Service Information

Trek MADONE 7-series brake ASSEMBLY

These instructions explain the unique assembly requirements of a
Trek Madone 7-Series integrated brakes: installation, adjustment,
and cable routing.

These instructions are written for an experienced mechanic, so

they do not explain basic assembly or procedures that might
be critical to the product or the safety of the rider. If you need
further assistance, consult a mechanic’s manual or contact
Trek Customer Service.

Table of Contents
General brake information.2
Front and Rear brake.......... 3
Rear brake cable routing.... 4

1 TREK SERVICE INFORMATION 14 June 2012

 Mounting screws Centering
The new Madone integrated The cable-pull screw also
brakes are a dual-pivot design, centers the brake.
but instead of pivoting on a The centering screws are held
bracket mounted to the frame in place with thread locker. If
with a single bolt, the brake a centering screw is adjusted Spacer
arms pivot on their mounting repeatedly, it could lose its
screws, which thread thread locker and thus lose
directly into the frame. If the adjustment. Re-apply thread
mounting screws are tightened locker as needed.
incorrectly, the brake arms
may not pivot smoothly. See Rim spacing
page 3 for full installation Some riders will want to use
instructions. both standard-width rims and
wider rims. To accommodate Spacer

Cable pull setting different rim widths, simply

On each brake there are two Brake lever Use set move the two 1mm spacers
set, or centering, screws, brand screw from the inside or outside
marked ‘H’ and ‘L’. Fully Shimano H
of the brake arm (see Table
engaging one screw (and fully SRAM /
Campagnolo
L
below). It is necessary to have
disengaging the other) sets the both spacers in the stack.
amount, or ratio, of cable pull. Any further adjustment,
There are two cable-pull including aligning the arms
ratios: the H centering screw with the fork crown, can be
Disengaged
is for Shimano, and the L accomplished with the cable
centering screw is for SRAM barrel adjuster.
and Campagnolo.
For your brake lever of choice, Table of spacer locations for rim widths
engage that centering screw. Rim width (mm) Spacer location
Back out the other screw until Engaged 19-21 Two between pad and arm
it no longer protrudes past 22-24 One spacer on each side of arm
the surface of the brake arm 25-27 Two outside arm

(disengaged). This setting is

not an ‘adjustment’; choose
one of the other.

2 TREK SERVICE INFORMATION 14 June 2012

 Front Brake
Installing a brake 7. Install the brake housing
This section explains how to and cable (before installing
install a brake on the new the rear brake, see the next
Madone. Follow this procedure sections).
for a front or rear brake.
8. Adjust the brake spacing
1. With the shorter mounting
with the pad spacers (see
bolt, install the Y-arm of the
page 2) and fine-tune with
brake. Tighten the mounting
the barrel adjuster.
bolt to 6-8Nm.
The bolt head should be
Pivot anvils
flush with the surface of the
brake arm, not proud.
2. Apply a small amount of
grease to the pivot anvil, the
place on the Y-arm where Rear Brake
the centering screw contacts The rear brake should be
the C-arm. installed by following the same
Centering
3. Disengage both centering screws procedure as the front brake.
screws (new brakes are This section explains special
shipped this way). considerations for the rear
3. With the longer mounting brake.
bolt, install the C-arm of the
brake. Tighten the mounting Quick-release
bolt to 6-8Nm. Because the rear brake is
Again, the bolt head should mounted under the chainstays,
Quick
be flush. the quick-release opener for release

4. With a 2mm hex wrench, the rear brake is located on

engage the correct centering the head tube. This allows the
screw (see page 2). rider to open the brake for a
5. Tighten the centering screw fast wheel change.
until both brake arms travel
Centering screws
smoothly through a full
The centering screws on the
range of motion and the Centering
rear brake are less accessible screws
brake is roughly centered.
than those on the front
6. For the rear brake, install the brake. If the screws are not
housing stop quick-release on accessible through the cut-
the head tube (see page 4). outs of the chain rings, it may
be convenient to cut off a
standard allen wrench to make
this adjustment easier.
3 TREK SERVICE INFORMATION 14 June 2012
 Rear Brake cable routing

This section explains how to 4. Pass the cable through the

install the rear brake cable. brake housing at the bottom
bracket and attach to the
Housing stop quick-release brake.
The housing stop incorporates Note: Take care to not cross the cables.
Tip: Place a light in the bottom bracket or
a brake quick-release to open head tube to illuminate the inside of the
the brake for quick wheel down tube.
Note: Use brake housing ferrules on all
changes. housing ends.
1. Place the housing stop in the
head tube of the frame and 5. Follow normal adjustment
install the countersunk bolt. procedures.
Tighten the bolt to 0.7Nm.
2. Pass the barrel adjuster
through the quick-release
lever and thread into the
housing stop.
4. Install the rear brake cable
and housing.

Cable routing
1. Thread the cable through
the housing stop on the
head tube and out the
bottom bracket.
2. Slide ‘cable donuts’ onto the
cable.
Note: Cable donuts prevent rattling from
cable movement inside the frame.

3. Prepare the brake cable

housing for the bottom
bracket. The rear brake
centers best with a housing
length of 180mm.

4 TREK SERVICE INFORMATION 14 June 2012