Trek Fetch+ 4 User manual

2023 FETCH+ 4
SERVICE MANUAL

i
2023 Fetch+ 4
Contents
Steering
pages 1-4
Cable system Adjust cable
tension
Replace steering
cables
Drivetrain
pages 5-9
Belt guard Drive unit cover Belt tensionerr Adjust belt tension Align belt
Routing
pages 10-14
Rear Front Instructions
Battery
pages 15-17
Guide Install battery
guide
Lock, cover and
charge port
Headsets
pages 18-20
Rear assembly Front assembly Instructions
Frame
pages 21-25
Floor plate and
mat
Cargo box Front cover Frame assembly
1 4
3 2
8 5
6 7
Frame-tightening
sequence
Accessories
pages 26-32
Front mudguard
and light
Rear mudguard
and light and light
Ring lock Kickstand Child seats
Copyright 2022 Trek Bicycle Corporation All Rights Reserved

ii
2023 Fetch+ 4
About this manual
Scope
This manual contains parts diagrams, specications (such
as grease and torque values), instructions and helpful tips
(such as the easiest direction to route cables).
This manual does not contain instructions on all
components (such as brake callipers). Refer to the original
manufacturer for more information.
Working on a front cargo bike
The length, weight and box size make working on this
bicycle more difcult. Do not use a regular repair stand to
lift the bicycle – use a ceiling-mounted hoist.
If you do not have a hoist, you can do many repairs by
tipping the bicycle on it’s side.
Interactive models
Additional info
There are additional manuals available at Trekbikes.com/
manuals.
• E-Cargo Owner’s Manual – comprehensive instructions
that come with your bicycle
• Bosch BES3 E-bike Manual – detailed instructions on
the e-system found under Electric bikes > 2023
Legend
Zip tie
Nm Torque value
Apply threadlocker
Apply appropriate grease
Warnings
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.

2023 Fetch+ 4
1
Steering Drivetrain Routing Battery Headsets Frame Accessories
Steering: cable system
1
18 Nm.
2
3
14 Nm.
7
3
8
9
11
18 Nm. 2
3
3
4
6
18 Nm.
5
18 Nm.
5
3
11
10
3
13 12
4 Nm.






14
4 Nm.
15
1 Cable mount (front) – W5257125
2Bolts (M8x20 mm)
5284657
3Washers (M8)
4Bolts (M8x80 mm)
5Nuts (M8)
6 Cable mount (rear) – W5257126
7Bolts (M8x20 mm) – 5284656
8Steerer tube (rear)
5284549
9Steering disc (rear)
10 Steering disc (front) – 5284720
11 Bolts (M5x20 mm) – 5304417
12 Bolts, T25 drive (M5x10 mm) – 5284857
13 Steering column cover – W5268883
14 Steering cables – 5284692
15 Fork – W5266799
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here
Or

2023 Fetch+ 4
2
Steering Drivetrain Routing Battery Headsets Frame Accessories
Steering: adjust cable tension
1. Loosen the four rear cable mount bolts (2) – do not
remove them.
2. Hold the tensioning bolt (4) in place and use a 13
mm wrench to loosen the tensioning nut (5). Then,
loosen the tensioning bolt (4) to remove tension from
the cables. Repeat for the other side.
3. Move the cable mount (6) to increase tension in the
cables.
4. Tighten both tensioning bolts (4) – alternating
between them to keep the cable mount parallel –
until they are snug into the cable mount (6). Then,
tighten both tensioning nuts (5) to 18 Nm.
5. Test the front wheel steering and adjust the cable
tension, if necessary. There should be no noticeable
slack when steering quickly.
• Too loose – the wheel will feel disconnected from
the steering.
• Too tight – the steering will feel heavy with a lot of
friction.
Notice: If the cables are too tight, the bearings
will wear out much faster than if the cables are
tensioned properly.
6. Tighten all four rear cable mount bolts (2) to 18 Nm
(see Step 1).
7. Tighten both tensioning nuts (5) to 18 Nm.

