 13.3).
Push the box down until it clicks into place on the track.
To release the box, press the button and slide the box up the track.
Figure 13.3. Sliding the draft box down the track
33
TREK SERVICE INFORMATION
17 July 2013
To Install A Speed Box
This box is placed on the top of the top tube (Figure 13.4). The box attaches to the frame
with two mounting bolts.
Tools and materials required
•
4 mm hex wrench
•
Torque wrench
Part
PN
Speed Box
436152
Part
Attachment bolt
Figure 13.4 Speed Box
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 top tube.
Tighten to 2-3 Nm.
34
TREK SERVICE INFORMATION
17 July 2013
Torque Spec
(Nm)
2-3
To Install A Bottle Cage
The custom Speed Concept bottle cage attaches to the mono-extension via a cage mount,
which allows a variety of positions. The cage includes an integrated computer mount.
Tools and materials required
•
3 and 4 mm hex wrench
•
Torque wrench
Part
PN
Bottle cage
436151
Computer mount
436163
Part
Torque Spec
(Nm)
Cage attachment bolt
Mount attachment
bolt
Figure 13.5 Speed Concept bottle cage
1.
Insert 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 monoextension
2.
Select a location for the cage and insert two bolts (Figure 13.7). Tighten to 3 Nm.
Figure 13.7. The cage can be attached at a choice of
locations
35
TREK SERVICE INFORMATION
17 July 2013
3
5.2
3.
Choose a method 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).
Figure 13.8. Computer mounts
Figure 13.9. Computer mounts
36
TREK SERVICE INFORMATION
17 July 2013
14. Crankset
The Speed Concept uses the same bearing system as a Madone; there are no parts that
thread into the frame. Instead, the bearings are a slip-fit into the frame. However, the Speed
Concept uses the new tighter fit of the bearings, which may require using a headset press
(see page 28). Do not use a hammer to install the bearings into the frame. If the bearing fit
is too tight, make sure the bearing seats are clean and free of debris.
Part
PN
Axle shield (two
pieces)
281823
Bearings kits are available for all major brand of cranksets: SRAM/TruVativ/Bontrager GXP,
Shimano HollowTech, Campagnolo UltraTorque, and FSA MegaExo. Each kit includes a
slightly different set of bearings, seals, and spacers. When installing other crankset systems,
follow the manufacturer’s instructions to achieve the correct assembly and adjustment.
To Install The Axle Shields
All bottom bracket systems share the same procedure to install the bottom bracket shields.
Do these steps before installing the bearings.
Your frame may already have the axle shields installed in the frame.
1.
Apply a light coat of grease to the male axle shield (smaller diameter, Figure 14.1).
Figure 14.1. Applying grease to the axle shield
2.
Place the male axle shield into the bottom bracket shell from the drive side (Figure
14.2).
3.
Place the female (larger diameter) axle shield into the bottom bracket shell from the
non-drive side.
Figure 14.2. Inserting one half of the axle shield into
frame
4. With a headset press (Figure 14.3), push together the two halves of the axle shield.
When they are inserted in the correct position, there will be an audible click.
5.
To install the bearings for your choice of crankset, go to the instructions on the
following pages.
Figure 14.3. Release tab
37
TREK SERVICE INFORMATION
17 July 2013
Pressing Crankset Bearings
The bearing fit is tighter in the Speed Concept than in early Madone models. If the bearings
do not slip in by hand, follow this procedure after you have installed the bearing shield
(page 28).
Notes:
• Be very careful when using the press. Too much force can crack the bottom bracket shell.
• Press in one bearing at a time.
Tools required
Installation
• Park Bearing Removal Tool BBT-90
• Brass punch
• Hammer
To Press A Bearing
1.
Install the bearing shield.
2.
Apply a liberal coat of grease to the contact surfaces of one bearing and the drive side
of the bottom bracket shell (Figure 14.4).
3.
Press 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.
Figure 14.4. Greasing the bearing and the frame saddle
6. Press the bearing into the bottom bracket shell until the bearing is flush with the shell.
To Remove A Bearing
If you cannot remove a bearing because it is stubborn, follow these directions.
1. Remove the crankset.
Figure 14.5. Using a headset press to install the bearings
2.
Slide the Park Bearing Removal Tool BBT-90 through one side of the bottom bracket
shell to the back side of the bearing.
