Trek MADONE 2019 User manual

2019 MADONE
ASSEMBLY MANUAL

Disc brakes and Di2 drivetrain
Disc brakes and mechanical drivetrain
2019 MADONE
Rim brakes and Di2 drivetrain
Rim brakes and mechanical drivetrain

Common procedures 3
Install Control Centre (Mechanical) 5
Install the Di2 Cables and Housings 9
Install Rear Disc Brake (Mechanical Drivetrain) 11
Install Rear Disc Brake (Di2 Drivetrain) 13
Install Front Disc Brake 14
Route Rear Rim Brake Housing 15
Install Fork and Headset 17
Install Stem (Mechanical) 20
Install Stem (Di2) 21
Install Handlebar and Shift Levers 22
Install Front Rim Brake 26
Adjust the Front Rim Brake 27
Install Rear Rim Brake 29
Install and Adjust Seatpost 31
Adjust the IsoSpeed System 33
Fit Measurements 34
Service Information 35
TABLE OF CONTENTS 1PROCEDURES COMMON TO ALL 2019 MADONE MODELS
NOTE There is plastic tubing inside the frame to
help with the initial routing of the cables and housings
through the frame.
TOOLS AND MATERIALS REQUIRED
• 2 mm hex • Torque wrenches • Cable cutter
• 4 mm hex • Sockets • Marker
• 5 mm hex
1. Prepare the housings. Cut to length and finish the
ends. Do not install the end caps yet.
NOTE The length for each housing by frame size
is shown in the table below.
Mechanical build housing lengths for the 2019 Madone
Total cable length recommendations
Frame
size
Housing specs [w/ 40 mm of stack]
are subject to trimming for a proper build
H1 Stem
Size
Bar
Size
FB
Housing
(mm)
RB
Housing
(mm)
FD/RD
Housing
(mm)
50
90 40 695 1125 825
52 705 1140 835
54 42 725 1165 855
56 100 755 1185 875
58
44
785 1210 920
60 110 815 1235 955
62 690 835 1245 980
*Notes: 1. Brake housings are intended to have 100 mm of housing protrud-
ing from each end (frame/fork and h-bar ends).
2. Derailleur housings are intended to have 100 mm protruding
from the h-bar end.
3. Brake housings only represent rim brake builds.
2. Install the chain keeper at the base of the front
derailleur hanger. Torque the bolt to 3 Nm.
NOTE The secondary wing bolt will be torqued
after chain installation.
3. Install the steer stop at the top of the head tube bore.
Torque the bolt to the recommended torque, but not
more than 0.7 Nm.
4. Install the front derailleur at the base of the front
derailleur hanger. Tighten the bolt just until the
derailleur is held. Do not fully tighten yet.
2 3

5. Install the rear derailleur on the the rear derailleur
hanger. Tighten to the OEM torque spec.
CUT THE FORK STEERER TUBE:
NOTE You will need to temporarily install the fork,
headset and stem together to get the correct location
for cutting the steerer tube.
1. Holding the fork legs, slide the stem down the steerer
tube until it is firmly seated on top of the bearing top
cap or shaped spacers. Lightly tighten the stem
pinch bolts.
2. Determine the preferred cut length. Use additional
spacers above the stem until you are certain about the
desired stack height (handlebar height).
3. Mark a fine line on the flat side of the steerer tube
along the top edge of the
stem.
4. If you are planning to use the 5 mm spacer recessed
in the stem, your actual cutting line should be 5 mm
below the pencil mark made in the prior step. If you
are planning on using a 5 mm headset spacer above
the stem, cut on the line.
5 mm
5. IMPORTANT: There is a 5 mm spacer built into the
stem which allows you to install the stem top cap flush
with the stem.
6. Disassemble the stem and headset from the steerer
tube.
7. Proceed with cutting the steerer at the selected
location from Steps 3/4 using a standard carbon
steerer cutting process.
If you’re building a mechanical drivetrain, go to Step 2.
Install the Mechanical Control Centre on page 5.
If you’re building a Di2 drivetrain, go to Step 3. Install
the Di2 Cables and Housings on page 9.
NOTE There is plastic tubing inside the frame
to help with initial cable and wire routing. It is not
intended to be left in the frame.
1. Refer to the table at the front of this manual to cut
the front and rear derailleur cable housings to the
appropriate lengths.
2. Attach ferrules to both ends of
the derailleur housings. Route the
cables into their housings.
3. Mark the FD housing with tape to
identify it.
4. Route the FD cable/housing from the head tube to the
cutout in the downtube.
5. Pass the FD cable through the top hole of the
control centre.
6. Set the control centre loosely in the downtube cutout.
7. Route the FD cable down the downtube and push it
through the bottom bracket guide slot.
2INSTALL THE MECHANICAL CONTROL CENTRE
TOOLS AND MATERIALS REQUIRED
• Park Tool Routing Kit • Marker • Ferrules
• Mechanical control centre • Rear derailleur cable stop • Rear derailleur cable liner
• Cable cutter • Bottom bracket guide • Ruler
4 5

