Trek 2023 FUEL EX User manual

2023 FUEL EX
SERVICE MANUAL

2023 Fuel EX
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
Torx tool
Drift size
Zip tie
Contents
Safety Active Braking
Pivot (ABP)
Rear shock
hardware and
dimensions
Frame guards —
carbon frame
Adjust the
geometry —
headset angle
Adjustable headset Rocker pivot and
seatstay
Adjust the
progression
Frame guards —
aluminum frame
Adjust the
geometry —
seatstay mino link
2023 Fuel EX
15
Specications
Chainline (1x only)
55mm
Chainring (1x only)
Minimum Maximum
28T Round: 34T
Oval: 32T
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 2.5"
27.5" (XS and S frame) 27.5" x 2.5"
Bottom bracket /ISCG tabs
Bottom bracket ISCG tabs
BSA 73 ISCG 05, 3 bolt
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 Carbon
Aluminum
XS 205mm
180mm
S (27.9” and
29” wheels) 225mm
210mm
M255mm
240mm
ML 266mm
250mm
L281mm
265mm
XL 316mm
300mm
XXL —
330mm
Seat tube inside diameter 34.9
Seat tube post clamp
outer diameter
39.5
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/
Wheel Size
Axle to Race
(mm)
Travel
(mm)
XS and S /
27.5" wheels
Recommended 534 140
Maximum 550 150
S, M, ML, L, XL, XXL /
29" wheels
Recommended 562 150
Maximum 578 160
Refer to the suspension setup card included with your bike
or the suspension calculator at
trekbikes.com/suspension-calculator.
Derailleur hanger Main pivot and
chainstay
Cable routing Down tube storage Specications
Copyright 2022 Trek Bicycle Corporation All Rights Reserved

2023 Fuel EX
2
Adjustable headset
1
2
3
4
5
6
7
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
Tools
• Headset press
• Grease

2023 Fuel EX
3
Derailleur hanger
25Nm
3
2
1
1Derailleur hanger
— W5271425
2Washer, 30mm
3Bolt
Tools
• 8mm hex tool
• Torque wrench (left-hand thread) with 8mm hex bit
WARNING
Do not apply grease to the derailleur hanger or bolt.
This bicycle frame is designed to use a Universal Derailleur
Hanger (UDH).
NOTICE: The thru axle must be compatible with a UDH
and must be M12x1.0 with a 12.7mm thread.
NOTICE: The washer is frame-specic. Install only the
washer size specied.
NOTICE: Do not over-tighten. Over-tightening the bolt
could cause the hanger to break.
For additional information about the UDH, refer to the
SRAM user manual at www.sram.com.

2023 Fuel EX
4
Active Braking Pivot (ABP)
Carbon frame
4
184mm
3
NOTICE: Thread must
be at least 12.7mm
6
5
20x30
20x30
2
15Nm
10Nm
1
12.7mm
7
Aluminum frame
4
184mm
3
NOTICE: Thread must
be at least 12.7mm
6
5
20x30
20x30
2
15Nm
10Nm
1
12.7mm
1Switch lever — W573860
2Thru axle — W583469
— W5272776
3Non-driveside ABP dropout nut
guide — W5269707
4Retaining ring — W5251279
5Bearings — W5256340
6Non-driveside ABP bolt —
W5251141
7Spacers — W583422
Tools
• Bearing press
• Cassette lockring tool
• Grease
• Threadlocker
•

2023 Fuel EX
5
Rocker pivot and seatstay
Important: Install driveside
bearing rst.
6
12x21
3
12x21
4
1
2
12x21
5
12x21
3
2
5
8Nm
3
3
1
8Nm
4
2
4
7
9
8
1Screws — W5270150
2Concave washers — W5270027
3Bearings — W5256341
4Seat tube pivot sleeve — W310155
5Hat style washers — W5270030
6Mino link nuts — W5270028
7Rocker pivot axle — W5270025
8Rocker pivot:
Search for part number listed below on trekbikes.com
to nd the color-matched part for your bike.
Carbon frame — 40783
Aluminum frame — 40780
9Seatstay:
Search for part number listed below on trekbikes.com
to nd the color-matched part for your bike.
Carbon frame — 40777
Aluminum frame — 38553
Tools
• Bearing press
• 4mm hex wrench
• Torque wrench with 4mm hex bit
• Grease
• Threadlocker

2023 Fuel EX
6
Main pivot and chainstay
1
2
3
2
4
5
17x26
17x26
15Nm
15Nm
5
7
Important: Install
driveside bearing rst
5
6
1Main pivot axle — W5270022
2Bearings — W5256338
3Main pivot sleeve — W600642
4Concave washer — W5270024
5Screw — W5270149
6Hat style washers — W5270023
7Chainstay:
Search trekbikes.com to nd the color-matched
part for your bike.
Carbon frame — 40776
Aluminum frame — 38552
Tools
• Bearing press
• 5mm hex tool
• Torque wrench with 8mm hex bit
• Grease
• Threadlocker

2023 Fuel EX
7
Rear shock hardware and dimensions
Shock Dimensions
Eye-to Eye-length: 185mm
Stroke length: 55mm
Upper width: 54mm x 10mm
Lower width: 40mm x 8mm
6
1
2
2
1
17Nm
17Nm
10Nm
3
4
12x21
6
12x21
6
5
6
1Upper bolts, M10 x 1 x 19mm — W5270031
2Bearings — W5256341
3Hat-style washers — W5270030
4Lower shock Mino nut — 5303333
5Lower shock Mino washer — 5303333
6Lower bolt, M8 x 1 x 60mm — W5274968
Tools
• Bearing press
• 6mm hex wrenches
• Torque wrench with 6mm bits
• Grease
Setup
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.

