Trek BOONE 2022 Operating manual

2022 BOONE
SERVICE MANUAL SUPPLEMENT

2022 Boone
1
Safety
WARNING
Properly tighten hardware
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
Reapply threadlocker
All reused-fasteners with pre-applied threadlocker
must be cleaned with isopropyl alcohol and have new
threadlocker applied before re-assembly. If threadlocker
is not applied, the fasteners may loosen which could
damage the bicycle and result in injury to the rider.
Legend
Grease
Do not apply grease
Threadlocker
Nm Torque
Zip tie
Contents
Safety Brake/shift routing
— mechanical
Brake routing —
eTap
T47 bottom
bracket
Fork and headset IsoSpeed
1mm
Chainkeeper Specications
Copyright 2021 Trek Bicycle Corporation All Rights Reserved

2022 Boone
2
Brake/shi routing — mechanical
3
2-3Nm
6
7
8
9
2
15
4
1 Rear derailleur hanger — W524188
2 Rear derailleur hanger bolts — W524884
3 Housing grommets — W330578
4 Front derailleur clamp — W5256886
5 Zip tie guide — W513997
6Front derailleur cable
7Rear derailleur cable
8Front brake hose
9Rear brake hose
Route the brake hoses
1. Connect the calipers to the brake hoses.
2. Route the rear brake hose through the grommet (3).
Route both hoses as shown.
3. Attach the calipers to the chainstay and fork. Do not
fully torque the mounting bolts until the calipers are
aligned correctly.

2022 Boone
3
Brake/shi routing — mechanical (continued)
Route the shift cables
1. Mark the rear shift cable with a marker. You will
need to tell the cables apart when you assemble the
headset.
2. Route the front derailleur shift cable through the
grommet (3). Route both shift cables through the
frame as shown.
3. Attach the derailleurs to the bicycle.
4. Connect the shift cables to the derailleurs.
Zip tie the shift cables and rear brake
hose
1. Bend the zip tie in half to create a crease. This will
make it easier to wrap the zip tie around the cables
and out through the hole.
2. Use a hook and a pick tool to hold the cables and
guide the zip tie around them.
3. Route the zip tie through the zip tie guide (5) as
shown below.
5
4. Insert the zip tie guide into the down tube and tighten
the zip tie.

2022 Boone
4
Brake routing — eTap
6
7
1
2
2-3Nm 4
3
5
1 Rear derailleur hanger — W524188
2 Rear derailleur hanger bolts — W524884
3 eTap grommet plug — 600209
4 Housing grommet — W330578
5Zip tie guide — W513997
6Front brake hose
7Rear brake hose
Route the brake hoses
1. Connect the calipers to the brake hoses.
2. Route the rear brake hose through the grommet (3).
Route both hoses as shown.
3. Attach the calipers to the chainstay and fork. Do not
fully torque the mounting bolts until the calipers are
aligned correctly.

2022 Boone
5
Brake routing — eTap (continued)
Zip tie the rear brake hose
1. Bend the zip tie in half to create a crease. This will
make it easier to wrap the zip tie around the cables
and out through the hole.
2. Use a hook and a pick tool to hold the cables and
guide the zip tie around them.
3. Route the zip tie through the zip tie guide (5) as
shown.
5
4. Insert the zip tie guide into the down tube and tighten
the zip tie.

2022 Boone
6
T47 bottom bracket
Install the bottom bracket
1. Apply grease to the threads on both sides of the
frame.
2. Using your hands, thread the bottom bracket onto
the frame.
NOTICE: Do not start tightening the bottom bracket
with a tool. Dirt and other contaminants can
damage the threading.
3. Use the proper tool to torque both sides to
specication (see the Tool and spline compatibility
table below).
4. If necessary, add spacers before installing the cranks
(see the Spacers required table at the top right).
Spacers required
The table below contains bottom bracket/crank
combinations that require spacers. Your bicycle may have
other combinations that do not require spacers.
Crank Bottom bracket
Spacers required
Drive
side
Non-drive
side
Shimano CeramicSpeed
24mm 0.5mm 0.5mm
SRAM DUB SRAM DUB 2-3mm —
GXP Wheels MFG 1.0mm —
non-driveside
washer
driveside
washer
SRAM GXP cranks
only
Tool and spline compatibility
Tool Praxis Unior Park Tool Wheels Mfg CeramicSpeed
Model
Part number
TP-2400
594148
TP-3028
594147
1671.T47
1043614
BBT-47
568922
BBTOOL-48-44
589307 —
Bottom bracket
manufacturer
Praxis 24mm X X
30mm X X
Wheels MFG X
SRAM DUB X X
Chris King X X
Ceramic-
Speed
24mm X X X
GXP X