3.
Position the punch on the inside ring of the bearing.
4. Gently tap the punch with the hammer, then move 90 degrees around the bearing and
tap again.
5.
Continue tapping and moving around the bearing. TAP GENTLY.
6. Go around the bearing and keep tapping.
DO NOT HIT HARD. Excessive force can damage the bottom bracket shell.
38
TREK SERVICE INFORMATION
17 July 2013
SRAM GXP
These instructions explain how to install a SRAM/TruVativ/Bontrager GXP crankset (Figure
1) in a new Speed Concept. To complete the installation, you will also need the SRAM
instructions, available at: http://www.sram.com/_media/techdocs/2005_gxp-05-r5-e.pdf
Part Description SRAM
Kit
404700
Ceramic kit
411814
Tools And Materials Required
• Crankset and bottom bracket
• 8 mm hex wrench
• Bearing installation tool PN 404694
• Rock “N” Roll Super Coat grease
• Bottom bracket parts
• TruVativ GXP installation instructions
Wave washer
Figure 14.6. SRAM bearing set
39
TREK SERVICE INFORMATION
17 July 2013
Seal
Bearing
Bearing with lip (facing in)
Metal seal
To Install The Bearings
1.
Apply a liberal coat of grease to the contact surfaces of one bearing and the drive side
of the bottom bracket shell (Figure 14.7).
Figure 14.7. Greasing the bearing and the frame saddle
2.
Slide a bearing 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.
Figure 14.8. Grease on the frame and the non-drive side
bearing (with the lip facing in)
3.
Press one bearing into the drive side of the bottom bracket shell (Figure 14.9).
4. Repeat steps 1-3 for the other bearing on the non-drive side.
Figure 14.9. Pressing the bearing into the frame
To Install The Drive-Side Crankarm
When handling the seals, avoid bending them. A bent seal will rub on the bearing, creating
drag.
1.
Apply a light coat of grease to the bearings on the face and the axle contact surface.
2.
Apply a light coat of grease to the metal inside of one bearing seal (Figure 14.10).
Figure 14.10. Greasing the bearing covers
40
TREK SERVICE INFORMATION
17 July 2013
3.
Install the wave washer and with the grease facing up, slide the bearing seal onto the
axle (Figure 14.11).
Figure 14.11. Sliding the wave washer and bearing cover
onto the axle
4. Apply a light coat of grease to the bearing contact area of the axle (Figure 14.12).
The grease areas should be about 1 inch (25 mm) wide. On the drive side, start at the
bearing seal. On the non-drive side, start at the splines and apply toward the drive side
of the axle.
Figure 14.12. Greasing the axle
5.
Insert the axle through the drive-side bearing in the bottom bracket (Figure 14.13).
Figure 14.13. Sliding the axle through the bearings
To Install The Non-Drive 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 TruVativ GXP installation instructions to complete to install the non-drive
crank arm.
4. Tighten the crank bolt to the torque specifications (see page 38).
5.
41
Follow the steps in “Inspecting the bottom bracket.”
TREK SERVICE INFORMATION
17 July 2013
Figure 14.14. Metal bearing cover in place over the
bearing
To Remove The Bottom Bracket Bearings
The Speed Concept bottom bracket bearing system is designed to be a slip fit. However,
after the first installation some bearings might be tight. If the bearings do not easily come
out 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.
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 the chain from the chainrings.
2.
Rotate the crank so that one of the arms is parallel to the seat tube.
3.
Put one hand on the crank arm and one hand on the seat tube, and attempt to move
the crank arm laterally toward and away from the seat tube.
4. Spin the cranks.
If the crank feels or sounds loose, or if the motion stops abruptly or you hear a grinding
noise coming from the bearings, readjust the bearings or take the bike to your Trek dealer.
42
TREK SERVICE INFORMATION
17 July 2013
Shimano HollowTech
These instructions explain how to install a Shimano HollowTech (Figure 1) in a new Speed
Concept. To complete the installation, you will also need the Shimano instructions, available
at: http://techdocs.Shimano.com/media/techdocs/content/cycle/SI/Dura-Ace/FC-78007803/SI_1F30H_En_v1_m56577569830605111.pdf.
