43. How to Assemble a New Bike
Overview of a boxed bike assembly. Shows how to put together a mail-order bike.
50% of the cost of the bicycle featured in this video was donated by JensonUSA.
These days you can get a great deal on a new bike by ordering online. Today we’ll learn how to properly assemble a mail order bike right out of the box. Since there are so many different types of bikes and components available, I’ll give a brief overview of the assembly. If you’re watching this video on bicycletutor.com, you can check the links in the text below for more specific instructions.
For this job you’ll need several tools. Ideally you should have a repair stand and a wheel truing stand. Other necessary tools include wire cutters, a set of metric allen keys, a set of metric open-end wrenches, flathead (-) and phillips (+) screwdrivers, cone wrenches, a pedal wrench and an air pump. You’ll also need some waterproof grease, chain oil and a rag.
Open the top flap and carefully pull everything out of the box. Apply some grease to the inside of the seat tube, slide the seatpost in to the minimum insertion mark, grease the threads of the seatpost bolt and tighten it just enough so it will hold the weight of the bike. Then clamp the seatpost in your repair stand.
Remove the front wheel by using wire cutters to carefully snip the zip ties. To save these for future use, cut them just before the head and then pull out and recycle the remaining piece of zip-tie. This leaves you with a short piece of zip-tie that can be used again for odd jobs. Remove the rest of the packaging and either recycle it, or save it so you can box your bike up in the future.
If your headset and bottom bracket have loose ball bearings, open them up and check for grease and adjust as needed. If you have sealed cartridge bearings in these places you can skip this step.
Now we’re ready to install the handlebar. Grease all of the stem bolt threads and shaft if you’re installing an older quill-style stem. Then center the handlebar and tighten the stem bolts evenly so the gap is equal on both sides. Tighten the top cap just enough to hold it in place.
Remove the rear wheel and cassette or freewheel, and open the hubs on both wheels to check for grease. Add more grease as needed and then adjust the hub cones so they spin freely with very little play. See the hub overhaul tutorial for adjustment instructions. Grease the cassette or freewheel’s threads before re-installing them.
It’s a good idea to grease the threads of the crank bolts, chainring bolts, and other bolts that hold accessories like water bottle cages. This will help them repel water and dirt and stop them from seizing up. Grease the pedal threads and install them. Remember that the left pedal always has a reverse thread, so you have to tighten it by turning counter-clockwise.
Set up and adjust your brakes. See the brake tutorials page for set-up instructions on specific brake types. Then lube the chain and adjust the derailleurs. Watch the front and rear derailleur tutorials to see how.
Apply any stickers and/or accessories and then remove the bike from the stand. Adjust your seat height and angle, align your handlebars and adjust your headset. See the headsets and handlebars pages for related tutorials… and then get out for ride!
New to this board so please go easy on me. If I've posted this in the wrong section (or even the wrong site?) I do apologise. Advice would be appreciated.
My name's Ben and I'm from Stockton-on-Tees in England.
I've recently purchased a Jack Taylor bike that was described as a 50th Anniversary model. Please see the photo's below.
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I read reviews about the Frog pedal saying that the cleats wear out quite fast compare to other cleats on the market.
What is your opinion, please?
I use EGGBEATER pedals but I think the spring gets loose too fast and my foot sometimes disengages from pedal...
I`m looking for a pedal I can use for touring (long rides).
Balthazar... Read more >>
Hello everyone. I currently have one hybrid (Forge) and one mountain bike (Diamondback). At my mom's house, my family has an old Roadmaster Mt Fury, and I was thinking of fixing it little by little. I do want to do a complete overhaul though just for fun.
Right now I am going to start with the brakes, shifters, seat, grips and possibly crank. I am going to install Shimano ez shifters, new seat, v brakes, and maybe crank on the diamondback, while the parts that are coming off, are going to the roadmaster.
After that though, I am pretty much going to buy the par... Read more >>
My wife and I were shopping around for new bikes. We hadn't ridden much for years. It's very confusing out there, given so many good brands and styles. We focused on hybrids because of the mix of paved roads, dirt trails and the like where we live (Ipswich, MA). No mountain biking.
