BIKE TECHNICIANS

WORKSHOP HANDBOOK

Professional workshop reference • Inspection • Diagnosis • Service • Quality Control

Edition 1 • September 2026

For workshop training and day-to-day reference

IMPORTANT: Exact torque values, service intervals, fluids, procedures and compatibility requirements vary by manufacturer and model. Always use the current manufacturer technical documentation for the specific component.

How to Use This Handbook

Use this handbook as a structured workshop guide, not as a substitute for manufacturer service manuals. The safest workflow is: identify → inspect → measure → diagnose → service → torque → adjust → test → document.

For any unfamiliar system, stop at the identification stage and obtain the correct technical information before disassembly.

Contents

1. 1. Purpose, Scope & Technician Standards

2. 2. Workshop Safety & Risk Control

3. 3. Workshop Intake & Inspection

4. 4. Tools, Measuring & Torque Control

5. 5. Cleaning & Lubrication

6. 6. Tyres, Tubes, Tubeless & Wheels

7. 7. Drivetrain Service

8. 8. Cranks, Bottom Brackets & Pedals

9. 9. Brake Systems

10. 10. Headsets, Steering & Cockpit

11. 11. Suspension Forks & Rear Shocks

12. 12. Bearings, Hubs & Freehubs

13. 13. Cables, Housing & Controls

14. 14. E-bike Technician Procedures

15. 15. Frames, Forks & Structural Inspection

16. 16. Torque, Fastener & Thread Procedures

17. 17. Diagnosis & Troubleshooting

18. 18. Service Procedures & Quality Control

19. 19. Preventive Maintenance Schedules

20. 20. Workshop Forms & Checklists

21. Appendix A. Core Workshop Checklists

22. Appendix B. Compatibility & Specification Reference

23. Appendix C. Technician Knowledge Checklist

1. Purpose, Scope & Technician Standards

Purpose

This handbook is a practical workshop reference for bicycle mechanics and bike technicians. It covers inspection, diagnosis, adjustment, replacement, lubrication, cleaning, wheel work, drivetrain service, braking systems, suspension, hydraulic systems, electronic shifting, e-bikes, troubleshooting, workshop safety, quality control and customer handover.

Technician principles

Work methodically. Confirm the complaint, inspect before disassembly, identify the system, use the correct tool, follow the component manufacturer's service information, measure rather than guess, document what was done, and test the finished bicycle. A safe repair is more important than a fast repair.

Golden rules

1) Manufacturer specifications take priority over generic values. 2) Never lubricate braking friction surfaces. 3) Never reuse a safety-critical fastener when the manufacturer specifies replacement. 4) Never assume a component is compatible because it physically fits. 5) Replace damaged or questionable safety-critical parts. 6) After service, perform a controlled functional check before returning the bicycle.

Workshop terminology

The modern professional term is bike technician. 'Mechanic', 'bicycle mechanic', and 'technician' may all appear in manuals and trade discussions, but this handbook uses bike technician as the primary term.

Quick Reference Table

Priority	Safety-critical defects	Repair or isolate before normal service
Priority	Reliability defects	Repair where they affect dependable operation
Priority	Performance	Tune after safety and basic function are established
Priority	Cosmetic	Record separately from mechanical condition

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

2. Workshop Safety & Risk Control

Personal protective equipment

Use safety glasses when cutting, grinding, spraying solvents, bleeding hydraulic systems or working with compressed air. Use suitable gloves for dirty or chemical work, but remove gloves when they reduce grip or tactile control around rotating machinery. Wear hearing protection around prolonged high-noise equipment.

Bicycle security

Support bicycles by approved frame or seatpost areas according to the stand manufacturer's instructions. Do not clamp thin-walled carbon tubes, aerodynamic structures or vulnerable components unless the manufacturer permits it. When lifting e-bikes or cargo bikes, assess weight and use a stable stand.

Chemical safety

Use cleaners, degreasers, sealants, brake fluids, mineral oils and aerosols according to their labels and safety data sheets. Never mix chemicals. Provide ventilation. Store flammables correctly and dispose of contaminated rags and fluids through appropriate waste channels.

