MUDD PPB - AssemblyUpdated 3 hours ago

This assembly guide and video walk you through unboxing, assembling, and performing initial component torque checks on your new 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, 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

Assembly takes approximately 30–45 minutes. Having a second person to assist with front wheel installation is recommended.

• 4 mm hex wrench
• 5 mm hex wrench
• 6 mm hex wrench
• 15 mm pedal wrench
• #2 Phillips (cross-tip) screwdriver
• Adjustable torque wrench
• Assembly grease (included in tool kit)

Step-by-Step Assembly Instructions

1. Unbox and Prep:

   Cut the shipping straps and remove the outer box from your bike. Remove all protective foam, zip ties, and parts boxes.

2. Handlebar & Headlight Display Assembly:
   • Remove the display/headlight assembly from its labeled box. Place the headlight display assembly over the stem, then mount the handlebars in position.
   • Snug the stem faceplate bolts evenly using a 5 mm hex wrench.
   • Torque the faceplate bolts to 6 Nm using an adjustable torque wrench.
   • Finish mounting the display assembly using the #2 Phillips screwdriver from your tool set.
3. Connecting Wires & Cable Management:

   Connect all wiring harness leads for the display and headlight to their matching color-coded connectors on the main cable assembly (located in front of the head tube below the handlebars). Neatly organize and route cables before proceeding.

4. Front Wheel Installation:
   • Have an assistant lift the front of the bike off the shipping crate while you align the front brake rotor into the caliper and guide the wheel axle into the fork dropouts.
   • Insert the axle hardware from the tool set, paying close attention to ensure the nut seats correctly into the fork dropout cutout.
   • Snug the axle using a 6 mm hex wrench.
   • Torque the front axle to 12 Nm using an adjustable torque wrench.
5. Seat Post Installation:

   Insert the seat post into the seat tube, adjust the saddle to your desired riding height, and lock it securely into place using the seat post quick-release clamp.

6. Front Fender Installation:
   • Remove the three M5 bolts from the backside of the fork legs and arch.
   • Position the front fender and thread the M5 bolts through the mounting tabs.
   • Snug the bolts using a 4 mm hex wrench, then torque them to 4 Nm using an adjustable torque wrench.
7. Pedal Installation:
   • Apply a light coat of included assembly grease to the threads of both pedal spindles.
   • Match each pedal to the corresponding crank arm using the "L" and "R" indicator stickers.
   • Thread the right pedal (marked "R") clockwise into the right crank arm and snug with a 15 mm wrench.
   • Thread the left pedal (marked "L") counter-clockwise (reverse thread) into the left crank arm and snug.
   • Torque both pedals to 35 Nm to complete assembly.

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.