8. Route the RD cable/housing from the head tube to the
cutout in the downtube.
9. Pass the RD cable through the bottom hole of the
control centre.
10. Route the RD cable down the downtube and push it
through the bottom bracket guide slot.
11. Do a visual check to make sure that the cables are
not crossed.
12. At the control centre, push the FD and RD housing
ferrules into the top and bottom holes of the
control centre.
NOTE It is important to have the ferrules fully
seated in the control centre.
13. Place the control centre in the downtube, but do not
attach the bolts at this time.
14. Install the bottom bracket guide and hold it in place
with the FD cable.
NOTE This is intended to keep the housing
secured in the downtube cable stop.
15. Put the FD cable in the front derailleur cable anchor
bolt and lightly tighten the bolt to keep the cable
in place.
16. Route the RD cable from the bottom bracket hole
up through the drive-side chainstay and out the rear
hole in the chainstay.
Bottom bracket
hole
17. Install the RD cable liner on the cable and insert it
into the chainstay.
18. Wrap the cable stop around the cable and install it
into the drive side dropout exit.
6 7

19. Install the short cable housing from the rear
derailleur to the chainstay.
NOTE This step may be OEM-specific.
20. Put the RD cable in the rear derailleur cable anchor
bolt and lightly tighten the bolt to keep the cable in
place.
If you’re installing disc brakes (Mechanical
Drivetrain), go to Step 4. Install the Rear Disc Brake
(Mechanical) on page 11. If you’re installing rim
brakes, go to Step 7. Route the Rim Brake Housing on
page 15.
1. Rear derailleur
A. Use the routing cable to pull the RD Di2 wire
forward from the chain stay to the control centre.
B. Attach the wire to the rear derailleur.
C. Insert the RD wire grommet into the bottom of
the drive-side dropout.
D. Tape the other end of the RD wire to the
downtube to hold it in place.
2. Front derailleur
NOTE You may wish to remove the front derailleur
to help ease Di2 routing.
A. Use the routing cable to pull the FD Di2 wire from
the frame hole above the FD to the control centre.
B. Plug the wire into the front derailleur.
C. Tape the other end of the FD wire to the
downtube to hold it in place.
D. Insert the FD wire grommet.
3. Cockpit to control centre
A. Use the routing cable to pull the cockpit wire
from the upper head tube bore down to the
control centre.
B. Tape the cockpit wire to the head tube to keep
it handy.
C. Connect all three Di2 wires (RD, FD, cockpit) to
the junction B box (SM-JC41). See page 10.
The orientation of the junction B box does not matter.
D. Pull the tape off all wires from the
downtube.
E Plug the RD and FD wires into the
bottom (rear) two ports.
F. Plug the cockpit wire into the top
(forward) side.
3INSTALL THE DI2 CABLES AND HOUSINGS
TOOLS AND MATERIALS REQUIRED
• Park Tool – Internal Cable Routing Kit (IR-1 or IR-1.2) • Junction B Box (SM JC41) • Electrical tape
FD Grommet
8 9