Compressed air

Do not use compressed air to spin bearings, freewheels or other components to high speed. Do not direct compressed air at skin. When inflating tyres, inspect rim and tyre compatibility and stay clear of the sidewall trajectory.

Battery safety

For e-bikes, identify the battery and drive-system manufacturer before service. Inspect for swelling, impact damage, overheating, leakage, damaged connectors or unusual odour. Do not open lithium battery packs unless trained and authorised for that battery system. Isolate a damaged battery and follow the manufacturer's safety procedure.

Test-ride safety

Use a controlled area. Check steering, brakes, wheels, tyres, crank security and quick-release/thru-axle security before riding. For a repaired bicycle, start slowly and progressively load the repaired system.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

3. Workshop Intake & Inspection

Initial interview

Record the customer's description verbatim where useful. Ask when the fault occurs, whether it is intermittent, what conditions trigger it, what happened immediately before it appeared, and whether another workshop or component has recently been involved.

Intake checklist

Record frame type and size, bicycle identification, visible damage, odometer or ride data if relevant, battery state for e-bikes, accessories, wheel condition, tyre condition, brake operation, shifting, steering, suspension and any customer-supplied parts.

Before touching anything

Photograph pre-existing damage when appropriate. Identify missing parts and unusual modifications. Note stripped fasteners, seized components, crash damage, worn consumables and signs of incorrect previous assembly.

Triage

Separate work into safety-critical defects, reliability defects, performance adjustments, cosmetic issues and optional upgrades. Safety-critical work should be resolved before performance tuning.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

4. Tools, Measuring & Torque Control

Essential hand tools

Hex keys, Torx drivers, screwdrivers, cable cutters, pick tools, pliers, tyre levers, spoke tools, cassette/freewheel tools, chain tools, pedal wrench, bottom-bracket tools, headset tools, bearing tools and workshop-specific adapters form the basic toolkit.

Torque tools

Use a calibrated torque wrench appropriate to the fastener size and torque range. Set the required value from the component manufacturer's specification. Ensure the tool is used in its intended direction and reset/store it according to the manufacturer's instructions.

Measurement

Useful measurements include tyre pressure, chain wear, rotor thickness, pad thickness, wheel dish, rim runout, spoke tension, bearing play, cable length, brake lever travel and suspension pressures or sag. Record measurements where they help diagnose recurring problems.

Thread and fastener identification

Identify thread type, diameter, pitch, length, head style and material before replacement. Do not substitute a similar-looking bolt without confirming compatibility. Carbon assemblies may require assembly compound rather than grease, depending on manufacturer instructions.

Quick Reference Table

Tool	Typical use	Key caution
Torque wrench	Controlled tightening	Use within calibrated range
Cable cutter	Brake/shift cables and housing	Use purpose-built cutter
Bearing press	Bearing installation	Load correct race
Chain checker	Chain wear	Use the gauge's specified method
Spoke tension meter	Wheel build/service	Use manufacturer/rim limits

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

5. Cleaning & Lubrication

Cleaning workflow

1) Remove loose dirt. 2) Protect sensitive openings. 3) Apply an appropriate cleaner. 4) Agitate contamination with suitable brushes. 5) Rinse or wipe according to the product and component requirements. 6) Dry completely. 7) Inspect. 8) Lubricate only the surfaces that require lubrication.

Drivetrain lubrication

Use a bicycle chain lubricant suited to the riding environment. Apply a small amount to the inside of each chain roller or link while rotating the drivetrain. Allow penetration where appropriate, then wipe excess from the outside plates. Excess lubricant attracts contamination.

Grease vs assembly compound

Grease is used where the component manufacturer specifies lubrication or anti-seize behaviour. Carbon assembly compound is used where increased friction is desired at compatible clamped interfaces. They are not interchangeable.

