FLO Cycling - How to Build a Road Bike, The Complete Guide

8/9/2019 FLO Cycling - How to Build a Road Bike, The Complete Guide

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FLO Cycling eBook Series

How to Build a Road Bike, The Complete Guide

FLO Cycling LLC

1st Edition


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....................................................................................................................Foreword 1............................................................................................................................Disclaimer 1

........................................................................Step 1 Bottom Bracket (GXP Type) 2........................................................................................................................................What you Need 2

............................................................................................................................Before you Get Started 2

...............................................................................................................................................Installation 3

..................................................................................................Step 2 Crankset & Pedals 5........................................................................................................................................What you Need 5

............................................................................................................................Before you Get Started 5

...............................................................................................................................................Installation 6

........................................................................................Step 3 Fork, Stem & Handlebar 8

........................................................................................................................................What you Need

8............................................................................................................................Before you Get Started 8

...............................................................................................................................................Installation 9

......................................................................................Step 4 Hanging the Derailleurs 12......................................................................................................................................What you Need 12

..........................................................................................................................Before you Get Started 12

.............................................................................................................................................Installation 13

..................................................................................................................Step 5 Saddle 15

......................................................................................................................................What you Need 15..........................................................................................................................Before you Get Started 15

.............................................................................................................................................Installation 16

.................................................................................................................Step 6 Shifters 17......................................................................................................................................What you Need 17


.............................................................................................................................................Installation 18

...............................................................................................Step 7 Cassette & Wheels 19

......................................................................................................................................What you Need 19..........................................................................................................................Before you Get Started 19

.............................................................................................................................................Installation 20

........................................................................................Step 8 Mounting Your Brakes 22......................................................................................................................................What you Need 22



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.............................................................................................................................................Installation 23

.............................................................................Step 9 Aligning your Rear Derailleur 24......................................................................................................................................What you Need 24


.............................................................................................................................................Installation 25

........................................................................Step 10 Cutting & Installing your Chain 26......................................................................................................................................What you Need 26


.............................................................................................................................................Installation 27

..............................................................................Step 11 Installing Cables & Housing 29......................................................................................................................................What you Need 29


.............................................................................................................................................Installation 30

..........................................................................Step 12 Connecting your Brake Cables 33......................................................................................................................................What you Need 33


.............................................................................................................................................Installation 34

..............................................................Step 13 Connecting the Rear Derailleur Cable 35......................................................................................................................................What you Need 35


.............................................................................................................................................Installation 36

.............................................................Step 14 Connecting the Front Derailleur Cable 37......................................................................................................................................What you Need 37


.............................................................................................................................................Installation 38

....................................................................................Step 15 Installing your Bar Tape 40......................................................................................................................................What you Need 40

..........................................................................................................................Before you Get Started

40.............................................................................................................................................Installation 41

................................................................................................................Conclusion 43


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FOREWORD

Thanks for downloading our eBook on how to build a road bike. We hope you enjoy it, and ndit useful in your quest to build a bike. The following book will walk you through the build processstep-by-step. There may be subtle differences between your bike and the bike we used to create

the eBook, but you should have no problems if you follow the guide. If you have any troublethroughout the process please feel free to contact us at [email protected] and we will do ourbest to provide you with answer.

SPECIAL T HANK YOU

We wanted to send out a special thank you to Park Tool for giving us permission to use thepictures of their products. All tool pictures included below are curtesy of Park Tool. For moreinformation about Park Tool and to learn where you can purchase their products, please visithttp://www.parktool.com .

Additionally, we would like to say thank you to Mike Sullivan for teaching us everything we knowabout building bikes.

