Rail (625Wh) New Trek Rail 2020-2021 Service Manual Supplement

[IMeasureStuff]

Trek have a new Rail 2020-2021 Service Manual Supplement

It has some excellent information, diagrams and part codes.

This should be a sticky post at the top of the page. It includes...

1. Inspect the Knock Block components
2. Install the Knock Block and Kiox mount in the headset
3. Rear derailleur hanger
4. Frame guards
5. Cable routing
6. RIB system without alignment plate
7. RIB system with alignment plate
8. Bosch drive unit removal/installation
9. Suspension hardware
10. Dropout hardware
11. Specifications

https://trek.scene7.com/is/content/TrekBicycleProducts/TK_Rail_MY20-21_ServiceManual_Rev1_EN_US_2021-06.pdf

 

[GrandesRoues]

Thansk for the info.
I didn't knew about the alignment plate. I haven't got one on my bike. Is this a new feature to prevent battery pop out ?

 

[IMeasureStuff]

Thansk for the info.
I didn't knew about the alignment plate. I haven't got one on my bike. Is this a new feature to prevent battery pop out ?

Yeah it must be a new thing to stop the battery falling out. I wonder if it's going to be sold as a kit. It would make sense, as it's a fairly common issue.

 

[GrandesRoues]

The alignment plate W5252805 can be found online.
But on my bike i have the cables on top of the battery, whereas in this manual it looks like the go under the alignment plate underside the battery ?

 

[IMeasureStuff]

The alignment plate W5252805 can be found online.
But on my bike i have the cables on top of the battery, whereas in this manual it looks like the go under the alignment plate underside the battery ?

What year Rail are you running? All the rails I have seen run the cables as shown in the manual.

 

[GrandesRoues]

I'm on holiday without my bike (2021 9.8). You must be right and my memory must be wrong !

 

[markloch]

Yeah it must be a new thing to stop the battery falling out. I wonder if it's going to be sold as a kit. It would make sense, as it's a fairly common issue.

My problem isn't the battery popping out, but the battery momentarily disconnecting (and powering off the drive unit) when on a bumpy descent. It typically happens at least once on 3 out of 4 rides.

Trek (we have a corporate-owned store nearby) has already tried adjusting it once, I haven't been back to tell them it's still happening but will be visiting later this week, see what they have to say about the plate - at a glance it looks like the plate would help, though unless the existing lower and upper docking brackets have threaded holes to accommodate the button head screws (item #2 on the w/alignment plate diagram), a refit kit would need to include new docking brackets as well.

 

[IMeasureStuff]

Yeah I had a look at the part numbers and it is more than just the plate that is new. When you take your bike back to trek, get them to also check that all the bolts on the battery are correctly tightened. Some of mine came loose.

 

[Orangie]

This is problem