junction B box
4. Di2 battery to control centre
A. Connect the battery to the control centre with zip
ties. Put one zip tie in the groove at the top of the
battery.
B. Connect the short Di2 battery wire to the battery.
IMPORTANT: The orientation of the battery on the
control centre must be aligned as shown.
5. Connect the battery to the junction B box
A. Connect the battery wire to the remaining
junction B box port at the top (forward)
side as shown.
B. Use a zip tie to connect the junction B box
to the battery.
6. Place the control centre in the downtube. Do not
install the bolts yet.
If you’re installing disc brakes, go to Step 5 – Install
Rear Disc Brake (Di2 Drivetrain) on page 13.
If you’re installing rim brakes, go to Step 7 – Route the
Rear Rim Brake Housing on page 15.
Zip
Tie
1. Route the rear brake hose
A. Slip the rubber grommet onto the brake hose.
B. Route the hose from the grommet hole on the
non-drive side chainstay to the control centre
access hole.
IMPORTANT: After routing, the RB hose must rest
above the FD and RD cables inside the frame.
C. Pull the hose out of the control centre hole.
2. Install the rear brake
A. Connect the rear brake to the non-drive side
chainstay. Tighten the bolt just until the brake is
snug. Do not fully tighten.
B. Install the grommet into the grommet hole on
the chainstay.
Grommet
3. Connect the rear brake hose
A. Use two zip ties to connect the RB hose to the
slots in the control centre as shown.
NOTE The brake hose must sit in the control
centre channel.
B. Do not over-tighten the zip ties. Snug them up
enough to stay in the control centre groove, but
loose enough so that the hose can slide in the
channel.
C. Place the control centre assembly into the
downtube.
Zip TiesHose in channel
4. Feed the RB hose up through the downtube towards
the head tube.
NOTE Make sure you don’t kink or coil the brake
hose. If the hose is coiled, it will kink
5. Pull the hose out the top of the upper head tube bore.
IMPORTANT: Make sure that the FD and RD
housings are seated in the control centre.
4INSTALL THE REAR DISC BRAKE MECHANICAL DRIVETRAIN
10 11

6. Connect the control centre to the downtube. Torque
the bolts to 3-4 Nm.
Go to Step 6 – Install the Front Disc Brake on page 14.
1. Route the rear brake hose
A. Slip the rubber grommet onto the brake hose.
B. Route the hose from the grommet hole on the
non-drive side chainstay to the control centre
access hole.
C. Pull the hose out of the control centre hole.
2. Install the rear brake
A. Connect the rear brake to the non-drive side
chainstay. Tighten the bolt just until the brake is
snug. Do not fully tighten.
B. Install the grommet into the grommet hole on
the chainstay.
Grommet
3. Connect the rear brake hose to the rear disc brake.
4. Feed the RB hose up through the downtube towards
the head tube.
NOTE Make sure you don’t kink or coil the brake
hose. If the hose is coiled, it will kink.
5. Pull the hose out the top of the upper head tube bore.
6. Connect the control centre to the downtube. Torque
the bolts to 3-4 Nm.
Go to Step 6 – Install the Front Disc Brake on page 14.
5INSTALL THE REAR DISC BRAKE Di2 DRIVETRAIN
12 13

1. Route the front brake hose
A. Put soap or grease on the brake hose for ease of
installation (approximately 200 mm).
B. Route the hose through the fork access hole
(non-drive side) and up through the hole at the
front of the steerer tube
2. Connect the brake to the fork. Tighten the bolt just
until the brake is snug. Do not fully tighten
Go to Step 8 – Install the Fork and Headset on page 17.
6INSTALL THE FRONT DISC BRAKE
1. Feed the routing wire such that you can pull
the RB housing from the head tube to the rear
of the seatmast.
REAR BRAKE CABLE
REAR BRAKE
HOUSING
INSTALLATION
CABLE
NOTE Be aware that the routing wire needs to
pass through three slots to exit out the rear of the
seatpost.
2. Cut the foam sleeve to size. To measure, place the
sleeve on the top tube, end to end. Cut off 30 mm
from each end.
7ROUTE THE REAR RIM BRAKE HOUSING
TOOLS AND MATERIALS REQUIRED
• Park Tool Routing Kit (IR-1 or IR-1.2) • Foam sleeve • Electrical tape
30 mm
30 mm
14 15