D ISCLAIMER

This eBook is put together as a reference only. Any bike built using this guide should be checkedby a bike building professional before the bike is ridden. Please verify all installation instructionswith the manufacturer of your components before installation. Your use of this eBook is at yourown risk. All information in this eBook is subject to change at any time without notice. TheeBook and its contents are provided on an as-is and as-available basis. To the fullest extentpermissible by law, with r egard to the content of this eBook, Flo Cycling makes no warranties orrepresentations of any kind whatsoever for the non-infringement, accuracy, merchantability,tness for a particular purpose of any content published in this eBook. With your use of thiseBook you assume total responsibility. Stopping your use of this eBook will be your sole remedyfor dissatisfaction with the content of the eBook. This limitation is part of the bargain betweenthe parties.

WWW .FLOCYCLING .COMP AGE 1
http://www.parktool.com/http://www.flocycling.com/http://www.flocycling.com/http://www.parktool.com/http://www.parktool.com/mailto:[email protected]:[email protected]


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STEP 1 BOTTOM BRACKET (GXP

T YPE )

WHAT YOU NEED

T OOLS :

Park Bottom Bracket Tool (Park BBT-19)

Torque Wrench (TW-2 or TW-6)

Park Polylube 1000 Lubricant (PPL-1)

Tools

P ARTS :

GXP Bottom Bracket

Parts

BEFORE YOU GET STARTED

Make sure your bottom bracket shell isproperly threaded, and clean.

If your bottom bracket shell is not properlythreaded it is recommended that you take itto a bike shop to have it properly chased.

There is an accompanying video availablehere .

S TEP 1 - BOTTOM BRACKET

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=MvawohTQjlchttp://www.youtube.com/watch?v=MvawohTQjlc


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INSTALLATION

1. Apply a thin layer of lubrication to thebottom bracket threads of the bicycleframe (see Figure 1).

Figure 1

2. Apply a thin layer of lubrication to thethreads of the bottom bracket bearingthreads (see Figure 2 & 3).

Figure 2

Figure 3

3. Insert the drive side of the bottom bracketinto the frame and get it nger tight (seeFigure 4). If you are using an Englishthread bottom bracket (BSA), and youlikely are since most production bikes soldin the USA have English thread bottombrackets, remember that the drive side ofthe bottom bracket has a reverse thread(counterclockwise to tighten). If bychance you are using an Italian threadbottom bracket, the drive side of thebottom bracket will have a standardthread.

Figure 4

4. Once the drive side of the bottom bracketis nger tight, tighten the bottom bracketto the proper torque using your bottombracket tool and torque wrench (seeFigure 5).

Figure 5

S TEP 1 - BOTTOM BRACKET

http://www.flocycling.com/http://www.flocycling.com/


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STEP 2 C RANKSET & P EDALS

WHAT YOU NEED

T OOLS :


Socket and Bit Set (SBS-1)

Hex Set or Pedal Wrench (HXS-1.2 orPW-5)


Tools

P ARTS :

Crankset (GXP Compatible)

Pedals

Parts


Make sure you have a properly installed

bottom bracket (see Section 1 of this book ifnot).


S TEP 2 - C RANKSET & P EDALS

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=tbFg6BKEU38http://www.youtube.com/watch?v=tbFg6BKEU38


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INSTALLATION

1. Apply a thin layer of lubrication to theinner bearing races, spline assembly, splineassembly threads, and the crank bolt

assembly (see Figure 1). Please watch the video for a more detailed view.

Figure 1

2. Insert the drive side of the crank throughthe drive side of the bottom bracket (seeFigure 2).

Figure 2

3. Connect the non-drive side crank arm tothe spline assembly and join the two with

an 8mm hex until nger tight (see Figure3).

Figure 3

4. Torque the 8mm hex to the manufacturersrecommended value using a torquewrench (see Figure 4).

Figure 4

5. Make sure there is no lateral play after thecrankset is assembled. If there is, back offthe 8mm hex and re-torque the crankset.It may take several attempts to ensurethere is no lateral play in the crankset. Ifthere is no lateral play, you have properlyinstalled your crankset (see Figure 5).




