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How to Build a Bike from a Box - Bike Assembly Guide

Congratulations on your new bike! We want your riding experience to be perfect on the first ride, so we always recommend bringing your bike to an evo store location to be built by a qualified mechanic. If you are unable to have a professional build your bike, or you just prefer the experience of building your own, this step-by-step guide will help you assemble your bike out of the box.  

We ship our bikes as fully built as possible to minimize the delay between you and the trails. That means we will just cover how to build a bike out of the box, not a ground-up build from a raw frame. 



Before you get going, you'll need to gather a few common bike tools. Make sure you have the following tools close to hand:
  • Metric Allen Wrenches 
  • Torx Wrench 
  • Torque Wrench 
  • Shock Pump 
  • Floor Pump  
  • Bike Grease 
  • Isopropyl Alcohol 
  • Carbon Paste (for carbon handlebars) 
  • Pedal Wrench (optional) 
  • Bike Stand (optional) 

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1. Remove Bike & Loose Items

Open the box and pull any loose items out, including the front wheel. There should be a small parts box or bag, too.

Carefully pull the bike out of the box, but avoid lifting it by the saddle. This could damage your dropper post, if you have one. Cut the zip ties and remove any protective packaging. Be careful not to cut the frame or components as you do so.

Double check the packaging for small parts, and don't throw anything away. Set any packaging to one side and hang onto it until the bike is fully assembled.

Please note that our bikes now come wrapped in sustainable cardboard packaging, not the foam in the picture and video.

2. Attach Handlebars

Carefully detangle any cables and remove the stem faceplate. If you have carbon handlebars, apply a small amount of carbon paste to the inside surface of the stem where it contacts the handlebar.

Position the handlebar in the center of the stem and adjust to your preferred angle - there should be some markings to guide you. Carefully reinstall the stem faceplate.

Starting with the top bolts, thread the bolts in by hand and then tighten with a torque wrench, taking care not to exceed the torque spec written on the stem. Many stems have a specific clamp orientation, so double check this before tightening.

3. Install Front Wheel & Check Brakes

Take the wheel out of the box, and remove the plastic hub protectors. Check these for hub end caps.

Installing a Thru Axle

Your front wheel will have one of two attachment styles - either a thru axle or a quick release system. If you have a thru axle system, the axle should already be attached to the fork. Unthread and remove this first.

Remove the brake pad spacer and install the front wheel, making sure to carefully slide the brake rotor into the caliper on the left hand side. Once you’re happy with the position, slide the axle through the hub and tighten.

Installing a Quick Release Axle

If your front wheel has a quick release axle, tighten the nut until you’re able to feel some resistance when you close the lever. If you’re unable to close the lever fully, back the nut out by a quarter turn and try again.

If the wheel slides from side to side, check to see if the hub end caps are properly installed. They may still be attached to the wheel packaging.

Check Brakes

Check the brakes by squeezing the brake levers. They should not feel spongy or pull to the handlebar. Adjust the brake levers to your preferred position by using the appropriate wrench. Check the rotors for residue and wipe clean with isopropyl alcohol if necessary.

4. Install Pedals & Check Shifting

Install Pedals

Pedals come with a dedicated left and right. Check which is which, and then apply a little grease to the threads. Using your pedal wrench or allen wrench, tighten the right pedal clockwise. Then, attach the left pedal and tighten counterclockwise. Take care not to overtighten - use a torque wrench if you have one.

Check Shifting

Starting in the highest gear, pedal forward while shifting. You should be able to move smoothly across the cassette, shifting one gear with each click.

5. Inflate Tires & Adjust Suspension

Inflate Tires

Your bike may or may not come with tubeless tires. Consult the mechanic’s notes in the box for your bike’s specific setup. Preferred tire inflation differs from one rider to the next. Be careful not exceed the maximum recommended pressure indicated on the tire sidewall.

Adjust Suspension

To get your suspension set up, check the manufacturer's recommended sag and pressure settings. Use a shock pump to adjust your fork and shock accordingly.

Consult evo's Suspension and Sag Setup Guide for more details.

6. Adjust Seatpost

Adjust the seatpost to your preferred height using the bolts at the seat tube collar. The proper torque will be indicated on the seat collar.

7. Enjoy Your Ride!

If more adjustments are needed, please call one of our stores to speak with a service mechanic. We’re happy to help. If test riding a bike, please use pavement (driveway/neighborhood) instead of local trails, which may cause damage to the bike. We cannot accept a return after a bike has been ridden on dirt trails. 

How to Adjust the Fit on Your New Bike

  • Brake levers and saddle ship in neutral positions (45° for levers, 0° for saddle). These can be adjusted for personal preference if desired.
  • When sitting on bike with the dropper post in the fully extended position, you should be able to make full leg extension at the bottom of your pedal stroke but not need to dip your hips side-to-side to reach full extension.
  • If you feel like your knees are too high into your chest, or vice versa, try raising or lowering the seatpost at the seatpost clamp.
  • If you feel that you have too much pressure on your palms, try raising the stem a spacer or two.
  • Always set the sag on your mountain bike suspension.

Learn More With Our Other Bike Guides:

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This is evo. We are a ski, snowboard, wake, skate, bike, surf, camp, and clothing online retailer with physical stores in SeattlePortlandDenver, Salt Lake City, Whistler, and Snoqualmie Pass. Our goal is to provide you with great information to make both your purchase and upkeep easy.

evo also likes to travel to remote places across the globe in search of world-class powder turns, epic waves, or legendary mountain biking locations through evoTrip Adventure Travel Trips. Or, if you prefer to travel on your own, check out our ski & snowboard resort travel guides and mountain bike trail guides.


Still have questions? Please call our customer care team at 1.866.386.1590 during Customer Care Hours. They can help you find the right setup to fit your needs.

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