Trek-Seed Pconcept

Service Information
Speed Concept 2011

The Trek Speed Concept bike is the fastest frameset we have ever made. To accomplish
this, we have used shaped tubes, hidden front and rear brakes, and very thin-walled carbon
tubes. Because of these unique features, the Speed Concept bike requires different or
additional assembly and adjustment techniques. Some of the tasks may have been done by
the factory. We include the instructions for these steps here for later reference when you
need to perform service on this bike.
We have also provided general maintenance information:
• Carbon fiber care
• Headset bearing installation
• Bottom bracket bearing installation for a variety of bottom bracket types
Note: Instructions for Shimano’s electronic Di2 are in a separate document. See your dealer.
These instructions are written for an experienced mechanic. If you need further information,
refer to your bicycle owner’s manual, the instructions in a bicycle mechanic’s handbook, or
consult your dealer.
Please save these instructions for future reference. Also check www.trekbikes.com for
updates.
Note about performing mechanical work on bicycles:

Many people think of bicycles as simple machines, almost toys. However, modern bicycles
use high-tech materials and designs that rely on correct maintenance and precision
workmanship. If any part on the bicycle is worn, corroded, rusted, loose, or damaged in
any other way, replace the part. If you do not have the correct tools or experience, do not
perform the tasks in this manual; take your bicycle to your dealer for service.
In some cases we provide several methods of checking the tightness or connection of parts.
The most preferable of these is always the one with the most precision. In other words,
correct mechanical work requires that all bolts be tightened with a torque wrench.
Incorrect mechanical work on your bicycle could lead to damage or premature breakage of a
part, which could cause you to fall and lead to serious injury or death.
Table of Contents
Working with Carbon Fiber Parts.................................................................... 1 Crankset
Pressing bearings........................................................................................... 19
Custom Components of the Speed Concept................................................2
SRAM GXP...................................................................................................... 20
Sizing the Bike......................................................................................................3 Shimano HollowTech.....................................................................................23
Seatpost Campagnolo UltraTorque.............................................................................27
To install the seatpost.....................................................................................4 Inspecting the bottom bracket................................................................... 29
To adjust the height of the saddle................................................................4 FSA MegaExo AL........................................................................................... 30
To reverse the seatpost head........................................................................4 Crankset Troubleshooting.............................................................................. 33
Using a Repair Stand

To attach the workstand clamp adapter.....................................................5
Headset Bearings and Fork

To remove the fork and bearings..................................................................6
To install the bearings and fork.....................................................................6
Cable Housings
To install the housing.......................................................................................7
To install the rubber top tube grommet......................................................7
Aerobar Assembly
To install the extensions and armrests.......................................................8
To install the shifters.......................................................................................9
To install the brake levers...............................................................................9
Aerobar Installation
To install the completed aerobar assembly.............................................10
Derailleur Cables
To connect the front derailleur cable.......................................................... 11
To connect the rear derailleur cable........................................................... 11
Front Brake
To install and adjust the front brake.......................................................... 12
Rear Brake
To install and adjust the rear brake............................................................ 14
DuoTrap Computer Sensor

To install a Duotrap sensor.......................................................................... 16
Draft Storage Box

To install a storage box................................................................................. 17
ii TREK SERVICE INFORMATION 02 November 2010

Working with Carbon Fiber Parts
Carbon fiber parts are different from metal parts, so they require different treatment.
Avoid sharp edges or excessive pressure

Carbon fiber composite can be damaged by sharp edges or clamping mechanisms which
cause a point load, or a high pressure area. Before installing any carbon fiber part, or
attaching any component to an existing carbon fiber part, follow these procedures to make
sure the parts or components are carbon-compatible.
As carbon frames have gotten lighter and lighter, you can now feel movement in the tubes
when you squeeze them. This is normal and no reflection of the strength of the frame.
However, repeated compression of the sides of the tubes is not good for them, and could
eventually lead to frame damage. Do not squeeze the frame tubing with your fingers, and
especially never clamp the tubing in any mechanical device, including car racks.
Clean carbon parts before installation

With some interfaces of metal parts, grease is used on the clamping surfaces to prevent
corrosion. When making adjustments, always grease the threads and shoulders of bolts.
Grease reduces corrosion and allows you to achieve the correct tightness without damaging
tools.
However, with most carbon parts you should avoid grease. If grease is applied to a carbon
part that is clamped, the part may slip in the clamp, even at the recommended torque
specification. When assembling parts that clamp a carbon surface, we recommend
applying one of the following special carbon prep products:
· Tacx carbon assembly compound
· Fiber Grip™ carbon fiber assembly gel from Finish Line
On the other hand, the bearing seats of the Speed Concept frameset do require grease, as
explained in these instructions.
Never modify the fork, frame, or components

The parts of the Speed Concept frameset have been carefully designed to meet the strength
and function requirements of safe riding. Modifying these parts in any way may make the
bike unsafe. As an example, removing the redundant wheel retention tabs on fork tips could
make the fork less functional.
Suspension forks can add stress to a bike frame. Never add a suspension fork to a road bike,
or change style and/or length of forks. If you are unsure if a fork is compatible with a frame,
call Trek customer service. Any modification of a frame, fork, or components means that the
bike no longer meets our specifications and will therefore void the bike’s warranty.
1 TREK SERVICE INFORMATION 02 November 2010

Custom Components of the
Speed Concept
The Speed Concept design incorporates a number of special parts with special features.
This section gives a brief explanation of some of the features, their use and maintenance,
and general information about the bike.
Compatibility of parts
Trek only recommends Bontrager parts for the Speed Concept bike because with these parts
the torque specifications and, crush strength have been evaluated by our engineering staff.
Other parts might not meet our requirements and could lead to damage.
Carbon fiber construction

Carbon fiber composite is by weight the lightest, strongest frame material available today.
Please read about special care needed for carbon fiber in your the Trek bicycle owner’s
manual.
Two fork designs: integrated and traditional direct-connect

The leading fork design provides the least wind drag of any bicycle we have ever designed.
With the carefully intergrated headtube / fork interface and hidden headset bearings, the
air flows smoothly across the frame. However, this design limits the rotation of the fork; if
you turn the aerobar too far the fork will contact the frame, possibly damaging the paint.
The traditional fork design is more economical with only a slight penalty in wind drag.
Internal cable routing

To minimize wind drag, the cables and housiing of the Speed Concept are hidden to the
maximum extent possible.
Seatpost for either time trial or triathlon

The cap of the seatpost can be removed and rotated 180 degrees to gain different positions.
In addition, there are different legnths of seatposts availabe.
Hidden brakes
Brakes will require re-adjustment if the wheels are changed because the brakes are sensitive
to rim width. There are no barrel adjusters.
Carbon rims
Make sure you use brake pads that are compatible with the rim material.

