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Assembly tips

After watching the appropriate 'Podcast' below, please take a few moments to review the notes for further clarification

Our bikes are supplied 95% assembled. I have therefore provided some assistance, by way of basic instructional videos, to help you complete the final assembly of your new bike. These videos are in the form of an overview to get you started and do not represent a direct movie representation of the complete manual. There are 3 videos ranging from budget infant/junior, budget junior/adult and better quality which will hopefully cover the majority of requirements.

There are a few things to remember.

1. There is always someone at the end of our telephone line to lend a hand if you're stuck.
2. When removing packaging, please be careful not to damage paintwork or saddle.
3. There is no need to apply maximum force when tightening nuts, bolts or skewers.
4. There is seldom comprehensive assembly instructions available both before you order a bike and after its purchase, however, reading the manual or watching the 'bikecasts' will help. That said, if you're nor sure, get somebody to build the bike on your behalf who is capable.
5. Re-install handlebars / stem.
a. The forks must face in the correct direction, i.e. the brakes are at the front of the forks.
There are 2 types of stem system:-
a. the A-head set system. Remove top nut and A-head cap. Install handlebar and stem onto top of the fork steerer tube, replace A-head cap and tighten bolt. Adjust handlebars to correct vertical position and align with forks, then tighten side bolts on handlebar stem. If the stem is already in place, you will need to remove the front securing plate by loosening the allen bolts, fit the handlebars and repace the securing plate.
b. on most budget bikes, the stem is of the quill type. Remove the plastic cover from the bottom of the stem and insert the stem into the fork steerer tube. Adjust the handlebars to correct vertical position, align with forks and tighten the allen bolt on the top of the stem.
6.Re-install front wheel.
As usual there are 2 ways to complete this:-
Locate the wheel into the forks and
a. tighten the nuts with a 14mm spanner ( infant bike ) or 15 mm spanner ( junior / adult budget bike ).
b. ensure that the quick release skewer is in the wheel axle. Hold the lever end of the quick release skewer, and turn the other end clockwise until finger tight. Lock the skewer by pushing it up or down to the closed position securing the wheel (you should feel resistance when locking the skewer). If it is too difficult to lock, unwind the non-lever end slightly and try again or if not enough resistance, tighten the non-lever end slightly and try again.
7.Re-install Pedals
Ideally, like the pedal threads, the seat post should be greased first. Then tightly screw the pedals in with a 15mm spanner. Please note the right hand pedal screws in clockwise, and the left hand pedal screws in anti clock wise and are usually labeled L and R respectively on the end of the screw thread. Ensure that they are screwed in squarely - no odd angles please and do not force the pedals in place - cross threaded pedals will not be covered under warranty. N.B. Currently replacement pedals and chainset will cost in excess of £40
8. Disc brake bedding-in period.
If your bike has disc brakes, it is normal for them to make a scraping sound until bedded in which is usually about 8-10 hours of continuous use.

Please take care when installing the front wheel into a bike with hydraulic disc brakes because if the brake lever is squeezed before the wheel is in place, the pads will close and there will be no space for the disc rotor. To push the pads back, insert a lever / skrewdriver between the pads taking care not to damage the pads or caliper.

Make sure that all cables are running free ( brakes and gears ) i.e. not wrapped awkwardly around the handlebars nor gear cables trapped by a prop stand.

A word of advice
Whilst you may want to wash / clean your bike, DO NOT use a jet wash as this will remove all of the grease from any area with moving parts and prevent smooth running.

And finally, take a look at our maintenance series of 'bikecasts'.

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