Begin by carefully opening the box. Be aware of the sharp staples that may have been used to secure the box and be mindful not to cut yourself on them.
For assembly you will need: cutters/scissors; #2 Philips head screwdriver; a 4,5,6mm allen keys; and a T-25 Torx wrench.
If for any reason, you do not have the proper tools or are not confident to safely assemble the bike yourself, it is recommended that you take your bike to a local bike shop for assistance or to have them assemble it. We recommend taking all bikes in for a safety check before riding. They may charge you a fee to do any of these services.
Any damage caused by improper assembly is not considered a manufacturer defect and will not be covered under warranty.
Once you have the bike box opened:
- Remove the saddle and seatpost.
- Remove the small parts box.
- Remove the bike.
Before proceeding, be sure that all parts and material are now removed from the box.
Now that your bike is out of the box:
- Begin by detaching the front wheel by cutting the zipties holding it to bike.
- Unpack the handlebar by cutting any zipties/removing any packaging.
Be very careful not to cut any of the bikes shifter or brake cables while doing so. Then carefully remove all of the packing material from the frame.
Install seat post to frame:
- Loosen the seat clamp
- Insert the seatpost into the seat tube. If you have bike grease you can apply a small amount to the seatpost before inserting it. Make sure that you have inserted the post past the minimum insertion/maximum extension line (printed on post near bottom).
- Finish by either clamping down the quick release lever or using a hex wrench to tighten (depending on which style you have). QR Seatpost clamp should have some resistance when closing, but not so much that it takes a lot of force to get it to close position. DO NOT OVERTIGHTEN
- When the bike is fully assembled you will then be able to fine tune the saddle adjustment based on your height. Refer to the Saddle Position section on page 12 in the DB Owner's Manual for guidance.
- If you are assembling a 2015 Sortie 3, Mason Pro, Mission 2 or Mission Pro please check the dropper seat post manufacturer’s website for proper instructions on how to install that post.
Position your bike in a comfortable working position. If you have a bike stand, that's your best bet.
It's now time to install your handlebar to the stem. Begin by making sure the cables are in the correct position - cables are not twisted or kinked and the shifter and brake lever on the right will control the rear of the bike while the shifter and brake lever on the left will control the front of the bike.
- Next, remove the stem bolts and faceplate,
- Place the bar in the stem and loosely re-secure the faceplate to the stem. Be sure that your cable routing is suitable and that there are no harsh bends or kinks in the cable.
Once the handlebar is loosely placed in the stem, make sure that it is positioned correctly and symmetrically before tightening the faceplate bolts. When tightening the bolts, tighten them alternately and equally to ensure that the faceplate is equally tight on every side. (use an "X" pattern for four bolt stems) The gap opening between the faceplate and the stem should be equal both on the top and on the bottom. NOTE: stem bolts are typically tightened to 4nm.
Install Rear Brake Cable Clamp
Set up of front (and rear) disc brakes:
- Make sure cable is run correctly along fork – ensure that the fork is in the correct position (the fork arch should be pointing forward, not towards the rear of the bike).
- Front cable should run in front of derailleur and rear brake cables.
- Run cable thru fork guide
- Run cable/caliper along inside of fork
- Install Front Caliper
- Top bolt – start by getting bolt threading started by hand
- Bottom Bolt - start by getting bolt threading started by hand
- Leave a little play in caliper, do not completely tighten top and bottom caliper bolt yet. Completion of front brake set up will happen after front wheel is installed.
- Leave caliper block in! (This is the piece of plastic between the caliper pads. It is a good idea to keep this piece of plastic so you can use it whenever the front wheel is not on the bike.)
Many of the mountain bikes will come with the front disc caliper installed. For set up and fine tuning adjustments specific to your model of brakes refer to the manufacturer's installation guides for set up and adjustment.
Now it's time to get your front wheel ready for installation. Start by pulling the plastic protective caps off of the disc/axle.
Some bikes may come with the front disc not installed on the wheel. NOTE: Try not to touch the flat side of the rotor (or minimally touch it) as that can cause squeaking. Prepare to install the front disc rotor. The disc and rotor bolts will be in the small parts box. Before attaching the front wheel, you'll want to secure the rotor to the wheel using the supplied bolts. Make sure to pay attention to the rotation direction of the rotor which will be marked on the disc with a direction arrow.
All disc bolts should be checked prior to front wheel installation to make sure they are tight to manufacturer's specs.
Next is to mount the front wheel on the fork – make sure fork is in the correct position before mounting wheel (fork arch should be pointing forward):
- If your bike comes with a standard quick release lever: The quick release lever should be on the non-drive side of the bike (the left hand side when you're sitting on the bike). Please note the correct positioning of the springs (smaller part of the spring points in towards the hub and spokes) and make sure that there is a spring on each side of the wheel. Insert skewer thru hub axle. Place spring on skewer and then tighten skewer nut a few turns. Proceed to step 13. Once tightened, make sure that the QR lever is tucked up to avoid snags.
- For bikes with a thru axle – please refer to attached guide from FOX on correct procedure when installing your front wheel with a thru axle system: Fox Thru Axle Instructions Here. Proceed to step 13.
Some tires will have a directional arrow indicating which way the tire should rotate. If the tire does please make sure the tire will be spinning in the correct direction once on the bike.
Make sure you remove the block spacer from front hydraulic brake caliper. DO NOT SQUEEZE FRONT BRAKE LEVER WITHOUT BLOCK OR WHEEL WITH DISC INSTALLED.
Install the front wheel so that the disc is on the same side as the caliper, being careful to make sure disc sits in between caliper pads and the tire should also be centered in fork.