Preparing and tightening fasteners
For each threaded fastener, apply a light coat of grease to the threads and shoulder of the
bolt or screw.
The correct torque is noted on or near every threaded fastener on the Speed Concept bike.
Because the specs are on the bike, we do not list them in this manual.
The specification on the bike tells you the maximum torque. Do not exceed it. However, you
should also try to tighten a bolt to close to the listed value; do not leave bolts loose. Either
condition, too loose or too tight, can cause a bolt or clamp to break.
When multiple fasteners attach a part, gradually tighten alternating bolts in small
increments; do not completely tighten one and then the other. As the bolts become snug,
check alignment of the parts and use a torque wrench for final tightening. When the
tightening is completed, all bolts of a given clamp must be tightened to the same torque.
For more information

Trek dealers have access to the Trek Customer Service department for information about
the Speed Concept bikes and parts, and can order any and all parts for the bikes through
standard channels. You can find updates to this manual at this web address:
www.trekbikes.com/us/en/support/manuals
Sizing the Bike

Before assembling the bike, make sure the frame is the correct size for the customer and
as much as possible, that you have chosen the correct stem and spacer stack. There is
information on our website that explains how to do this. Visit or website:
www.trekbikes.com/us/en/support/manuals

Seatpost Tools and materials required
• 5 mm allen wrench
The Speed Concept seatpost has an aerodynamic shape (Figure 1), so cannot be turned or • Park Polylube 1000 grease
reversed in the frame. However, the head of the seatpost is reversible to allow for a wide
variety of seating positions.
The seatpost can be inserted dry or with carbon prep on the part that is inside the frame.
If the seatpost does not provide enough adjustment, an optional head for the seatpost is
available with a different setback (see Table 1, below).
To install the seatpost

1. Select a seatpost from Table 1, below.
Table 1. Seatpost lengths and setbacks
Seatpost PN
Setback (mm) Length (mm)
275 421511
+
/- 10 335 421512
Head only 419629
275 419097
Figure 1. Speed Concept seatpost
+
/- 35 335 419096
Head only 419630
2. Grease the threads of the wedge bolt (Figure 2).

3. Re-install the bolt.
4. Wipe excess grease from the clamp.
5. Insert the seatpost and tighten the wedge bolt.
To reverse the seatpost head

1. Loosen and remove the two head bolts (Figure 3). Figure 2. Wedge bolt that secures the seatpost
2. Remove the head, turn it around, and re-insert it into the seatpost.
3. Grease the threads, insert the bolts, and tighten.
To adjust the height of the saddle

1. Loosen the wedge bolt.
2. Slide the post up or down as necessary.
3. Make sure the minimum insertion mark is inside the frame.
4. Tighten the wedge bolt.

Figure 3. Bolts holding head on seatpost

Using a Repair Stand Tools and materials required
• Workstand
Use special care when putting the new Speed Concept frame in a workstand. The only • Workstand clamp adapter,
accepted or recommended method is to use the special workstand clamp adapter designed PN 403494 (includes pads
specifically for this frameset (Figure 1). The adapter clamps only to the seatpost, which must PN 416102)
be installed first.
To attach the workstand clamp adapter

1. Open the workstand clamp adapter (Figure 1).
2. Wrap the adapter around the seatpost.
If needed, extend the seatpost to provide room for the adapter.
3. Insert the base of the seatpost clamp in the workstand.
Figure 1. Seatpost clamp.

Headset Bearings and Fork
This section explains how to install the integrated fork on the Speed Concept bike, including
removing and installing the headset bearings.
If the fork is already in the bike, you can go to the next section, installing the housings.
Although you can replace the fork without disconnecting the derailleur cables and rear
brake cable, this procedure may be easier with the cables disconnected. These instructions
explain the steps without removing these cables.
To remove the fork and bearings Pinch bolt

Aerobar
attachment holes
1. Disconnect the front brake cable.
2. Loosen and remove the four aerobar attachment screws (Figure 1), and remove the
aerobar.
3. Loosen the pinch bolt that clamps the steering axle nut (Figure 1).
4. Loosen and remove the three stem attachment bolts (Figure 2), and remove the stem.
5. While you support the fork, loosen and remove the steering axle nut (Figure 2).
6. Apply light pressure to the fork to slide the steering axle out of the bearings.
The bearings should drop out. Figure 1. Location on stem of aerobar attachment
bolts
Steering axle Stem
To install the bearings and fork

nut attachmentt
holes
1. Apply a light coat of grease to the bearing contact surfaces.

2. With your hands, align the upper bearing and press it into the frame.
3. Apply a light coat of grease to the steering axle and slide the lower bearing onto the
axle.
4. Slide the steering axle through the headtube from the bottom and through the upper
bearing.
Be careful not to bump the fork against the frame during insertion.
Figure 2. Location on stem of stem attachment bolts
5. Attach the steering axle nut and tighten to 2.5Nm.
6. Reattach the stem, and then the aerobar, following the normal procedures.
7. Reconnect the front brake and adjust.

