Bontrager SPEED LIMIT ROAD BRAKESETS Owner`s manual
Contents
1. Wave washer not First verify that the crank has been tightened to the torque compressed fully specifications see page 38 Most issues with play in This is usually caused b insufficient ne on ras Agi GXP crankarms are resolved when the arms are properly drive crank arm y tightened In rare instances a tolerance stack can be created by the five f this does not solve the issue add a 0 5mm washer spacer critical parts non drive bearing drive bearing drive side seal PN 294162 between the wave washer and seal Figure 1 bottom bracket shell and axle length to increase the bearing preload Spline of GXP crankarm is Remove the crankarm and re install with plenty of grease undersized Verify that the crank has been tightened to the torque We have seen some variation in ey n the tolerance of GXP crankarms specifications see page 38 Ifthe installation torque isnot Re check the bearings after installation The GXP axle sufficient the crank arm will not completely compress the shield spline is tapered so it requires that the crank be completely and bearing race tightened to seat on the axle 33 TREK SERVICE INFORMATION 24 May 2010 Spacer Wave washer Seal Bearing Figure 1 SRAM bearing set Q m Crank is rubbing or there is excessive drag If you notice that the crank arms rotate poorly there are several possible issues Out of spec or bent non drive metal seal The inside2. and the drive side of the bottom bracket shell Figure 11 2 With the plastic bearing shield facing out press one bearing into the drive side of the bottom bracket shell Figure 12 3 Repeat Steps 1 2 for the other bearing on the non drive side 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 13 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 2 Insert the axle through the drive side bearing in the bottom bracket Figure 14 31 TREK SERVICE INFORMATION 24 May 2010 N Figure 11 Greasing the bearing and the frame saddle rS Figure 12 Pressing the bearing into the frame with the shield on the outside Figure 13 Greasing the axle yN Figure 14 Sliding the axle through the bearings WV TREK 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 15 3 Follow the FSA instructions to complete the installation 4 Follow the steps in Inspecting the bottom bracket To remove the bottom bracket bearings T
3. chamfer of the metal seal Figure 2 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 oufer race of the bearing Bearing not seated properly e The axle shield might not be seated completely in the frame Figure 3 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 Install a new metal seal same Part Number 282865 We have revised the metal seal by adding a ring of material 0 3mm thick to the seal around the inner diameter This will move the outer edge of the seal away from the bearing 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 Enduro bearing 0 75mm inside the shell GXP non drive bearing 0 25mm outside the shell GXP triple crankset can t be properly preloaded Although some cranksets change the arm configuration to add clearance for a third chainring the GXP crankset uses a longer axle Without additional spacers a longer axle will not compress the bearing Different axle lengths require different spacers Triple GXP crank axles are 5mm longer than doubles 34 TREK SERVICE INFORMATION 24 May 2010 Install a 5mm thick spacer Part Number 291276 between the wave washer and the red be
4. one bearing seal Figure 4 Install the wave washer and with the grease facing up slide the bearing seal onto the axle Figure 5 Apply a light coat of grease to the bearing contact area of the axle Figure 6 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 Insert the axle through the drive side bearing in the bottom bracket Figure 7 21 TREK SERVICE INFORMATION 24 May 2010 Figure 1 Greasing the bearing and the frame saddle Figure 2 Grease on the frame and the non drive side bearing with the lip facing in Figure 4 Greasing the bearing covers WV TREK 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 8 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 Follow the steps in Inspecting the bottom bracket 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
5. the housing Note Only 4mm housing will fit into the derailleur housing stops 1 Detach the bottom bracket cable guide 2 Slide a piece of 4mm shift housing through the top tube housing window Figure 1 down the down tube and into the non drive shift housing stop in the bottom bracket cable guide To determine the length of housing use the previous piece as a guide or install a new 1500mm piece that you will resize later 3 Leave the housing long do not cut it Where the upper end of the housing exits the top tube mark it with a piece of tape This is to differentiate it from the rear housing 4 Slide a piece of 4mm shift housing through the top tube housing window down the down tube and into the drive side shift housing stop in the bottom bracket cable guide To determine the length of housing use the previous piece as a guide or install a new 1500mm piece that you will resize later 5 Slide a piece of brake housing through the top tube housing window down the down tube and out of the bottom bracket Figure 2 The housing should be in the middle between the two derailleur housing stops To determine the length of housing use the previous piece as a guide or install a new 700mm piece that you will resize later 6 Leave the housing long do not cut it yet 7 Re install the bottom bracket cable guide TA TRefAll IKA Fi O install the ru There is a seal or rubber grommet that seals around the ho