Bearing contamination

Keep degreaser and high-pressure water away from sealed bearing interfaces unless the service procedure specifically calls for it. Cleaning a bicycle is not the same as pressure-washing a bearing.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

6. Tyres, Tubes, Tubeless & Wheels

Tyre inspection

Inspect tread, sidewalls, bead seating, cuts, bulges, embedded glass or wire, casing damage and age-related deterioration. Check that the tyre is compatible with the rim and wheel system.

Tube replacement

Find and remove the cause of the puncture, not just the tube. Inspect tyre interior, rim tape, valve hole and spoke ends. Inflate progressively and verify that the bead seats evenly around the rim.

Tubeless setup

Confirm tubeless-compatible rim and tyre. Inspect rim tape for complete coverage and good adhesion. Install the valve correctly, mount the tyre without damaging the bead, add the manufacturer's recommended sealant quantity, seat the bead using suitable inflation equipment, rotate and distribute sealant, and check for leaks.

Tubeless troubleshooting

Slow leaks may arise from valve cores, valve interfaces, rim tape, porous sidewalls, punctures or bead seating. Locate the leak systematically rather than repeatedly adding sealant.

Wheel inspection

Check radial and lateral runout, dish, spoke tension, rim damage, hub play, axle security and bearing condition. A wheel that is true but has damaged spokes or a cracked rim is not a satisfactory repair.

Quick Reference Table

Inspection	Tyre bead	No cuts, bead damage or uneven seating
Inspection	Rim tape	Continuous coverage over spoke holes
Inspection	Valve	Secure and leak-free
Inspection	Wheel	No cracks, severe dents or loose spokes

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

7. Drivetrain Service

Chain wear

Measure chain elongation with an appropriate chain-wear gauge or manufacturer's specified method. Replace the chain at the system's service threshold. Early replacement can reduce wear on expensive chainrings and sprockets.

Chain installation

Use the correct chain length for the drivetrain and frame. Route the chain correctly through the rear derailleur. Use only the joining method approved for that chain—such as a specified connecting pin or quick link—and observe reuse limits.

Cassette and freehub

Inspect tooth profiles, damaged splines, lockring condition, freehub body condition and bearing play. Remove and install with the correct tools. Do not overtighten beyond the manufacturer's specification.

Front derailleur

Set mounting position, alignment and limits according to the drivetrain manufacturer's procedure. Cable tension and electronic trim should be adjusted only after the mechanical alignment is correct.

Rear derailleur

Confirm hanger alignment before chasing shifting problems. Set limit screws, mounting position, chain length, cable tension and indexing in the correct order. For modern systems, follow the manufacturer's setup sequence.

Electronic shifting

Check battery state, wiring/connectors, firmware requirements, pairing or system status, derailleur position and error indications. Do not bend, pinch or force electronic wires and plugs.

Quick Reference Table

Symptom	Skips under load	Check chain/cassette wear, chain fit and freehub
Symptom	Won't reach largest cog	Check hanger alignment and limit setting
Symptom	Slow shifts	Check cable friction, housing and indexing
Symptom	Chain drops	Check limits, chainring, chain length and alignment

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

8. Cranks, Bottom Brackets & Pedals

Crank inspection

Check crank arms for cracks, impact damage, looseness and interface wear. Confirm the crank fixing system before removing it; different interfaces require different extraction or release procedures.

Bottom bracket diagnosis

Distinguish bearing roughness from crank, spindle, chainring, frame or pedal noise. Check preload, play and contamination before replacing bearings. A creak is a symptom, not a diagnosis.

Pedals

Confirm left/right threads. Inspect pedal threads, axle condition and bearing play. Grease or prepare threads as specified by the pedal and crank manufacturers. Tighten to specification with the correct tool.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

9. Brake Systems

Rim brakes

Inspect pad alignment, pad wear, rim condition, cable housing, cable corrosion, lever travel, centering and release mechanisms. Keep lubricant and degreaser away from braking surfaces.

Mechanical disc brakes

Inspect rotor condition, pad wear, caliper alignment, cable/housing condition and lever travel. Confirm rotor and pad compatibility. Bed-in new pads and rotors according to the manufacturer's procedure.