2023 Fetch+ 4
3
Steering Drivetrain Routing Battery Headsets Frame Accessories
Steering: replace steering cables
Replace all four cables every two years or 10,000
km/6,000 mi.
NOTE: If a cable is damaged and needs repair, replace all
four cables – not just the damaged one.
Remove the cables from the rear disc
1. Cut the three zip ties connecting the steering cables
to the frame (see the zip tie locations on page 1).
2. Loosen the four rear cable mount bolts (2) – do not
remove them.
3. Hold the tensioning bolt (4) in place and use a 13
mm wrench to loosen the tensioning nut (5). Then,
loosen the tensioning bolt to remove tension from the
cables. Repeat for the other side.
4. Remove the two bolts (11) securing the steering
cables in the rear cable mount.
5. Slide the cable mount (6) towards the steering disc to
relieve tension on the cables.
6. Remove the cables from the steering disc.
Remove the cables from the front disc
1. Loosen the two bolts (11) securing the steering
cables in the front cable mount (1).
2. Remove the cables from the front steering disc.

2023 Fetch+ 4
4
Steering Drivetrain Routing Battery Headsets Frame Accessories
Insert the cables into the front disc
NOTE: The cables may be slightly different lengths – there
is no certain order in which you need to install them. They
will stretch and even out after use.
1. Route the four cables through the frame brackets.
2. Route one cable into the lower section of the front
steering disc. Then, route another cable in the upper
section. Install one bolt (12) into the cable mount
and torque to 4 Nm to secure the two cables.
IMPORTANT: Make sure the cable end stop is fully
inserted into the cable mount or you will not have
enough slack when you install the cables in the rear
disc.
2
1
3
3. Repeat Step 2 for the other side.
Insert the cables into the rear disc
1. Route the rear cables as shown below.
1
3
2
2. Tension the cables followings Steps 3-7 on page 2.
3. Use six zip ties to attach the cables to the frame as
shown below.






Steering: replace the steering cables (continued)

2023 Fetch+ 4
5
Steering Drivetrain Routing Battery Headsets Frame Accessories
Drivetrain: belt guard
22 Nm.
3
5 Nm.
1
1
2
2 Nm.
1
3
5 Nm.
4
5
6
7
8
8
9
1Washers (M5)
5284857
2Bolts, T25 drive (M5x10
mm)
3Bolt M6x10 mm
4 Beltring (50T) – W5285189
5Sprocket (22T) – W590978
6Belt (128T) – W571473
7Belt guard
5280793
8Belt guard bracket
9Belt guard bracket addition
*North America only
Before removing the belt
• Remove the belt guard
• Remove the rear wheel
• Remove the driveside crank arm
• Release tension in the belt (see page 8)
See the manufacturer’s specications for more info:
GatesCarbonDrive.com.
Click
here
Or

2023 Fetch+ 4
6
Steering Drivetrain Routing Battery Headsets Frame Accessories
Drivetrain: drive unit cover
1
2
4 Nm.
13
2 Nm.
3
2 Nm.
4
4
5
6
7
7
8
20Nm.
20Nm.
1Washers (M5)
5284548
2Bolts, T25 drive (M5x10 mm)
3Bolts, T25 drive (M4.8x13 mm)
4Sheet nuts (M4.8)
5Drive unit cover (non-drive side)
5280792
6Drive unit cover (drive side)
7Mounting bolts, T40 drive (M8x16 mm) – *1270.016.470
8Bosch connect module BCM3100 – *EB13.200.02L
*Bosch part numbers are not available on Trekbikes.com.
Click
here
Or