6. 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 22 TREK SERVICE INFORMATION 24 May 2010 Figure 5 Sliding the wave washer and bearing cover onto the axle Figure 6 Greasing the axle 4 Figure 7 Sliding the axle through the bearings md Figure 8 Metal bearing cover in place over the bearing WV TREK Shimano HollowTlech Tools and materials required These instructions explain how to install a Shimano HollowTech Figure 1 in a new Speed Crankset and bottom bracket Concept To complete the installation you will also need the Shimano instructions available Shimano FC16 crank arm installation tool at http techdocs Shimano
7. K Using a Repair Stand Use special care when putting the new Speed Concept frame in a workstand The only accepted or recommended method is to use the special workstand clamp adapter designed specifically for this frameset Figure 1 The adapter clamps only to the seatpost which must be installed first 1 Open the workstand clamp adapter Figure 1 2 Wrap the adapter around the seatpost If needed extend the seatpost to provide room for the adapter 3 Insert the base of the seatpost clamp in the workstand Tools and materials required Workstand Workstand clamp adapter PN 403494 includes pads PN 416102 Figure 1 Seatpost clamp WV TREK Headset Bearings and Fork This section explains how to install the integrated fork on the Speed Concept bike including removing and installing the headset bearings If the fork is already in the bike you can go to the next section installing the housings Although you can replace the fork without disconnecting the derailleur cables and rear brake cable this procedure may be easier with the cables disconnected These instructions explain the steps without removing these cables rmamrnsin tap AN NIAAA A TA O SITIO V c IIS poearnngs Pinch bolt 1 Disconnect the front brake cable 2 Loosen and remove the four aerobar attachment screws Figure 1 and remove the aerobar Loosen the pinch bolt that clamps the steering axle nut F
8. WV TREK drive side seal seat Figure 6 3 Slide the drive side axle through the seal seat and bottom bracket shell Figure 8 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 9 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 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 29 TREK SERVICE INFORMATION Figure 6 Greasing the bearing cups Figure 7 Inserting the Wave washer after the washer on the non drive side A Figure 8 Inserting the non drive side ax
9. Y TREK Service Information The Trek Speed Concept bike is the fastest frameset we have ever made To accomplish this we have used shaped tubes hidden front and rear brakes and very thin walled carbon tubes Because of these unique features the Speed Concept bike requires different or additional assembly and adjustment techniques Some of the tasks 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 We have also provided general maintenance information Carbon fiber care Headset bearing installation Bottom bracket bearing installation for a variety of bottom bracket types Note Instructions for Shimano s electronic Di2 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 Please save these instructions for future reference Also check www trekbikes com for updates 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 co
10. al carbon prep products Tacx carbon assembly compound Fiber Grip carbon fiber assembly gel from Finish Line 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 may make the bike unsafe As an example removing the redundant wheel retention tabs on fork tips could make the fork less functional Suspension forks can add stress to a bike frame Never add a suspension fork to a road bike or change style and or length of forks If you are unsure if a fork is compatible with a frame call Trek customer service 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 WV TREK Custom Components of the Speed Concept 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 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 req