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Figure 5

6. Apply a thin layer of lubrication to yourpedal threads (see Figure 6).

Figure 6

7. Install pedal washers on your pedals ifnecessary (see Figure 7).

Figure 7

8. Insert the pedals into the crank arms andtighten using an 8mm hex or pedalwrench (see Figure 8). Remember that the

right pedal has a standard thread(clockwise to tighten) and the left pedalhas a reverse thread (counterclockwise totighten).

Figure 8

9. Torque your pedals to the manufacturersrecommendation.

10. You now have properly installed pedals(see Figure 9).

Figure 9




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STEP 3 FORK , STEM & H ANDLEBAR

WHAT YOU NEED

T OOLS :



Hex Set (HXS-1.2)

Tools

P ARTS :

Fork (Compatible with frame)

Headset

Stem Handlebar

Parts


Make sure you have a crown race properly

press t on your fork. If not, you can installone using a crown race setting tool or havea bike shop install one for you.


S TEP 3 - FORK , S TEM & H ANDLEBAR

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=pa3j8XWYOTAhttp://www.youtube.com/watch?v=pa3j8XWYOTA


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INSTALLATION

1. Place the lower headset bearing on thefork (beveled edge up) (see Figure 1).

Figure 1

2. Insert the steer tube into the head tube ofthe frame (see Figure 2). Be sure thelower headset bearing seats properly.

Figure 2

3. Place the upper headset bearing on thesteer tube (beveled edge down) and besure it seats properly (see Figure 3).

Figure 3

4. Place the upper bearing race on the steertube (see Figure 4).

Figure 4

5. Place the spacer(s) on the steer tube (ifrequired, this is headset dependent)

6. Place the upper bearing cover on the steertube (see Figure 5).

Figure 5




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7. Install headset spacers on the steer tube ifrequired to raise the height of thehandlebars (see Figure 6). This ultimatelydepends on the type of t you would like.You may want to consult with aprofessional bike tter.

Figure 6

8. Place the stem on your steer tube (seeFigure 7). Leave the stem clamp loose fornow.

Figure 7

9. Place additional headset spacers on thesteer tube if required (see Figure 8). It is

often a good idea to place additionalheadset spacers on the steer tube to allow

you to adjust your t later on. Addingheadset spacers now, will allow you toraise your handlebars in the future ifneeded. Not much is needed, " 1should be sufcient. Note: Make sure

the top edge of your headset spacersor stem are slightly higher than thelength of your steer tube. This isrequired to properly tighten theheadset.

Figure 8

10. Place the headset cap on your steer tubeand tighten the headset cap bolt into thestar nut using a hex tool (see Figure 9).

Figure 9

11. Before setting the nal torque on yourheadset cap bolt, make sure your stem isaligned straight with respect to the frame.

Once everything is properly alignedtorque your headset cap bolt to themanufacturers recommended torque

value.

12. Tighten the steer tube clamp bolt(s) on your stem to secure it to the steer tube. Be




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sure to follow your stem manufacturersrecommended torque value.

13. Remove the faceplate of your stem inpreparation for installing the handlebar

(see Figure 10).

Figure 10

14. Place your handlebar into the handlebarclamp and put the stem faceplate backinto place (see Figure 11). Note: If youare using a carbon s tem orhandlebar, it may be benecial touse carbon ber glue. Carbonber stems and handlebars oftenhave torque ratings to low to preventthe handlebar from being heldsecurely in place. Carbon ber gluehelps create a better bond andprevents handlebars from shiftingout of place.

Figure 11

15. Tighten your stem faceplate bolts using ahex key (nger tight only) (see Figure 12).

Figure 12

16. Torque the faceplate bolts to the

manufacturers recommended torque value using a torque wrench.

17. You now have a properly installed fork,headset, stem and handlebar (see Figure13).

Figure 13




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S T E P 4 H A N G I N G T H E

DERAILLEURS

WHAT YOU NEED

T OOLS :



Hex Set (HXS-1.2)


Tools

P ARTS :

Front Derailleur Clamp on Front Derailleur Mounting

Bracket (if required)

Rear Derailleur

Parts


Make sure your derailleurs are compatiblewith the number of gears on your cranksetand cassette.