Cable Housings Tools and materials required
• Derailleur cable and 4 mm housing
If the housings are already in place, go to the next section. If you are assembling a new bike, • Brake cable and 5 mm housing
don’t be confused by the backwards cables in the housing; those cables are just there to • Housing cutters
hold the housing in place during shipping. • Cable liner
If you are replacing cables or housing, you must remove the stem and aerobar before • Tape
proceeding.
To install the housing Housing window
Note: Only 4mm housing will fit into the derailleur housing stops.
1. Detach the bottom bracket cable guide.
2. Slide a piece of 4mm shift housing through the top tube housing window (Figure 1),
down the down tube, and into the non-drive shift housing stop in the bottom bracket
cable guide.
To determine the length of housing, use the previous piece as a guide, or install a new
1500mm piece that you will resize later.
3. Leave the housing long (do not cut it). Where the upper end of the housing exits the
top tube, mark it with a piece of tape. This is to differentiate it from the rear housing. Figure 1. Housing window in the top tube
4. Slide a piece of 4mm shift housing through the top tube housing window, down the
Brake housing
down tube, and into the drive-side shift housing stop in the bottom bracket cable guide.
5. Slide a piece of brake housing through the top tube housing window, down the down
tube, and out of the bottom bracket (Figure 2). The housing should be in the middle,
between the two derailleur housing stops.
6. Leave the housing long (do not cut it yet).
7. Re-install the bottom bracket cable guide.
Figure 2. Brake housing protruding from the bottom
bracket shell
To install the rubber top tube grommet

Derailleur housing
There is a seal, or rubber grommet, that seals around the housing and into the hole in the
top tube (Figure 3). It has three holes in it, one for each of the cables that run through the
frame.
1. Slide the brake housing through the cutout in the grommet and into the rear most hole
(lower hole in the picture).
2. Slide the derailleur housings through the cutout in the grommet and place the front
Brake housing
derailleur housing on the left and rear derailleur housing on the right.
3. With the round, box end of an 8mm wrench, press the edges of the grommet until it Figure 3. Top tube housing grommet
snaps fully into place and sits flush with the top tube.
If it is not flush, it will rub on the stem when the aerobar is turned.

Aerobar Assembly
This section explains how to assemble the aerobar: the extensions, armrests, shift levers,
and brake levers.
The size of stem (Table 3, page 10) controls the reach and height of the aerobar. The elbow
pads are attached to the top of the aerobar, and their height is controlled by a spacer stack.
The first spacer is permanently attached to the aerobar (Figure 2).
Figure 1. Completed aerobar assembly
To install the extensions and armrests
To install the extension tubes to the aerobar

The following letter references (A, B, C, etc.) are for Figure 3. The arm rests, arm pads, and
extension tubes have a left and right part; these instructions do not say left or right, but
assume you use left parts on the left, etc.
1. Determine the desired width and height of the extensions and armrests.
2. Loosely attach the upper brackets (I) and lower brackets (J) to the aerobar. Insert
two extension tube clamp screws (H) through an upper bracket and a lower bracket,
Figure 2. Permanent spacer bonded to aerobar
through the spacers and aerobar, and into the nuts (L).
Determine the appropriate screw length from Table 2, below.
A H
B
Table 2. Spacers (mm) and required bolts length (mm) I
C
D
Spacer(s) Screw E
F
5 30 J M
G K
10 30
10 + 5 30
10 + 10 45 N
L
25 45
25 + 5 45 Figure 2. Aerobar assembly diagram and parts list
Note: for clarity, not all parts snown
25 + 10 60
Part name Quantity
25 + 10 + 5 60 A Arm pad, right and left 1 ea
B Screw, arm pad holder 4
25 + 10 + 10 60 C Arm pad holder, right and left 1 ea
D Pinch bolt, arm rest bracket 2
25 + 10 + 10 + 5 75 E Arm rest bracket 2
F Pinch bolt, extension tube clamp 4
G Extension tube clamp 2
H Screw, extension tube clamp 4
3. Place an extension tube clamp (G) between the upper and lower brackets, and tighten I Upper bracket, extension tube clamp 2
J Lower bracket, extension tube clamp 2
the extension clamp bolts until snug. K Spacers see
Table 2
4. Slide an extension tube (M) through the extension tube clamp and adjust the position L Nut, extension tube clamp
M Extension tube 2
of the extension tube to the desired length and rotational angle. N Aerobar 1
Do not clamp the end of the carbon tube; leave a minimum of 15 mm of extension tube
exposed behind the arm rest bracket (E).

5. Insert the extension tube clamp pinch bolts (F) and tighten.
6. Slide an arm rest bracket (E) onto the extension tube.
7. Insert the arm rest bracket pinch bolt (D).
8. Adjust the arm rest bracket to the desired angle, and tighten the pinch bolt.
Note: extreme angle adjustment might limit the ability of the arm pad holders to align
correctly.
9. Repeats steps 2-8 for the other side of the aerobar.
10. Tighten all the fasteners.
To install the arm pad holders and arm pads

The width of the arm pad holders can be customized to suit your body type and riding style.
1. Insert two arm pad holder screws (B) through the desired holes of an arm pad holder
(C) and into the arm rest bracket (E).
Two screws are required per side to prevent the arm pad holders from spinning on the
arm rest bracket.
2. Tighten the arm pad holder screws.
3. Repeat steps 1-2 for the other side.
4. Place the arm pads on the hook-and-loop fasteners of the arm pad holders.
To install the shifters

Install the shifters in the extensions following normal installation procedures. Do not
overtighten the clamp wedge mechanism. Do not exceed 45 lb•in (5 N•m).
Do not drill or cut the extension tubes. Tighten the shift lever mounting bolt until the shift
lever is firmly in place.
To install the brake levers

Install the brake levers following normal installation procedures. Do not overtighten the
clamp or wedge mechanisms.

Aerobar Installation
After the housing is in the frame and you have assembled the aerobar, you can complete
the aerobar installation. This requires that you simultaneously insert the housings into
the aerobar and install the stem attachment hardware. If you anticipate possible stem or
extension changes, you can leave up to 5cm extra housing. This much extra housing can be
pushed into the downtube.
Figure 1. “Stem” of Speed Concept bike
To install the completed aerobar assembly Front brake

cable exit
Housing exit to stem
1. Choose a stem (Figure 1) from Table 3, below.
Table 3. Stem sizes (mm) and part numbers
Near Far
reach/rise reach/rise
50/10 100/10
Low 302464 302467
60/45 100/45
Medium 302465 302468 Shift housing ports
Figure 2. Cable routing through aerobar
80/75 110/75
High 302466 302469
Aerobar attachment
2. Put a ferrule on the front brake housing.

