Trek Alloy Rail 5 Gen 3 User manual

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

2023 Alloy Rail
1
Safety
WARNING
Properly tighten hardware
Always tighten hardware to the specied 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 thread-
locker 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
Contents
2023 Aluminum Rail
15
Specications
Chainline (1x only)
52mm
• Boost hub with offset chainring.
Chainring (1x only)
• 34T
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 sufcient 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.
Wheel set Maximum tire size
29" 29" x 2.6"
Water bottle t
Small: Compatible only with the Bontrager Voda 15 bottle.
Requires the cage spacer included with the bike.
Medium: Requires the bottle cage spacer included with
the bike.
Seat post
WARNING
Always follow the seatpost manufacturer’s minimum
insertion recommendation. Failure to follow the recom-
mendation could cause damage to the seatpost and
result in injury to the rider.
Measurement
Maximum insertion Frame
S220mm
M230mm
L260mm
XL 310mm
Seat tube inside diameter 31.6mm
Seat tube post clamp outer diameter 36.4mm
Kickstand mount
• Requires kickstand mounting bracket W581379and
two M6x1.0x25mm bolts
18mm
M6x1.0x25
W581379
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.
Travel
Axle to Race
Frame size Axle to Race
(mm)
Travel
(mm)
S, M, ML, L, XL Recommended 570 160
Maximum 580 170
Safety Rocker pivot and
seatstay and seat
stay
Shock mounts RIB — battery
assembly
Drive unit and
mounting bolts
Specications
0.5°
Headset with Knock
Block
Adjust the geom-
etry
Cable routing RIB — docking
assembly
Battery charge
port cover
Active Braking Pivot
(ABP)
Main pivot and
chainstay and
chainstay
Frame guards Remote Speed sensor
Copyright 2022 Trek Bicycle Corporation All Rights Reserved

2023 Alloy Rail
2
Headset with Knock Block
1
4
5
6
7
3
2
2.5
2Nm
1Upper bearing cover
— 5252157
2Chip bolt — W532763
3Knock Block chip
4Compression ring — W532842
5Upper bearing — W531676
6Lower bearing, 1.5" diameter — W532843
7Crown race, for 1.5" diameter lower bearing —
W532844
Tools
• 2.5mm hex tool
• Grease

2023 Alloy Rail
3
Active Braking Pivot (ABP)
4
3
6
5
2
15Nm
10Nm
1
5
20x30
20x30
7
8
9
25Nm
8
1Switch lever — W573860
2Thru axle — W583469
— W5272776
3Non-driveside ABP dropout nut —
W5269707
4Retaining ring — W5251279
5Bearings — W5256340
6Non-driveside ABP bolt — W5251141
7Derailleur hanger
— W5271425
8Washer
9Bolt (left-hand thread)
Tools
• Bearing press, 20x30 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-specic. 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.

2023 Alloy Rail
4
Rocker pivot and seatstay
7
10
11
5
21x12
6
622Nm
3
19x10
8
19x10
2
2
3
4
17Nm
4
17Nm
1
1
Important: Install
driveside bearing
rst.
4
7
12
21x12
9
8
1Bolts — W5270150
2Bearings — W5256339
3Concave washers — W5289553
4Spacers — W529969
5Mino links — W5270028
6Rocker axle — W600627
7Spacers — W290057
8Bearings — W5256341
9Seat tube pivot sleeve — W310155
10 Nut — W311582
11 Seatstay — 44378
Search trekbikes.com to nd the color-matched part
for your bike.
12 Rocker link — 37992.
Search trekbikes.com to nd the color-matched part
for your bike.
Tools
• Bearing press, 19x10 and 21x12 drifts
• 4mm and 6mm hex wrenches
• Torque wrench with 4mm and 5mm hex bits

2023 Alloy Rail
5
Adjust the geometry
Flip the Mino links in the seatstay pivot to change the bike’s geometry to t 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 Slacker head tube angle
0.5° 0.5°
Mino links in the high position Mino links in the low position
• Pulls in the front fork for quicker steering
• Raises the bottom bracket for improved climbing
• 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
5
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.

2023 Alloy Rail
6
Main pivot and chainstay
1
2
3
52
3
4
8
26x17
26x17
30Nm
6
Important: Install driveside
bearing rst.
1Nut — W584134
— 599909
2Spacers — W440921
3Bearings — W5256338
4Main pivot sleeve — W500592
5Main pivot axle — W601376
6Chainstay — 44377
Search trekbikes.com to nd the color-matched
part for your bike.
Tools
• Bearing press, 26x17 drift
• 8mm hex tool
• Torque wrench with 8mm hex bit
• Grease

