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The 2022 E-Caliber is an electric mountain bike from Trek, designed with a focus on integrated suspension and a lightweight Fazua drive system. This service manual supplement provides detailed instructions for maintenance, assembly, and technical specifications, ensuring optimal performance and longevity of the bicycle.
The Trek E-Caliber is an e-mountain bike that combines the agility of a traditional mountain bike with the assistance of an electric motor. Its primary function is to provide an enhanced riding experience on various terrains, offering power assistance for climbs and extended rides, while maintaining the feel and handling of a high-performance trail bike. The integrated IsoStrut suspension system is a key feature, providing 60mm of rear travel that is designed to be lightweight and efficient, suitable for cross-country and light trail riding. The Fazua drive system offers a natural pedaling feel, with the motor and battery designed to be removable, allowing riders to convert the E-Caliber into a non-electric mountain bike for a different riding experience.
Suspension:
Frame and Geometry:
Seatpost Insertion (Minimum):
Fazua System:
IsoStrut Remote Lockout Cable: The IsoStrut features a remote lockout for on-the-fly suspension adjustments. The cable routing involves guiding the wire through the top tube, head tube, and then around the lockout spool on the IsoStrut. The set screw for the lockout spool should be torqued to 1Nm. Proper installation ensures the mechanism works satisfactorily, allowing riders to optimize suspension performance for different terrains.
Air Volume Spacer Adjustment: The air volume spacer allows riders to fine-tune the shock's air spring progression. This procedure involves releasing air pressure from the shock, removing the shock from the carriage, unthreading the lock ring, and then adding or removing spacers. After adjustment, the shock must be re-inflated to the correct pressure, and the sag procedure performed to determine the proper rider setting. This feature enables customization of the suspension feel, from a more linear to a more progressive response.
Universal Derailleur Hanger (UDH): The E-Caliber frame is designed to use a Universal Derailleur Hanger (UDH), ensuring broad compatibility with modern drivetrains. It's crucial to use a thru axle compatible with UDH, specifically M12x1.0 with a 12.7mm thread. The hanger bolt should be torqued to 25Nm, with a warning against over-tightening to prevent breakage.
Cabling Overview: The manual provides a detailed diagram for routing various cables, including speed sensor, rear brake, dropper post, IsoStrut lockout, controller, and rear derailleur cables. This ensures clean integration and optimal function of all components.
Headset with Knock Block: Maintenance involves inspecting components for damage or excessive wear, applying grease to bearing bores, and correctly installing bearings and the crown race. The Knock Block chip bolt should be torqued to 2Nm, ensuring the steering limit function is maintained.
Frame and Drive System Guards: The bike includes chainstay and down tube guards to protect the frame from impacts. These guards are secured with fasteners, with specific torque values (3Nm for drive unit guard fasteners). It's important to clean the frame surface with isopropyl alcohol before applying the guards, but avoid cleaning the entire frame with isopropyl alcohol as it can damage the paint.
Rear Triangle and Chainstay Bridge: Assembly of the rear triangle involves installing the IsoStrut axle, end cap bolt, front IsoStrut bolts, and chainstay bridge bolts. Specific torque values are provided: IsoStrut rear axle to 10Nm, chainstay bridge bolts to 8Nm, and front IsoStrut bolts to 5Nm. Grease should be applied to the IsoStrut rear axle and the flat surfaces of the chainstay bridge.
Main Pivot: Maintenance of the main pivot involves pressing in bearings, inserting the sleeve, and installing the main pivot bolt and nut. The main pivot bolt should be torqued to 30Nm. Grease should be applied to the shoulder of the main pivot bolt to ensure smooth operation.
Carriage Wiper Seals and Bushings: This is a critical maintenance procedure for the IsoStrut. It involves removing the shock from the carriage, extracting old seals and bushings using specialized tools (Delrin rod, slide hammer, expanding collet), and then installing new ones. It's crucial to use clean tools to prevent grit from damaging the shock. Grease should not be applied to the bushings. After replacing seals and bushings, foam blocks and a foam ring are installed, followed by adding 15cc of 10wt fork bath oil to the IsoStrut. The compression sleeve and oil plug are then installed, and the damper body bolt torqued to 7Nm. Finally, the IsoStrut rear axle and front IsoStrut washers and bolts are torqued to 10Nm and 5Nm, respectively.
General Safety and Warnings: The manual emphasizes the importance of torquing hardware to specified values to prevent component failure or loosening, which could lead to injury. It also warns against using threadlocker on reused fasteners without cleaning them with isopropyl alcohol. Specific warnings are given for fork length, seatpost insertion, and over-tightening the derailleur hanger bolt.
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