Trek Alloy Rail 7 Gen 3 - User Manual

2023 Alloy Rail
5, 7, and 9 Gen 3
SERVICE MANUAL
Rev 1 September 2023

Summary

Headset with Knock Block

Active Braking Pivot (ABP)

Rocker Pivot and Seatstay Assembly

Main Pivot and Chainstay Maintenance

Shock Mount Configurations

RIB Battery Assembly

RIB Docking Assembly

Lower Docking Assembly

Details components and assembly for the lower RIB docking system.

Upper Docking Assembly

Details components and assembly for the upper RIB docking system.

Drive System Components

Drive Unit and Mounting Bolts

Installation of drive unit and mounting bolts with torque specifications.

Overview

1. Function Description
2. Important Technical Specifications
3. Frame
4. Headset with Knock Block
5. Active Braking Pivot (ABP)
6. Rocker Pivot and Seatstay
7. Main Pivot and Chainstay
8. Shock Mounts
9. Cable Routing
10. Frame Guards
11. Remote (LED Remote)
12. RIB – Battery Assembly
13. RIB – Docking Assembly
14. Drive System Components
15. Battery Charge Port Cover
16. Speed Sensor
17. Chainline (1x only)
18. Chainring (1x only)
19. Rear Brake Mount
20. Maximum Tire Size
21. Water Bottle Fit
22. Seat Post
23. Fork
24. Usage Features
25. Maintenance Features

The Trek 2023 Alloy Rail 5, 7, and 9 Gen 3 is a full-suspension electric mountain bike designed for trail riding. This service manual provides detailed instructions for assembly, maintenance, and adjustment of various components, ensuring optimal performance and safety.

Function Description:

The Trek Alloy Rail is an e-MTB that integrates a powerful electric drive system with a robust full-suspension frame, offering assistance for climbing and enhanced control on descents. The bike features a "Knock Block" headset to prevent fork crown damage to the frame, an Active Braking Pivot (ABP) for consistent suspension performance under braking, and Mino links for geometry adjustment. The Bosch Smart System provides electric assistance, with a battery integrated into the down tube and a remote control for managing power modes.

Important Technical Specifications:

Frame:

• Material: Alloy
• Suspension: Full suspension with ABP
• Geometry Adjustment: Mino links in the seatstay pivot allow for two geometry settings:
  • High Position (Steeper Head Tube Angle): Pulls in the front fork for quicker steering, raises the bottom bracket for improved climbing.
  • Low Position (Slacker Head Tube Angle): Pushes the head tube angle back and pushes out the front fork for slower, more stable steering at high speed, lowers the bottom bracket for more stability.
• Compatibility: Designed to use a Universal Derailleur Hanger (UDH).
• Wheel Size Compatibility: If using a 29" front wheel and a 27.5" rear wheel, the Mino links must be in the high position.

Headset with Knock Block:

• Upper Bearing Cover: Part number W532763
• Chip Bolt: Part number W532763 (2.5mm hex tool, 2Nm torque)
• Knock Block Chip: Part number 5252157
• Compression Ring: Part number W532842
• Upper Bearing: Part number W531676
• Lower Bearing: 1.5" diameter, part number W532843
• Crown Race: For 1.5" diameter lower bearing, part number W532844

Active Braking Pivot (ABP):

• Switch Lever: Part number W573860
• Thru Axle: Part number W583469 (8mm hex tool, 25Nm torque)
• Non-driveside ABP Dropout Nut: Part number W5269707
• Retaining Ring: Part number W5251279
• Bearings: Part number W5256340
• Non-driveside ABP Bolt: Part number W5251141 (8mm hex tool, 10Nm torque)
• Derailleur Hanger: Universal Derailleur Hanger (UDH) compatible.
• Washer: Frame-specific, part number W5271425.
• Bolt (left-hand thread): Part number W5272776 (8mm hex bit, 20x30 drift, 15Nm torque)

Rocker Pivot and Seatstay:

• Bolts: Part number W5270150 (4mm and 6mm hex wrenches, 17Nm torque for seatstay bolts, 22Nm for rocker axle)
• Bearings: Part numbers W5256339 (19x10) and W5256341 (21x12)
• Concave Washers: Part number W5289553
• Spacers: Part numbers W529969 and W290057
• Mino Links: Part number W5270028 (5mm hex tool, 17Nm torque)
• Rocker Axle: Part number W600627
• Seat Tube Pivot Sleeve: Part number W311555
• Nut: Part number W311582
• Seatstay: Part number 44378 (color-matched, search trekbikes.com)
• Rocker Link: Part number 37992 (color-matched, search trekbikes.com)

Main Pivot and Chainstay:

