Trek Fuel EX 2020 & 2021 Service Manual Supplement

Table of Contents

• 1. Knock Block headset
• 2. Bottom bracket
• 3. Down tube storage (carbon frames only)
• 4. Rear derailleur hanger
• 5. Frame guards
• 6. Cable routing
• 7. Suspension hardware replacement parts
• 8. Dropout hardware
• 9. Specifications

1. Knock Block headset

The 2020 and 2021 Fuel EX models feature the Knock Block headset system.

Installation Steps:

1. Apply grease to the upper and lower head tube bearing bores.
2. Apply grease to the inside bearing seats for the compression ring and the crown race.
3. Install the crown race, then the lower bearing on the steerer tube.
4. Insert the steerer tube into the bottom of the head tube.
5. Install the upper bearing and the compression ring onto the steerer tube.
6. Insert the Knock Block chip into the frame. Do not tighten.
7. Install the upper bearing cover.
8. Install spacers as necessary.
9. Insert the Knock Block chip bolt and tighten to 2Nm.

Diagram Description: An exploded view of the Knock Block headset components including the chip bolt, knock block chip, upper bearing cover, compression ring, upper bearing, head tube, lower bearing, and crown race.

2. Bottom bracket

The 2020 and 2021 Fuel EX models use the BB92 press-fit standard bottom bracket. Refer to your bottom bracket manufacturer's manual for removal and installation instructions.

Diagram Description: An illustration showing the BB92 press-fit bottom bracket installed in the bicycle frame.

3. Down tube storage (carbon frames only)

Diagram Description: An illustration of the down tube storage cutout with item 1 highlighted in red, indicating all parts included.

Installation Steps:

1. Position the window frame so the cable routing tab is on the drive side of the bike.
2. Insert the window frame into the down tube storage cutout.
3. Torque the bolts to 1.2Nm.

4. Rear derailleur hanger

For derailleur with Active Braking Pivot hardware kit, see page 7.

CAUTION: Do not apply grease between the hanger and the bicycle frame.

CAUTION: Do not apply grease to the hanger bolt threads.

Installation Steps:

1. Insert the hanger on the inside of the drive side chainstay.
2. Install the washer on the derailleur hanger bolt.
3. Insert the bolt into the frame.
4. Make sure to have the hanger in the correct position as shown.
5. Torque the hanger bolt to 25Nm (left-hand thread).

Diagram Description: An illustration showing the correct and incorrect installation of the rear derailleur hanger, with a checkmark for correct and an X for incorrect.

5. Frame guards

Diagram Description: An illustration of the bicycle frame with numbered callouts indicating the locations for frame guards and associated hardware.

Installation Steps:

1. Use isopropyl alcohol to clean the frame surfaces that mate with the guards as shown in the diagram. CAUTION: Do not clean the entire frame with isopropyl alcohol.
2. Remove the protective covering for the adhesive.
3. Carbon frame only: Use two button head screws to attach the:
   • Down tube guard
   • Chainstay guard

6. Cable routing

Steps:

1. Attach zip ties as shown in the diagram.
2. In the down tube, zip tie the following cables between the bicycle frame and the storage frame (cable routing tab):
   • Rear derailleur housing
   • Rear brake hose
   • Dropper housing (when applicable)
3. Route the cables:
   • Carbon frame: Route rear derailleur housing through the chainstay guard.
   • Aluminum frame: Route the rear derailleur housing internal through the chainstay.

Diagram Description: Illustrations showing cable routing for 2020 carbon frame, 2021 carbon frame, and 2020/2021 alloy frame, with numbered callouts for zip tie locations and cable paths.

7. Suspension hardware replacement parts

Rocker Link

*Install drive-side rocker pivot bearing first, then the bearing sleeve, then the non-drive side bearing.

Rocker link hardware kit: two each of pivot spacers and bearings. One axle bearing sleeve and one rocker nut. (Part number: 599910, Quantity: 1)

Main Pivot Point

*Install drive-side rocker pivot bearing first, then the bearing sleeve, then the non-drive side bearing.

Main pivot point hardware kit: one pivot nut, two spacers, two bearings, one sleeve, and one axle. (Part number: 599909, Quantity: 1)

Diagram Description: Illustrations showing the Rocker Link and Main Pivot Point with numbered callouts for all hardware components.

8. Dropout hardware

Active Braking Pivot universal hardware kit: universal derailleur hanger with bolt and washer, one axle guide, one axle nut, two spacers and two bearings. (Part number: 599911, Quantity: 1)

Diagram Description: An illustration of the Active Braking Pivot dropout and skewer with numbered callouts for hardware components.

9. Specifications