Trek DOMANE+ AL 2023 User manual

2023 DOMANE+ AL
SERVICE MANUAL

2023 Domane+ AL
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 thread-
locker 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
Apply appropriate grease
Apply threadlocker
Nm Torque
Cable (zip) tie
Additional info
Additional manuals are available at Trekbikes.com/
manuals.
• Owner’s Manual — comprehensive instructions that
come with your bicycle
• Hyena E-bike Owner’s Manual — detailed instructions
on the e-system found under Electric bikes > 2023
Contents
Brake/shift routing E-system Remove the rear wheel Remove the bottom bracket/
torque sensor
Install the bottom bracket/
torque sensor
Remove the battery Install the battery Fork and headset
Chainkeeper Frame mounts Specications
Copyright 2022 Trek Bicycle Corporation All Rights Reserved

2023 Domane+ AL
2
Brake/shi routing
4
3
1
2
5
6
2Nm
1 Derailleur hanger bolts (M3x6.4mm) — W318604
2 Derailleur hanger — W5268484
3Rear brake hose
4Rear derailleur cable
5Front brake hose
6Front derailleur cable

2023 Domane+ AL
3
E-system
T30
T20
T10


10
11
11
88
7
7
6
9
4
5
14
3
2
1
12
13 13
12
6 7 8
11Nm
11Nm
2Nm
2Nm
3Nm
3Nm
2Nm
15
13
6Nm
1 Hub motor — W5266204
2 Remote — W5257327
3 Torque sensor — W5257770
4Controller — W5252986
5Battery — W5255878
6Bolts, T30 (M6x8mm) — W5258222
7Bolts, T10 (M4x6mm) — 5269023
8Bolts, T10 (M3x8mm) — W285213
9Bottom bracket cover — W5263932
10 Cable guide
5284388
11 Cable guide bolt (M4x6mm)
12 Anti-rotational ange nuts
5288641
13 Axle bolts
14 Charge port cover — W5263927
15 Wire grommet — W5268283

2023 Domane+ AL
4
Remove the rear wheel
1. Shift to the smallest rear cog (highest gear) and
front, inner chainring.
2. Unplug the motor cable at the chainstay and remove
the cable from the cable guide (10).
3. Remove both axle bolts (13) and ange nuts (12).
13 13
12 12

2023 Domane+ AL
5
Remove the bottom bracket/torque sensor
AUTHORIZED DEALERS ONLY: Only authorized dealers should perform service on the e-system. Improper handling, tools
used, or torque applied to these parts may result in damage to the e-system components and cables.
1. Remove the three bolts from the bottom bracket
cover (9).
T10
2. Remove the bottom bracket cover (9) and slide it up
the front derailleur housing.
9
3. Unplug the torque sensor cable.
NOTICE: Do not pull the cables apart by the wires —
this can damage them.
NOTICE: If you do not disconnect the plug, you
may damage the torque sensor cable when you try
removing the bottom bracket cup.
4. Remove the non-driveside cup.
5. Pull out the torque sensor/bottom bracket.
6. Remove the driveside bottom bracket cup.

2023 Domane+ AL
6
Install the bottom bracket/torque sensor
AUTHORIZED DEALERS ONLY: Only authorized dealers should perform service on the e-system. Improper handling, tools
used, or torque applied to these parts may result in damage to the e-system components and cables.
1. Install the driveside cup and tighten it to 35Nm.
35Nm
2. Insert the torque sensor and cable — notched side
rst — into the non-drive side of the frame.
3. Reconnect the bottom bracket/torque sensor cable.
4. Fit all cables into the bottom bracket shell and install
the cover. Tighten the bolts (8) to 2Nm.
8
9
8
2Nm
2Nm
T10

2023 Domane+ AL
7
Remove the battery
AUTHORIZED DEALERS ONLY: Only authorized dealers should perform service on the e-system. Improper handling, tools
used, or torque applied to these parts may result in damage to the e-system components and cables.
1. Remove the bottom bracket/torque sensor (see
page 5).
2. Cut the zip tie holding the motor cable to the frame.
Unplug the motor cable.
3. Unplug all cables in the bottom bracket shell.
NOTICE: Do not pull the cables apart by the wires —
this can damage them.
4. Remove the two bolts (6) under the down tube.
T30
6
6
5. Rotate the bicycle and slide the battery assembly out.
NOTICE: Don’t drop it! The battery can slide out easily
and fall to the oor, causing damage.
6. Unplug the battery and remove the bolts (7)
connecting the controller to the battery.
7
7
T10

2023 Domane+ AL
8
Install the battery
AUTHORIZED DEALERS ONLY: Only authorized dealers should perform service on the e-system. Improper handling, tools
used, or torque applied to these parts may result in damage to the e-system components and cables.
1. Use the four bolts (7) to attach the controller to the
battery (if they are disconnected). Torque the bolts to
3Nm.
2. Position the cables to the sides of the down tube and
slide the battery assembly into the down tube.
Do not force it — the battery should slide in without
putting extra pressure on it. Readjust the cables, if
necessary.
Rear derailleur
Rear brake
Front derailleur
Remote
NOTICE: Make sure no cables are between the
charge port opening and the battery — you won’t be
able to plug in the charger if they are in the way.
3. Tighten the battery bolts (6) to 6Nm.
T30
6
6Nm
4. Install the bottom bracket/torque sensor (see
page 6).
5. Reconnect all cables.
6. Connect the motor cable plug and attach the motor
cable to the chainstay using a zip tie.


7. Fit all cables into the bottom bracket shell and install
the cover (9). Tighten the bolts (8) to 2Nm.
8
9
8
2Nm
2Nm

2023 Domane+ AL
9
Fork and headset
1
30mm
max Optional
spacers
3
4
2
1 Top cover — W590959
2Compression ring — W532842
3Upper headset bearing — W531676
4Lower headset bearing — 417578

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10
Chainkeeper
3
1
2
43Nm
1Nm
1Bolt (M4x22mm)
5305773
2Chainkeeper
3 Flat washer (M5x10mm)
4Bolt (M5x16mm)
Adjust the chainkeeper
1. Shift to the lowest gear (largest rear cassette cog) and front, inner chainring.
2. Loosen the bolt (1) on the chainkeeper.
3. Rotate the loose piece (shown in red below) so there is 1mm of horizontal clearance to the chain.
1mm
4. Tighten the bolt (1) to 1Nm.

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11
Frame mounts
Fenders and rear rack
1
3
1Bolts (M4x8mm) — W575056
2Seat stay bridge — W503255
3*Hole cover — W308963
*Used to cover fender and rack
mount bosses
2
1
3Nm
Access plug
Remove the hole cover (1) and use the upper access hole
to push the remote out.
1
1
1Hole cover
Water bottle cage mounts
2
1
3
3
3
2Nm
2Nm
1 2
1Bolts (M5x16.5mm)
2Bolts (M5x8mm) — W598484
3Washers (M5)

2023 Domane+ AL
12
Specifications
Frame
AL+
Rear hub OLD 141mm
Front hub OLD 100mm
Upper fork steerer tube OD 28.6mm
Lower fork steerer tube OD 38.1mm
Brake rotor diameter min/max Front 140/160mm
Rear 140/160mm
700c tire, max width With fenders 32mm
Without fenders 38mm
Fender compatible Front Yes
Rear Yes
Chainline/chainring
Chainline Max chainring teeth (T)
Small Large Single (1x)
Shimano 43.5mm 34T 50T —