She got a Marin San Raphael. I was having a tougher time until I tried a lot yesterday, including a Specialized Crossroads. To me, this stood out because it felt the most nimble and responsive, and seemed lighter than the rest. Also, I didn't want a front suspension fork.
I'd pretty much se... Read more >>
I have recently changed out the Suntour XCM V3 forks on my Trek 4500 that were shot for some F1rst Platinum air forks. The difference is like night and day. The rough tracks I used to find tough going are not a problem anymore. I have never ridden a bike with high end forks so I cannot compare performance. All I know is that for me, this is a great upgrade for a good price.
Anyway, I digress.... I would like to change out the Suntour forks on my other bike, but can only find F1rst Air forks in that area. (I could buy from Ebay, but prefer to be able to physically check w... Read more >>
I'd lke to add a bike computer for my new bike.Can somebody give me any suggestion?
Just watch a vedio in YOUTUBE: There are three kind of bike computers. It is hard for me to choose. Does anyone know about one of them? which one do you prefer to? Thanks for your help in advance.... Read more >>
hi Im a big time commuter and i use my bike to get basically every, were every day, its a raleigh with 27 1,1/4 wheels steel i think, and i was wondering if aluminum was a good choice for me. I live in Cleveland so it bumpy pretty much every were i go, i weigh 140 pounds i like to ride fast and i want to get some more speed out of my bike especially for hills thnx for the help
for the help dont have a pick of it this is one i found on th... Read more >>
I have two offers on the table
Jamis Ventura Race
- 20 pounds
- carbon fork and stays
- ridden for 15km
- Shimano 105 grouping
- Alex-190 wheels
Jamis Xenith Race
- 17 pounds
- full carbon, frame/fork
- ridden for 150km
- Shimano Ultegra grouping
- Mavic Axum wheels
Which is a better deal?... Read more >>
Hello I love bikes and currently ride a road bike. My favorite to place be is on my bike. Now that my kids are getting older they are wanting to do some family bike rides. So in order for me not to look crazy I thought a fixie would be a great way to customize and make a bike mines.
So I was able to score a bike off of a friend. It is an old Ross bike and I was thinking of turning it into a fixie. Attached are some pics I just took Friday of the bike.
I was thinking of getting new color spokes (not sure what color or brand)
I am thinking about buying a Peugeot Tourmalet. I think it is a 1992, but am not sure.
The seller is asking $375. Is this a reasonable price? What could I sell the bike for in 5 years?
Thanks for the advice.
... Read more >>
just started project on Ladies Model - everything pretty much original and in decent shape, need advice on a) moving column shifters to bar location, and b) increasing rear cassette (5) to a triple - what brands can I use? Any comments will be helpful... Read more >>
Don't know if I have missed a discussion on this, but I have been looking at the frames made in China and most of the reviews have been good. A carbon frame and fork for $300 seems too good to be true. Does anyone know anything about the various frames on e-bay of different values ($300 - 500) and what is different about each of them. They all come in carbon black - does anyone have a feel for the cost of an acceptable, moderate quality, two color paint job?... Read more >>
Is an Altus rear derailleur compatible with an 8 speed Acera or Alivio cassette? And, also, which chains would suit this set up?
Thanks... Read more >>
So, I bought a bike that I immediately fell in love with, not paying any attention to the specifics. The bicycle is a cruiser and is 28", I'm 5'2. The bicycle is way too tall for me to ride comfortably and for long periods of time. I love ride trails and this bicycle prevents that from being an easy ride.
I do not want to have to resort to buying a new bicycle so I am hoping that someone will have any ideas on how to convert the tire size from 28" to 24 or 26".
My dad was worried that the brakes will not move 4 or 2 inches. Any suggestions would be extremely helpful!... Read more >>
Hello, first post here need some help please. I bought a used 2011 Specialized Rockhopper Expert 29er and I think I need a new crankset. Here is a link to my bike.
I am fairly handy but never really worked on bikes before so I want to make sure if I replace the crank, that I order everything I need including tools. I am getting a bit of roc... Read more >>