Packaging Your Bike for Shipping

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.