GB/T 3566-2026Assembly requirements for bicycles (English PDF)

5.1.1 Brake handle

5.1.1.1 The front brake lever should be installed on the right side of the handlebar, and the rear brake lever should be installed on the left side of the handlebar.

5.1.1.2 The angles of the left and right brake handles relative to the horizontal plane should be consistent, and the brake handle face should be tilted downwards (except for the pendant type handle cross tube).

5.1.1.3 The brake handle should be easy to operate and should quickly reset after being released.

5.1.2 Brake

5.1.2.1 After the flange brake is installed on the bicycle, its brake pads should be in parallel contact with the rim, at the same height, and the brake pads on both sides should simultaneously contact the rim. When the brake lever is not activated, the gap between the brake pads and the wheel rim should not exceed 3mm.

5.1.2.2 After the disc brake is installed on the bicycle, the arrow on the brake disc should be aligned with the riding direction.

5.1.2.3 After the expansion brake or holding brake is installed on the bicycle, its brake pad clearance should be adjusted appropriately to achieve the braking purpose, and it should be able to brake quickly after release. Reset.

5.1.2.4 After the brakes are installed on the bicycle, when the brakes are applied, the brake pads or friction plates should not come into contact with any other parts besides the brake body. After the brake is released, the brake pads or disc brake calipers should be able to quickly reset without jamming or shifting, and there should be no contact between the rotating wheels and the brake body.

5.1.3 Brake control lines After the brake control cable is installed on the bicycle, its length should be sufficient for operation and there should be no obvious slack.

5.2 Handlebar Assembly

5.2.1 After the seat tube is installed on the bicycle, its insertion depth into the front fork seat tube should not be less than its minimum insertion depth or the effective stop position. After the stem is clamped, the distance between the upper surface of the fork stem and the upper surface of the handlebar stem should not exceed 5mm, and the top cap should be pressed down on the handlebar stem. The end face is then locked.

5.2.2 After installing the cross tube on the bicycle, it should be perpendicular to the center plane of the front wheel without any deviation. When installing the cross tube onto the stem tube, its clamp... The positional error should not exceed 3mm.

5.2.3 After the handle is installed on the handlebar, its left and right sides should be symmetrical.

5.2.4 The steering screw, wedge-shaped steering nut, and ball bearing components of the fork assembly should be lubricated with an appropriate amount of grease.

5.2.5 The handlebar sleeves and handlebar caps on the horizontal tubes should be installed in place.

5.2.6 When wrapping the horizontal tube with the drooping type, the wrapping should be neat, secure and not loose.

5.2.7 The tightening torque of the core screw, the vertical tube clamping screw, and the end handle mounting screw shall meet the requirements of Appendix A.

5.3.1 Central Axis

5.3.1.1 Before the bottom bracket assembly is installed into the frame joint, an appropriate amount of grease should be applied to the ball bearings.

5.3.1.2 The axle cups of bottom brackets A, C, and E types should be pressed flat into the frame joint. After the right axle cup of bottom brackets B and D types is locked, it should be flush with the frame joint. There should be no gap at the end face. After the central shaft cup lock nut is tightened, the central shaft should rotate flexibly without loosening.

5.3.2 Front Fork

5.3.2.1 Before assembling the fork with the frame, apply an appropriate amount of grease to the ball bearing components of the fork assembly.

5.3.2.2 After the front fork is assembled with the frame, the front fork should rotate freely without any looseness.

5.4.1 Wheel spoke weaving

5.4.1.1 The front and rear wheel spokes should be woven using any of the methods shown in Figure 1, depending on the rim type. The valve stem hole should be located on the spoke. Between the spokes. After the wheel spokes are woven, the spokes on both sides of the front or rear axle should be symmetrically installed on the rim to ensure that the spoke weave is aligned vertically. Consistent.

5.4.1.2 The spoke tension of the wheel shall meet the requirements of Table

1.After assembly, the spoke tension shall be uniform, and no threaded end of the spoke shall be exposed outside the spoke nut.

