Juggernaut Ultra 1000 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. Fender will be attached to 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 Ultra 1000 base model, 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
- Then make sure when the stem is facing forward make sure front brake is on the left (same side as the rear) adjust by loosening 2 bolts at the top of the fork
How to Install the Front Wheel
The front wheel on the Ultra 1000 utilizes a quick-release skewer with the RST Guide fork.
- Locate the quick-release skewer. This is typically found in the charger box, the tool box, or zip-tied to the front wheel
- Unscrew the end cap and slide the outer spring off of the skewer
- Place the wheel between the dropouts of the fork, being careful not to scrape the brake rotor on the brake pads
- Insert the skewer into the wheel and slide the outer spring onto the other side of the skewer
- Thread the end cap onto the skewer and tighten the quick-release until there is significant resistance at the halfway point of closing the lever
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
The stock Ultra 1000 comes with a full metal fender and a wired light. Please read the instructions before proceeding ahead with the installation.
- 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 a bag in the tool/charger box
3. Attach both fender and headlight to upper mount in the order: Washer, headlight, fork, fender, washer then locknut
4. 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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