2023 Fetch+ 4
7
Steering Drivetrain Routing Battery Headsets Frame Accessories
Drivetrain: belt tensioner
7
9
10
11
1
4
7Nm.
2
2
3
3
5
6
8
12
5 Nm.
12 5 Nm.
1Belt roller
5291300
2Washers (M8)
3Bearings
4Bolt (M8x40 mm)
5Bolt socket set screw – W5282014
6Tensioner arm
5280807
7Tensioning bolt (M8x100 mm)
8Bolt (M6x60 mm)
9Tensioning nut (upper)
10 Tensioning nut (lower)
11 Coupling nut
12 Bolt M6x10 mm
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here
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2023 Fetch+ 4
8
Steering Drivetrain Routing Battery Headsets Frame Accessories
Drivetrain: adjust belt tension
Measure the belt tension
DESIRED TENSION: 45-60 Hz (15.5 to 20.4 kg/35-45 lb)
Gates Krikit Tension Gauge
1. Measure the belt tension using a tension gauge
(such as the Gates Krikit Tension Gauge). See the
technical manual at GatesCarbonDrive.com.
Source: Gates Corporation
TIP: You can also measure the tension using the
methods listed below. Trek suggests using the
Gates Krikit Tension Gauge for the most precise
measurement.
• Your nger – push down in the middle of the
belt. There should be 6-12 mm of vertical
movement.
• Gates Carbon Drive app on your phone – this app
measures belt tension through sound. Use the
desired tension listed above.
2. Rotate the cranks a 1/4 turn and measure the
tension again. Repeat this at four different positions
and average the measurements. If there is not
enough tension, tighten the belt following the
procedure to the right.
NOTE: If there is a large difference between
measurements, the front belt ring may be misaligned
(see page 9).
Source: Gates Corporation
Tension the belt
1. Hold the tensioning bolt (7) in place and use a 13
mm spanner to loosen the coupling nut (11).
2. Tighten the tensioning bolt (7) until you reach proper
belt tension.
3. Verify the belt tension at different crank positions
and average the results. Tighten or loosen the
tensioning bolt (7), if necessary.
4. Hold the tensioning bolt (7) in place and use a 13
mm wrench to tighten the coupling nut (11).
5. Rotate the cranks forwards and backwards to make
sure the belt is centred on the belt roller (1).
6. Verify the tension and adjust, if necessary.

2023 Fetch+ 4
9
Steering Drivetrain Routing Battery Headsets Frame Accessories
Drivetrain: align belt
Centre the belt on the belt roller
The notch in the middle is slightly off-centre.
8.2mm 8.7mm
N
a
r
r
o
w
W
i
d
e
The belt may become off-centre in the belt roller over
time. If the belt continually touches the outer belt roller
edge while pedalling, ip the belt roller around 180°. This
moves the belt roller 0.7 mm outwards.
Adjust the belt angle
The belt roller should be parallel to the belt. If the belt
roller gets out of alignment, tighten or loosen the set screw
(5). This adjusts the angle of the tensioner arm.
1. Tighten or loosen the set screw until the belt is
parallel to the belt roller.
2. Verify the belt tension and adjust, if necessary (see
page 8).

2023 Fetch+ 4
10
Steering Drivetrain Routing Battery Headsets Frame Accessories
Routing: rear
Standard
set-up
Bosch smart
system set-up
9
11
10
3
6
9
11
10
3
12
213
4
5
6
7
8
4
11
11
12
9
15 4 Nm.
14
13




5
6
7
16
9
5
6
4
8
7
7
17
1Cable manager – W316706
2Bolt (M4x6 mm)
5284750
3Speed sensor and wire
4Front brake hose.
5Dropper post cable
6Remote wire
7Shift cables
8Rear brake hose
9Front light wire
10 Rear light wire
11 Drive unit cable
12 Bosch Connect Module – 5282027
Europe and North America only
13 Cable bracket – W5290750
14 Washers (M5)
5304416
15 Bolts (M5x10 mm)
16 Rear light – W504513
17 Cable guides – W5309355
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here
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2023 Fetch+ 4
11
Steering Drivetrain Routing Battery Headsets Frame Accessories
Routing: front
17
4 Nm.
16
18


4
9
4Front brake hose.
9Front light wire
16 Bolt (M5x10 mm), T25 drive
5304417
17 Washer (M5)
18 Cable clamp – W2016621