3. Slide the housing into the aerobar (Figure 2) until you can connect the aerobar to the
stem.
4. Install the aerobar attachment screws (Figure 3) and tighten.
5. Cut the housings to length.
6. Install the brake cable through the brake housing, and the derailleur cables into the
correct housing for the front and rear derailleurs; but do not attach the cables to the
derailleurs or rear brake yet. Figure 3. Stem attached to fork
If you did not mark the derailleur housings, you will have to determine the correct
housing for each cable through trial-and-error. Front
cover
7. Install the screws that secure the stem cap (Figure 4): two cover hinge screws and the screw
front cover screw.
Cover
hinge
screws
Figure 4. Cover on stem

Derailleur Cables Cable liner
At this point in the assembly, the cables should be in the housing that runs through the
downtube. These instructions explain the correct routing through the bottom bracket cable
guide and to each of the derailleurs.
Figure 1. Cable liner for front derailleur in bottom

bracket cable guide
To connect the front derailleur cable

1. Slide a piece of cable liner onto the front derailleur cable until the liner touches the
back of the housing stop in the bottom bracket (Figure 1).
Drive side
2. Orient the front derailleur liner grommet (Figure 2) and slide it onto the liner (Figure 3),
and then snap the grommet into the frame hole in the seat tube.
3. Cut the liner so that it does not interfere with the action of the front derailleur.
4. Attach the cable to the derailleur and adjust as normal.
To connect the rear derailleur cable Figure 2. Correct orientation of seat tube grommet
1. From the bottom bracket cable guide, run the bare cable (with no liner) through the
chainstay and out the dropout exit hole.
2. Install the dropout housing stop in the dropout exit hole (Figure 4).
3. Measure and cut the rear derailleur housing.
4. Install the housing, connect the cable to the derailleur, and adjust the derailleur as
normal.
Figure 3. Seat tube grommet on cable liner to front

derailleur
Figure 4. Rear derailleur cable passing through the

dropout housing stop

Front Brake
Wedge Cover
The front brake on the Speed Concept bike (Figure 1) is hidden from the wind and from your
Arm with
eyes. But when correctly assembled and adjusted, they work very well. The Speed Concept roller
brakes use wedge/roller actuation (Figure 2), so cable tension is critical.

The design of the front and rear brake design is different, so the instructions are also. Follow
the steps carefully, in order.
Cover
attachment
screws
Figure 1. Exploded view of front brake
To install and adjust the front brake

1. Place a ferrule on the end of the housing to be inserted in the aerobar.
2. Slide the housing through the aerobar (The routing varies according to the stem size;
see Figure 3 or Figure 4).
continued
Figure 2. Wedge between rollers
Figure 3. Housing (and cable) route through aerobar

for low/near and medium/near stems
Figure 4. Housing route through aerobar for all stems

except low/near and medium/near

Front Brake (cont.)
3. Measure the housing at the lever, then cut to length (Figure 5).
4. Slide the cable through the housing.
5. Slide the wedge up the cable, and place it between the rollers (Figure 3).
6. Pull the cable tight and note the position of the wedge on the cable.
7. Remove the wedge from the rollers, move the wedge up the cable about 1 mm, and
tighten the cable clamp bolt.
Hold the top and bottom surfaces of the wedge with pliers or an adjustable wrench
while you tighten the nut (Figure 6).
Note: Do not leave the wedge in the brake while you tighten the nut; this could damage Figure 5. Setting the length and cutting the housing
the wedge.
8. Re-install the wedge between the rollers.
Do not cut the cable yet. Tuck the cable out of the way.
9. Set the pad spacer (see Table 4, below) and align the brake pads with the rim.
Table 4. Brake pad spacing between pads and brake arms
Rim width, mm Spacer location

19 Inside brake arms
21 Inside brake arms
23 Outside brake arms
Figure 6. Hold the wedge while you tighten the clamp
25 Outside brake arms bolt
Tab
10. Size and cut the cable, and reattach the wedge.
11. Finish the end of the cable so that it will not interfere with the brake return spring.
If you choose to only cut the cable and not dress the end, the extended tunnel of the
wedge prevents immediate fraying of the cable.
If desired, solder the end. Or install a cable crimp, then bend it forward.
12. Engage the tab of the brake cover with the fork, then swing the brake cover into place
and install the two attachment screws (Figure 7). Attachment screws
13. Center and space the pads precisely with the brake with the adjusting screws (Figure 8
shows the screws, which are accessible through holes in the brake cover).
Figure 7. Front brake cover
14. Install the grommets into the heads of the attachment screws.
Figure 8. Adjusting screw for front brake (screw is

accessible through cover)

Rear Brake Noodle
Mounting bracket
Cover
Wedge
The rear brake (Figure 1) on the Speed Concept bike use a wedge/roller actuation (Figure Arm with roller
2), so cable tension is critical. Booster
The design of the front and rear brake design is different, so the instructions are also. Follow
the steps carefully, in order. The rear brake is inside a cover (Figure 3), under the bottom
bracket. It is mounted on a bracket that is bolted to the frame. The bracket can be moved,
allowing you to center the brake.
Cover attachment screws
Figure 1. Exploded diagram of rear brake
To install and adjust the rear brake

1. Loosen the two bracket attachment bolts (Figure 4), center the brake, and retighten the
bolts.
2. Slide the cable out through the housing, the noodle (short plastic liner in the cable
guide), and the cable guide of the mounting bracket (Figure 1).
If the brake housing has come out of the housing stop of the mounting bracket (Figure
4), remove the bracket, install the housing in the stop, and reinstall the bracket.
3. Slide the wedge up the cable, and place it between the rollers (Figure 2).
4. Loosen the cable clamp bolt, pull the cable tight, and note the position of the wedge on
the cable. Figure 2. Wedge and rollers
continued
Attachment screws
Figure 3. Cover for rear brake
Bracket attachment bolts
Figure 4. Brake bracket attached to frame