Part
description
Shimano
Kit
404699
Ceramic kit
411813
Tools and materials required
1. • Crankset and bottom bracket
2. • Shimano FC16 crank arm installation tool
3. • 5 mm Hex Wrench
4. • Bearing installation tool PN 404694
5. • Rock “N” Roll Super Coat grease
6. • Bottom bracket parts
Seal
Figure 14.15. Shimano bearing set
43
TREK SERVICE INFORMATION
17 July 2013
Bearing
Bearing
Seal
To Install The Bearings
1.
Apply a liberal coat of grease to the contact surfaces of one bearing and the drive side
of the bottom bracket shell (Figure 14.16).
2.
Slide a bearing onto the installation tool.
Either side of the bearing is the “right side.”
Figure 14.16. Greasing the bearing and the frame seat
3.
Press one bearing 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.
Figure 14.17. Pressing the bearing into the frame
To Install The Drive-Side Crankarm
When handling the seals, avoid bending them. A bent seal will rub on the bearing, creating
drag.
1.
Apply a light coat of grease to the bearings on the face and the axle contact surface.
2.
Apply a light coat of grease to the metal inside of one bearing seal (Figure 14.18).
Figure 14.18. Greasing the bearing covers
3.
With the grease facing up, slide the bearing seal onto the axle (Figure 14.19).
Figure 14.19. Sliding the bearing cover onto the axle
44
TREK SERVICE INFORMATION
17 July 2013
4. Apply a light coat of grease to the bearing contact area of the axle (Figure 14.20).
The grease areas should be about 1 inch (25 mm) wide. On the drive side, start at the
bearing seal. On the non-drive side, start at the splines and apply toward the drive side
of the axle.
Figure 14.20. Greasing the axle
5.
Insert the axle through the drive-side bearing in the bottom bracket (Figure 14.21).
Figure 14.21. Sliding the axle through the bearings
To Install The Non-Drive Side Crankarm
1.
Apply a 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 on the axle and slide the crank onto the
axle.
The non-drive crank arm should point 180 degrees opposite of the drive-side crank
arm.
Figure 14.22. Pressing in the second bearing cover
4. With the plastic installation tool, press the crank onto the axle (Figure 14.23) as far as
it will go.
5.
Release the installation tool and spin the cranks 10 to 20 revolutions.
6. Follow the Shimano instructions to complete the installation.
7.
Follow the steps in “Inspecting the bottom bracket.”
Figure 14.23. Pressing the crank arm onto the axle
45
TREK SERVICE INFORMATION
17 July 2013
To Remove The Bottom Bracket Bearings
The Speed Concept bottom bracket bearing system is designed to be a slip fit. However,
after the first installation some bearings might be tight. If the bearings do not easily come
out by hand, you may use the following method to remove them.
1. 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. 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.
Lift the chain from the chainrings.
2.
Rotate the crank so that one of the arms is parallel to the seat tube.
3.
Put one hand on the crank arm and one hand on the seat tube, and attempt to move
the crank arm laterally toward and away from the seat tube.
4. Spin the cranks.
If the crank feels or sounds loose, or if the motion stops abruptly or you hear a grinding
noise coming from the bearings, readjust the bearings or take the bike to your Trek
dealer.
46
TREK SERVICE INFORMATION
17 July 2013
Campagnolo UltraTorque
The Speed Concept uses a special bearing system that has no parts that thread into
the frame. Instead, the bearings are a slip-fit into the frame. However, the Campagnolo
UltraTorque system requires you to attach bearing supports (seal seats) to the Speed
Concept bottom bracket shell (Figure 1). This section explains how to do that.
Part Description Campagnolo
Kit
The seal seats might fit into the frame tightly. In this case, you might need to tap the cups
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 seal seats are clean and free of debris.
Tools And Materials Required
To complete the installation, you will need the Campagnolo instructions, available at: http://
www.campagnolo.com/pdf/7225306_Ultra_torque_05_07.pdf.
Also read the warning: http://www.campagnolo.com/pdf/7225365_warning_Ultra_
Torque_0607.pdf
• Crankset and bottom bracket (bearings come pressed onto the axle halves)
• Plastic crank arm installation tool
• LocTite® 638 retaining compound, TCG 408082
• LocTite® primer 7649, TCG 408083
• 5 mm Hex Wrench
• Rock “N” Roll Super Coat grease
• Bottom bracket parts
Wave washer
Bearing
Washer
Figure 14.24. Campagnolo bearing set
47
TREK SERVICE INFORMATION
17 July 2013
Seal seat
Washer
Bearing
407383
To Install The Seal Seats
1.
