Remove the front wheel using a 6mm hex wrench, Insert the red brake pad spacer in the front brake caliper and the yellow brake lever block in the front brake lever, this will prevent the front brake being pulled in transit. Insert the front axle back into the fork and thread it in a few threads to keep it secure. For the prolog once the yellow brake lever block is in place loosen the brake lever and rotate it down 90 degrees then tighten it down.
Steps 2
Remove the 3mm bolt under the fork to loosen the front fender. Once loose rotate the front fender forward so it clears the box. Next using protective wrap, Wrap the front fender and secure the wrap this will prevent any kind of damage in transit.
Steps 3
Ensure the bike is in the easiest gear to keep the derailleur safe in transit. Using the same protective wrap used on the front wrap the rear fender and secure the wrap
Steps 4
Loosen the four 4mm bolts on the faceplate of the stem in a star pattern and rotate the handlebar 90 degrees to the riders left.
Step 5
When preparing the box tray the foam blocks for the front fork need to be set up to match the size. Use the images above to arrange the blocks to match your bike’s size. Once the blocks are arranged slide the fork into the block making sure the brake caliper is on the left side of the foam block. Now that the fork is in slide the narrower piece of foam under the rear wheel and slide it into the slot in the rear tray. Also make sure the cranks are lever to make the bike fit in the tray.
Steps 6
Insert the front wheel into the slot in the front tray making sure the wider piece of foam is between the wheel and the bike. Also make sure the brake rotor is facing the frame to prevent damage in transit.
Step 7
Using all the foam blocks that came with the bike, place them on the bike to match the image above. The round small pieces go on the end of the handlebars, The saddle specific one covers the saddle and the other two go on the frame the larger of the two at the front covering the headlight. Make sure the front wheel is held in place by the two frame pieces of foam.
Steps 8
The seat post for the prolog needs to be inserted in the gap between the fork and the nose of the saddle inserted in the hole at the front of the tray. make sure to secure the top of the tabs with tape to stop the seat post coming loose in transit.
Steps 9
Slide the tray and bike into the box making sure all the foam slides in and is secure in the box. Once the bike is secure in the box seal the box with either tape or glue. Now that the bike is all boxed up reach out to Lemond customer service and we will arrange for the bike to be returned to our warehouse.
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