MTB Assembly Manual

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Assembly Manual

Mountain Bike


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Assembly Manual Mountain Bike

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Assembly Manual

Mountain Bike

I. Unpacking the box 4

II. Getting the front wheel ready 4

III. Fitting the front wheel 5

IV. Fixing the front wheel into the fork 9

V. Adjusting the handlebars 10

VI. Fitting the saddle 10

VII. Fitting the pedals 11

VIII. Test run 12


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Dear Customer,

Congratulations on the purchase of your new mountain bike.

With the aid of this Assembly Manual you will be able tocomplete 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 t 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.


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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 tted.

Take out the package of accessories.

Fig. 1

II. Getting the front wheel ready

Remove the two plastic protective covers on the wheel Hub.

Open up the package of accessories and take out the quick

release skewer. (Fig. 2)

Fig. 2 Quick release skewer

A

B

CD

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)


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Fig. 3 Fit the quick release lever

on the left hand side

(when sitting on the bike)

Fig. 4 Quick release skewer

when tted

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)

III. Fitting the front wheel

Once the front wheel is ready to be tted into the fork,

proceed as follows (depending on the type of brakes):

Important: Get a second person to help you when tting the

front wheel or alternatively usea bike stand.

Remove the plastic protection from the fork dropouts (Fig. 5)

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)


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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 nden Sie unter Point IV

Fig. 8

Important: Make sure, when tting the front wheel, that the

fork dropouts are sitting completely on the axle!

Important: Make sure that the brake disc is sitting centrallybetween 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. 9 Insert the brake disc centrally

Attention: Check that the front wheel is rotating freely. The

wheel has not been tted 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


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Close the quick release skewer on the hub - more

about this under Point IV

Important: Make sure, when tting the front wheel, that thefork dropouts are sitting completely on the axle!

Now t the V-brake by pressing together both arms of the

brake with one hand so that the faces of the brake pads sit at

on the wheel rim.

Using the other hand, pull the guide tube of the V-braketowards the counter bracket so that the end of the guide tube

can be tted (Fig. 10 and 11)

Pull the rubber sleeve over the end of the guide tube

Fig. 10 Fig. 11

Important: Check that the front wheel is rotating freely.

The wheel has not been tted properly if the wheel is not

running straight or if the brake is clearly rubbing!

c.) Wheels with hydraulic calliper brakes

Open the quick release with the word Closeon the

left-hand brake calliper (Fig. 12, 13, 14)

Fig. 12 Fig. 13 Fig. 14

Detach the left-hand brake calliper from the quick release

socket. (Fig. 15 and 16)


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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 t the front wheel in correctly. Apump is provided for

this. Please read the manufacturers recommended tyre pressure

on the tyre!

Important: Make sure, when tting the front wheel,

that the fork dropouts are sitting completely on the axle!

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 wordCloseis facing outwards (Fig. 18)

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 tted properly if the wheel is not

running straight or if the brake is clearly rubbing!


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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. 19 Fig. 20

Attention: If the quick release skewer is correctly closed,

the wordCloseshould be legible on the outside of the lever!

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 yourmultifunctional tool

Lift up the bike and t the front wheel

Insert the stub axle from the right-hand leg of the fork

through the stub axle hub (Fig. 21)

Fig. 21 Fitting the stub axle

Fit the stub axle screw to the left-hand left of the fork

(Fig. 22)Tighten all the screws on both fork dropouts (g. 23)


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Fig. 22 Fig. 23

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

Fig. 24 Fig. 25 Fig. 26

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!

VI. Fitting the saddle

Insert the seat pin into the seat tube and adjust

the height of the saddle (g. 27)

Fig. 27 Fig. 28


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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)

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 tted (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 t the pedals with force will inevitably damage the threads!


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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 ttings and quick release skewers on your mountain bike

are tight. Test out the suspension to ensure that it is workingcorrectly and has sufcient suspension tension.

Important: In your own interest, we would recommend that

you have your bike inspected after approx. 100 km. Bikes cannot

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 qualied 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 Trafc

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 manufactur-

ers operating manuals to fully understand all of the technical

features of your bike.

Have fun with your new bike!


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Space for notes:


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Space for notes:


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Date post:	04-Apr-2018
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MTB Assembly Manual

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