Trek Carbon Rail 9.8 Gen 3 2022 Operating manual

2022 and 2023 Carbon Rail
9.8 and 9.9 Gen 3
SERVICE MANUAL SUPPLEMENT
Rev 3 January 2023

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
1
Safety
WARNING
Tighten hardware properly
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
Re-apply threadlocker
All reused-fasteners with a pre-applied threadlocker
must be cleaned with isopropyl alcohol and have new
threadlocker applied before re-assembly. If a threadlock-
er 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
2022 Carbon Rail 9.8 and 9.9
12
Specications
Chainline (1x only)
52mm
• Boost hub with offset chainring.
Chainring (1x only)
• 34T only
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"
27.5" rear with the mino link in
the high position
27.5″ x 2.8″
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.
1
3
2
Item Measurement
1 Maximum insertion Frame
S230mm
M
L260mm
XL 310mm
2 Minimum insertion 75mm*
3Seat tube inside diameter 34.9mm
Seat tube post clamp outer diameter 39.5mm
*Follow the seatpost manufacturer’s guidelines.
Kickstand mount
• Requires W581379 and two M6x1.0x25mm bolts
18mm
M6x1.0x25
W581379
Safety Active Braking
Pivot (ABP)
Main pivot and
chainstay
Frame guards Drive unit and
mounting bolts
Specications
2022 Carbon Rail 9.8 and 9.9
13
Suspension
The rst step in suspension setup is to determine the sag. All other settings should be adjusted after determining the sag.
Refer to the suspension setup card included with your bike or the suspension calculator at
Trekbikes.com/suspension-calculator.
For recommended rebound settings refer to the suspension calculator at Trekbikes.com/suspension-calculator.
Fork
WARNING
Exceeding the recommended maximum fork length could
damage the bicycle and result in injury to the rider.
Travel
Sag
Axle to Crown
Frame/
Wheel
Size
Axle to Race (mm) Travel
(mm)
Sag
(mm)
S, M, ML,
L, XL, XXL
Recommended 571-576 160 24
Maximum 586 170 25.5
Shock
Mount Width
Bottom mount 54mm
Top mount 40mm
Eye to Eye
Stroke
Sag
Description Dimension
Eye-to-eye length 230mm
Stroke length 57.5mm
Recommended sag
30%, 17.25mm
Headset with
Knock Block
Rocker pivot and
seat stay
Shock mounts RIB — battery
assembly
Battery charge
port
Suspension
0.5°
Dérailleur hanger Adjust the
geometry
Cable routing RIB — docking
assembly
Speed sensor
Copyright 2021 Trek Bicycle Corporation All Rights Reserved

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
2
Headset with Knock Block
1
4
5
6
7
2
3
8
2.5
2Nm
1Upper bearing cover
– 5252161
2Chip bolt
3Knock Block chip – W532763
4Compression ring – W532842
5Upper bearing – W531676
6Lower bearing, 1.8" diameter. – W5269809
7Crown race, for 1.8" diameter lower bearing – W5283203
8Display mount – W5254476
Tools
• 2.5 mm hex tool
• Grease

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
3
Dérailleur hanger
3
1
2
8
25 Nm
1Dérailleur hanger
– W5271425
2Washer
3Bolt
Tools
• 8 mm hex tool
• Torque wrench (left-hand thread) with 8 mm hex bit
WARNING
Do not apply grease to the derailleur hanger or bolt. Only
apply grease to the thru axle.
This bicycle frame is designed to use a Universal Derailleur
Hanger (UDH).
NOTICE: The thru axle must be compatible with a UDH
and must be M12x1.0 with a 12.7 mm thread.
NOTICE: The washer is frame-specic. Install only the
washer compatible with your frame.
NOTICE: Do not over-tighten. 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.

