BIKE ASSEMBLY QUICK START GUIDE
Congratulations! Your bike has arrived in a rugged and tough Bike Flights box, now let's get it assembled!
These boxes are the premier shipping container for ready-to-assemble bikes. Take care as you open the box so you can re-use this valuable resource.
For more bike boxes and instructions on packing for your next trip visit: Bikeflights.com
Prepare For Bike Assembly
Gather your tools. You will need the following to build your bike:
Knife or Sharp Edge
Allen Wrenches
Torx Wrenches
Scissors or Clippers
Torque Wrench
Center Lock Tool
LET'S OPEN THE BOX
Use a knife to carefully cut along the taped edge. Slicing only the tape will keep you from cutting up the valuable treasures. As a bonus, this rugged box can be reused a couple of times so save this box for future shipping on your next adventure!
Remove the Lid
Lay your bike bike box flat on the floor, remove the top, and set aside.
Detach Your New Bike
Remove your wheel bags and remove your frame from the straps or bungees securing it in your bike box.
Leave your bike in your bike box to begin assembly. Your bike box will provide a barrier between the floor and your bike.
Disconnect All Secured Parts
Clip all zip ties and disconnect your secured accessory bag, your seat post, and your handlebars from your bike. Some bikes may have a small box of additional parts.
Remove the Padding From Your Bike
Clip all zip ties and remove all padding from your frame, fork, handlebars, crank arms, and derailleur.
Install Your Seatpost
Insert your seat post into your seat tube.
Align and adjust to allow enough room for your repair stand clamp if you have one. Tighten your seat clamp to your frame’s torque spec. (This is marked on the frame clamp and is a critical precaution to ensure your post is tight and the frame doesn't get damaged.)
Secure Your Bike In A Workstand
Using a bike stand will make for quicker and easier assembly, but If you don’t have a bike stand, skip this step, and continue using your bike box as a barrier between the floor and your bike.
Align And Tighten Your Derailleur
With your derailleur loosely connected to your hanger, rotate your derailleur until the B-Screw and B-Screw Tab sit higher than your derailleur hanger.
Slowly tighten your derailleur mounting bolt to your hanger, catching the B-Screw tab on the edge of derailleur hanger.
Align And Tighten Your Derailleur
With your derailleur loosely connected to your hanger, rotate your derailleur until the B-Screw and B-Screw Tab sit higher than your derailleur hanger.
Slowly tighten your derailleur mounting bolt to your hanger, catching the B-Screw tab on the edge of derailleur hanger.
Install Your Handle Bar
Center your handlebars and rotate them to your marked placement.
Tighten to your stem’s torque spec.
Install Your Accessories
Install your bottle cages, fenders, lights, GPS, and other accessories.
Tightening to their proper torque specs.
Install Your Disc Brake Rotors
Install your disc brake rotors onto your hubs, and ensure that they are facing their proper direction. Be careful not to let the rotor come into contact with any oils or grease. Your new brakes have been bedded at our shop but could use another few gentle miles of easy brake application. Getting this done on your first ride will help ensure a ride relatively free of brake howl.
Tighten your disc brake rotors to your hub’s torque spec.
Install Your Wheels
Install your wheels into your bike frame, and secure with your thru axles or your skewers.
Install Your Pedals
Install your pedals in your crank arms. (Most new bikes do not come with pedals.)
Your right pedal is threaded regularly (clockwise to tighten), while your left pedal is reverse threaded (counter-clockwise to tighten.)
Check Your Gears
Spin your crank arms with your rear wheel elevated, and cycle through your gears to ensure smooth shifting.
Adjust if necessary. If you need help with this step, reach out to our customer service and we'll setup an appointment to help you with a video call.
Check Your Brakes
Spin your wheels to make sure your brakes are not rubbing.
Squeeze your brake levers to ensure they are properly engaging.
Check Your Assembled Bike
Double-check that all bolts are tightened properly and that your bike is safe to ride.
Test Ride Your Completed Bike
With your helmet on, perform a short safe bike ride to test your bike.
Bring your multitool to make tweaks and adjustments if necessary.
Gather Your Packing MaterialsS
Consolidate all of your packing foam, packing straps, bungees, zip ties, tape, accessory bags, and other items used for packing.
Keep all of these items in your bike box, bike bag, or bike case so that they are easy to find and ready to use for your next bike shipment.
Ride!
After your bike is safely built and tested, get out there and enjoy the ride! Remember, gently apply the brakes a few times to help them bed in before ripping off on that first epic downhill. This will help your brakes from squeaking in the future.