Rear brake (cont.)
5. Remove the wedge from the rollers, move the wedge up the cable about 1 mm, and
tighten the cable clamp bolt. Hold the top and bottom surfaces of the wedge with a
pliers or an adjustable wrench while you tighten the nut (Figure 5).
Note: Do not leave the wedge in the brake while you tighten the nut; this will break the
delrin guide on the back of the wedge.
6. Re-install the wedge.
Do not cut the cable yet. Tuck the cable out of the way.
7. Set the pad spacers (see Table 5 below) and align the brake pads with the rim.
The rear brake does not have a centering screw. To move the brake side-to-side, loosen Figure 5. Holding the wedge while tightening the cable
the bracket attachment bolts, reposition the brake, and re-tighten the bolts. clamp nut
Table 5. Brake pad spacing between NEW pads and brake arms, mm of spacers for two pad types
Rim width Brake pad type

(mm) Rubber Cork
19 3 Not compatible
20 3 3
21 1.5 3
22 1.5 3
23 1.5 3 Figure 6. Brake booster (rear brake only)
24 0 3
25 0 1.5
8. If needed, re-center the brake.

9. Size and cut the cable, and reattach the wedge.
10. Finish the end of the cable so that it will not interfere with the brake return spring.
If you choose to only cut the cable and not add anything, the extended tunnel of the
wedge prevents immediate fraying of the cable.
If desired, solder the end. Or install a cable crimp, then bend it downward.
11. Place the brake booster over the brake (Figure 6).
Figure 7. Attaching the rear brake cover over the brake
12. Install the three brake cover attachment screws (Figure 7), two of which also attach the booster
brake booster.

DuoTrap Computer Sensor
The 2011 Speed Concept frame includes a special pocket on the left chainstay for
installation of the Bontrager DuoTrap sensor that combines speed and cadence sensing in a
single, wireless unit. This unit attaches through a hole in the chainstay (Figure 1).
To install a Duotrap sensor

1. Remove the attachment screw and the cover plate over the chainstay.
2. Slide the cylindrical part of the sensor through the chainstay (Figure 2) until the sensor
sits flush (Figure 3).
3. Install the attachment screw and tighten.
4. Place the rubber plug over the attachment screw (Figure 3).
Figure 1. Hole through the chainstay for Duotrap sensor
Figure 2. Sliding the speed cylinder of a Duotrap sensor

through the chainstay
Rubber plug
Figure 3. Duotrap sensor installed on chainstay

Draft Storage Box
The 2011 Speed Concept frame can be equipped with an optional storage box (Figure 1)
which is placed behind the seat tube, out of the wind resistance. The box is held in place by
clamping the seatstays.
To install a storage box Side tab
1. Squeeze the side tabs (Figure 1) to open the lid.

2. Loosen the clamp bolt (Figure 2).
You do not need to completely remove the bolt.
3. Remove the rear wheel from the frame.
4. Slide the draft box between the seatstays (Figure 3).
5. While holding the draft box in position (Figure 1), tighten the clamp bolt until the draft
box is secure.
Figure 1. Draft storage box behind the seat tube
(seatpost removed)
Figure 2. Clamp bolt in bottom of draft box
Figure 3. Placing draft box between seatstays

Crankset
The Speed Concept uses the same bearing system as a Madone; there are no parts that
thread into the frame. Instead, the bearings are a slip-fit into the frame. However, the Speed
Concept uses the new tighter fit of the bearings, which may require using a headset press
(see page 19).
Bearings kits are available for all major brand of cranksets: SRAM/TruVativ/Bontrager GXP,
Shimano HollowTech, Campagnolo UltraTorque, and FSA MegaExo.
Each kit includes a slightly different set of bearings, seals, and spacers. When installing
other crankset systems, follow the manufacturer’s instructions to achieve the correct
assembly and adjustment.
Do not use a hammer or bearing press to install the bearings into the frame. If the bearing fit
is too tight, make sure the bearing seats are clean and free of debris.
All bottom bracket systems share the same procedure to install the bottom bracket shields.
Do these steps before installing the bearings.
To install the axle shields Figure 1. Applying grease to the axle shield
Your frame may already have the axle shields installed in the frame.
1. Apply a light coat of grease to the male axle shield (smaller diameter, Figure 1).
2. Place the male axle shield into the bottom bracket shell from the drive side (Figure 2).
3. Place the female (larger diameter) axle shield into the bottom bracket shell from the
non-drive side.
4. With the installation tool (Figure 3), push together the two halves of the axle shield.
When they are inserted in the correct position, there will be an audible click.
5. Go to the instructions (on the following pages) for the bearing system you want to
install.
Figure 2. Inserting one half of the axle shield into frame
Figure 3. Release tab

Pressing bearings Tools required
The bearing fit is tighter in the Speed Concept than in early Madone models. If the bearings Installation
do not slip in by hand, follow this procedure after you have installed the bearing shield • Park headset press
(page 21). Removal
Notes: • Brass punch
• Be very careful when using the press. Too much force can crack the bottom bracket shell. • Hammer
• Press in one bearing at a time.
To press a bearing
1. Install the bearing shield.
2. Press the bearing into the frame by hand as far as possible.
3. With the cup guide on the bearing side (Figure 1), slide the bearing press through the
bearing and frame.
4. Center the guide in the bearing.
Figure 1. Using a headset press to install the bearings
5. Press the bearing into the bottom bracket shell until the bearing is flush with the shell.
To remove a bearing
If you cannot remove a bearing because it is stubborn, follow these directions.
1. Remove the crankset.
2. Slide the punch through one side of the bottom bracket shell to the back side of the
bearing.
3. Position the punch on the inside ring of the bearing.
4. Gently tap the punch with the hammer, then move 90 degrees around the bearing and
tap again.
5. Continue tapping and moving around the bearing. TAP GENTLY.
6. Go around the bearing and keep tapping.
DO NOT HIT HARD. Excessive force can damage the bottom bracket shell.

