TREK 2023 Rail 9.9 X0 AXS T Type Gen 4 Bicycle Instruction Manual

TREK 2023 Rail 9.9 X0 AXS T Type Gen 4 Bicycle

Product Information

2023 Carbon Rail
The 2023 Carbon Rail is a high-performance bicycle frame designed for advanced riders. It features a lightweight carbon fiber construction that provides excellent strength and durability while keeping the weight to a minimum. The frame is available in four sizes: 9.5, 9.7, 9.8, and 9.9 Gen 4.

Specifications

• Frame Sizes: 9.5, 9.7, 9.8, and 9.9 Gen 4
• Material: Carbon Fiber
• Headset with Knock Block
• Active Braking Pivot (ABP)

Product Usage Instructions

Adjusting the Geometry
The 2023 Carbon Rail allows you to adjust the geometry of the bike to suit your riding preferences. Follow the steps below to adjust the geometry:

1. Locate the adjustable components on the frame, such as the headset and knock block.
2. Use the appropriate tools to loosen the bolts securing these components.
3. Make the necessary adjustments to achieve your desired geometry.
4. Tighten the bolts securely to ensure the components are properly locked in place.

Cable Routing with System Controller and Mini Remote
The 2023 Carbon Rail features a cable routing system that is compatible with the System Controller and Mini Remote. Follow the steps below to route the cables:

1. Identify the cable routing points on the frame.
2. Insert the cables through the designated routing holes.
3. Secure the cables using the provided cable clips or ties.
4. Ensure the cables are properly aligned and free from any obstructions.

RIB – Docking Assembly
The RIB (Rear Integrated Brake) docking assembly allows for easy installation and adjustment of the rear brake. Follow the steps below to use the RIB docking assembly:

1. Locate the RIB docking assembly on the frame.
2. Insert the rear brake into the docking assembly.
3. Adjust the position and angle of the brake as needed.
4. Tighten the bolts securely to ensure the brake is properly secured.

Wheel Set and Tire Size
The 2023 Carbon Rail is compatible with different wheel sizes and tire sizes. Follow the guidelines below for selecting the appropriate wheel set and tire size:

• Wheel Set: The frame is compatible with both 29″ and 27.5″ rear wheels.
• Tire Size: The maximum tire size for 29″ wheels is 2.6, and for 27.5″ wheels, it is 2.8.

Water Bottle Fit
The compatibility of water bottle fit depends on the frame size and specific model. Refer to the guidelines below for water bottle fit:

• Small Frame: Compatible only with the Bontrager Voda 15 bottle. Requires the cage spacer included with the bike.
• Rail 9.9 with AirWiz: There is not enough clearance to fit a water bottle.
• Medium Frame: Requires the bottle cage spacer included with the bike. Rail 9.9 with AirWiz requires the bottle cage to be positioned as far toward the headtube as possible.

Seat Post Insertion
When installing a seat post, it is important to follow the manufacturer’s minimum insertion recommendation. Failure to do so may result in damage to the seat post and potential injury to the rider. Refer to the following measurements for maximum insertion:

• Frame Size S: Maximum insertion of 230mm
• Frame Size M: Maximum insertion of 260mm
• Frame Size L: Maximum insertion of 310mm
• Frame Size XL: Maximum insertion of 34.9mm

Fork
The fork of the 2023 Carbon Rail can be adjusted according to your suspension preferences. Refer to the suspension setup card included with your bike or use the suspension calculator at Trekbikes.com/suspension-calculator for specific instructions. It is important not to exceed the recommended maximum fork length, as doing so could damage the bicycle and result in injury to the rider. The recommended travel and axle-to-race measurements are as follows:

Frame Size| Axle to Race (mm) – Recommended| Axle to Race (mm) – Maximum| Travel (mm)
---|---|---|---
S, M, ML, L, XL| 571-576| 586| 160 or 170

Contents

Safety

WARNING
Properly tighten hardware
Always tighten hardware to the specified torque. Over-tightening hardware could deform or break the hardware or components. Under-tightening hardware could cause hardware or components to become loose. Either situation could damage the bicycle and result in injury to the rider.

WARNING
Reapply threadlocker
All reused fasteners with pre-applied threadlocker must be cleaned with isopropyl alcohol and have new threadlocker applied before re-assembly. If the threadlocker is not applied, the fasteners may loosen which could damage the bicycle and result in injury to the rider.

