Assembly Instructions for Maxwell 27.5
Thank you for your purchase of a Trailcraft Full Suspension Mountain Bike! All Trailcraft Cycles are
packed in the best quality double-wall corrugated box to protect the bike. For shipping purposes the bike
has been disassembled. Full assembly has been previously completed, though cables can stretch so
there may need to be some fine tuning with the shifter barrel adjusters upon arrival or after a few rides.
Prior to shipping:
1. Your bike has been packed in two different boxes. Wheels in one, frame in the other.
2. Your handlebars have been removed, shift/brake levers have been well wrapped in bubble wrap or
foam packaging material. They will hang along the fork – also wrapped in bubble wrap/foam packaging.
3. The stem has been left in position on the fork steerer tube, along with the top cap and stem spacers left
installed. The stem is sometimes turned inwards towards the saddle so it fits in the box.
4. Both wheels have been removed, the thru-axles will remain in the fork and the frame. Extra cardboard
inserts or small empty boxes may be present to take up air volume for additional protection.
Upon arrival of your Trailcraft Maxwell 27.5
1. Open boxes and remove the front and rear wheels, and cardboard inserts. Note that the plastic
protector might pull the axle caps off the hubs of the wheel, you might have to gently pull the cap off of
the round plastic hub protector and push it back into the hub end.
2. Pull the bike out of the second box by holding the back of the saddle and fork leg.
3. Remove all packaging and front and rear axles from the bike.
4. Reinstall the rear derailleur onto the derailleur hanger with a
5mm allen key
. Make sure that there is
no gap between the point of the hanger and the stopper (see picture below).
5. Remove brake caliper shipping spacers (orange block) from the brake. It will pull out with a swift tug.
DO NOT SQUEEZE THE BRAKES.
6. Install wheels and tighten the axles ensuring the chain is properly wrapped around the cassette and
chainring. (see picture below)
7.
Loosen the top cap bolt and stem cinch bolts so the stem moves freely. Rotate the stem so the face
plate is facing forward. If your child is on the younger/smaller side, you can also flip the stem in the
negative position to get the bars lower and place the spacer(s) on top of the stem. Tighten the top cap
of the stem with a
5mm allen key
so there is no play in the headset spacers but the fork still moves
smoothly. Use a
T20 or 4mm allen key
to cinch the stem on to the steer tube.
8. Loosen the 4 stem faceplate bolts. Remove handlebars from packaging and install on the stem. Do not
over tighten stem bolts (torque to 5nm)
9.
Install right and left side brake/shift levers. The front brake lever goes on the left and the rear brake
lever and shifter go on the right. If they have separate clamps, you can install the brake or shifter first
for the best reach. Do not tighten yet!
