Bicycle assembly instructions

 

A Pelago bicycle purchased from the webstore will arrive to you pre-assembled in a box, and most of the parts are already installed. The bicycle is packed in the box to prevent it from damage in shipping, and that's why some parts are not installed. Don't worry - assembling the bike is easy and soon you'll be riding.

 

These instructions are detailed with photos to make sure that everything will be installed correctly. If you just need a step-by-step list, please click here.

 

1. Tools needed for assembly

 

For assembling the bike you'll only need a basic set of tools: 4, 5 and 6mm allen keys, which usually can be found in a simple multi-tool. In addition you'll need 10mm and 15mm wrenches or an adjustable wrench. You'll also need a pump for the tyres and a small amount of grease or vaseline.

 

2. Bicycle arrives in a box

 

When you receive the box(es), inspect them for possible damage. If there's visible holes or bumps in the boxes, take a photo of them. Don't get rid of the box yet.

 

3. Take the bike out of the box

 

Open the box and grab the bike from the top tube. Lift the bike off the box. If you have a repair stand, attach the bike to the stand.

 

4. Remove packing material and inspect bike

 

Remove all the packaging material and inspect the bike and parts for damage. Also check that all parts are included in the box (some large accessories such as baskets come in a separate box). When you remove the zip-ties of the front wheel, make sure the wheel doesn't drop when it becomes loose.

 

5. Install the handlebars

 

When you start assembling the bike, first install handlebars.

 

Bristol / Brooklyn: the stem is already attached to the handlebars. Install the stem to the bicycle frame, and set it's height so that the maximum insert line is not visible. At this point you don't have to put the handlebar straight, just tighten the stem bolt with a 6mm hex key.

 

Other bikes: the stem is already installed to the frame. Remove bolts from the stem faceplate and insert it back with the handlebar. Tighten the bolts with a 4mm hex key by cross-tightening the bolts carefully. At this point you don't need to put the handlebar for the right angle, just make sure that the bolts are evenly tightened and that the cables run in the right way towards the frame.

 

6. Install the front wheel and fender

 

This is the trickiest part of the assembly process, but tricky doesn't mean difficult.

 

If your bike has fenders, install the front wheel with the fenders. First attach the fender from the L-bracket to the fork crown, but don't overtighten the bolt. Then install the front wheel.

 

Bristol, Brooklyn, Capri, San Sebastian: tighten the wheel axle bolts with a 15mm wrench. Make sure that the wheel is inserted all the way up on the dropouts.

 

Other bikes: when inserting the wheel, first insert the quick-release skewer to the front wheel. The opening lever goes to the disc side of the wheel. Then align the wheel and the disc to the front fork's disc brake. Then push the wheel to the dropouts and tighten the skewer. First tighten the right side of the skewer and then close the quick-release lever.

 

After this part you'll need to mount the fender at the dropouts. Slide the struts to the clips so that the fender is positioned center to the wheel and tighten the clips with a 4mm hex key. You can use the pre-installed rear fender as an example.

 

When the wheel and fender's lower mount are installed, tighten the fender's upper mount at the fork crown. If the bike has a caliper brake, align the brake so that the brake pads are not rubbing the wheel. At this point you can also align the brake pads to touch the rim and not the tyre.

 

7. Install the seat post and saddle

 

Add a small amount of grease to the seatpost and slide it into the seat tube. There's a maximum insert line on the seat post. Tighten the seat post binder bolt, but don't overtighten.

 

Install the saddle to the seat post. You need to loosen the seat post bolt in order to turn the upper part 90 degrees to be able to insert the saddle's rails in between the seat post clamps. Then turn the upper part back and tighten the bolt. When the saddle stays firmly on the seat post, you can adjust the angle of the saddle and position on the rails. Finally when the saddle position and angle are adjusted, tighten the bolt. Brooks leather saddles should be angled slightly pointing to the sky.

 

Please note that on your first rides you'll probably be adjusting saddle height, angle and position so at this point don't mind too much about the correct position.

 

Finally, adjust the seat post so that the saddle is in correct line, and tighten the seat post bolt. Don't overtighten - the bolt can snap!

 

8. Install the pedals

 

Install the pedals that came along the bike, or pedals you've bought elsewhere. The important thing is to install the pedals on the correct sides of the bike. The pedal axles have letters "R" for right side (crank/chain side) and "L" for left side. The right sided pedal is tightened clockwise and the left sided pedal is tightened counter-clockwise. This is very important, as installing the pedals to incorrect sides will most likely break the threads in the crank.

 

Before installing, add some grease to the pedal threads.

 

9. Adjusting the bike

 

Now the bike is generally assembled. You'll need to do some adjustments and final check-ups before you can ride the bike:

 

- First adjust the handlebar and stem. On Bristol and Brooklyn, loosen the stem and handlebar bolts to change the angle of the components. When they're in line, tighten the bolts.

 

- On other bikes. adjust the stem to center position and tighten the two stem bolts on the side. To adjust the handlebar angle, loosen the stem faceplate bolts slightly and adjust the handlebars. Re-tighten.

 

- Check that the brakes are correctly aligned and the wheels don't rub the brake pads. Check that the cranks run freely and the chain doesn't rattle anywhere. Adjust disc brakes if the discs rub the pads.

 

- Check every bolt on the bike that they're not loose. Especially check that the front and rear wheel skewers and bolts are tightened.

 

- Check that the fenders are correctly aligned and the struts are in installed all the way to the clips. Check that fenders do not rattle and/or touch the tyres.

 

10. First ride

 

On your first ride(s) keep a multi-tool with you. Prepare to make some adjustments to your riding position, mostly to the saddle position. Remember that there are many parts that can be adjusted to reach a comfortable riding position.

 

Also, listen to the bike: pay attention to possible rattles or noises. A well-maintained Pelago bike is completely silent.