11. and note the position of the wedge on the cable continued 14 TREK SERVICE INFORMATION 24 May 2010 Noodle y Cover Mounting bracket Wedge Arm with roller Booster Cover attachment screws Figure 1 Exploded diagram of rear brake Figure 2 Wedge and rollers Attachment screws Figure 3 Cover for rear brake Bracket attachment bolts Figure 4 Brake bracket attached to frame Q m Rear brake cont 5 Remove the wedge from the rollers move the wedge up the cable about 1 mm and tighten the cable clamp bolt Hold the top and bottom surfaces of the wedge with a pliers or an adjustable wrench while you tighten the nut Figure 5 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 6 Re install the wedge Do not cut the cable yet Tuck the cable out of the way 7 Set the pad spacers see Table 5 below and align the brake pads with the rim The rear brake does not have a centering screw To move the brake side to side loosen the bracket attachment bolts reposition the brake and re tighten the bolts Figure 5 Holding the wedge while tightening the cable clamp nut Table 5 Brake pad spacing between pads and brake arms mm for two pad types Rim Brake pad type width Rubber Cork mm Figure 6 Brake booster rear brake only 8 If needed re c
12. ar derailleur housing Install the housing connect the cable to the derailleur and adjust the derailleur as normal Cable liner Figure 1 Cable liner for front derailleur in bottom bracket cable guide Drive side Figure 2 Correct orientation of seat tube grommet Figure 3 Seat tube grommet on cable liner to front derailleur Figure 4 Rear derailleur cable passing through the dropout housing stop WV TREK Front Brake The front brake on the Speed Concept bike Figure 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 Figure 2 so cable tension is critical The design of the front and rear brake design is different so the instructions are also Follow the steps carefully in order L L lo install and adjust the front brake 1 Place a ferrule on the end of the housing to be inserted in the aerobar 2 Slide the housing through the aerobar The routing varies according to the stem size see Figure 3 or Figure 4 continued 12 TREK SERVICE INFORMATION 24 May 2010 P Wedge Arm with roller attachment screws Figure 1 Exploded view of front brake Figure 2 Wedge between rollers PR Figure 3 Housing and cable route through aerobar for low near and medium near stems a Figure 4 Housing route t
13. aring seal Figure 4 Metal seal Figure 2 SRAM bearing set Figure 3 Inserting one half of the axle shield into frame Spacer Seal Bearing lave washer Figure 4 SRAM bearing set
14. bon fiber parts are different from metal parts so they require different treatment 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 Clean carbon parts before installation With some interfaces of metal parts grease is used on the clamping surfaces to prevent corrosion When making adjustments always grease the threads and shoulders of bolts Grease reduces corrosion and allows you to achieve the correct tightness without damaging tools However 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 When assembling parts that clamp a carbon surface we recommend applying one of the following speci
15. coat of grease to the bearings on the face and the axle contact surface Apply a light coat of grease to the metal inside of one bearing seal Figure 4 With the grease facing up slide the bearing seal onto the axle Figure 5 Apply a light coat of grease to the bearing contact area of the axle Figure 6 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 Insert the axle through the drive side bearing in the bottom bracket Figure 7 25 TREK SERVICE INFORMATION 24 May 2010 Figure 4 Greasing the bearing covers Figure 6 Greasing the axle Figure 7 Sliding the axle through the bearings Q m 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 8 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 4 With the plastic installation tool press the crank onto the axle Figure 9 as far as it will go r r Figure 8 Pressing in the second bearing cover 5 Release the installation tool and spin the cranks 10 to 20 revolutions s 6 Follow the Shimano instructions to
16. com media techdocs content cycle SI Dura Ace FC 7800 7803 SI _1F30H_En_v1_m56577569830605111 pdf 5 mm Allen Wrench Bearing installation tool PN 404694 Rock N Roll Super Coat grease Bottom bracket parts e yo Seal Bearing Bearing Seal Figure 1 Shimano bearing set Part description Shimano Kit 404699 Ceramic kit 411813 Drive side parts 281824 295213 Bearing Ceramic bearing 281820 281823 Seal Axle shield Wave washer Non drive side parts 281824 295213 Bearing Ceramic bearing 281820 281822 Seal Axle shield 23 TREK SERVICE INFORMATION 24 May 2010 WV TREK 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 2 2 Slide a bearing onto the installation tool Either side of the bearing is the right side 3 Press one bearing into the drive side of the bottom bracket shell Figure 3 To remove the installation tool press the release tab Figure 3 4 Repeat steps 1 3 for the other bearing on the non drive side 24 TREK SERVICE INFORMATION 24 May 2010 Figure 2 Greasing the bearing and the frame seat Figure 3 Pressing the bearing into the frame Q m To install the drive side crankarm When handling the seals avoid bending them A bent seal will rub on the bearing creating drag 1 2 3 Apply a light