S TEP 4 - H ANGING THE D ERAILLEURS

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=y7WdO2sCXsghttp://www.youtube.com/watch?v=y7WdO2sCXsg


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INSTALLATION

1. Connect the front derailleur to the frontderailleur-mounting bracket (braze on orclamp on) using the front derailleur-

mounting bolt. Ensure the front derailleurcage is in line with the chain rings andthat there is a 1-3mm gap between the topof the chain ring and the bottom of thefront derailleur (see Figure 1). See the

video for additional information.

Figure 1

2. Connect the front derailleur bolt using a5mm hex. Get it nger tight (see Figure2).

Figure 2

3. Torque the front derailleur bolt to themanufacturers recommended value usinga torque wrench (see Figure 3).

Figure 3

4. Apply a thin layer of lubrication to therear derailleur threads (see Figure 4).

Figure 4

5. Connect the rear derailleur to the rearderailleur hanger using a 5mm hex (seeFigure 5). Be sure to keep the B-Adjustwasher tab above ledge on your rearderailleur hanger. Please watch the reardera i l l eu r v ideo fo r add i t iona linformation.

S TEP 4 - H ANGING THE D ERAILLEURS



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STEP 5 SADDLE

WHAT YOU NEED

T OOLS :



Hex Set (HXS-1.2)

Tools

P ARTS :

Saddle

Parts


Selecting the correct saddle can be a

frustrating process. Be sure to get an expertopinion from your local bike shop beforepurchasing a saddle.


S TEP 5 - S ADDLE

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=Y2sG1i_YMskhttp://www.youtube.com/watch?v=Y2sG1i_YMsk


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INSTALLATION

1. Installing your saddle will more than likelybe slightly different for everyone followingthis e-book. This is because saddle clamps

vary depending on what type of seat post you use. Following the steps below andwatching the accompanying video shouldensure that you properly install yoursaddle.

2. Loosen your saddle clamp on your seatpost and insert the saddle rails (see Figure1).

Figure 1

3. Once your saddle is in the properposition, tighten the saddle clamp aroundthe saddle rails using your hex tool (seeFigure 2).

Figure 2

4. Torque settings will typically depend onwhat type of rails your saddle has. Be

sure to check your saddle manufacturersrecommendation (specically for saddleswith carbon ber rails) and nishtightening with a torque wrench.

5. You now have a properly installed saddle(see Figure 3).

Figure 3

S TEP 5 - S ADDLE



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STEP 6 SHIFTERS

WHAT YOU NEED

T OOLS :



Hex Set (HXS-1.2)

Tools

P ARTS :

Shifters

Parts


Be sure to completely unload both of yourshifters. An unloaded shifter would put thechain in the small ring of the crankset andthe smallest gear of your cassette. This willbe necessary later on when you install theshift cables.


S TEP 6 - S HIFTERS

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=KZIduE3-J7ohttp://www.youtube.com/watch?v=KZIduE3-J7o


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INSTALLATION

1. Roll back the hoods of your shifters toexpose the handlebar clamp and bolt (seeFigure 1).

Figure 1

2. Loosen your handlebar clamp bolt andslide the left hand shifter into place. Besure to watch the video for positioningtips. Once the shifter is in place tightenthe handlebar clamp bolt using a hex toolto secure the shifter to the handlebar(nger tight only) (see Figure 2).

Figure 2

3. Torque the handlebar clamp bolt to themanufacturers recommended value usinga torque wrench (see Figure 3).

Figure 3

4. Repeat this process to install the righthand shifter.

5. You now have properly installed shifters(see Figure 4). Note: Keep your hoodsrolled back for now. Youll need toinstall cabling and bar tape rst.