2023 Fetch+ 4
12
Steering Drivetrain Routing Battery Headsets Frame Accessories
Routing: instructions
Rear headset
1. Route all handlebar cables/wires/hoses down
through the frame – except the front brake. Use the
current housing as a guide when pulling a new one
through.
4
85
6
7
2. Route the cables through the frame. Remove the
steering column cover (see page 1) and non-driveside
motor cover (see page 6) to access the cables easier.
NOTE: Remove the motor to have additional access
to the cables (see page 6).
3. Install the cable guides (17).
4
85
6
7
7
Speed sensor
Route the wire from the back – through the chainstay – to
the drive unit.
1
2

2023 Fetch+ 4
13
Steering Drivetrain Routing Battery Headsets Frame Accessories
Routing: instructions (continued)
Rear light
You must remove the rear wheel to route the wire. Make
sure there is no slack in the wire between the mudguard
and the tyre.
Drive unit cable
With the drive unit removed, connect the drive unit cable
(11) at both ends before reinstalling the drive unit.

2023 Fetch+ 4
14
Steering Drivetrain Routing Battery Headsets Frame Accessories
Routing: instructions (continued)
Front brake and front light
Route the front brake hose and front light wire – starting from the front – under the frame as shown below.
Note: The front brake hose must have enough slack to turn the front wheel back and forth fully – without interference. The
brake hose must have a 10 mm (3/8” in) gap to the cargo frame as shown below.
10mm



2023 Fetch+ 4
15
Steering Drivetrain Routing Battery Headsets Frame Accessories
Battery: guide
1
4 Nm.
14 Nm.
2
2
23
4 Nm. 4
5
6
11
10
9
8
7
4.5 Nm.
3 Nm.
1Bolts, T25 (M5x10 mm)
5284856
2Washers (M5)
3Bolts (M5x14 mm)
4Mounting extension – W5269383
5Guide rail – *EB12.100.01R
6Bolts, T20 (M5x9 mm) – *EB12.100.01Y
7Damper foil plug – *EB12.100.01Z
8Bolts, T25 (M4x16 mm) – *EB12.100.01X
9Cradle – *EB12.100.01B
10 Battery adapter – *EB12.100.015
11 Clamp ring – *EB12.100.02D
*Bosch part numbers are not available on
Trekbikes.com.
Click
here
Or

2023 Fetch+ 4
16
Steering Drivetrain Routing Battery Headsets Frame Accessories
Battery: install battery guide
Make sure all cables are routed in front of the battery guide before installing it.
1. Insert the battery guide assembly into the frame.
2. Install the two upper (1) battery guide bolts. Torque
to 4 Nm.
3
4 Nm.
3. Install the two lower (3) battery guide bolts. Torque to
4 Nm.
3
4 Nm.

2023 Fetch+ 4
17
Steering Drivetrain Routing Battery Headsets Frame Accessories
Battery: lock, cover and charge port
12
13
1.5 Nm.
14
15
1.2 Nm.
16
17
18
19
3 Nm.
20
21
22
23
1.5 Nm.
15
1.2 Nm.
12 Battery cover – W5257032
13 Bolts, T15 (M3.5x12 mm) – *EB12.100.01G
14 Cover – *EB12.100.01A
15 Bolts, T15 (M3x7 mm) – *EB12.100.01G
16 Battery lock – W5277876
17 Locking assembly – *EB12.100.01D
18 PowerTube 750 W battery – *EB12.100.00X
19 Bolts (M5x10 mm) – 5272902
20 Charge port cover – W5251862
21 O-ring – *EB12.120.019
22 Charge plug – *EB12.120.04B
23 Bolts (M3x10 mm) – 5284849
*Bosch part numbers are not available on
Trekbikes.com.
WARNINGS: BATTERY USE
• A short circuit in the electric system and/or
damage to the battery might lead to overheating.
In an extremely rare case, a battery that has been
severely impacted could potentially catch re.
• Only charge the battery with a Bosch smart system
charger. Using the wrong charger risks the life of
the battery and presents a potential re hazard.
• Only use the charger in dry, indoor areas.
• Do not leave a charging battery unattended.
• When the battery is fully charged, disconnect the
charger from the battery and wall socket.
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