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
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