Figure 4

S TEP 6 - S HIFTERS



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STEP 7 C ASSETTE & WHEELS

WHAT YOU NEED

T OOLS :



Cassette Lockring Tool (FR-5)

Alternate* Adjustable Wrench (PAW-12)

Tools

P ARTS :

Cassette

Wheels Quick Release Skewers

Parts


Be sure your cassette is compatible with

your rear derailleur. For example, makesure if you have a 10 speed derailleur that

you are using a 10 speed cassette.

Install your tires before installing yourwheels. You can learn how to install yourtires here .


S TEP 7 - C ASSETTE & W HEELS

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=IEFWcvDGqdchttp://www.youtube.com/watch?v=IEFWcvDGqdchttp://www.youtube.com/watch?v=w5cm8T1KusUhttp://www.youtube.com/watch?v=w5cm8T1KusU


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INSTALLATION

1. Your cassette will have a specic keyedpattern that will mate with the hub bodyon your wheel. Be sure to line the keyed

tting of the hub body up with yourcassette. For a Shimano/SRAM stylecassette, I typically look for the thinnestraised ridge and use that as a referencepoint when installing the cassette.

2. Start by placing the largest gear(s) on rst(see Figure 1). Often times the threelargest gears are connected together.

Figure 1

3. Continue placing the gears and spacers onthe hub body in the proper order (seeFigure 2). If you do not know the properorder of gears and spacers, please refer tothe manufacturers manual for yourcassette.

Figure 2

4. Once you have placed all of the gears onthe hub body, screw the cassette lock ringinto place using a cassette lock ring tooland wrench (see Figure 3). Be sure totorque the cassette lock ring to themanufacturers recommended torque

value.

Figure 3

5. Insert the rear wheel into the reardropouts of the bicycle (see Figure 4).Note: Make sure you tires are installedrst. If you need help installing your tires,please follow our other tutorial here(clincher only).

Figure 4

6. Tighten the quick release (see Figure 5).Make sure the quick release lever is on thenon-drive side of the bicycle.




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Figure 5

7. You can repeat the same process for thefront wheel with the exception ofinstalling a cassette.

8. You now have a properly installed cassetteand wheelset.




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STEP 8 M OUNTING YOUR BRAKES

WHAT YOU NEED

T OOLS :



Hex Set (HXS-1.2)

Tools

P ARTS :

Front and Rear Brakes

Parts


If you are using wheels with carbon brake

tracks it is highly recommended that youuse carbon compatible brake pads. Checkwith the manufacturer of your wheels fortheir recommendation.


S TEP 8 - M OUNTING YOUR BRAKES

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=KSvYyUo0pc8http://www.youtube.com/watch?v=KSvYyUo0pc8


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INSTALLATION

1. Place any spacers on the brake bolt beforeplacing the brake on the frameset (seeFigure 1).

Figure 1

2. Insert the brake bolt into the brakebolthole in the bicycle frame, and connectthe brake bolt nut using a hex tool (ngertight only) (see Figure 2).

Figure 2

3. Center the brake pads on both sides ofthe brake track on the wheel and tightenthe break bolt nut to the manufacturersrecommended value using a torquewrench.

4. You can repeat this process on the frontbrake.

5. You now have properly mounted brakes.

S TEP 8 - M OUNTING YOUR BRAKES



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INSTALLATION

1. Align the center of your upper guidepulley teeth with the outside edge of theteeth of your smallest gear on your

cassette using the Hi limit adjustmentscrew (see Figure 1). Be sure to watch the video for additional information.

Figure 1

2. Push the rear derailleur towards the frameand align the center of your upper guidepulley teeth with the center of the teeth ofthe largest gear on your cassette using theLo limit adjustment screw (see Figure 2).Be sure to watch the video for additionalinformation.

Figure 2

3. Set the chain gap using the B-Adjustscrew. You will want approximately 6mmbetween the bottom of the gears of yourcassette and the top of the upper guide

pulley teeth throughout the entire arc ofthe rear derailleur (see Figure 3). Be sureto watch the video for additionalinformation.

