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Hello. Neubee here.
What's is the most fork travel/upgrade that I can put on 2020 Trek Top Fuel 8 XL going from Rockshock silver 120mm that is a stock fork. I regularly bottom out although pressure is by spec and there is nothing wrong with it otherwise.

I am 250lbs and was told any increase in travel will change geometry significantly and put a lot of pressure on steer tube causing it to crack.

Some places are mentioning it is safe to go 140mm...no idea, Trek website has no documentation on it.

I appreciate any insights.
 

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The plastic Motion Control damper in your fork has very poor performance capability. No small bump compliance and is overwhelmed when the speed goes up. You can't upgrade the damper. A working fork at 130 would be a major improvement. A used Pike with a Charger2 damper or a Marzocchi Bomber Z2 or DVO Diamond would change things.
 
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