Trek ALLOY FUEL EXE User manual

2024 ALLOY FUEL EXE

SERVICE MANUAL

Rev 1 August 2023

2024 Alloy Fuel EXe

Contents

Safety Adjustable headset Adjust the geometry —

headset angle

Active Braking Pivot

(ABP)

Rocker pivot and

seatstay

Main pivot and

chainstay

Rear shock hardware

and dimensions

Adjust the geometry —

Mino link

Brake and mechanical

shift routing

Speed sensor routing

Dropper post routing Remote and display AXS shift routing Guards and water

bottle mounts

Charge port cover

Wiring harness, cable

tray organizer, and

access panel

Motor cover Drive unit Adjust the compensa-

tion fasteners

Re-install the cranks

2023 FuelExe

Specications

Chainline (1x only)

55mm

Chainring (1x only)

Minimum Maximum

30T 34T Round

Oval rings of any size are not recommended as they will

affect motor performance.

Rear brake mount

Minimum Maximum

180mm, direct mount Adaptable to 203mm

Maximum tire size

29" x 2.5"

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.

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.

Minimum insertion 75mm

Maximum insertion

Small 190mm

Medium 225mm

Large 250mm

Extra Large 285mm

Seat tube inside diameter 22.5mm

Seat tube post clamp outer diameter 39.7mm

Fork

WARNING

Exceeding the recommended maximum fork length could

damage the bicycle and result in injury to the rider.

Travel

Sag

Axle to Crown

Frame/Size Axle to Crown (mm) Travel(mm)

S, M, ML, L, XL Recommended 557 150

Maximum 567 160

Recommended sag: Refer to the suspension setup card

included with your bike or the suspension calculator at

Trekbikes.com/suspension-calculator.

TK_Fuel_Ex-e_ServiceManual_MY23.indd 18TK_Fuel_Ex-e_ServiceManual_MY23.indd 18 4/11/2022 4:17:10 PM4/11/2022 4:17:10 PM

Battery Remove and install the

battery

Ride the bike without

the battery

Connect lights to the

TQ Smart Box

Specications

2024 Alloy Fuel EXe

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.

Scope

This manual contains parts diagrams, specications (such

as grease and torque values), instructions, and helpful

tips. It does not contain instructions for all components

(such as brake calipers). Refer to the original manufactur-

er for more information.

Legend

Apply grease

Do not apply grease

Apply threadlocker

Nm Torque

Zip tie

Additional resources

• TQ e-system quick start guide: trekbikes.com/manuals

• TQ service manuals: tq-ebike.com/en/support/manuals

• Trek’s YouTube channel: youtube.com/trekbikes

2024 Alloy Fuel EXe

Adjustable headset

1Upper bearing cover — W5275173

— W5285212

2Compression ring — W532842

3Upper bearing — W531676

4Upper cup, 0° angle — 5304949

5Press-t lower cup, 0° angle — 5304949

6Lower bearing — W532843

7Crown race — W532844

2024 Alloy Fuel EXe

Adjust the geometry — headset angle

0°

-1°

+1°

Tools

• Upper angled cup:

XS - L frames — W5295319

XL - XXL frames — W5295274

• Lower angled cup — W5294449

• Adjustable headset alignment tool — 5310000

• Headset cup removal tool

• 8mm hex tool (150mm minimum length for XL frame)

• Headset cup press

• Painter’s tape

• Grease

Remove components

1. Remove the fork.

2. Remove the upper headset assembly.

3. Use the headset cup removal tool to remove the lower

headset cup.

Install the alignment tool

1. Use the alignment tool to mark the centerline to which

you will align the lower cup.

2. Thread the hex tool through the upper alignment tool.

Insert the tools into the upper head tube.

3. Position the lower alignment tool with the notches to

the front and back of the head tube.

4. Thread the lower alignment tool over the hex tool. The

hex tool will keep the notches aligned as you insert the

alignment tool.

5. Place a piece of painter’s tape on the head tube, then

draw a line on the tape that aligns with the notch.