Figure 3

4. You have now successfully aligned yourrear derailleur.

S TEP 9 - A LIGNING YOUR BRAKES



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STEP 10 C UTTING & INSTALLING

YOUR C HAIN

WHAT YOU NEED

T OOLS :

Chain Tool (CT-3 or CT-4.2)

Tools

P ARTS :

Chain

Chain Connector Link (Optional)

Parts


Make sure your chain is compatible with your cassette and derailleurs.


S TEP 10 - C UTTING & INSTALLING YOUR C HAIN

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=JY1XxU_y2u0http://www.youtube.com/watch?v=JY1XxU_y2u0


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INSTALLATION

1. To measure the proper length of yourchain, wrap it around the big chain ring of

your crankset and the largest gear of your

cassette while bypassing the rearderailleur.

2. Bring the chain together and add 2additional links to nd the proper chainlength. If you are using a chain connectorlink be sure to add only 1 additional link(see Figure 1). Note: Make sure whenthe chain is cut that both ends areinner links. This will be required forconnecting the chain using the chain

connector link.

Figure 1

3. Cut the chain using a chain-cutting tool(see Figure 2).

Figure 2

4. Feed the chain through the rear derailleur.Watching the accompanying video willprovide a better visual demonstration ofhow to feed your chain through the rearderailleur.

5. Begin by passing the chain over the top ofthe cassette (see Figure 3).

Figure 3

6. Pass the chain over and around the upperguide pulley being sure you pass throughany chain guides (see Figure 4).

Figure 4

7. Pass the chain over and around the lowerguide pulley being sure to pass throughany chain guides (see Figure 5).




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Figure 5

8. Bring the two ends of the chain togetherand connect the chain via the chainconnector link (see Figure 6).

Figure 6

9. You now have a properly installed chain.




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STEP 11 INSTALLING C ABLES &

H OUSING

WHAT YOU NEED

T OOLS :

Cutters (SP-7)

Tools

P ARTS :

Brake and Shift Cables

Brake and Shift Cable Housing

End Caps (Ferrules for Brake and Shift

Cable Housing)

Parts


Cable housing comes in two different sizes.Be sure you have both shift cable housingAND brake cable housing.


S TEP 11 - I NSTALLING C ABLES & H OUSING

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=j5aJLIWXnSMhttp://www.youtube.com/watch?v=j5aJLIWXnSM


33/46

INSTALLATION

1. Actuate the brake lever and insert thebrake cable into the hole at the top of thebrake lever (see Figure 1). Note: Inside

the brake cable hole at the top of thebrake lever is a cable stopcylinder. The cable stop cylinderhas a countersunk side and anon-countersunk side. Make surethat the head of the brake cableseats in the counter sunk side of thecable stop cylinder.

Figure 1

2. As you continue to feed the brake cableinto the brake cable hole, it will eventuallypop out of the back end of the shifter.Continue feeding the brake cable all ofthe way through the shifter until the headproperly seats in the cable stop cylinder(see Figure 2).

Figure 2

3. Before inserting the shift cable, be sure tocompletely unload your shift lever.Unloading your shift levers is theequivalent of having your chain in thesmallest gear of your cassette or thesmallest chain ring.

4. Insert the shift cable into the shift cablehole. The shift cable will pop out of theother side of the shifter (see Figure 3).Continue feeding the cable all of the waythrough the shifter until the head of thecable properly seats inside of the shifter(see Figure 4).

Figure 3

Figure 4

5. Cut lengths of brake and shifter cablehousing to run from your shifter to yourbrake and shifter housing stops on yourframe. For the front brake, you will onlyneed enough housing to reach the frontbrake. Note: This may be slightly




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different if you have internal cablerouting. Often times you will pusha complete length of housingthrough the frame instead of endingat cable stops. Make sure you leaveenough length so that your handlebarturns freely without any restriction fromthe cable housing. Please watch theaccompanying video for more informationand a better visual demonstration.