Hydraulic disc brakes

Inspect hoses, fittings, calipers, pistons, pads, rotors and lever feel. Use only the specified hydraulic fluid. Keep fluid off pads and braking surfaces. Bleed using the correct fittings, procedure and fluid.

Bleeding principles

Protect painted surfaces and components from fluid contamination. Use clean tools and fresh fluid as specified. Remove air without introducing contamination. Confirm lever feel and inspect every connection for leaks before riding.

Brake bedding

New pads and/or rotors require controlled bedding to establish a stable friction interface. Follow the manufacturer's sequence and location requirements. Avoid holding the brake continuously during bedding.

Quick Reference Table

Problem	Soft hydraulic lever	Check air, leaks, pad/rotor condition and lever system
Problem	Squeal	Check contamination, bedding, alignment and component condition
Problem	Dragging rotor	Check caliper alignment, piston return, rotor runout and axle seating
Problem	Weak braking	Check pad/rotor condition, contamination, bedding and system setup

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

10. Headsets, Steering & Cockpit

Headset diagnosis

Check for play by applying the front brake and gently rocking the bicycle. Roughness or indexing may indicate bearing, race, preload or fork issues. Separate headset play from loose stem, axle or brake components.

Headset adjustment

For conventional threadless systems, preload is normally set through the top cap before the stem is fully clamped to the steerer. Once preload is correct, tighten the stem steerer bolts to the specified torque and recheck steering.

Carbon cockpit

Follow the component manufacturer's torque and assembly instructions. Inspect for crushing, cracks, delamination or damage. Use specified friction compound where required.

Steerer safety

Never exceed the manufacturer's minimum insertion requirements or use an unapproved steerer configuration. Inspect the fork crown, steerer and compression hardware after impacts.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

11. Suspension Forks & Rear Shocks

Pre-service inspection

Inspect stanchions, seals, lowers, crown, steerer, axle interfaces, air valve caps, rebound/compression controls and mounting hardware. Look for scratches, oil contamination and play.

Sag

Set rider sag using the suspension manufacturer's recommended procedure and range. Record rider weight, riding kit and settings where useful. Sag is a starting point, not a substitute for functional testing.

Air springs

Use a suitable shock pump. Do not rely on a tyre pump. Equalise positive/negative chambers when the design requires it and observe the manufacturer's pressure limits.

Service intervals

Follow the suspension manufacturer's service intervals and procedures. Different models have different oil volumes, lubricants, seals and torque values; never substitute a generic fluid or volume without confirmation.

Damage

A scored stanchion, leaking damper, damaged crown or excessive bushing play can be safety-critical. Escalate specialist repairs when the required equipment or training is unavailable.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

12. Bearings, Hubs & Freehubs

Bearing diagnosis

Check preload and play before disassembly. Roughness may come from bearings, seals, axle interfaces or contamination. Rotate unloaded bearings gently; do not spin them at high speed with compressed air.

Hub service

Identify hub design and bearing arrangement before removal. Protect seals and spacers. Replace bearings using appropriate drifts or presses that load the correct bearing race.

Freehub service

Inspect pawls, ratchets, springs, seals and lubrication requirements. Use the lubricant specified for the freehub mechanism. Excessive or incorrect grease can affect engagement on some systems.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

13. Cables, Housing & Controls

Cable replacement

Use dedicated cable cutters. Cut housing squarely and restore liners or ferrules as required. Route housing without sharp bends or compression. Ensure steering remains free through the full range.

Cable lubrication

Many modern coated cables are intended to run dry or with specific preparation. Do not automatically oil every cable. Follow the cable manufacturer's requirements.

Control setup

Set lever position, reach, free stroke and clamp torque to suit the component and rider. Confirm that controls do not interfere with steering or other controls.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

14. E-bike Technician Procedures

System identification

Record motor, battery, display/controller and drive-system family before diagnosis. Different systems have different diagnostic software, error codes, firmware and service procedures.

Electrical inspection

Check connectors, wiring, battery seating, charger connection, display function and visible damage. Never bypass protective devices or bridge connectors to 'test' a system unless the manufacturer procedure explicitly requires it.

