Trek 2020 & 2021 Fuel EX Service Manual Supplement
Table of Contents
1. Knock Block headset
Description
| Description | Part number |
|---|---|
| Knock Block 58-degree complete headset | 5252156 |
| Knock Block 58-degree upper assembly | 5252157 |
Installation Steps:
- Apply grease to the upper and lower head tube bearing-bores.
- Apply grease to the inside bearing seats for the compression ring and the crown race.
- Install the crown race, then the lower bearing on the steerer tube.
- Insert the steerer tube into the bottom of the head tube.
- Install the upper bearing and the compression ring onto the steerer tube.
- Insert the Knock Block chip into the frame. Do not tighten.
- Install the upper bearing cover.
- Install spacers as necessary.
- Insert the Knock Block chip bolt and tighten to 2 Nm.
Diagram Description: Exploded view of the Knock Block headset components including 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.
Use your bottom bracket manufacturer's manual for removal and installation instructions.
Diagram Description: Illustration showing the bottom bracket area of the bicycle frame.
3. Down tube storage (carbon frames only)
| Item number | Description | Part number |
|---|---|---|
| 1 | Storage door, window frame and hardware | W583862 |
Item number 1 includes all parts in red.
Installation Steps:
- Position the window frame so the cable routing tab is on the drive side of the bike.
- Insert the window frame into the down tube storage cut-out.
- Torque the bolts to 1.2Nm.
4. Rear derailleur hanger
| Item number | Description | Part number |
|---|---|---|
| 1 | Derailleur hanger, bolt and 30 mm washer | W583423 |
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:
- Insert the hanger on the inside of the driveside chainstay.
- Install the washer on the derailleur hanger bolt.
- Insert the bolt into the frame.
- Make sure to have the hanger in the correct position as shown. [X symbol for incorrect, checkmark symbol for correct]
- Torque the hanger bolt to 25 Nm (left-hand thread).
5. Frame guards
| Item | Description | Part number | Quantity |
|---|---|---|---|
| 1 | Seatstay, carbon frames only | W583089 | 1 |
| 2 | Upper down tube | W529228 | 1 |
| 3 | Lower down tube, carbon frames only | W583088 | 1 |
| Lower down tube, aluminium frames only | W532098 | 1 | |
| 4 | Lower down tube guard hardware, carbon frames only | 1042535 | 2 |
| 5 | Chainstay, 2021 carbon frames only | W1048535 | 1 |
| Chainstay, aluminium frames only | 5263821 | 1 | |
| 6 | Chainstay, 2020 carbon frames only | W583087 | 1 |
Installation Steps:
- Use isopropyl alcohol to clean the frame surfaces that mate with the guards as shown below.
CAUTION: Do not clean the entire frame with isopropyl alcohol.
- Remove the protective covering for the adhesive.
- Carbon frame only: Use two button head screws to attach the:
- Down tube guard
- Chainstay guard
Diagram Description: Illustration showing the location of frame guards on the bicycle frame, with numbered parts.
6. Cable routing
| Item | Description | Part number | Quantity |
|---|---|---|---|
| 1 | Cable entry guide | W519232 | 2 |
| 2 | Cable hardware, M4x0.7x16mm | W532763 | 2 |
| 3 | Bottom bracket cable exit guide – carbon only | W583807 | 1 |
| 4 | Chainstay brake exit guide – carbon frame only | W543605 | 1 |
| 5 | Cable hardware, M3x05x12mm – carbon frame only | W318529 | 1 |
Installation Steps:
- Attach zip ties as shown.
- 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)
- Route the cables.
- Carbon frame: Route rear derailleur housing through the chainstay guard.
- Aluminium frame: Route the rear derailleur housing internal through the chainstay.
Diagram Description:
2020 carbon frame cable routing: Illustration showing cable routing paths for rear derailleur, rear brake, and dropper post on a 2020 carbon frame, with numbered zip tie locations.
