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Trek Madone 2008 Assembly Tips & Tricks

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Revised October 29, 2007
2008 New MadoNe
asseMbly tips
The 2008 Trek Madone is the lightest, strongest frameset we have ever made. To accomplish
this, we have used shaped tubes, an integral seatmast with seatmast cap, internal rear brake
inner wire, and very thin-walled carbon tubes.
Madone requires different or additional assembly techniques, provided here:
• Putting the bike in a workstand
• Attaching and adjusting the saddle
• Inner wire routing for front derailleur and rear brake
We have also provided general maintenance information:
• Carbon fiber care
• Headset bearing installation
• Bottom bracket bearing installation
Check www.trekbikes.com for updates. These instructions are written for an experienced me-
chanic. 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.
Contents
Working with carbon fiber parts .................................................1
Putting the frame in a repair stand ............................................2
Preparing the seatmast cap for the saddle .................................3
Adjusting the saddle ...................................................................4
Front derailleur inner wire installation ......................................6
Rear brake inner wire installation ..............................................7
Headset installation ....................................................................9
Fork crown cap replacement .....................................................12
Crankset installation .................................................................15
Installing a Shimano or SRAM Crankset ............................................... 16
Installing a Campagnolo Crankset ......................................................... 19
Because of these unique features, the 2008 Trek
© Copyright 2007 Trek Bicycle Corporation
All rights reserved

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  • Page 1: Table Of Contents

    2008 New MadoNe asseMbly tips The 2008 Trek Madone is the lightest, strongest frameset we have ever made. To accomplish this, we have used shaped tubes, an integral seatmast with seatmast cap, internal rear brake Because of these unique features, the 2008 Trek inner wire, and very thin-walled carbon tubes.

  • Page 2: Working With Carbon Fiber Parts

    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.

  • Page 3: Putting The Frame In A Repair Stand

    puttiNg the fraMe iN a repair staNd Use special care when putting the new Madone frame in a workstand. The only accepted or recommended meth- od is to use the special workstand clamp adapter de- signed specifically for this frameset. The adapter clamps to the seatmast cap (only), which must be installed first.

  • Page 4: Preparing The Seatmast Cap For The Saddle

    prepariNg the seatMast Cap for the saddle The seatmast cap must be prepared for use. This service will make the sadddle adjustment easier and also more secure. tools and materials required Saddle rail Cones Saddle • 5 mm allen wrench clip with nut rail clip •...

  • Page 5: Adjusting The Saddle

    adjustiNg the saddle The seatmast on the 2008 Madone frame uses a “No Cut” System. The closed end of the seat- mast provides strength required for the system. Do not cut the seatmast on this frame. Note: Do not use grease between the seatmast and the seatmast cap. For the best performance, the seatmast should be clean before installation of the cap, as explained on page 1.
  • Page 6 The Madone saddle rail clamp also provides several degrees of lateral angle adjustment so you can align the saddle (Figure 7). The saddle rail clamp is a mating ball and socket system that is easy to use. Figure 7. Angular (side-to-side) adjustment of the saddle to adjust the saddle angle 1.

  • Page 7: Front Derailleur Inner Wire Installation

    The front derailleur inner wire on the 2008 Trek Ma- done starts out following a normal path. However, after passing through the bottom bracket inner wire guide, the inner wire goes through a special tunnel built through the frame.

  • Page 8: Rear Brake Inner Wire Installation

    rear brake iNNer wire iNstallatioN The 2008 Madone uses an internal inner wire route for the rear brake. The inner wire housing does not run continuously through the frame, but instead uses spe- cial housing stops. This design is lighter and provides a firmer feel to the lever when applying the rear brake.
  • Page 9 6. Insert the housing stop into the exit window. 7. Install the fixing screw (Figure 17) and tight- en the screw to 8-10 lb•in (1 Nm). to install the rear brake housing 1. Cut the housing to the desired length. 2.

  • Page 10: Headset Installation

    headset iNstallatioN The headset of the 2008 Madone uses a 1.5” lower bearing and 1 1/8” upper bearing. The bearings are slip-fit into the frame. There are many benefits to this design, and one is that the 2008 Madone headset is a tool-less installation. The bearings are slip fit, so a headset press or fork race setting tool are not needed.
  • Page 11 to install the bearings 1. Apply a light coat of grease to the inner race of the lower bearing. 2. Install the bearing on the steerer (Figure 21). The bearing is symmetrical, so either side is “right-side up.” Figure 21. Lower bearing on fork crown 3.
  • Page 12 Once a month inspect the headset of your bicycle to see that it is not loose, nor too tight. If your headset bearings are loose or too tight, do not ride the bicycle. Readjust the bearings or take your bike to your Trek dealer for service. to check is the headset is too loose 1.

  • Page 13: Fork Crown Cap Replacement

    fork CrowN Cap replaCeMeNt This section explains how to remove the fork crown cap from a Madone fork, and also how to install a new one. to remove a fork crown cap 1. Stand the fork upside down with the end of the steerer on a solid surface (Figure 27).
  • Page 14 Installing the crown has two tasks: clean the parts and bond them together. to clean the fork and fork crown cap 1. With the old crown cap off, thoroughly clean the fork with a lint-free cloth and mild de- greaser (Figure 30). 2.
  • Page 15 Figure 35. Stand the fork up to install the fork crown cap 1. With the crown on the fork, clamp the fork steerer in a work stand (Figure 35). 2. Dry-fit the fork crown; make sure it fits well before you apply any glue. The large, protrud- ing lip of the crown cap should face the front of the fork (Figures 35 and 37).

  • Page 16: Crankset Installation

    CraNkset iNstallatioN The 2008 Madone uses a special bearing system that has no parts that thread into the frame. Instead, the bearings are a slip-fit into the frame. Bearings kits will be available for all major brand of cranksets: Bontrager (TruVativ GXP), Shimano, Campagnolo, SRAM, and FSA. The Campagnolo system requires you to attach bearing supports to the Madone’s bottom bracket shell, covered separately on pages 16-20.

  • Page 17: Installing A Shimano Or Sram Crankset

    iNstalliNg a shiMaNo or sraM CraNkset to install the bearing shields Your frame may already have the bearing shields in- stalled in the frame. 1. Apply a light coat of grease to the male axle shield (smaller diameter, Figure 29). 2.
  • Page 18 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 face and the axle contact surface of the bearings. 2.
  • Page 19 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.

  • Page 20: Installing A Campagnolo Crankset

    iNstalliNg a CaMpagNolo CraNkset The 2008 Madone 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 system requires you to attach bearing supports to the Madone’s bottom bracket shell. This section explains how to do that.
  • Page 21 to install the bearing shields Your frame may already have the bearing shields installed in the frame. 1. Apply a light coat of grease to the male axle shield (smaller diameter, Figure 41). 2. Place the male axle shield into the bottom bracket shell from the drive side (Figure 42).
  • Page 22 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 46) and the non-drive side seal seat (Figure 47). 3.
  • Page 23 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.

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