Water ingress

If water intrusion is suspected, stop and inspect before powering the system repeatedly. Drying, connector inspection and manufacturer-specific diagnostics may be required.

Battery handling

Do not dismantle a battery pack or alter battery protection electronics without appropriate authorisation, training and equipment. A damaged lithium battery can present fire and injury hazards.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

15. Frames, Forks & Structural Inspection

Frame inspection

Clean enough to see the structure. Inspect welds, joints, dropouts, pivots, cable ports, mounts and contact points. Look for dents, cracks, paint disruption, corrosion, delamination and unusual movement.

Carbon inspection

Inspect for impact damage, cracks, crushed areas, unusual sounds or visible fibre disruption. Carbon damage can be internal and difficult to assess visually. When in doubt, follow the frame manufacturer's inspection or replacement policy.

Alignment

Check derailleur hanger alignment, wheel seating and obvious frame alignment issues. Do not cold-set or straighten a frame or fork unless the manufacturer and construction permit the procedure and you have the required expertise.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

16. Torque, Fastener & Thread Procedures

Torque sequence

Clean and inspect threads, identify the correct fastener, lightly prepare the interface only as specified, engage threads by hand, tighten progressively and finish with a calibrated torque wrench.

Threadlocker

Use threadlocker only where specified or appropriate for the application. Confirm strength, cure requirements and whether future service is expected. Do not substitute permanent threadlocker for a serviceable fastening system.

Seized fasteners

Stop before rounding the head. Apply an appropriate penetrant where safe, allow time to work, use the correct bit and support the component. Escalate extraction or drilling if the risk of damage is high.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

17. Diagnosis & Troubleshooting

No parts cannon

Do not replace multiple components simply because a fault is difficult. Establish a test, change one variable at a time where practical, and verify the result. Document the evidence supporting the repair.

Noise diagnosis

Classify the noise by load, cadence, steering angle, braking state, temperature and terrain. Check interfaces systematically: pedals, cleats, crank, bottom bracket, chainring, cassette, freehub, saddle/seatpost, headset, stem, axles and brake mounts.

Poor shifting

Check derailleur hanger alignment, cable friction, housing condition, limit screws, chain wear, cassette/chainring wear, chain length and drivetrain compatibility before fine indexing.

Poor braking

Check pad/rotor contamination, alignment, wear, hydraulic air, hose condition, cable friction, rotor runout and bedding. A soft hydraulic lever and a dragging brake require different diagnoses.

Punctures

Inspect the tyre inside and outside, rim tape, spoke holes, valve, tube and riding conditions. Repeated punctures at the same location often identify the underlying cause.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

18. Service Procedures & Quality Control

Standard service sequence

1) Intake and photograph. 2) Safety inspection. 3) Clean as needed. 4) Diagnose. 5) Obtain approval for additional work where required. 6) Disassemble. 7) Replace/service parts. 8) Reassemble using specified procedures. 9) Torque-check. 10) Adjust. 11) Test. 12) Final inspection and document.

Final QC checklist

Confirm wheel security, tyre pressure, brake operation, rotor/pad condition, shifting across the available gears, crank and pedal security, headset adjustment, cockpit security, axle security, suspension function where fitted, accessories, battery seating on e-bikes, and absence of tools or loose parts.

Road-test checklist

Perform a short controlled test. Check straight-line tracking, braking power and modulation, shifting under appropriate load, unusual noises, steering, wheel security and any repaired component. Reinspect if anything feels abnormal.

Handover

Explain the work completed, parts replaced, remaining wear items, bedding-in requirements, maintenance intervals and any limitations. Provide the customer with the next recommended service action.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

19. Preventive Maintenance Schedules

Every ride / before ride

Tyre condition and pressure; brake function; wheel security; quick-release or thru-axle security; handlebar/stem security; obvious drivetrain problems; e-bike battery/system condition where applicable.