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
4
Active Braking Pivot (ABP)
1
4
3
55
3
2
10 Nm 15 Nm
20x30 20x30
1Thru axle — W583470
– 599911
2Non-driveside dropout – W583420
3Bearings – W583424
4Dropout axle – W583419
5Spacers – W583422
Tools
• Bearing press, 20x30 drift
• Cassette lockring
• Grease
NOTICE: The thru axle must be compatible with a UDH
and must be M12x1.0 with a 12.7 mm thread.

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
5
Rocker pivot and seat stay
5
67
8
7
69
22 Nm
17 Nm
3
2
4 42
3
1
17 Nm
4
4
5
21x12
21x12
19x10
19x10
1
10
11
1Bolts – W600629
2Bearings – W529224
3Spacers – W529969
4Mino link – W529223
5Rocker axle – W535469
– 599910
6Spacers – W290057
7Bearings – W586543
8Seat tube pivot sleeve – W310155
9Nut – W311582
10 Seatstay – 30893. Search trekbikes.com to nd the
colour-matched part for your bike.
11 Rocker link – 30969. Search trekbikes.com to nd
the colour-matched part for your bike.
Tools
• Bearing press, 19x10 and 21x12 drifts
• 4mm and 5mm hex wrenches
• Torque wrench with 4mm and 5mm hex bits
Seat tube pivot
Important: Press in driveside bearing rst.

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
6
Adjust the geometry
Flip the Mino link in the seatstay pivot to change the bike’s geometry to t your riding style or the terrain.
Notice: If using a 29" wheel up front and a 27.5" wheel in the back, the minolink must be in the high position.
Steeper head tube angle Slacker head tube angle
0.5°
Mino link in the high position Mino link 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 0.5° and pushes out
the front fork for slower steering that is more stable at
high speed
• Lowers the bottom bracket up to 9 mm for more stability
Tools
• 5 mm hex tool
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 Link high: Lift the bike by the seat tube. This will pull the rear triangle up and forward.
Mino Link 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.

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
7
Main pivot and chainstay
123
5
2
3
4
8
26x17
26x17
30 Nm
6
1Nut – W584134
– 599909
2Spacers – W440921
3Bearings – W302025
4Main pivot sleeve – W500592
5Main pivot axle – W601376
6Chainstay – 30891. Search trekbikes.com to nd
the colour-matched part for your bike.
Tools
• Bearing press, 26x17 drift
• 8 mm hex tool
• Torque wrench with 8mm hex bit
• Grease
Important: Press in the driveside bearing rst.

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
8
Shock mounts
Standard
2
3
23
4
4
2
3
3
2
5
1
5
10x19
10x19
10x19
10x19
10 Nm
10 Nm
6
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 – W293466
3Spacers – W529969
4Standard lower shock mount bolts – 5258210
5Thru shaft shock mount bolts – W600630
Thru shaft
2
3
2
3
3
2
3
2
5
5
5
5
10x19
10x19
10x19
10x19
17 Nm
17 Nm
5

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
9
Cable Routing
14
1
2
15
12
13
11
10
9
3
4
9
10
8
5
1
2.5
2.5
0.5 Nm
0.5 Nm
2
Dropper post cable
is routed through a
cable tunnel

 Secure cables with zip ties.
Drive side
Non-drive side
6
1Dropper post
2Display to remote
3Derailleur
4 Rear brake
5Display to drive unit
6Front light (aftermarket option)
7Speed sensor
8Battery power
9Flat head screws – W532763
10 Cable guides – W519232
11 Cable exit grommets – W5255861
12 Countersink screw – W524884
13 Grommet – W543605
14 Speed sensor chainstay plug – W587873
15 Speed sensor – 5284750
Zip tie

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
10
Frame guards
2
6
7
88
5
4
or
4
Notice: (5) Must be used with (3).
3
2.5Nm
5Nm
3
5Nm
3
1
9
1 Seatstay guard – W5255862
2Chainstay guard – W587594
3Screws (S and M frames only) – W596821
4Bolts (L and XL frames only) – W549307
5Cage spacer (S and M frames only) – W5256157
6Down tube guard – W590604
7Drive unit guard – W5253938
8Screws – W549305
9Foam pads – W5303275
Adhesive guards and pads 1 269
Use isopropyl alcohol to clean the frame surface where the
chainstay (2) and seatstay guards (1) 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.

