How to Assemble a New Bike
Overview of a boxed bike assembly. Shows how to put together a mail-order bike.
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 bikeride.com, you can check the links in the text below for more specific instructions.
Tools
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.
Unpacking
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.
Assembly
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.
Watch the wheel-truing tutorial to see how to de-stress and true the wheels. Then inflate the tires to the recommended pressure and install both wheels on the bike.
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!
Related Links
- Mtn Bike Riders: Mail-Order Bike Assembly
- Park Tool: New Bike Assembly
- Bicycle Torque Specifications
Related Tools
- Park Tool SK-3 Starter Mechanic Tool Kit
- Park Tool PK-3 Professional Tool Kit
- Park Tool PCS-9 Repair Stand
- Park Tool PCS-4 Repair Stand
- Park Tool TS-8 Home Truing Stand
- Park Tool TS-2.2 Home Truing Stand
Categories
Discuss this topic in the Bicycle Repairs and Mechanics Forum
Schwinn 3rd Avenue 700C hybrid
Lastest post 1 day agoThe bike, new, was $199 from an Amazon dealer, and it came with a load of great reviews and very few negative ones. That should be a warning to anyone looking for a new bike; the shills are out there. If anyone buys one with the idea of putting it together and going for a ride, they would be disappointed. Walmart bikes are better. Seriously! I knew that it would need some work because you do...
Read moreBike pedal nut spins in place
Lastest post 3 days agoHi All, Got a new Trek MTB and attempted to change the pedals. Unscrew the drive side pedal easily by turning anti-clockwise; all good there. This is where my noob mistake happen... Did the same by turning the left side pedal the same way (anti-clockwise) and over crank it such that the bolt is now just spinning clockwise and anti-clockwise without coming off. It's not loose.. just spinning in ...
Read moreOil can spouts
Lastest post 3 days agoYears ago, oil cans had long spouts. Even the throw away cans had long spouts, but makers started putting little nubby spouts on the cans which makes it hard to get into some places such as my bike derailleurs. To oil those I have to pour oil onto a screwdriver blade and let it run down. The cans of '3 in 1' oil I used as a kid, on my bike, had a long spout. So after digging around I found cans w...
Read moreBrake lever hood replacement
Lastest post 3 days agoDoes anyone know of an aftermarket brake hood that (reasonably) fits Suntour GPX brake levers?...
Read moreReplace disc brake pads
Lastest post 6 days agoFirst time doing this, I have to be 100% confident. Are there any risks and potential failures that have to be considered before switching the disc brake pads? I just bought the same pads I have had before, Shimano B01S resin. Will switchem th tomorrow hopefully. Nothing much can go wrong, right?...
Read moreTools for removing disc brake rotors
Lastest post 1 week agoHi all. Couple more questions from the mountain biking beginner. What tool is the best for unmounting/mounting disc brake rotors? I currently have CUBE ZX20 32H wheelset if that helps. Also how can I fix a very slightly bent rotor? It's not very noticeable but still bothers me with that sound ... squeeks against the pads once in a while....
Read moreUsing Evapo-rust for bolts
Lastest post 2 weeks agoI just wanted to show how I rescue rusty bits and pieces using Evapo-rust. does a decent job for just soaking, letting it work, then rinse and lightly scrub and then off to the bench polisher. this is how to start off and I will post pics of the finished bolts when complete. I think you will be pleasantly surprised at the results. ...
Read moreForum update: Mark your thread as solved
Lastest post 2 weeks agoHello, bike riders! In order to improve forum members' experience, we have implemented an option to mark your threads/questions as solved ✅ Currently we have added this option only for the Bicycle Repairs and Mechanics section, and threads can be marked as solved only by the thread's author or forum moderator. Such addition will allow forum members and new visitors to identify 1) already solve...
Read moreCannondale Warranty is a SCAM! Manufacturing fault nearly cost me my life.
Lastest post 2 weeks agoI am the original owner of Cannondale Quick 2016, which I have purchased from one of the Authorized Cannondale shops. Everything went well to begin with, and the bike rode very well. But one day, while cycling on a straight, tarmacked road, all of a sudden my front wheel begun to wobble uncontrollably; the wobble was strong enough to set me straight under a heavy traffic, it was a very near miss. ...
Read moreNew to bike repair- brake caliper selection question.
Lastest post 2 weeks agoxposting this to a few forums as I truly don't know where to start! Link to current setup https://imgur.com/a/Uxwkd54 I come from a car repair background and am trying to learn more about bikes. I have a bianchi I use to commute, and an ol' fuji single speed I'm using as a learner. Just toyed around on the brakes a minute and one part broke (old). Yay! New parts! But how do I know which caliper...
Read moreBrake pads for Old Peugeot
Lastest post 2 weeks agoHello! Recently I was "given" an old Peugeot bike. Checking its decails and the number on the shift derailleur I found out is from 1982. The brakes and brake pads are original. I might not replace the brakes just yet, but will for sure replace the pads since they´re old an hardened. Do any of you know which pads might suit this? BRAKES.jpg (Size: 149.58 KB / Downloads: 10) ht...
Read moreShimano chain master link
Lastest post 2 weeks agoHi. I have Shimano HG601 chain 11-speed and I want to add the master link to it. Watched some videos but I have to be 100% sure, that is why I hereby present my brief plan: 1. there is a black link in the chain 2. I use the chain tool to push that black pin out 3. then I add the master link 4. finish up with using the special tongs to press that master link into the chain Does this look like a g...
Read moreIs it possible to upgrade freehub from 10 speed to 11 speed
Lastest post 3 weeks agoAlmost finished by bike upgrade, only to find my freehub is too small for new cassette. Is it possible to upgrade the freehub from 10 speed to 11 speed or do I have to buy new wheels? Wheels are Shimano RX05......
Read moreSeized bike stem?
Lastest post 3 weeks agoHiya, on tour at the moment. Realising from hand and wrist pins that my flat bars are a bit low for me. I opened the little cap and undid the hex bolt, but the stem seems to have seized to the frame. Any tips on unseizing it without damaging it? Someone suggested wd40, which I don’t have. Would regular chain lube (tf2 all weather) overnight work?...
Read moreThru Axle 150mm x 15mm needed
Lastest post 3 weeks agoIMG_2496.jpg (Size: 203.54 KB / Downloads: 7) asked this question over on /r/fatbike and i'll ask here as well: i bought a used fat bike, a mongoose argus comp, that was upgraded with a rockshox bluto 100mm suspension fork. I have a full squish XC bike, and with no real need for the supsension on the fatbike, i purchased the stock mongoose alloy rigid fork ($50). I am planni...
Read more
