L.L.Bean Bikes with Threaded Headsets Assembly Instruction Manual
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 4/4/11
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern. pg.1
Final Assembly Instructions – Bikes with Threaded Headsets
Thank you for buying your new bicycle from L.L.Bean. Read these instructions carefully before beginning the final
assembly. Prior to shipping, our expert cycling technicians completely assembled and tuned your bicycle to ensure that
all components are functioning properly. However, for shipping purposes we have to partially disassemble your bicycle.
Although this bicycle has been factory pre-assembled, some loosening may have occurred during shipping and handling.
WARNING: BEFORE ATTEMPTING TO RIDE THIS BICYCLE, read the enclosed Owner’s Manual thoroughly. The
Owner’s Manual includes important information on customizing your bike for an optimal fit.
Tools required for final assembly:
• Cutting-type pliers – for removal of packaging materials, including “zip-ties”
• 5mm & 6mm Allen wrenches – for tightening stem bolt
• 15mm wrench or adjustable wrench – for tightening pedals
• Phillips head screwdriver – for tightening the front reflector
BEFORE GETTING STARTED:
PLEASE REMOVE BICYCLE FROM BOX AND REMOVE PACKAGING MATERIAL. Recommended tool –
diagonal cutting pliers, wire cutter, heavy duty shears, or multi-tool wire cutter.
FYI - Your bicycle may appear different
from those in photos.
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 4/4/11
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern. pg.2
Assembly Instructions
1. FRONT WHEEL AND FORK
To fit your bike into the shipping box, the front fork may have been reversed
and the front wheel has been removed.
Brakes must be in front of the fork as seen here.
If you find the brakes behind the fork, spin the fork 180 degrees. Spin so the brake cable does not wrap around the head
tube. In proper position, the fork ends will face forward and brakes will be in front of the fork.
The brake cable may have been connected for shipping. It will need to be disconnected to install the wheel. To
disconnect, hold the brake arms together and remove the silver insert from the cable stop. To reconnect after wheel is
on, hold the brake arms together and insert the silver insert into the cable stop as show in the photo or as seen on the
rear brake of your bike.
To install the quick-release front wheel:
Remove the quick-release front skewer from the parts box. Check for the tread
direction on the tire sidewall (if the tread is directional there will be an arrow
on the sidewall).
With the tire in the correct direction, insert the wheel between the fork blades
so that the axle seats firmly at the top of the slots, which are at the tips of the
fork blades (the fork dropouts). Remove adjusting nut from skewer and slide
skewer through the fork and axle.
There should be a spring on each end of the skewer. Both should be facing with
the small end into the fork (refer to pictures below). While holding the wheel
firmly to the top of the slots in the fork dropout and at the same time centering
the wheel rim in the fork, tension and secure the quick release lever.
Quickrelease
in correct
closed
position
Head tube
Correct brake
position
Silver insert
Cable stop
Silver insert
connected to
cable stop
Disconnected
brake cable
Properly
connected
brake cable
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 4/4/11
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern. pg.3
Correct quick-release tensioning:
1. Turn the lever to the open position so that the curved part faces away from the bicycle.
2. While holding the lever in one hand, tighten the adjusting nut until it stops.
3. Pivot the lever towards the closed position. When the lever is halfway closed, there must be firm resistance to turn it
beyond that point. If resistance is not firm, open the lever and tighten the adjusting nut in a clockwise direction.
4. Continue to pivot the lever all the way to the closed position so that the curved part faces the bicycle.
Note: If you can fully close the quick release without wrapping your fingers around the fork for leverage, and the lever
does not leave a clear imprint in the palm of your hand, the tension is insufficient. Open the lever, turn the adjustment
nut and try again. Continue until quick release lever closes properly. Reconnect the brake cable as explained above.
Please also refer to the Owner’s Manual for additional information.
2. INSTALL HANDLEBAR AND STEM.
Required tool – 6mm Allen wrench.
If there is a protective plastic cap on the end of the stem, remove and
discard it before inserting into the head tube. Insert handlebar stem
into head tube. You may need to loosen the stem bolt slightly.
Make sure to insert stem past the “minimum insertion line,” and then
adjust to desired height. Before tightening, align stem and handlebar
with the front wheel.
The stem
bolt works
by drawing
this wedged
piece up
until it locks
the stem in
place.
Minimum
insertion
line
Head
tube
Stem bolt
head
Tighten and
loosen the stem
bolt with a
6mm Allen
wrench. Turn
clockwise to
tighten counter
clockwise to
loosen
Stem
Correctly
installed
skewer
Note
direction
of springs
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