Assembly and Maintenance

This guide walks you through assembling your Wabi complete build. Please read through before starting so you have a clear sense of the process.

Most bikes arrive 90% assembled (except for some 58-60cm models), and the assembly steps are straightforward using basic tools.

If you’re unsure about any step, we recommend having a local bike mechanic assemble the bike.

If you have any questions at any point, feel free to reach out:
📧 support@wabicycles.com
📞 844-746-0777

 

Quick Start Overview

Assembly is simple and typically follows this order:

  1. Unbox and inspect the bike.
  2. Install handlebars.
  3. Install the front wheel.
  4. Install the seatpost and pedals.
  5. Inflate tires and do a final check.

Most customers complete this in under an hour.

58-60cm Classics, Lightings and Thunders

Due to shipping size restrictions, most larger frames require a bit more setup:

  • Thunder (58cm & 60cm): fork reinstallation and rear wheel retensioned.
  • Classic & Lightning (58cm & 60cm): fork reinstallation.
  • Special models: no additional assembly required.

You'll find the additional steps below the standard assembly process. 

 

Tools

You’ll only need a few basic tools:

  • Metric hex (Allen) wrenches:
    • 3mm – bottle cage bolts
    • 4mm – handlebars
    • 5mm – seatpost clamp and front wheel
    • 6mm – saddle adjustment and most pedals
    • 8mm – some pedals (optional)
  • Bike grease
  • Air pump (presta-compatible)

If you ordered non-Wabi wheels, you’ll also need a 15mm wrench.

💡 Our Basic Assembly Kit includes the hex wrenches and grease if you don’t already have tools.

Tool Notes

  • Always use high-quality metric tools—SAE tools can strip bolts.
  • Make sure the wrench is fully seated before tightening.
  • Avoid using small multi-tools for high-torque bolts.
  • A torque wrench is helpful but not required (guidance provided below).
  • For unpacking, have scissors or snips handy.
  • Apply grease to the seatpost and pedals before installing.

 

Unpacking and Inspecting 

    • Inspect the box for damage and take photos if needed.
    • Open carefully to avoid catching the bike on staples.
    • Remove loose items like pedals and saddle first.
    • Lift the bike out by the top tube and place it on a soft, stable surface.
    • Carefully remove packaging (zip ties, foam, wrap) to avoid scratching the frame.
    • Remove plastic protectors from the fork and rear dropouts—they tap out easily.
    • Double-check that all parts are present and the bike looks correct.

    If anything seems off, contact us right away.

    Here's a short video for guidance:

     

    Component Installation

    Your bike was fully assembled and tested before shipping. The following components need to be installed:

    Handlebar Installation

    • Remove the 4 bolts from the stem faceplate.
    • Position the handlebars in the stem.
    • Reinstall the faceplate and tighten bolts evenly by hand.
    • Finish tightening in an X pattern, ¼ turn at a time.
    • Final torque: 4Nm (35 in/lbs)

    Front Wheel Installation (Wabi Wheels)

    • Install the wheel using the supplied bolts.
    • Tighten to 10Nm (88 in/lbs).

    Your brakes have a quick-release (QR) lever:

    • Up position: open (for installing/removing the wheel)
    • Down position: closed (required for riding)

    Make sure the QR is closed before riding, or braking performance will be affected.

    Front Wheel (Non-Wabi Wheels)

    • Install using axle nuts and a 15mm wrench.
    • Tighten to approximately 20Nm.

    Here's a short video for guidance:


    Seatpost & Saddle Installation

    ⚠️ Important: On Classic, Special, and Thunder frames with an integrated seat collar, the left side is a fixed nut. Do not turn it—tighten only from the right side.

    • Insert the seatpost past the minimum insertion line.
      • For Classics and Thunders, add about ¼ inch more.
    • Not inserting far enough can damage the frame.
    • Riders over 225 lbs near the limit should consider a longer seatpost.

    Before installing:

    • Apply grease inside the seat tube.

    Then:

    • Tighten the seat binder bolt to 5Nm (44 in/lbs).