SRAM GXP Part description SRAM
These instructions explain how to install a SRAM/TruVativ/Bontrager GXP crankset (Figure Kit 404700
1) in a new Speed Concept. To complete the installation, you will also need the SRAM Ceramic kit 411814
instructions, available at: http://www.sram.com/_media/techdocs/2005_gxp-05-r5-e.pdf Drive side parts
Bearing 281824
Tools and materials required Ceramic 293617
• Crankset and bottom bracket Bearing
• 8 mm allen wrench Seal 281820

Axle shield 281823
• Bearing installation tool PN 404694
Wave washer 282866
• Rock “N” Roll Super Coat grease
Non-drive side parts
• Bottom bracket parts Bearing 282864
• TruVativ GXP installation instructions Ceramic 293618
Bearing
Seal 282865
Axle shield 281822
Wave washer Seal Bearing Bearing with lip (facing in) Metal seal
Figure 1. SRAM bearing set

To install the bearings
1. Apply a liberal coat of grease to the contact surfaces of one bearing and the drive side
of the bottom bracket shell (Figure 1).
2. Slide a bearing onto the installation tool.
Either side of the drive-side bearing is the “right side.” The non-drive bearing on GXP
systems has a lip (Figure 2). Install the bearing so that the lip faces in.
3. Press one bearing into the drive side of the bottom bracket shell (Figure 3).
To remove the installation tool, press the release tab.
4. Repeat steps 1-3 for the other bearing on the non-drive side.
Figure 1. Greasing the bearing and the frame saddle
To install the drive-side crankarm

When handling the seals, avoid bending them. A bent seal will rub on the bearing, creating
drag.
1. Apply a light coat of grease to the bearings on the face and the axle contact surface.
2. Apply a light coat of grease to the metal inside of one bearing seal (Figure 4).
3. Install the wave washer and with the grease facing up, slide the bearing seal onto the
axle (Figure 5).
4. Apply a light coat of grease to the bearing contact area of the axle (Figure 6).
The grease areas should be about 1 inch (25 mm) wide. On the drive side, start at the
bearing seal. On the non-drive side, start at the splines and apply toward the drive side Figure 2. Grease on the frame and the non-drive side
bearing (with the lip facing in)
of the axle
5. Insert the axle through the drive-side bearing in the bottom bracket (Figure 7).
Figure 3. Pressing the bearing into the frame
Figure 4. Greasing the bearing covers

To install the non-drive side crankarm
1. Apply a light coat of grease to the inside of the metal bearing seal.
2. With the grease side toward the bearing, slide the bearing seal onto the axle (Figure 8).
3. Follow the TruVativ GXP installation instructions to complete to install the non-drive
crank arm.
4. Tighten the crank bolt to the torque specifications (see page 38).
5. Follow the steps in “Inspecting the bottom bracket.”
To remove the bottom bracket bearings Figure 5. Sliding the wave washer and bearing cover
onto the axle
The Speed Concept bottom bracket bearing system is designed to be a slip fit. However,
after the first installation some bearings might be tight. If the bearings do not easily come
out by hand, you may use the following method to remove them.
1. Slide the crank axle into the bearing so that the bearing is over the non-drive side of the
axle, about 1 inch (25 mm) from the non-drive end.
2. Gently rock the axle while you pull the axle out.
Inspecting the bottom bracket

Every 3 months check the bottom bracket adjustment.
Figure 6. Greasing the axle
To check the bottom bracket bearing adjustment

1. Lift the chain from the chainrings.
2. Rotate the crank so that one of the arms is parallel to the seat tube.
3. Put one hand on the crank arm and one hand on the seat tube, and attempt to move
the crank arm laterally toward and away from the seat tube.
4. Spin the cranks.
If the crank feels or sounds loose, or if the motion stops abruptly or you hear a grinding
noise coming from the bearings, readjust the bearings or take the bike to your Trek dealer.
Figure 7. Sliding the axle through the bearings
Figure 8. Metal bearing cover in place over the bearing

Shimano HollowTech Tools and materials required
These instructions explain how to install a Shimano HollowTech (Figure 1) in a new Speed • Crankset and bottom bracket
Concept. To complete the installation, you will also need the Shimano instructions, available • Shimano FC16 crank arm installation tool
at: http://techdocs.Shimano.com/media/techdocs/content/cycle/SI/Dura-Ace/FC-7800- • 5 mm Allen Wrench
7803/SI_1F30H_En_v1_m56577569830605111.pdf.
• Bearing installation tool PN 404694
• Bottom bracket parts
Seal Bearing Bearing Seal
Figure 1. Shimano bearing set
Part description Shimano

Kit 404699
Ceramic kit 411813
Drive side parts
Bearing 281824
Ceramic 295213
bearing
Seal 281820
Axle shield 281823
Wave washer -
Bearing 281824
Ceramic 295213
bearing
Seal 281820
Axle shield 281822

2. Slide a bearing onto the installation tool.
Either side of the bearing is the “right side.”
3. Press one bearing into the drive side of the bottom bracket shell (Figure 3).
To remove the installation tool, press the release tab (Figure 3).
4. Repeat steps 1-3 for the other bearing on the non-drive side.
Figure 2. Greasing the bearing and the frame seat
Figure 3. Pressing the bearing into the frame

When handling the seals, avoid bending them. A bent seal will rub on the bearing, creating
drag.
1. Apply a light coat of grease to the bearings on the face and the axle contact surface.
2. Apply a light coat of grease to the metal inside of one bearing seal (Figure 4).
3. With the grease facing up, slide the bearing seal onto the axle (Figure 5).
4. Apply a light coat of grease to the bearing contact area of the axle (Figure 6).
bearing seal. On the non-drive side, start at the splines and apply toward the drive side
Figure 4. Greasing the bearing covers
of the axle
Figure 5. Sliding the bearing cover onto the axle

