How to assemble your new bike

Whether you’re looking to purchase a new bike from Freeborn or have already placed your order, you can rest assured that your new bicycle will be packaged carefully, and arrive with only minimal assembly required.

Once your order has been placed one of our qualified mechanics will hand-build your bike leaving only a few minor adjustments for you to do once your new bike arrives. Your mechanic will also complete a rigorous Pre-delivery Inspection (PDI) before carefully re-packing for delivery to you.

We know you’ll want to get riding straight away, that is why we’ve put together the steps below to make sure you’re out riding in no time. If you have any questions regarding receiving a bike from us or get stuck at any point in the assembly process be sure to call one of our experts on 01403 258474

Tools you will need

Your new bike should arrive with the basic tools needed to assemble it. The style of tools we pack can vary depending on supply. You will also need a pair of scissors or snips to cut zip-ties and a pair of pliers to remove the box staples.

Unpacking

Depending on the bike you have ordered it may arrive with you in one large box or a large box along with a smaller parts box. If your bike has arrived in two boxes don’t worry there is still not much assembly required.

Your bike may arrive in a different branded box to what you were expecting. Don’t worry. Once we have assembled and tested your bike it will often need to be packed into a different sized box to the original.

Pull open the stapled flap on the top of your bike box. Try not to tear the box and be careful not to cut yourself on the staples.

Once opened carefully remove the staples from the box using a pair of pliers.

Bend the box flaps outwards to make it easier to remove the bike.

Take out any loose items or accessories along with the front wheel before removing the bike.

Carefully pull the bike out of the box. Grab a friend to help if it feels too heavy for you.

Open up your accessory pack. Inside you will find everything you should need to assemble the bike including a multi tool. If your bike comes with pedals you will find these in here too. If your bike comes supplied with keys to secure the battery into the frame, you will find them attached to your battery charger. Locate any manuals or guides and be sure to familiarize yourself with any instructions specific to your bike.

Remove all of the packing from the bike. It’s a good idea to keep the packaging until you have fully assembled and tested your bike.

Pre-install the handlebar

Use the correct allen key to remove the stem face plate.

Orientate the handlebars so the gear shifter is on the underside of the handlebars.

The cables should drop down from the controls on the handlebars and into the guides on the frame. They often cross once as they do but should not be twisted around each other.

Place the handlebar in the clamp and re-attached the face plate over the handlebars just tight enough to hold the handlebars in place but not so tight you can’t adjust their angle. We will adjust and secure the assembly later.

Pre-Installing the front mudguard

If your bike has come supplied with full length mudguards the front one will need to be attached.

At this stage you just need to attach the guard. Later we will adjust it and torque the bolts.

Attach the mudguard to the support rod. Some will just need a twist and click.

Attach the top of the mudguard to the back of the fork brace. Attach the front light bracket if it is hanging loose at the same time.

Attach the ends of the support rod to either fork leg using the correct sized allen key.

Installing the front wheel

If your wheel was packed in a cardboard sleeve remove it now.

Remove the plastic wheel protectors making sure hub caps do not get stuck in the wheel protectors.

Remove the brake spacer from the caliper. If it is secured with a zip tie please cut this first. Once removed do not pull the front brake lever until the wheel is fully installed.

There are two main types of front wheel axle, quick release and bolt thru. The process for installing differs between the two types.

Quick Release Axle

Grab the quick release skewer from your accessories box.

Un-screw the nut and pull off one of the conical springs. Slide the skewer through the hub from the disc side. Slide the conical spring back on, small end first and then screw the nut back on 2 or 3 turns.

Turning to the bike, remove the plastic fork protector. If it is tight, stand on the protector and pull the bike up.

Pick up the front of the bike with one hand and with the other line up the wheel beneath the fork. Carefully lower the fork onto the wheel making sure the disc brake rotor slides in between the brake pads and the fork dropouts rest onto either side of the hub.

Make sure the wheel is sat in the middle of the fork, not off to one side.

Make sure the quick release lever is facing outwards. Hold the lever in one hand and tighten up the nut using the other. Keep tightening the nut until the lever becomes tight to close. You need to make sure when you close the lever it is tight. You should get a slight depression in the palm of your hand and this should be the right tightness.

