Trek Powerfly FS Series User manual

2023 Powerfly FS
Gen 3 FS 9 EQ, FS 7, FS 4 EQ, and FS 4
SERVICE MANUAL

2023 Powery FS
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
Safety Main pivot and
chainstay
Frame guards Front mudguard Remote and
displays
Speed sensor
2023 Powery FS
15
Specications
Chainline (1x only)
52mm
• Boost hub with offset chainring.
Max chainring (1x only)
• 46T
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.
Frame Maximumtire size
XS,S 27.5" x 2.6"
M,L, XL 29" x 2.6"
Water bottle t
XSand S frames: Use a Bontrager side-load cage and a
21oz (621ml) bottle.
Seatpost
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
XS 180mm
S207mm
M215mm
L246mm
XL 297mm
Seat tube inside diameter 31.6mm
Seat tube post clamp outer diameter 36.4mm
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
Framesize Axleto Race
(mm)
Travel
(mm)
XS,S Recommended 505.5 100
Maximum 520 120
M,L, XL Recommended 540 120
Maximum 545 120
Active Braking Pivot
(ABP)
Shock mounts Full-size rear
mudguard and rack
RIB — battery
assembly
Drive unit and
mounting bolts
Specications
Rocker pivot and
seat stay
Cable routing Mini rear mudguard RIB — docking
assembly
Battery: charge
port cover
Copyright 2022 Trek Bicycle Corporation All Rights Reserved

2023 Powery FS
2
Active Braking Pivot (ABP)
4
184 mm
3
NOTICE: Thread must
be at least 12.7 mm
6
2
15 Nm
10 Nm
1
12.7 mm
5
20x30
20x30
7
8
9
25 Nm
8
5
1Switch lever – W573860
2Thru axle —W583469
— W5272776
3Non-driveside ABP dropout nut —
W5269707
4Retaining ring — W5251279
5Bearings —W5256340
6Non-driveside ABP bolt —
W5251141
7Dérailleur hanger
— W5271425
8Washer
9Bolt (left-hand thread)
Tools
• Bearing press, 20x30 drift
• Cassette lock ring tool
• Grease
• 8mm hex tool
• Torque wrench (left-hand thread) with 8 mm 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. Only
apply grease to 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 Powery FS
3
Rocker pivot and seat stay
4
8
2
10x19
9
17 Nm
1
3
9
210x19
17 Nm
9
1
12x21
12x21
5
5
4
5
7
17 Nm
6
1Seat stay bolts, M10 x 21 mm — W1051358
2Seat stay bearings, 10 x 19 x 8 mm — W5256339
3Spacers, 16 x 10 x 3 mm – W529969
4Spacers, 18 x 12 x 3 mm — W574 411
5Rocker pivot bearings, 12 x 21 x 8 mm — W5256341
6Rocker pivot axle nut, M8 x 11 mm
— 5256640
7Rocker pivot axle, M16 x 83 mm
8Seat stay — 44376
Search trekbikes.com to nd the colour-matched part
for your bike.
9Rocker link — 33983
Search trekbikes.com to nd the colour-matched part
for your bike.
Tools
• Bearing press, 10 x1 9 and 12 x 21 drifts
• 5 mm and 9 mm hex wrenches
• Torque wrench with 5 mm and 9 mm hex bits

2023 Powery FS
4
Main pivot and chain stay
Important: Install the driveside bearing
rst.
1
2
6
30 Nm
8
2
17x26
3
4
17x26
3
5
1Nut, M16 x 1.5 mm — W584134
— 5256639
2Spacers, 22 x 17 x 3 mm — W440921
3Bearings, 17 x 26 x 10 mm — W5256338
4Main pivot sleeve — W500592
5Main pivot axle, M8 x 62.5 mm —
W601376
6Chainstay — 44377
Search trekbikes.com to nd the colour-matched part for
your bike.
Tools
• Bearing press, 17 x 26 drift
• 8 mm hex tool
• Torque wrench with 8mm hex bit
• Grease

2023 Powery FS
5
Shock mounts
3
4
2
4
10 Nm
10 Nm
10 Nm
2
5
5
5
5
1
10x19
10x19
Tools
• Bearing press, 10 x1 9 drift
• 5mm hex tool
• Torque wrench with 5 mm hex bit
• Grease
1Shock linkage — 5256637
2Upper shock bolt, M8 x 33 mm — W600364
3Lower shock axle, M6 x 69 mm — 5256638
4Bearings, 10 x 19 x 5mm — W5256337
5Lower shock bolt, M6 x 11 mm — 5256638
Dimensions
Shock Dimensions
Eye-to-eye length: 190 mm
Stroke length: 45 mm
Upper width: 20 mm
Lower width: 20 mm

