Trek Madone 2016 Assembly Manual
2016 MADONE ASSEMBLY MANUAL
FD
RD
RB
2016 MADONE
And with that understated note, after more than three
years and tens of thousands of hours of development,
the final Madone prototype was approved.
The 2016 Madone development project was the most
ambitious we have ever undertaken. Our self-imposed
directive: throw convention to the wind (literally) and
redefine aero road bike performance.
Along the way, we completely reinvented the way
CFD (computational fluid dynamics) can optimize
bicycle aerodynamics, using cloud-based cluster
computing, the most advanced commercial CFD
software, and rigorous wind tunnel correlation. We
optimized every millimeter, every component, every
detail of the bike, even water bottle placement.
Our job didn’t end with aerodynamics. We’d set our
sights much higher: an aero bike with exceptional ride
quality. We adapted our groundbreaking IsoSpeed
system to this new aero platform with an innovative
tube-in-tube design, and we logged thousands of
miles in the velodrome and on the road, testing
compliance and handling and general ride feel using
sophisticated instruments—along with opinionated
feedback from our most demanding test riders, the
Trek Factory Racing team.
Hundreds of people had a hand in making the 2016
Madone a reality, from engineers to product managers
to graphic designers to carbon techs on the Waterloo
factory floor. It wouldn’t be the bike it is today without
each of their contributions. At the end of the long
development process, we knew we’d all achieved
something amazing. This is the one.
Sincerely,
The Madone Development Team
FD
FD
RD
RD
RB
FB
TABLE OF CONTENTS
Introduction 2
1. Installing housings in the handlebar 3
Installing the front derailleur housing 3
Installing the rear derailleur housing 5
Installing the rear brake housing 5
Installing the front brake housing 6
Installing the rear brake guide cable 6
2. Installing levers on the handlebar 7
Installing the levers and cables 7
Installing the rear brake housing 8
3. Installing the fork and the handlebar 9
Guiding the housings to the cutouts 9
Installing the fork 10
Cutting the fork 10
4. Installing the front brake 13
Installing the front brake cable/front brake arms 13
Adjusting the front brake 14
Installing the vector wings and brake cover 15
5. Installing the rear brake 16
6. Installing the Control Center (mechanical) 17
7. Installing Di2 wires in the handlebar 20
Installing the front derailleur Di2 wire 20
Installing the rear derailleur Di2 wire 21
8. Installing the Control Center (Di2) 22
Installing the Di2 junction box 22
Charging the battery 23
Trimming the derailleurs 23
9. Installing the chain keeper 24
10. Installing and adjusting the seatpost 25
11. Making basic fit adjustments 26
Raising handlebar height 26
Lowering handlebar height 26
12. Attaching the light or reflector 27
Attaching the rear bracket and light or reflector 27
Attaching the front mount 27
13. Traveling with your Madone 28
Removing the handlebar 28
Attaching the handlebar to frame 28
14. Fit measurements 29
15. Service Information 30
Madone 9 Series seat tube water bottle screws 30
1
Madone
THE ULTIMATE RACE BIKE
Congratulations.
If you’re reading this assembly manual, odds
are you’re about to lay hands on the most
advanced road bicycle Trek has ever made.
The all-new Madone represents a complete
redefinition of the road bike ideal. Unburdened
by convention, Trek engineers chased a new
vision—a bike that would not only set a new
standard in aerodynamic design, but would
ride like no other aero race bike.
The result: an exquisite race machine with
unparalleled aerodynamics, unmatched ride
quality, and unprecedented integration.
We didn’t just build a new aero road bike.
We built the ultimate race bike.
2
FBC
FDC
RDC
RBC
R D
R D
FB
FB
RB
RB
F D
F D
The 2016 Madone has a completely new
handlebar with internal cabling.
Installing the front derailleur
housing in the handlebar
TOOLS AND MATERIALS REQUIRED
• Installation cable (1) with
shift head
• Handlebar
• Derailleur housings (2)
• Brake housings (2)
• Hook tool
1. Prepare the housing. Cut it to length and finish the
ends (but do not install end caps).
NOTES
• One installation cable can be reused to install all
the housings.
• The length for each housing, by frame size, is
shown in the table at right.
2. Pass the installation cable completely through the
housing.
INSTALLATION CABLE
HOUSING
CABLE HEAD
Refer to precut/pre-installed housing lengths in table
below according to frame size.
Mechanical build housing lengths for 2016 madone
Total cable length recommendations
Frame size Recommended housing length in mm (as shipped*)
H1
Front
brake
Front
derailleur
Rear
brake
Rear
derailleur
50 595 670 1080 715
52 595 650 1105 695
54 605 650 1110 705
56 625 660 1110 705
58 645 675 1140 725
60 665 695 1160 74 0
62 690 715 1150 760
H2
Front
brake
Front
derailleur
Rear
brake
Rear
derailleur
50 615 655 1070 700
52 625 670 1095 715
54 640 675 1105 730
56 655 700 1130 735
58 680 710 1140 750
60 665 695 1150 745
62 715 745 1165 790
* Lengths as shipped include 80mm of excess housing to allow for
trimming to optional length based on bike setup.
NOTE
These lengths are subject to further trimming for
proper installation.
1 INSTALLING HOUSINGS IN THE HANDLEBAR
3
1
INSTALLING HOUSINGS IN THE HANDLEBAR
3. On the bottom of the stem, identify the correct hole for
the front derailleur (FD).