2021 carbon frame cable routing: Illustration showing cable routing paths for rear derailleur, rear brake, and dropper post on a 2021 carbon frame, with numbered zip tie locations.
2020 and 2021 alloy frame cable routing: Illustration showing cable routing paths for rear brake, rear derailleur, and dropper post on a 2020/2021 alloy frame, with numbered zip tie locations.
7. Suspension hardware replacement parts
ROCKER LINK
| Item number | Description | Part number | Quantity |
|---|---|---|---|
| 7 | Mino link bolt | W579296 | 2 |
| 8 | Mino link spacer | W529969 | 2 |
| 9 | Mino link bearing | W529224 | 2 |
| 10 | Mino link nut | W529223 | 2 |
| 11 | Rocker pivot axle | W535469 | 1 |
| 12 | Rocker pivot spacer | W290057 | 2 |
| 13 | Rocker pivot bearing* | W586543 | 2 |
| 14 | Rocker pivot bearing sleeve | W310155 | 1 |
| 15 | Rocker pivot nut | W311582 | 1 |
Rocker link hardware kit: two each of pivot spacers and bearings. One axle bearing sleeve and one rocker nut.
*Install drive-side rocker pivot bearing first, then the bearing sleeve, then the non-drive side bearing.
MAIN PIVOT POINT
| Item number | Description | Part number | Quantity |
|---|---|---|---|
| 16 | Main pivot nut | W584134 | 1 |
| 17 | Main pivot spacer | W440921 | 2 |
| 18 | Main pivot bearing* | W302025 | 2 |
| 19 | Main pivot sleeve | Kit only | 1 |
| 20 | Main pivot axle | Kit only | 1 |
Main pivot point hardware kit: one pivot nut, two spacers, two bearings, one sleeve and one axle.
*Install drive-side rocker pivot bearing first, then the bearing sleeve, then the non-drive side bearing.
THRU-SHAFT/TRUNNION
| Item number | Description | Part number | Quantity |
|---|---|---|---|
| 21 | Thru shaft shock bolt | W583804 | 4 |
| 22 | Shock pivot spacer | W529969 | 4 |
| 23 | Shock pivot bearing | W293466 | 4 |
STANDARD EYELET
| Item number | Description | Part number | Quantity |
|---|---|---|---|
| 22 | Shock pivot spacer | W529969 | 4 |
| 23 | Shock pivot bearing | W293466 | 4 |
| 24 | Upper pin mount shock hardware kit | 599898 | 1 |
| 25 | Upper pin mount shock hardware kit | 599899 | 1 |
Diagram Description: Illustrations showing suspension hardware components for the rocker link, main pivot point, and shock eyelets, with numbered parts.
8. Dropout hardware
| Item number | Description | Part number | Quantity |
|---|---|---|---|
| 26 | Bearing | W583424 | 2 |
| 27 | Spacer (carbon frame only) | W583422 | 2 |
| 28 | Axle guide | W583419 | 1 |
| 29 | Axle nut | W583420 | 1 |
| 30 | Rear skewer | W583469 | 1 |
Active Braking Pivot universal hardware kit: universal derailleur hanger with bolt and washer, one axle guide, one axle nut, two spacers and two bearings.
Diagram Description: Illustration of the Active Braking Pivot dropout and skewer with numbered components.
9. Specifications
| Specification | Value |
|---|---|
| Maximum chainline (single) | 55 mm |
| Minimum chainline (single) | 52 mm |
| Max chainring for 55 mm chainline | 36T round, 34T oval |
| Max chainring for 52 mm chainline | 34T round, 32T oval |
| Minimum chainring for 52/55 mm chainline | 28T |
| Fork travel | 140 mm |
| Maximum fork travel | 150 mm |
| Maximum tyre size | 29.0 x 2.60 |
| Shock eye-to-eye length | 210 mm |
| Shock stroke length | 55 mm |
| Upper shock mounting width | 54 mm |
| Lower shock mounting width | 50 mm with 10 mm offset to non-drive side |
| Bolt diameter | 10 mm |
