Build Your Bike - Gerard Cycles

Getting Started

Congratulations on choosing to assemble your new Gerard Cycles bike. Below is a list of tools you’ll need and step-by-step directions. If you feel this is beyond your abilities, please call your local bike shop or our mobile bike-build partner, velófix (depending on service area).
Estimated assembly time: Under one hour

Tools Required

Hex wrenches: 4mm, 6mm, 8mm (if installing Shimano pedals)
Torque wrench (recommended)
Carbon anti-seize compound
Lubricating grease (if installing pedals)
Tire pump (with Presta fitting)

Assembly Steps

Step 1

Open shipping box carefully and remove all packing materials from bike or frameset.

Keep shipping box and all packaging for 30 days (in case of return or exchange). Then dispose of responsibly.

Note any damage to the shipping box and photograph.

Carefully remove all packing material.

Be careful to remove all protective pieces.

Step 2

Carefully inspect frameset and all components for damage and record frameset serial number.
Note any damage, photograph, and contact Gerard Cycles.
Supplied parts include:

Gerard FlexPost (FlexPost RX) seatpost and saddle
Shimano Di2 E-Tube Plug Tool (battery wire) (Di2 bike models only)
Shimano Di2 battery charger (Di2 bike models only)
Pedals (optional)
Other optional equipment. (follow manufacturer’s installation instructions)

Inspect the entire frameset and all components and parts.

Serial number is located under bottom bracket.

Step 3

Disc brake bikes: Remove supplied thru axle from frame fork.

Install front wheel on fork, insert thru axle, and tighten.

Rim brake bikes: Install front wheel using supplied quick-release skewer. Tighten securely.

Remove and save caliper block for future use.

Use 6mm hex wrench. Torque to 12 nm.

Step 4

Remove headset compression cap on top of steerer tube and place handlebar stem over fork steerer tube.

Use 6mm hex wrench on top of compression cap.

Gently fit stem down over steerer tube.

Step 5

Replace headset compression cap and tighten hand-tight to preload headset bearing tension.
To determine optimum tightness:

Hold the front brake lever and with the other hand, grasp the space between the bearing cover ring and the bike frame.
Push/pull the bike back and forth to see if there’s any movement between them.
If there is, tighten the the headset compression cap 1/8 of a turn.
Continue checking for movement and tightening the headset compression cap this way until there’s no discernable movement.
Make sure that the handlebar still freely moves from side to side.

Use 6mm hex wrench.

Check for any play between the bearing cover ring and frame.

Step 5a

Straighten handlebar to align with front wheel and tighten stem bolts.

Carefully align the handlebar with the front wheel.

Use 4mm and 6mm hex wrenches.

Step 5b

To continue to check for correct headset bearing tension, hold the front wheel off the ground and turn the handlebar side to side. Front fork/wheel should move freely with no discernable stiffness or impingement

If there is any, loosen the stem bolts, loosen the headset compression cap 1/4 of a turn, and re-tighten the stem bolts.

Repeat these steps until the headset is properly adjusted.
Then torque stem bolts to 5 nm.

With front wheel off the ground, turn handlebar side to side, checking for free movement of headset.

Tighten stem bolts using 4mm and 6mm hex wrenches.
Torque to 5 nm.

Step 6

Shimano Di2 groupsets only: Untape Di2 battery wire from toptube, making sure it doesn’t fall inside seattube.

Lightly coat inside of seattube (first few inches) with anti-seize compound.

Insert Di2 battery plug into supplied E-Tube Plug Tool.

Coat inside of seattube with anti-seize compound.

Insert Di2 battery plug into E-Tube Plug Tool.

Step 6a

The Di2 battery is pre-installed in the open end of the seatpost (saddle attached).

Use the E-Tube Plug Tool tool to guide the plug into the battery socket and push firmly until the plug snaps into place. You should feel and/or hear a positive click.

Check for a secure connection by lightly tugging on the Di2 battery wire.

Make sure you feel and/or hear a positive click when making the connection.

Check for a secure connection by lightly tugging on the Di2 battery wire.

Step 7

Insert seatpost in seattube to desired height, taking care to safely guide the battery wire down into seattube. Align nose of saddle with toptube/steered tube and tighten seatpost clamp using 4mm hex wrench.

Make sure to protect the battery wire from damage.

Use 4mm hex wrench. Torque to 6 nm.

Step 8

If installing pedals: Lightly grease pedal spindle threads and screw into crank arms. Tighten hand tight using 8mm hex wrench. Pedals are labeled Left and Right.

Important note: The right-side (drive side) pedal has a conventional thread (tightens clockwise, loosens counterclockwise).
The left-side (non-drive side) pedal has a reverse thread (tightens counterclockwise, loosens clockwise).

(8mm hex wrench inserts into pedal spindle from the rear, but threading directions assume a front orientation.)

Lightly grease pedal spindle threads.

Screw pedals into crank arms hand tight using 8mm hex wrench.

Step 9

Inflate tires to desired pressure.

Correct air pressure depends on type of wheel/tire, rider’s weight, and weather conditions.

A good starting pressure Is:

Clincher tires/tubes: 90-100 lbs. (6.2-6.9 bar).
Tubeless tires: 80-90 lbs.

Inflate tires to desired pressure.

Tire should feel very solid. Use a pressure gauge if possible.

Step 10

Test ride your new Gerard Cycles bike:

In a safe area test steering and brakes.
Run through all gear combinations with all derailleurs.

Enjoy your new Gerard Cycles bike!

Have fun and be safe.

Visit Us

107 6th St. S.
Kirkland, WA 98033 USA

Contact Us

Email | [email protected]
Phone | +1 425 241 2026