New Bike Day! How to Assemble Your New E-Bike

New Bike Day! How to Assemble Your New E-Bike

Happy New Bike Day!

Fist of all congratulations on your new e-bike. We are super stoked for you and your new ride and in an effort to get you up and running as quickly and as safely as possible, we’ve built this page to attempt to answer the most common technical issues.

First: We have done a quality assurance inspection on the bicycle before it left our facility to make sure the bike we sent out was the right bike, with all of its components, and it was in good shape when it left our facility.

Second: We are providing you with a rebate to a professional bicycle mechanic to pay for the bicycle assembly. Having your bicycle assembled by a professional bicycle mechanic from a reputable shop or mobile mechanic is the most important thing you can do to insure your bicycle is safe, built properly, adjusted correctly and rides the way it should. Every bicycle will require fine adjustment after assembly.

Third: We have a service department you can contact who are dedicated to getting you up and running and keeping your bicycle on the road.

New bikes are shipped partially assembled, requiring a skilled mechanic to complete assembly and run through safety checks. Depending on the bicycle, it will be shipped with its front wheel removed, the rear derailleur and chain removed, the handlebars removed, front brakes blocked, seat and seatpost removed, fenders and racks removed, through-axles or quick-releases removed, rear derailleur hanger removed, both tires partially deflated, and display removed.

The most important rule:

"Never assume anything while building a bike. That small accessory box that is usually empty may have an important part in it. Some bolts may only be finger-tight."

-Robin Williams, probably

 

Step 1: Inspect the Box

When receiving the bike from the shipper, check for serious damage. If there are holes in the box or you see the box being mishandled, you may wish to open the box to do a more thorough inspection before signing off on it.

Shipping damage can include:

  • Bent derailleur hanger tabs, caused by laying the box on its side.

  • A misaligned starnut in the headset, caused by turning the box upside down

  • A charger that does not work

  • Aesthetic imperfections such as scratches or paint transfers

Most of these are easy and cheap to fix; some will be replaced or reimbursed by the manufacturer.

Inspect the bike while unboxing.

The best case and most common scenario is that your bike arrives in a fully intact box that looks great: you can take the entire box to the shop or unpack it with the mobile tech. If you decide to unpack the box to take it to the shop for assembly, be sure to take all of the components, the bag, the manual, and don’t throw anything away until your bicycle is completely assembled.

  • If there are signs of damage on the box, look for signs of impact on the inside of the box, then check the part that made that dent in the cardboard. Please take a photo of any damage to the box that may indicate a shipping issue.

  • Remove the bike from the box and remove any protective wrapping.

  • Ensure that the brake spacer is securely in the caliper, especially if the bike uses hydraulic disc brakes.

Be aware that an e-bike with battery can weigh up to eighty pounds depending on the model, so use a good lifting technique, and only mount the bicycle to a quality bicycle work stand that is rated for that weight.

Be aware that many electric bicycles have internally routed wiring, so be mindful of this when removing stems, seatposts, handlebars, or mounting external components. Damaging this wiring could cause the e-bike to malfunction.

Mount the handlebar to the stem or headset.

  • If the stem is already mounted, attach the handlebars as you would on any bicycle: be mindful of the display cable and brake cables to ensure that the routing will not bind against the frame when turning the bars. If the brake cables rest against the frame, install anti-friction tape to protect the frame. Check routing of the brake hoses through the yoke and down the front suspension to ensure that they are not bound, obstructed or conflicting with the full travel of the front fork.

  • After attaching the handlebars, check for play in the headset.

  • If display is not mounted, mount display to the bars and turn the bicycle on by pressing the power button, usually located on the battery. Check for power at the display. It should turn on and be right side up. If it is upside down it has most likely been attached to the wrong side of the handlebars.

  • If the stem is attached to the handlebar, remove the headset cap and cardboard spacer from the headset. Place stem over headset then thread the headset cap into place by hand. Before torquing to spec, apply downward force on the frame and/or upward force on the fork to ensure the fork's crown race is seated into the lower headset. After tightening the main headset bolt, tighten the horizontal pinch bolts around the upper headset.

***If adjustments are required, loosen these pinch bolts first.***

Step 5: Front Wheel, Brake, Axle and Pedals

Locate the quick-release skewer/thru-axle and pedals, usually inside a small accessory box or bag.

  • Apply grease to the threads on the pedals and the skewer.

  • Remove the brake spacer without touching the brake pads with your hands. Be mindful that on some e-bikes the speed sensor magnet is attached near the discs and can be damaged or misaligned.

  • Insert the skewer into the front wheel, assuring that the tips of the conical springs are facing inward.

  • Brake calipers are shipped blocked open and they are not tightened down on the frame. Take great care when aligning the caliper to avoid rubbing. Brake rotors can be straightened with the Park Tool DT-2. Check for proper operation. Failure to tighten the caliper to the frame can cause complete failure of the front brake.

  • Remove the brake spacer from the caliper and mount the front wheel to the fork.

  • Pedals are installed in the standard fashion. The pedals are labeled right and left with the right pedal having a counterclockwise thread. Torque pedals to spec as loose pedals will work themselves out of the crank arms and destroy the crank arms and can become a serious hazard.

Step 6: Seatpost and Saddle
  • On many e-bikes there are cables that run through the seatpost to a light behind the saddle. Cutting this seatpost requires that the bike casing be opened to disconnect this cable. This should be done by an authorized shop with specific training.

  • On many mountain bikes, there is a cable run for the dropper post in the frame to the bottom of the seatpost. The dropper posts will have instructions on installation included in the documentation. These are identical to the dropper posts on a standard mountain bike. You may need cable and housing cutters, measuring calipers, crimpers, and small hex wrenches to install the dropper post.

A seat post is adjusted in the standard manner: be aware that over-torquing the seat post collar can cause damage to dropper posts, please follow torque specifications.

  • The rear derailleur may be removed for shipping either with or without its derailleur hanger attached.

  • This derailleur is identical to the derailleur on a standard bicycle and installs in the same manner.

  • Make sure that the derailleur hanger and derailleur mounting surface are free from any dirt, packing materials or debris: any misalignment can cause the shifting to be erratic.

  • When mounting the derailleur, make sure the tension adjustment screw rests on the adjustment tab.

  • If there is any doubt about the derailleur hanger, check with the Park Tool DAG-2.2 or equivalent derailleur hanger alignment gauge.

  • Torque attachment bolt to spec.

  • Chains are measured and include either a “missing link” or an installation pin. The chain should not need to be shortened.

  • Chain routing is the same as on a standard bicycle.

  • E-bike chains are often specific to e-bikes and a standard bicycle chain may not give acceptable performance.

  • The battery should be fully charged as soon as possible after receiving your e-bike. They are shipped at less than half charge as mandated for shipping.

  • Check battery mounting by installing the battery and checking for looseness.

  • If battery is loose or will not lock into place, contact customer service (this is rare, and easy to adjust but is specific to each bicycle).

  1. Check that front and rear brakes function properly and that their hand pressure is adjusted to be the same.

  2. Check that air pressure in each tire is within the range printed on each tire.

  3. Check that headset clamps and seatpost clamps are tight.

  4. Check that quick releases or through axles are tight.

  5. Check that battery is secure in its locking mechanism.

  6. Check that display is installed properly and all buttons are functional.

  7. Check all gears.






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