Trek 2021 E-CALIBER Operating manual

2021 E-CALIBER
SERVICE MANUAL SUPPLEMENT

2021 E-Caliber Service Manual
1
Contents
Safety 1
Headset with Knock Block 2
Frame and drive system guards 3
Rear triangle and chainstay bridge 4
Main pivot 6
Dérailleur hanger 7
Cabling overview 8
IsoStrut remote lockout cable 9
IsoStrut 10
Air volume spacer 11
Carriage wiper seals and bushings 14
Fazua system 19
Specications 20
Suspension 21
Safety
WARNING
Alwaystightenhardwaretothespeciedtorque.
Over-tightening hardware could deform or break the
hardwareorcomponents.Under-tighteninghardware
couldcausehardwareorcomponentstobecomeloose.
Either situation could damage the bicycle and result in
injurytotherider.
WARNING
All reused-fasteners with a pre-applied threadlocker
must be cleaned with isopropyl alcohol and have new
threadlockerappliedbeforere-assembly.Ifathreadlock-
er is not applied, the fasteners may loosen, which could
damagethebicycleandresultininjurytotherider.
Copyright 2021 Trek Bicycle Corporation All Rights Reserved

2021 E-Caliber Service Manual
2
Headset with Knock Block
1
2
3
4
5
6
7
Item Description
Quantity in
Assembly Part Number Torque (Nm)
1 Upperbearingcover 1
5252159
—
2 Knock Block chip bolt 1 2
3 Knock Block chip, 62 degrees 1 —
4 Compression ring 1 —
5 Upperbearing 1 —
6 Lower bearing 1 5252158 —
7 Crown race 1 —
Tools
• 2.5mmhextool
• Torquewrenchwith2.5mmhexbit
• Headset tools
• Grease
1. Inspectthecomponentsfordamageorexcessive
wear.
• Knock Block chip (3)
• Undersidechanneloftheupperbearingcover(1)
• Interlocking keys of the upper bearing cover (1)
and the stem
2. Replaceanydamagedorworncomponents.
3. Apply grease to:
• Upperandlowerheadtubebearingbores.
• Inside of the bearing seats of the compression
ring(4)andthecrownrace(7).
4. Install the crown race (7), then the lower the bearing
(6)ontothesteerertube.
5. Insert the steerer tube into the bottom of the head
tube.
6. Install the upper bearing (5), then the compression
ring(4)ontothesteerertube.
7. Insert the Knock Block chip (3) and bolt (2) into the
frame,butdonottightenit.
8. Installtheupperbearingcover(1).
9. Installspacersasneeded.
10. TorquetheKnockBlockchipbolt(2)to2Nm.

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Frame and drive system guards
1
3
4
3
2
Item Description
Quantity in
Assembly Part Number Torque (Nm)
1 Chainstay guard 1 W582883 —
2 Down tube guard 1 W582884 —
3 Drive unit guard fasteners 4 5269023 3
4 Drive unit guard 1 W1040440 —
Chainstay and down tube guards
Useisopropylalcoholtocleantheframesurfacewherethe
guardsattach.Waitforthealcoholtodrybeforeapplying
theguards.
Notice: Do not clean the entire frame with isopropyl
alcohol.Isopropylalcoholcoulddamagethepaint.

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Rear triangle and chainstay bridge
1
3
2
4
4
5
Item Description
Quantity in
Assembly Part Number Torque (Nm)
1 RearIsoStrutaxle 1 591626 10
2 End cap bolt 1 —
3 Front IsoStrut bolt and washer 2 W584485 5
4 Chainstay bridge bolt 4 5265697 8
5 Chainstay bridge, charcoal colour 1 5266755 —
Tools
• Bike repair stand
• Torquewrenchwith6mmhexbit,T25andT30
Torxbits
• Grease
Important: You must have the main pivot bearing and
sleeve (See the Main pivot section on page 6) and the
IsoStrut (See the IsoStrut section on page 10) installed
on the rear triangle before attaching the rear triangle to
theframe.
1. Puttheseatpostintoabikerepairstand.
2. Fitthereartriangleintothemainframe.
3. InstallthetwofrontIsoStrutboltsandwashers(3).
Important: Donottorquetheboltsatthistime.
4. Apply greasetotheIsoStrutrearaxle(1).
5. InstalltheIsoStrutrearaxle(1)andendcapbolt(2).
Important: Donottorquetheboltsatthistime.
6. Applygreasetotheatsurfacesofthechainstay
bridge(5).