6. After the cable housing is cut to theproper length, install end caps (ferrules) tothe ends of your housing.

7. Feed the brake and shift cables into their

respective housing and insert the ends ofthe cable housing into the guides of yourshifters (see Figure 5 & Figure 6).

Figure 5

Figure 6

8. Feed your cables and housing into theirrespective cable stops (or internal routingholes)

9. At this point the housing for your front

brake and derailleur should be complete.Your rear brake and derailleur cablingshould need once more piece of housingeach.

10. Starting with your rear brake, continuerunning the bare cable to the second cablestop. Now you will need to cut a smallpiece of cable housing to run from thesecond cable stop to the rear brake. Besure to cover both ends of the cable

housing with end caps (ferrules). Run thecable through the last piece of cablehousing (see Figure 7). This will completethe cable and housing run for your rearbrake. Well connect the brake cable in alater step.

Figure 7

11. Both the front and rear derailleur cablingshould run to the bottom of the bottom

bracket. There will be a guide for eachderailleur cable underneath the bottombracket. Feed each derailleur cablethrough its respective guide. We haventincluded a picture for this because eachbike is different. Just keep in mind thatthe front derailleur cable will typically




35/46

feed through the frame and pop out nearthe front derailleur, and the rear derailleurwill be guided towards the rear of thebicycle.

12. At this point you have completely run thecabling for your front derailleur. We willconnect the derailleur cable in a later step.

13. After you have run your rear derailleurcable through its guide underneath thebottom bracket, continue running thebare cable along the drive side chain stayuntil you reach a cable stop.

14. Cut a piece of cable housing to run fromthe cable stop on your chain stay to thebarrel adjuster on your rear derailleur (seeFigure 8). Note: This piece ofhousing will create a loop as it turnsaround to feed the cable into thebar re l ad j us t e r o f t h e r e a rderailleur. Be sure to not make thisloop too small, as it will restrict themotion of the cable inside. Youwont want to make it too largeeither. Watch the accompanyingvideo to get an idea of the propersize piece of cable housing.

Figure 8

15. Once the cable housing is cut, feed thederailleur cable through the last piece ofhousing to complete your rear derailleur

cable run. We will connect the rearderailleur cable in another step.




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STEP 12 C ONNECTING YOUR BRAKE

C ABLES

WHAT YOU NEED

T OOLS :



Hex Set (HXS-1.2)

Cutters (SP-7)

Pliers (NP-6)

Tools

P ARTS :

Cable Tips/End Caps

Parts


Make sure your brake and shift cables arefree of any cuts or frays before installing.


S TEP 12 - C ONNECTING YOUR BRAKE C ABLES

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=kJJGngeYMVshttp://www.youtube.com/watch?v=kJJGngeYMVs


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INSTALLATION

1. Begin by turning the barrel adjusterclockwise all of the way to the end of itsrange. Then back it off one full turn.

2. To connect the rear derailleur cable, makesure you have completed running yourcable through the last piece of cablehousing and the rear derailleur barreladjuster.

3. Pass the cable over/through the cableguide (if applicable) and under the rearderailleur cable bolt (see Figure 1).

Figure 1

4. Pull the rear derailleur cable tightremoving all slack and tighten thederailleur cable bolt to the manufacturersrecommended torque value.

5. If this is a new rear derailleur cable it willmore than likely stretch after shiftingthrough your gears the rst few times.After shifting through the gears the rstfew times, be sure to back off the rear

derailleur cable bolt and repeat the abovesteps.