Bolt Thru Axle

First start by removing the axle from the fork. Most through axles are threaded but please check in your user manually for any information specific to your bike.

Unthread the through axle by turning it anti clockwise and remove it from the fork.

Line up the brake rotor on the front wheel with the brake caliper. Then carefully seat the fork dropouts onto the wheel. Re-insert the through axle and gently turn it clockwise using the correct allen key or lever if it has one, It should turn easily. If you meet resistance, stop, unscrew it and line it up again. Once you have screwed it in all the way give it an extra quarter turn to tighten it firmly.

Once you have fitted the wheel. Pick up the front of the bike and gently spin the wheel. It should spin freely.

Finish attaching the front mudguard.

Check if the mudguard is centered left to right over the tyre and the gap between the tyre and guard is roughly the same end to end.

Spin your front wheel to check if the mudguard is rubbing. If the wheel rubs on the guard it will need to be adjusted. Use adjustment on the support rod and where the guard attaches to the fork brace.

Adjust until the tyre no longer rubs on the guard when spun. Ideally the mudguard should be an even distance away from the tyre along its whole length.

Once you are happy with the position of the mudguard check all bolts are tight.

Finish attaching the handlebars

Now it’s time to finish installing the handlebar. Make sure the handlebar is sat centered in the stem. Most handlebars will have markings to either side of the stem to help gauge this.

Adjust the angle of the handlebars to your desired position. Normally this will be with brake levers pointing down slight from level.

Now tighten the stem faceplate bolts taking note of the torque setting printed on the stem. It’s best to alternate tightening the bolts diagonally.

Make sure the gap between the stem and faceplate is even between all 4 bolts. This ensures your handlebars will not slip under load.

Install the seat and seat post.

Loosen both front and back bolts on the seatpost.

Carefully slide the saddle over the seatpost and slot the saddle rails into the clamp assembly on the seatpost.

Do up both bolts equally but do not tighten them down yet.

Next insert the seatpost into the frame. Carefully slide the seatpost into the frame. There will already be grease or fiber grip applied to the frame. Select your desired height and gently tighten the seat collar bolt noting the torque printed on it.

Using the fore and aft bolts on the seatpost, adjust the angle of the seat to your desired position. If you are not sure what will be comfortable yet, start by adjusting the seat so it is horizontal.

Once adjusted, do up both fore and aft bolts equally until they stop, then do each up another half a turn to make sure they are tight.

Installing the pedals

If your bike comes with pedals you should find them in the accessory pack.

Some pedals are installed using an allen key rather than a 15mm pedal spanner

First identify which pedal is for the right and which is for the left and side of the bike. They will be clearly labelled. It’s vital to get this right because the pedals are threaded in opposite directions.

Let’s start with the right hand side, the drive side. Line up the pedal with the crank arm and, using your hands, rotate it gently clockwise. The pedal should screw into the crank very easily. If you feel any resistance stop, unscrew the pedal and start again. It’s very easy to cross thread the pedal so make sure to thread it in full just using your hands.

Once fully seated use the supplied allen key or spanner and tighten up another quarter of a turn. Firmly tighten the pedal into the crank.

Now lets install the left hand side, the non drive side. This pedal uses a reverse thread. As before, line up the pedal with the crank but this time turn the pedal anti clockwise. Again only thread it in using your hands and stop if you feel resistance. Once fully seated use the supplied allen key or spanner and tighten up another quarter of a turn. Firmly tighten the pedal into the crank.

Attach the display

To make sure your display arrives safely it may have been packed separately to the handlebar.

Most display and remotes attach using a single allen key bolt. Undo the bolt on the securing clamp.

Clip the remote around the handlebar and gently do the allen key bolt back up. Beware you only need to do the bolt up until it stops. Do not over tighten it.

The final checks

You are almost ready to go, but before you do we need to do some final checks. Make sure all of the assembled parts are torqued correctly, everything is aligned correctly and there is nothing loose.

Make sure your tyres are inflated to the correct pressure for your needs. The recommended pressure range is marked on the tyre sidewall.

That’s it. You’re ready to get out and ride.

Don’t forget we are here to help with any questions you might have.

Thank you from everyone at Freeborn. We hope you enjoy your new bike!