2019 MULE Assembly


Required Tools:

  • Cutting Pliers (to cut box poly strapping and heavy bike banding)
  • Scissors (to remove bubble wrap)
  • Allen wrenches (3mm, 4mm, 5mm, 6mm)
  • Wrenches (10mm, 15mm)
  • Approximate Assembly Time: 30 – 45minutes

 

1. Cut banding straps from exterior of box and open box.
2. Remove “Tool Kit” box containing pedals, headlight, rear derailleur guard, battery charger, and hardware from box.
3. Remove rear pannier rack from box.
4. Remove bike from box. (Lay box on side and slide out or use two people to lift out)
5. Cut banding straps to release front tire from frame of bike. (Use caution in cutting banding straps, paying particular attention to brake, derailleur and all other cables on bike)
6. Cut banding straps to remove front and rear fenders from front tire.
7. Cut banding straps to release handle bars from frame of bike. (Avoid letting handlebars hang for extended periods and thus putting stress on cables. Make certain cable connections have not pulled apart during this step or in shipping)
8. Remove remaining bubble wrap, foam, and shipping materials as needed to protect bike during assembly.
9. Using 4mm Allen wrench remove 4 screws from bicycle stem (See Picture Below)

10. After removing front plate of bicycle stem insert center of handle bars into bicycle stem and replace front plate and 4 screws to secure handlebars. (Make certain handlebars are positioned with the throttle to the left and the rapid-fire index shifting levers on the right. Slightly insert each of the 4 screws prior to tightening. Also, prior to tightening, rotate handlebars forward or backwards to customize position of handlebars to rider)

11. Display screen is easily rotated by hand forwards or backwards to customize to rider.
12. Remove plastic spacer from bottom of front forks.
13. Loosen bolts on both sides of front hub axle (axle of front wheel).
14. Remove plastic insert from between front brake pads.
15. With bolt and washer located together at each end of the front hub axle place the front hub axle into the ends of the front forks and the front brake rotor between the brake pads. (Tighten bolt and washer to secure the tire into place using a 15mm wrench)

16. Remove pedals from “Tool Kit” box.
17. Differentiate the right pedal from the left pedal by locating the small “CR-L” (for the left) and “CR-R” (for the right) inscribed on the bolt of the pedal. (See Picture)

18. Attach right pedal by screwing into right crank in clockwise pattern using 15mm wrench
19. Attach left pedal by screwing into left crank in counterclockwise pattern using 15mm wrench
20. Make certain crank bolts are tightened using 10mm Allen wrench.

21. Attach front fender and headlight to front fork bracket using long bolt from hardware package, 5mm Allen wrench, and 10mm wrench (Note: Place light bracket and fender bracket on the backside of the fork bracket) After tilting headlight forward to expose backside, plug red (positive wire) into the left side of the head light and black (negative wire) into the right side of the head light.

22. Fasten lower pannier rack arms to frame using a 4mm Allen wrench.
23. Fasten upper pannier rack arms to frame using 4mm Allen wrench & 10mm wrench. (Note: Pannier rack often requires being slightly molded to fit frame of bike by pushing (squeezing) inwardly on upper pannier arms. Thus narrowing upper arms to fit frame of bike)

24. Slide rear fender under pannier rack and attach to seat post using 5mm Allen wrench. (Note: Two shims are included with rear fender, use the thinner of the 2 shims and discard the thicker shim. Attach to seat post as shown below making sure to attach just under suspension of seat post so as to allow for wider range of raising/lower seat post.  Rear fender can be micro adjusted using plastic bolts and may require adjustment on seat post to fit fluctuating rider heights)

25. Optional: Drill two small holes in rear fender just below center cross beam of pannier rack and fasten rear fender to pannier rack using zip tie to stabilize fender. (See photo below) (Note: This will slightly limit ability to raise or lower seat post for riders of different heights)

26. Install rear derailleur/brush guard using 2 screws and washers with 3mm Allen wrench.

27. Battery typically has partial charge straight from box. Fully charging prior to initial use is recommended. Battery can be charged while on bike or it can be removed and charged off of bike.
28. Two keys are zip-tied to handlebars. Keys are only used to remove battery from bike. Simply insert key into lock and turn, while pulling out and up on battery handle to remove battery.
29. To re-insert battery, key is not needed: simply place bottom of battery into lower slot and firmly push top of battery into upper slot. (Note: make sure battery is locked firmly into place prior to riding as a loose battery may cause inadvertent loss of power or battery may fall out of chamber and become damaged. After reinserting, check battery attachment by pulling out and up on handle to ensure it is securely fastened)
30. Assembly is now complete: However, minor adjustments are often necessary to precisely fit ebike to rider. These adjustments can include rotating locking handle grips, moving/rotating brake levers, throttle and shifters. These adjustments are easily performed. However, feel free to contact us via email or phone with any questions.
31. Note: A Suspension Adjustment video and Display Use video can each be viewed under “Support” on the BackCountry eBikes website.
32. Regular and routine maintenance of your ebike is not only recommended, but highly essential to ensure proper function, safety, and longevity of your ebike.
33. Always wear a helmet and other protective gear while riding.
34. Always know and observe traffic and trail laws and regulations.