Grizzly 72v PPB - Assembly VideoUpdated a minute ago

This assembly guide and video walk you through unboxing, assembling, and performing initial component torque checks on your new Grizzly 72V PPB electric motorized bike.

CRITICAL WARNING: Always power cycle—Dissipate Controller Energy (DCE)—your electric motorized bike before connecting or disconnecting any electrical components during assembly. On dual-battery models like the Grizzly 72V, both batteries must be removed to perform a proper DCE. Step-by-step guidance is available in our Power Cycle (DCE) Guide.

Assembly Video Guide

Required Tools & Materials

• 2.5 mm hex wrench
• 3 mm hex wrench
• 4 mm hex wrench
• 5 mm hex wrench
• Adjustable torque wrench (with 5 mm hex driver bit)
• 15 mm open-end pedal wrench
• Rubber mallet or soft-faced hammer
• Bicycle maintenance grease

Step-by-Step Assembly Instructions

1. Unbox the Bike:
   • Remove the outer shipping box and all protective packaging foam from the frame.
   • Remove all parts and accessories from the box labeled "Tool Set."
2. Install the Handlebars:
   • Using the 4 mm hex wrench, remove the top stem clamp bolts.
   • Position the handlebars centered within the clamp.
   • Thread the bolts back in and snug them up evenly in an "X" cross pattern using the 4 mm hex wrench.
   • Torque all four top stem clamp bolts to 5–6 Nm using an adjustable torque wrench.
3. Mount the Display:
   • Center the display mount on the horizontal crossbar of the handlebars.
   • Tighten all mounting bracket hardware securely using 2.5 mm and 3 mm hex wrenches.
4. Check Brake Levers:
   • Confirm that both hydraulic brake lever assemblies are angled comfortably for operation.
   • Torque the lever clamp bolts to 5–6 Nm.
5. Install the Front Wheel:
   • Slide the temporary plastic shipping axle out of the fork dropouts (gently tap with a rubber mallet if binding occurs).
   • Ensure the inner sleeve spacer inside the front hub is aligned centered with the axle pass-through hole.
   • Insert the wheel hub spacers onto the left and right sides of the front hub.
   • Have an assistant lift the front of the frame while you align the front disc brake rotor into the caliper and guide the axle through the fork dropouts.
   • Applying a light coat of bicycle maintenance grease to the OEM front axle beforehand will ease installation. Tap gently with a rubber mallet if needed to seat fully.
   • Using a 5 mm hex wrench and a torque wrench with a 5 mm bit, torque both front axle bolts to 10–12 Nm.
6. Remove Fender Mounting Bolts:
   • Unscrew the four M6 bolts located underneath the fork crown using your hex wrench.
   • Set these bolts aside—they will be used to attach the front fender to the lower fork arch.
7. Verify Rear Axle Torque:
   • Using a torque wrench, confirm that both rear axle nuts are torqued securely to 50–60 Nm.
8. Install the Pedals:
   • Apply a light layer of maintenance grease to the threads of both pedal spindles.
   • Thread the right pedal (marked "R") clockwise into the right crank arm and tighten firmly with a 15 mm open-end wrench.
   • Thread the left pedal (marked "L") counter-clockwise (reverse thread) into the left crank arm and tighten firmly with a 15 mm open-end wrench.

Need Further Assistance?

If you encounter any issues during assembly or have technical questions, please reach out to our technical support team through our Contact Form.

IMPORTANT: Photos and videos are essential for resolving technical support tickets. Please attach clear photos or videos of any assembly hardware or component alignment issues when submitting your ticket.