The 2024 Alloy Fuel EXe is an electric mountain bike designed for versatile trail riding, offering adjustable geometry and integrated electronic components. This service manual provides detailed instructions for assembly, maintenance, and troubleshooting of its key systems.
Function Description:
The Alloy Fuel EXe is a full-suspension e-mountain bike featuring a TQ HPR50 drive unit, designed to provide assistance while pedaling. Its adjustable headset and Mino Link allow riders to customize the bike's geometry to suit different riding styles and terrains, offering options for steeper or slacker head tube angles and corresponding changes to bottom bracket height. The bike integrates various electronic components, including a TQ Smart Box for light and electronic shifting connections, a speed sensor, and a removable battery system. The frame is designed to use a Universal Derailleur Hanger (UDH), ensuring broad compatibility with modern drivetrains.
Important Technical Specifications:
Drive Unit:
- Motor: TQ HPR50 (details on specific models for SRAM and Shimano drivetrains are provided, e.g., FSA spider for SRAM spec models W5275013, e*Thirteen chainring for Shimano Spec models W5272388).
- Lockring: 5289572.
- Compensation Fasteners: 5289570 (left-hand thread, adjustable for replacement drive units).
- Crank Installation: Cranks must be installed in the UP position, aligned with spindle notches, to ensure proper system learning.
Battery System:
- Battery: 5289554.
- Charge Level LEDs: Indicate battery charge in 20% increments.
- Battery Pull Handle: 5273188.
- Battery End Caps: Upper (W5298492), Lower (W5273187).
- Fasteners: M3x6mm (W581747), M4x12 (5317852).
- Operation without Battery: Requires installing a clip nut (stored inside the battery cover) to secure the motor cover.
Suspension:
- Rear Shock Dimensions:
- Eye-to-Eye Length: 205mm
- Stroke Length: 60mm
- Upper Width: 54mm x 10mm
- Lower Width: 40mm x 8mm
- Recommended Sag: 30% (18mm).
- Bearings: 12x21x8 (W5256341).
- Upper Bolts: M10x19mm (W5270031).
- Lower Bolt: M8x60mm (W5274968).
- Fork Compatibility:
- Axle to Crown (Recommended): 565mm (for 150mm travel).
- Axle to Crown (Maximum): 575mm (for 160mm travel).
- Travel: 150mm (recommended), 160mm (maximum).
- WARNING: Exceeding maximum fork length can damage the bicycle.
Geometry (Adjustable via Mino Link and Headset):
- Headset Angle: Adjustable between 0°, +1°, and -1°.
- Adjustable Headset Components:
- Upper bearing cover: W5275173
- Compression ring: W532842
- Upper bearing: W531676
- Upper cup, 0° angle: 5304949 (XS-L frames: W5295319, XL-XXL frames: W5295274)
- Press-fit lower cup, 0° angle: 5304949 (W5294449)
- Lower bearing: W532843
- Crown race: W532844
- Headset alignment tool: 5310000
- Mino Link Positions:
- High Position (Steeper Head Tube Angle): Quicker steering, raised bottom bracket.
- Low Position (Slacker Head Tube Angle): Head tube angle pushed back 0.5°, slower steering (more stable at high speed), bottom bracket lowered up to 9mm.
Drivetrain & Frame:
- Chainline (1x only): 55mm.
- Chainring (1x only): Minimum 30T, Maximum 34T Round. Oval rings not recommended due to potential motor performance impact.
- Rear Brake Mount: 180mm (direct mount) to 203mm (adaptable).
- OLD (Rear Hub): 148mm.
- Maximum Tire Size: 29" x 2.5" (6mm clearance recommended).
- Seatpost:
- Minimum Insertion: 75mm.
- Maximum Insertion: Small 190mm, Medium 225mm, Large 250mm, Extra Large 280mm.
- Seat Tube Inside Diameter: 34.9mm.
- Seat Tube Post Clamp Outer Diameter: 39.7mm.
- WARNING: Always follow manufacturer's minimum insertion recommendation.
ABP (Active Braking Pivot) System:
- Switch Lever: W573860.
- Thru Axle: 12x184.5mm (W583469).
- Non-driveside ABP Dropout Nut Guide: W5269707.
- Retaining Ring: W5251279.
- Bearings: 20x30x7 (W5256340).
- Non-driveside ABP Bolt: W5251141.
- Derailleur Hanger: W5271425 (UDH compatible).
- Washer: 30mm (frame-specific).
- WARNING: Do not apply grease to derailleur hanger or bolt.
Rocker Pivot and Seatstay:
- Fasteners: M6x25mm (W5270150), M5x18mm (W5256244).