3. Pass the RB housing through the foam sleeve so that
there is 200 mm of housing beyond the rear end of
the sleeve. Secure the sleeve with electrical tape at
both ends.
4. Attach the routing tool to the RB housing and pull the
housing back through the head tube and out the RB
cable exit hole in the seat tube until 65-70 mm of the
housing is visible.
5. Tape the housing flush with the seat tube.
Go to Step 8 – Install the Fork and Headset on page 17.
65-70mm
1. For the rim brake only, route the front brake housing
down through the access hole in the steerer tube so
that the housing extends out the back of the fork by
100 mm.
2. For the rim brake only, tape off the housing flush with
the fork to ensure that there is no housing movement.
3. For the rim brake only, tape the upper end of the FB
housing to identify it.
4. Install the lower headset bearing.
A. Capture the FB hose inside the bearing.
B. Place the bearing up and over the steerer tube.
5. Feed the FB housing up through the head tube
from below.
6. Push the steerer tube up into the head tube.
7. Support the fork during installation, as shown.
8. For disc brakes, tape the upper end of the brake hose
to identify it.
TIP
Build the bike close to a bench to support the fork
while installing the cable and housings.
8INSTALL THE FORK AND HEADSET
TOOLS AND MATERIALS REQUIRED
• Tape
100 mm
16 17

9. Arrange the housings in the head tube prior to
installing the upper head tube bearing.
• Non-drive side RD & RB
• Drive side FD & FB
NOTE Make sure that the RB hose is behind – to the
rear of – the RD housing.
10. Install the upper head tube bearing.
11. Install the compression ring.
IMPORTANT: The middle notch in the
compression ring must align with the groove
in the fork steerer tube.
12. As you install the compression ring, be sure to push
all housings back into the frame slightly to avoid
housing kinks.
Di2 NOTE Make sure that the Di2 wire is not
twisted around either brake housing.
NOTE Make sure that the RB hose is not kinked
from the headset compression ring back through the
top tube.
13. Install the bearing top cap.
Make sure that
the RB hose is
not kinked.
RB Hose
RB Housing
14. Interlock the required spacers and slide them down
the steerer tube to interface with the bearing top
cap.
Pins
Detents
The top caps and shaped spacers have pins and detents
that align as they stack.
If you’re building a mechanical drivetrain, go to Step 9
– Install the Stem (Mechanical Drivetrain) on page 20.
If you’re building a Di2 drivetrain, go to Step 10 –
Install the Stem (Di2 Drivetrain) on page 21.
18 19

1. Feed the FB & RB hoses and FD & RD housings through
the stem.
2. Fit the stem over the steerer tube.
3. As you slide the stem down the steerer tube, align the
detents on the spacers or bearing top cap with the
detents on the bottom of the stem.
Detents Pins
4. Install the expander into the fork. Follow the
recommended torque values to properly secure
the expander.
EXPANDER
NOTE
The black wedge
faces forwards
5. If needed, install additional standard-round spacers
above the stem.
6. Install the stem cap and preload the headset bearings
with a max torque of 4 Nm.
7. Align the stem and tighten the stem pinch bolts to the
recommended torque.
The two detents in the bottom of the stem align with the
pins on the shaped spacers.
Go to Step 11 – Install the Handlebar and Shift Levers
on page 22.
9INSTALL THE STEM MECHANICAL DRIVETRAIN
1. Connect the JC200 connector to the short end of the
Y wire.
2. Route the wire assembly through the stem body.
TIP Push the Y end of the wire through the back
of the stem and out the stem end.
3. Push the FB and RB housings through the stem.
4. Connect the short end of the Y wire to the cockpit
wire.
5. Feed the FB and RB housings through the stem as
shown.
NOTE The JC200 connector must ultimately rest
inside the stem.
NOTE Make sure that the Di2 wires and the brake
housings are not twisted together.
6. Install the stem onto the steerer tube.
7. Fit the stem over the steerer tube.
8. As you slide the stem down the steerer tube, align the
detents on the spacers or bearing top cap with the
detents on the bottom of the stem.
Detents Pins
9. Install the expander into the fork. Follow the
recommended torque values to properly secure
the expander.
10. If needed, install additional standard-round spacers
above the stem.
11. Install the stem cap and preload the headset
bearings with a max torque of 4 Nm.
12. Align the stem and tighten the stem pinch bolts to
the recommended torque.
Go to Step 11 – Install the Handlebar and Shift Levers
on page 22.
10 INSTALL THE STEM Di2 DRIVETRAIN
20 21