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Rear triangle and chainstay bridge (continued)
7. Insert the chainstay bridge (5) inside the rear
triangle.
4
4
5
8. Install the four bridge bolts (4) to attach the bridge to
thereartriangle.
9. If applicable, install the main pivot hardware before
torquingthebridgebolts(4).SeetheMain pivot
section on page 6.
10. Torque:
• Chainstaybridgebolts(4)to8Nm.
• IsoStrutrearaxle(1)to10Nm.
• FrontIsoStrutbolts(3)to5Nm.

2021 E-Caliber Service Manual
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Main pivot
1
234
3
2
5
Item Description Quantity in
Assembly
Part Number Torque (Nm)
1 Main pivot nut 1 W584134 —
2 Washer 2 W440921 —
3 Main pivot bearing 2 W302025" —
4 Main pivot sleeve 1 W600642 —
5 Main pivot bolt 1 W600628 30
Tools
• Bearing press
• 8mmhextool
• Torquewrenchwith8mmhexbit
• Grease
1. Pressinthedrive-sidebearing(3).
2. Insertthesleeve(4)fromthenon-driveside.
3. Pressinthenon-drive-sidebearing(3).
4. Position the chainstay over the seat tube, ensuring
thatthemainpivotholesarealigned.
Tip: Slidethelongarmofthehextoolfromthenon-
drive-sideandthroughthealignedpivotholes.For
eachstep,slidethecomponentontothehextoolto
alignthecomponentsoneachsideofthemainpivot.
5. Apply grease to the shoulder of the main pivot
bolt(5).
6. Insert the drive-side washer (2) between the bearing
thechainstay.
7. Partially insert the main pivot bolt (5) from the drive
side.
8. Insert the non-drive-side washer (2) between the
bearingandthechainstay.
9. Fullyinsertthemainpivotbolt(5).
10. Installthenut(1).
11. Torquethemainpivotbolt(5)to30Nm.

2021 E-Caliber Service Manual
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Dérailleur hanger
1
2
Item Description Quantity in
Assembly
Part Number Torque (Nm)
1 Thruaxle,M12X1.0X15MM 1 W600321 10
2 Dérailleur hanger 1
W600660
—
Hanger bolt, left-handed thread 1 25
Washer, 25mm 1 —
ThisbicycleframeisdesignedtouseaUniversalDerailleur
Hanger(UDH).
NOTICE: ThethruaxlemustbecompatiblewithaUDH
andmustbeM12x1.0witha12.7mmthread.
NOTICE: Thewasherisframe-specic.Installonlythe
washercompatiblewithyourframe.
WARNING
Donotapplygreasetothederailleurhangerorbolt.Only
applygreasetothethruaxle.
1. Insert the hanger on the inside of the drive-side
chainstay.
2. Installthewasheronthederailleurhangerbolt.
3. Inserttheboltintotheframe.
4. Makesurethehangerispositionedasshownbelow.
5. Torquethehangerboltto25Nm.
NOTICE: Donotover-tighten.Over-tighteningthebolt
couldcausethehangertobreak.
ForadditionalinformationabouttheUDH,refertothe
SRAM user manual at sram.com.

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Cabling overview








1
4
5
6
9
10
11
12
7
8
2
3
Item Description Quantity in
Assembly
Part Number Torque (Nm)
1 Bolt 1 W562831 3
2 Speed sensor 1 W581396 —
3 Rear brake cable 1 — —
4 Speed sensor cable 1 — —
5 Dropper post cable 1 — —
6 IsoStrut lockout cable 1 — —
7 Head tube cable guide 2 W519232" —
8 Head tube cable guide fastener 2 W532763 1
9 Controller cable 1 — —
10 Down tube cable guide 3 W591416 —
11 Rear derailleur cable 1 — —
12 Grommet, for use with wireless derailleur only 1 5259425 —
Zip tie location 4 — —
Routeandziptiethecablesasshownintheillustrationabove.
Dropper cable
• For detailed dropper remote instructions, please refer
to the Drop Lock Remote manual at trekbikes.com/
manuals.
IsoStrut cable
• See the IsoStrut remote lockout cable section on
page 9.