BOTTOM OF STEM
Installation sequence of the four housings.
4
2
3
R D
FB
RB
F D
FBC
FDC
RDC
RBC
1
REAR
DERAILLEUR
REAR
BRAKE
FRONT BRAKE
FRONT
DERAILLEUR
Stem after all four housings have been installed.
FBC
FDC
RDC
RBC
4. Push the installation cable through the bottom of the
stem toward the lever exit hole.
FDC
F D
LEVER EXIT HOLE
TIP
You may have to use a HOOK to pull the cable out.
HOOK
5. When the cable exits the lever exit hole, use the
cable to pull the housing through the bar until
60mm of housing protrudes from the handlebar.
You can help ease the housing through by
wiggling it a bit.
FDC
60mm
4
1
INSTALLING HOUSINGS IN THE HANDLEBAR
6. Remove the installation cable from the housing.
FDC
60mm
Installing the rear derailleur
housing in the handlebar
1. Repeat the same steps as performed for
front derailleur, but use the hole marked RDC.
FBC
FDC
RDC
RBC
R D
REAR DERAILLEUR
Installing the rear brake
housing in the handlebar
1. Repeat the same steps as performed for
front derailleur, but use the hole marked RBC.
FBC
FDC
RDC
RBC
RB
REAR BRAKE
NOTE
The rear brake housing must be behind the rear
derailleur housing as the housings exit the shared
stem hole. (See tip below.)
RBC
FBC
RDC
RBC
TIP
You can make sure the rear brake housing is in its
proper position behind the shift housing by passing the
brake housing through the hole on the outside of the
handlebar and then bending it back into the inner hole.
The cable may bend sharply during this process—just
be careful to avoid a permanent kink.
NOTE
As the brake housing exits the lever hole, it should
always be on top of the derailleur housing.
DERAILLEUR
BRAKE
5
Installing the front brake
housing in the handlebar
1. Repeat the same steps as performed for the
front derailleur, but use the hole marked FBC.
FBC
FDC
RDC
RBC
FB
FRONT BRAKE
NOTE
Handlebar should now have FOUR HOUSINGS.
FBC
FDC
RDC
RBC
Installing the rear brake
guide cable
TOOLS AND MATERIALS REQUIRED
• Spare cable (1)
• Frame
• Tape
TIP
This step is easier if the frame is turned upside down.
1. Pass an installation cable through the hole in the
rear of the seat tube (rear brake housing stop
hole), the holes in the inner seat mast, and the top
tube. The cable should exit the cutout in the head
tube, to the rear of the upper headset bearing.
CUTOUT
HOLES IN THE INNER
SEAT MAST
BRAKE CABLE
REAR BRAKE
HOUSING
STOP HOLE
2. Lightly tape this cable in place while other guide
cables are installed.
1
INSTALLING HOUSINGS IN THE HANDLEBAR
6
2 INSTALLING LEVERS ON THE HANDLEBAR
Installing the levers and cables
TOOLS AND MATERIALS REQUIRED
• Brake cables (2)
• Derailleurs (2)
• Levers (2)
• Handlebar
(with housings installed)
1. Slide the levers onto the handlebar, but stop
before they contact the housings. Do not tighten
the clamp bolts yet.
BRAKE HOUSING (TOP)
DERAILLEUR HOUSING (BOTTOM)
2. Install the front derailleur cable and front brake
cable into the left lever. Fully seat the cable heads.
NOTE
Do not cut the housing. 60mm should protrude
from the lever holes in the handlebar.
This is to aid in installing the housing
into the shifter. You will push the
housing back through the frame to
get it to the proper length.
3. Place end caps onto the lever end of
the derailleur housings.
NOTE
Ensure that the brake housing is on top of the
derailleur housing and not twisted.
DERAILLEUR
BRAKE
4. Pass all the cables into
the housings.
5. Place the housings into
the proper housing stops
on the levers.
6. Slide the levers to the preferred position.
If the housings do not pass freely through
the stem, lightly pull on the housing where
it comes out of the stem.
7. Tighten the lever clamps. At this point, the levers
are positioned on the handlebar, the housings
extend out of the stem, and the housings have
cables in them.
7
Installing the rear brake housing
TOOLS AND MATERIALS REQUIRED
• Frame
• Electrical tape
• Foam sleeve
• Handlebar
(with levers installed)
• Non-drive side
bearing top cap
1. Pass the rear brake housing through the non-drive
side of the top cap.
FBC
FDC
RDC
RBC
NON-DRIVE SIDE
BEARING TOP CAP
SMALLER END
TOWARDS FRONT
OF BIKE
ACCESS
HOLE
REAR BRAKE HOUSING
2. To minimize rattle of the housing in the top tube,
pass the housing through the foam sleeve until the
front edge of the sleeve nearest the handlebar is
60mm from where the housing exits the bottom of
the stem. Secure the foam with tape.
60mm
FOAM SLEEVE
2
INSTALLING THE REAR BRAKE HOUSING
3. Pull the rear brake cable halfway
out of the lever.
REAR BRAKE
CABLE
4. Slide the rear brake housing onto the installation
cable coming out of the head tube, until the two
cables meet.
REAR BRAKE CABLE
REAR BRAKE
HOUSING
INSTALLATION
CABLE
5. Push the housing through the top tube until it
pushes the installation cable out the hole in the
rear of the seat tube.
8
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