Trek 2023 FX+ User manual

2023 FX+ / DUAL SPORT+
SERVICE MANUAL SUPPLEMENT

2023 FX+ / Dual Sport+
1
Safety
WARNING
Tighten hardware properly
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
Re-apply threadlocker
All reused-fasteners with a pre-applied threadlocker
must be cleaned with isopropyl alcohol and have new
threadlocker applied before re-assembly. If a threadlock-
er is not applied, the fasteners may loosen, which could
damage the bicycle and result in injury to the rider.
Legend
Apply appropriate grease
Apply threadlocker
Nm Torque
Cable (zip) tie
More e-bike information
For additional information about the e-bike system, go to
the Electric bikes section at trekbikes.com/manuals.
Contents
Brake/shift routing E-system components
and routing
Battery and controller
assembly
Bottom bracket/torque
sensor
Fork and headset
Chainguard Mudguards and rack Light routing – FX+ Light routing – DS+ Specications
Copyright 2022 Trek Bicycle Corporation All Rights Reserved
Dual Sport+
FX+

2023 FX+ / Dual Sport+
2
Brake/shi routing
2Nm.
1
2




3
4
5








1 Derailleur hanger bolts (M3x7 mm) – W318604
2 Derailleur hanger – W5268484
3Rear derailleur cable
4Rear brake hose
5Front brake hose

2023 FX+ / Dual Sport+
3
E-system components and routing
6
6
T30
6 Nm.
T30
T20
7
3 Nm.
6 Nm.
T20
3 Nm.
7
82Nm.
9
10
2 Nm.
11
14
13
12
11 Nm
13 11 Nm
1
2
3
4
5


T10
1 Hub motor – W5266204
2 Remote – W5260746
3 Torque sensor – W5257770
4Controller – W5252986
5Battery – W5255878
6T30 drive bolts (M6x8 mm) – W5258222
7T10 drive bolts (M4x6mm) – 5269023
8T10 drive bolts (M3x8 mm)
5284384
9Bottom bracket cover
10 Cable guide
5284388
11 Cable guide bolt (M4x6 mm)
12 Anti-rotational ange nut
5288641
13 Axle bolt
14 Charge port cover – W5263927
Before removing the rear wheel
1. Shift to the smallest rear cog (highest gear).
2. Unplug the motor cable at the chainstay.
3. Remove the cable-guide bolt (11).
4. Remove both axle bolts (13) and ange nuts (12).
Wiring diagram
NOTE: Light wiring diagrams are on pages 10-11.
1
23
45

2023 FX+ / Dual Sport+
4
Battery and controller assembly
AUTHORISED DEALERS ONLY: Only authorised dealers should perform service on the e-system. Improper handling, tools used
or torque applied to these parts may result in damage to the e-system components and cables.
Remove the battery
1. Remove the bottom bracket cover (9).
T10
2. Cut the zip tie holding the motor cable to the frame.
3. Unplug all cables in the bottom bracket shell.
NOTICE: Do not pull the cables apart by the wires –
this can damage them.
4. Remove the two bolts (6) under the down tube.
T30
5. Rotate the bicycle and slide the battery assembly out
(this uses gravity).
NOTICE: Don’t drop it! The battery can slide out easily
and fall to the oor, causing damage.
6. Unplug the battery from the controller and remove
the bolts (7) connecting the controller to the battery.

2023 FX+ / Dual Sport+
5
Install the battery
1. Use the four bolts (7) to attach the controller to the
battery. Torque the bolts to 3 Nm.
2. Slide the battery assembly into the down tube –
positioning the cables on the top of the battery as
shown below. Readjust the cables, if necessary.
NOTICE: Do not force it – the battery should slide in
without applying extra pressure.
Remote
Front light
Brake
Derailleur
3. Ensure that there are no cables between the charge
port opening and the battery.
TIP: Insert an unplugged charger to help align the
charge port.
4. Install and tighten the bolts (6) to 6 Nm.
T30
5. Connect all cables.
6. Zip tie the rear brake hose to the chainstay in two
places. Zip tie the motor cable to the chainstay in the
forward position only.
7. Fit all cables into the bottom bracket shell and install
the cover (9).
NOTICE: Do not pinch the cables.
Battery and controller assembly (continued)