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IsoStrut remote lockout cable
Tools
• Cable cutter
• Torquewrenchwith2mmhexbit
1. Installthecableintheremotelockout.
2. Route the cable through the hole in the bottom of the
top tube just in front of the IsoStrut and out the drive
sideoftheheadtubehole.
3. Attheheadtube,routethewirethroughthecable.
4. AttheIsoStrut,slidetheferruleonthewire.
5. Guidethewirethroughtheslotinthecablestop.
6. Route the wire around the lockout spool and install
thesetscrew.Torqueto1Nm.
Drive side Non-driveside
7. Testthatthemechanismworkssatisfactorily.
8. Cut the wire to the appropriate length (20-30 mm)
andcrimpanendcaponit.

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IsoStrut
6
1
2
3
4
3
2
5
7
8
9
10
Item Description Quantity in
Assembly
Part Number Torque (Nm)
1 Damper body nut 1
W580727
—
2 O-ring 2 —
3 Guide bushing 2 —
4 Damper body sleeve 1 —
5 Damper body bolt 1 7
6 Foxshock,performance,black 1 W587198 —
Foxshock,performance,kashima W587197 —
7 Compression sleeve 1 591626 —
8 Shock oil plug 1 W580727
9 End cap bolt 1 591626 —
10 RearIsoStrutaxle 110
Tools
• Torquewrenchwith5mmhexbit
1. Assemble the body bolt (5), body sleeve (4), one
o-ring(2)andoneguidebushing(3)asshownbelow.
2. Inserttheassemblyintothebottomofthecarriage.
3. Installtheupperguidebushing(3)intothecarriage.
4. Installtheo-ring(2)ontothedamperbodynut(1).
5. Install damper body nut (1) with o-ring (2) into the
carriage.
6. Torquethedamperbodybolt(5)to7Nm.

2021 E-Caliber Service Manual
11
Air volume spacer
Item Description Part Number
1 Foxairvolumespacerkit 595583
Tools
• BSA30 Open-ended bottom bracket tool
• Spanner pliers
• Loctite Blue 243 threadlocker or similar
• Parallel jaws pliers
• T25torxdrivewrench
• Torquewrench
• Shock pump
• Spacers
• Soft cloth
• Grease
Note: This procedure should be performed with the
IsoStrutinstalledonthebike.
Note the current air pressure
1. Useashockpumptochecktheairpressureinthe
shock.Makeanoteofthecurrentairpressuresoyou
canre-inatetheshockafterchangingtheairspacer.
2. Graduallybleedtheairfromtheairvalve.
Tip: You do not need to compress the shock because
youwillneedsomeairinthenegativeairspring.
Release the shock from the carriage
1. Remove the two bolts and washers at the front of the
shock.
2. Loosen,butDONOTREMOVEtherearaxle.
3. Turnthelockoutleveranti-clockwisetotheopen/
unlockedposition.

2021 E-Caliber Service Manual
12
Air volume spacer (continued)
4. Sitontheseattocompressthesuspension.Thefront
of the IsoStrut will move away from the top tube to
provideclearancefortheBSA30wrench.
5. Position your body on the seat to keep the shock
compressed, and use the BSA30 wrench to break the
lockringlooseandunthreaditfromthecarriage.
NOTICE: Useasoftclothtoprotectthetoptube
fromscratchesthattheBSA30wrenchmaycause.
6. Once the ring is unthreaded from the shock, the front
endoftheshockwillextendforwardstorevealan
o-ring,aroundmetalplateandtheairspacer.
1 2 3
Item Description
1 O-ring
2 Round metal plate
3 Air spacer
Replace the air spacer
1. Clean off any dirt or residue from the threads and the
lockring.
2. Movetheroundmetalplatetowardstheo-ring.Usea
spannerplierstoremovetheairvolumespacer.
3. Putanewspacerinplacearoundthedampershaft.
Tip: Depending on the size of the spacer, it may be
helpful to use the spanner pliers or a parallel jaws
plierstotthespacerinplace.
4. You should hear a ‘snap’ when the spacer snaps into
the front end of the shock.

