How to Reassemble Your New Bike

Posted June 16, 2021 in Bike Fitting, Bike Maintenance, About ERIK'S by eriksbikeshop

Thanks for purchasing your new bike online from ERIK’S! Once you’ve received your bike securely packaged in a box, you will need to do a few minor reassembly steps to get it ready to ride. Please read the instructions carefully before reassembling your bike. Also, watch the bike reassembly video below, which walks you through the reassembly process.

New Bike Reassembly Instructional PDF and Video

Click to download the PDF instructions.

Tools You’ll Need to Reassemble Your Bike

Before your new bike was shipped to you, it was fully built by our professional assembly team, which then carefully re-boxed the bike for shipping. The following instructions are intended to help you reassemble your bike. If you don’t feel confident with performing these steps, we recommend that you have your bike reassembled by a qualified local bicycle mechanic.

If you’re ready to start reassembling your bike, here are our recommendations for essential tools to make sure you have on hand:

Steps to Reassemble a General Bike

Before you remove the bike from the box, please inspect it for any obvious shipping damage. If the box appears to have major damage from shipping, be sure to save the box in its current state so the shipping company can review the packaging if and when you make a claim.

Step 1: Preparation

  • Carefully cut open the box, using caution to not cut or damage any parts of the bicycle inside, especially the tires.
  • Slowly lift the bike out of the box and carefully stand it on the floor. You can lean the bike against the empty shipping box if needed.
  • Use the side cutters to carefully cut any zip-ties holding parts to the frame.
  • Use the box cutter to carefully remove any packing materials from the frame.

Step 2: Install Seat Post

* View PDF if you have a dropper post instead.

  • Loosen the seat post clamp using the appropriate Allen wrench. If it’s a quick-release, open the quick-release lever.
  • Prepare the seat post. If both the frame and the seat post are made of aluminum or steel, apply grease to the seat post and to the opening in the frame. If either the frame OR the seat post are made of carbon fiber, apply carbon prep paste to the seat post and to the opening in the frame.
  • Insert the seat post into the frame. The seat post should slide in easily. If it doesn’t, loosen the seat post clamp more.
  • Ensure that the seat post is inserted into the frame to at least the minimum insertion point. The minimum insertion marker should be inside the frame to a point at or below the seat post clamp bolt. Final seat height will be set later but the post must always be set to at least this depth at all times.
  • Ensure that the seat is straight in the frame. The narrow end of the saddle should be parallel with the top tube of the frame and point to the handlebars.
  • If the seat post clamp is a bolt-on, tighten the seat post clamp using a torque wrench set to the manufacturer’s recommended torque specification. If it is a quick-release, tighten to a point that the quick-release starts to feel tension at 90° and there is good force applied when fully closed.
  • If you have a workstand available, you can now clamp the seat post into it. Use care with carbon fiber seat posts. If you don’t have a workstand, you can use the empty box to help stabilize the bike as you proceed.

Step 3: Install the Handlebars

  • Remove all faceplate bolts with the appropriate Allen wrench.
  • Insert the handlebar into the stem opening and align it so the handlebars are centered in the stem. If you are using a carbon fiber stem or handlebar, apply Carbon Prep Paste to the clamping area.
  • Replace the stem plate and insert the stem plate bolts. Tighten each bolt until they are almost tight, but the handlebar can still be adjusted.
  • There should be an even gap on the top and the bottom of the stem. You will do the final leveling and tightening of the bars once the wheel is installed.

Step 4a: Install the Front Rim Brakes

  • If your new bike has rim brakes, the brake caliper may have been removed. To reinstall the caliper, remove the long nut from the threaded post. Leave the serrated washer in place, next to the caliper with the serrated edge of the washer facing out, toward the bike.
  • Place the brake caliper-threaded post into the front of the fork.
  • Place the long nut through the back of the fork and twist to begin threading.
  • Using the appropriate size Allen wrench, tighten the long nut. Tighten until secure; the brake caliper should still be able to rotate.
  • STOP! Complete Step 5 now to install the wheel and step 5a to install the quick-release axle, 5b for a thru-axle, or 5c for a bolt-on. The wheel needs to be fully installed to continue.
  • Squeeze the brake together so it makes light contact with the rim and insert cable and housing into barrel adjuster and through cable pinch bolt.
  • Using the appropriate Allen wrench, tighten the cinch bolt.
  • Once the cable is firmly held by the cinch bolt, you can release from holding the brakes to the rim.
  • Pull the brake lever quickly and hard and hold it tight for two seconds. This centers the brake caliper with the rim.
  • After holding the brake lever for two seconds, release.
  • Spin the front wheel and listen for any sign of rubbing between the brake pads and rim.
  • Tighten the long nut on the back of the fork to the manufacturer’s recommend torque specification.

