Core-5 Assembly Video
Assembling with the help of the video guide is the recommended method to reduce questions or issues with assembly.
Important Tips to Avoid Common Mistakes
- Please be very careful when connecting your display. The black arrows must be aligned or the pins or plug may be permanently damaged
- Before installing the fork, make sure cable and wire routing is routed on the left to avoid damage/tension.
- Your stem on your handlebar may need to be loosened and adjusted as well to match the video. For some frame types it is installed backwards to minimize chance of damage to components.
- The stem should be pointing forward with the display/throttle on the left, and the shifter on the right
- Crank Arms - must be at 180° from each other. If you put them on at the wrong angle, you may need a crank puller tool to remove them.
- Before installing the pedals, It's very important to apply a conservative amount of grease to the pedal threads. This will ensure the pedals are making a solid seat into the crank arms and help mitigate the pedals from being seized in the crank arm.
- The left pedal goes on the left. It is reverse thread, rotate counter clockwise to tighten. Properly align and thread it in by hand.
- The right pedal must go on the right. It has a standard thread, rotate clockwise to tighten. Align it and thread it in by hand.
- Then tighten both pedals with a 15mm wrench no wider than the flats.
- Make sure your fork is on correctly and not backwards (brake caliper and rotor goes on the left side of the bike).
- Before installing handlebars, check wire and cable routing again, you may need to flip (left to right, right to left, front to back, back to front).
- When you tighten the stem onto the handlebar clamp area, make sure the gap at each bolt is similar size. You should gently tighten the screws in a crisscross pattern making sure the gap is the same at all locations.
- Do not touch the brake rotors with your fingers. The oil can contaminate them and cause them to be noisy when used.
- The headlight will be installed on the fork using a single bolt and nut.
Fork & Headset Assembly
If you are not familiar with installing this or not familiar with bicycle part names, it may be best to have it assembled by a bike shop. Please watch the assembly video carefully.
As with many bike components, proper installation is important to avoid damage to the bike and to avoid injury while riding the bike.
The bearings now come pre-installed into the cup (as shown below) which is installed in the headtube. This means assembly is easier, but will look slightly different than the video.
- Carefully remove all components from the fork steerer tube except for the race.
- Take note of where the wires are routed. It is best to install the fork with the wires routed on the left.
- Install fork fully, make sure it is seated well with the bottom of the head tube and the lower bearing that is inside the bottom of the head tube.
- Once the fork is installed through the headtube, place the compression ring on top of the fork steerer tube. The compression ring has a "split" in it. It is not a complete circle.
- Slide it down the fork steerer tube, the lip of the compression ring will insert just inside of the bearing when the fork steerer tube is properly centered. This may take some adjustment to get it to sit just right.
- Next place the cone spacer or conical spacer on. Make sure the plastic/ring or dust cover is also installed with this. It should fit right on this spacer.
- Add remaining cylindrtical spacers on steerer tube.
- Put stem on on steerer tube (but do not tighten bolts yet!). Are you handle bars on correct? Are the wires and cables routed properly?
- Insert top cap and bolt, carefully tighten the top cap bolt as shown in the video until you begin to feel resistance rotating the fork, at that point you may even back it off a few degrees. Does it the fork turn smoothly? It should not shift up and down relative to the head tube.
- Now you can tighten bolts on stem where it connects to the steerer tube. Please be careful and slowly tighten in a criss cross pattern. Do not over tighten or you may strip the stem.
- Check to make sure, there is no "play" in the fork. If the fork is properly seated and tightened, the fork should not shift up and down relative to the head tube of the frame.
Headlight Assembly
Before Riding - After Assembly Tuning
Assembly Complete? Now is a great time to:
- Tune your derailleur with the bike off and check to make sure the hanger is properly aligned.
- Failure to do this may cause damage to your rear wheel, power cable, derailleur, and derailleur hanger.
- Make sure your brakes are well adjusted and tuned.
- Double check your cable routing.