2022 Boone
7
Fork and headset
3
2
4
5
1
1 Spacer (5mm) — 5253930
2 Frame routing cap grommet — W5253580
3 Frame routing cap — W5253579
4 Headset split ring — W5266050
5Headset bearings — W540243
6Front derailleur cable
7Rear derailleur cable
8Front brake hose
9Rear brake hose
Install the headset
1. Clean the steerer tube using isopropyl alcohol.
2. Grease both bearings (5), the fork crown race, and
the inside of the head tube as shown to the left.
3. Insert the fork into the head tube.
TIP: Support the fork with a table during the
assembly.
4. Route the shift cables and brake hoses through
the split ring (4) as shown below (see pages 2-5 for
different routing examples).
Mechanical routing example
6
7
8
9
4
5. Complete the headset assembly as shown to the left.
NOTE: If cutting the steerer tube, cut 2mm above
the stem. Make sure the stem is in its nal position
with the required spacers underneath.

2022 Boone
8
IsoSpeed
2
1
3
4
6
7
8
9
5
1 Bolt
kit W569265
2 Wave washer
3 Washer
4Flanged bushing
5Cylindrical bushing
6Nut
7Cap, non-driveside (as shown) — 5253577
8 Cap, driveside (as shown) — 5253576
9 Grommet — W5253578
Install the IsoSpeed
1. Carefully remove the IsoSpeed covers (7, 8) with a
paint-safe plastic pry bar.
2. Disassemble the bolt (1) and nut (6).
3. Use a 50/50 isopropyl alcohol/water mix to clean the
nut threads (6), bolt threads (1), and the inside of the
bushings (4, 5).
4. Apply grease to the bolt (1) and nut (6) as shown
below.
NOTICE: Do not apply grease to the threads.
6
1

2022 Boone
9
5. Apply threadlocker to the nut threads (6).
6. Place the washers on the bolt. Tighten the nut to
10Nm while securing the bolt with a wrench as
shown below.
10Nm
7
.
8
8
.
0
8
.
2
6
3 2
1
7. Re-install the IsoSpeed covers.
8. Allow the assembly to cure for 24 hours at room
temperature (72°F/22°C).
IsoSpeed (continued)

2022 Boone
10
Chainkeeper
Adjust the chainkeeper — 1x chainring
1. Shift to the lowest gear (largest rear cassette cog).
2. Loosen the screw on the back of the chainkeeper.
3. Move the loose piece up or down so there is 1mm of vertical clearance to the chain.
4. Tighten the screw on the back of the chainkeeper.
1mm
3Nm Clearance Adjust clearance
541421
(38-46T)
Adjust the chainkeeper — 2x chainrings
1. Shift to the lowest gear (largest rear cassette cog) and inner chainring.
2. Loosen the screw holding the chainkeeper in place.
3. Rotate the chainkeeper so there is 1mm of horizontal clearance to the chain.
4. Tighten the screw to 3Nm.
1mm
318145
(36-42T)
315465
(30-36T)
3Nm
Clearance Adjust clearance

2022 Boone
11
Specifications
All models
Rear hub OLD 142mm
Seat post OD 30mm
Seat post clamp ID 30.15mm
Upper fork steerer tube OD 28.6mm
Lower fork steerer tube OD 38.1mm
Bottom bracket type/width T47/85.5mm
Brake rotor diameter 140/160mm
Chainline (1x) 49.7mm
Chainline (2x) 43.5mm
Chainring max (1x) 42t
Chainring max (2x) Small 34t
Large 50t
Tire width max 700c 38mm (1.5”)
Fender mount — rear No
Fender mount — front No
Rack mount No
Dropper post compatibility No