Trek Rail 9.5 Gen 4 User manual

2023 Carbon Rail
9.5, 9.7, 9.8, and 9.9 Gen 4
SERVICE MANUAL
Rev 1 January 2023

2023 Carbon Rail
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
0.5°
Headset with Knock
Block
Adjust the
geometry
Cable routing with
System Controller
System controller
and mini remote
RIB — docking
assembly
Battery
charge port
2023 Carbon 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.
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″
Water bottle t
Small frame: 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.
Medium frame: 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
Frame size Axle to Race
(mm)
Travel
(mm)
S, M, ML, L, XL Recommended 571-576 160
Maximum 586 170
Active Braking Pivot
(ABP)
Main pivot and
chainstay
Cable routing with
LED Remote
Display cover and
LED remote
Drive unit and
mounting bolts
Specications
Rocker pivot and
seatstay
Shock mounts Frame guards and
water bottle cage
bolts
RIB — battery
assembly
Speed sensor
Copyright 2022 Trek Bicycle Corporation All Rights Reserved

2023 Carbon Rail
2
Headset with Knock Block
1
4
5
6
7
3
2
2.5
2Nm
1Upper bearing cover
— 5252161
2Chip bolt — W532763
3Knock Block chip
4Compression ring — W532842
5Upper bearing — W531676
6Lower bearing, 1.8" diameter — W5269809
7Crown race, for 1.5" diameter lower bearing
(Rail 9.5) — W5269810
Crown race, for 1.8” diameter lower bearing
Rail 9.7, 9.8, 9.9) — W5283203
Tools
• 2.5mm hex tool
• Grease

2023 Carbon Rail
3
Active Braking Pivot (ABP)
Rail 9.8 and Rail 9.9 — Carbon seatstay and chainstay
184mm
3
NOTICE: Thread must
be at least 12.7mm
6
5
2
15Nm
10Nm
1
12.7mm
7
20x30 20x30
9
10
25Nm
8
8
Rail 9.5 and Rail 9.7 — Alloy seatstay and chainstay
2
10Nm
1
4
184mm
3
NOTICE: Thread must
be at least 12.7mm
6
5
15Nm
12.7mm
20x30 20x30
8
9
10
25Nm
8
1Switch lever — W573860
2Thru axle — W583470
— 599911
3Non-driveside ABP dropout nut —
W583419
4Retaining ring — W5251279
5Bearings — W583424
6Non-driveside ABP bolt — W583420
7Spacers — W583422
(carbon chainstays only)
8Derailleur hanger
— W5271425
9Washer
10 Bolt (left-hand thread)
Tools
• Bearing press, 20x30 drift
• Cassette lockring tool
• Grease
• 8mm hex tool
• Torque wrench (left-hand thread) with 8mm hex bi

2023 Carbon Rail
4
Rocker pivot and seatstay
7
10
11
5
21x12
5
622Nm
3
19x10
8
19x10
2
2
3
4
17Nm
4
17Nm
1
1
Important: Install
driveside bearing
rst.
4
7
12
21x12
9
8
1Bolts — W5270150
2Bearings — W5256339
3Concave washers — W5289553
4Spacers — W529969
5Mino links — W5270028
6Rocker axle — W600627
7Spacers — W290057
8Bearings — W5256341
9Seat tube pivot sleeve — W310155
10 Nut — W311582
11 Seatstay, carbon — 30893
Seatstay, aluminum — 35491
Search trekbikes.com to nd the color-matched part
for your bike.
12 Rocker link — 30969. Search trekbikes.com to nd
the color-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