Trek Powerfly HT Sport EQ 4 User manual

2023 Powerfly HT
Sport EQ 4 and Sport EQ 7 Gen 3
4, 5 and 7 Gen 4
SERVICE MANUAL

2023 Powery HT
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 Powery Hard Tail
12
Specifications
Chainline (1x only)
52mm
• Boosthub with of fset chainring.
Max chainring (1x only)
• 38T
Rear brake mount
Minimum Maximum
180mm,direct mount Adaptableto 203mm
Maximum tire size
Notice:Measurements of actual tires may vary. Always
verify there is sufcient clearance between the tire and
theframe. Improper tire size could damage the bicycle
frame.Trek recommends 6mm clearance above and on
bothsides of the tire.
Framesize Maximumtire size
XS,S 27.5″ x 2.6"
M,L, XL 27.5" x 2.8", 29" x 2.6"
Water bottle t
XSand S: Maximum 15 oz bottle on Seat tube and 21 oz
bottledown tube.
Seat post
WARNING
Alwaysfollow the seatpost manufacturer’s minimum
insertion recommendation. Failureto follow the recom-
mendationcould cause damage to the seatpost and
resultin injur y to the rider.
Measurement
Maximum insertion Frame
XS 232mm
S 265mm
M291mm
L 341mm
XL 392mm
Seattube inside diameter 31.6mm
Seattube post clamp outer diameter 36.4mm
Fork
Referto the suspension setup card included with your bike
orthe suspension calculator at
Trekbikes.com/suspension-calculator.
WARNING
Exceeding the recommended maximum fork length could
damagethe bicycle and result in injur y tothe rider.
Travel
Axle to Race
Framesize Axleto Race
(mm)
Travel
(mm)
XS,S Recommended 455 80
Maximum 492 100
M,L, XL Recommended 509 100
Maximum 526 120
Safety Rear fender and
rack — 29" wheel
RIB — battery
assembly
Drive unit and
mounting bolts
Specications
Thru axle and
derailleur hanger
Rear fender and
rack — 27.5” wheel
RIB — docking
assembly
Battery charge port
cover
Cable routing Front fender Remote and
displays
Speed sensor
Copyright 2022 Trek Bicycle Corporation All Rights Reserved

2023 Powery HT
2
Thru axle and derailleur hanger
1
2
3
10Nm
23Nm
174mm
1Thru axle, 174 x 12mm — W518983
2Derailleur hanger — W572370
3Closed convert hardtail and horizontal sliding drop-
out hardware, M12 x 1mm — W318004
Tools
• Grease
• Torque wrench with 20mm socket

2023 Powery HT
3
Cable routing
10
11
7
6
2
55
Non-drive side
3
2
4
5
1
XS and S frames
5
4
3
1
2
8
10
M, L, and XL frames
34
5
1
2
9
11
12




5
0.4Nm
0.4Nm
6
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, XS and S frames — W594006
9Housing guides, M, L, XL frames — W519232
10 Bolts, M3 x 10mm — W285213
11 Bolts, M4 x 16mm — W532763
12 Frame plug for Bosch light cable — W334049
Zip ties
*Bosch part number. Not available on trekbikes.com.

2023 Powery HT
4
Frame guards
1
3
3
3
5Nm
5Nm
3
2
1 Chainstay guard — W591958
2Drive unit guard — W5272058
3Screws, stainless steel, M5 x 10mm — W549305
Adhesive guard 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 HT
5
Rear fender and rack — 29"wheel
4
5Nm
3
5Nm
4
5
5
64 5
3
1
2
5 x 20 5 x 14
1 Rear rack — W5289961
2Rear fender, 29" wheel — W583413
3Bolts, stainless steel, M5 x 14mm
— 601265
4Bolts, stainless steel, M5 x 20mm
5Washers, stainless steel, M5 x 1mm
6Spacer, aluminum, 7.5mm

2023 Powery HT
6
Rear fender and rack — 27.5”wheel
1
2
8
9
10
3
4
5
7
7
6
7
5Nm
M5 X 35
5Nm
M5 x 14
46
5Nm
3
5Nm
5
M5 x 30 M5 x 20
1 Rear rack — W5289961
2Rear fender, 27.5" wheel — W585734
3Bolts, stainless steel, M5 x 20mm
— 601266
4Bolt, stainless steel, M5 X 35mm
5Bolt, stainless steel, M5 x 14mm
6Bolts, stainless steel, M5 x 30mm
7Washers, stainless steel, M5 x 1mm
8Spacer, aluminum, 24.5mm
9Spacer, aluminum, 16mm
10 Spacer, aluminum, 13.8mm

2023 Powery HT
7
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, nylon — W506324
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

2023 Powery HT
8
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
9Battery cover — 44370
Search trekbikes.com to nd the color-matched part for
your bike.
*Bosch part number. Not available on trekbikes.com.

2023 Powery HT
9
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 HT
10
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 HT
11
Drive system components
Drive unit and mounting bolts
20Nm
20Nm
1
1
1 Mounting bolts, TP40 — 5265419
Speed sensor
1
2
3
1Speed sensor — 5284750
2Bolt, stainless steel, M4 x 8mm — W562831
3Rotor mount speed sensor magnet — W5252927
Battery charge port cover
1
3
4
2
1 Nm
1 Charge port cover — 44372
Search trekbikes.com to nd the color-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 HT
12
Specifications
Chainline (1x only)
52mm
• Boost hub with offset chainring.
Max chainring (1x only)
• 38T
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 size Maximum tire size
XS, S 27.5″ x 2.6"
M, L, XL 27.5" x 2.8", 29" x 2.6"
Water bottle t
XS and S: Maximum 15 oz bottle on seat tube and 21 oz
bottle down tube.
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
XS 232mm
S265mm
M 291mm
L341mm
XL 392mm
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 455 80
Maximum 492 100
M, L, XL Recommended 509 100
Maximum 526 120