2023 Fuel EX
8
Adjust the progression
The shock mino links can be ipped to ne tune the shock performance for the terrain or rider preference.
Tools
• 6mm hex tool
• Torque wrench with 6mm hex bit
1. Remove the lower shock mount bolt.
2. Flip the mino link nut and washer to the desired positions.
3. Re-insert the shock bolt and torque to 10Nm.
Less progression More progression
More reactive to repeated fast mid-size bumps and
square-edge hits.
More bottom out resistance over big hits and drops
10Nm
6
10Nm
6

2023 Fuel EX
9
Cable routing
2 3
1
4
5
6
7
1.7Nm
1
2
• Two separate cable tunnels for rear
brake hose and derailleur housing run
the length of the frame.
• Dropper post cable continues up the
seat tube.






3
1 Dropper cable
2Rear brake hose
3Derailleur housing
4Plug — W5275264
5Rubber housing guide
— 5275988
6Exit guide
7Bolt — W532763
Zip tie

2023 Fuel EX
10
Frame guards — carbon frame
2
7
4
3
8
5
6
3Nm
4
2.5
1Nm
2.5
1Nm
4
2.5 1Nm
2.5
1


1 Seatstay adhesive guard — W5271371
2Brake hose adhesive guard — W326986
3Main pivot mud ap — W5275234
4Button head screws — W598484
5Upper down tube guard:
XS – ML frames — W5283184
L – XL frames — W5283185
6Lower down tube guard:
XS and S frames — W5283181
M – XL frames — W5283182
7Button head screws — W575056
8Chainstay guard — W5273604
Adhesive Guards 12
Use isopropyl alcohol to clean the frame surface where the
guard attaches. Wait for the alcohol to dry before applying
the guard.
Notice: Do not clean the entire frame with isopropyl
alcohol. Isopropyl alcohol could damage the paint.

2023 Fuel EX
11
Frame guards — aluminum frame
1
2
3
5
4
1Nm
2.5
2.5
1Nm
4
2.5
1Nm




1Brake hose adhesive guard — W326986
Use isopropyl alcohol to clean the frame surface
where the guard attaches. Wait for the alcohol to dry
before applying the guard.
Notice: Do not clean the entire frame with isopropyl
alcohol. Isopropyl alcohol could damage the paint.
2Upper down tube guard:
XS – S (27.5” wheels) frames — W5284323
S (29” wheels) – ML frames — W5279933
L – XXL frames — W5283420
3Lower down tube guard — W5279934
4Button head screws — W575056
5Chainstay guard — W5271370

2023 Fuel EX
12
Down tube storage
Carbon frame
3
2
1.5Nm
2.5
4
4
1.5Nm
2.5
1
1.5Nm
4
4
1 Water bottle cage bolt, 8mm long
— W5257590
2Water bottle cage bolt, 16mm long
3Storage door
4Button head screws — W575056
(includes nuts, not used on
carbon frames)
Aluminum frame
2
4
1.5Nm
3
5
5
1.5Nm
1.5Nm
4
1.5Nm
4
42.5
2.5
1
1 Water bottle cage bolt, 8mm long
— W583862
2Water bottle cage bolt, 16mm long
3Storage door
4Button head screws
— 1042535
5Nuts

2023 Fuel EX
13
Adjust the geometry — headset angle
0°
-1°
+1°
or
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
Use the alignment tool to mark the centerline to which you
will align the lower cup.
1. Thread the hex tool through the upper alignment tool.
Insert the tools into the upper head tube.
2. Position the lower alignment tool with the notches to
the front and back of the head tube.
3. Thread the lower alignment tool over the hex tool. The
hex tool will keep the notches aligned as you insert the
alignment tool.
4. Place a piece of painter’s tape on the head tube, then
draw a line on the tape that aligns with the notch.
5. 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.

2023 Fuel EX
14
Adjust the geometry — seatstay mino link
Tools
• 4mm and 6mm hex tools
• Torque wrench with 4mm and 6mm bits
• Small clean towel or cloth
1. Remove the rear wheel.
2. Place a small clean towel or cloth over the down tube to
protect the paint.
3. Remove the upper shock mount hardware. Use the
6mm hex tool to remove the bolts.
4. Lower the shock and rest it on the towel or cloth cover-
ing the down tube.
5. Rotate the rocker pivot forward to pull the mino links
into the window in front of the seat tube.
6. Use a 4mm hex tool to turn the screw in the mino link
to ip the link to either the slacker or steeper position.
Repeat this process with the other mino link.
Slacker Steeper
4
7. Torque the screws to 8Nm.
8. Re-install the upper shock hardware and torque the
bolts to 8Nm.

2023 Fuel EX
15
Specications
Chainline (1x only)
55mm
Chainring (1x only)
Minimum Maximum
28T Round: 34T
Oval: 32T
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 2.5"
27.5" (XS and S frame) 27.5" x 2.5"
Bottom bracket /ISCG tabs
Bottom bracket ISCG tabs
BSA 73 ISCG 05, 3 bolt
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 Carbon Aluminum
XS 205mm 180mm
S (27.5” and 29”
wheels) 225mm 210mm
M255mm 240mm
ML 266mm 250mm
L281mm 265mm
XL 316mm 300mm
XXL — 330mm
Seat tube inside diameter 34.9
Seat tube post clamp outer diam-
eter
39.5
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/
Wheel Size
Axle to Race
(mm)
Travel
(mm)
XS and S
27.5" wheels
Recommended 534 140
Maximum 550 150
S, M, ML, L, XL, XXL
29" wheels
Recommended 562 150
Maximum 578 160
Refer to the suspension setup card included with your bike
or the suspension calculator at
trekbikes.com/suspension-calculator.