• Nut: Part number W584134
• Spacers: Part number W440921
• Bearings: Part number W5256338 (26x17)
• Main Pivot Sleeve: Part number W500592
• Main Pivot Axle: Part number W601376 (8mm hex tool, 30Nm torque)
• Chainstay: Part number 44377 (color-matched, search trekbikes.com)

Shock Mounts:

• Standard Upper Shock Mount Bolt and End Cap: Part number 5258209 (5mm hex wrench, 10Nm torque)
• Bearings: Part number W5256337 (10x19)
• Spacers: 16x10x5mm (W536414) and 16x10x3mm (W529969)
• Standard Lower Shock Mount Bolts: Part number 599900 (6mm hex wrench, 10Nm torque)
• Trunnion Shock Mount Bolts: Part number W5289626 (6mm hex wrench, 17Nm torque)
• Shock Dimensions:
  • Eye-to-Eye length: 230mm
  • Stroke length: 57.5mm
  • Upper width: 54mm
  • Lower width: 40mm

Cable Routing:

• Dropper Post Housing
• LED Remote Cable: Bosch part number EB12.120.005* (not available on trekbikes.com)
• Derailleur Housing
• Rear Brake Hose
• Light Cable(s): (Lights not included)
• Speed Sensor Cable
• Battery Power Cable: Bosch part number EB12.120.00T* (not available on trekbikes.com)
• Flat Head Screws: Part number W532763 (2.5mm hex tool, 0.5Nm torque)
• Cable Guides: Part number W519232 (2.5mm hex tool, 0.5Nm torque)
• Cable Exit Grommets: Part number W5255861
• Speed Sensor Assembly: See page 13 for details.

Frame Guards:

• Upper Down Tube Guards: Part number 556549
• Lower Down Tube Guard: Part number W5276240
• Chainstay Guard: Part number W5276239
• Drive Unit Guard: Part number W5269899
• Screws: Part number W549305 (5Nm torque)
• Top Hat Spacers: Part number W5272256

Remote (LED Remote):

• LED Remote: Part number 5288736
• LED Remote Universal Clamp: Part number 5288743
• LED Remote Cable: Bosch part number EB12.120.005* (not available on trekbikes.com)

RIB – Battery Assembly:

• Battery (Vertical, Smart System):
  • 500Wh: Bosch part number EB12.100.018*
  • 625Wh: Bosch part number EB12.100.012* (not available on trekbikes.com)
• Socket Head Screws (M3x12): Part number W5257054 (T10 Torx tool, 4Nm torque)
• Spacer (For 500Wh battery): Part number W5252256
• Push Pin and Spring: Part number 5312675
• Battery Handle Assembly: Part number W5252236
• Bolts (M3x8): Part number W5269016 (T10 Torx tool, 2.5Nm torque)
• Docking Bracket: Part number W5252240
• Bolts (M3x20): Part number W5254060 (T10 Torx tool, 2.5Nm torque)
• Cover (625W battery): Part number 44371 (color-matched, search trekbikes.com)

RIB – Docking Assembly:

• Alignment Plate: Part number W5252805 (2Nm torque)
• Screws: Part number W5257257 (2Nm torque)
• Locknuts
• Countersunk Bolts: Part number W5257257 (3Nm torque)
• T25 Security Screws: Part number W5257257 (5Nm torque)
• Washers
• Lower Docking Bracket: Part number W5277571
• Upper Docking Bracket: Part number W5277571
• Battery Connection Plug: Bosch part number EB12.100.015* (not available on trekbikes.com)
• Power Connection Retention Bracket: Part number 5312122
• Screws: Part number W549307 (3Nm torque)
• Lower Battery Mounting Plug: Part number W5252293
• Upper Lock Cover: Part number W5252292
• Bumpers: Part number 579326
• Ejector Assembly: Part number 579324
• Lock Assembly: Part number W562311

Drive System Components:

• Mounting Bolts (TP40): Part number 5265419 (Bosch 1270.016.470) (20Nm torque)

Battery Charge Port Cover:

• Charge Port Cover: Part number 44374 (color-matched, search trekbikes.com)
• Base: Part number W5251862
• Charge Socket: Bosch part number EB12.120.04A* (not available on trekbikes.com)
• Bolts: Part number 5284849 (1Nm torque)

Speed Sensor:

• Speed Sensor: Part number 5284750
• Bolt: Part number W562831

Chainline (1x only):

• 52mm
• Boost hub with offset chainring.

Chainring (1x only):

• 34T

Rear Brake Mount:

• Minimum: 180mm, direct mount
• Maximum: Adaptable to 203mm

Maximum Tire Size:

• Wheel set: 29"
• Maximum tire size: 29" x 2.6"
• Note: Always verify sufficient clearance (6mm above and on both sides) between tire and frame.

