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Service Information
Assembly manual
Every bike must be completely assembled and adjusted before delivery to a customer.
Some companies do a lot of this work for you; others do not. With experience, your store
will know what steps are reliably fullled by a manufacturer for a given model. Consult
your shop manager to nd which steps apply to a particular product.
Many of the procedures in these instructions are ordered to save time. As an
example, truing the wheels before adjusting the brakes means the pads will be
correctly centered over the rim the rst time.
We suggest you work out the order of procedures that best meet your time needs,
and then follow the exact same procedure on every bike. Continuity of the procedure
will help prevent forgetting steps. It also allows an interrupted mechanic to quickly
and easily resume the assembly.
Note that some bikes have special requirements, and instructions for some of these
are listed on page 73 of this manual.
Basic mechanical skills required
These instructions are for someone with a basic familiarity of bicycles, and some
mechanical experience. The assembler should know all the parts of the bike, and have
some experience in correctly tightening fasteners, such as nuts, screws, and bolts.
For those with less experience, additional resources may be required. The appendix
of this manual includes an explanation of torque, the tightening of fasteners, and
torque specications. Also provided are references to more exhaustive mechanical
instructions for those who need additional information.
CAUTION- Bicycles have many rotating or moving parts which can pinch
or cut. Keep hands away from moving parts. Avoid working on a bicycle if
another person is moving or operating the bike.
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