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

2023 Carbon Rail
5
Adjust the geometry
Flip the Mino links in the seatstay pivot to change the bike’s geometry to t your riding style or the terrain.
Notice: If using a 29" front wheel and a 27.5" rear wheel, the Mino links must be in the high position.
Steeper head tube angle Slacker head tube angle
0.5° 0.5°
Mino links in the high position Mino links in the low position
• Pulls in the front fork for quicker steering
• Raises the bottom bracket for improved climbing
• Pushes the head tube angle back and pushes out the
front fork for slower steering that is more stable at high
speed
• Lowers the bottom bracket for more stability
5
Tools
• 5mm hex tool
• Torque wrench with 5mm hex bit
1. With the bike on the ground, loosen and remove one Mino link chip.
2. Loosen and remove the other Mino link chip.
3. Position the bike:
Mino links high: Lift the bike by the seat tube. This will pull the rear triangle up and forward.
Mino links low: With the chips removed, gravity will pull the rear triangle down and back.
4. Place one Mino link chip into the desired position. Slightly tighten the Mino link bolt.
5. Install the other Mino link chip into the same position. Slightly tighten the Mino link bolt.
6. Torque both Mino link bolts to 17Nm.

2023 Carbon Rail
6
Main pivot and chainstay
1
2
3
2
3
4
8
26x17
26x17
30Nm
6
Important: Install driveside
bearing rst.
5
1Nut — W584134
— 599909
2Spacers — W440921
3Bearings — W5256338
4Main pivot sleeve — W500592
5Main pivot axle — W601376
6Chainstay, carbon — 30891
Chainstay, aluminum — 35490
Search trekbikes.com to nd the color-matched
part for your bike.
Tools
• Bearing press, 26x17 drift
• 8mm hex tool
• Torque wrench with 8mm hex bit
• Grease

2023 Carbon Rail
7
Shock mounts
Standard
2
3
2
3
2
3
3
2
1
5
10x19
10x19
10x19
10x19
10Nm
10Nm
6
4
Tools
• Bearing press, 10x19 drift
• 5mm and 6mm hex wrenches
• Torque wrench with 5mm and 6mm hex bits
1Standard upper shock mount bolt and end cap — 5258209
2Bearings — W5256337
3Spacers — W529969
4Standard lower shock mount bolts — 5258210
5Thru shaft shock mount bolts — W600630
Trunnion
2
3
2
3
3
2
3
2
5
5
10x19
10x19
10x19
10x19
17Nm
5
5
17Nm
Dimensions
Shock Dimensions
Eye-to Eye-length: 230mm
Stroke length: 57.5mm
Upper width: 54mm
Lower width: 40mm

2023 Carbon Rail
8
Cable routing — Rail 9.8 and 9.9 with System Controller
2.5
0.5Nm
8
2.5
0.5Nm
8
9
9
Dropper post
cable is routed
through a cable
tunnel
2
4
3
5
1
7
6
2
55
12
11
1
3
4
2
10
13
Non-drive side
5
6
4 7

2 3 5


1Dropper post cable
2Controller cable — EB12.120.006*
3Derailleur housing
4 Rear brake hose
5Light cable(s) (Lights not included)
6Speed sensor cable
7Battery power cable — EB12.120.04A*
8Flat head screws — W532763
9Cable guides — W519232
10 Cable exit grommets — W5255861
11 Grommet — W543605
12 Countersink screw — W524884
13 Speed sensor assembly — See page 14.
Zip tie
*Bosch part number. Not available on trekbikes.com.
5

2023 Carbon Rail
9
Cable routing — Rail 9.5 and 9.7 with LED Remote
2.5
0.5Nm
8
2.5
0.5Nm
8
9
9
Dropper post
cable is routed
through a cable
tunnel
2
4
3
5
10
1
11
7
6
2
55
1
2
4
3
4 7

2 3 5


5
6
Non-drive side
1Dropper post cable
2LED Remote cable — EB12.120.005*
3Derailleur housing
4 Rear brake hose
5Light cable(s) (Lights not included)
6Speed sensor cable
7Battery power cable — EB12.120.04A*
8Flat head screws — W532763
9Cable guides — W519232
10 Cable exit grommets — W5255861
11 Speed sensor assembly — See page 14.
Zip tie
*Bosch part number. Not available on trekbikes.com.

2023 Carbon Rail
10
Frame guards and water bottle cage bolts
2
1
6
7
88
3
5Nm
5Nm 3
9
5
3
4
(Must be used with 3)
1 Seatstay guard — W5255862
2Chainstay guard — W587594
3Screw (S, M frames only) — W596821
4Bolt (L and XL frames only) — W549307
5Cage spacer (S, M frames only) — W5256157
6Down tube guard — W590604
7Drive unit guard — W5253938
8Screws — W549305
9Foam pads — W5303275
Adhesive guards and pads 1 269
Use isopropyl alcohol to clean the frame surface where the
guards and pads attach. Wait for the alcohol to dry before
applying the guards.
Notice: Do not clean the entire frame with isopropyl
alcohol. Isopropyl alcohol could damage the paint.

2023 Carbon Rail
11
Display and remote
Rail 9.8 and Rail 9.9
System controller
12
3
1 Bolt — W5287174
2System controller*
3Display grommet — W5285659
*Bosch part number. Not available on trekbikes.com.
Mini remote
1 Mini remote*
*Bosch part number. Not available on trekbikes.com.
Rail 9.5 and Rail 9.7
Display cover
12
1 Bolt — W5287174
2Display cover — W5291499
LED remote
1
2
1 LED remote — 5288736
2LED remote universal clamp — 5288743
LED Remote cable (See Cable routing — Rail
9.5 and 9.7 with LED Remote on page 9) —
EB12.120.005*
*Bosch part number. Not available on trekbikes.com.

2023 Carbon Rail
12
RIB — battery assembly
7
6
6
1
3
2
4
5
4
T10
4Nm
T10
2.5Nm
T10
2.5Nm
1Battery, vertical, Smart System,
S frame, 625Wh — EB12.100.012*
M - XL frame -750Wh — 5288731
2Push pin and spring — 5312675
3Battery handle assembly — W5252236
4Bolts, M3x8 — W5269016
5Docking bracket — W5252240
6Bolts, M3x20 — W5254060
7Cover, 625Wh battery — 37359
Cover, 750Wh battery — 37360
Search trekbikes.com to nd the color-matched
part for your bike.
*Bosch part number. Not available on trekbikes.com.

2023 Carbon Rail
13
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
S frame, 650Wh battery — W5252805
M–XL frame, 750Wh battery — W5252806
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 Carbon Rail
14
Drive system components
Drive unit and mounting bolts
120Nm
20Nm
1
1 Mounting bolts, TP40 — 5265419
Battery charge port
1
3
4
2
1.5Nm
1 Charge port cover — 44374
Search trekbikes.com to nd the color-matched
part for your bike.
2 Base — W5251862
3Charge socket — EB12.120.04A*
4Bolts — W5276241
*Bosch part number. Not available on trekbikes.com.
Speed sensor
1
2
3
4
1 Speed sensor chainstay plug — W587873
2Speed sensor — 5284750
3Bolt — W562831
4Rotor mount speed sensor magnet — W5252927

2023 Carbon Rail
15
Specifications
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
both 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 W581379 and
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