Trek 2021 E-CALIBER Operating manual
2021 E-CALIBER
SERVICE MANUAL SUPPLEMENT
2021 E-Caliber Service Manual
1
Contents
Safety 1
Headset with Knock Block 2
Frame and drive system guards 3
Rear triangle and chainstay bridge 4
Main pivot 6
Dérailleur hanger 7
Cabling overview 8
IsoStrut remote lockout cable 9
IsoStrut 10
Air volume spacer 11
Carriage wiper seals and bushings 14
Fazua system 19
Specications 20
Suspension 21
Safety
WARNING
Alwaystightenhardwaretothespeciedtorque.
Over-tightening hardware could deform or break the
hardwareorcomponents.Under-tighteninghardware
couldcausehardwareorcomponentstobecomeloose.
Either situation could damage the bicycle and result in
injurytotherider.
WARNING
All reused-fasteners with a pre-applied threadlocker
must be cleaned with isopropyl alcohol and have new
threadlockerappliedbeforere-assembly.Ifathreadlock-
er is not applied, the fasteners may loosen, which could
damagethebicycleandresultininjurytotherider.
Copyright 2021 Trek Bicycle Corporation All Rights Reserved
2021 E-Caliber Service Manual
2
Headset with Knock Block
1
2
3
4
5
6
7
Item Description
Quantity in
Assembly Part Number Torque (Nm)
1 Upperbearingcover 1
5252159
—
2 Knock Block chip bolt 1 2
3 Knock Block chip, 62 degrees 1 —
4 Compression ring 1 —
5 Upperbearing 1 —
6 Lower bearing 1 5252158 —
7 Crown race 1 —
Tools
• 2.5mmhextool
• Torquewrenchwith2.5mmhexbit
• Headset tools
• Grease
1. Inspectthecomponentsfordamageorexcessive
wear.
• Knock Block chip (3)
• Undersidechanneloftheupperbearingcover(1)
• Interlocking keys of the upper bearing cover (1)
and the stem
2. Replaceanydamagedorworncomponents.
3. Apply grease to:
• Upperandlowerheadtubebearingbores.
• Inside of the bearing seats of the compression
ring(4)andthecrownrace(7).
4. Install the crown race (7), then the lower the bearing
(6)ontothesteerertube.
5. Insert the steerer tube into the bottom of the head
tube.
6. Install the upper bearing (5), then the compression
ring(4)ontothesteerertube.
7. Insert the Knock Block chip (3) and bolt (2) into the
frame,butdonottightenit.
8. Installtheupperbearingcover(1).
9. Installspacersasneeded.
10. TorquetheKnockBlockchipbolt(2)to2Nm.
2021 E-Caliber Service Manual
3
Frame and drive system guards
1
3
4
3
2
Item Description
Quantity in
Assembly Part Number Torque (Nm)
1 Chainstay guard 1 W582883 —
2 Down tube guard 1 W582884 —
3 Drive unit guard fasteners 4 5269023 3
4 Drive unit guard 1 W1040440 —
Chainstay and down tube guards
Useisopropylalcoholtocleantheframesurfacewherethe
guardsattach.Waitforthealcoholtodrybeforeapplying
theguards.
Notice: Do not clean the entire frame with isopropyl
alcohol.Isopropylalcoholcoulddamagethepaint.
2021 E-Caliber Service Manual
4
Rear triangle and chainstay bridge
1
3
2
4
4
5
Item Description
Quantity in
Assembly Part Number Torque (Nm)
1 RearIsoStrutaxle 1 591626 10
2 End cap bolt 1 —
3 Front IsoStrut bolt and washer 2 W584485 5
4 Chainstay bridge bolt 4 5265697 8
5 Chainstay bridge, charcoal colour 1 5266755 —
Tools
• Bike repair stand
• Torquewrenchwith6mmhexbit,T25andT30
Torxbits
• Grease
Important: You must have the main pivot bearing and
sleeve (See the Main pivot section on page 6) and the
IsoStrut (See the IsoStrut section on page 10) installed
on the rear triangle before attaching the rear triangle to
theframe.
1. Puttheseatpostintoabikerepairstand.
2. Fitthereartriangleintothemainframe.
3. InstallthetwofrontIsoStrutboltsandwashers(3).
Important: Donottorquetheboltsatthistime.
4. Apply greasetotheIsoStrutrearaxle(1).
5. InstalltheIsoStrutrearaxle(1)andendcapbolt(2).
Important: Donottorquetheboltsatthistime.
6. Applygreasetotheatsurfacesofthechainstay
bridge(5).
2021 E-Caliber Service Manual
5
Rear triangle and chainstay bridge (continued)
7. Insert the chainstay bridge (5) inside the rear
triangle.
4
4
5
8. Install the four bridge bolts (4) to attach the bridge to
thereartriangle.
