Trek FUEL EX 2023 User manual

2023 FUEL EX
SERVICE MANUAL
Rev 2 October 2023

2023 Fuel EX
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 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
Routing with AXS
shift
Adjust the
geometry – head-
set angle
Adjustable headset Rocker pivot and
seat stay
Adjust the
progression
Frame guards —
aluminium frame
Adjust the
geometry – seat
stay 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.
Dérailleur hanger Main pivot and
chain stay
Routing with
mechanical shift
Routing with
AXS shift
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
Dérailleur hanger
25Nm.
3
2
1
1Dérailleur hanger
– W5271425
2Washer, 30 mm
3Bolt
Tools
• 8mm hex tool
• Torque wrench (left-hand thread) with 8 mm 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 12.7 mm 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
3
6
5
20x30
20x30
2
15Nm
10Nm
1
7
Aluminium frame
4
3
6
5
2
15 Nm
10 Nm
1
20x30
20x30
1Switch lever – W573860
2Thru axle – W583469
– W5272776
3Non-driveside ABP drop-out nut
guide – W5269707
4Retaining ring – W5251279
5Bearings – W5256340
6Non-driveside ABP bolt –
W5251141
7Spacers – W583422
Tools
• Bearing press
• Cassette lock ring tool
• Grease
• Threadlocker
•

2023 Fuel EX
5
Rocker pivot and seat stay
Important: Install the 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 colour-matched part for your bike.
Carbon frame – 40783
Aluminium frame – 40780
9Seat stay:
Search for part number listed below on trekbikes.com
to nd the colour-matched part for your bike.
Carbon frame – 40777
Aluminium frame – 38553
Tools
• Bearing press
• 4 mm hex wrench
• Torque wrench with 4mm hex bit
• Grease
• Threadlocker

2023 Fuel EX
6
Main pivot and chain stay
1
2
3
2
4
5
17x26
17x26
15 Nm
15 Nm
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 colour-matched
part for your bike.
Carbon frame – 40776
Aluminium 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: 185 mm
Stroke length: 55 mm
Upper width: 54 mm x 10 mm
Lower width: 40 mm x 8 mm
6
1
2
2
1
17Nm.
17Nm.
10Nm.
3
4
12x21
6
12x21
6
5
6
1Upper bolts, M10 x 1 x 19 mm – W5270031
2Bearings – W5256341
3Hat-style washers – W5270030
4Lower shock Mino nut – 5303333
5Lower shock Mino washer – 5303333
6Lower bolt, M8 x 1 x 60 mm – W5274968
Tools
• Bearing press
• 6 mm hex wrenches
• Torque wrench with 6 mm bits
• Grease
Set-up
Refer to the suspension set-up 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 6 mm 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 10 Nm.
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
Routing with mechanical shi
2 3
1
6
7
8
1.7Nm
• 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.






4
5
1 Dropper cable
2Rear brake hose
3Derailleur housing
4Plug – W5275264
5Plug — W5309144
6Rubber housing guide
– 5275988
7Exit guide
8Bolt – W532763
Zip tie

2023 Fuel EX
10
Routing with AXS shi
5
6
7
1.7Nm
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.


4
1
3
4
1 Dropper cable
2Rear brake hose
3Plug — W5275264
4Plug — W5309144
5Rubber housing guide
— 5275988
6Exit guide
7Bolt — W532763
Zip tie

2023 Fuel EX
11
Frame guards – carbon frame
7
M4 x 6M4 x 10
4
2
7
4
3
8
5
6
3Nm
4
2.5
1Nm
2.5
1Nm
4
2.5 1Nm
2.5
1


9
10
1 Seat stay adhesive guard – W5271371
2Brake hose adhesive guard – W326986
4Main pivot mud ap – W5275234
4Button head screws – W1052364
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
9Chainstay strike guard — W5273260
10 Rotor guard — W580881
Adhesive Guards 12
Use isopropyl alcohol to clean the frame surface where
the guard is attached. 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.
Brazed Guards 910
1. To improve adhesion, use sandpaper to roughen the
backside of the guard and the area of the frame where
epoxy will be applied.
2. Attach the guard with a two-part epoxy.
3. Allow the guard and epoxy to cure for 24 hours.

2023 Fuel EX
12
Frame guards — aluminium frame
7
M4 x 6M4 x 10
4
2
7
4
3
8
5
6
3Nm
4
2.5
1Nm
2.5
1Nm
4
2.5 1Nm
2.5
1


9
10
1Brake hose adhesive guard – W326986
Use isopropyl alcohol to clean the frame surface
where the guard is attached. 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
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
• 8 mm hex tool (150 mm 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 centreline 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 and verify that the notch on the
lower cup is aligned with the line on the tape. If it is not,
remove the cup and reinstall in the correct position.
7. Remove the painter’s tape.

2023 Fuel EX
14
Adjust the geometry – seat stay Mino link
Tools
• 4 mm and 6 mm hex tools
• Torque wrench with 4 mm and 6 mm 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 6
mm 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 4 mm 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 8 Nm.
8. Re-install the upper shock hardware and torque the
bolts to 8 Nm.

2023 Fuel EX
15
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, 8 mm
long
– W5257590
2Water bottle cage bolt, 16 mm
long
3Storage door
4Button head screws – W575056
(includes nuts, not used on
carbon frames)
Aluminium 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, 8 mm long
– W583862
2Water bottle cage bolt, 16 mm long
3Storage door
4Button head screws
– 1042535
5Nuts

2023 Fuel EX
16
Specications
Chain line (1x only)
55mm
Chain ring (1x only)
Minimum Maximum
28T Round: 34T
Oval: 32T
Rear brake mount
Minimum Maximum
180 mm, direct mount Adaptable to 203 mm
Maximum tyre size
Notice: Measurements of actual tyres may vary. Always
verify that there is sufcient clearance between the tyre
and the frame. Improper tyre size could damage the
bicycle frame. Trek recommends 6 mm clearance above
and on the sides of the tyre.
Wheel set Maximum tyre size
2.9 cm/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 seat post manufacturer’s minimum
insertion recommendation. Failure to follow the recom-
mendation could cause damage to the seat post and
result in injury to the rider.
Measurement
Maximum
insertion
Frame Carbon Aluminium
XS 205 mm 180 mm
S (27.9” and 29”
wheels) 225 mm 210 mm
M255 mm 240 mm
ML 266 mm 250 mm
L281 mm 265 mm
XL 316 mm 300 mm
XXL — 330 mm
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 set-up card included with your
bike or the suspension calculator at
trekbikes.com/suspension-calculator.