- Quick Release Skewer- tighten the skewer nut until it touches the fork lightly.
- Then start to close the skewer lever.
- Once tightened, make sure that the QR lever is tucked up to avoid snags. The QR lever should close with some resistance, but not too much that hard to close or open.
- Most levers are stamped with "close" to indicate quick release is closed.
- Thru Axle
- Install Wheel, disc/caliper alignment
- Insert Thru Axle and tighten
- Close lever
Complete Front Brake set up.
- Squeeze front brake lever - do not squeeze brake lever if the wheel and caliper are not installed.
- While holding the front brake lever, alternate tightening the top and bottom caliper bolts, until tight to manufacturer's specifications.
- Spin wheel to make sure disc passes between caliper brake pads.
For pedal installation, your pedals will show what side they are meant to go on with an "L" or "R" on the end of the spindle or axle (depending on the pedal). We recommend applying a small amount of grease to each pedals thread before installing.
Start by hand threading in the left, non-drive side (when seated on the bike) pedal. The pedal will be indicated by an L on either the spindle or the axle (depending on the pedal). Tighten by turning your 15mm to the left. (counter clockwise)
Take the right pedal (this should be indicated by an R on the pedal which can be seen on the end of the spindle or on the axle depending on the pedal) and thread into the drive side crank arm (right side when facing forward on bike). Tighten by turning your 15mm pedal wrench to the right. (clockwise)
Do not force a pedal that will not thread on easily or you can cross thread the crank arm which will result in a damaged product. Damage caused by improper pedal installation will not be covered under warranty.
Now it is time to make sure the front and rear derailleurs are set properly. While pedaling bike, shift rear derailleur to lowest (largest cog) in the rear.
- Make sure that low adjustment screw ("L" stamped on derailleur) is set so it hits the stop so that derailleur cannot shift past that gear and into rear wheel spokes.
- Correct chain line
While pedaling the bike, shift the rear derailleur to highest gear(smallest cog) in the rear.
- Make sure that High adjustment screw ("H" stamped on Derailleur) is set to ensure it hits the stop so the derailleur cannot shift the chain past that gear and into the bike frame.
- Correct chain line
For proper rear derailleur alignment and adjustment, please refer to the manufacture's instructions for your specific derailleur model. On Shimano rear derailleurs, the jockey wheel should line up directly below smallest cog. On SRAM rear derailleurs, the jockey wheel should line up just to the right of the smallest cog.
Now it's time to make sure the rear derailleur will shift appropriately up and down the rear cog set. Proper shifting is all related to cable tension. Begin by pedaling the bike with the chain in the highest gear (smallest cog). Each "click" of the rear/right shifter should correspond to the chain moving up the gears one cog at a time. To adjust the cable's tension, use the adjusting barrel at the rear derailleur/or at the shifter to tune the shifting. If the chain shifts past the desired gear, the cable tension is too high. Turn the adjusting barrel clockwise to ease cable tension. If chain is not shifting to desired gear, turn adjusting barrel counterclockwise to increase tension on cable until chain shifts to desired gear.
Additional help link:
Next, adjust the front derailleur. Check to make sure front derailleur height and alignment are correct.
- Set derailleur angle so outside plate lines up with large chain ring. Make sure the chain is sitting on th smallest chainring (if there are only two) or the middle chainring (if there are three).
- Check height of derailleur using guide sticker on derailleur. If there is not a guide sticker, the outside front derailleur plate should sit about 2mm above larger chain ring on crank.
Now it's time to set front derailleur adjustment screws. To start this step, shift the rear derailleur so that the bike is in its lowest gear (largest cog) in the back and the small chainring on the cranks.
- Check the distance of chain to inner plate of front derailleur
- Set front low set screw so that inner plate is approx. 1-2mm from chain. ("L" stamped on Derailleur)
To start this step, shift the rear derailleur so that the bike is in its highest gear (smallest cog) in the back and the shift the front derailleur into the largest chainring.
- Check the distance of chain to outer plate of front derailleur
- Set the high limit screw so that the outer front derailleur plate is approximately 1-2mm from chain. ("H" stamped on Derailleur)
As a last step, shift through the rear gears starting out in the smaller chainring on the cranks and then in the larger to make sure that the shifting runs smoothly.
Align your bars to the front wheel.
Tighten stem cap bolt.
While the handlebars are still aligned with the front wheel tighten the stem bolts. Most stems have a 4nm maximum torque setting.
Inflate your tires. Each tire will have a recommended PSI on the sidewall. Please follow the recommended inflation setting.
- Take off valve cap
- Pump up tire to recommended tire pressure.
The final step is to go through the entire bike one more time to make sure that:
- every bolt on the bike is tight
- your wheels are secured in place so that your front and rear brakes are functioning properly
- the handlebars are tight and don't move when you hold the front wheel between your legs and twist them
- your suspension has been adjusted to the proper recommended settings
For those with air forks or shocks: It’s highly recommended that you see your fork manufacturers set up instructions online prior to suspension set up. Fox Tuning Tips
If, for any reason, you do not have the proper tools or are not confident to safely assemble the bike yourself it is recommended that you take your bike to a local bike shop for assistance or to have them assemble it. We highly recommend taking any bike to a local bike shop for a safety check and regular tune ups. The bike shop may charge a fee to do any work on your bike.
Please note: Any damaged caused by improper assembly is not considered a manufacturer defect and will not be covered under warranty.
Make sure to register your bike by simply filling out form found in the back of your owner’s manual and mail it in, OR you can register your bike online at Diamondback’s webpage: here for Diamondback.