2023 Alloy Rail
7
Shock mounts
Standard
2
4
4
2
2
3
3
2
1
5
10x19
10x19
10x19
10x19
10Nm
10Nm
6
5
Tools
• Bearing press, 10x19 drift
• 5mm and 6mm hex wrenches
• Torque wrench with 5mm and 6mm hex bits
1Standard upper shock mount bolt and end cap — 5258209
2Bearings — W5256337
3Spacers, 16 x 10 x 5mm — W536414
4Spacers, 16 x 10 x 3mm — W529969
5Standard lower shock mount bolts — 599900
6Trunnion shock mount bolts — W5289626
Trunnion
2
4
2
3
3
2
4
2
6
5
10x19
10x19
10x19
10x19
17Nm
5
6
17Nm
Dimensions
Shock Dimensions
Eye-to Eye-length: 230mm
Stroke length: 57.5mm
Upper width: 54mm
Lower width: 40mm

2023 Alloy Rail
8
Cable routing
2.5
0.5Nm
8
2.5
0.5Nm
8
9
9
10
7
6
2
55
1
2
4
3
1
5
2
3


Non-drive side
5
4


532
4 7
6
11
1Dropper post housing
2LED Remote cable — EB12.120.005*
3Derailleur housing
4 Rear brake hose
5Light cable(s) (Lights not included)
6Speed sensor cable
7Battery power cable — EB12.120.00T*
8Flat head screws — W532763
9Cable guides — W519232
10 Cable exit grommets — W5255861
11 Speed sensor assembly — See page 13.
Zip tie
*Bosch part number. Not available on trekbikes.com.

2023 Alloy Rail
9
Frame guards
4
5
5
3
5Nm
5Nm 3
3
2
1
6
6
1 Upper down tube guards — 556549
2Lower down tube guard — W5276240
3Chainstay guard — W5276239
4Drive unit guard — W5269899
5Screws — W549305
6Top hat spacers — W5272256
Adhesive guards 1 23
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.

2023 Alloy Rail
10
Remote
LED remote
1
2
1 LED remote — 5288736
2LED remote universal clamp — 5288743
LED Remote cable (See Cable routing on page 8)
— EB12.120.005*
*Bosch part number. Not available on trekbikes.com.

2023 Alloy Rail
11
RIB — battery assembly
6
7
6
2
8
1
4
9
5
8
3
2.5
2.5Nm
T10
4Nm
T10
2.5Nm
1Battery, Vertical, Smart System, 500W — EB12.100.018*
Battery, Vertical, Smart System, 625W — EB12.100.012*
2Socket head screws, M3x12 — W5257054
3Spacer (For 500Wh battery) — W5252256
4Push pin and spring — 5312675
5Battery handle assembly — W5252236
6Bolts, M3x8 — W5269016
7Docking bracket — W5252240
8Bolts, M3x20 — W5254060
9Cover, 625W battery — 44371
Search trekbikes.com to nd the color-matched part for
your bike.
*Bosch part number. Not available on trekbikes.com.

2023 Alloy Rail
12
RIB — docking assembly
2
2
15
15
Lower assembly
1
3
4
Upper assembly
3
11
16
17
2
6
7
5
Tip: Use the hex tool to depress
the plunger to create access to
the screw in the ejector assembly.
1
12
10
2
8
4
14
13
3
7
9
1
11
8
2
15
2.5 3 3 T25
7
3
2Nm 2Nm 3Nm 3Nm 5Nm
1Alignment plate — W5252805
2Screws
— 5257257
4Locknuts
8Screws
11 Countersunk bolts
15 T25 security screws
13 Washers
3Lower docking bracket
— 5277571
14 Upper docking bracket
5Battery connection plug — EB12.100.015*
6Power connection retention bracket
— 5312122
7Screws — W549307
9Lower battery mounting plug — W5252293
16 Upper lock cover — W5252292
17 Bumpers — 579326
10 Ejector assembly — 579324
12 Lock assembly — W562311
*Bosch part number. Not available on trekbikes.com.

2023 Alloy Rail
13
Drive system components
Drive unit and mounting bolts
120Nm
20Nm
1
1 Mounting bolts, TP40 — 5265419
(Bosch 1270.016.470)
Battery charge port cover
1
3
4
2
1 Nm
1 Charge port cover — 4 4374
Search trekbikes.com to nd the color-matched
part for your bike.
2 Base — W5251862
3Charge socket — EB12.120.04A*
4Bolts — 5284849
*Bosch part number. Not available on trekbikes.com.
Speed sensor
1
2
1Speed sensor — 5284750
2Bolt — W562831

2023 Alloy Rail
14
Specications
Chainline (1x only)
52mm
• Boost hub with offset chainring.
Chainring (1x only)
• 34T
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 sufcient 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.
Wheel set Maximum tire size
29" 29" x 2.6"
Water bottle t
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 recom-
mendation could cause damage to the seatpost and
result in injury to the rider.
Measurement
Maximum insertion Frame
S220mm
M230mm
L260mm
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
18mm
M6x1.0x25
W581379
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.
Travel
Axle to Race
Frame size Axle to Race
(mm)
Travel
(mm)
S, M, ML, L, XL Recommended 570 160
Maximum 580 170