Regular workshop inspection

Chain wear; brake pad wear; rotor condition; cable/housing condition; wheel trueness and spoke condition; bearing play; tyre wear; drivetrain tooth wear; suspension condition; fastener torque where appropriate.

Seasonal / periodic

Deep clean, drivetrain service, bearing inspection, hydraulic brake service as required, suspension service according to manufacturer schedule, tubeless sealant inspection, corrosion inspection, and replacement of consumables approaching limits.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

20. Workshop Forms & Checklists

Job card fields

Customer details; bicycle identification; date; reported fault; pre-existing damage; measurements; diagnosis; approved work; parts; technician; torque-critical operations; test ride; final QC; customer communication; follow-up recommendation.

Safety refusal / escalation

Document unsafe conditions such as structural damage, incompatible parts, severely damaged tyres, compromised batteries, hydraulic leaks or other faults that cannot be safely repaired with available equipment. Explain the reason clearly and recommend the appropriate specialist or manufacturer pathway.

Technician sign-off

A professional sign-off should confirm that the listed work was completed and the bicycle passed the workshop's final functional inspection. It should not imply that the bicycle is guaranteed against future failures or damage outside the completed scope.

Technician workflow

• Identify the exact system and model.

• Inspect for safety-critical damage or wear.

• Measure the relevant condition before adjusting.

• Use the manufacturer's service procedure and specification.

• Clean, lubricate or replace only what is appropriate.

• Reassemble with correct interfaces and controlled torque.

• Perform adjustment and functional checks.

• Test ride when appropriate and safe.

• Record work completed and outstanding recommendations.

Appendix A. Core Workshop Checklists

Quick safety check

□ Tyres sound and correctly seated □ Wheels secure □ Brakes operate □ Brake pads/rotors acceptable □ Cranks/pedals secure □ Headset free of dangerous play □ Stem/handlebar secure □ No obvious structural damage □ Drivetrain operates □ E-bike system/battery visually safe where fitted

Full service checklist

□ Intake photographs □ Frame/fork inspection □ Wheel inspection □ Tyre/tube/tubeless inspection □ Hub/bearing inspection □ Headset inspection □ Bottom bracket/crank inspection □ Drivetrain wear measurement □ Brake inspection/service □ Cable/housing inspection □ Suspension inspection □ Fastener/torque audit □ Clean/lubricate □ Adjust gears □ Adjust brakes □ Test ride □ Final QC □ Handover notes

Appendix B. Compatibility & Specification Reference

Rule of compatibility

Confirm frame, fork, wheel, tyre, axle, rotor, cassette/freehub, chain, derailleur, shifter, crank, bottom bracket, brake, headset, cockpit and electronic-system compatibility before installation. Physical fit alone is not proof of safe compatibility.

Manufacturer documentation

For exact torque values, oil volumes, brake fluids, suspension service procedures, electronic diagnostics, battery procedures, bearing specifications and component limits, consult the current manufacturer's technical documentation for the exact model and revision.

Appendix C. Technician Knowledge Checklist

Competency areas

A competent technician should understand fastener torque; threads; bearing adjustment; wheel geometry; spoke tension; drivetrain indexing; hydraulic braking; cable routing; tubeless systems; suspension basics; carbon inspection; e-bike electrical safety; component compatibility; diagnostic reasoning; safe test riding; workshop chemical handling; and customer communication.

When to escalate

Escalate work involving structural carbon damage, advanced suspension damper rebuilding, lithium battery pack repair, complex electronic faults, frame alignment beyond your equipment's capability, or any procedure for which the required manufacturer documentation, tooling or training is unavailable.

 

Final Workshop Reference

When in doubt: stop, identify the component, find the current manufacturer documentation, and confirm the procedure before proceeding.

Five-point release test

• 1. Structure — frame, fork, cockpit and critical mounts appear sound.

• 2. Wheels — axles secure, wheels correctly seated, tyres sound and inflated appropriately.

• 3. Brakes — levers feel correct and both braking systems function as expected.

• 4. Drivetrain — cranks and pedals secure; gears operate across the usable range.

• 5. Controls — steering is smooth and all serviced components are secure.