Congratulations on receiving your new Spot mountain bike! Getting everything up and running can be done with basic tools and mechanical knowledge. If you are uncomfortable with assembling your bike yourself, we highly recommend having your new Spot put together by a professional.
Tools that may be required include 3, 4, 5, and 6mm Allen wrenches, along with a T25 wrench to fully assemble the bike. We also strongly suggest using a torque wrench during assembly.
Please Note: Certain bikes and builds may have very slightly different assembly procedures. If you have any questions during the assembly process, feel free to reach out to us by email at firstname.lastname@example.org or over the phone at 303-278-3955.
Step 1Open the top of the box and unfold the flaps. Your bike will be attached to one removable panel and the wheels will be attached to a second removable panel.
Begin by removing both panels from the box and setting them on the ground.
Before unclipping the zip ties that attach the wheels, remove the plastic hub protectors on the opposite side of the panel. (PLEASE NOTE: These protectors can easily remove the required hub end cap when they are taken off. Please check to ensure that the black metal end cap stays on the hub, and if accidentally removed, reinstall it by hand by pressing it back onto the hub that it came off of. Bearings should NOT be visible when looking at the side of the hub.)
Unclip the zip ties that secure the wheels to the cardboard panel and remove the wheels.
Unclip the handlebar from the upper flap. You’ll see it attached on it’s own.
On the back of the panel that secures the bike, unclip the zip tie that holds in the accessory bag and shock pump.
Cut the plastic wrap securing the frame to the panel and remove the frame.
Cut the zip ties that attach the brake levers to the side panel. Note, they are labeled ‘R’ and ‘L’ for easy right and left identification.
SRAM disc brake manual here
Shimano XTR 9120 4-piston disc brake manual here
Shimano XTR 9100 2-piston disc brake manual here
With the bike placed in a stand or a safe place to work on it, straighten the stem and torque the two pinch bolts to the torque value stated on the stem. You may have to readjust the direction slightly once the bike is completed. Stem installation instructions here:
Remove the 4 bolts that hold the stem face plate in place.
Install the handlebars and reinstall the face plate clamp using the 4 bolts and torque to 5Nm.
For SRAM brakes, remove the bolt from the brake clamp and wrap the clamp around the bars in order to install the brakes on their respective sides. Unless requested otherwise, the rear brake should be mounted on the right and the front brake on the left. For Shimano brakes, it is easiest to remove the grips using a 3mm Allen wrench so the brakes can be slid onto the bar.
Once the brake levers are mounted on the bars, install the dropper post lever. You’ll see that the bolt to secure the dropper lever to the pre-installed bar mount is bolted into the lever. Remove the bolt and reinstall the lever on the left handlebar clamp.
Remove the chain from the small accessories bag that was detached from the packaging earlier. Wrap the chain around the chainring and route it through the rear derailleur by going in front of the upper pulley wheel and then behind the lower pulley wheel.
Connect the chain using the quick link provided. For SRAM chains, ensure that the “bulge” on the link faces outwards. For Shimano chains, ensure the arrow on the link is pointing in the direction of pedaling force. Once it is connected and partially seated, hold the rear brake and apply pressure to the crank to seat it fully into place.
Step 17Next, remove the brake pad spacers from the front and rear brakes. Once they are removed, install the front and rear wheels. Torque the rear axle to the value stated on the axle itself. For non-bolt on front axles, tighten the axle until the lever properly snugs up when closed. The axle lever will be clocked to point straight up, parallel to the fork leg when snug. For bolt on front axles, torque to the printed spec.
Non-bolt on front axle:
Now that the wheels are installed, put the bike on the ground and check that the stem is aligned properly and that the brake levers are at the desired position. Adjust and re-torque as necessary.
Step 19Once pedals (not included) are installed, use the dropper post lever on the handlebar to bring the saddle to its highest position. Once the dropper post is raised, adjust the saddle height by loosening the seat post clamp and moving it to your preferred height. In other words, you want the dropper post to be fully extended when determining your preferred pedaling saddle height.
Refer to the appropriate suspension setup guide for your mountain bike under our Support Product Documentation page:
Use the included shock pump to add or release air and get the suspension to a proper starting point given your riding weight with all applicable gear.