6. Once complete, cut the excess cable andattach and end cap (ferrule) (see Figure 2).

Figure 2

7. You now have a properly connected rearderailleur cable.

S TEP 13 - C ONNECTING THE R EAR D ERAILLEUR C ABLE



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STEP 14 C ONNECTING THE FRONT

DERAILLEUR C ABLE

WHAT YOU NEED

T OOLS :



Hex Set (HXS-1.2)

Cutters (SP-7)

Pliers (NP-6)

Tools

P ARTS :

Cable Tips/End Caps

Parts


To prevent the chain from falling off of thecassette, you can install a chain catcher.These are not necessary but can come inhandy.


S TEP 14 - C ONNECTING THE FRONT D ERAILLEUR C ABLE

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=iBu-yY6BWUchttp://www.youtube.com/watch?v=iBu-yY6BWUc


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INSTALLATION

1. Before you connect your front derailleurcable you will want to set the Lo limitadjustment screw. To do this put your

chain in the small ring of your crankset (itshould already be there by default) andshift to the largest gear of your cassette.

2. From the back end of the bike, look downthe chain-line to see the chains positionrelative to the inner left hand side of thederailleur cage.

3. Adjust your LO limit adjustment screw sothere is 1mm of space between the chainand the derailleur cage (see Figure 1).Note: Watching the accompanyingvideo will provide additionalinformation and provide a bettervisual representation.

Figure 1

4. Next we will want to connect the frontderailleur cable. Begin by passing thecable under the front derailleur cable bolt.

5. Pull the cable tight to remove all of theslack in the cable (see Figure 2).

Figure 2

6. Tighten the derailleur cable bolt to themanufacturers recommended torque

value using a torque wrench (see Figure3).

Figure 3

7. Its now time to set the HI limit of yourfront derailleur. Shift your chain into thebig ring of the crankset and the smallestgear of your cassette.

8. From the back end of the bike, look downthe chain-line to see the chains positionrelative to the inner right hand side of thederailleur cage.

9. Adjust your HI limit adjustment screw sothere is 1mm of space between the chainand the derailleur cage (see Figure 4).Note: Watching the accompanyingvideo will provide additional




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information and provide a bettervisual representation.

Figure 4

10. If this is a new front derailleur cable it will

more than likely stretch after shiftingthrough your gears the rst few times.After shifting through the gears the rstfew times, be sure to back off the frontderailleur cable bolt and re-tension thecable.

11. Once complete, cut the excess cable andattach and end cap (ferrule) (see Figure 5).

Figure 5

12. You now have a properly connected rearderailleur cable.




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STEP 15 INSTALLING YOUR BAR

T APE

WHAT YOU NEED

T OOLS :

Scissors

P ARTS :

Handlebar Tape

Handlebar End Plugs

Electrical Tape

Parts


Handlebar Tape comes in a variety oftextures and colors. Be sure to ask yourlocal bike shop about what type ofhandlebar tape would best suit you.


S TEP 15 - I NSTALLING YOUR BAR T APE

http://www.flocycling.com/http://www.flocycling.com/http://www.youtube.com/watch?v=BONWhb7trVIhttp://www.youtube.com/watch?v=BONWhb7trVI


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INSTALLATION

1. Begin by taping your cables into placewith electrical tape (see Figure 1).

Figure 1

2. Cover your shifter clamps with a smallpiece of handlebar tape (usually providedwith your bar tape and already cut tolength) (see Figure 2).

Figure 2

3. Beginning wrapping the bar tape aroundthe end of the handlebar. Make sure topull it tight (see Figure 3).

Figure 3

4. Be sure to get full coverage around theshifters. Note: Watch the video foradditional information.

5. Finish by taping the end of the handlebartape with electrical tape (see Figure 4).

Figure 4

6. Roll your hoods back (see Figure 5).

Figure 5

7. Install your bar end plugs (see Figure 6).




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Figure 6

8. You now have properly instal ledhandlebar tape.




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C ONCLUSION

Thanks for reading our eBook on how to build a road bike. We hope you enjoyed it. Now getout and ride that new bike of yours!

Documents

FLO Cycling - How to Build a Road Bike, The Complete Guide