    Saddle adjustment:

    • The saddle comes pre-positioned.
    • If needed, adjust forward/back or angle.
    • Tighten the saddle bolt to 22Nm, checking the position before final tightening.

    Here's a short video for guidance:

     

    Installing Pedals

    Installing Pedals

    ⚠️ Important: Pedals are side-specific and thread differently to prevent loosening while riding. 

    • Right (drive side): tightens clockwise
    • Left (non-drive side): tightens counterclockwise

    Pedals are usually labeled L/R. If not, you can identify them by grooves/knurling on the spindle or the thread direction.

    The left pedal will have a groove or knurling on the spindle, and the threads will go up to the left. 

    The right pedal will have threads that go up to the right.

    Before installing:

    • Apply grease to the pedal threads.

    Then:

    • Thread carefully by hand first to avoid cross-threading.
    • Tighten firmly (~35–40Nm).

    Pedals should feel very snug—this prevents them from loosening or damaging the crank.

    Here's a short video for guidance:

     

    Inflating Tires

    • Tires are deflated for shipping, so inspect before inflating.
    • Check that the tube is not pinched between the tire and rim.

    Begin inflating with your pump.

    At around 40–50 PSI:

    • Pause and inspect the tire.
    • Make sure there are no bulges or visible tube.

    If you see an issue:

    • Deflate the tire.
    • Reposition the tube.
    • Start again.

    Finish inflating to your preferred pressure, but do not exceed the max PSI listed on the tire sidewall.

     

    Additional Assembly (58cm & 60cm Models)

    Fork Installation (Classic & Lightning)

    Fork installation is more involved but still manageable with care.

    • Insert the fork into the headtube.
    • Reinstall headset components in order.
    • Add spacers and install the stem.
    • Install and lightly tighten the top cap.
    • Install the front wheel.
    • Align the stem and preload the headset.
    • Install and align the front brake.

    The headset should feel snug with no play, but not overly tight.

    Here's a short video for guidance:

    Thunder: Fork + Cantilever Brake

    For Thunders with cantilever brakes:

    • Follow the initial fork steps above.
    • Install cable hanger and spacers.
    • Attach the brake cable and arms.
    • Align and test brake function.

    Make sure brakes move freely and engage evenly.

    Here's a short video for guidance:

    Rear Wheel Retensioning (Thunder 58cm and 60cm)

    For some larger frames, the wheel has to be pushed forward in the dropouts so the chain is not tensioned. 

    To reset:

    • Loosen axle nuts/bolts slightly.
    • Pull the wheel straight back.
    • Aim for about ½" of chain slack at the tightest point.
    • Rotate the cranks to check consistency.
    • Center the wheel evenly between the chainstays.
    • Tighten bolts while holding alignment.

    After tightening:

    • Re-check tension
    • Spin the wheel to ensure smooth movement

    Here's a short video for guidance:

     

    Torque (By Feel)

    If you’re not using a torque wrench:

    • Torque depends on force and wrench length
    • A longer wrench requires less force

    Example:

    • 53 in/lbs =
      • 53 lbs at 1 inch
      • ~26 lbs at 2 inches
      • ~13 lbs at 4 inches

    A simple way to think about it:
    Tightening a bolt is like lifting a weight at the end of the wrench.

    Use steady, controlled pressure—avoid sudden force.

     

    Before Your First Ride

    Take a moment to double-check everything:

    • Wheels are securely fastened
    • Brakes are working properly
    • Pedals are tight
    • Chain tension is correct
    • Tires are properly inflated
    • Handlebars and stem are aligned

    Safety Notes

    • After a few rides, re-check crank bolts (40Nm)
    • Always wear a helmet
    • Keep brakes installed
    • Periodically check wheel tightness


    Maintenance

    Regular care will keep your bike running smoothly:

    • Store indoors to prevent rust
    • Clean and dry after wet rides
    • Lubricate the chain regularly
    • Re-grease the seatpost periodically
    • Check inside the seat tube for rust and treat if needed

    Need Help?

    We’re always happy to help:
    📧 support@wabicycles.com
    📞 844-746-0777