5.4.1.3 The radial and axial runout of the wheel should not exceed 1 mm for wheels used with flange brakes; and should not exceed 1 mm for wheels used with non-flange brakes. 2mm. The radial and axial runout of a racing bicycle wheel should not exceed 0.7mm.

5.4.1.4 The center planes of the front and rear wheels should be located at the center of the vertical distance between the two mounting planes of the front and rear axles, respectively, with the two relative positions offset from each other. The difference should not exceed 2mm.

Note. The vertical distance between the two mounting planes of the front and rear axles refers to the outer end faces of the two axle stops for ordinary axles; if there are lock nuts on the axle stops, it refers to the outer end faces of the two lock nuts. The sleeve installed on the rear axle of a multi-stage flywheel refers to the axle stop and the outer end face of the sleeve.

5.4.2 Inner and outer tires

5.4.2.1 For inner tubes with lining tape, the lining tape should be evenly distributed after installation on the rim and should cover the spoke holes and spoke nut.

5.4.2.2 After the valve stem is installed on the wheel rim, it should be located between the spokes and without any misalignment.

5.4.2.3 After the tire is mounted on the rim, its arrow should be aligned with the direction of wheel rotation when the bicycle is moving forward. For pneumatic tires, follow the tire markings. After inflation to standard tire pressure, the outer tire should show no obvious twisting or bulging. For tubeless tires, inflate to the standard tire pressure marked on the tire; the outer tire should show no twisting. Bending or bulging. Pneumatic tires should be free from twisting and should not detach from the rim.

5.4.3 Wheel/Tire Assembly

5.4.3.1 After the wheel/tire assembly is installed on the vehicle, the rims of the front and rear wheels should be parallel to the center planes of the front fork and frame, respectively, and parallel to the center planes of the front fork. The relative deviation of the clearance between the legs, the upright fork, and the flat fork on both sides of the frame should not exceed 2mm for wheels with flange brakes, and should not exceed 2mm for wheels without flange brakes. It should not exceed 4mm.

5.4.3.2 The front and rear wheels should rotate flexibly and be able to swing back and forth before they stop rotating.

5.5.1 Sprocket and/or drive pulley crank

5.5.1.1 After the crankpin type crank is installed with the bottom shaft, the installation directions of the two crankpins should be opposite, and the outer side of the crank should be flush with the two end faces of the bottom shaft rollers. The sprocket and right crank should be level and not loose or detached.

5.5.1.2 After the square tenon type crank and spline type crank are installed with the bottom bracket, their left and right crank directions should be 180°, and the cranks should not interfere with any part of the frame when rotating. There should be no contact between the positions.

5.5.1.3 After the integrated crankshaft is installed with the frame joint, the ball joint within the frame joint should be correctly oriented. The gear, locking plate, and other accessories... The parts should be installed in place without gaps.

5.5.1.4 After the non-threaded two-piece crankset is installed with the bottom bracket and sprocket, the right crank and chain link should be correctly installed, and the left and right cranks and bottom bracket should be correctly installed. The installation should be in place, with the left and right cranks aligned at 180°. The tightening torque of the mounting bolts should be greater than

0.7 N·m and not greater than

1.5 N·m. The cranks should rotate... It should not come into contact with any part of the frame when in motion.

5.5.2 Foot pedals After the pedals and cranks are installed, the tightening torque of the left and right pedal shafts should meet the requirements of Appendix A.

5.5.3 Chains and Drive Belts

5.5.3.1 After the chain is installed on the bicycle, its spring clip should be installed on the outside, with the open end opposite to the direction of chain movement when riding the bicycle. The exposed portions of the joints and connecting pins should be even. The chain should move freely without noise, slippage, or loosening; the chain tension should be appropriate, and it should operate at single speed. For bicycles with internal gears and a rear axle, the chain slack should be less than 10mm.

5.5.3.2 After the drive belt is installed on the bicycle, it should move freely on the front and rear drive pulleys, and the sag should be less than 12mm.