17. complete the installation 7 Follow the steps in Inspecting the bottom bracket 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 Figure 9 Pressing the crank arm onto the axle 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 26 TREK SERVICE INFORMATION 24 May 2010 WV TREK Campagnolo Ultralorque 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 Cam
18. e Speed Concept seatpost has an aerodynamic shape Figure 1 so cannot be turned or reversed in the frame However the head of the seatpost is reversible to allow for a wide variety of seating positions The seatpost can be inserted dry or with carbon prep on the part that is inside the frame If the seatpost does not provide enough adjustment an optional head for the seatpost is available with a different setback see Table 1 below 1 Select a seatpost from Table 1 below Table 1 Seatpost lengths and setbacks Seatpost PN Setback mm Length mm 275 421511 10 335 421512 Head only 419629 275 419097 35 335 419096 Head only 419630 Grease the threads of the wedge bolt Figure 2 Re install the bolt Wipe excess grease from the clamp u a wN Insert the seatpost and tighten the wedge bolt IO reverse TNe seaTtoosT Neda 1 Loosen and remove the two head bolts Figure 3 2 Remove the head turn it around and re insert it into the seatpost 3 Grease the threads insert the bolts and tighten 1 Loosen the wedge bolt 2 Slide the post up or down as necessary 3 Make sure the minimum insertion mark is inside the frame 4 Tighten the wedge bolt Tools and materials required 5 mm allen wrench Park Polylube 1000 grease Figure 1 Speed Concept seatpost Figure 2 Wedge bolt that secures the seatpost Figure 3 Bolts holding head on seatpost WV TRE
19. enter the brake 9 Size and cut the cable and reattach the wedge 10 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 add anything 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 11 Place the brake booster over the brake Figure 6 12 Install the three brake cover attachment screws Figure 7 two of which also attach the brake booster Figure 7 Attaching the rear brake cover over the brake booster 15 TREK SERVICE INFORMATION 24 May 2010 Q m DuoTrap Computer Sensor The 2011 Speed Concept frame includes a special pocket on the left chainstay for installation of the Bontrager DuoTrap sensor that combines speed and cadence sensing in a single wireless unit This unit attaches through a hole in the chainstay Figure 1 To install a Duotrap sensor 1 Remove the attachment screw and the cover plate over the chainstay 2 Slide the cylindrical part of the sensor through the chainstay Figure 2 until the sensor sits flush Figure 3 3 Install the attachment screw and tighten 4 Place the rubber plug over the attachment screw Figure 3 16 TREK SERVICE INFORMATION 24 May 2010 Figure 1 Hole through the chainstay for Duotrap sensor Figure 2 Sliding the speed cylinder of a Duotrap sensor through the c
20. hainstay Rubber plug Figure 3 Duotrap sensor installed on chainstay WV TREK Draft Storage Box The 2011 Speed Concept frame can be equipped with an optional storage box Figure 1 which is placed behind the seat tube out of the wind resistance The box is held in place by clamping the seatstays 1 Squeeze the side tabs Figure 1 to open the lid 2 Loosen the clamp bolt Figure 2 You do not need to completely remove the bolt 3 Remove the rear wheel from the frame 4 Slide the draft box between the seatstays Figure 3 5 While holding the draft box in position Figure 1 tighten the clamp bolt until the draft box is secure Side tab Figure 1 Draft storage box behind the seat tube seatpost removed Figure 3 Placing draft box between seatstays Q m 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 19 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 t
21. he 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 32 TREK SERVICE INFORMATION 24 May 2010 Figure 15 Pressing the crank arm onto the axle WV TREK 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
22. he correct assembly and adjustment Do not use a hammer or bearing press 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 All bottom bracket systems share the same procedure to install the bottom bracket shields Do these steps before installing the bearings To install the axle shields 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 1 2 Place the male axle shield into the bottom bracket shell from the drive side Figure 2 3 Place the female larger diameter axle shield into the bottom bracket shell from the non drive side 4 With the installation tool Figure 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 Goto the instructions on the following pages for the bearing system you want to install 18 TREK SERVICE INFORMATION 24 May 2010 Figure 1 Applying grease to the axle shield Figure 2 Inserting one half of the axle shield into frame Figure 3 Release tab WV TREK Pressing 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 21 Notes Be very careful
