important: Nuts and bolts on your bike should always be tightened to the manufacturer's specifications.

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!

Alex Ramon

A bicycle geek since early childhood, spent his twenties as a mechanic in bike shops. His passions include flatland BMX, unicycles, cycle touring, mountain biking and road riding.

Recommended Tools

Discuss this topic in the Bicycle Repairs and Mechanics Forum

Make a freewheel removal tool

Weak spring tension on the derailleur will result in sprockets wearing out faster

New Stator For My Ride1up Core 5

Jumps a Gear

Lock ring clearance

Derailleur causing issues

Latest post 1 week ago

Hello there, I had managed to replace my inner tube and outer tyre successfully, however since then I have been trying to re-fit my rear tyre back onto the frame to no avail. Initially I thought the axel was at an angle. I have undone the nuts and bolts many times, rode the bike, then either the tyre starts rubbing with the frame, or the pedals become really stiff to rotate. But today I have r...

Wheel not turning

Latest post 1 week ago

Recently bought an Amigo scooter, I went to make a turn and the handlebar locked up, the wheel wouldn't turn and I fell off of the bike. I only had it for a day prior to that and felt it lock up a little the first day but brushed it off. do you all know what the cause could be?...

Amigo Polo Scooter

Latest post 1 week ago

Can anyone help me figure out how my one day old scooter's handle bars locked up while i was making a turn ? It is the Amigo Polo and I literally had it for one day, is there a way to fix this ?...

How do you remove a freewheel when the tool does not work?

Latest post 1 week ago

I have these Chinese freewheels. On the inside are ridges which are supposed to be there so you can use the tool to remove it. With these freewheels, the ridges are very low. I have a tool, also made in China, and the ridges on the tool are also very low. So when trying to use the tool to remove the freewheel, it does not grip properly, and it can't be used to remove the freewheel. The metal on ...