5.5.4 Speed Transmission Device

5.5.4.1 External speed change device 5.5.4.1.1 After the external gearbox is installed and adjusted on the bicycle, shifting gears within its gear range should be correct and clear, with no chain slippage. There should be no contact or friction with the external transmission device. 5.5.4.1.2 After the external electronic gear shifter is installed and adjusted on the bicycle, its shifting within the gear range should be correct and clear.

5.5.4.2 Internal transmission device After the wheel with an internal derailleur rear axle is installed and adjusted on the bicycle, shifting gears within the gear range should be correct and clear. There should be no gaps between them.

5.5.5 Chain Cover After the chain guard is installed on the bicycle, it should be properly positioned without looseness and should not rub against the chain, sprocket, or crank.

5.5.6 Installing Fasteners Fasteners for various components in the drive system (crank mounting bolts, sprocket mounting nuts, external derailleur mounting bolts, derailleur mounting nuts) The tightening torque of fasteners (such as nails, chain adjusting screws, chain cover mounting screws, etc.) should meet the requirements of Appendix A.

5.6 Saddle and Saddlepost Assembly

5.6.1 After the seat tube is installed on the bicycle, its insertion depth into the frame seat tube should not be less than its minimum insertion depth or the effective stop position.

5.6.2 After the saddle is installed on the saddle tube, its position should be straight and without obvious deviation. The saddle surface should be horizontal.

5.6.3 The tightening torque of the saddle-to-saddle tube clamping bolts and the saddle tube-to-frame rear joint clamping bolts shall meet the requirements of Appendix A.

5.7 Mud Plate Assembly

5.7.1 After the front and rear mudguards are installed on the bicycle, the rotation of the front and rear wheels and the steering of the front wheel should not be hindered, and the mudguards should not be twisted.

5.7.2 The tightening torque of the mounting bolts for the front and rear mudguards shall meet the requirements of Appendix A.

5.8 Lighting System Assembly

5.8.1 The lighting system consists of one front light and/or one rear light. The lighting system should function properly after installation on the bicycle, and the fixed installation... The beam should not be blocked/obstructed.

5.8.3 After the lighting system is installed on the bicycle, there should be no breaks or visible cracks at any point where it is attached to the fixing device, and no bolts should be missing. Effective or loosened.

5.8.4 The tightening torque of the mounting bolts for the lighting system shall meet the requirements of Appendix A.

5.9 Reflector Assembly

5.9.1 After the front reflector is installed on the bicycle, the reference axis of its mirror surface should be kept horizontal and parallel to the center plane of the frame. Its upper, lower, and... The left and right angular deviation should not exceed 5°. Bicycles equipped with headlights should be fitted with a wide-angle reflector or a general reflector; bicycles without headlights should not be equipped with them. The bicycle should be equipped with a wide-angle reflector. The front reflector should be white (transparent).

5.9.2 After the rear reflector is installed on the bicycle, the reference axis of its mirror surface should be kept horizontal and parallel to the center plane of the frame. Its upper, lower, and... The left and right angular deviation should not exceed 5°. Bicycles equipped with rear lights should have a wide-angle rear reflector or a standard reflector added; bicycles without rear lights should not have one. The bicycle with the lights should be equipped with a wide-angle rear reflector. The rear reflector should be red.

5.9.3 Side reflectors should be mounted on the front and rear wheels of the bicycle, or on the reflective strips on both sides of the tire. Side reflectors mounted on the spokes... The center of the reflector should be 76mm from the inside of the wheel rim. Side reflectors should be white (transparent) or yellow; the color of side reflectors mounted on the front and rear wheels should be... Consistent.

5.9.4 The tightening torque of the reflector mounting bolts shall meet the requirements of Appendix A.

5.10 Assembly of the horn device The horn device should be installed in an easily accessible location on the bicycle, and its operation should not interfere with the operation of adjacent operating devices (such as gear shifters). After the horn device is installed, its rotational torque should not be less than 3 N·m.

