500 Series Assembly Video

Assembling with the help of the video guide is the recommended method to reduce questions or issues with assembly.

Preassembly tips and advice

  • If you are uncomfortable with bike mechanics, it is best to have it assembled by a bike shop or expert.
  • Carefully remove ONLY the packing zip ties, do not cut any wires, cables, or zip ties that are used to route wires.
  • You will remove all small parts from the fork steerer tube prior to installing the fork.
  • The headset construction is historically the most difficult part for many customers.
    - Pro tip: Follow along with the headset section of the assembly video at 1/4 speed.
  • There is a plastic spacer supporting the front brake caliper between the brake pad area. Note that squeezing the brake lever without the spacer or bike rotor installed will clamp the pistons closed. It is recommended to save the spacer to use anytime you remove the front wheel.
  • Avoid touching the brake rotors with your fingers. The natural oil present on your hands will contaminate the rotors, reduce braking efficacy and create a loud whining pitch when braking.
  • Apply grease to the pedal threads, seat post and fork steerer tube before installation

Headset (see 2nd video below), fork, top cap - If you are not familiar with installing this or not familiar with bicycle part names, it may be best to have it assembled by a bike shop. Please watch video carefully.

As with many bike components, proper installation is important to avoid damage to the bike and to avoid injury while riding the bike. 
If you are unsure, stop, take some pictures and contact us.

  1. Carefully install fork fully, make sure it is seated well with the bottom of the head tube and the lower bearing that is inside the bottom of the head tube. Only the crown race should be on the fork steerer tube at this time. The lower bearings are already in the lower cup at the bottom of the head tube. Along with a dust cover.
  2. Once the fork is installed through the head tube, place the compression ring on the top of the fork steerer tube. The compression ring has a "split" in it. It is not a complete circle.
  3. Slide it down, the lip of the compression ring will insert just inside of the bearing when the fork steerer tube is properly centered. This make take some adjustment to get it to sit just right.
  4. Next place the cone spacer or conical spacer on. Make sure the plastic/ring or dust cover is also installed with this. It should fit right on this spacer.
  5. Add remaining spacers on steerer tube.
  6. Put stem on on steerer tube (but do not tighten bolts yet!). Are you handle bars on correct? Are the wires and cables routed properly?
  7. Insert top cap and bolt, carefully tighten the top cap bolt as shown in the video until you begin to feel resistance rotating the fork, at that point you may even back it off a few degrees. Does it the fork turn smoothly? Does the fork shift up and down relative to the head tube? It should not shift up and down relative to the head tube. 
  8. Now you can tighten bolts on stem where it connects to steerer tube. Please be careful and slowly tighten in a crisscross pattern. Do not over tighten or you may strip the stem.
  9. Check to make sure, there is no "play" in the fork. If the fork is properly seated and tightened, the fork should not shift up and down relative to the head tube of the frame.

Assembly Complete? Now is a great time to:

  1. Tune your derailleur with bike off and verify hanger is straight:Click Here
    1. Failure to do this may cause damage to your rear wheel, power cable, derailleur, and derailleur hanger.
  2. Make sure your brakes are well adjusted and tuned.
  3. Double check your cable routing.
  4. Adjust your fenders.