Trek DOMANE AL GEN 4 2024 User manual

SERVICE MANUAL
2024 DOMANE AL GEN 4

Domane AL Gen 4
1
Contents
About this manual Brake/shift routing
Universal derailleur hanger
(UDH) Chainkeeper
Headset Install the headset Frame mounts
Copyright 2023 Trek Bicycle Corporation All Rights Reserved

Domane AL Gen 4
2
About this manual
Scope
This manual contains parts diagrams, specications (such
as grease and torque values), instructions, part numbers,
and helpful tips. It does not contain instructions for all
components (such as brake calipers). Refer to the original
manufacturer for more information.
Replacement parts
Trek recommends using only Trek OEM (original
manufacturer) replacement parts.
Additional info
The Owner’s Manual is available at
Trekbikes.com/manuals.
Legend
Cable (zip) tie
Nm Torque value
Apply appropriate threadlocker
Apply appropriate grease
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.

Domane AL Gen 4
3
Brake/shi routing

7
See
Headset
for routing
detail
2.5Nm
8
3
352
65
1
3
5
21
2
9
4
7
2.5Nm
10
5
1Front brake hose
2 Rear brake hose
3Rear derailleur housings
4Rear derailleur cable
5Front derailleur housing
6Front derailleur cable
7 Fastener (M5x10mm)
W575392
8 Cable guide
9Foam sleeves — W528082
10
Cable guide (P-clamp) — 553369
NOTE: This part is used with Shimano 105
front derailleurs only.

Domane AL Gen 4
4
Universal derailleur hanger (UDH)
5
10Nm
4
1
2
3
25Nm
1Rear derailleur hanger
NOTICE: Do not apply grease.
W600660
2Washer (25mm)
3
Bolt (M12)
NOTICE: Do not apply grease. Left-hand thread. Do not
over-tighten. Over-tightening could cause the hanger to
break.
4Lever (6mm allen) — 5321899
5Thru-axle (M12x166mm) — 5312169
For additional information about the UDH, refer to the
SRAM user manual at sram.com.

Domane AL Gen 4
5
Chainkeeper
Rotate the chainkeeper as necessary so
there is 1mm of clearance to the chain.
1mm
1
5Nm
3
2
1Fastener (M5x16mm)
431223
2Chainkeeper (30-36T)
3Washer

Domane AL Gen 4
6
Headset
See Install the headset on pages 7-9 for complete instructions.
1
3
IMPORTANT: Fully tighten the top
two fasteners before the bottom
two (there will be a gap on the
bottom).
Ridge on top
≤10Nm
≤4Nm
2
Steerer tube/fork
4
5
6
7
8
9
9
10
11
12
5.2Nm
12
5.2Nm
13
13
Optional spacers
1Top cap fastener
W547432
2Top cap
3Compression plug
4Spacers, 5mm — 5253930
5Spacers, 10mm — 5253931
6Shroud — W5308932
7Bearing cover — W5274615
8Split ring — W5274269
9Bearings — W540243
10 Stem, Elite (°7 x 80mm)
587666
11 Faceplates
12 Stem fasteners (M5x15mm)
13 Washers (M5)

Domane AL Gen 4
7
Install the headset
1. Install the compression plug into the steerer tube.
≤10Nm
2. Grease the headset bearings and locations shown
below.

Domane AL Gen 4
8
3. Route the split ring down the steerer tube and seat it
into the upper bearing.
1Rear derailleur housing
2 Rear brake hose
3Front brake hose
4Front derailleur housing
1
2 3
4
Split ring
4. Route the bearing cover and shroud through the
housings and snap them together. Make sure to
press together any gaps.
TIP: Squeeze the shroud from the sides to attach it to
the bearing cover more easily.
Hooks
1
2 3
4
Install the headset (continued)

Domane AL Gen 4
9
5. Slide the spacers and stem down the steerer tube —
do not tighten the stem fasteners.
Required spacer
6. Install the top cap and top cap fastener.
≤4Nm
7. Tighten the stem fasteners — alternating between
them — until both are torqued to 5.2Nm.
5.2Nm 5.2Nm
8. Install the faceplates and faceplate fasteners. Fully
tighten the top two bolts before the bottom two (there
will be a gap on the bottom).
5.2Nm
X4
Ridge
Gap
Install the headset (continued)

Domane AL Gen 4
10
Frame mounts
Rear fender bridge
1
2.5Nm
2
1Fasteners (M4x10mm) — W5308932
2Fender bridge — W5312166
Water bottle mounts
NOTE: Water bottle cages are sold separately.
1
2.5Nm
1Fasteners (M5x16mm) — 5257275

Domane AL Gen 4
11
Specifications
Frame
Domane AL
Rear hub OLD 142mm
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
Tire width max 700c
With fenders 35mm
Without fenders 42mm (as measured when
the tire is seated on the rim)
Fender compatible Front Yes
Rear Yes
Chainline/chainring
Chainline Max chainring teeth (T)
Small Large Single (1x)
43.5mm 39T 53T
43.5mm — — 50T