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Related Manuals for Trek ALLOY FUEL EXE
Summary of Contents for Trek ALLOY FUEL EXE
- Page 1 2024 ALLOY FUEL EXE SERVICE MANUAL Rev 1 August 2023...
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Page 2: Table Of Contents
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. Frame/Size... -
Page 3: Safety
2024 Alloy Fuel EXe Safety Legend WARNING Properly tighten hardware Always tighten hardware to the specified torque. Apply grease 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 Do not apply grease injury to the rider. - Page 4 2024 Alloy Fuel EXe Adjustable headset Upper bearing cover — W5275173 Compression ring — W532842 Upper bearing — W531676 Upper cup, 0° angle — 5304949 — W5285212 Press-fit lower cup, 0° angle — 5304949 Lower bearing — W532843 Crown race —...
- Page 5 2024 Alloy Fuel EXe Adjust the geometry — headset angle -1° 0° +1° Install the angled cups 1. Grease the cups and head tube bores. Tools • Upper angled cup: XS - L frames — W5295319 XL - XXL frames —...
- Page 6 2024 Alloy Fuel EXe Active Braking Pivot (ABP) This bicycle frame is designed to use a Universal Derailleur Hanger (UDH). For additional information about the UDH, refer to the SRAM user manual at sram.com. 25Nm Derailleur hanger Switch lever —...
- Page 7 2024 Alloy Fuel EXe Rocker pivot and seatstay M5x18 M6x25 Important: Install driveside bearing first. Torque order Important: Loosely tighten all screws and bolts, then torque in the order shown below. To achieve proper torque on all bolts, rocker link pinch bolts (8) must be torqued last.
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Page 8: Main Pivot And Chainstay
2024 Alloy Fuel EXe Main pivot and chainstay 15Nm Important: Install driveside bearing first Main pivot axle, M8x80.5mm — W5270022 Frame spacers — W440921 Bearings, 17x26x10 — W5256338 Main pivot sleeve — W600642 Concave washer — W5270024 Fastener, M8x35mm —... -
Page 9: Rear Shock Hardware And Dimensions
Eye-to Eye-length: 205mm Stroke length: 60mm Upper width: 54mm x 10mm Lower width: 40mm x 8mm For a list of compatible shocks, refer to the FAQ on the MY24 Alloy Fuel EXe 15Nm page on trekbikes.com. 17Nm Setup Upper bolts, M10x19mm —... - Page 10 2024 Alloy Fuel EXe Adjust the geometry — Mino link Flip the Mino link to change the bike’s geometry to fit your riding style or the terrain. Steeper head tube angle Slacker head tube angle 0.5° Mino link in the high position Mino link in the low position •...
- Page 11 2024 Alloy Fuel EXe Brake and mechanical shift routing Brake hose Zip tie Mechanical shift cable housing Cable tunnels 1. Remove the display from the top tube for easier access. 2. Route the brake hose and shift housing back to front.
- Page 12 2024 Alloy Fuel EXe Speed sensor routing For detailed service instructions: Refer to the TQ service manuals found on tq-ebike.com/en/support/manuals. M4x6 Zip tie to brake hose NOTICE: To disconnect the speed sensor from the drive unit, hold each connector and gently pull them apart.
- Page 13 2024 Alloy Fuel EXe Dropper post routing 0.5Nm 1. Remove the battery cover and the battery. Exit guide — W519232 (See page 23.) Fastener, M4x9mm — W532763 2. Remove the access cover (See page 17.) 3. Route the dropper post housing from the bottom of the bike up through the seat tube and up through the cable tray in the down tube.
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Page 14: Remote And Display
2024 Alloy Fuel EXe Remote and display For detailed service instructions: Refer to the TQ service manuals found on tq-ebike.com/en/support/manuals. 0.5Nm Remote, including fastener and cable — 5289561 Display — 5289562 — 5289562 Fastener, M3x20mm — 5305631... - Page 15 2024 Alloy Fuel EXe AXS shift routing AXS-equipped bikes include the TQ Smart Box. It has connections for front light, rear light, aux 12, and electronic shifting. Hole is open. Connect SRAM AXS cable and TQ Smart Box cable here.
