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Related Manuals for Trek Alloy Rail 5 Gen 3
Summary of Contents for Trek Alloy Rail 5 Gen 3
- Page 1 2023 Alloy Rail 5, 7, and 9 Gen 3 SERVICE MANUAL Rev 1 September 2023...
- Page 2 Improper tire size could damage the bicycle Trekbikes.com/suspension-calculator. frame. Trek recommends 6mm clearance above and on the sides of the tire. WARNING Wheel set...
- Page 3 2023 Alloy Rail Headset with Knock Block Tools Upper bearing cover • 2.5mm hex tool Chip bolt — W532763 — 5252157 • Grease Knock Block chip Compression ring — W532842 Upper bearing — W531676 Lower bearing, 1.5" diameter — W532843 Crown race, for 1.5"...
- Page 4 2023 Alloy Rail Active Braking Pivot (ABP) 20x30 20x30 25Nm Switch lever — W573860 Tools Thru axle — W583469 • Bearing press, 20x30 drift • Cassette lockring tool Non-driveside ABP dropout nut — • Grease W5269707 • 8mm hex tool —...
- Page 5 2023 Alloy Rail Rocker pivot and seatstay 21x12 17Nm 19x10 21x12 Important: Install 19x10 driveside bearing first. 17Nm 22Nm Seatstay — 44378 Bolts — W5270150 Search trekbikes.com to find the color-matched part for your bike. Bearings — W5256339 Rocker link — 37992. Search trekbikes.com to find the color-matched part...
- Page 6 2023 Alloy Rail Adjust the geometry Flip the Mino links in the seatstay pivot to change the bike’s geometry to fit 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°...
- Page 7 2023 Alloy Rail Main pivot and chainstay 30Nm 26x17 26x17 Important: Install driveside bearing first. Tools Nut — W584134 • Bearing press, 26x17 drift Spacers — W440921 • 8mm hex tool • Torque wrench with 8mm hex bit Bearings — W5256338 —...
- Page 8 2023 Alloy Rail Shock mounts Standard Trunnion 17Nm 10x19 10x19 10Nm 10x19 10x19 17Nm 10x19 10x19 10Nm 10x19 10x19 Tools • Bearing press, 10x19 drift • 5mm and 6mm hex wrenches • Torque wrench with 5mm and 6mm hex bits Dimensions Standard upper shock mount bolt and end cap —...
- Page 9 2023 Alloy Rail Cable routing 0.5Nm 0.5Nm Non-drive side Dropper post housing Flat head screws — W532763 LED Remote cable — EB12.120.005* Cable guides — W519232 10 Cable exit grommets — Derailleur housing W5255861 11 Speed sensor assembly — See Rear brake hose page 13.
- Page 10 2023 Alloy Rail Frame guards Upper down tube guards — 556549 Adhesive guards Lower down tube guard — W5276240 Use isopropyl alcohol to clean the frame surface where the guards and pads attach. Wait for the alcohol to dry before Chainstay guard —...
- Page 11 2023 Alloy Rail Remote LED remote LED remote — 5288736 LED remote universal clamp — 5288743 LED Remote cable (See Cable routing on page 8) — EB12.120.005* *Bosch part number. Not available on trekbikes.com.
- Page 12 2023 Alloy Rail RIB — battery assembly 2.5Nm 2.5Nm Battery, Vertical, Smart System, 500W — EB12.100.018* Bolts, M3x8 — W5269016 Battery, Vertical, Smart System, 625W — EB12.100.012* Docking bracket — W5252240 Socket head screws, M3x12 — W5257054 Bolts, M3x20 — W5254060 Spacer (For 500Wh battery) —...
- Page 13 2023 Alloy Rail RIB — docking assembly Lower assembly Upper assembly Tip: Use the hex tool to depress the plunger to create access to the screw in the ejector assembly. 2Nm 2Nm Alignment plate — W5252805 Battery connection plug — EB12.100.015* Screws Power connection retention bracket —...
- Page 14 2023 Alloy Rail Drive system components Drive unit and mounting bolts Speed sensor 20Nm 20Nm Speed sensor — 5284750 Mounting bolts, TP40 — 5265419 (Bosch 1270.016.470) Bolt — W562831 Battery charge port cover 1 Nm Charge port cover — 44374 Search trekbikes.com to find the color-matched...
- Page 15 Improper tire size could damage the bicycle Trekbikes.com/suspension-calculator. frame. Trek recommends 6mm clearance above and on both sides of the tire. WARNING Wheel set...
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