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
11
RIB — battery assembly
7
6
6
1
3
2
4
5
4
T10
4Nm
T10
2.5Nm
T10
2.5Nm
1Battery, vertical, Smart System,
S frame, 625Wh — EB12.100.012*
M - XL frame -750Wh — 5288731
2Push pin and spring — 5312675
3Battery handle assembly — W5252236
4Bolts, M3x8 — W5269016
5Docking bracket — W5252240
6Bolts, M3x20 — W5254060
7Cover, 625Wh battery — 37359
Cover, 750Wh battery — 37360
Search trekbikes.com to nd the color-matched part
for your bike.
*Bosch part number. Not available on trekbikes.com.

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
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.

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
13
Drive system components
Drive unit and mounting bolts
120Nm
20Nm
1
1 Mounting bolts, TP40 — 5265419
Battery charge port
1
3
4
2
1.5Nm
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 — W5276241
*Bosch part number. Not available on trekbikes.com.
Speed sensor
1
2
3
4
1 Speed sensor chainstay plug — W587873
2Speed sensor — 5284750
3Bolt — W562831
4Rotor mount speed sensor magnet — W5252927

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
14
Specifications
Chainline (1x only)
52 mm
• Boost hub with offset chainring.
Chainring (1x only)
• 34T only
Rear brake mount
Minimum Maximum
180mm, direct mount Adaptable to 203 mm
Maximum tyre size
Notice: Measurements of actual tyres may vary. Always
verify there is sufcient clearance between the tyre and
the frame. Improper tyre size could damage the bicycle
frame. Trek recommends 6 mm clearance above and on
the sides of the tyre.
Wheel set Maximum tyre size
29" 29" x 2.6"
27.5" rear with the mino link in
the high position
27.5″ x 2.8″
Water bottle t on small frames
Rail 9.8: Use Bontrager Voda 15 bottle
9.9 with AirWiz: There is not enough clearance to t a
water bottle.
Seat post
WARNING
Always follow the seat post manufacturer’s minimum
insertion recommendation. Failure to follow the recom-
mendation could cause damage to the seatpost and
result in injury to the rider.
1
3
2
Item Measurement
1 Maximum insertion Frame
S230 mm
M
L260 mm
XL 310 mm
2 Minimum insertion 75 mm*
3Seat tube inside diameter 34.9 mm
Seat tube post clamp outer diameter 39.5 mm
*Follow the seatpost manufacturer’s guidelines.
Kickstand mount
• Requires kickstand mounting bracket W581379 and
two M6x1.0x25 mm bolts
18 mm
M6x1.0x25
W581379

2022 and 2023 Carbon Rail 9.8 and 9.9 Gen 3
15
Suspension
The rst step in suspension setup is to determine the sag. All other settings should be adjusted after determining the sag.
Refer to the suspension setup card included with your bike or the suspension calculator at
Trekbikes.com/suspension-calculator.
For recommended rebound settings refer to the suspension calculator at Trekbikes.com/suspension-calculator.
Fork
WARNING
Exceeding the recommended maximum fork length could
damage the bicycle and result in injury to the rider.
Travel
Sag
Axle to Crown
Frame/
Wheel Size
Axle to Crown (mm) Travel
(mm)
Sag
(mm)
S, M, ML, L,
XL, XXL
Recommended 571–576 160 24
Maximum 586 170 25.5
Shock
Mount Width
Bottom mount 54 mm
Top mount 40 mm
Eye to Eye
Stroke
Sag
Description Dimension
Eye-to-eye length 230 mm
Stroke length 57.5 mm
Recommended sag 30%, 17.25 mm