1. Prepare for Assembly: Remove the bike from its box and ensure the workspace is organized and ready for efficient assembly.

2. Attach Documentation: Staple the customer order to the top tube or apply the price sticker to the reflector for clear identification.

3. Unpack the Bike: Carefully remove all packaging materials, ensuring no components, accompanying documents, small parts, or chargers are misplaced.

4. Dispose of Rubbish: Take the packaging materials to the two large bins located outside. Sort waste efficiently:

   • Place recyclable cardboard in the designated cardboard bin.

   • Place other materials in the general waste bin.

5. Inflate Tyres: Inflate the tyres to the correct pressure based on the bike type:

   • Road bikes: 80 psi

   • Hybrid bikes: 60 psi

   • Recreational mountain bikes: 40 psi

   • Performance mountain bikes: 30 psi

   • Kids' bikes: 30 psi

6. Communicate Completion: Clearly notify the Head Mechanic (Craig Larsen) or the next relevant staff member:

   • Identify who or what the bike is for.

   • Confirm that the bike has been prepared to a Level 1 Prep Build standard.

1. Complete and Confirm Level 1 Prep Build: Ensure level 1 prep build is complete before starting Level 2.

2. Install Seat Post:

   • Apply a small amount of grease to the seat post.

   • For adult bikes, set the seat post to the maximum extension.

   • For kids' bikes, adjust the seat post to the minimum height required to fit securely in the Park Tool stand.

3. Fit Handlebars:

   • Attach the handlebars to the stem.

   • Ensure the stem faceplate has an even gap between the top and bottom screws.

   • For higher-level bikes, adjust to ensure no gap at the top of the faceplate, if specified.

4. Attach Pedals:

   • Apply a small amount of grease to the pedal threads.

   • Use a pedal washer for square-edged faced pedals.

5. Fit Safety Accessories:

   • Install the bell on the left-hand side of the handlebars.

   • Securely attach both the front and rear reflectors.

6. Communicate Completion:

   • Notify the Head Mechanic (Craig Larsen) or the next relevant staff member

   • Clearly identify who or what the bike is for

   • Confirm the bike has been fully prepared to Level 2 standards

1. Confirm Level 1 and Level 2 Completion: Ensure both Level 1 and Level 2 are complete before beginning Level 3.

2. Fit Front Disc Brake Calliper or V-Brake:

   • For disc brakes, attach the front calliper to the fork and tighten the bolts until just before they take full tension.

   • For V-brakes, fit the cable and noodle loosely to allow for further adjustment.

3. Install Front Wheel:

   • Fit the front wheel, ensuring it is square and properly seated in the fork.

   • Place the bike on the ground with both wheels to ensure alignment if necessary.

4. Adjust Front and Rear Brakes:

   • Set up both brakes to achieve the correct lever throw for the right and left brake levers.

   • Ensure there is no rubbing on the rotors or rims during operation.

   • Part tool resources for disc brake and v-brake

5. Report and Note Brake Issues:

   • If an issue arises related to the brakes that is beyond your skillset, notify Craig Larsen or a senior staff member.

   • As well as write a note of the issue on a post-it and attach it to the bike for clarity.

6. Communicate Completion:

   • Notify the Head Mechanic (Craig Larsen) or the next relevant staff member

   • Clearly identify who or what the bike is for

   • Confirm the bike has been fully prepared to Level 3 standards

1. Confirm Level 3 Completion: Ensure Level 1, Level 2, Level 3 are complete before starting Level 4

2. Adjust Rear Gears:

   • Fine-tune the rear derailleur for smooth shifting across all gears

   • Ensure proper alignment, tension, and limit screw settings

   • Refer to the video tutorial for guidance: Rear Derailleur Adjustment

3. Adjust Front Gears:

   • Set up the front derailleur to shift smoothly between chainrings

   • Adjust limit screws and cable tension for precise operation

   • Refer to the video tutorial for guidance: Front Derailleur Adjustment

4. Test Shifting Performance:

   • Shift through all gears on both the front and rear derailleurs, ensuring smooth transitions and no chain rub