DERAILLEURS
1. Push the routing wire through the bottom of the
handlebar toward the FB lever exit hole.
2. Use the routing wire to pull the FD cable through
the handlebar.
FDC
LEVER EXIT HOLE
FOR DI2 WIRES
3. Pass the FD Di2 wire through the hole on the outside
of the handlebar, and then bend it back into the inner
hole, as shown.
4. Tape the FD Di2 wire to the handlebar.
5. Repeat the routing procedure for the RD cable in the
RB lever exit hole.
BRAKES
6. Push the routing wire through the centre of the
handlebar towards the FB lever exit hole.
7. Use the routing wire to pull the FB housing through
the handlebar.
8. When the routing wire exits the lever exit hole, use the
wire to pull the housing through the handlebar and out
the shifter hole. You can wiggle the housing a bit to
help ease it through.
11 INSTALL THE HANDLEBAR AND SHIFT LEVERS
AT THIS POINT, YOU SHOULD HAVE A COMBINATION OF FOUR POSSIBLE CONFIGURATIONS:
Drivetrain Brakes Configuration
Mechanical Disc FD housing/cable, RD housing/cable, FB hose, RB hose
Mechanical Rim FD housing/cable, RD housing/cable, FB housing, RB housing
Di2 Disc FD and RD Di2 wires (from the Y wire), FB hose, RB hose
Di2 Rim FD and RD Di2 wires (from the Y wire), FB housing, RB housing
TOOLS AND MATERIALS REQUIRED
• Park Tool Routing Kit (IR-1 or IR-1.2) • Handlebar
• Shift levers • Tape measure
9. As the bike is orientated upright, the RB housing
should be on the top of all other housings coming out
the handlebar exit hole.
DERAILLEUR
BRAKE
10. Repeat the procedure for the RB housing to the RB
lever exit hole.
FDC
LEVER EXIT HOLE
11. Place the handlebar in the stem.
NOTE You may need to pull out the brake and/
or derailleur housings from the shift lever holes as you
align the handlebar with the stem.
Di2 NOTE Make sure that the JC200 connector is
inside the stem and that the wires are not bunched
or kinked.
12. Attach the stem faceplate. Install the rear two bolts
first.
IMPORTANT: It is critical that the rear two bolts are
torqued first; then torque the front two bolts.
Di2 ONLY
13. Install the Di2 wire for the charge port. One end of
the wire plugs into the charge port. The other end
connects to the handlebar shifter lever.
Rear bolts must
be torqued first.
Front bolts must be
torqued second.
22 23

INSTALL THE SHIFT LEVERS
1. On the drive side, insert the RD housing and the RB
housing into the applicable locations in the shifter
body. Measure the depths of the seated housings. You
will use these measurements later in Step 4.
2. Place the drive-side shift lever on the handlebar to the
desired location.
3. Take the measurement from the rear of the
handlebar exit hole to the housing insertion point
on the shift lever.
4. Now add on your insertion depth from Step 1, plus
another 10-20 mm.
Example for rear brake:
Insertion depth (Step 1) = 40 mm
Rear of exit hole to shifter body (Step 3) = 40 mm
Add an additional 10-20 mm (Step 4) = 15 mm
Total cut length would be 95 mm
5. Make note of the shift lever location, then move the
shift lever down the handlebar to make room for
cutting the housing.
6. Measuring from the rear of the handlebar exit hole, cut
off the total length from the RD housing.
7. Re-install the RD housing ferrule.
8. Repeat Steps 1-6 for RB, FB and FD housings.
9. Re-install the FD housing ferrule.
10. On the drive side, push the shift lever back up on
the handlebar to the desired location while inserting
the housings in place in the shifter body. Tighten the
bolts to the recommended torque value.
11. Repeat Step 10 for the non-drive-side shift lever.
12. Route the derailleur cables back through the frame
to their respective derailleurs.
If you’re installing rim brakes, go to Step 12 – Install
the Front Rim Brake on page 26.
If you have disc brakes, go to Step 15 – Install and
Adjust the Seatpost on page 31.
24 25