2021 E-Caliber Service Manual
13
Air volume spacer (continued)
Tighten the lock ring
1. Add Loctite Blue 243 threadlocker or similar to
a minimum of two threads, covering 60-90°of
threads.
2. Standbehindtheseatandpulltheseatuptoextend
thesuspension.Thiswillbringthelockringincontact
withthestrut.
3. UsetheBSA30wrenchtoturnthelockringontothe
strut.
Tip: For the best results, sit on the rear tyre for this
steptobalancethebike.
4. As you tighten the lock ring, orientate the upper air
capasshownbelow.
Size small frame: theairllvalvealignswiththe
mountingtab.
Size medium, large and extra large frames: the
cablehangeralignswiththemountingtab.
5. PlacethetorquewrenchintheholeintheBSA30
wrench.Torquethelockringto17Nm.
6. Verifythattheshockispositionedtoacceptashock
pumptotheairvalve.Ifthereisinterference,reposi-
tiontheshock.
7. Install the washers and bolts at the front of the
shock.Torquetheboltsto5Nm.
8. Torquetherearshockaxleto10Nm.
9. Usetheshockpumptore-inatetheshockairpres-
sure to the PSI noted prior to beginning the air spacer
procedure.
10. Perform the sag procedure to determine the proper
ridersettingforthestrut.

2021 E-Caliber Service Manual
14
Carriage wiper seals and bushings
1
2
3
2
4
1
3
Item Description
Quantity in
Assembly Part Number Kit
1 Carriage wiper seal 2 — 592550
2 Carriage wiper bushing 2 595247
3 Foam block 2 —
4 Foam ring 1 —
Tools for replacing the seals
• IsoStrutsealandbushingpresstoolset.Available
aspartnumber593490.
• Delrinrod,1inch(25.4mm)
• Headset press
• Fork bath oil, 10 wt
Tools for replacing the bushings
• Slide hammer
• 30-36Expandingcollet
• IsoStrutsealandbushingpresstoolset.Available
as part number 593490
• Bushing sizer
• Clean, dry cloth
NOTICE: Inspect all tools prior to use to make sure
theyareclean.Dirtytoolscoulddepositgritinto
the shock which could mar surfaces and create
frictionthatcoulddamagetheshock.
Remove the shock from the carriage
1. RemovetheIsoStruthardware.SeeIsoStrut section
on page 10.
2. Removetheshockfromthecarriage.

2021 E-Caliber Service Manual
15
Carriage wiper seals and bushings (continued)
Remove the carriage seals
1. UsetheDelrinrodtopulloutthefrontseal.
Tip: You may need to move the rod around the car-
riagetoremovetheseal.
2. Pulloutthefoamring.Thisistheonlyfoamringinthe
carriage.
3. UsetheDelrinrodtopullouttherearseal.
If you are replacing only the seals, jump to Carriage wiper
seals and bushings (continued) section on page 17.
If you are replacing both the seals and the bushings, con-
tinue with the Replace the bushings section on page 15.
Replace the bushings
NOTICE: Donotapplygreasetothebushings.
1. Put the slide hammer with the collet attached inside
thefrontendofthecarriage.
NOTICE: Take care to engage only the bushing,
andNOTtheinteriorofthecarriage.Engagingthe
carriagecoulddamagethecarriage.
2. Thread the collet to engage the bushing lip.
Tip: Be careful not to engage the lip inside the car-
riage.Engagethebushingonly.
3. Usetheslidehammertoremovethebushing.
4. Repeatsteps1to3toremovetherearbushing.
5. Wipe the bushing bores with a clean, dry cloth to
removeanydebris.

