TK Fuel Ex ServiceManual MY23 Rev1 EN-US 2023-01-19
2023 FUEL EX
SERVICE MANUAL
Rev 1 November 2022
Contents
2023 Fuel EX
Safety
Active Braking Pivot (ABP)
Rear shock
hardware and dimensions
Frame guards -- carbon frame
Adjust the geometry -- headset angle
Adjustable headset
Rocker pivot and seatstay
Derailleur hanger
Safety
Main pivot and chainstay
Adjust the progression
Cable routing
Frame guards -- aluminum frame Down tube storage
Adjust the geometry -- seatstay mino link
Specifications Chainline (1x only)
55mm
Chainring (1x only)
Minimum 28T
Maximum
Round: 34T Oval: 32T
Rear brake mount
Minimum 180mm, direct mount
Maximum Adaptable to 203mm
Maximum tire size
Notice: Measurements of actual tires may vary. Always verify there is sufficient 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 29" 27.5" (XS and S frame)
Maximum tire size
29" x 2.5" 27.5" x 2.5"
Bottom bracket /ISCG tabs
2023 Fuel EX
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 Frame insertion XS
S (27.9" and 29" wheels) M
ML
L
XL
XXL Seat tube inside diameter Seat tube post clamp outer diameter
Carbon 205mm
225mm
255mm 266mm 281mm 316mm
-- 34.9 39.5
Aluminum 180mm
210mm
240mm 250mm 265mm 300mm 330mm
Fork
WARNING Exceeding the recommended maximum fork length could damage the bicycle and result in injury to the rider.
Travel Sag
Axle to Crown
Specifications ISCG 05, 3 bolt
XS and S /
27.5" wheels S, M, ML, L, XL, XXL /
Recommended Maximum
Recommended Maximum
Refer to the suspension setup card included with your bike or the suspension calculator at trekbikes.com/suspension-calculator.
Legend
WARNING
Properly tighten hardware
Always tighten hardware to the specified 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 threadlocker 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.
Apply grease
Do not apply grease
Apply threadlocker
Nm
Torque
Hex tool
Torx tool Drift size
Zip tie
Copyright 2022 Trek Bicycle Corporation All Rights Reserved
1
Adjustable headset
1 2 3 4
1 Upper bearing cover -- W5275173 2 Compression ring -- W532842 3 Upper bearing -- W531676 4 Upper cup, 0° angle -- 5304949 5 Press-fit lower cup, 0° angle -- 5304949 6 Lower bearing -- W532843 7 Crown race -- W532844
Tools
· Headset press · Grease
5 6 7
-- W5285212
2023 Fuel EX
2
Derailleur hanger
2023 Fuel EX
1
2
25Nm
3
1 Derailleur hanger 2 Washer, 30mm 3 Bolt
-- W5271425
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-specific. Install only the washer size specified.
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.
3
Active Braking Pivot (ABP)
Carbon frame
1 184mm
3 15Nm
10Nm
12.7mm 6
NOTICE: Thread must 2 be at least 12.7mm
4
20x30
7 20x30
5
Aluminum frame
1
184mm
3
10Nm 2
12.7mm 6
NOTICE: Thread must be at least 12.7mm
4
1 Switch lever -- W573860
2 Thru axle -- W583469
3
Non-driveside ABP dropout nut guide -- W5269707
4 Retaining ring -- W5251279
5 Bearings -- W5256340 6 Non-driveside ABP bolt --
W5251141 7 Spacers -- W583422
15Nm
20x30
20x30
5
Tools
· Bearing press · Cassette lockring tool · Grease ·· Threadlocker
-- W5272776
2023 Fuel EX
4
Rocker pivot and seatstay
2 3
12x21
1
4
8Nm
2023 Fuel EX
2
12x21
3 4
6
3 12x21
9 2
4
8Nm 1
1 Screws -- W5270150 2 Concave washers -- W5270027 3 Bearings -- W5256341 4 Seat tube pivot sleeve -- W310155 5 Hat style washers -- W5270030 6 Mino link nuts -- W5270028 7 Rocker pivot axle -- W5270025
5
5
8
12x21
3
Important: Install driveside bearing first.
7
8
Rocker pivot: Search for part number listed below on trekbikes.com
to find the color-matched part for your bike.
Carbon frame -- 40783
Aluminum frame -- 40780
9
Seatstay: Search for part number listed below on trekbikes.com
to find the color-matched part for your bike.
Carbon frame -- 40777
Aluminum frame -- 38553
Tools
· Bearing press · 4mm hex wrench · Torque wrench with 4mm hex bit · Grease · Threadlocker
5
Main pivot and chainstay
2023 Fuel EX
5
5
15Nm
7
6
4
17x26
2 3
Important: Install
2 17x26
driveside bearing first
1 Main pivot axle -- W5270022
2 Bearings -- W5256338
3 Main pivot sleeve -- W600642
4 Concave washer -- W5270024
5 Screw -- W5270149
6 Hat style washers -- W5270023
7
Chainstay: Search trekbikes.com to find the color-matched
part for your bike.
Carbon frame -- 40776
Aluminum frame -- 38552
15Nm
5
1
Tools
· Bearing press · 5mm hex tool · Torque wrench with 8mm hex bit · Grease · Threadlocker
6
Rear shock hardware and dimensions
2023 Fuel EX
2 12x21
6 17Nm 1
4
2 12x21
3
6 17Nm
1
6 10Nm
6 5
Shock Dimensions Eye-to Eye-length: 185mm
Stroke length: 55mm
Upper width: 54mm x 10mm
Lower width: 40mm x 8mm
1 Upper bolts, M10 x 1 x 19mm -- W5270031 2 Bearings -- W5256341 3 Hat-style washers -- W5270030 4 Lower shock Mino nut -- 5303333 5 Lower shock Mino washer -- 5303333 6 Lower bolt, M8 x 1 x 60mm -- W5274968
Tools
· Bearing press · 6mm hex wrenches · Torque wrench with 6mm bits · Grease
Setup
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.
