Trek ALLOY FUEL EXE User manual

2024 ALLOY FUEL EXE
SERVICE MANUAL
Rev 1 August 2023

2024 Alloy Fuel EXe
1
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
18
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
Copyright 2023 Trek Bicycle Corporation All Rights Reserved

2024 Alloy Fuel EXe
2
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
3
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

2024 Alloy Fuel EXe
4
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
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
5
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
4
3
5
2
15Nm
10Nm
1
6
7
9
8
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
6
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
4
8Nm
5Nm
5Nm
1
1
62
3
7
2
3
6
2
2
3
3
95
8
M6x25M5x18
8
1
10
11
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.
1
2
3
8Nm
17Nm
5Nm
Non-drive sideDrive side

2024 Alloy Fuel EXe
7
Main pivot and chainstay
Important: Install driveside
bearing rst
1
2
4
6
5
2
3
3
15Nm
7
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
8
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
1
2
3
4
2
1
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
9
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
1
2
3
Drive sideNon-drive side

2024 Alloy Fuel EXe
10
Brake and mechanical shi routing
1. Remove the display from the top tube for easier access.
2. Route the brake hose and shift housing back to front.
1 Cable housing grommet — W329119
2E-shift hole plug — W547906
(Plugged with manual shift)

Zip tie
Cable tunnels




Mechanical shift cable
housing
Brake hose
Zip tie
12

2024 Alloy Fuel EXe
11
Speed sensor routing
For detailed service instructions:
Refer to the TQ service manuals found on tq-ebike.com/en/support/manuals.
M4x6


Zip tie to brake hose
1Nm
1
2
1-8mm
3
4
NOTICE: To disconnect the speed
sensor from the drive unit, hold
each connector and gently pull
them apart. Do not pull the cable.
Pulling the cable could damage
the speed sensor.
1 Speed sensor cable and clip — 5289567
2Fastener, M4x6mm — W575056
3Magnet — 5289568
4Cable housing grommet — W329119
Zip tie
To connect the speed sensor to the motor, remove the:
• Battery cover and battery (See Remove and install the
battery on page 23.)
• Access cover
Replacement tip
1. To aid in removing the cable, use an internal routing tool
to guide the cable as you remove it.
2. Attach a new wire and reverse the process.

2024 Alloy Fuel EXe
12
Dropper post routing
0.5Nm
1
2
1 Exit guide — W519232
2Fastener, M4x9mm — W532763
1. Remove the battery cover and the battery.
(See page 23.)
2. Remove the access cover (See page 17.)
3. Route the dropper post housing from the bottom of the
bike up through the seat tube and up through the cable
tray in the down tube.

2024 Alloy Fuel EXe
13
Remote and display
For detailed service instructions:
Refer to the TQ service manuals found on tq-ebike.com/en/support/manuals.
0.5Nm
3
1Nm 1
2
1Remote, including fastener and cable — 5289561
2Display — 5289562
— 5289562
3Fastener, M3x20mm — 5305631

2024 Alloy Fuel EXe
14
AXS shi routing
AXS-equipped bikes include the TQ
Smart Box. It has connections for
front light, rear light, aux 12, and
electronic shifting.
2
1
3
Battery cable
1TQ Smart Box — 5289564
2Foam blocks, set of two — 5305634
3TQ Smart Box AXS adapter cable — 5289566
4Battery cable (See page 17.)
5SRAM AXS cable — W5303844
Connect SRAM AXS
cable and TQ Smart
Box cable here.
Hole is open.
5
1. Remove the battery cover and the battery.
(See page 23.)
2. Remove the access cover (See page 17.)
3. Connect the TQ Smart Box AXS adapter cable to the
smart box as shown above.
4. Place the foam blocks above and below the Smart Box
as shown above. Compress the blocks to the Smart Box
and insert the assembly through the display opening in
the top tube.
5. Re-install the display.

2024 Alloy Fuel EXe
15
Guards and water bottle mounts
2Nm
2Nm
13
M4x6 M6x19
9
1
13 2
10
11
12
6
7
3
3
9
9
2Nm
8




4
5
M5x8
3
M5x16
4
2Nm
1Nm
5Nm
5Nm
1Brake hose adhesive guard — W326986
2Main pivot mud ap — W5304910
3Fasteners, M5x8mm — W549307
4Fastener, M5x16mm, (Small frames only) — W596821
5Cage spacer (Small frames only) — W5256157
6Shuttle adhesive guard (optional) — W5280162
7Down tube adhesive guard — W5273589
8Chain guide with fasteners — W5276728
9Battery mount fasteners, M6x19 — W5305015
10 Chainstay guard — W5306830
11 Clip nut (Use when battery is not installed) — W5284890
12 Battery cover — W5271937
13 Fasteners, M4x6mm — W575056
Adhesive Guards 167
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.

2024 Alloy Fuel EXe
16
Charge port cover
0.5Nm
2
1
1 Fasteners, M2.5x8mm
— 5289578
2Charge port cover
Tip: Not sure if you have a T8 Torx wrench? Before you buy a
new one check your SRAM bleed kit to see if one is included
with the kit.
Tip: Use a 5mm hex wrench inserted through the top battery
mount hole to hold the charge port into place while tighten-
ing the fasteners.
T8
5

2024 Alloy Fuel EXe
17
Battery cable, cable tray organizer, and access panel
1
2
3
7
4
5
1
M3x10
5
1
M4x6
6
1Nm
0.5Nm
1Nm
1Fasteners, M4x6mm — W575056
2Cable tray — W5274993
3M4 sliding nut — W5283261
4Charge port holder — W5274996
5Fasteners, M3x10mm — W545633
6Wiring harness, includes charge port cover —
5289573
7Access cover — W5271943
Cable tray replacement tip
Measure, then position parts
to align with frame holes.
Do not
grease the
track.
Measure

2024 Alloy Fuel EXe
18
Motor cover
For detailed service instructions:
Refer to the TQ service manuals found on tq-ebike.com/en/support/manuals.
3
2
1
M6x19
3
M4x6
1
1
0.8Nm
0.8Nm
1Nm
See Guards
and water bot-
tle mounts on
page 15.
M4x6
2
4
1 Fasteners, M4x6mm — 5269023
2 Fasteners, M4x6mm — W57056
3Battery mount fastener, M6x19mm — W5305015
4Motor cover — W5306829

2024 Alloy Fuel EXe
19
Drive unit
Apply grease to the shaft seal and
o-ring of the lockring.
Tools
• BB-UN55 bottom bracket tool —
part number 536183
Drive side
SRAM
drivetrain
Shimano
drivetrain
5
3
3
64
20Nm
20Nm
Non-drive side
1
2
50Nm
NOTICE: Before assembling the
chainring, spider and lockring, place
the included protective sleeve over
the bottom bracket spindle. Failure
to use the sleeve could damage the
seal on the lockring and allow water
to damage the motor. Remove after
assembly.
1 Front motor fastener, 73mm
— 5289570
2Rear motor fastener, 62mm
3Nut insert — W5304866
4Lockring — 5289572
5FSA spider for SRAM spec models — W5275013
6e*Thirteen chainring for Shimano Spec models —
W5272388
NOTICE: Do not carry the drive unit by the cables because
this could damage the drive unit.