1. Apply a light coat of grease to the inside of the other bearing seal.
2. With the grease side toward the bearing, slide the bearing seal onto the axle (Figure 8).
3. Align the non-drive crank arm with the groove on the axle and slide the crank onto the
axle.
The non-drive crank arm should point 180 degrees opposite of the drive-side crank
arm.
4. With the plastic installation tool, press the crank onto the axle (Figure 9) as far as it
will go.
Figure 8. Pressing in the second bearing cover
5. Release the installation tool and spin the cranks 10 to 20 revolutions.
6. Follow the Shimano instructions to complete the installation.
To remove the bottom bracket bearings

Figure 9. Pressing the crank arm onto the axle


4. Spin the cranks.
noise coming from the bearings, readjust the bearings or take the bike to your Trek
dealer.

Campagnolo UltraTorque
The Speed Concept uses a special bearing system that has no parts that thread into
the frame. Instead, the bearings are a slip-fit into the frame. However, the Campagnolo
UltraTorque system requires you to attach bearing supports (seal seats) to the Speed
Concept bottom bracket shell (Figure 1). This section explains how to do that.
The seal seats might fit into the frame tightly. In this case, you might need to tap the cups
with a soft-faced mallet. However, do not use a hammer or bearing press to install the
bearings into the frame. If the bearing fit is too tight, make sure the seal seats are clean and
free of debris.
Wave washer
Bearing Washer Seal seat

Washer Bearing
Figure 1. Campagnolo bearing set

Part Campagnolo
description
Kit 407383
Tools and materials required
Drive side parts
To complete the installation, you will need the Campagnolo instructions, available at: http://
Bearing Campy part
www.campagnolo.com/pdf/7225306_Ultra_torque_05_07.pdf.
Seal seat 281825
Also read the warning: http://www.campagnolo.com/pdf/7225365_warning_Ultra_
Axle shield 281823
Torque_0607.pdf
Washer 281826
• Crankset and bottom bracket (bearings come pressed onto the axle halves)
• Plastic crank arm installation tool
Bearing Campy part
• LocTite® 638 retaining compound, TCG 408082
Seal seat 281825
• LocTite® primer 7649, TCG 408083
Wave 281827
• 5 mm Allen Wrench
washer
Axle shield 281823
Washer 281826

To install the seal seats
1. Clean all surfaces to be bonded (bottom bracket shell, seal seats) with alcohol wipes or
similar (Figure 2).
2. Apply a thin film of LocTite Primer to the outer step of the bearings cups and the
outer shoulder of the bottom bracket shell (Figure 3). Allow the primer to evaporate
completely.
3. Apply LocTite 638 to the faced of the seal seat that contacts the bottom bracket shell.
4. Press the seal seat into the frame (Figure 4). If needed, tap lightly with a soft-faced
mallet.
Figure 2. Cleaning bonding surfaces with an alcohol
Let the LocTite cure for at least 24 hours before inserting the bearings. wipe
To install the non-drive side bearings

1. Insert a washer into the non-drive side seal seat.
2. Apply a liberal coat of grease to the contact surfaces of the bearing (Figure 5) and the
non-drive side seal seat (Figure 6). Insert the Wave washer into the non-drive side seal
seat (Figure 7).
3. Slide the non-drive side axle through the seal seat and bottom bracket shell (Figure 8).
To install the drive side bearings

Figure 3. Applying LocTite primer to the outer step of
1. Insert a washer into the drive side seal seat. the bearing cups
2. Apply a liberal coat of grease to the contact surfaces of the bearing (Figure 5) and the
Figure 4. Inserting the bearing cups into the bottom

bracket shell
Figure 5. Greasing the bearings

drive side seal seat (Figure 6).
3. Slide the drive side axle through the seal seat and bottom bracket shell (Figure 8).
4. Line up the splines of the bottom bracket axle and press the axle together. If necessary,
tap the ends together with the heel of your palms.
5. Insert the crank bolt from the drive side (Figure 9) and tighten to the torque
specifications (see page 38).
To remove the bottom bracket bearings Figure 6. Greasing the bearing cups
With the Campagnolo system, each of the two bearings are pressed onto one of the
halves of the bottom bracket axle. To remove the bearings, follow the Campagnolo service
instructions.


Figure 7. Inserting the Wave washer (after the washer)
2. Rotate the crank so that one of the arms is parallel to the seat tube. on the non-drive side
4. Spin the cranks.
dealer.
Figure 8. Inserting the non-drive side axle
Figure 9. Tightening the axle bolt

FSA MegaExo AL Part FSA
These instructions and parts are for the aluminum FSA cranks only. The current “B” kit will description
not work for FSA carbon cranks. BB90 bearing kit “B” 293227
The Speed Concept uses a special bearing system that has no parts that thread into the Drive side parts
frame. Instead, the bearings are a slip-fit into the frame (Figure 10). This section explains Axle shield 281823
how to install the bearings and crankset. Bearing 300162
The bearings might fit into the frame tightly. In this case, you might need to tap them with Seal 294668
a soft-faced mallet. However, do not use a hammer or bearing press to install the bearings Non-drive side parts
into the frame. If the bearing fit is too tight, make sure the bearings are clean and free of Axle shield 281822
debris. Bearing 300162
Seal 294668
Tools and materials required

To complete the installation, you will also need the FSA instructions, available at:
http://www.road.fullspeedahead.com/downloadfly.aspx?download=downloads/
Install_MegaExoAlloy.pdf.
• Crankset and bearings (bearing shields come pressed onto the bearings)
• 5 mm Allen Wrench
Bearing with shield pressed on

Bearing with shield pressed on
Figure 10. FSA bearing set

2. With the plastic bearing shield facing out, press one bearing into the drive side of the
bottom bracket shell (Figure 12).
3. Repeat Steps 1-2 for the other bearing on the non-drive side.

