Trek MADONE SL 2022 Operating manual

2022 MADONE SL
SERVICE MANUAL SUPPLEMENT

2022 Madone SL Service Manual
1
Safety
WARNING
Tighten hardware properly
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
Re-apply threadlocker
All reused-fasteners with pre-applied threadlocker
must be cleaned with isopropyl alcohol and have
new threadlocker applied (Loctite 243 or equivalent)
before re-assembly. If a threadlocker is not applied, the
fasteners may loosen, which could damage the bicycle
and result in injury to the rider.
Legend
apply grease
apply threadlocker
Nm torque value
zip tie
Contents
Brake lines 2
Shift cables – mechanical 3
T47 bottom bracket (BB) 4
Fork and headset 5
IsoSpeed 7
Seatpost 8
Copyright 2021 Trek Bicycle Corporation All Rights Reserved

2022 Madone SL Service Manual
2
Brake lines
25mm
1 2
The calliper mounting bolt
channel is 25 mm on all
2022 Madone SL bicycles.
1 Housing grommet – W330578
2 DuoTrap cover – W521455
Route the front hose
1. Connect the calliper to the front brake hose using a
new barb and olive.
2. Route the brake hose through the lower end of the
fork to the steerer tube.
3. Attach the calliper to the fork. Do not torque the
mounting bolts fully until the calliper is aligned cor-
rectly.
Route the rear hose
1. Connect the calliper to the rear brake hose using a
new barb and olive.
2. Feed the hose through the grommet.
3. Route the brake hose through the chainstay to the
head tube.
4. Attach the calliper to the bicycle. Do not torque
the mounting bolts fully until the calliper is aligned
correctly.
For additional information on brakes, refer to the user
manuals on the websites below:
• SRAM www.SRAM.com
• Shimano www.Shimano.com

2022 Madone SL Service Manual
3
Shi cables – mechanical
2–3 Nm
6 Nm
2–3 Nm
1
2 3
4
5
6
7
3 Nm
8 9
10
eTap only
1 Rear housing grommet – W317292
2 Rear derailleur hanger – W524188
3 Rear derailleur hanger bolts – W318604
4 Front housing grommet – W326042
5Front derailleur hanger – W531901
6 Front derailleur bolt – W543903
7 Chainkeeper parts – 5373827
8 Control centre – W1044890
9 Flat head bolts – W304515
10 eTap grommet plug – W547906
Route the cables back to front
1. Feed each cable through the corresponding
grommet.
2. Route the rear shift cable through the seat stay to the
head tube.
3. Route the front shift cable through the seat tube to
the head tube.
4. Mark the front and rear shift cables with masking
tape. You will need to tell them apart when you
assemble the headset.
5. Attach each derailleur to the bicycle.
6. Connect the shift cables to the derailleurs.
7. Zip tie the shift cables and rear brake hose to the
control centre.

2022 Madone SL Service Manual
4
T47 bottom bracket (BB)
Install the BB
1. Apply grease to the threading on both sides of the
frame.
2. Using your hands, thread the BB onto the frame.
NOTICE: Do not start by tightening the BB with a
tool. Dirt and other contaminants can damage the
threading.
3. Use the proper tool to torque both sides to spec
(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 BB/crank combinations that
require spacers. Your bicycle may have other combinations
that do not require spacers.
Crank BB (inboard)
Spacers required
Drive
side
Non-drive
side
Shimano CeramicSpeed
24 mm 0.5 mm 0.5 mm
SRAM DUB SRAM DUB 2–3 mm —
GXP Wheels MFG 1.0 mm —
non-drive side
washer
drive side
washer
SRAM GXP
cranks only
Tool and spline compatibility
Tool Praxis Unior Park Wheels MFG CeramicSpeed
Model
Part number
TP-2400
594148
TP-3028
594147
1671.T47
1043614
BBT-47
568922
BBTOOL-48-44
589307 —
BB manufacturer
Praxis
24
mm
X X
30
mm
X X
Wheels MFG X
SRAM DUB X X
Chris King X X
Ceramic-
Speed
24
mm
X X X
GXP X

2022 Madone SL Service Manual
5
Fork and headset
2–4 Nm
9–10 Nm
0.7 Nm
1
2
3
4
5
6
7
8
9
10
12
11
The arrow on the expander
plug must face forward.
optional spacers
1 Expander plug – W5257464
2 Spacer (5 mm) – 5253930
3 Stem (as shown) – 564744
4 Routing spacer – W5264867
5Spacers (5 mm) – 5253093
6 Spacers (15 mm) – 5253094
7 Top cap (black) – W5251927
8 Steerer stop bolt – W318529
9 Steerer stop – W5265664
10 Split ring – W563834
11 Upper headset bearing – W513538
12 Lower headset bearing – W540243

2022 Madone SL Service Manual
6
Fork and headset
Install the headset
1. Clean the steerer tube using isopropyl alcohol.
2. Grease both bearings, the crown race and the inside
of the head tube as shown below.
12
11
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 lines through the
split ring.
FB
RB
FD RD
5. Assemble the headset to the stem as shown on
page 5. Make sure the stem is in its nal position
with the required spacers underneath.
6. Cut the steerer tube 2 mm above the stem.
2mm
7. Assemble the rest of the headset. Do not tighten the
expander plug fully.
8. Attach the handlebars and levers.
9. Tighten the expander plug screw to your desired
steering stiffness.
2-4 Nm
loosen bolts
to adjust
rear derailleur
rear brake
front brake
front derailleur

2022 Madone SL Service Manual
7
IsoSpeed
stiff
soft
To adjust the ride feel,
loosen both bolts shown
above and move the slider.
NOTICE: Do not apply grease to
the frame pockets. Only apply
grease to the parts shown to the
right.
8 Nm
2 Nm
2 Nm
2 Nm
16
1
1
59
6
1
2
13
12
910 11
8
7
4
3
6
5
14 17
15
16
NOTICE: Carefully remove the covers
with a paint-safe plastic pry-bar.
1Nut
kit W569265
9Damper carriage
kit W564007
2 Cylindrical bushing 10 Damper housing
3 Washer 11 Damper
4Wave washer 12 Buttonhead screw
5Bolt 13 Flathead screw
6 Flanged bushing – W561683 14 Adjustment slider – W564294
7 Internal cover – W565904 15 Bumper – 598668
8External cover (black as shown) – W573720 16 Screw – 579510
17 Washer – 581552

2022 Madone SL Service Manual
8
Seatpost
5 Nm
7 Nm
9 Nm
4 Nm
1
2
3
4
7
8
6
5
1 Wedge
kit W574676
2 Bolt
3 Plate
4 Wedge bolts
5Pinch bolt
6 Pinch bolt/saddle tilt clamp ears (7x7 mm)
– W524900
7 Seatpost tail – W557630
8 Seat mast cap (dark grey as shown) – W569842