Begin by carefully cutting through the cardboard bike box with a sharp box cutter or a pair of scissors. Please be aware of the sharp staples that may have been used to secure the box.
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 removing all of the packing material from the frame and detatching the wheel and handlebar by cutting all zipties that may be holding parts together.
Be very careful not to cut any of the bikes shifter or brake cables while doing so.
Install seat post into frame:
- Loosen the seat clamp and insert the seatpost into the seat tube. If you have bike grease you can apply a small amount to the seatpost before inserting it, but this is not necessary. Finish by either clamping down the quick release lever or using a hex wrench to tighten (depending on which style you have). Make sure that you have inserted the post past the minimum insertion/maximum extension line (printed on post near bottom). DO NOT OVERTIGHTEN – ESPECIALLY ON CARBON PRODUCTS.
Position your bike in a comfortable working position. If you have a bike stand, that's your best bet to assemble bike.
It’s now time to install your handlebar to the stem. Do so by removing the stem bolts and faceplate, placing the bar in the stem and re-securing 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 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. The gap opening between the faceplate and the stem should be equal both on the top and on the bottom. DO NOT OVERTIGHTEN – ESPECIALLY ON CARBON PRODUCTS.
Now that your handlebars and seatpost are securely fastened, it’s time to get your front wheel ready for installation. Start by pulling the plastic protective caps off of the axle. Please note that some hubs have little spacers which are pressed loosely onto the axle. Be sure not to throw these spacers away with the safety caps.
Now install skewer through the axle of the front wheel. Also please note the correct positioning of the springs on the skewer when mounting.
You can now mount the front wheel on the fork, Note that the quick release lever should be on the non-drive side of the bike which is the left hand side when you’re sitting on the bike). Once tightened, make sure that the QR lever is tucked up to avoid snags.
Once the wheel is in and secure, it’s now time to mount the front brake caliper to the fork. Start by unscrewing the recessed brake bolt from the bolt on the caliper. Insert the caliper bolt through the front of the fork crown and then thread the recessed brake bolt through the back, securing the caliper. The caliper should be approximately centered to the wheel.
Run the front brake cable through the barrel adjuster and tighten down the cable tensioner. Once hand tightened, you can then close the quick release lever on the brake caliper to secure the brake. This will shift the brake pads closer to the rim.
Once your front brake cable is properly adjusted, cut excess cable off leaving approximately 1.5” of cable and crimp cable end cap to avoid the cable from fraying.
Your brake pads may need adjusting once brake is assembled. To do so, grasp brake pad with one hand and loosen brake pad bolt. Align pad to be parallel with rim surface and retighten brake bolt. You do not want the pad to come into contact with the tire.
For pedal installation, we recommend applying a small amount of grease to each pedals thread before installing. Next, 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. Tighten by turning your 15mm pedal wrench to the right.
For the non-drive side (or left facing forward on bike) pedal, turn left to tighten.
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.
Now it’s time to inflate your tires. Each tire will have a manufacture’s recommended PSI on the sidewall. Please follow the recommended inflation setting.
Last step is to go through the entire bike one more time to make sure that every bolt is tight, that your wheels are secured in place, that your front and rear brakes are functioning properly, that the handle bars are tight and don’t move when you hold the front wheel between your legs and twist them, and that your suspension has been adjusted to the proper recommended settings
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.
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