6. Remove both pieces of the alignment tool.

Install the angled cups

1. Grease the cups and head tube bores.

2. Position the upper cup and insert it into the head tube.

Slacker Steeper

3. Position the lower cup to match the angle of the upper

cup.

Slacker Steeper

4. Align the notch on the cup with the line on the painter’s

tape.

5. Press in the lower cup. Note: position the press with

the handle above the head tube.

6. Remove the press. Verify the notch on the lower cup is

aligned with the line on the tape. If it is not, remove cup

and reinstall in correct position.

7. Remove the painter’s tape.

2024 Alloy Fuel EXe

Active Braking Pivot (ABP)

This bicycle frame is designed to use a Universal Derailleur Hanger (UDH). For additional information about the UDH, refer to

the SRAM user manual at sram.com.

25Nm

15Nm

10Nm

1Switch lever — W573860

2Thru axle, 12X184.5mm, —

W583469

— W5272776

3Non-driveside ABP dropout nut guide

— W5269707

4Retaining ring — W5251279

5Bearings, 20x30x7 — W5256340

6Non-driveside ABP bolt — W5251141

7Derailleur hanger

WARNING: Do not apply grease.

— W5271425

8Washer, 30mm

NOTICE: The washer is frame-spe-

cic. Install only the washer size

specied.

9Bolt

WARNING: Do not apply grease.

Do not over-tighten. Over-tightening

the bolt could cause the hanger to

break.

2024 Alloy Fuel EXe

Rocker pivot and seatstay

Important: Install driveside

bearing rst.

Torque order

Important: Loosely tighten all screws and bolts, then torque

in the order shown below. To achieve proper torque on all

bolts, rocker link pinch bolts (8) must be torqued last.

8Nm

5Nm

M6x25M5x18

1Fasteners, M6x25mm — W5270150

2Concave washers — W5270027

3Bearings, 12x21x8 — W5256341

4Hat style washers — W5270030

5Mino link nuts — W5270028

6Frame spacers, 18x12x2 — W290057

7Rocker pivot axle — W5307024

8Rocker link pinch bolts, M5x18mm — W5256244

9*Seatstay — 45460

10 *Driveside rocker link

— 45461

11 *Non-driveside rocker link

*Search trekbikes.com to nd the color-matched part for your

bike.

8Nm

17Nm

5Nm

Non-drive sideDrive side

2024 Alloy Fuel EXe

Main pivot and chainstay

Important: Install driveside

bearing rst

15Nm

1Main pivot axle, M8x80.5mm — W5270022

2Frame spacers — W440921

3Bearings, 17x26x10 — W5256338

4Main pivot sleeve — W600642

5Concave washer — W5270024

6Fastener, M8x35mm — W5270149

7Chainstay — 45459

Search trekbikes.com to nd the color-matched

part for your bike.

2024 Alloy Fuel EXe

Rear shock hardware and dimensions

Shock Dimensions

Eye-to Eye-length: 205mm

Stroke length: 60mm

Upper width: 54mm x 10mm

Lower width: 40mm x 8mm

For a list of compatible shocks, refer

to the FAQ on the MY24 Alloy Fuel EXe

page on trekbikes.com.

15Nm

17Nm

17Nm 5

1Upper bolts, M10x19mm — W5270031

2Bearings, 12x21x8 — W5256341

3Hat-style washers — W5270030

4Nut, 8mm

— W5274968

5Lower bolt, M8x60mm

Setup

Recommended sag: 30%, 18mm

Refer to the suspension setup card included with your bike

or the suspension calculator at

trekbikes.com/suspension-calculator.

For recommended rebound settings refer to the suspen-

sion calculator at trekbikes.com/suspension-calculator.

2024 Alloy Fuel EXe

Adjust the geometry — Mino link

Flip the Mino link to change the bike’s geometry to t your riding style or the terrain.

Steeper head tube angle Slacker head tube angle

0.5°

Mino link in the high position Mino link 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 0.5° and pushes out the

front fork for slower steering that is more stable at high speed

• Lowers the bottom bracket up to 9mm for more stability

Loosen

Torque 8Nm

Loosen

Flip Flip

Torque 8Nm

Drive sideNon-drive side

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