General Assembly Instructions

You’ll need the following tools to assemble your new Airborne Bicycle.

— Diagonal cutters

— 4, 5, and 6mm allen wrenches

— A pedal wrench or a 15mm open end wrench

— Torque wrench (recommended)

— Bearing grease

— Shock pump

— Bike pump

Remove your new Airborne Bicycle from the box. Carefully start cutting the zip ties used for packaging with your diagonal cutters. Discard all of the packing materials and lay out all of the parts to prepare for assembly.

Remove the four (4) stem faceplate bolts with a 4mm allen wrench. Put the handlebars in place (don’t forget to make sure that the cables are on the correct sides of the stem). Grease the bolt threads and re-attach the faceplate. Set your bars to your preferred riding position and then tighten the stem bolts to hold the bars in place. Most handlebars have recommended torque settings listed on them. If you have a torque wrench, use it. Do not overtighten your stem bolts!

Check the fork! Some models ship with the forks backwards to protect the shock while in transit. During assembly, make sure that the fork dropouts are facing forward and that the disc brakes are on the non-drive (left) side of the bike. If you need to turn the forks around, see step #7 for headset adjustment instructions.

Insert the front wheel into the fork dropouts with the disc rotor and quick release lever on the non-drive (left) side. Make sure the wheel is straight in the dropouts and then tighten the quick release.

Insert the front wheel between the fork with the disc rotor on the non-drive (left) side. Grease the end of the thru-axle and insert it on the non-drive (left) side. Tighten the thru-axle.

Insert the front wheel between the fork. Insert the thru-axle on the drive (right) side and center. Grease the button cap threads and install on the non-drive (left) side with a 6mm allen key for pre-load. Finally, tighten the four (4) front pinch bolts with a 4mm allen key.

Grease the seat post and insert it in the seat tube. Adjust the saddle to your desired riding height. As a general rule of thumb, you are aiming for your knee to be almost locked out when your crank is at the bottom (6 o’clock) position. Make sure to pay attention to the minimum insertion line marked on the seat post. Tighten the seat post clamp bolt with a 5mm allen wrench. If you have a torque wrench, use it and tighten to 5 Nm.

Your Airborne Bicycle does not come with pedals. Pedals are sold separately. Typically each pedal is marked with a L or R on either the end of the axle or somewhere on the pedal body. The right side pedal threads into the drive (right) side crank arm clockwise. The left side is reverse threaded so you’ll need to turn it counter clockwise to tighten. Pay close attention to this or you will damage the crank arm threads if you get it backwards. Grease the threads before installing and then tighten with a pedal wrench or 15mm open end wrench.

Pull the front brake and rock your bike forwards and backwards. If you don’t feel any play, you’re good to go. If you do feel play, the headset is loose and needs to be adjusted. Loosen the side stem bolts with a 4mm allen key. Tighten the top cap gently with a 5mm allen key until the play is eliminated and then re-tighten the stem bolts (make sure your bars are straight first).

Using a bike pump, inflate the front and rear tires to your desired pressure. The maximum tire pressure will be listed on the side of the tire, just like an automobile. Do not exceed these pressures. If your bike has front suspension you will need to adjust the fork air pressure (based on your weight) with a shock pump.  Most forks come with recommended listed on them (look for a sticker on the back of the fork leg).