Trek Powerfly Gen 3 FS 9 EQ User manual

2023 Powerfly FS
Gen 3 FS 9 EQ, FS 7, FS 4 EQ, and FS 4
SERVICE MANUAL
Rev 1 October 2023

2023 Powery FS
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
Safety Main pivot and
chainstay
Frame guards Front fender Remote and
displays
Speed sensor
2023Carbon Rail
16
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.
Wheelset Maximumtire size
29" 29" x 2.6"
27.5" rear with the mino link in
thehigh position
27.5″ x 2.8″
Water bottle t
Smallframe: Compatible only with the Bontrager Voda 15
bottle. Requires the cage spacer included with the bike.
Rail 9.9 with AirWiz: There is not enough clearance to t a
water bottle.
Mediumframe: Requires the bottle cage spacer included
with the bike. Rail 9.9 with AirWiz requires the bottle cage
to be positioned as far toward the headtube as possible.
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
S230mm
M
L260mm
XL 310mm
Seat tube inside diameter 34.9mm
Seat tube post clamp outer diameter 39.5mm
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
Framesize Axleto Race
(mm)
Travel
(mm)
S, M, ML, L, XL Recommended 571- 576 160
Maximum 586 170
Active Braking Pivot
(ABP)
Shock mounts Full-size rear fender
and rack
RIB — battery
assembly
Drive unit and
mounting bolts
Specications
Rocker pivot and
seat stay
Cable routing Mini rear fender 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
3
6
2
15Nm
10Nm
1
5
20x30
20x30
7
8
9
25Nm
8
5
1Switch lever — W573860
2Thru axle, 184mm — 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 Powery FS
3
Rocker pivot and seatstay
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
1Seatstay bolts, M10 x 21mm — W1051358
2Seatstay bearings, 10 x 19 x 8mm — W5256339
3Spacers, 16 x 10 x 3mm — W529969
4Spacers, 18 x 12 x 3mm — W574 411
5Rocker pivot bearings, 12 x 21 x 8mm — W5256341
6Rocker pivot axle nut, M8 x 11mm
— 5256640
7Rocker pivot axle, M16 x 83mm
8Seatstay — 44376
Search trekbikes.com to nd the color-matched part
for your bike.
9Rocker link — 33983
Search trekbikes.com to nd the color-matched part
for your bike.
Tools
• Bearing press, 10 x1 9 and 12 x 21 drifts
• 5mm and 9mm hex wrenches
• Torque wrench with 5mm and 9mm hex bits

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

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

2023 Powery FS
6
Cable routing
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
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 — EB12.120.00T*
8Housing guides — W594006
9Bolts, M3 x 10mm — W285213
10 Supernova Powery Cargo Rack E3 Tail Light 2 —
W1047565
*Bosch part number. Not available on trekbikes.com.

2023 Powery FS
7
Frame guards
1
2
3
3
35Nm
5Nm
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 attaches. 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 fender and rack
1
2
5
5
3
3
4
3
5Nm
5
5Nm
M5 x 12 M5 x 14
1 Rear rack — W5289962
2Rear fender — W600725
3Bolts, stainless steel , M5 x 14mm
— 5251710
4Washers, stainless steel, M5 x 1mm
5Bolts, stainless steel , M5 x 12mm — W584855

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

2023 Powery FS
10
Front fender
29"wheel
5
7
2
27.5"wheel
5
3
7
4
1
8
8
5
5Nm
6
5.5Nm
3
5Nm
M5 x 12 M6 x 10 M5 x 8
8
M5 x 10
4Nm
6
1 Front fender and strut, 27.5” — 601256
2 Front fender and strut, 29” — 601257
3Screw, M5 x 12mm, stainless steel — W584855
4Washer — 5319894
5Bolt, M6 x 10mm, stainless steel
(Longer bolt may be required if using a
light mounting bracket)
— 601267
6Bolt, M5 x 8mm, stainless steel
7Washer, M5 x 1mm, stainless steel
8Bolts, M5 x 10mm, stainless steel — W549305
*Fender parts for 29 wheel 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
2.5Nm
T10
4Nm
T10
2.5Nm
1Battery, Vertical, Smart System,
500Wh — EB12.100.018*
625Wh — EB12.100.012*
2Socket head screws, M3 x 12mm — W5257054
3Spacer (for use with 500Wh 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 color-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
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 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
20Nm
20Nm
1
1
1 Mounting bolts, TP40 — 5265419
(Bosch 1270.016.470)
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 color-matched
part for your bike.
2 Base — W5251862
3Charge socket — EB12.120.04A*
4Bolts, M3 x 6mm — 5284849
*Bosch part number. Not available on trekbikes.com.

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 Maximum tire 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
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
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