Trek TOP FUEL 2022 Operating manual

2022 TOP FUEL
SERVICE MANUAL SUPPLEMENT

2022 Top Fuel
1
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.
Legend
Apply grease
Do not apply grease
Apply threadlocker
Nm Torque
Zip tie
Contents
Safety Active Braking
Pivot (ABP)
Shock mounts Frame guards —
carbon frame
Specications
Headset with
Knock Block
Rocker pivot Adjust the
geometry
Frame guards —
aluminum frame
Suspension
Derailleur hanger Main pivot Cabling Down tube storage
Copyright 2021 Trek Bicycle Corporation All Rights Reserved

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Headset with Knock Block
Notice: To operate the bicylce without a Knock Block chip, a non-block chip must be installed.
1
4
5
6
7
2
3
2Nm
8
or
1Upper bearing cover
— 5252161
— 5252160
2Chip bolt
3Knock Block chip
4Compression ring
5Upper bearing
6Lower bearing
7Crown race
8Non block chip — W1048249
Tools
• 2.5mm hex tool
• Torque wrench with 2.5mm hex bit
• Grease

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Derailleur hanger
25Nm
3
2
1
1Derailleur hanger
— W583423
2Washer, 30mm
3Bolt
Tools
• 8mm hex tool
• Torque wrench (left-hand thread) with 8mm 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 12.7mm 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.

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Active Braking Pivot (ABP)
Carbon frame
1
5
10Nm
34664
2
15Nm
Aluminum frame
12
34
5
4
10Nm 15Nm
1Thru axle — W583469
— W5272776
2Non-driveside dropout — W5251141
3Retaining ring — W5251279
4Bearing — W5256340
5Dropout — W5269707
6Spacer — W583422
(for use with carbon frame only)
Tools
• Bearing press
• Cassette lockring tool
• Grease
NOTICE: The thru axle must be compatible with a UDH
and must be M12x1.0 with a 12.7mm thread.
Apply grease to:
• Threads of the thru axle (1)
• Shoulders of non-driveside dropout (2) and the
dropout (5)

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Rocker pivot
4
5
6
7
65
8
22Nm
17Nm
3
2
3
1
17Nm
1
Seatstay
2
2
1Bolt — W600629
2Hat-style washer (2mm hat height) — W5257190
3Bearing — W5257592
4Rocker axle — W600627
5Spacer — W290057
6Bearing — W5256341
7Seat tube pivot sleeve — W310155
8Nut — W311582
Tools
• Bearing press
• 5mm and 6mm hex wrenches
• Torque wrench with 5mm and 6mm hex bits
Apply grease to the :
• Seat tube bearing bore
• Rocker pivot seat stay bearing bores
• Rocker pivot non-driveside seat tube pivot
• Do not apply grease to rocker pivot drive side seat tube
pivot.
Seat tube pivot
Important: Press in driveside bearing rst.

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Main pivot
1
2
3
5
2
3
4
30Nm
Chainstay
1Nut — W584134
2Spacer — W440921
3Bearing — W5256338
4Main pivot sleeve — W500592
5Main pivot axle — W601376
Tools
• Bearing press
• 8mm hex tool
• Torque wrench with 8mm hex bit
• Grease
Apply grease to:
• The bearing bores as shown above.
Important: Press in the driveside bearing rst.

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Shock mounts
5
6
1
2
2
1
4
17Nm
17Nm
10Nm
3
3
1Bolt — W5257188
2Bearing — W5257592
3Hat-style washer (4mm hat height) — W5257189
4Lower shock Mino nut
— 5280295
5Lower shock Mino spacer
5Socket head cap screw — W5251046
Tools
• Bearing press
• 5mm and 6mm hex wrenches
• Torque wrench with 5mm and 6mm bits
Apply grease to:
• The bores as shown above.

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Adjust the geometry
Flip the lower shock mount Mino nut and spacer 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 nut and spacer in the high position Mino nut and spacer 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
Tools
• 6mm hex tool
• Torque wrench with 6mm hex bit
1. Remove the lower shock bolt. For the location, see the Shock mounts on page 7.
2. Flip the lower shock Mino nut and spacer to the desired position.
3. Re-install the lower shock bolt and torque to 10Nm.

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Cable routing


5
6


2




1.7Nm
3
4
1
Carbon frames only.
1 Dropper cable
2Rear brake cable
3Derailleur cable
4Rubber housing guide
— 5275988
5Exit guide
6Bolt — W532763
Zip tie
Route cables
Notes
• All models feature cable routing tunnels.
• Route cables rst, then install seat tube cable exit
guide components (4, 5 and 6).
Route cables:
• Rear brake: back to front
• Derailleur: back to front
• Dropper: head tube to seatpost
Aluminum frame derailleur and brake routing
To improve access to the cable entry holes located behind
the chainstay bridge:
1. Remove the upper shock mount bolt.
2. Rotate the rear triangle up.

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Frame guards — carbon frame
6
1
2
4
5
0.8Nm
0.8Nm
2
0.8Nm 2
2
0.8Nm 3
0.8Nm
1 Chainstay guard — W5257206
2Button head screw — 1042535
3Button head screw — 327526
4Downtube guard — 5280104
5Shuttle guard — W5257546
6Frame protection decal — W326986
Shuttle guard
Use isopropyl alcohol to clean the frame surface where
the guard (4) 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.

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Frame guards — aluminum frame
1
2
3
0.8Nm




4
1 Chainstay guard — W5259518
2Button head screw for chainstay guard — 1042535
3Downtube guard — W5258504
4Frame protection decal — W326986
Zip tie
Downtube guard
Use isopropyl alcohol to clean the frame surface where
the guard (3) 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.

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12
Down tube storage
Carbon frame
1
2
1.5Nm
1 Storage door
— W583862
2Button head screws — 547053
(includes nuts, not used on
carbon frames)
Aluminum frame
1
2
2
1.5Nm
1.5Nm
3
3
1 Storage door
— W583862
2Button head screw
— 1042535
3Nut

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Specications
Chainline (1x only)
55mm
Chainring (1x only)
Minimum Maximum
28T 36T round
34T oval
Rear brake mount
Minimum Maximum
160mm, direct mount Adaptable to 180mm
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"
(Extra small frame only)
27" x 2.5"
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.
1
3
2
Item Measurement
1 Maximum
insertion
Frame Carbon Aluminum
XS 205mm —
S245mm
M270mm
M/L 285mm
L300mm
XL 320mm 350mm
XXL — 390mm
2 Minimum insertion 75mm*
3Seat tube inside diameter 34.9mm
Seat tube post clamp
outer diameter
39.5mm
*Follow the seatpost manufacturer’s guidelines.
Bottom bracket /ISCG tabs
Bottom bracket ISCG tabs
BSA73 ISCG 05

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Suspension
The rst step in suspension setup is to determine the sag. All other settings should be adjusted after determining the sag.
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 suspension calculator at Trekbikes.com/suspension-calculator.
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)
Sag
(15%)
(mm)
XS
27.5" wheels
Recommended 512 120 18
Maximum 522 130 19.5
S, M, ML, L, XL, XXL
29" wheels
Recommended 531 120 18
Maximum 541 130 19.5
Shock
Mount Width
Upper mount 54mm x 10mm Trunnion
Lower mount 30mm x 8mm
Eye to Eye
Stroke
Sag
Description Dimension
Eye-to-eye 185mm
Stroke 50mm
Recommended sag 28% (14mm)