1. Apply a light coat of grease to the axle surface where the bearings will be in contact Figure 11. Greasing the bearing and the frame saddle
(Figure 13).
bearing seal. On the non-drive side, start at the splines and apply toward the drive side
of the axle
Figure 12. Pressing the bearing into the frame with the
shield on the outside

1. Align the non-drive crank arm with the groove on the axle and slide the crank onto the
axle.
The non-drive crank arm should point 180 degrees opposite of the drive-side crank
arm.
2. Install the FSA crank bolt and tighten to their torque specifications (Figure 15).
3. Follow the FSA instructions to complete the installation.
Figure 15. Pressing the crank arm onto the axle

To remove the bottom bracket bearings


4. Spin the cranks.
dealer.

Crankset Troubleshooting
This section describes problems that occasionally occur, and possible solutions. If these
solutions do not solve a problem, contact Customer Service.
Bearing play in a GXP crank or bottom bracket assembly

The crank feels loose when grasped at the pedal end and rocked side-to-side.
Cause Solution
Wave washer not First, verify that the crank has been tightened to the torque
compressed fully specifications (see page 38). Most issues with play in
This is usually caused by
insufficient torque on the non- GXP crankarms are resolved when the arms are properly
drive crank arm.
tightened.
In rare instances a tolerance
stack can be created by the five If this does not solve the issue, add a 0.5mm washer/spacer
critical parts: non-drive bearing, Spacer
drive bearing, drive-side seal, (PN 294162) between the wave washer and seal (Figure 1)
bottom bracket shell, and axle
length. to increase the bearing preload.
Spline of GXP crankarm is Remove the crankarm and re-install with plenty of grease.
undersized Verify that the crank has been tightened to the torque
• We have seen some variation in
the tolerance of GXP crankarms. specifications (see page 38).
Wave washer Seal Bearing
• If the installation torque is not Re-check the bearings after installation. The GXP axle
sufficient, the crank arm will not
completely compress the shield spline is tapered, so it requires that the crank be completely Figure 1. SRAM bearing set
and bearing race.
tightened to seat on the axle.

Crank is rubbing or there is excessive drag
If you notice that the crank arms rotate poorly, there are several possible issues.
Cause Solution
Out of spec or bent non-drive metal seal Install a new metal seal (same Part
• The inside chamfer of the metal seal (Figure 2) rubs
on the outer race of the bearing. Number: 282865). We have revised the
• The metal seal deforms under the compressive load metal seal by adding a ring of material,
of the non-drive arm and rubs on the outer race of the
Metal seal
bearing. 0.3mm thick, to the seal around the inner
diameter. This will move the outer edge of
the seal away from the bearing.
Bearing not seated properly Make sure the halves of the axle shield
• The axle shield might not be seated completely in the
frame (Figure 3) causing the flange of the shield to foul are snapped together, and then remove
the bearing.
and reinstall the bearing. When properly
• A tight bore can cause the installer to think the
bearing is seated when it is not. installed the bearing will not sit even with
bottom bracket shell.
•Enduro bearing: 0.75mm inside the shell.
•GXP non-drive bearing: 0.25mm outside
the shell
Figure 3. Inserting one half of the axle shield into frame
GXP triple crankset can’t be properly preloaded

Although some cranksets change the arm configuration to add clearance for a third
chainring, the GXP crankset uses a longer axle. Without additional spacers, a longer axle
will not compress the bearing.. Spacer
Cause Solution
Different axle lengths require different Install a 5mm thick spacer (Part Number
spacers 291276) between the wave washer and the
Triple GXP crank axles are 5mm longer than doubles.
red bearing seal (Figure 4).
Seal Bearing
Wave washer

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Service Information

Speed Concept 2011

Note about performing mechanical work on bicycles:

Seatpost Campagnolo UltraTorque.............................................................................27

To install the seatpost.....................................................................................4 Inspecting the bottom bracket................................................................... 29

To adjust the height of the saddle................................................................4 FSA MegaExo AL........................................................................................... 30

To reverse the seatpost head........................................................................4 Crankset Troubleshooting.............................................................................. 33

Using a Repair Stand

Headset Bearings and Fork

DuoTrap Computer Sensor

Draft Storage Box

ii TREK SERVICE INFORMATION 02 November 2010

Avoid sharp edges or excessive pressure

Clean carbon parts before installation

Never modify the fork, frame, or components

1 TREK SERVICE INFORMATION 02 November 2010

Carbon fiber construction

Two fork designs: integrated and traditional direct-connect

Internal cable routing

Seatpost for either time trial or triathlon

2 TREK SERVICE INFORMATION 02 November 2010

For more information

Sizing the Bike

3 TREK SERVICE INFORMATION 02 November 2010

To install the seatpost

Table 1. Seatpost lengths and setbacks

2. Grease the threads of the wedge bolt (Figure 2).

To reverse the seatpost head

To adjust the height of the saddle

4. Tighten the wedge bolt.

4 TREK SERVICE INFORMATION 02 November 2010

To attach the workstand clamp adapter

Figure 1. Seatpost clamp.

5 TREK SERVICE INFORMATION 02 November 2010

To remove the fork and bearings Pinch bolt

Steering axle Stem

To install the bearings and fork

1. Apply a light coat of grease to the bearing contact surfaces.

6 TREK SERVICE INFORMATION 02 November 2010

To install the housing Housing window

To install the rubber top tube grommet

7 TREK SERVICE INFORMATION 02 November 2010

Figure 1. Completed aerobar assembly

To install the extensions and armrests

To install the extension tubes to the aerobar

8 TREK SERVICE INFORMATION 02 November 2010

To install the arm pad holders and arm pads

To install the shifters

To install the brake levers

9 TREK SERVICE INFORMATION 02 November 2010

Figure 1. “Stem” of Speed Concept bike

To install the completed aerobar assembly Front brake

1. Choose a stem (Figure 1) from Table 3, below.

Table 3. Stem sizes (mm) and part numbers

2. Put a ferrule on the front brake housing.

front cover screw.

Figure 4. Cover on stem

10 TREK SERVICE INFORMATION 02 November 2010

Figure 1. Cable liner for front derailleur in bottom