Step 4b: Install the Front Disc Brakes

  • If your new bike has Disc Brakes the front brake caliper may have been removed and a caliper spacer placed in-between the brake pads. The caliper bolts will have been reinstalled into the mounts on the fork.
  • Remove the mounting bolts from the fork.
  • Loosely mount the caliper to the fork using the appropriate Allen wrench. The bolts should only be finger tight and the caliper should be able to move slightly.
  • Remove the caliper spacer.
  • Important: Once the spacer is removed from the caliper, do not pull the brake lever. This will close the brake pads inside the caliper and you may not be able to proceed.
  • STOP! Complete Step 5 now to install the wheel and step 5a to install the quick-release axle, 5b for a thru-axle, or 5c for a bolt-on. The wheel needs to be fully installed to continue.
  • With the wheel installed, pull the front brake lever a number of times to center the caliper with the rotor.
  • On the last brake lever pull, hold the brake down and tighten the bolts on the caliper with the appropriate Allen Wrench. Tighten enough so the caliper won’t move when the brake lever is released.
  • Spin the wheel to check for any rubbing. Fine tuning may be necessary to remove contact between the rotor and brake pads.
  • Once the caliper is centered on the rotor, tighten the caliper bolts to the manufacturer’s recommended torque specifications.

Step 5a: Install the Front Wheel Quick Release Axle

  • If your bike is equipped with quick release wheels, start by opening the brake caliper. For road brakes, turn the release lever up to open the brake.
  • V-brakes should already be open. If not, remove the brake noodle from the noodle holder cage.
  • Locate the Quick Release Skewer in the parts box.
  • Remove the nut and one cone-shaped spring from the skewer. Ensure that the other cone shaped spring is installed correctly with the wide end facing towards the lever.
  • Insert the Quick Release Skewer into the hub of the wheel so that the lever is on the non-drive side of the bike. This is the side without the chain. Check the tire for the rotation arrow.
  • Place the remaining cone-shaped spring onto the skewer with the wide side out and install
    the nut.
  • Install the wheel into the fork. If the bike uses rim brakes, you may need to apply a small amount of force to get the tire through the brake pads. If the bike uses disc brakes, center the rotor between the brake pads.
  • Place the wheel on the ground and let the axle center in the fork.
  • Hold the Quick Release Lever parallel to the ground and tighten the Quick Release Nut until you feel tension.
  • Using the palm of your hand, push the Quick Release Lever up against the fork leg. The Quick Release Lever should leave a slight imprint on your palm when you are done.
  • If needed, return the lever to parallel to the ground and tighten the nut more until this level of force is needed to tighten the Quick Release Lever.
  • Most Quick Release skewers are stamped with Open and Close designations. If you can read Open, then the QR is not safe to ride.
  • Please note: It is imperative that the Quick Release Skewer is installed correctly before riding. Riding with an improperly installed Quick Release Skewer can result in injury or death. If you have any doubts that the Quick Release Skewer is installed correctly, please verify the installation with a qualified, professional bike mechanic.
  • STOP! Go back to Step 4 and finish installing your bike’s brakes.

Step 5b: Install the Front Wheel Thru-Axle

  • Insert the wheel into the fork and align the brake rotor between the brake pads.
  • Insert the Thru Axle into the fork and hub. One side of the fork will have threads for the axle.
  • Tighten with a torque wrench to the manufacturer’s recommended torque specifications.
  • STOP! Go back to Step 4 and finish installing your bike’s brakes.

Step 5c: Install the Front Wheel Bolt-On Axle

  • Ensure that the bolts are loosened enough to fit in the fork and align all washers. If the wheel is equipped with retaining clip safety washers, place those so that they are directly against the axle nuts.
  • Install the wheel in the fork and align thecretaining clip safety washers so that thectab of the washer fits in the hole in the fork.
  • Tighten the bolts with the appropriate wrench until tight.
  • STOP! Go back to Step 4 and finish installing your bike’s brakes.

Step 5d: Close V-Brakes If Equipped

  • If your bike is equipped with a rim V-brake, ensure that the brake noodle holder cage is flipped down and close the brake with your hand.
  • Insert the brake noodle into the noodle holder cage and ensure that the noodle is fully seated, and release your hand from holding the brake.
  • Pick up the front wheel and spin to ensure that the brake is not rubbing. If it is, ensure that the noodle is fully seated.

