TREK Rail 5 Gen 3 Electric Bikes Brisbane Owner’s Manual

2023 Alloy Rail
5, 7, and 9 Gen 3

Rev 1 September 2023
SERVICE MANUAL

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 threadlocker is not applied, the fasteners may loosen which could damage the bicycle and result in injury to the rider.

Legend

| Apply grease
---|---
| Do not apply grease
| Apply threadlocker
| Torque
| Hex tool size
| Torx tool
| Drift size
| Zip tie

Headset with Knock Block

1. Upper bearing cover
2. Chip bolt — W532763 — 5252157
3. Knock Block chip
4. Compression ring — W532842
5. Upper bearing — W531676
6. Lower bearing, 1.5″ diameter — W532843
7. Crown race, for 1.5″ diameter lower bearing — W532844

Tools

• 2.5mm hex tool
• Grease

Active Braking Pivot (ABP)

1. Switch lever — W573860

2. Thru axle — W583469

3. Non-driveside ABP dropout nut — W5269707

4. Retaining ring — W5251279

5. Bearings — W5256340

6. Non-driveside ABP bolt — W5251141

7. Derailleur hanger
   — W5272776
   — W5271425

8. Washer

9. Bolt (left-hand thread)

Tools

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

This bicycle frame is designed to use a Universal Derailleur Hanger (UDH).
WARNING
Do not apply grease to the derailleur hanger or bolt.
Apply grease to only the thru axle.

NOTICE: The washer 8 is frame-specific. Install only the washer compatible with your frame.
NOTICE: Do not over-tighten 9 . Over-tightening the bolt could cause the hanger to break.
For additional information about the UDH, refer to the SRAM user manual at www.sram.com.

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 — 44378
    Search trekbikes.com to find the color-matched part for your bike.

12. Rocker link — 37992.
    Search trekbikes.com to find the color-matched part for your bike.

Tools

• Bearing press, 19×10 and 21×12 drifts
• 4mm and 6mm 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

• 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

1. Nut — W584134
2. Spacers — W440921
3. Bearings — W5256338 — 599909
4. Main pivot sleeve — W500592
5. Main pivot axle — W601376
6. Chainstay — 44377
   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, 16 x 10 x 5mm — W536414
4. Spacers, 16 x 10 x 3mm — W529969
5. Standard lower shock mount bolts — 599900
6. Trunnion shock mount bolts — W5289626

Dimensions

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

Cable routing

1. Dropper post housing
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 13.
    Zip tie

*Bosch part number. Not available on trekbikes.com.

Frame guards

1. Upper down tube guards — 556549
2. Lower down tube guard — W5276240
3. Chainstay guard — W5276239
4. Drive unit guard — W5269899
5. Screws — W549305
6. Top hat spacers — W5272256

Adhesive guards 1 2 3
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.

Remote
LED remote

1. LED remote — 5288736
2. LED remote universal clamp — 5288743
   LED Remote cable (See Cable routing on page 8)
   — EB12.120.005*

RIB — battery assembly

1. Battery, Vertical, Smart System, 500W — EB12.100.018
   Battery, Vertical, Smart System, 625W — EB12.100.012

2. Socket head screws, M3x12 — W5257054

3. Spacer (For 500Wh battery) — W5252256

4. Push pin and spring — 5312675

5. Battery handle assembly — W5252236

6. Bolts, M3x8 — W5269016

7. Docking bracket — W5252240

8. Bolts, M3x20 — W5254060

9. Cover, 625W battery — 44371
   Search trekbikes.com to find the color-matched part for your bike.

RIB — docking assembly

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

Drive system components

Drive unit and mounting bolts

1. Mounting bolts, TP40 — 5265419
   (Bosch 1270.016.470)

Speed sensor

1. Speed sensor — 5284750
2. Bolt — W562831

Battery charge port cover

1. Charge port cover — 44374
   Search 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)

• Boost hub with offset chainring.

Chainring (1x only)

• 34T

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.

Water bottle fit
Small frame: does not have mounts for a water bottle cage.

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| 220mm
M| 230mm
L| 260mm
 XL| 310mm
Seat tube inside diameter| 31.6mm
Seat tube post clamp outer diameter| 36.4mm

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.

References

• Trek Bikes - The world's best bikes and cycling gear
• SRAM
• Trek 2022 Rail 29 Matte Finish Rocker Links - Trek Bikes (AU)
• Trek-Diamant 2021 RIB Battery Mount Hardware Kit - Trek Bikes
• Trek Rear Shock Pin-to-Trunnion 18.5mm Head Hardware - Trek Bikes
• Trek-Diamant 2021 RIB Carbon Frame Battery Mount Baseplate - Trek Bikes
• Trek-Diamant Bosch 750 Smart Speed Sensor Cable - Trek Bikes
• Trek Bolt M3x10x0.5 Cylinder Head Thread Locker - Trek Bikes
• Trek BES3 RIB Power Connector Retention Bracket - Trek Bikes
• Trek/Diamant RIB Assembly Upper Handle Spring & Plunger Kit - Trek Bikes
• Trek-Diamant RIB Ejector Frame Assembly - Trek Bikes (GB)
• Trek Main Pivot Hardware Kit - Trek Bikes
• Trek 2009 Top Fuel Rocker Link Pivot Spacer - Trek Bikes
• Trek Rocker Pivot Nut Insert - Trek Bikes (GB)
• Trek Full Suspension Spacer 22mm x 17mm x 3mm - Trek Bikes (AU)
• Trek 2015-2022 Full Suspension Trail Main Pivot Spacer - Trek Bikes (AU)
• Trek Control Freak Headtube Plug - Trek Bikes
• Trek 2022 ABP Non-Drive Dropout Bolt - Trek Bikes (AU)
• Trek 2022 Session 29 ABP Retaining Ring - Trek Bikes
• Trek-Diamant 2022-2023 Bosch Smart System Charge Port Cover - Trek Bikes
• Trek 2022 Rail Carbon 29 RIB Smart System Battery Handle - Trek Bikes (GB)
• Trek 2022 Rail Carbon 29 RIB Smart System Battery End Cap - Trek Bikes
• Trek/Diamant RIB 2023 Bosch Smart System Battery Spacer - Trek Bikes
• Trek M3x0.5 Self-Tapping Socket Head Cap Screws - Trek Bikes
• Trek Full Suspension Heavy Contact Sealed Bearing 10x19x5mm - Trek Bikes (GB)
• Trek Full Suspension Heavy Contact Sealed Bearing 17x26x10mm - Trek Bikes
• Trek Full Suspension Heavy Contact Sealed Bearing 10x19x8mm - Trek Bikes
• Trek Full Suspension Heavy Contact Sealed Bearing 20x30x7mm - Trek Bikes
• Trek M3x0.5 Countersunk Flat Head Cap Screws - Trek Bikes
• Trek 2022 ABP UDH Non-Drive Dropout Guide Nut - Trek Bikes (AU)
• Trek 2021-2023 Powerfly FS & 2020-2021 Aluminum Rail Motor Armor - Trek Bikes
• Trek 2023-2024 Fuel EXe Mino Link Nut - Trek Bikes
• Trek 2023-2024 Fuel EXe Rocker Pivot Flat Head Cap Bolt - Trek Bikes
• Trek Universal Derailleur Hanger for ABP - Trek Bikes
• Trek 2023 Aluminum Rail Chainstay Armor - Trek Bikes

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