Clean all surfaces to be bonded (bottom bracket shell, seal seats) with alcohol wipes or
similar (Figure 14.25).
Figure 14.25. Cleaning bonding surfaces with an alcohol
wipe
2.
Apply a thin film of LocTite 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 seal seat that contacts the bottom bracket shell.
Figure 14.26. Applying LocTite primer to the outer step
of the bearing cups
4. Press the seal seat into the frame (Figure 14.27). If needed, tap lightly with a soft-faced
mallet.
Let the LocTite cure for at least 24 hours before inserting the bearings.
Figure 14.27. Inserting the bearing cups into the bottom
bracket shell
To Install The Non-Drive Side Bearings
1.
Insert a washer into the non-drive side seal seat.
2.
Apply a liberal coat of grease to the contact surfaces of the bearing (Figure 14.28) and
the non-drive side seal seat (Figure 14.29).
Figure 14.28. Greasing the bearings
48
TREK SERVICE INFORMATION
17 July 2013
Figure 14.29. Greasing the bearing cups
3.
Insert the wave washer into the non-drive side seal seat (Figure 14.30).
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).
Figure 14.31. Inserting the non-drive side axle
To Install The Drive Side Bearings
1.
Insert a washer into the drive side seal seat.
2.
Apply a liberal coat of grease to the contact surfaces of the bearing (Figure 14.32) and
the drive side seal seat (Figure 14.33).
Figure 14.32. Tightening the axle bolt
49
TREK SERVICE INFORMATION
17 July 2013
3.
Slide the drive side axle through the seal seat and bottom bracket shell (Figure 9).
4. Line up the splines of the bottom bracket axle and press the axle together. If necessary,
tap the ends together with the heel of your palms.
5.
Insert the crank bolt from the drive side (Figure 10) and tighten to the torque
specifications (see page 38).
6. Follow the steps in “Inspecting the bottom bracket.”
To Remove The Bottom Bracket Bearings
With the Campagnolo system, each of the two bearings 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 bracket adjustment.
To Check The Bottom Bracket Bearing Adjustment
1.
Lift the chain from the chainrings.
2.
Rotate the crank so that one of the arms is parallel to the seat tube.
3.
Put one hand on the crank arm and one hand on the seat tube, and attempt to move
the crank arm laterally toward and away from the seat tube.
4. Spin the cranks.
If the crank feels or sounds loose, or if the motion stops abruptly or you hear a grinding
noise coming from the bearings, readjust the bearings or take the bike to your Trek
dealer.
50
TREK SERVICE INFORMATION
17 July 2013
FSA MegaExo AL
Part Description FSA
These instructions and parts are for the aluminum FSA cranks only. The current “B” kit will
not work for FSA carbon cranks.
BB90 bearing kit “B”
The Speed Concept uses a special bearing system that has no parts that thread into the
frame. Instead, the bearings are a slip-fit into the frame (Figure 11). This section explains
how to install the bearings and crankset.
The bearings might fit into the frame tightly. In this case, you might need 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 Materials Required
To complete the installation, you will also need the FSA instructions, available at:
http://www.road.fullspeedahead.com/downloadfly.aspx?download=downloads/
Install_MegaExoAlloy.pdf.
• Crankset and bearings (bearing shields come pressed onto the bearings)
• 5 mm Hex Wrench
• Rock “N” Roll Super Coat grease
• Bottom bracket parts
Bearing with shield pressed on
Bearing with shield pressed on
Figure 14.33. FSA bearing set
51
TREK SERVICE INFORMATION
17 July 2013
293227
To Install The Bearings
1.
Apply a liberal coat of grease to the contact surfaces of one bearing and the drive side
of the bottom bracket shell (Figure 14.34).
Figure 14.34. Greasing the bearing and the frame saddle
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.
Figure 14.35. Pressing the bearing into the frame with
the shield on the outside
To Install The Drive-Side Crankarm
1.
Apply a light coat of grease to the axle surface where the bearings will be in contact
(Figure 14.36).
