2023 Carbon Rail Service Manual

Safety Information

▲ 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
• Nm Torque
• # Hex tool size
• # Torx tool
• # Drift size
• # Zip tie

Headset with Knock Block

Tools: 2.5mm hex tool, Grease

• 1 Upper bearing cover
• 2 Chip bolt - W532763
• 3 Knock Block chip
• 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
• Crown race, for 1.8" diameter lower bearing (Rail 9.7, 9.8, 9.9) - W5283203

Active Braking Pivot (ABP)

Rail 9.8 and Rail 9.9 – Carbon seatstay and chainstay

Tools: Bearing press, 20x30 drift, Cassette lockring tool, Grease, 8mm hex tool, Torque wrench (left-hand thread) with 8mm hex bit

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

Rail 9.5 and Rail 9.7 – Alloy seatstay and chainstay

Tools: Bearing press, 20x30 drift, Cassette lockring tool, Grease, 8mm hex tool, Torque wrench (left-hand thread) with 8mm hex bit

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

Rocker pivot and seatstay

Tools: Bearing press, 19x10 and 21x12 drifts, 4mm and 5mm hex wrenches, Torque wrench with 4mm and 5mm hex bits

• 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.

Important: Install driveside bearing first.

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

Procedure:

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

Tools: Bearing press, 26x17 drift, 8mm hex tool, Torque wrench with 8mm hex bit, Grease

• 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.

Important: Install driveside bearing first.

Shock mounts

Standard

Tools: Bearing press, 10x19 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

Trunnion

Tools: Bearing press, 10x19 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

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

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

Note: Dropper post cable is routed through a cable tunnel.

Cable routing – 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

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

Note: Dropper post cable is routed through a cable tunnel.

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

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

System controller

• 1 Bolt - W5287174
• 2 System controller - 5315896
• 3 Display grommet - W5285659

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

Mini remote

• 1 Mini remote - 5315897

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

Rail 9.5 and Rail 9.7

Display cover

• 1 Bolt - W5287174
• 2 Display cover - W5291499

LED remote

• 1 LED remote - 5288736
• 2 LED remote universal clamp - 5288743
• LED Remote cable (See Cable routing – Rail 9.5 and 9.7 with LED Remote on page 9) - EB12.120.005*

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

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 - 37360. Search trekbikes.com to find the color-matched part for your bike.

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

RIB — docking assembly

Lower assembly

• 1 Alignment plate, S frame, 650Wh battery - W5252805
• M-XL frame, 750Wh battery - W5252806
• 2 Screws
• 3 Lower docking bracket - W5277571
• 4 Locknuts
• 8 Screws
• 11 Countersunk bolts
• 13 Washers
• 14 Upper docking bracket

Upper assembly

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

Tip: Use the hex tool to depress the plunger to create access to the screw in the ejector assembly.

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

Drive system components

Drive unit and mounting bolts

• 1 Mounting bolts, TP40 - 5265419 (Bosch 1270.016.470)

Speed sensor

• 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 - 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

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