   • Check the drivetrain under light resistance to simulate real riding conditions

5. Report and Note Gear Issues:

   • If an issue arises with the gears that is beyond your skillset, notify Craig Larsen or a senior staff member

   • Document the issue on a post-it note and attach it to the bike for clarity

6. Communicate Completion:

   • Notify the Head Mechanic (Craig Larsen) or the next relevant staff member

   • Clearly identify who or what the bike is for

   • Confirm the bike has been fully prepared to Level 4 standards

1. Confirm Level 4 Completion: Ensure Level 1, Level 2, Level 3 and Level 4 are complete before starting Level 5.

2. Install Dropper Post:

   • Properly install and set up a dropper post, ensuring smooth operation

   • For guidance, refer to the video tutorial: Dropper Post Installation

3. Install Internal Cables:

   • Route and secure internal cables correctly, ensuring they are cleanly installed and do not interfere with the bike's functionality

   • Refer to the video tutorial for guidance: Installing Internal Cables

4. Set Up Wireless Gears:

   • For road bikes, follow the instructions to pair and adjust wireless groupsets

     1. Tutorial: Road Bike Wireless Gear Setup.

   • For mountain bikes, pair and adjust the wireless system, ensuring smooth shifting and proper gear indexing

     1. Tutorial: Mountain Bike Wireless Gear Setup.

5. Shimano Di2 Gear Setup:

   • Set up and fine-tune Shimano Di2 electronic groupsets

   • Ensure firmware is up-to-date, gears are paired correctly, and the system shifts seamlessly

6. Test Advanced Features:

   • Confirm the functionality of the dropper post, internal cabling, and electronic or wireless shifting

7. Report and Note Issues:

   • If any issues arise with advanced systems, notify Craig Larsen or a senior staff member

   • Document the issue on a post-it note and attach it securely to the bike for clarity

8. Communicate Completion:

   • Notify the Head Mechanic (Craig Larsen) or the next relevant staff member

   • Clearly identify who or what the bike is for

   • Confirm the bike has been fully prepared to Level 5 standards for review

1. Consistent Mastery of Levels 1–5:

   • Ensure you have demonstrated competence and consistency in all tasks from Levels 1 through 5.

   • Be proficient in performing all steps independently and efficiently.

2. Fit Handlebar Tape:

   • Install bar tape neatly and securely, ensuring a professional finish with even tension and clean edges.

3. Build a Bike from Start to Finish:

   • Assemble a bike completely, starting from unpacking to final adjustments, including all systems and components.

   • Perform quality control checks at every stage to ensure a flawless build.

4. Complete Suspension Setup:

   • Set up and adjust front and rear suspension systems for optimal performance based on the bike's specifications and rider requirements.

5. Perform a Basic Bike Fitting:

   • Adjust the bike for the rider's optimal comfort and efficiency, including seat height, handlebar position, and reach.

   • Ensure the bike is tailored to the rider's specific needs and riding style.

6. Pre-Sale Bike Check:

   • Ability to conduct thorough check of bikes for pre-sale, ensuring they meet all safety and quality standards.

   • Confirm that the bikes are fully functional and ready for delivery to the customer.

7. Comprehensive Bike Knowledge:

   • Demonstrate the ability to cover every aspect of a bike build and adjustment, from mechanical systems to advanced features.

8. Communicate Completion and Resolve Issues:

   • Notify the customer directly when the bike is ready for pickup or delivery.

   • If any issues are identified that require external support, communicate promptly with the relevant suppliers or service agents to resolve them and document the actions taken.

   • Liaise with the Head Mechanic (Craig Larsen) or the next relevant staff member to ensure all resolutions are in line with company standards.

At Level 6, you represent a high standard of expertise and independence, capable of handling complex builds, addressing technical issues, ensuring bikes are customer-ready, and maintaining clear communication with all stakeholders.