Trek MARLIN 6 User manual

2024 MARLIN+
SERVICE MANUAL

2024 Marlin+
1
Contents
Safety Rear
axle
Guards
Safety Rear axle Guards and covers
Routing
Brake and rear
shift routing
Seat postSeat post
dropper post routing
Speed sensor
routing
Battery and remote
routing
Motor
and
battery
Charge port cover Motor guard Motor parts Lower the motor
4 Nm
Battery parts Remove the battery Install the battery
Mud-
guards
and
racks
29"
29"
27.5"
27.5"
Rear mudguard –
29” wheel
Rear rack –
29” wheel
Rear mudguard –
29” wheel
Rear rack –
27.5” wheel
Rear mudguard –
27.5” wheel
Light
routing
(optional)
Specs
2024Marlin+
20
Specifications
Chainline (1x only)
52mm
Chainring (1x only)
Minimum Maximum
32T 36T
Oval rings of any size are notrecommended as they will
affect motor performance.
Rear brake mount
Minimum Maximum
180mm, direct mount Adaptable to 203mm
OLD
Rear Hub: 148mm
Maximum tire size
Note: Marlin+ is not designed for mixedwheel sizes.
XS, S: 27.5" x 2.6" (2.4" with fenders)
M, L, XL: 29" x 2.6" (2.4" with fenders)
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. Trekrecommends 6mm clearance above and on
the sides of the tire.
Seatpost
WARNING
Always followthe seatpost manufacturer’s minimum
insertion recommendation. Failure to followthe recom-
mendation could cause damage to the seatpost and
result in injury to the rider.
Minimum insertion: Refer toseatpost manufacturer
Maximum insertion
Extra Small: 210mm
Small: 240
Medium: 290mm
Large: 320mm
Extra Large 370mm
Seat tube inside diameter: 31.6mm
Seat tube post clamp outer diameter: 36.4 mm
Fork
WARNING
Exceeding the recommended maximum forklength could
damage the bicycle and result in injury to the rider.
Travel
Sag
Axle to Crown
Frame/Size Axle to Crown (mm) Travel (mm)
XS Recommended 492 100
Maximum 504 110
S Recommended 512 120
Maximum 524 130
M, L, XL Recommended 531 120
Maximum 543 130
Recommended sag: Referto the suspension calculator at
Trekbikes.com/suspension-calculator.
Kickstand mount
Compatible kickstand: W330289
Rear light routing –
through the mud-
guard
Rear light routing –
through the chain-
stay
Front light routing Specications
Copyright 2023 Trek Bicycle Corporation All Rights Reserved

2024 Marlin+
2
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.
Scope
This manual contains parts diagrams, specications (such
as grease and torque values), instructions and helpful tips.
It does not contain instructions for all components (such
as brake callipers). Refer to the original manufacturer for
more information.
Legend
Apply grease
Do not apply grease
Apply threadlocker
Nm Torque
Zip tie
Additional resources
• Bosch Purion remote quick start guide: trekbikes.com/manuals
• Bosch E-bike Owner’s Manual: trekbikes.com/manuals
• Trek’s YouTube channel: youtube.com/trekbikes

2024 Marlin+
3
Rear axle
This bicycle frame is designed to use a Universal Derailleur Hanger (UDH). For additional information about the UDH, refer to
the SRAM user manual at sram.com.
25 Nm
10 Nm
1
2
345
1Switch lever – W573860
2Thru axle, 12 mm – W600321
3Dérailleur hanger
NOTICE: Do not apply grease.
– W5271425
4Washer, 25 mm
NOTICE: The washer is frame-specic. Install only the washer size specied.
5Bolt, M12
NOTICE: Do not apply grease. Do not overtighten. Overtightening may damage
the hanger.

2024 Marlin+
4
Brake and rear shi routing


Zip ties
Tip:
Remove the non-driveside motor cover to easily route
the brake hose and rear shift housing.

2024 Marlin+
5
Seat post dropper post routing
Tip:
Remove the non-driveside
motor cover to easily
route the housing up the
seat tube.
Tip:
Remove the motor guard to easily route
the housing under the motor.
If routing the housing without the motor
installed, be sure to leave extra slack in
the housing to eventually route under
the motor.
Route the dropper housing
between the motor bolt
and the motor.

2024 Marlin+
6
Speed sensor routing
1
2
3
Non-drive side shown. Motor cover removed.
1.5 Nm
Zip ties


4
Refer to the Bosch service manual for instructions
on installing the speed-sensor components.
1 Speed sensor cable:
Bosch part number – EB11.200.011
Trek part number (available in some markets) – 5318757
2Speed sensor clip, Bosch part number 1270.016.038
3Fastener, M4x6 mm – W575056
4 Speed sensor magnet – 599404

2024 Marlin+
7
Battery and remote routing
Non-drive side shown. Motor cover
removed.
Battery to charge port cable
Remote cable
Battery cable

2024 Marlin+
8
Frame guards and covers
2
1


Non-drive side
3
4
M4x6
4
Zip ties
1.5 Nm
Align the front of the
guard with the weld.
1Chainstay guard – W5308950
2Downtube guard – W5312189
Use isopropyl alcohol to clean the frame surface where the
guard is attached. Wait for the alcohol to dry before applying
the guard.
NOTICE: Do not clean the entire frame with isopropyl alcohol.
Isopropyl alcohol could damage the paint.
3Motor access cover – 5312747
4Fasteners, M4x6 – W575056
NOTICE: Maximum fastener length is 6 mm. Longer
fasteners could damage the brake hose and rear shift
housing.