2023 FX+ / Dual Sport+
6
Bottom bracket/torque sensor
AUTHORISED DEALERS ONLY: Only authorised dealers should perform service on the e-system. Improper handling, tools used
or torque applied to these parts may result in damage to the e-system components and cables.
Remove the bottom bracket
Remove the chain guard, cranks and pedals before
following these instructions.
1. Remove the bottom bracket cover (9).
T10
2. Disconnect the torque sensor cable.
NOTICE: Do not pull the cables apart by the wires –
this can damage them.
NOTICE: If you do not disconnect the plug, you
will damage the torque-sensor cable when you try
removing the bottom bracket cup.
3. Remove the non-driveside cup.
4. Pull out the torque sensor/bottom bracket.
5. Remove the driveside bottom bracket cup, if
necessary.
Install the bottom bracket
1. Install the driveside cup. Torque to 35 Nm.
2. Insert the torque sensor and cable – notched side
rst – into the non-driveside.
3. Install the non-driveside cup. Torque to 35Nm.
4. Reconnect the bottom bracket/torque sensor cable.
5. Fit all cables into the bottom bracket shell and install
the cover (9).
NOTICE: Do not pinch the cables.

2023 FX+ / Dual Sport+
7
Fork and headset
4
2
3
1
30 mm
max
Optional
spacers
5
1 Spacer (5 mm) – 5253930
2Headset routing cap – W5260269
3Routing split ring – W5294453
4Headset bearings – 5269847
5Crown race reducer – 5283141
Split ring routing
Front
brake
Rear
brake
Rear
derailleur
Front
light
Remote

2023 FX+ / Dual Sport+
8
Chain guard (aermarket on Dual Sport+)
4Nm.
1
4Nm.
1
2
4Nm.
1
2
2
3
4
1Bolts (M5x8 mm)
5284386
2Washers (M5)
3 Seat stay bracket
4Chain guard

2023 FX+ / Dual Sport+
9
Mudguards and rack (aermarket on Dual Sport+)
1
23
7
18
7
9
5
16
11
15
16
13
15
12
8
4Nm.
3Nm.
3Nm.
4Nm.
10
515
5
16
3Nm.
15
17
4Nm.
4
12
10
11
15 16
3Nm.
14
6
19
1 Stay clips
5258253
2 Damping rubbers
3 Mudguard stay (330 mm) – W1049503
4Mudguard stay (310 mm) – W5254584
5 Mudguard strut – W600320
6 Spacers (12x5 mm) – 504881
7Spacers (15x5 mm)
5260275
8Spacer (15x15 mm)
9 Slot cover – W1049294
10 Mudguard stay mounts – 5258260
11 Knurled washers
12 Locknut (M5)
5260273
13 Bolt (M5x30 mm)
14 Bolt-nuts – W317707
15 Flat washers (M5)
16 Bolts (M5x14 mm)
5260274
17 Bolts, M4 hex
18 Bolt, M3 hex (M5x25
mm)
19 Rack (70 mm wide) – W597296

2023 FX+ / Dual Sport+
10
Light routing – FX+
NOTE: These lights are designed for 6 volts. If you use a light with a higher voltage, it may not function properly and could take
power away from the e-bike motor.
+
–

2023 FX+ / Dual Sport+
11
Light routing – Dual Sport+
NOTE: These lights are designed for 6 volts. If you use a light with a higher voltage, it may not function properly and could take
power away from the e-bike motor.
+
–

2023 FX+ / Dual Sport+
12
Specications
FX+ / Dual Sport+
Rear hub outer limit dimension (OLD) 144.5 mm
Front hub outer limit dimension (OLD) 100 mm
Fork steerer tube outer dimension (OD) 28.6 mm
Bottom bracket type/width T47
Brake rotor diameter min/max 160 mm
Chainline 49 mm
Chain ring max 18 kg/46t
Tyre width max 700c
(without mudguards)
Front 50 mm
Rear 50 mm
Tyre width max 700c
(with mudguards)
Front 40 mm
Rear 40 mm