Juggernaut Classic Assembly Follow
Overview
- Open the box and remove the main bike body.
- Remove all packing material from the bike.
- Remove the front wheel from the box and install. The fender will be attached to the front tire
- Mount handlebars
- Install front wheel
- Install pedals
- Install front fender and headlight
- Install seat post
Your bike should now be ready to ride. If you are having any difficulties with this
assembly, please contact us or take your bike to a local bicycle shop.
These instructions are applicable to the Juggernaut Classic with the RST Guide suspension fork.
How to Install Handlebars
- Remove the faceplate from the front side of the stem via 4 Allen key bolts
- Place handlebar onto the stem and hold the faceplate
- Carefully thread in one bolt by hand about 2 or 3 turns
- Now start threading the other 3 bolts
- In an X pattern gradually tighten the 4 bolts while making sure the top and bottom of the faceplate are evenly spaced
How to Install Front Wheel
- Locate Quick Release skewer in charger box
- Unscrew one side and remove one spring
- Insert skewer with lever one the brake side
- Slide spring onto a skewer with the smaller cone towards the wheel
- Screw on end nut 1 turn
- Remove protector and slide fork onto wheel while carefully aligning brake rotor into the caliper
- With bike upright and weight on the front tighten end nut on a skewer and close cam lever (cam lever is tight when it has resistance at 50% of closer, then close all the way)
Note: If fender is rubbing on wheel,
- Loosen upper mount and adjust the slotted mount to clear the tire.
- If rubbing on the side the metal stay can be bent as needed to clear
How to Install Pedals
- Apply a small amount of grease to the pedal threads
- Note there is a right and a left pedal, they have different thread directions and are labelled with an R and L respectively
- Insert the right pedal into the right crank arm, turn the pedal axle clockwise to tighten, use a
15mm pedal wrench to tighten - Insert the left pedal into the left crank arm, turn the pedal axle anti-clockwise to tighten,
use a 15mm pedal wrench to tighten
How to Install Fender and Headlight
- Locate the fender hardware:
- 2x M5x bolts (on bottom of the fork)
- M6 Bolt w/ nut on top of the fork
- Hardware may also be found in the charger/toolbox
- Attach both fender and headlight to upper mount in the order: Washer, headlight, fork, fender, washer then locknut
- Attach fender stay eyelets to lower mounts on each side
How to Install Seat Post
- Apply a small amount of grease to the lower portion of the post
- Open cam lever on seat collar
- Slide post to the desired height (seat post has a minimum insertion lever marked on it,
make sure this line is completely hidden within the frame) - Close cam lever (cam lever is tight when it has resistance at 50% of closer, then close
all the way)
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