Legend

Headset with Knock Block

1. Upper bearing cover [5252161]
2. Chip bolt — W532763 — [5252161]
3. Knock Block chip [5252161]
4. Compression ring — W532842
5. Upper bearing — W531676
6. Lower bearing, 1.8″ diameter — W5269809
7. Crown race, for 1.5″ diameter lower bearing (Rail 9.5) — W5269810
8. Crown race, for 1.8” diameter lower bearing
9. Rail 9.7, 9.8, 9.9) — W5283203

Tools

• 2.5mm hex tool
• Grease

Active Braking Pivot (ABP)

Rail 9.8 and Rail 9.9 — Carbon seat stay and chainstay

Rail 9.5 and Rail 9.7 — Alloy seat stay and chainstay

1. 1 Switch lever — W573860
2. Thru axle — W583470 [599911]
3. Non-driveside ABP dropout nut —W583419 [599911]
4. Retaining ring — W5251279 [599911]
5. Bearings — W583424 [599911]
6. Non-driveside ABP bolt — W583420 [599911]
7. Spacers — W583422 (carbon chainstays only) [599911]
8. Derailleur hanger
9. [W5271425]
10. Washer — [W5271425]
11. Bolt (left-hand thread) [W5271425]

Tools

• Bearing press, 20×30 drift
• Cassette lockring tool
• Grease
• 8mm hex tool
• Torque wrench (left-hand thread) with 8mm hex bi

Rocker pivot and seatstay

1. Bolts — W5270150

2. Bearings — W5256339

3. Concave washers — W5289553

4. Spacers — W529969

5. Mino links — W5270028

6. Rocker axle — W600627

7. Spacers — W290057

8. Bearings — W5256341

9. Seat tube pivot sleeve — W310155

10. Nut — W311582

11. Seatstay, carbon — 30893
    Seatstay, aluminum — 35491
    Search trekbikes.com to find the color-matched part for your bike.

12. Rocker link — 30969. Search trekbikes.com to find the color-matched part for your bike.

Tools

• Bearing press, 19×10 and 21×12 drifts
• 4mm and 5mm hex wrenches
• Torque wrench with 4mm and 5mm hex bits

Adjust the geometry

Flip the Mino links in the seatstay pivot to change the bike’s geometry to fit your riding style or the terrain.

Notice : If using a 29″ front wheel and a 27.5″ rear wheel, the Mino links must be in the high position.

Steeper head tube angle

Mino links in the high position Mino links in the low position

• Pulls in the front fork for quicker steering
• Raises the bottom bracket for improved climbing

Slacker head tube angle

Mino links in the low position

• Pushes the head tube angle back and pushes out the front fork for slower steering that is more stable at high speed
• Lowers the bottom bracket for more stability

Tools

• 5mm hex tool
• Torque wrench with 5mm hex bit

1. With the bike on the ground, loosen and remove one Mino link chip.

2. Loosen and remove the other Mino link chip.

3. Position the bike:
   Mino links high: Lift the bike by the seat tube. This will pull the rear triangle up and forward.
   Mino links low: With the chips removed, gravity will pull the rear triangle down and back.

4. Place one Mino link chip into the desired position. Slightly tighten the Mino link bolt.

5. Install the other Mino link chip into the same position. Slightly tighten the Mino link bolt.

6. Torque both Mino link bolts to 17Nm.

Main pivot and chainstay

[599909]

1. Nut — W584134
2. Spacers — W440921
3. Bearings — W5256338
4. Main pivot sleeve — W500592
5. Main pivot axle — W601376
6. Chainstay, carbon — 30891
   Chainstay, aluminum — 35490 Search trekbikes.com to find the color-matched part for your bike.

Tools

• Bearing press, 26×17 drift
• 8mm hex tool
• Torque wrench with 8mm hex bit
• Grease

Shock mounts

Tools

• Bearing press, 10×19 drift
• 5mm and 6mm hex wrenches
• Torque wrench with 5mm and 6mm hex bits

1. Standard upper shock mount bolt and end cap — 5258209
2. Bearings — W5256337
3. Spacers — W529969
4. Standard lower shock mount bolts — 5258210
5. Thru shaft shock mount bolts — W600630

Dimensions

• Shock Dimensions
• Eye-to Eye-length: 230mm
• Stroke length: 57.5mm
• Upper width: 54mm
• Lower width: 40mm

Cable routing

Rail 9.8 and 9.9 with System Controller

1. Dropper post cable
2. Controller cable — EB12.120.006*
3. Derailleur housing
4. Rear brake hose
5. Light cable(s) (Lights not included)
6. Speed sensor cable
7. Battery power cable — EB12.120.04A*
8. Flat head screws — W532763
9. Cable guides — W519232
10. Cable exit grommets — W5255861
11. Grommet — W543605
12. Countersink screw — W524884
13. Speed sensor assembly — See page 14.

Zip tie

Rail 9.5 and 9.7 with LED Remote

1. Dropper post cable
2. LED Remote cable — EB12.120.005*
3. Derailleur housing
4. Rear brake hose
5. Light cable(s) (Lights not included)
6. Speed sensor cable
7. Battery power cable — EB12.120.00T*
8. Flat head screws — W532763
9. Cable guides — W519232
10. Cable exit grommets — W5255861
11. Speed sensor assembly — See page 14.

Zip tie

Frame guards and water bottle cage bolts

1. Seatstay guard — W5255862
2. Chainstay guard — W587594
3. Screw (S, M frames only) — W596821
4. Bolt (L and XL frames only) — W549307
5. Cage spacer (S, M frames only) — W5256157
6. Down tube guard — W590604
7. Drive unit guard — W5253938
8. Screws — W549305
9. Foam pads — W5307155

Adhesive guards and pads 1 2 6 9
Use isopropyl alcohol to clean the frame surface where the guards and pads attach. Wait for the alcohol to dry before applying the guards.

