Packaging Your Bike for Shipping

Learn to properly package your bike for shipping to another location or back to QuietKat for service under warranty.

Materials Needed:

  • Foam pieces
  • Heavy-duty zip ties
  • Disk brake covers
  • Disk brake caliper spacer
  • Pedal wrench (15mm)
  • 4mm Allen wrench
  • 5mm Allen wrench
  • Packing tape
  • Box

Procedure:

  1. Protect the Frame:

    • Wrap the down tube (with battery housing) using a long piece of foam.
    • Secure the foam with heavy-duty zip ties.
    • Wrap the top tube and handlebars, using two pieces if necessary.
  2. Remove Pedals:

    • Use a 15mm pedal wrench to remove the pedals.
    • Remember that the drive-side pedal is regular threaded, while the non-drive side is reverse threaded.
    • Wrap pedals with foam to place in the box. You can zip tie the pedals together for more secure shipping. 
  3. Loosen Stem and Remove Handlebars:

    • Use a 4mm Allen wrench to loosen the four bolts holding the handlebars onto the stem.
    • Carefully remove the stem cap and handlebars.
    • Reinstall the stem cap loosely for safekeeping during the shipment.
  4. Secure Handlebars:

    • Orient the handlebars parallel to the fork. You should not need to disconnect any cables.
    • Use a zip tie to secure the handlebars to the top tube.
    • Ensure it's snug but not too tight.
  5. Remove Front Wheel:

    • If your bike has a thru axle, remove the front wheel from the thru axle.
    • If your bike does not have a thru axle, using a 15mm wrench, loosen the two nuts on either end of the axle and remove the wheel straight from the frame.
    • If you have an Apex or Ridgerunner, use a 4mm Allen wrench to loosen the clamps at the bottom of the fork and then remove the thru axle.
  6. Wrap Fork, Handlebar, and Stem:

    • Wrap foam around the fork leg and secure it to the handlebar using a zip tie.
    • Wrap foam around the stem and tie it securely.
  7. Drop the Bike into the Box:

    • Lift the front and back of the bike simultaneously with the help from a friend.
    • Lower the bike straight into the box, ensuring no components bind along the way.
  8. Add Additional Protection:

    • Place a disk brake protector on the side of the box and drop the front wheel next to the bike.
  9. Seal the Box:

    • Close the box securely.
    • Seal all edges with packing tape for maximum protection during shipping.
  10. Final Check:

    • Ensure all components are securely wrapped.
    • Confirm that pedals are snugly wrapped.
    • Double-check that handlebars are securely tied to the top tube.

By following these steps, you've properly packaged your bike for shipping, whether it's for warranty service or your next adventure.