5.11 Assembly of brackets and luggage racks

5.11.1 After the double brackets are installed on the bicycle, they should be symmetrical with respect to the wheels without any tilt. When the bicycle is erected, it should be able to stand vertically and stably.

5.11.2 After the luggage rack is installed on the bicycle, it should be symmetrical with respect to the wheels without any deviation.

5.11.3 The tightening torque of the mounting bolts for luggage racks and brackets shall meet the requirements of Appendix A.

6.1.1 Brake handle

6.1.1.1 Visually inspect the installation positions of the left and right brake levers on the bicycle.

6.1.1.2 Visually inspect whether the mounting angles of the left and right brake levers of the bicycle are consistent and whether the brake lever surfaces are tilted downwards.

6.1.1.3 Grip and release the brake handle with your hand to check if the brake handle resets quickly.

6.1.2 Brake

6.1.3 Brake control lines Visually inspect the bicycle's brake cable for slack when the brake lever is not under force. Operate the brake lever and check the cable's position within the sleeve. Check if the wiring is smooth and if there is any obstruction.

6.2 Handlebar Assembly

6.2.1 Visually inspect the minimum insertion depth markings on the bicycle's stem tube, or check if the effective stop is inside the fork stem tube. The stem tube is clamped. Afterwards, use calipers to measure whether the distance between the upper end face of the riser tube and the upper end face of the fork riser tube meets the requirements of 5.2.1, and visually inspect the top cover. Press down on the cross section of the riser and lock it.

6.2.2 Visually inspect whether the handlebar tube of the bicycle is perpendicular to the center plane of the front wheel, and measure the width of the knurled side of the handlebar tube protruding from the seat tube clamp. Difference in degree.

6.2.3 Visually inspect whether the left and right handlebar ends on the bicycle handlebar cross tube are installed symmetrically.

6.24 Visually inspect the threaded joints of the steering screw and wedge nut for adequate lubrication, and check the ball joints of the fork assembly for adequate lubrication. Lubricating oil.

6.2.5 Visually and tactilely inspect whether the handlebar sleeves and handlebar caps are properly installed on the bicycle handlebar cross tubes.

6.2.6 Visually inspect whether the horizontal tube wrapping is properly, neatly, securely, and without loosening.

6.2.7 The tightening torque of the stem screw, stem clamp screw, and end grip mounting screw is tested using a torque wrench.

6.3 Assembly of frame and fork

6.3.1 Central Axis Visually inspect the bottom bracket cup and frame joint for grease, and check the ball bearings of the bottom bracket assembly for adequate grease. (Bottom bracket A, bottom bracket...) Check if the C and E type cup bearings are flat with the frame joint end face. Rotate the crankshaft back and forth by hand to feel if the bottom bracket rotates smoothly and if the bottom bracket rolling joint is... Are there any obstructions or loosening?

6.3.2 Front Fork Visually inspect the ball joints of the fork assembly for adequate grease. Rotate the fork back and forth by hand to check if it rotates smoothly. Check for any obvious obstruction or looseness at the component.

6.4.1 Wheel spoke weaving

6.4.1.1 Visually inspect whether the wheel spokes are correctly woven and whether the valve stem hole is located between the spokes.

6.4.1.2 Place the spoke tension meter approximately 60 mm from the rim, as shown in Figure 3, and check the tension value of each spoke to see if it meets the requirements of Table 1. The requirement is to visually inspect whether there is any exposed thread on the spoke ends.

6.4.1.3 Place the wheel on a special test stand and use a dial indicator to measure its radial and axial runout on one side of the rim.

6.4.1.4 As shown in Figure 4, using a special tool, measure the mounting plane of the front or rear axle on both sides of the wheel rim, respectively, and the distance measured by the special tool. To measure the distance between surfaces, take two measurements on each side. First, randomly select one point for measurement, then use the perpendicular direction of the first measurement point as the second measurement point, and measure the maximum distance. The difference between the maximum and minimum values is the relative deviation.

