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Specific steps for cleaning and applying adhesive frame guards.
Specific mounting details for front mudguards on 27.5-inch wheels.
Specific mounting details for front mudguards on 29-inch wheels.
Details the installation of the lower section of the docking assembly.
Details the installation of the upper section of the docking assembly.
Details the LED remote control unit and its features.
Information regarding the Kiox 300 display unit.
Information regarding the Intuvia 100 display unit.
Details on chain line and maximum chain ring size.
Information on rear brake mount standards and maximum tyre clearance.
Guidance on water bottle fitment and seat post insertion.
Specifications and recommendations for fork setup.
This document serves as the service manual for the 2023 Trek Powerfly FS electric mountain bike, specifically covering the Gen 3 FS 9 EQ, FS 7, FS 4 EQ, and FS 4 models. It provides comprehensive instructions and diagrams for the assembly, disassembly, and maintenance of various components, ensuring proper function and longevity of the bicycle.
The manual begins with a table of contents that categorizes the different sections of the bike for easy navigation, including safety guidelines, main pivot and chainstay, frame guards, front mudguard, Active Braking Pivot (ABP), shock mounts, full-size rear mudguard and rack, RIB – battery assembly, drive unit and mounting bolts, specifications, rocker pivot and seat stay, cable routing, mini rear mudguard, RIB – docking assembly, and battery charge port cover. Each section is accompanied by detailed illustrations and part numbers to guide the user through the service procedures.
A crucial aspect emphasized throughout the manual is safety and proper maintenance. Warnings are prominently displayed to highlight critical steps, such as tightening hardware to the specified torque. Over-tightening can deform or break components, while under-tightening can lead to loose parts, both potentially causing damage to the bicycle and injury to the rider. The manual also stresses the importance of re-applying threadlocker on all reused fasteners. Before re-assembly, these fasteners must be cleaned with isopropyl alcohol, and new threadlocker applied. Failure to do so can result in fasteners loosening, which could damage the bicycle and lead to rider injury. A legend is provided to clarify symbols used in the diagrams, indicating where to apply grease, where not to apply grease, where to apply threadlocker, torque values, and the required hex, Torx, and drift tool sizes, as well as zip tie locations.
The Active Braking Pivot (ABP) section details the components and assembly of the ABP system, which is a key feature for maintaining active suspension performance during braking. It includes instructions for the switch lever, thru axle, non-driveside ABP dropout nut, retaining ring, bearings, non-driveside ABP bolt, derailleur hanger, washer, and left-hand thread bolt. Specific torque values are provided for each bolt, such as 10 Nm for the switch lever bolt and 25 Nm for the left-hand thread bolt. The manual also specifies the tools required, including a bearing press, cassette lock ring tool, grease, 8mm hex tool, and a torque wrench with an 8mm hex bit. A warning advises against applying grease to the derailleur hanger or bolt, only to the thru axle. It also notes that the washer is frame-specific and warns against over-tightening the bolt to prevent hanger breakage. The frame is designed to use a Universal Derailleur Hanger (UDH), and users are directed to SRAM's user manual for additional information.
The Rocker pivot and seat stay section outlines the assembly of these critical suspension components. It lists parts such as seat stay bolts, seat stay bearings, spacers, rocker pivot bearings, rocker pivot axle nut, and rocker pivot axle. Torque values are given for the seat stay bolts (17 Nm) and rocker pivot axle nut (17 Nm). Required tools include a bearing press, 5mm and 9mm hex wrenches, and a torque wrench with 5mm and 9mm hex bits. The manual also provides part numbers for the seat stay and rocker link, directing users to trekbikes.com to find color-matched parts for their specific bike.
The Main pivot and chain stay section covers the assembly of the main pivot and chainstay, providing instructions for the nut, spacers, bearings, main pivot sleeve, main pivot axle, and chainstay. An important note highlights that the driveside bearing should be installed first. Torque for the main pivot axle is specified at 30 Nm. Tools required include a bearing press, 8mm hex tool, torque wrench with an 8mm hex bit, and grease. Part numbers for the chainstay are provided, with a recommendation to search trekbikes.com for color-matched parts.
