Assembly Manual Mountain Bike

Assembly Manual

Mountain Bike

Assembly Manual Mountain Bike

I. Unpacking the box II. Getting the front wheel ready III. Fitting the front wheel IV. Fixing the front wheel into the fork V. Adjusting the handlebars VI. Fitting the saddle VII. Fitting the pedals VIII. Test run 2

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Assembly Manual

Mountain Bike

Dear Customer, Congratulations on the purchase of your new mountain bike. With the aid of this Assembly Manual you will be able to complete the assembly of your bike in a couple of steps at home. All the necessary assembly work and pre-adjustments to the gears and brakes have already been done by our bike builders. You only need to fit the front wheel, saddle and pedals. All the tools needed can be found in the box of accessories enclosed with your bike. Attention: It is essential that you also read the manufacturers own operating manuals to fully understand all of the technical features of your bike.

Assembly Manual

Mountain Bike Open up the package of accessories and take out the quick release skewer. (Fig. 2)

I. Unpacking the box

Open up the special shipping box and remove the rectangular protective cardboard on the rear wheel. Take the wheel out of the box, followed by the saddle and then the bike frame, which has the rear wheel already fitted. Take out the package of accessories.

B D C

A
Fig. 2 Quick release skewer

Loosen the acorn nut (B) on the quick release skewer and remove the springs (C) Insert the quick release skewer with the spring (D) into the axle of the hub (Fig. 3) From the other side replace the second spring (D) onto the skewer and gently tighten the acorn nut (B) (Fig. 4)
Fig. 1

II. Getting the front wheel ready

Remove the two plastic protective covers on the wheel Hub.

Assembly Manual

Mountain Bike Important: Get a second person to help you when fitting the front wheel or alternatively usea bike stand. Remove the plastic protection from the fork dropouts (Fig. 5)

Fig. 3 Fit the quick release lever on the left hand side (when sitting on the bike)

Fig. 4 Quick release skewer when fitted

Important: The conical ends of the two springs (C) and (D) should always point towards the hub axle! Important: Make sure that the quick release lever is always on the left hand side of the front wheel (when sitting on the bike)

Fig. 5 Remove protection from the fork

a.) Wheels with hydraulic disc brakes Lift the mountain bike by its stem with one hand Remove the shipping protection from the hydraulic disc brakes, by pulling the plastic out of the disc brake calliper (Fig. 6 and 7)

III. Fitting the front wheel

Once the front wheel is ready to be fitted into the fork, proceed as follows (depending on the type of brakes):

Assembly Manual

Mountain Bike Important: Make sure, when fitting the front wheel, that the fork dropouts are sitting completely on the axle! Important: Make sure that the brake disc is sitting centrally between the brake pads and is rotating freely! Slight rubbing noises are quite normal at the start break in the disc brake (approx. 30 full brake pulls) and possibly adjust the brake if you need to.

Fig. 6

Fig. 7

Attention: Do not touch the front brake lever once the shipping protection has been removed from the disc brake calliper! Fit the front wheel into the fork (in the correct direction of rotation) (Fig. 8) Schlieen Sie den Schnellspanner an der Nabe mehr Informationen zu diesem Thema finden Sie unter Point IV

Fig. 9 Insert the brake disc centrally

Attention: Check that the front wheel is rotating freely. The wheel has not been fitted properly if the wheel is not running straight or if the brake is clearly rubbing!

b.) Wheel with mechanical V-brakes Lift the mountain bike by its stem with one hand Fit the front wheel in the direction it is to rotate

Fig. 8

Assembly Manual Close the quick release skewer on the hub - more about this under Point IV Important: Make sure, when fitting the front wheel, that the fork dropouts are sitting completely on the axle!

Mountain Bike Important: Check that the front wheel is rotating freely. The wheel has not been fitted properly if the wheel is not running straight or if the brake is clearly rubbing!

c.) Wheels with hydraulic calliper brakes Now fit the V-brake by pressing together both arms of the brake with one hand so that the faces of the brake pads sit flat on the wheel rim. Using the other hand, pull the guide tube of the V-brake towards the counter bracket so that the end of the guide tube can be fitted (Fig. 10 and 11) Pull the rubber sleeve over the end of the guide tube
Fig. 12 Fig. 13 Fig. 14

Open the quick release with the word Close on the left-hand brake calliper (Fig. 12, 13, 14)

Detach the left-hand brake calliper from the quick release socket. (Fig. 15 and 16)

Fig. 10

Fig. 11

Assembly Manual

Mountain Bike Close the quick release skewer on the hub of the front wheel more details about this under Point IV Attach the left-hand brake calliper onto the quick release socket (Fig. 17) Close the quick release on the left-hand brake calliper, so that the word Close is facing outwards (Fig. 18)

Fig. 15

Fig. 16

Lift up the mountain bike with one hand Fit the front wheel in the direction it is to rotate Important: You may need to let some pressure out of the inner tube to fit the front wheel in correctly. A pump is provided for this. Please read the manufacturers recommended tyre pressure on the tyre! Important: Make sure, when fitting the front wheel, that the fork dropouts are sitting completely on the axle!