2024 Marlin+
9
Charge port cover
2
1
M3x6
2
0.8 Nm
1 Charge door assembly – W5312791
2Fasteners, M3x6 – W5276241

2024 Marlin+
10
Motor guard
M5x14
3
3
2
4 Nm
4
3
4 Nm
1
When re-installing the
motor guard make sure
the rubber seals are po-
sitioned outside the bike
frame.
TIP:
Install the motor guard
Install the front spacer and fastener rst, then install the
rear spacers and fasteners. This will make it easier to
align the front fastener with the threads in the battery.
1 Motor guard – W5306871
2Hat-style spacers – W5272256
3Fasteners, M5x14 – W5314651
4Hat-style spacer – W5315181

2024 Marlin+
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Motor parts
25 Nm
2
1
3
1Motor mount bracket fasteners – Bosch part number. Refer to Bosch service information.
2Motor mount bracket – W561438
3Motor fasteners, M8x60 – 5251047

2024 Marlin+
12
Lower the motor
For access to routing and battery connections the motor can be lowered, rather than completely removed.
1. Remove the seat post dropper lever from the handlebar. This will create slack in the seat post dropper routing so the rout-
ing can be repositioned to allow the motor to be lowered.
2. Remove the motor guard. See Motor guard on page 10.
3. Loosen bolts 1and 3 Remove bolt 2.
1
2
3
4. Support the motor with one hand and use your other hand to remove bolt 3.
5. Slowly lower the motor. The motor will hang from the frame by the remaining bolt 1.

2024 Marlin+
13
Battery parts
M5x14
3
M5x12
1
1
2
3
4
4 Nm
4 Nm
1Fastener, M5x12 – W5314650
2Washer – W5315181
3Fastener, M5x14 – W5314651
4Battery, horizontal xed mount – Bosch part numbers:
US – EB12.100.046
EU/AUS/NZ – EB12.100.048

2024 Marlin+
14
Remove the battery
NOTICE: Only professional bike mechanics should remove the battery.
Tip: Before beginning this procedure remove the
seat post dropper lever from the handlebar. This
will create slack in the hosing that runs under the
motor and make it easier to remove the motor.
1
2
3
Rotate the bike in the stand so the
headtube is lower than the motor
cavity, This will prevent the battery
from sliding out of the frame in
the next step.
4
5
The battery is now loose in the frame. Place one hand
below the downtube to catch the battery. Use the other
hand to rotate the bike in the stand. The battery will
slide out of the downtube.

2024 Marlin+
15
Install the battery
Rotate the bike in the stand
so the headtube is lower than
the motor cavity. The battery
stop aligns the battery with
the mounting hole in the
frame. Loosely tighten the
fastener.
1
2
Loosely tighten the fas-
tener to hold the battery
in place.
3
25 Nm
4
4 Nm
5
4 Nm
6
7
4 Nm

2024 Marlin+
16
Front mudguard
The front mudguard is sold separately.
29"wheel
5
7
2
27.5"wheel
5
3
7
4
1
88
5
5 Nm
6
5.5 Nm
3
5 Nm
M5 x 12 M6 x 10 M5 x 8
8
M5 x 10
4 Nm
6
1 Front mudguard and strut, 27.5” – 601256
2 Front mudguard and strut, 29” – 601257
3Screw, M5 x 12 mm, stainless steel – W584855
4Washer, nylon – 5319894
5Bolt, M6 x 10 mm, stainless steel
(a longer bolt may be required if using a
light mounting bracket)
– 601267
6Bolt, M5 x 8 mm, stainless steel
7Washer, M5 x 1 mm, stainless steel
8Bolts, M5 x 10 mm, stainless steel – W549305
*Mudguard parts for the 29" wheel are only compatible with the originally equipped SR SUNTOUR or RockShox fork.

2024 Marlin+
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Rear rack – 29" wheel
The rear rack is sold separately. Proper installation requires the mudguard to be installed with the lower portion of the rack.
The upper portion of the rack is detachable.
2
2
3
1
5 Nm
M5x14
2
5 Nm
1 Rear rack
– W5289962
2Fasteners, stainless steel, M5 x 14 mm
3Washers, stainless steel, M5 x 1 mm

2024 Marlin+
18
Rear mudguard – 29"wheel
The rear mudguard is sold separately. Proper installation requires the mudguard to be installed with the lower portion of the
rack.
The upper portion of the rack is detachable.
2
2
3
3
42 5
4
M5x14
3
M5x20
1
5 Nm
5 Nm
5 Nm
1Rear mudguard, 29" wheel – W5309614
2Washers, stainless steel, M5 x 1 mm
– 5315939
3Fasteners, stainless steel, M5 x 14 mm
4Fastener, stainless steel, M5 x 20 mm
5Spacer, aluminium, 7.5 mm

2024 Marlin+
19
Rear rack – 27.5"wheel
The rear rack is sold separately. Proper installation requires the mudguard to be installed with the lower portion of the rack.
The upper portion of the rack is detachable.
2
2
3
1
M5x12
2
5 Nm
5 Nm
1 Rear rack
– W5289962
2Fasteners, stainless steel , M5 x 14 mm
3Washers, stainless steel, M5 x 1 mm