1. Pull the front brake cable a safe distance back from the
housing end. Cut the brake housing flush with the rear
surface of the fork.
Cut here
FRONT BRAKE
CABLE SAFELY OUT
OF CUT ZONE
2. Finish the end of the housing so that there are no
sharp ends that could rub on the brake cable.
3. Install the brake cable and fully seat the cable end.
4. With the fork turned to full left, route the brake cable
through the housing stop, slip the housing stop up
until you can fully seat the brake housing into the stop.
Connect the brake housing stop to the fork and tighten
the countersunk bolt to 6 Nm.
5. Install the front brake arms and tighten the bolts to the
recommended torque.
6. Install the brake cover and tighten the bolts to the
recommended torque.
Brake arm bolts Brake cover bolts
Go to Step 13 – Adjust the Front Rim Brake on page 27.
12 INSTALL THE FRONT RIM BRAKE 13 ADJUST THE FRONT RIM BRAKE
1. With the fork turned to full left, slide the brake wedge
onto the cable. Do not tighten.
NOTE The front wedge is gold. The rear wedge
is black.
2. Slide the wedge up the brake cable and install it in the
rollers of the brake arms at the ‘home’ location. Make
sure that the wedge sits in the brake cover groove.
3. While you pull the cable tight, use a marker to draw
a line on the brake cable at both the top and bottom
edges of the brake wedge.
MARK
MARK
15 mm
4. Remove the wedge from between the rollers and slide
it up the cable (towards the fork). Cut the cable at the
bottom line.
CUT ON THE
BOTTOM LINE
5. Slide the wedge back down to just bury the top cable
mark inside the wedge, approximately 1.5 mm.
APPROX. 1.5 mm
6. While you hold the wedge flat with a 9 mm spanner,
tighten the cable clamp screws to the recommended
torque.
7. Reinstall the wedge between the brake arm rollers.
8. Install the front wheel.
9. If needed, replace the brake pads to correspond with
the rim material (carbon vs aluminium). The pad
retention screw must be installed to retain the pads.
10. Loosen the pad carrier bolts, lightly engage the
brake and position the pads on the rim. Tighten the
pad carrier bolts to 5 Nm.
26 27

11. Squeeze the brake lever fully to seat the housing and
to stretch the brake cable.
12. Symmetrically adjust the spacing between the pads
and the rim with the pad width spacing bolts.
13. Keeping the brake wedge centred, there should be
about 1.5 mm clearance between a pad and the rim.
You’ll centre precisely in the next steps.
1.5 mm
NOTE Do not use the wedge height to adjust for
rim width. If the wedge is positioned incorrectly, it may
rub on the cover.
14. Symmetrically adjust the centring bolts to adjust the
lever feel.
15. Use the appropriate centring bolt to make the final
centring adjustment.
NOTE For example, tightening the drive side
centring bolt will pull the drive side pad away from the
rim and vice versa.
16. Tighten the stem pinch bolts to recommended
torque.
Go to Step 14 – Install the Rear Rim Brake on page 29.
Pad width
spacing bolt
Centring bolt
1. Pull the rear brake cable slightly out of the lever.
REAR BRAKE
CABLE
2. Remove the tape from the housing at the frame.
3. With the handlebar rotated all the way to the right, cut
the rear brake housing so that it extends 20 mm out
the back of the seat tube.
20mm
4. Check the RB housing extending
from the rear of the frame. If
necessary, finish the end of the
housing to make sure that there
are no sharp ends to rub the brake
cable.
5. Route the rear brake cable through the housing from
the drive side shift lever back to the frame exit hole.
6. Install the end cap with integrated liner.
7. Fully seat the brake cable head in the shift lever.
14 INSTALL THE REAR RIM BRAKE
TOOLS AND MATERIALS REQUIRED
• Housing stop and bolt • Cable cutter
• Ferrule with integrated liner • Pliers
28 29