Notice : Do not clean the entire frame with isopropyl alcohol. Isopropyl alcohol could damage the paint.

Display and remote

Rail 9.8 and Rail 9.9

1. Bolt — W5287174
2. System controller — 5315896
3. Display grommet — W5285659

Mini remote

Mini remote — 5315897

Rail 9.5 and Rail 9.7

1. Bolt — W5287174
2. Display cover — W5291499

LED remote

1. LED remote — 5288736
2. LED remote universal clamp — 5288743LED Remote cable (See Cable routing — Rail9.5 and 9.7 with LED Remote on page 9) — EB12.120.005*

RIB — battery assembly

1. Battery, vertical, Smart System,S frame, 625Wh — EB12.100.012* M – XL frame -750Wh — 5288731
2. Push pin and spring — 5312675
3. Battery handle assembly — W5252236
4. Bolts, M3x8 — W5269016
5. Docking bracket — W5252240
6. Bolts, M3x20 — W5254060
7. Cover, 625Wh battery — 37359 Cover, 750Wh battery — 37360Search trekbikes.com to find the color-matched part for your bike.

RIB — docking assembly

1. 1 S frame, 650Wh battery — W5252805 M–XL frame, 750Wh battery — W5252806
2. 2 Screws [5257257]
3. 4 Locknuts  [5257257]
4. 8 Screws  [5257257]
5. 11 Countersunk bolts   [5257257]
6. 15 T25 security screws [5312122]
7. 13 Washers [5312122]
8. 3 Lower docking bracket [5277571]
9. 14 Upper docking bracket [5277571]
10. 5 Battery connection plug — EB12.100.015*
11. 6 Power connection retention bracket
12. 7 Screws — W549307
13. 9 Lower battery mounting plug — W5252293
14. 16 Upper lock cover — W5252292
15. 17 Bumpers — 579326
16. 10 Ejector assembly — 579324
17. 12 Lock assembly — W562311

Drive system components

Drive unit and mounting bolts

Mounting bolts, TP40 — 5265419 (Bosch 1270.016.470)

1. Speed sensor chainstay plug — W587873
2. Speed sensor — 5284750
3.  Bolt — W562831
4. Rotor mount speed sensor magnet — W5252927

Battery charge port

1. Charge port cover — 44374Search trekbikes.com to find the color-matched part for your bike.
2. Base — W5251862
3. Charge socket — EB12.120.04A*
4. Bolts — 5284849

Specifications

Chainline (1x only)

• 52mm
• Boost hub with offset chainring.

Chainring (1x only)
34T only

Rear brake mount

Maximum tire size
Notice : Measurements of actual tires may vary. Always verify there is sufficient clearance between the tire and the frame. Improper tire size could damage the bicycle frame. Trek recommends 6mm clearance above and on both sides of the tire.

27.5″ rear with the mino link in

the high position

| 27.5″ x 2.8″

Water bottle fit

Small frame : Compatible only with the Bontrager Voda 15 bottle. Requires the cage spacer included with the bike. Rail 9.9 with AirWiz: There is not enough clearance to fit a water bottle.

Medium frame : Requires the bottle cage spacer included with the bike. Rail 9.9 with AirWiz requires the bottle cage to be positioned as far toward the headtube as possible

Seat post
WARNING
Always follow the seatpost manufacturer’s minimum insertion recommendation. Failure to follow the recommendation could cause damage to the seatpost and result in injury to the rider

Measurement

Maximum insertion| Frame
S|

230mm

M
L| 260mm
XL| 310mm
Seat tube inside diameter| 34.9mm
Seat tube post clamp outer diameter| 39.5mm

Kickstand mount
Requires kickstand mounting bracket W581379 and two M6x1.0x25mm bolts

Fork

Refer to the suspension setup card included with your bike or the suspension calculator at Trekbikes.com/suspension-calculator.

WARNING

Exceeding the recommended maximum fork length could damage the bicycle and result in injury to the rider.

FAQ

A: The maximum tire size is 29 x 2.6 for 29

Q: Can I use any water bottle with the 2023 Carbon Rail?

A: The compatibility of water bottles depends on the frame size and specific model. Please refer to the product information section for detailed information on water bottle fit.

Q: How should I adjust the geometry of the bike?

A: To adjust the geometry, follow the instructions provided in the product usage instructions section. Use the appropriate tools and ensure that all bolts are securely tightened after making adjustments.

Q: What is the recommended torque for tightening hardware on the 2023 Carbon Rail?

A: Always tighten hardware to the specified torque. Over-tightening or under- tightening hardware could result in damage to the bicycle and potential injury to the rider. Refer to the torque specifications provided in the product information section.

References

• Trek Bikes - The world's best bikes and cycling gear

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