- Concave Washers: W5270027.
- Bearings: 12x21x8 (W5256341).
- Hat Style Washers: W5270030.
- Mino Link Nuts: W5270028.
- Frame Spacers: 18x12x2 (W290057).
- Rocker Pivot Axle: W5307024.
- Seatstay: 45460.
- Rocker Links: Driveside (45461), Non-driveside (45461).
Main Pivot and Chainstay:
- Main Pivot Axle: M8x80.5mm (W5270022).
- Frame Spacers: W440921.
- Bearings: 17x26x10 (W5256338).
- Main Pivot Sleeve: W600642.
- Concave Washer: W5270024.
- Fastener: M8x35mm (W5270149).
- Chainstay: 45459.
Guards and Mounts:
- Brake Hose Adhesive Guard: W326986.
- Main Pivot Mud Flap: W5304910.
- Shuttle Adhesive Guard (optional): W5280162.
- Down Tube Adhesive Guard: W5273589.
- Chain Guide with Fasteners: W5276728.
- Battery Mount Fasteners: M6x19 (W5305015).
- Chainstay Guard: W5306830.
- Clip Nut: W5284890 (used when battery is not installed).
- Battery Cover: W5271937.
- Fasteners: M4x6mm (W575056), M5x8mm (W549307), M5x16mm (W596821 - small frames only).
- Cage Spacer (Small frames only): W5256157.
Wiring and Routing:
- Speed Sensor Cable and Clip: 5289567.
- Magnet: 5289568.
- Cable Housing Grommet: W329119.
- Dropper Post Exit Guide: W519232.
- Dropper Post Fastener: M4x9mm (W532763).
- Remote (including fastener and cable): 5289561.
- Display: 5289562.
- Display Fastener: M3x20mm (5305631).
- TQ Smart Box: 5289564.
- Foam Blocks (for Smart Box): 5305634.
- TQ Smart Box AXS Adapter Cable: 5289566.
- SRAM AXS Cable: W5303844.
- Wiring Harness (includes charge port cover): 5289573.
- Access Cover: W5271943.
- Cable Tray: W5274993.
- M4 Sliding Nut: W5283261.
- Charge Port Holder: W5274996.
- Charge Port Cover: 5289578.
- Charge Port Fasteners: M2.5x8mm (5289578).
Usage Features:
- Adjustable Geometry: The adjustable headset and Mino Link allow riders to fine-tune the bike's handling characteristics for different trails. A steeper head tube angle provides quicker steering and a higher bottom bracket, while a slacker angle offers more stability at high speeds and a lower bottom bracket.
- Integrated Electronics: The TQ HPR50 drive unit provides pedal assistance, controlled via a remote and display. The TQ Smart Box allows for the connection of front and rear lights, as well as electronic shifting systems like SRAM AXS, drawing power from the main battery.
- Removable Battery: The battery is designed for easy removal and installation, facilitating charging or replacement. The bike can also be ridden without the battery by securing the motor cover with a clip nut.
- Speed Sensor: An integrated speed sensor provides accurate data to the drive unit for optimal performance.
- Internal Cable Routing: Brake hoses, mechanical shift cables, dropper post housing, and electronic wiring are routed internally for a clean aesthetic and protection from trail debris.
Maintenance Features:
- Detailed Service Instructions: The manual provides step-by-step instructions for tasks such as headset adjustment, ABP maintenance, rocker pivot and chainstay assembly, rear shock hardware installation, drive unit installation, and battery management.
- Torque Specifications: Specific torque values are provided for all fasteners to ensure proper assembly and prevent damage.
- Grease and Threadlocker Application: Clear instructions on where to apply grease and reapply threadlocker are given, crucial for component longevity and safety.
- Component Identification: Part numbers are listed for easy identification and ordering of replacement parts.
- Special Tools: Mentions of specific tools like a headset cup press, 8mm hex tool, and BB-UN55 bottom bracket tool are included where necessary.
- Troubleshooting Tips: Advice on proper crank installation and handling of the speed sensor cable is provided to prevent common issues.
- Additional Resources: References to TQ e-system quick start guides, TQ service manuals, and Trek's YouTube channel offer further support.
- Adhesive Guard Application: Instructions for cleaning frame surfaces with isopropyl alcohol before applying adhesive guards.
- Cable Tray Replacement Tip: Emphasizes measuring and aligning parts with frame holes and explicitly states not to grease the cable tray track.
- Drive Unit Compensation Fasteners: Instructions for adjusting these fasteners when replacing the drive unit to match the frame.
- Charge Port Cover: Instructions for removal and installation, including a tip for holding the charge port in place during tightening.
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