23. hrough aerobar for all stems except low near and medium near WV TREK Front Brake cont 3 4 5 6 7 10 11 12 13 Measure the housing at the lever then cut to length Figure 5 Slide the cable through the housing Slide the wedge up the cable and place it between the rollers Figure 3 Pull the cable tight and note the position of the wedge on the cable Remove the wedge from the rollers move the wedge up the cable about 1 mm and tighten the cable clamp bolt Hold the top and bottom surfaces of the wedge with pliers or an adjustable wrench while you tighten the nut Figure 6 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 between the rollers Do not cut the cable yet Tuck the cable out of the way Set the pad spacers see Table 4 below and align the brake pads with the rim Table 4 Brake pad spacing between pads and brake arms mm for two pad types Rim Brake pad type width Rubber Cork mm Size and cut the cable and reattach the wedge 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 Engage the tab of the brake c
24. igure 1 Loosen and remove the three stem attachment bolts Figure 2 and remove the stem While you support the fork loosen and remove the steering axle nut Figure 2 nn pY A Apply light pressure to the fork to slide the steering axle out of the bearings Aerobar attachment holes y The bearings should drop out Figure 1 Location on stem of aerobar attachment bolts 1 Apply a light coat of grease to the bearing contact surfaces 2 With your hands align the upper bearing and press it into the frame 3 Apply alight coat of grease to the steering axle and slide the lower bearing onto the axle 4 Slide the steering axle through the headtube from the bottom and through the upper bearing Be careful not to bump the fork against the frame during insertion Steering axle Stem attachment holes nut Figure 2 Location on stem of stem attachment bolts 5 Attach the steering axle nut and tighten to 2 5Nm 6 Reattach the stem and then the aerobar following the normal procedures 7 Reconnect the front brake and adjust WV TREK Cable Housings If the housings are already in place go to the next section 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 stem and aerobar before proceeding O install
25. le m A Figure 9 Tightening the axle bolt These instructions and parts are for the aluminum FSA cranks only The current B kit will not work for FSA carbon cranks 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 10 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 or bearing press 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 Allen Wrench Rock N Roll Super Coat grease Bottom bracket parts Bearing with shield pressed on Part FSA description BB90 bearing kit B 293227 C serme foo ea oee mee O renea a2 C ieor 200162 C ea foe Bearing with shield pressed on Figure 10 FSA bearing set 30 TREK SERVICE INFORMATION Q m To install the bearings 1 Apply a liberal coat of grease to the contact surfaces of one bearing
26. nstructions available at http www sram com _media techdocs 2005_gxp 05 r5 e pdf 281824 Tools and materials required Ceramie 293617 Crankset and bottom bracket Bearing 8 mm allen wrench 281820 er Axle shield 281823 Bearing installation tool PN 404694 Rock N Roll Super Coat grease Meee Bottom bracket parts 282864 TruVativ GXP installation instructions Ceramic 293618 Bearing Axle shield 281822 n Wave washer Seal Bearing Bearing with lip facing in Metal seal Figure 1 SRAM bearing set 20 TREK SERVICE INFORMATION 24 May 2010 Q m 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 1 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 2 Install the bearing so that the lip faces in Press one bearing into the drive side of the bottom bracket shell Figure 3 To remove the installation tool press the release tab Repeat steps 1 3 for the other bearing on the non drive side To install the drive side crankarm When handling the seals avoid bending them A bent seal will rub on the bearing creating drag 1 2 3 Apply a light coat of grease to the bearings on the face and the axle contact surface Apply a light coat of grease to the metal inside of
27. ot mark the derailleur housings you will have to determine the correct housing for each cable through trial and error 7 Install the screws that secure the stem cap Figure 4 two cover hinge screws and the front cover screw Figure 1 Stem of Speed Concept bike Front brake cable exit Housing exit to stem Shift housing ports Figure 2 Cable routing through aerobar Aerobar attachment d y Figure 3 Stem attached to fork Figure 4 Cover on stem WV TREK Derailleur Cables At this point in the assembly the cables should be in the housing that runs through the downtube These instructions explain the correct routing through the bottom bracket cable guide and to each of the derailleurs Slide a piece of cable liner onto the front derailleur cable until the liner touches the back of the housing stop in the bottom bracket Figure 1 Orient the front derailleur liner grommet Figure 2 and slide it onto the liner Figure 3 and then snap the grommet into the frame hole in the seat tube Cut the liner so that it does not interfere with the action of the front derailleur Attach the cable to the derailleur and adjust as normal From the bottom bracket cable guide run the bare cable with no liner through the chainstay and out the dropout exit hole Install the dropout housing stop in the dropout exit hole Figure 4 Measure and cut the re