8. Pass the brake cable and lined end cap into the rear
brake housing stop.
9. Push the excess housing back into the frame until the
hook feature of the housing stop engages the bottom
of the slot on the inside of the damper housing.
10. Install the M4 countersunk bolt and torque to the
recommended value.
HOOK FEATURE
11. Proceed with the same assembly steps used in
the set-up of the front rim brake, including wedge
installation and brake adjustment.
NOTE The wedge for the rear brake is coloured
black.
Go to Step 15 – Install and Adjust the Seatpost
on page 31.
1. Remove any tape or rubber band from around the
seatpost wedge prior to installation.
2. Install the lower seal into the bottom of the seatpost.
NOTE For full seatpost insertion, you may need to
remove the lower seal.
3. Insert the seatpost into the seatmast. Be sure to have
the wedge placed in the seatpost prior to insertion.
4. Tighten the bolts just until the seatpost and wedge are
snug. Do not fully tighten yet.
Seatpost
Bolts
5. Install the saddle. Ensure that the clamp ear correctly
fits the saddle rail shape.
6. To adjust the angle of the top of the saddle, loosen
the rear pinch bolt, adjust the angle, then re-tighten
the bolt.
15 INSTALL AND ADJUST THE SEATPOST
TOOLS AND MATERIALS REQUIRED
• Saddle • Seatpost wedge and bolts • Long stem 5 mm hex wrench
• Seatpost • Lower seal • Torque wrench
Seatpost
wedge
30 31

7. To adjust the fore/aft position of the saddle, loosen the
side rail clamp bolt, slide the saddle, then re-tighten
the bolt.
8. To adjust the seat height, loosen two seatpost clamp
bolts, adjust the height and re-tighten the bolts to the
recommended torque value.
Seatpost
Bolts
NOTE: Use a long-stem 5 mm socket on your torque
wrench to tighten the seatpost bolts. This will allow an
improved fit on the bolt and will prevent marks on the
bike finish.
1. From the rear base of the seatmast, use the 2.5mm
Allen™ key to loosen the damper preload set screw
out 5mm.
Set screw
RIM
BRAKE
DISC
BRAKE
2. Under the top tube, use the 4mm Allen™ key to
remove the top tube pinch bolt.
Top tube pinch bolt
The seatmast and decoupler will tip forwards to expose the
adjustment slider.
Adjustment slider
3. Reference the slider decal to help determine the
desired setting.
NOTE Moving the slider forwards will allow for
more deflection and greater flex. Moving the slider
backwards will cause less deflection and a stiffer ride.
4. Tighten the top tube pinch bolt to the value on the top
tube decal.
5. Tighten the damper preload set screw to 2Nm.
ADJUST THE ISOSPEED SYSTEM
TOOLS REQUIRED
• 2.5mm Allen™ key • 4 mm Allen™ key
16
32 33

17 SERVICE INFORMATION
Di2 Handlebar Specifications for Reference
Frame Size Bar Size Y-Wire Spec Charge port to DS Shifter
50
40
JC130-SM [350 mm/50 mm/450
mm]
JC130-MM [550mm/50
mm/550mm]
SD50 -[350 mm]
52
54
42
56
58
4460
62
Di2 Frame Specifications for Reference
Frame Size Stem to DT Junction B Battery to DT Junction B FD to DT Junction B
RD to DT Junction B
SD50 -[950 mm]
50 SD50 -[650 mm]
SD50 -[150 mm] SD50 -[550 mm]
52 SD50 -[650 mm]
54 SD50 -[700 mm]
56 SD50 -[700 mm]
58 SD50 -[750 mm]
60 SD50 -[750 mm]
62 SD50 -[800 mm]
16 FIT MEASUREMENTS
Saddle X
9
Saddle height
(BB to top centre of saddle)
Saddle tilt
Saddle Y
Saddle set-back
Handlebar X
Saddle-to-bar drop
Handlebar Y
BIKE MEASUREMENTS (CM)
Saddle height
Saddle model
Saddle size
Saddle tilt
Saddle set-back
Seatpost offset
Saddle tip to bar
Saddle tip to shifter
Saddle-to-bar drop
Stem length/angle
Handlebar width
Handlebar model
Headset spacer height
Crank arm length (mm)
Handlebar X coordinate
Handlebar Y coordinate
Saddle X coordinate
Saddle Y coordinate
3534

date miles/km
SERVICE NOTES
hours