- Page 16 2024 Alloy Fuel EXe Guards and water bottle mounts M5x16 M6x19 M5x8 M4x6 Brake hose adhesive guard — W326986 10 Chainstay guard — W5306830 Main pivot mud flap — W5304910 11 Clip nut (Use when battery is not installed) —...
- Page 17 2024 Alloy Fuel EXe Charge port cover 0.5Nm Fasteners, M2.5x8mm — 5289578 Charge port cover Tip: Not sure if you have a T8 Torx wrench? Before you buy a new one check your SRAM bleed kit to see if one is included with the kit.
- Page 18 2024 Alloy Fuel EXe Battery cable, cable tray organizer, and access panel 0.5Nm M4x6 M3x10 Cable tray replacement tip Fasteners, M4x6mm — W575056 Cable tray — W5274993 M4 sliding nut — W5283261 Do not Charge port holder — W5274996 grease the track.
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Page 19: Motor Cover
2024 Alloy Fuel EXe Motor cover For detailed service instructions: Refer to the TQ service manuals found on tq-ebike.com/en/support/manuals. 0.8Nm Guards 0.8Nm and water bot- tle mounts on page 15. M4x6 M4x6 M6x19 Fasteners, M4x6mm — 5269023 Fasteners, M4x6mm —... - Page 20 2024 Alloy Fuel EXe Drive unit Drive side SRAM drivetrain NOTICE: Before assembling the chainring, spider and lockring, place the included protective sleeve over the bottom bracket spindle. Failure to use the sleeve could damage the Shimano seal on the lockring and allow water...
- Page 21 2024 Alloy Fuel EXe Adjust the compensation fasteners Before mounting a replacement drive unit, adjust the compensation fasteners (tighten or loosen) to match the bike frame as shown. The fasteners have a left-hand thread. NOTE: Only adjust the compensation fasteners if you are replacing the drive unit.
- Page 22 2024 Alloy Fuel EXe Re-install the cranks Note: A CWP-7 Crank Puller may be helpful to remove some types of crank arms. The TQ system is designed for cranks to be installed in the UP position and in alignment with the notches on spindle. Installing the cranks in a different position will cause the drive unit to run rough for a few hundred meters until the system re-learns the position of the cranks.
- Page 23 2024 Alloy Fuel EXe Battery For detailed service instructions: Refer the TQ service manuals found on tq-ebike.com/en/support/manuals. Charge level LEDs Light sensor M3x6 M4x12 Fasteners, M3x6mm — W581747 Assembly Assemble the handle in the orientation shown above, and Upper battery end cap —...
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Page 24: Remove And Install The Battery
2024 Alloy Fuel EXe Remove and install the battery Remove the battery Re-install and partially tighten the screw to hold the battery. NOTICE: Guide the battery out of the frame. When the last battery mount screw is re- moved, the battery will slide out of the frame. -
Page 25: Ride The Bike Without The Battery
2024 Alloy Fuel EXe Ride the bike without the battery The battery helps hold the motor cover in place. To ride the bike without the battery, you must install the clip nut to hold the motor cover in place. The clip nut is stored on the inside of the battery cover. -
Page 26: Connect Lights To The Tq Smart Box
2024 Alloy Fuel EXe Connect lights to the TQ Smart Box Smart Box outputs Light adapter cable with Micro A connector Lights can be connected to the TQ Smart Box and powered by the bike battery. The Smart Box power outputs must be activat- ed via the Dealer Service Tool (bike shop use only). -
Page 27: Specifications
NOTICE: Measurements of actual tires may vary. Always Travel 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. Axle to Crown Frame/Size...
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