The grease areas should be about 1 inch (25 mm) wide. On the drive side, start at the
bearing seal. On the non-drive side, start at the splines and apply toward the drive side
of the axle
Figure 14.36. Greasing the axle
2.
Insert the axle through the drive-side bearing in the bottom bracket (Figure 14.37).
Figure 14.37. Sliding the axle through the bearings
52
TREK SERVICE INFORMATION
17 July 2013
To Install The Non-Drive Side Crankarm
1.
Align the non-drive crank arm with the groove on the axle and slide the crank onto the
axle.
The non-drive crank arm should point 180 degrees opposite of the drive-side crank
arm.
2.
Install the FSA crank bolt and tighten to their torque specifications (Figure 14.38).
3.
Follow the FSA instructions to complete the installation.
4. Follow the steps in “Inspecting the bottom bracket.”
Figure 14.38. Pressing the crank arm onto the axle
To Remove The Bottom Bracket Bearings
The Speed Concept bottom bracket bearing system is designed to be a slip fit. However,
after the first installation some bearings might be tight. If the bearings do not easily come
out 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.
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.
Lift the chain from the chainrings.
2.
Rotate the crank so that one of the arms is parallel to the seat tube.
3.
Put one hand on the crank arm and one hand on the seat tube, and attempt to move
the crank arm laterally toward and away from the seat tube.
4. Spin the cranks.
If the crank feels or sounds loose, or if the motion stops abruptly or you hear a grinding
noise coming from the bearings, readjust the bearings or take the bike to your Trek
dealer.
53
TREK SERVICE INFORMATION
17 July 2013
Crankset Troubleshooting
This section describes problems that occasionally occur, and possible solutions. If these
solutions do not solve a problem, contact Customer Service.
Bearing Play In A GXP Crank Or Bottom Bracket Assembly
The crank feels loose when grasped at the pedal end and rocked side-to-side.
Cause
Solution
Wave washer not
compressed fully
First, verify that the crank has been tightened to the torque
specifications (see page 38). Most issues with play in
GXP crankarms are resolved when the arms are properly
tightened.
This is usually caused by
insufficient torque on the nondrive crank arm.
In rare instances a tolerance stack
can be created by the five critical
parts: non-drive bearing, drive
bearing, drive-side seal, bottom
bracket shell, and axle length.
If this does not solve the issue, add a 0.5 mm washer/spacer
(PN 294162) between the wave washer and seal
(Figure 14.39) to increase the bearing preload.
Spline of GXP crankarm is
undersized
Remove the crankarm and re-install with plenty of grease.
Verify that the crank has been tightened to the torque
specifications (see page 38).
• We have seen some variation in
the tolerance of GXP crankarms.
• If the installation torque is not
sufficient, the crank arm will not
completely compress the shield
and bearing race.
54
Re-check the bearings after installation. The GXP axle
spline is tapered, so it requires that the crank be completely
tightened to seat on the axle.
TREK SERVICE INFORMATION
17 July 2013
Spacer
Wave washer
Seal
Figure 14.39. SRAM bearing set
Bearing
Crank Is Rubbing Or There Is Excessive Drag
If you notice that the crank arms rotate poorly, there are several possible issues.
Cause
Solution
Out of spec or bent non-drive metal seal
Install a new metal seal (same Part
Number: 282865). We have revised the
metal seal by adding a ring of material,
0.3 mm thick, to the seal around the inner
diameter. This will move the outer edge of
the seal away from the bearing.
• The inside chamfer of the metal seal (Figure 14.40)
rubs on the outer race of the bearing.
• The metal seal deforms under the compressive load
of the non-drive arm and rubs on the outer race of the
bearing.
Bearing not seated properly
• The axle shield might not be seated completely in the
frame (Figure 14.41) causing the flange of the shield to
foul the bearing.
• A tight bore can cause the installer to think the bearing
is seated when it is not.
Make sure the halves of the axle shield
are snapped together, and then remove
and reinstall the bearing. When properly
installed the bearing will not sit even with
bottom bracket shell.
Metal seal
Figure 14.40. SRAM bearing set
•Enduro bearing: 0.75 mm inside the shell.
•GXP non-drive bearing: 0.25 mm outside
the shell
Figure 14.41. Inserting one half of the axle shield into
frame
55
TREK SERVICE INFORMATION
17 July 2013
Download PDF

advertising