6.4.2 Inner and outer tires

6.4.2.1 Remove the outer tire and inner tube, and visually inspect whether the inner tube liner is installed evenly and whether it can completely cover the spoke holes.

6.4.2.2 Visually inspect whether the valve position is between the spokes and whether it is skewed.

6.4.2.3 Visually inspect whether the tread pattern of the tires is aligned with the direction of wheel rotation when the bicycle is moving forward. Visually inspect the inflatable tires for any... There are obvious signs of twisting and bulging; check whether the tires without inflation are twisted or detached from the rim.

6.4.3 Wheel/Tire Assembly

6.4.3.1 Lift the bicycle with the tires installed and take measurement points on the outside of its front fork, frame swingarm, and stem fork (see Figure 5). Use a depth caliper. The measurement is taken using a ruler perpendicular to the axial plane of the wheel rim. The difference between the values measured on both sides of the wheel rim is the relative deviation.

6.4.3.2 Gently move the front and rear wheels by hand and visually check whether they rotate flexibly and whether they can swing back and forth when about to stop.

6.5.1 Sprocket and/or drive pulley crank

6.5.1.1 Visually inspect whether the left and right crank pins are installed in opposite directions; whether the outer side of the crank is flush with the two ends of the center shaft roller. Rotate the crank by hand. Visually inspect the sprocket or drive pulley to see if it is loose or detached from the crank.

6.5.1.2 Visually inspect whether the left and right tenon-type or spline-type cranks are 180° apart. Rotate the cranks by hand and visually inspect the cranks and... Check for any scratches or dents on the frame.

6.5.1.3 Visually inspect whether the ball joint of the integrated crank is correctly installed in the joint of the frame, and whether accessories such as the geared chainring and locking plates are installed correctly. Position. Turn the sprocket crank by hand to check if it is smooth and if there is any looseness or play.

6.5.1.4 Visually inspect whether the non-threaded two-piece crankset is correctly installed with the bottom bracket and sprocket, and whether the left and right cranks are at 180°. Check by hand. Rotate the sprocket crank to check if it is in contact with the frame. Use a torque wrench to measure the tightening torque of the mounting bolts to ensure they meet the requirements.

6.5.2 Foot pedals The tightening torque of the left and right pedal axles was measured using a torque wrench.

6.5.3 Chains and Drive Belts

6.5.3.1 Chain Install a spring clip chain on a bicycle, checking the position and orientation of the spring clip. Inspect the chain joint; the pin should be exposed. Check for evenness. Rotate the chain and feel for any unusual noises or other abnormalities. Then, as shown in Figure 6, use a specialized measuring tool... Press the two ends onto the top of the meshing points of the flywheel and chain and the sprocket and chain respectively, apply a downward force F of 10N in the middle, and measure the sag.

6.5.3.2 Transmission Belt As shown in Figure 6, a drive belt is installed on a bicycle. The two ends of a special measuring tool are pressed onto the rear and front pulleys of the drive belt, respectively. At the top and middle of the top, a downward force F of 10N is applied, and the sagging is measured.

6.5.4 Speed Transmission Device

6.5.4.1 External speed change device For bicycles with external derailleurs, while turning the crank to rotate the rear wheel, shift the gear control lever or electronic control switch to check each gear. Check whether the gear shifting is correct, clear, and timely, and whether there is any neutral shift, chain slippage, or scraping noise.

6.5.4.2 Internal transmission device 6.5.4.2.1 Gear shifting test The testing method for shifting gears on a bicycle equipped with internal gears is as follows:

a) For non-automatic internal gear bicycles, when the crank is turned to turn the rear wheel, the shift control lever or electronic control button is engaged. Check the gear position display to ensure it is correct and clear when shifting between gears, and to ensure the shift response is timely.

b) For bicycles with automatic internal gears, check each gear when turning the crank to rotate the rear wheel and engage the internal gear system for automatic shifting. Check whether the output speed is correct and clear when shifting gears. 6.5.4.2.2 Neutral Test The method for testing the neutral gear on an internally geared bicycle is as follows:

a) For bicycles equipped with internal gears, after installation and adjustment, fix the rear wheel and move the shift control lever or electronic control button to shift gears. The internal gear shifts back and forth between two adjacent gears. Visually check if the crankshaft is rotating. Repeat this process for all gears.

b) For automatic internal gear bicycles, it is necessary to ride and test whether there is a feeling of the pedals slipping during gear shifting.