Water Bottle Fit:

• Small frame: Does not have mounts for a water bottle cage.

Seat Post:

• Seat tube inside diameter: 31.6mm
• Seat tube post clamp outer diameter: 36.4mm
• Maximum Insertion:
  • S: 220mm
  • M: 230mm
  • L: 260mm
  • XL: 310mm
• Warning: Always follow the seatpost manufacturer's minimum insertion recommendation.

Fork:

• Refer to the suspension setup card or Trek's suspension calculator (Trekbikes.com/suspension-calculator).
• Warning: Exceeding recommended maximum fork length could damage the bicycle and result in injury.
• Axle to Race (mm) / Travel (mm):
  • S, M, ML, L, XL: Recommended 570 / 160
  • S, M, ML, L, XL: Maximum 580 / 170

Usage Features:

• Geometry Adjustment: The Mino links allow riders to fine-tune the bike's geometry (head tube angle and bottom bracket height) to match their riding style or terrain preferences. This provides versatility for different trail conditions, from steep climbs to fast descents.
• Electric Assist: The Bosch Smart System provides pedal assistance, making climbs easier and extending ride range. The LED remote allows for easy control of power modes.
• Integrated Battery: The RIB (Removable Integrated Battery) system neatly houses the battery within the down tube, protecting it from elements and impacts while maintaining a clean aesthetic. The battery is easily removable for charging or security.
• Knock Block: This feature prevents the fork crown from striking the frame during a crash or extreme steering angles, protecting the frame from damage.
• ABP (Active Braking Pivot): Ensures that the suspension remains active and effective even under heavy braking, providing consistent traction and control.
• UDH Compatibility: The frame is designed to use a Universal Derailleur Hanger, which is a standardized, widely available component, simplifying replacement if needed.

Maintenance Features:

• Detailed Torque Specifications: The manual provides precise torque values for all fasteners, crucial for proper assembly and preventing damage or loosening of components.
• Threadlocker Application: Instructions specify when to apply new threadlocker, emphasizing the importance of cleaning reused fasteners with isopropyl alcohol before re-assembly to ensure secure connections.
• Grease Application: Clear guidance on where to apply grease (e.g., thru axle) and where not to apply it (e.g., derailleur hanger or bolt) helps prevent component damage and ensures smooth operation.
• Bearing Press and Drifts: Specific tools like bearing presses and drifts (e.g., 20x30, 19x10, 21x12, 26x17) are listed for proper bearing installation and removal, indicating a design that allows for component servicing.
• Adhesive Guard Installation: Instructions for cleaning frame surfaces with isopropyl alcohol before applying frame guards ensure proper adhesion and protection.
• Color-Matched Parts: For components like the seatstay, rocker link, and battery cover, the manual directs users to trekbikes.com to find color-matched replacement parts, maintaining the bike's aesthetic.
• Bosch Part Numbers: Specific Bosch part numbers are provided for drive unit components, battery, and cables, although some are noted as not available directly from trekbikes.com, indicating specialized sourcing for certain e-bike specific parts.
• Safety Warnings: Prominent warnings regarding proper tightening of hardware, reapplication of threadlocker, and adherence to seatpost and fork specifications highlight critical safety considerations for maintenance.

Trek Alloy Rail 7 Gen 3 Specifications

General

Shifters	Shimano SLX M7100, 12-speed
Cassette	Shimano SLX M7100, 10-51, 12-speed
Wheel Size	29"
Saddle	Bontrager Arvada, steel rails, 138mm width
Handlebar	Bontrager Alloy, 31.8mm, 15mm rise, 780mm width
Frame Material	Alpha Platinum Aluminum
Frame Features	Removable Integrated Battery, internal cable routing, magnesium rocker link, Boost148
Fork	RockShox 35 Gold RL, DebonAir spring, Motion Control damper, tapered steerer, 44mm offset, Boost110, 15mm Maxle Stealth
Shock	RockShox Deluxe Select+
Motor	Bosch Performance Line CX, 85Nm
Battery	Bosch PowerTube
Display	Bosch Purion
Controller	Bosch LED remote
Rear Derailleur	Shimano XT M8100, long cage, 12-speed
Crank	E*thirteen E*spec Plus
Chain	Shimano SLX M7100
Wheelset	Bontrager Line Comp 30, Tubeless Ready
Front Tire	Bontrager XR5 Team Issue, Tubeless Ready, 29x2.50"
Rear Tire	Bontrager XR5 Team Issue, Tubeless Ready, 29x2.50"
Tires	Bontrager XR5 Team Issue, Tubeless Ready, 29x2.50"
Stem	Bontrager, 31.8mm, 7-degree
Drivetrain	1x12