28. over with the fork then swing the brake cover into place and install the two attachment screws Figure 7 Center the brake with the set screws Figure 8 shows the screws which are accessible through holes in the brake cover 13 TREK SERVICE INFORMATION 24 May 2010 g o gt Figure 6 Hold the wedge while you tighten the clamp bolt Tab xN Attachment screws Figure 7 Front brake cover Figure 8 Centering screw for front brake screw is accessible through cover WV TREK Rear Brake The rear brake Figure 1 on the Speed Concept bike use a wedge roller actuation Figure 2 so cable tension is critical The design of the front and rear brake design is different so the instructions are also Follow the steps carefully in order The rear brake is inside a cover Figure 3 under the bottom bracket It is mounted on a bracket that is bolted to the frame The bracket can be moved allowing you to center the brake Ta aatal arna Ah iek tbe raar arana lo install and adjust the rear brake 1 Loosen the two bracket attachment bolts Figure 4 center the brake and retighten the bolts 2 Slide the cable out through the housing the noodle short plastic liner in the cable guide and the cable guide of the mounting bracket Figure 1 3 Slide the wedge up the cable and place it between the rollers Figure 2 4 Loosen the cable clamp bolt pull the cable tight
29. pagnolo 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 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 or bearing press 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 Wave washer Bearing Washer Seal seat Washer Figure 1 Campagnolo bearing set Tools and materials required To complete the installation you will need the Campagnolo instructions available at http www campagnolo com pdf 7225306_Ultra_torque_O05_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 Allen Wrench Rock N Roll Super Coat grease Bottom bracket parts 27 TREK SERVICE INFORMATION 24 May 2010 Part description Kit Drive side parts Bearing Seal seat Axle shield Washer Non drive side parts Bearing Seal seat Wave washer Axle shield Washer Campagnolo 407383 Campy part 281825 281823 281826 281825 281827 281823 281826 WV TREK To ins
30. r Part name Arm pad right and left Screw arm pad holder Arm pad holder right and left Pinch bolt arm rest bracket Arm rest bracket Pinch bolt extension tube clamp Extension tube clamp Screw extension tube clamp Upper bracket extension tube clamp Lower bracket extension tube clamp Spacers Nut extension tube clamp Extension tube Aerobar Quantity 1ea 4 1ea NNANA NN see Table 2 WV TREK Insert the extension tube clamp pinch bolts F and tighten Slide an arm rest bracket E onto the extension tube Insert the arm rest bracket pinch bolt D o ND y Adjust the arm rest bracket to the desired angle and tighten the pinch bolt Note extreme angle adjustment might limit the ability of the arm pad holders to align correctly 9 Repeats steps 2 8 for the other side of the aerobar 10 Tighten all the fasteners To install the arm pad holders and arm pads The width of the arm pad holders can be customized to suit your body type and riding style 1 Insert two arm pad holder screws B through the desired holes of an arm pad holder C and into the arm rest bracket E Two screws are required per side to prevent the arm pad holders from spinning on the arm rest bracket 2 Tighten the arm pad holder screws 3 Repeat steps 1 2 for the other side 4 Place the arm pads on the hook and loop fasteners of the arm pad holders Install the shifters in the extensions following normal ins
31. rrect 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 Y TREK Table of Contents Working with Carbon Fiber Parts sssssssssssrriserrssssssssssnrrrrrreeesssssssssrrrrreenens Custom Sizing th Components of the Speed Concept sssssssssssiriiserrssrssssssrrrrrreessss e Bike nome E A Seatpost To instal o instal Rear Bra o instal o instal To adjust the height of the saddle PREG EATPOSE iseis 4 To reverse the seatpost head o cecesccscssessesseesessestesesseseesssseessssaneaseseseesesees 4 Using a Repair Stand To attach the workstand clamp adapter cecescessesesecsessesesesteseseeseseesees 5 Headset Bearings and Fork To remove the fork and bearings w ccecessessesesestestestessesssseesesnsstesnesteseseesees 6 To install the bearings ANd fOrK cessessesesesestessestessesesseesesnsstssnesteseeseesees 6 Cable Housings To install the NOUSING cccccescesestessessssessesssssesnsstssusssseesssseenssns