2023 Powery FS
6
Cable routing
1Dropper post cable
2Display cable – EB12.120.005*
3Derailleur housing
4 Rear brake hose
5Light cables (lights included only on Powery
Equipped models)
6Speed sensor cable
7Battery power cable – EB12.120.04A*
8Housing guides — W594006
9Bolts, M3 x 10 mm — W285213
10 Supernova Powery Cargo Rack E3 Tail Light 2 —
W1047565
*Bosch part number. Not available on trekbikes.com.
7
6
2
55
0.4Nm
9
1
2
3
Non-drive side
5
4
4
1
23
82
8
9
0.4Nm
25
9
6
10

2023 Powery FS
7
Frame guards
1
2
3
3
35 Nm
5 Nm
3
4
4
1 Chainstay guard — W587594
2Drive unit guard — W5269899
3Screws, stainless steel, M5xx10 — W549305
4Top hat spacers — W5272256
Adhesive guards 1
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.

2023 Powery FS
8
Full-size rear mudguard and rack
1
2
5
5
3
3
4
3
5 Nm
5
5 Nm
M5 x 12 M5 x 14
1 Rear rack — W5289962
2Rear mudguard — W600725
3Bolts, stainless steel , M5 x 14 mm
— 5251710
4Washers, stainless steel, M5 x 1 mm
5Bolts, stainless steel , M5 x 12 mm — W584855

2023 Powery FS
9
Mini rear mudguard
3
2
1
2
5 Nm
1 Mini mudguard — W1040072
2Bolts, stainless steel, M5 x 14 mm,
— 5251710
3Washers, at, stainless steel, M5 x 1 mm

2023 Powery FS
10
Front mudguard
29"wheel
5
7
2
27.5"wheel
5
3
7
4
1
8
8
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 12mm, stainless steel — W584855
4Washer, nylon — W506324
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 29 wheels are compatible with only the originally equipped SR SUNTOUR fork.

2023 Powery FS
11
RIB – battery assembly
6
7
6
2
8
1
4
9
5
8
3
2.5
2.5 Nm
T10
4 Nm
T10
2.5 Nm
1Battery, Vertical, Smart System,
500 Wh – EB12.100.018*
625 Wh – EB12.100.012*
2Socket head screws, M3 x 12 mm — W5257054
3Spacer (for use with 500 Wh battery) — W5252256
4Push pin and spring — 5312675
5Battery handle assembly — W5252236
6Bolts, M3 x 8mm — W5269016
7Docking bracket — W5252240
8Bolts, M3 x 20mm — W5254060
9Cover — 44370
Search trekbikes.com to nd the colour-matched part
for your bike.
*Bosch part number. Not available on trekbikes.com.

2023 Powery FS
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
2 Nm 2 Nm 3 Nm 3 Nm 5 Nm
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 — W52522 3
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 Powery FS
13
Remote and displays
LED remote
1
2
1 LED remote — 5288736
2LED remote universal clamp — 5288743
Kiox 300
Kiox 300 — 5288735
Intuvia 100
Intuvia 100 — EB13.100.00F
*Bosch part number. Not available on trekbikes.com.

2023 Powery FS
14
Drive system components
Drive unit and mounting bolts
20 Nm
20 Nm
1
1
1 Mounting bolts, TP40 — 5265419
Speed sensor
1
2
3
1Speed sensor — 5284750
2Bolt — W562831
3Rotor mount speed sensor magnet — W5252927
Battery: charge port cover
1
3
4
2
1 Nm
1 Charge port cover — 44373
Search trekbikes.com to nd the colour-matched
part for your bike.
2 Base — W5251862
3Charge socket — EB12.120.04A*
4Bolts, M3 x 6mm — W5276241
*Bosch part number. Not available on trekbikes.com.

2023 Powery FS
15
Specifications
Chain line (1x only)
52 mm
• Boost hub with offset chain ring.
Max chain ring (1x only)
• 46T
Rear brake mount
Minimum Maximum
180 mm, direct mount Adaptable to 203 mm
Maximum tyre size
Notice: Measurements of actual tyres may vary. Always
verify that there is sufcient clearance between the tyre
and the frame. Improper tyre size could damage the
bicycle frame. Trek recommends 6mm clearance above
and on both sides of the tyre.
Frame Maximum tyre size
XS, S 27.5" x 2.6"
M, L, XL 29" x 2.6"
Water bottle t
XS and S frames: Use a Bontrager side-load cage and a
621 ml 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 seat post and
result in injury to the rider.
Measurement
Maximum insertion Frame
XS 180 mm
S207 mm
M215 mm
L246 mm
XL 297 mm
Seat tube inside diameter 31.6 mm
Seat tube post clamp outer diameter 36.4 mm
Fork
Refer to the suspension set-up 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)
XS, S Recommended 505.5 100
Maximum 520 120
M, L, XL Recommended 540 120
Maximum 545 120