TREK 2023 Powerfly FS Gen 3 Bicycle Chain User Manual

: August 28, 2024
: TREK

Table of Contents

TREK 2023 Powerfly FS Gen 3 Bicycle Chain
Safety
Legend
Shock mounts
Cable routing
Frame guards
RIB
Remote and displays
Drive system components
Specifications
FAQ
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

TREK 2023 Powerfly FS Gen 3 Bicycle Chain

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

Active Braking Pivot (ABP)

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

Tools

Bearing press, 10 x1 9 and 12 x 21 drifts
5mm and 9mm hex wrenches
Torque wrench with 5mm and 9mm hex bits

Main pivot and chainstay

Tools

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

Shock mounts

Tools

Bearing press, 10 x1 9 drift
5mm hex tool
Torque wrench with 5mm hex bit
Grease

1. Shock linkage — 5256637
Upper shock bolt, M8 x 33mm — W600364
Lower shock axle, M6 x 69mm — 5256638
4. Bearings, 10 x 19 x 5mm — W5256337
5. Lower shock bolt, M6 x 11mm — 5256638

Dimensions

Shock Dimensions
- Eye-to Eye-length: 190mm
- Stroke length: 45mm
- Upper width: 20mm
- Lower width: 20mm

Cable routing

Dropper post cable
Display cable — EB12.120.005*
Derailleur housing
Rear brake hose
Light cables (Lights included only on Powerfly Equipped models)
Speed sensor cable
Battery power cable — EB12.120.00T*
8. Housing guides — W594006
Bolts, M3 x 10mm — W285213
10 Supernova Powerfly Cargo Rack E3 Tail Light 2 — W1047565

Frame guards

1 Chainstay guard — W587594
2 Drive unit guard — W5269899
Screws, stainless steel, M5xx10 — W549305
4 Top hat spacers — W5272256

Adhesive guards 1

Use isopropyl alcohol to clean the frame surface where the guard attaches. Wait for the alcohol to dry before applying the guard.

Notice

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

Full-size rear fender and rack

1 Rear rack — W5289962
2 Rear fender — W600725
Bolts, stainless steel , M5 x 14mm
- 5251710
4 Washers, stainless steel, M5 x 1mm
Bolts, stainless steel , M5 x 12mm — W584855\

Mini rear fender

1 Mini fender — W1040072
Bolts, stainless steel, M5 x 14mm,
- 5251710
3 Washers, flat, stainless steel, M5 x 1mm

Front fender

1 Front fender and strut, 27.5” — 601256
2 Front fender and strut, 29” — 601257
Screw, M5 x 12mm, stainless steel — W584855
4 Washer — 5319894
Bolt, M6 x 10mm, stainless steel (Longer bolt may be required if using a light mounting bracket)
Bolt, M5 x 8mm, stainless steel
- 601267
7 Washer, M5 x 1mm, stainless steel
Bolts, M5 x 10mm, stainless steel — W549305

Fender parts for 29 wheel are compatible with only the originally equipped SR SUNTOUR fork.

RIB

RIB — battery assembly

1 Battery, Vertical, Smart System,
- 500Wh — EB12.100.018*
- 625Wh — EB12.100.012*
Socket head screws, M3 x 12mm — W5257054
3 Spacer (for use with 500Wh battery) — W5252256
4 Push pin and spring — 5312675
5 Battery handle assembly — W5252236
Bolts, M3 x 8mm — W5269016
7 Docking bracket — W5252240
8 Bolts, M3 x 20mm — W5254060
9 Cover — 44370
- Search trekbikes.com to find the color-matched part for your bike.

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

RIB — docking assembly

1 Alignment plate — W5252805
2 Screws
- — 5257257
4 Locknuts
8 Screws
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

Remote and displays

LED remote

LED remote — 5288736
LED remote universal clamp — 5288743

Kiox 300

Kiox 300 — 5288735

Intuvia 100

Intuvia 100 — EB13.100.00F

Bosch part number. Not available on trekbikes.com.

Drive system components

Drive unit and mounting bolts

Mounting bolts, TP40 — 5265419
- (Bosch 1270.016.470)

Speed sensor

Speed sensor — 5284750
Bolt — W562831
Rotor mount speed sensor magnet — W5252927

Battery charge port cover

Charge port cover — 44373
- Search trekbikes.com to find the color-matched part for your bike.
Base — W5251862
Charge socket — EB12.120.04A*
Bolts, M3 x 6mm — 5284849

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

Specifications

Chainline (1x only)

Boost hub with offset chainring.

Max chainring (1x only)

46T

Rear brake mount

Minimum	Maximum
180mm, direct mount	Adaptable to 203mm

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.

Frame	Maximum tire size
XS, S	27.5″ x 2.6″
M, L, XL	29″ x 2.6″

Water bottle fit

XS and S frames: Use a Bontrager side-load cage and a 21oz (621ml) bottle.

Seatpost

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
XS| 180mm
S| 207mm
M| 215mm
L| 246mm
XL| 297mm
Seat tube inside diameter| 31.6mm
Seat tube post clamp outer diameter| 36.4mm

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.

Frame size	Axle to Race (mm)	Travel (mm)
XS, S	Recommended	505.5
Maximum	520	120
M, L, XL	Recommended	540
Maximum	545	120

FAQ

Q: What should I do if my tire size is different from the recommended maximum size?
- A: 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 the sides of the tire.
Q: How should I maintain the seat post?
- A: 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.
Q: What is the recommended fork travel length?
- A: Refer to the suspension setup card included with your bike or the suspension calculator at Trekbikes.com/suspension-calculator. Exceeding the recommended maximum fork length could damage the bicycle and result in injury to the rider.