TREK 2023 Fuel EX Mountain Installation Guide

TREK 2023 Fuel EX Mountain

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 tyre size: 29 x 2.5 for 29″ wheels, 27.5 x 2.5 for 27.5″ wheels
• Bottom bracket / ISCG tabs: ISCG 05, 3 bolt
• Seat post: Refer to the measurement table for maximum frame insertion
• Fork: Refer to the suspension setup card or suspension calculator for recommended maximum travel and axle-to-crown measurement

Contents

Safety

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 thread locker
All reused fasteners with pre-applied thread locker must be cleaned with isopropyl alcohol and have a new thread locker applied before re-assembly. If the threadlocker is not applied, the fasteners may loosen which could damage the bicycle and result in injury to the rider.

Legend

Adjustable headset

Derailleur hanger

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.

Active Braking Pivot (ABP)

Carbon frame

Tools

• Bearing press
• Cassette lockring tool
• Grease
• Threadlocker

Rocker pivot and seatstay

Tools

• Bearing press
• 4mm hex wrench
• Torque wrench with 4mm hex bit
• Grease
• Threadlocker

Main pivot and chainstay

Tools

• Bearing press
• 5mm hex tool
• Torque wrench with 8mm hex bit
• Grease
• Threadlocker

Rear shock hardware and dimensions

Shock Dimensions

• Eye-to Eye-length: 185mm
• Stroke length : 55mm
• Upper width: 54mm x 10mm
• Lower width: 40mm x 8mm

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 suspen-sion calculator at trekbikes.com/suspension-calculator.

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

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.

More progression
More bottom-out resistance over big hits and drops

Cable routing

Frame guards — carbon frame

Frame guards — aluminum frame

Down tube storage

Carbon frame

Adjust the geometry — headset angle

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.

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.
3. Position the lower cup to match the angle of the upper cup.
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 the cup and reinstall it in the correct position.
7. Remove the painter’s tape.

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.
4. Lower the shock and rest it on the towel or cloth covering the down tube.
5. Rotate the rocker pivot forward to pull the minor links into the window in front of the seat tube.
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.

Specifications

Chainline (1x only)

Chainring (1x only)

Oval: 32T

Rear brake mount

Maximum tyre size
Notice: Measurements of actual tyres 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.

Bottom bracket /ISCG tabs

Seat post

WARNING: Always follow the seatpost manufacturer’s minimum insertion recommendation. Failure to follow the recommendation could cause damage to the seat post and result in injury to the rider.

Measurement

Maximum

insertion

| Frame| Carbon| Aluminum
XS| 205mm| 180mm
S (27.5” and 29”

wheels)

| 225mm| 210mm
M| 255mm| 240mm
ML| 266mm| 250mm
L| 281mm| 265mm
XL| 316mm| 300mm
XXL| —| 330mm
Seat tube inside diameter| 34.9
Seat tube post clamp outer diam- eter| 39.5

Fork

WARNING: Exceeding the recommended maximum fork length could damage the bicycle and result in injury to the rider.

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.

FAQ

• Q: What should I do if my tyre size exceeds the recommended maximum?
  • A: Always verify there is sufficient clearance between the tyre and the frame. Improper tyre size could damage the bicycle frame. Trek recommends maintaining a 6mm clearance above and on the sides of the tyre to prevent any damage.
• Q: How do I know if my fork length is within the recommended limits?
  • A: Refer to the suspension setup card included with your bike or use the suspension calculator at trekbikes.com/suspension-calculator to ensure your fork travel and axle to crown measurements are within the recommended maximums to avoid damaging the bicycle and risking injury.

References

• Trek Bikes - The world's best bikes and cycling gear
• SRAM

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