9. If applicable, install the main pivot hardware before
torquingthebridgebolts(4).SeetheMain pivot
section on page 6.
10. Torque:
• Chainstaybridgebolts(4)to8Nm.
• IsoStrutrearaxle(1)to10Nm.
• FrontIsoStrutbolts(3)to5Nm.
2021 E-Caliber Service Manual
6
Main pivot
1
234
3
2
5
Item Description Quantity in
Assembly
Part Number Torque (Nm)
1 Main pivot nut 1 W584134 —
2 Washer 2 W440921 —
3 Main pivot bearing 2 W302025" —
4 Main pivot sleeve 1 W600642 —
5 Main pivot bolt 1 W600628 30
Tools
• Bearing press
• 8mmhextool
• Torquewrenchwith8mmhexbit
• Grease
1. Pressinthedrive-sidebearing(3).
2. Insertthesleeve(4)fromthenon-driveside.
3. Pressinthenon-drive-sidebearing(3).
4. Position the chainstay over the seat tube, ensuring
thatthemainpivotholesarealigned.
Tip: Slidethelongarmofthehextoolfromthenon-
drive-sideandthroughthealignedpivotholes.For
eachstep,slidethecomponentontothehextoolto
alignthecomponentsoneachsideofthemainpivot.
5. Apply grease to the shoulder of the main pivot
bolt(5).
6. Insert the drive-side washer (2) between the bearing
thechainstay.
7. Partially insert the main pivot bolt (5) from the drive
side.
8. Insert the non-drive-side washer (2) between the
bearingandthechainstay.
9. Fullyinsertthemainpivotbolt(5).
10. Installthenut(1).
11. Torquethemainpivotbolt(5)to30Nm.
2021 E-Caliber Service Manual
7
Dérailleur hanger
1
2
Item Description Quantity in
Assembly
Part Number Torque (Nm)
1 Thruaxle,M12X1.0X15MM 1 W600321 10
2 Dérailleur hanger 1
W600660
—
Hanger bolt, left-handed thread 1 25
Washer, 25mm 1 —
ThisbicycleframeisdesignedtouseaUniversalDerailleur
Hanger(UDH).
NOTICE: ThethruaxlemustbecompatiblewithaUDH
andmustbeM12x1.0witha12.7mmthread.
NOTICE: Thewasherisframe-specic.Installonlythe
washercompatiblewithyourframe.
WARNING
Donotapplygreasetothederailleurhangerorbolt.Only
applygreasetothethruaxle.
1. Insert the hanger on the inside of the drive-side
chainstay.
2. Installthewasheronthederailleurhangerbolt.
3. Inserttheboltintotheframe.
4. Makesurethehangerispositionedasshownbelow.
5. Torquethehangerboltto25Nm.
NOTICE: Donotover-tighten.Over-tighteningthebolt
couldcausethehangertobreak.
ForadditionalinformationabouttheUDH,refertothe
SRAM user manual at sram.com.
2021 E-Caliber Service Manual
8
Cabling overview
1
4
5
6
9
10
11
12
7
8
2
3
Item Description Quantity in
Assembly
Part Number Torque (Nm)
1 Bolt 1 W562831 3
2 Speed sensor 1 W581396 —
3 Rear brake cable 1 — —
4 Speed sensor cable 1 — —
5 Dropper post cable 1 — —
6 IsoStrut lockout cable 1 — —
7 Head tube cable guide 2 W519232" —
8 Head tube cable guide fastener 2 W532763 1
9 Controller cable 1 — —
10 Down tube cable guide 3 W591416 —
11 Rear derailleur cable 1 — —
12 Grommet, for use with wireless derailleur only 1 5259425 —
Zip tie location 4 — —
Routeandziptiethecablesasshownintheillustrationabove.
Dropper cable
• For detailed dropper remote instructions, please refer
to the Drop Lock Remote manual at trekbikes.com/
manuals.
IsoStrut cable
• See the IsoStrut remote lockout cable section on
page 9.
2021 E-Caliber Service Manual
9
IsoStrut remote lockout cable
Tools
• Cable cutter
• Torquewrenchwith2mmhexbit
1. Installthecableintheremotelockout.
2. Route the cable through the hole in the bottom of the
top tube just in front of the IsoStrut and out the drive
sideoftheheadtubehole.
3. Attheheadtube,routethewirethroughthecable.
4. AttheIsoStrut,slidetheferruleonthewire.
5. Guidethewirethroughtheslotinthecablestop.
6. Route the wire around the lockout spool and install
thesetscrew.Torqueto1Nm.
Drive side Non-driveside
7. Testthatthemechanismworkssatisfactorily.
8. Cut the wire to the appropriate length (20-30 mm)
andcrimpanendcaponit.
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