7
Adjust the progression
The shock mino links can be flipped to fine tune the shock performance for the terrain or rider preference.
Tools
· 6mm hex tool · Torque wrench with 6mm hex bit
2023 Fuel EX
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 10Nm.
Less progression More reactive to repeated fast mid-size bumps and square-edge hits.
6 10Nm
More progression More bottom out resistance over big hits and drops
6 10Nm
8
Cable routing
5 6 7 1.7Nm
2023 Fuel EX
1 2 3
2
3
1
4
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1 Dropper cable 2 Rear brake hose 3 Derailleur housing 4 Plug -- W5275264
5 Rubber housing guide 6 Exit guide 7 Bolt -- W532763
Zip tie
-- 5275988
9
Frame guards -- carbon frame
2
4
3 2.5
1Nm
2023 Fuel EX
10
8 9
4
6
2.5
1Nm
1
5
2.5
1Nm
4
3Nm 7 2.5
4 7
M4 x 10 M4 x 6
1 Seatstay adhesive guard -- W5271371
2 Brake hose adhesive guard -- W326986
3 Main pivot mud flap -- W5275234
4 Button head screws -- W1052364 5 Upper down tube guard:
XS ML frames -- W5283184 L XL frames -- W5283185 6 Lower down tube guard: XS and S frames -- W5283181 M XL frames -- W5283182 7 Button head screws -- W575056
8 Chainstay guard -- W5273604
9 Chainstay strike guard -- W5273260
10 Rotor guard -- W580881
Adhesive guards 1 2
Use isopropyl alcohol to clean the frame surface where the guard 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.
Brazed Guards 9 10
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.
10
Frame guards -- aluminum frame
1
2023 Fuel EX 2
5 3
4 2.5 1Nm
1 Brake hose adhesive guard -- W326986 Use isopropyl alcohol to clean the frame surface where the guard 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.
2 Upper down tube guard: XS S (27.5" wheels) frames -- W5284323 S (29" wheels) ML frames -- W5279933 L XXL frames -- W5283420
1Nm
1Nm
2.5
2.5 4
4 M4 x 6
3 Lower down tube guard -- W5279934 4 Button head screws -- W575056 5 Chainstay guard -- W5271370
11
Down tube storage
Carbon frame
2 1.5Nm
1
4
1.5Nm
3
4
1.5Nm
2.5
4
2023 Fuel EX
Aluminum frame
2 1.5Nm
4
3
2.5 4 1.5Nm
5
2.5 4
1.5Nm 4 1
4 2.5 1.5Nm
1 Water bottle cage bolt, 8mm long
2 Water bottle cage bolt, 16mm long
3 Storage door
4
Button head screws -- W575056 (includes nuts, not used on
carbon frames)
-- W5257590
5
1 Water bottle cage bolt, 8mm long 2 Water bottle cage bolt, 16mm long
3 Storage door
4 Button head screws 5 Nuts
-- 1042535
-- W583862
12
Adjust the geometry -- headset angle
0°
+1°
-1°
or
Install the angled cups
1. Grease the cups and head tube bores.
2023 Fuel EX
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
Use the alignment tool to mark the centerline to which you will align the lower cup.
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
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.
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.
13
2023 Fuel EX
Adjust the geometry -- seatstay mino link
Tools
· 4mm and 6mm hex tools · Torque wrench with 4mm and 6mm 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
6mm hex tool to remove the bolts.
6. Use a 4mm hex tool to turn the screw in the mino link to flip the link to either the slacker or steeper position. Repeat this process with the other mino link.
Slacker
Steeper
4
4. Lower the shock and rest it on the towel or cloth covering the down tube.
7. Torque the screws to 8Nm. 8. Re-install the upper shock hardware and torque the
bolts to 8Nm.
5. Rotate the rocker pivot forward to pull the mino links into the window in front of the seat tube.
14
Specifications
Chainline (1x only)
55mm
Chainring (1x only)
Minimum 28T
Maximum
Round: 34T Oval: 32T
Rear brake mount
Minimum 180mm, direct mount
Maximum Adaptable to 203mm
Maximum tire size
Notice: Measurements of actual tires may vary. Always verify there is sufficient 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 29" 27.5" (XS and S frame)
Maximum tire size
29" x 2.5" 27.5" x 2.5"
Bottom bracket /ISCG tabs
2023 Fuel EX
Seat post
WARNING
Always follow the seatpost manufacturer's minimum insertion recommendation. Failure to follow the recommendation could cause damage to the seatpost and result in injury to the rider.
Measurement Maximum Frame insertion XS
S (27.5" and 29" wheels)
M
ML
L
XL
XXL Seat tube inside diameter Seat tube post clamp outer diameter
Carbon Aluminum 205mm 180mm
225mm 210mm
255mm
266mm 281mm 316mm
-- 34.9 39.5
240mm
250mm 265mm 300mm 330mm
Fork
WARNING
Exceeding the recommended maximum fork length could damage the bicycle and result in injury to the rider.
Travel Sag
Axle to Crown
Bottom bracket BSA 73
ISCG tabs ISCG 05, 3 bolt
Frame/
Axle to Race
Travel
Wheel Size
(mm)
(mm)
XS and S
Recommended 534 140
27.5" wheels
Maximum
550 150
S, M, ML, L, XL, XXL Recommended 562 150
29" wheels
Maximum
578 160
Refer to the suspension setup card included with your bike or the suspension calculator at trekbikes.com/suspension-calculator.
15
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