32. ssesesstsseeneeseey 7 To install the rubber top tube ZrOMMEta cccccecsesseseesessesesestesesteseeneesees 7 Aerobar Assembly To install the extensions and armrests eescccceeseeeseeeeseseesteeeeeteeeeeeees 8 ToiinstallithesMiterS ceiccel nation asics hesecersdieenmenas nausea 9 Toiinstallithe brake l Vers wcsicens ici inde scteenneien ancien inert 9 Aerobar Installation To install the completed aerobar assembly wuss 10 Derailleur Cables To connect the front derailleur CaDIC cccecccssessssessesesssesesessseseeseseseeeess 11 To connect the rear derailleur cable wi ccceeccccssecsssessssesesseetesesssesesesceseseess 11 Front Brake and adjust the front Drake wees 12 ke and adjust the rear brake cccscssssssesesssesssseesesssestesseseeseesees 14 DuoTrap Computer Sensor a Duotrap SENSO siisessecdsniwisnsivecceranneneiceaimminaanee 16 Draft Storage Box To instal ii TREK SERVICE INFORMATION astora ge DOR esneyen EE ENR 17 24 May 2010 Crankset Pressing bearings vescesescsssessessessessessesnsstessssessecsessessesusauesusstssesssseesesssausanseseaes 19 SRAM GX Poyrcinasmniaem ana aa aaan 20 Shimano Hollow TEC issena 23 Campagnolo Ultra TOGU E sensnsnissciann 27 Inspecting the bottom bracket cccccsesesesssesssesessesssstesneseseseeseeneenees 29 FSA MegaExg Al nosrersiesescnnrienun oana a EE 30 Crankset Troubleshooting sncscsriiiiieninnssaniianiiiiaiiaii 33 WV TREK Working with Carbon Fiber Parts Car
33. stall the extension tubes to the aerobar The following letter references A B C etc are for Figure 3 The arm rests arm pads and extension tubes have a left and right part these instructions do not say left or right but assume you use left parts on the left etc 1 Determine the desired width and height of the extensions and armrests 2 Loosely attach the upper brackets 1 and lower brackets J to the aerobar Insert two extension tube clamp screws H through an upper bracket and a lower bracket through the spacers and aerobar and into the nuts L Determine the appropriate screw length from Table 2 below Table 2 Spacers mm and required bolts length mm Spacer s Screw 10 10 25 2545 25 10 25 10 5 2 O10 25 10 10 5 3 Place an extension tube clamp G between the upper and lower brackets and tighten the extension clamp bolts until snug 4 Slide an extension tube M through the extension tube clamp and adjust the position of the extension tube to the desired length and rotational angle Do not clamp the end of the carbon tube leave a minimum of 15 mm of extension tube exposed behind the arm rest bracket E SE INFORMATION 24 May 2010 Figure 1 Completed aerobar assembly Figure 2 Permanent spacer bonded to aerobar SA e lt OM gy T Figure 2 Aerobar assembly diagram and parts list Note for clarity not all parts snown ROoTTOMNMMIOIADYS zz
34. tall the seal seats 1 Clean all surfaces to be bonded bottom bracket shell seal seats with alcohol wipes or similar Figure 2 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 3 Allow the primer to evaporate completely 3 Apply LocTite 638 to the faced of the seal seat that contacts the bottom bracket shell 4 Press the seal seat into the frame Figure 4 If needed tap lightly with a soft faced mallet Let the LocTite cure for at least 24 hours before inserting the bearings 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 5 and the non drive side seal seat Figure 6 Insert the Wave washer into the non drive side seal seat Figure 7 3 Slide the non drive side axle through the seal seat and bottom bracket shell Figure 8 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 5 and the 28 TREK SERVICE INFORMATION q w Figure 2 Cleaning bonding surfaces with an alcohol wipe Figure 3 Applying Loctite primer to the outer step of the bearing cups Figure 4 Inserting the bearing cups into the bottom bracket shell Figure 5 Greasing the bearings
35. tallation procedures Do not overtighten the clamp wedge mechanism Do not exceed 45 Ibsin 5 Nsm Do not drill or cut the extension tubes Tighten the shift lever mounting bolt until the shift lever is firmly in place Install the brake levers following normal installation procedures Do not overtighten the clamp or wedge mechanisms WV TREK Aerobar Installation After the housing is in the frame and you have assembled the aerobar you can complete the aerobar installation This requires that you simultaneously insert the housings into the aerobar and install the stem attachment hardware If you anticipate possible stem or extension changes you can leave up to 5cm extra housing This much extra housing can be pushed into the downtube 1 Choose a stem Figure 1 from Table 3 below Table 3 Stem sizes mm and part numbers Near Far reach rise reach rise L 50 10 100 10 ow 302464 302467 60 45 100 45 Medium 302465 302468 80 75 110 75 High 302466 302469 2 Puta ferrule on the front brake housing 3 Slide the housing into the aerobar Figure 2 until you can connect the aerobar to the stem 4 Install the aerobar attachment screws Figure 3 and tighten 5 Cut the housings to length 6 Install the brake cable through the brake housing and the derailleur cables into the correct housing for the front and rear derailleurs but do not attach the cables to the derailleurs or rear brake yet If you did n
