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Bike Assembly Guide

Congratulations on your new bike! For us, there’s nothing more exciting than building your bike. In this article we will show you how to assemble your brand new machine. Don’t worry, it won’t be super challenging, as we have already done most of the work for you.


 

Also make sure to check out some hot tips from the freeride legend Matt Jones, on his last visit to the Bikes Online Headquarters:



Feel free to scroll through the following assembly guides for each specific component. We've added the links to the in depth articles where you'll also find detailed videos covering each of the processes. Alternatively, you may also check out our YouTube channel "How to Video Guides" playlist for all related content.

 


REMOVING THE BIKE FROM THE BOX

Place your bike box in a nice open area to make assembly easy. For more detailed information, you can also check out our Unboxing Guide.



  1. Open the top of the box and remove the small parts box. This contains everything you will need to build your bike.

  2. On top, you will see a torque wrench, to ensure you don’t over tighten any bolts when assembling your bike, and a pedal spanner. 

  3. Beneath you will find manuals, a bell, rubber frame protectors, quick release axle, reflectors, any tools or parts associated with the bike and components, and some bikes will even include a spare derailleur hanger, make sure you keep all of these parts as you need them for the assembly and in the future.

  4. Carefully lift the bike out of the box and place it on the floor, alternatively, you can hook the front fork over the edge of the box. This makes for a simple work stand to free up both your hands.

  5. Then remove all the packaging and place it all to one side, make sure you keep it all in case you ever need to transport your bike or return it.



INSTALLING THE HANDLEBARS

Next, you need to attach your handlebars to the bike.  You may also see our Handlebars Installation Guide for more detailed information.



  1. Start by removing the faceplate of the stem, this will require a 4 or 5mm hex key, depending on the model.

  2. Ensuring the cables aren’t twisted, place the center of the handlebar on the stem. Reattach the faceplate and tighten the bolts to 5nm, using an alternating diagonal pattern to make sure even tension is applied. 

  3. You can check this by looking at the gap between the stem and the faceplate from above and below the stem.



INSTALLING THE SEATPOST

As part of our pro build the inside of the seat tube should already be greased. If you have a dropper post, you may also check out our Dropper Post Installation Guide.



  1. If you have a regular seat post, simply insert the seat post in the seat tube, ensuring the minimum insertion depth is below the top of the seat tube.

  2. Then tighten the seat post clamp to 6nm. If your bike has a quick release, ensure the lever is pointing forward when closed and you get enough pressure on the lever to feel resistance around half way, which should leave a mark on your palm.

  3. If your bike has a dropper post all you need to do is insert the cable end with the clamp into the actuator, making sure the cable end sits nicely in the slot.

  4. Once inserted, pull the cable through at the headtube or at the bottom of the seat tube depending on the bike as you insert the seat post into the seat tube.

  5. Then tighten the seat clamp using your provided torque wrench to the recommended torque on the seat post clamp.



INSTALLING THE PEDALS

Next, you need to install the pedals. Like the seat post, the threads in the crank should already be greased. For more details, please see our Pedals installation Guide.



  1. The pedals are labelled left and right, either with a sticker or etched on the axle.

  2. The threads on the bolts are different but always remember that both pedals always tighten turning towards the front of the bike.

  3. Install the right pedal first by hand, screwing it clockwise, then use the pedal spanner and tighten it firmly.

  4. Then install the left pedal again by hand first, screwing it anti-clockwise, then use the pedal spanner and tighten it firmly.



INSTALLING THE FRONT WHEEL

Lastly, you need to install your front wheel. You can find more information on our Front wheel installation Guide.



  1. Firstly check the plastic packaging protectors that came on the wheels to see if the hub  spacers didn’t get caught on the packaging. If your bike comes with a quick-release skewer, it will be in the small parts box that came with the bike.

  2. Remove the nut and one spring. Then insert the skewer with the quick release lever on the left-hand side of the wheel, this will be the side with the disc brake rotor. Install the spring with the small end first and then screw on the nut two turns.

  3. Now you can install the wheel into the forks. If the bike uses rim brakes you will need to turn the quick release cam to open up the brakes. If your bike has disc brakes remove the plastic spacer and be careful not to squeeze the brakes. Lastly, ensure the brake rotor goes easily into the calliper.

  4. Then tighten the nut, continually checking the tension of the quick release lever. Once it starts to become firm at roughly 90 degrees, you can close the lever. It should leave an imprint on your palm. It is best to have the lever pointing vertical or facing backward and not contacting any part of the frame.

  5. If your bike has a thru-axle, remove the axles from the fork, then place the front wheel into the fork. Place the axle through the fork. Then hand thread the axle turning clockwise. The axles will tighten by using an Allen key or have a lever. If it tightens using an allen key, tighten it to the recommended torque using the provided torque wrench. If it uses a lever, tighten it, continually checking the tension of the lever. Once it starts to become firm at roughly 90 degrees, you can close the lever. It should leave an imprint on your palm.

  6. Lastly, if your bike has rim brakes don’t forget to turn the rim brake cam back to the closed position.



FINAL CHECK

Your bike is now finally built, it is always good practice to go over all the bolts on the bike to make sure they are tight. For more comprehensive guides, please refer to our Initial Adjustments and Initial Bike Fit articles.

  1. Check to make sure the rear axle is tight.

  2. After your first ride check all the bolts, pedals, and axles again as they may come loose after the first ride.

  3. It is also important to get your bike serviced within the first 3 months through one of our National Service Network or your local bike shop as the gear and brakes may need minor adjusting as part of the break-in period.

  4. If you are having any trouble with any part of the installation, check out our individual videos on each of the bike build steps, and be sure to check out our video on how to set up your bike to fit you before your first ride.

 


CONCLUSION

Regardless of the specific bike model, the following video wil cover all aspects mentioned in this article - so make sure to check it out:



And now you should be able to complete the assembly steps of your new bike.

To help you get your head around servicing and care instructions in addition to the articles mentioned above, we have put together the following reading list:

 

  1. Periodical Maintenance

  2. Safety Check

  3. Repacking your bike

  4. Storing your bike 

  5. Transporting your bike

  6. Customizing your bike

  7. Service Advice & Costs

  8. Suspension Service Schedule

  9. National Service Network


Feel free to contact us in case you have any questions or concerns and happy riding!

 


Disclaimer of Liability:

Bikes Online endeavours to ensure the quality of information contained in this Help Center is accurate however does not guarantee. Inadequate professional knowledge can lead to serious accidents to self and product, Bikes Online are not liable for any damage or injury resulting from these attempts. This applies particularly to damage resulting from incorrect repairs, adjustments or services. If in any doubt you should send your bike to a professional store, mechanic or qualified specialist. Bikes Online gives no guarantee or accepts liability for any of the information contained in this Help Center.

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