Step 6: Level Handlebars and Torque Faceplate Bolts

  • Rotate the handlebars until they are in the correct position. Flat handlebars should be rotated so that the levers are at a 45° angle. Drop handlebars should be level across the top.
  • Tighten each bolt evenly, maintaining the even gap on the top and the bottom of the stem plate until you reach the manufacturer’s recommended torque specification.
  • Please note: It is imperative that the handlebar is installed correctly before riding. Over-tightening of the bolts can damage the stem and/or handlebars which can lead to failure and injury or damage. Under-tightening of the bolts can result in the bars moving, which can lead to failure and injury or damage. If you have any doubts that the handlebar is installed correctly, please verify the installation with a qualified, professional bike mechanic.

Step 7: Air Up Your Tires

  • We are required to ship your new bike with minimal air in the tires to ensure against explosion due to changes in atmospheric pressure. This means that you will need to fill your tires during the initial build and then again before each ride.
  • To fill a tire that uses a Presta valve, remove the valve cover and open the valve by turning the knurled knob at the top of the valve as far as it will go.
  • Push the pump head fully onto the valve stem and lock in place.
  • Check the sidewall of the tire for the recommended pressure range.
  • Fill the tires to your desired pressure.
  • If you do not have a pump that will directly fill a Presta valve, you can use a Presta valve adapter. To
    use the adapter, remove the valve cap, turn the knurled knob at the top of the valve as far as it will
    go, thread the Presta valve adapter onto the valve stem, and fill the tire as normal to your desired
    pressure.

Step 8: Install Pedals

  • Locate the pedals in the parts box or provide your own pedals.
  • All pedals are left or right specific. Left and right is determined as you sit on the bike and
    face forward.
  • These pedals must be installed on the correct side of the cranks. Failure to install the pedals on the
    correct side can result in failure resulting in injury or damage.
  • Apply grease to the threads of the pedals.
  • Thread the pedals into the crank arm using finger pressure at first, and then using a pedal wrench or Allen key, depending on the pedal.
  • Please note: Always turn the wrench towards the front of the bike to ensure that you are tightening in the correct direction. The left pedal and crank arm are reverse threaded and therefore tightens in a counterclockwise direction.

Step 9: Set Up Air Suspension If Equipped

  • If your bike is equipped with an air suspension fork or shock, visit the manufacturer’s website for the proper air settings for your specific equipment.
  • You will need a shock pump to fill a suspension fork or shock. These suspension specific pumps are capable of filling suspension components to a high pressure with a low volume of air. A standard bike pump can damage or destroy suspension components if used.
  • Attach a shock pump to the suspension component and fill to the correct air pressure. Be sure to replace all valve caps when done. Do this for both fork and frame suspension.
  • You want your body weight to take up some of the travel of the suspension component. This is called sag. To check your sag, fill the suspension component to the recommended starting point. Sit on the bike dressed as you would for riding with all of your gear, water, backpacks, etc., fully loaded.
  • Move the O-ring that is on the suspension component until it makes contact with the shock body.
  • Get off the bike without pushing into the suspension and check how much of the suspension (sag) you used. Adjust the air pressure until you are in the recommended sag range for your new bike.
  • Set your rebound and compression settings based on manufacturer’s recommendations.

Step 10: Install Reflectors

  • It is the law in most states that reflectors must be installed on all bikes.
  • Remove the front and rear reflectors from the box.
  • With a screw driver, Install the white front reflector on the handlebars and the red rear
    reflector on the seat post.

Step 11: Final Checks

  • Spin both front and rear wheel to ensure that the brakes are not rubbing. If you experience brake rub, ensure that the wheels are installed properly and are properly centered. Off-center wheels are common with Quick Release wheels. If the wheels are centered correctly, ensure that the brakes are properly centered on the rim.
  • Apply the brakes and ensure that the pads make contact with the braking surface before the lever hits the handlebar. You should be able to apply a good amount of pressure to the brake lever even after the brakes make contact with the braking surface.
  • Shift through all of the gears to ensure that they are all working and there is minimal chain rub. Some chain rub is normal when you are in cross-chain gear combinations.
  • Set your final seat height and ensure that the saddle clamp bolt or quick release lever is set to the correct torque specifications.
  • Double check the torque specifications of your handlebars and stem faceplate.
  • Double check to be sure that your wheel quick releases and that the axle bolts or thru axle is set correctly and at the proper torque, if applicable.
  • GO RIDE!

Contact ERIK’S If You Need Assistance

If your bike was delivered damaged and/or your shipment was incorrect, please fill out ERIK’S Web Shipping Damage or Loss Notification. You can also review our shipping policies here.

And of course, if you have any questions, feel free to give us a call (877-885-2453) or email us at help@eriksbikeshop.com.

Enjoy your new ride!