36. to the threads and shoulder of the bolt or screw The correct torque is noted on or near every threaded fastener on the Speed Concept bike Because the specs are on the bike we do not list them in this manual The specification on the bike tells you the maximum torque Do not exceed it However you should also try to tighten a bolt to close to the listed value do not leave bolts loose 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 do not completely tighten one and then the other As the bolts become snug check alignment of the parts and 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 Trek dealers have access to the Trek Customer Service department for information about the Speed Concept bikes and parts and 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 Sizing the Bike Before assembling the bike make sure the frame is the correct size for the customer 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 or website www trekbikes com us en support manuals WV TREK Seatpost Th
37. uirements 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 the Trek bicycle owner s manual Two fork designs integrated and traditional direct connect The leading fork design provides the least wind drag of any bicycle we have ever designed With the carefully intergrated headtube fork interface and hidden headset bearings 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 The traditional fork design is more economical with only a slight penalty in wind drag Internal cable routing To minimize wind drag the cables and housiing of the Speed Concept are hidden to the maximum extent possible Seatpost for either time trial or triathlon The cap of the seatpost can be removed and rotated 180 degrees to gain different positions In addition there are different legnths of seatposts availabe Hidden brakes Brakes will require re adjustment if the wheels are changed because the brakes are sensitive to rim width There are no barrel adjusters Carbon rims Make sure you use brake pads that are compatible with the rim material WV TREK Preparing and tightening fasteners For each threaded fastener apply a light coat of grease
38. using and into the hole in the top tube Figure 3 It has three holes in it one for each of the cables that run through the frame 1 Slide the brake housing through the cutout in the grommet and into the rear most hole lower hole in the picture 2 Slide the derailleur housings through the cutout in the grommet and place the front derailleur housing on the left and rear derailleur housing on the right 3 With the round box end of an 8mm wrench press the edges of the grommet until it snaps fully into place and sits flush with the top tube If it is not flush it will rub on the stem when the aerobar is turned Tools and materials required Derailleur cable and 4 mm housing Brake cable and 5 mm housing Housing cutters Cable liner Tape Housing window Figure 1 Housing window in the top tube Brake housing Figure 2 Brake housing protruding from the bottom bracket shell Derailleur housing Brake housing Figure 3 Top tube housing grommet WV TREK Aerobar Assembly This section explains how to assemble the aerobar the extensions armrests shift levers and brake levers The size of stem Table 3 page 10 controls the reach and height of the aerobar The elbow pads are attached to the top of the aerobar and their height is controlled by a spacer stack The first spacer is permanently attached to the aerobar Figure 2 Z gt D To install To in
39. when using the press Too much force can crack the bottom bracket shell Press in one bearing at a time To press a bearing 1 2 3 Install the bearing shield Press the bearing into the frame by hand as far as possible With the cup guide on the bearing side Figure 1 slide the bearing press through the bearing and frame Center the guide in the bearing 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 2 Remove the crankset Slide the punch through one side of the bottom bracket shell to the back side of the bearing Position the punch on the inside ring of the bearing Gently tap the punch with the hammer then move 90 degrees around the bearing and tap again Continue tapping and moving around the bearing TAP GENTLY Go around the bearing and keep tapping DO NOT HIT HARD Excessive force can damage the bottom bracket shell 19 TREK SERVICE INFORMATION 24 May 2010 Tools required Installation Park headset press Removal Brass punch Hammer Figure 1 Using a headset press to install the bearings WV TREK SRAM GXP Part description SRAM These instructions explain how to install a SRAM TruVativ Bontrager GXP crankset Figure 404700 1 in a new Speed Concept To complete the installation you will also need the SRAM 411814 i
Download Pdf Manuals
Related Search