2021 E-Caliber Service Manual
16
Carriage wiper seals and bushings (continued)
6. Load a new bushing onto each bushing installation
tool.
Bushing
Usethissideofthetoolforpressingin
bushings.
Seal
Usethissideofthetoolforpressingin
seals.
NOTICE: Do not use grease when installing the
bushings.Usinggreasecouldcausethebushings
toslipoutofplace.
7. Put one tool with one bushing into the front of the
carriage, and the other tool with the other bushing
intotherearofthecarriage.
8. Insert the upper half of the headset press into the
frontofthecarriage.
9. Insert the lower half of the headset press into the
rearendofthecarriageandlockitintoplace.
10. Spin the headset press until it is snug against the
bushingtool.Checkforthecorrectalignmentofthe
press,toolsandbushings.Rotatethepresstopush
thebushingsintoplace.It’snormaltohavedifferent
gapsatthefrontandrearofthecarriage.
11. Tightenthepressuntilyoufeelresistance.Onceyou
feelresistance,removethepressandbothtools.
12. Inspect the bushings to verify that they are pressed
deepenoughintothecarriage.Fromthetopofthe
bushing to the step above the bushing, the measure-
ments should be:
Front=16.9mm Rear=10.5mm
13. From the front of the carriage, use the bushing sizer
tosizethebushing.Thesizercanberotatedtothe
leftortotheright.
14. Repeat step 13 three to four times, alternating be-
tweenthefrontandrearbushings.

2021 E-Caliber Service Manual
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Carriage wiper seals and bushings (continued)
Replace the wiper seals
1. Wipe the seal surface inside the carriage to remove
debris.
2. Loadanewsealontoeachsealinstallationtool.
Seal
Usethissideofthetoolforpressingin
seals.
Bushing
Usethissideofthetoolforpressingin
bushings.
3. Put one tool with one seal into the front of the car-
riage, and the other tool with the other seal into the
rearofthecarriage.
4. Insert the upper half of the headset press into the
frontofthecarriage.
5. Insert the lower half of the headset press into the
rearendofthecarriageandlockitintoplace.
6. Spin the headset press until it is snug against the
sealtool.Checkforthecorrectalignmentofthe
press,toolsandseals.Rotatethepresstopushthe
sealsintoplace.
7. Tightenthepressuntilyoufeelresistance.Onceyou
feelresistance,removethepressandtools.
8. Inspect the seals to verify that there is no gap be-
tweenthesealandthecarriage.
9. Soakthefoamringin10wtforkbathoil.
10. Installthefoamringintothefrontofthecarriage.

2021 E-Caliber Service Manual
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Carriage wiper seals and bushings (continued)
Install the IsoStrut into the carriage
1. Removethecompressionsleeve.
2. Carefullypullouttheoilplugfromtheshock.
3. Place the foam blocks into the carriage and position
themagainstthesidesofthecarriage.Donotsoak
thefoamblocksinforkbathoilpriortoinstallation.
4. Lightlyoiltheinsideofthecarriageseals.
5. With the sag o-ring in place on the shock, insert the
shockintothecarriage.
Install the damper body hardware
See IsoStrut section on page 10.
Add oil to the carriage
1. UseasyringetolltheIsoStrutwith15ccof10wt
oil.
2. Firmly press the oil plug back into the aft end of the
shock.Makesurethattheplugistightlyseatedinthe
opening.
3. Install the compression sleeve intotheoilplug.
4. InstalltheIsoStrutrearaxleandendcapnut.Torque
theaxleto10Nm.
Tip: If the compression sleeve will not allow the rear
IsoStrut hardware to pass through, the oil plug is not
fullyseatedintotheshock.(Seestep2.)
5. InstallthefrontIsoStrutwashersandbolts.Torque
theboltsto5Nm.
6. WipeoffanyexcessoilfromtheIsoStrut.

2021 E-Caliber Service Manual
19
Fazua system
Service manual and parts
Bicycle retailers
Refertothe2021Domane+LTFazuasystemmanual.
Consumers
ContactyourlocalTrekretailerforassistance.