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.