Fig. 17

Fig. 18

Important: It is essential that you also read the Magura Operating Manual! Important: Check that the front wheel is rotating freely. The wheel has not been fitted properly if the wheel is not running straight or if the brake is clearly rubbing!

Assembly Manual

Mountain Bike b.) Using a stub axle Remove the stub axle from the packet of accessories Loosen the stub axle screw using the correct Allen key on your multifunctional tool Lift up the bike and fit the front wheel Insert the stub axle from the right-hand leg of the fork through the stub axle hub (Fig. 21)

IV. Fixing the front wheel into the fork

a.) Using a quick release skewer Close the quick release skewer by rotating the lever by 180 (Fig. 19 and 20) Attention: When tightening the quick release lever (A) it should meet resistance at about the halfway point. Otherwise you will have to increase the tension using the acorn nut (B) on the opposite side of the hub! (c.f. page 2, Fig. 2)

Fig. 21 Fitting the stub axle

Fig. 19

Fig. 20

Fit the stub axle screw to the left-hand left of the fork (Fig. 22) Tighten all the screws on both fork dropouts (fig. 23)

Attention: If the quick release skewer is correctly closed, the word Close should be legible on the outside of the lever!

Assembly Manual

Mountain Bike

Fig. 24

Fig. 25

Fig. 26

Fig. 22

Fig. 23

Attention: Make sure that there is an even tightening torque on all of the stem locking screws. The clearance of the stem clamp has to be identical, otherwise there is a risk of a serious material defect on the handlebars!

V. Adjusting the handlebars

Using the multifunctional tool (Fig. 24) Select the correct Allen key to loosen the stem locking screws on the handlebars (Fig. 25) Make the necessary adjustments to your handlebars. Make sure that the handlebars are centrally aligned in the stem clamp (Fig. 26) Once you have adjusted the handlebars, tighten the locking screws on the front cross-wise

VI. Fitting the saddle

Insert the seat pin into the seat tube and adjust the height of the saddle (fig. 27)

Fig. 27

Fig. 28

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Assembly Manual Attention: Ensure when adjusting the height of the saddle that the seat pin is not pulled out further than the maximum height! Failure to comply with this could result in serious material defects or accidents! (Fig. 30)

Mountain Bike

VII. Fitting the pedals

Remove the pedals from the accessoriespackage, if you have ordered pedals. Identify the right-hand pedal and screw it in a clockwise direction onto the right-hand crank (Fig. 29) Screw the left-hand pedal in an anti-clockwise direction onto the left-hand crank Tighten both pedals with a 15 mm spanner and, after a few miles, check once again that they are still tightly fitted (Fig. 30)
Fig. 29 Fitting the right-hand pedal to the right-hand crank Fig. 30 Tighten the right-hand pedal in a clockwise direction

Important: The right-hand crank is always on the side of the chainset. Attention: Failure to note the markings on the pedals or trying to fit the pedals with force will inevitably damage the threads!

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Assembly Manual

Mountain Bike correctly adjusted without a certain period of running-in. Mechanical components, like brakes, gears and bearings have to be checked and readjusted after a certain time. An initial inspection by qualified technicians will guarantee that your bike has a long life so that you can enjoy unlimited cycling enjoyment. Important: Keep a note of your frame number! The frame number is generally located on the bottom bracket the position may vary with different manufacturers (seat pin, head tube). It is easiest to note down your frame number on the invoice for your bike. Attention: Mountain bikes, which do not have lights, do not comply with the requirements of 67 of the German Road Traffic Licensing Regulations (StVZO). Please be aware that these sports bikes are not permitted to travel on public roads. Attention: It is essential that you also read the manufacturers operating manuals to fully understand all of the technical features of your bike.

VIII. Test run

Your new mountain bike is now ready to ride and you should take it out for a test run straight away. (Fig. 31)

Fig. 31

Important: Before heading out, please check that all of the screw fittings and quick release skewers on your mountain bike are tight. Test out the suspension to ensure that it is working correctly and has sufficient suspension tension. Important: In your own interest, we would recommend that you have your bike inspected after approx. 100 km. Bikes cannot

Have fun with your new bike!

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Assembly Manual Space for notes:

Mountain Bike

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Assembly Manual Space for notes:

Mountain Bike

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Assembly Manual Space for notes:

Mountain Bike

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