The Shock mounts section details the installation of the shock linkage, upper shock bolt, lower shock axle, bearings, and lower shock bolt. Torque values are provided for the upper shock bolt (10 Nm) and lower shock bolt (10 Nm). The necessary tools are a bearing press, 5mm hex tool, torque wrench with a 5mm hex bit, and grease. Dimensions for the shock, including eye-to-eye length, stroke length, upper width, and lower width, are also provided.
Cable routing is meticulously illustrated, showing the paths for the dropper post cable, display cable, derailleur housing, rear brake hose, light cables (for equipped models), speed sensor cable, and battery power cable. Torque values are given for housing guides (0.4 Nm) and bolts (0.4 Nm). Part numbers for housing guides, bolts, and the Supernova Powerfly Cargo Rack E3 Tail Light 2 are included.
Frame guards, including the chainstay guard and drive unit guard, are covered in a dedicated section. Instructions for screws and top hat spacers are provided, with torque values for the screws (5 Nm). A special note on adhesive guards advises cleaning the frame surface with isopropyl alcohol and allowing it to dry before application, with a warning not to clean the entire frame with isopropyl alcohol as it could damage the paint.
The Full-size rear mudguard and rack section provides assembly instructions for the rear rack, rear mudguard, bolts, and washers. Torque values for the bolts are specified at 5 Nm. Similarly, the Mini rear mudguard section details its assembly, including bolts and washers, with a torque value of 5 Nm for the bolts.
Front mudguard installation is described for both 27.5" and 29" wheels. It covers the front mudguard and strut, screws, nylon washers, and various bolts. Torque values are provided for the screws (5.5 Nm for M6 x 10, 4 Nm for M5 x 10, 5 Nm for M5 x 12 and M5 x 8). A note specifies that mudguard parts for 29" wheels are only compatible with the originally equipped SR SUNTOUR fork.
The RIB – battery assembly section provides detailed instructions for the battery, socket head screws, spacer (for 500 Wh battery), push pin and spring, and battery handle assembly. Torque values are given for the socket head screws (2.5 Nm) and bolts (4 Nm for M3 x 8mm, 2.5 Nm for M3 x 20mm). It also covers the docking bracket, cover, and directs users to trekbikes.com for color-matched cover parts.
The RIB – docking assembly section is divided into lower and upper assembly. The lower assembly includes alignment plate, screws, locknuts, countersunk bolts, T25 security screws, washers, and lower docking bracket. Torque values are specified for various screws (2 Nm, 3 Nm, 5 Nm). The upper assembly covers the battery connection plug, power connection retention bracket, screws, lower battery mounting plug, upper lock cover, bumpers, ejector assembly, and lock assembly. A tip suggests using a hex tool to depress the plunger for access to the screw in the ejector assembly.
The Remote and displays section provides information on the LED remote, LED remote universal clamp, Kiox 300, and Intuvia 100. Part numbers are provided for these components.
The Drive system components section covers the drive unit and mounting bolts, specifying a torque of 20 Nm for the mounting bolts. It also details the speed sensor, bolt, and rotor mount speed sensor magnet, with part numbers for each. The Battery: charge port cover section includes instructions for the charge port cover, base, charge socket, and bolts, with a torque value of 1 Nm for the bolts. Users are directed to trekbikes.com for color-matched charge port covers.
Finally, the Specifications section provides important details such as chain line (1x only) at 52 mm, max chain ring (1x only) at 46T, and rear brake mount minimum (180 mm, direct mount) and maximum (adaptable to 203 mm). It also includes maximum tire size recommendations for different frame sizes (XS, S, M, L, XL) and wheel sizes (27.5" x 2.6" and 29" x 2.6"), emphasizing the need for 6mm clearance. Water bottle fit recommendations are given for XS and S frames. The seat post section includes a warning to follow the manufacturer's minimum insertion recommendation to avoid damage and injury, along with maximum insertion measurements for various frame sizes and seat tube dimensions. Fork specifications direct users to the suspension set-up card or trekbikes.com/suspension-calculator, with a warning about exceeding recommended maximum fork length. Travel and axle-to-race dimensions are provided for different frame sizes.
General| Frame | Aluminum |
|---|---|
| Motor | Bosch |
| Battery | Bosch |
| Display | Bosch |
| Maximum weight limit | 136 kg (rider + cargo + bike) |
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