6.5.5 Chain guard Visually and tactilely check if the chain guard is loose. Manually rotate the crank to visually check if the chain guard rubs against the chain, sprocket, and crank.

6.5.6 Installing Fasteners Use a torque wrench to install fasteners on various components of the drive system (crank mounting bolts, sprocket mounting nuts, external derailleur mounting bolts, derailleur chain). The tightening torque of the mounting screws, chain adjusting screws, chain cover mounting screws, etc., is tested.

6.6 Saddle and Saddlepost Assembly

6.6.1 Visually inspect the minimum insertion depth marking on the bicycle's saddle tube, or whether the effective stop is inside the frame seat tube.

6.6.2 Visually inspect whether the vertical plane of the saddle center is parallel to the center plane of the frame and whether the saddle surface is horizontal.

6.6.3 The tightening torque of the saddle-to-saddle tube clamping bolts and the saddle tube-to-frame rear joint bolts was tested using a torque wrench.

6.7 Mud Plate Assembly

6.7.1 Rotate the front and rear wheels by hand and visually inspect whether the mudguards are rubbing against the wheel/tire assembly and whether the mudguards are twisted.

6.7.2 The tightening torque of the mudplate mounting bolts was tested using a torque wrench.

6.8 Lighting System Assembly

6.8.1 Visually inspect the bicycle lighting system to ensure it has a front light and/or a rear light, and that the front light and/or rear light are not obstructed by mounting devices. Block/shield the beam. Turn the switch on and off manually, and visually check that the lighting system is working properly.

6.8.2 When the bicycle is unloaded, a screen is installed 4000mm directly in front of the headlight, so that the low beam of the headlight shines onto the screen. Measure the height h1 of the center of the low beam transmission (i.e., the height of the luminaire) from the ground, and simultaneously measure the height of the midpoint of the low beam cutoff line from the ground in the vertical direction. Height region h2.

6.8.3 Visually inspect the lighting system and mounting hardware for breaks or visible cracks; check by touch for loose mounting bolts. Invalid.

6.8.4 The tightening torque of the mounting bolts of the lighting system shall be tested using a torque wrench.

6.9 Reflector Assembly

6.9.1 Visually inspect whether the installation of the front reflector meets the requirements for type, quantity, and color. Use an angle measuring instrument to measure the installation angle of the front reflector. Does the deviation meet the requirements?

6.9.2 Visually inspect whether the installation of the rear reflectors meets the requirements for type, quantity, and color. Use an angle measuring instrument to measure the installation angle of the front reflectors. Does the deviation meet the requirements?

6.9.3 Visually inspect whether the installation of the side reflectors meets the requirements for type, quantity, location, and color.

6.9.4 The tightening torque of the reflector mounting bolts was tested using a torque wrench.

6.10 Assembly of the horn device The tactile inspection checks are performed to check for interference between the horn device and adjacent operating devices. A specialized inspection tool is used to measure the rotational torque of the horn device. test.

6.11 Assembly of brackets and luggage racks

6.11.1 Visually inspect whether the double supports and wheels are symmetrical; check whether the vehicle can stand stably after being supported vertically.

6.11.2 Visually inspect whether the luggage rack and wheels are symmetrical and whether there is any obvious deviation.

6.11.3 The tightening torque of the luggage rack and bracket mounting bolts shall be tested using a torque wrench.

6.12 Testing equipment and instruments The test used testing equipment and instruments that meet the requirements of GB/T 12742.