YOELEO G21 Disc Brake Gravel Frameset: Installation and Assembly Guide

1. Scope of This Assembly Guide

This manual serves as a guide for assembling the YOELEO G21 Disk from a frameset to a complete bicycle. Due to the complexity of the YOELEO frameset, it is intended for expert mechanics at Authorized YOELEO Dealers or experienced local bike shops familiar with internal cable routing. Instructions for electronic groupsets are primarily for Shimano Di2 wiring; SRAM eTAP or Campagnolo EPS may differ. A video guide and digital version are available at https://www.yoeleobike.com/.

2. General Notes on Assembly

• Inspect all components (frame, fork, seatpost, handlebar, headset top cap, spacers) for sharp edges, burrs, or cracks before assembly.
• If any cracks are found, do not proceed with assembly and contact YOELEO Customer Service or a dealer immediately.
• Ensure all edges of the handlebar, stem, top cap, and spacers contacting the steerer tube are rounded to prevent stress points.
• Do not drill, remove parts, or modify frame components without YOELEO HQ authorization, as this could lead to injury or death.
• Only install compatible components to maintain the integrity of the assembly.

3. Tools and Torque Specification

Using correct tightening torques is crucial for proper function and to prevent damage. Threads may require greasing or thread-lockers. Suggested thread-lockers include Loctite 222 or equivalent low-strength options. Avoid lithium-based greases for threads. Carbon grip paste (not ceramic grease) should be used on the seat post. Recheck bolt tightness after the first ride and periodically.

4. Housing and Hose Length Recommendation

Recommended housing and hose lengths for the YOELEO G21 Disk, which should be cut to fit the frame and handlebar size:

Disc Brake Hose Lengths (mm)

Cable Housing Lengths (mm) - Mechanical Groupset

5. Installation and Hose Routing

Detailed steps for routing and installation:

5.1 & 5.2: Rear Brake Hose and Caliper Installation

Route the rear brake hose from the left chainstay hole to the top tube, ensuring it passes above the Bottom Bracket (BB) sleeve. Refer to Section 4 for correct hose length. Install the rear brake caliper to the left chainstay and tighten the bolt until the brake is locked. Final tightening occurs after alignment with the disc rotor. Follow the brake manufacturer's OEM assembly instructions.

5.3 & 5.4: Front Brake Hose and Caliper Installation

Route the front brake hose through the fork entry hole (left fork arm) and up to the exit hole on the steerer tube. Refer to Section 4 for correct hose length. Install the front brake caliper to the fork and tighten the bolt until locked. Final tightening is done after alignment with the disc rotor. Follow the brake manufacturer's OEM assembly instructions.

5.5: Steerer Tube Assembly Preparation

Install the crown race and lower headset bearing (Black Bearing, 7mm) into the frame seat. Apply grease around the bearing frame seat.

5.6: Mechanical Groupset Installation

• 5.6.1 Rear Derailleur Installation: Install the rear derailleur to its hanger and tighten according to OEM torque specifications.
• 5.6.2 Front Derailleur Installation: Install the front derailleur to its hanger and tighten the bolt. Final tightening follows OEM specifications during tuning.
• 5.6.3 Rear Derailleur Cable Routing: Route the rear derailleur cable housing from the right chainstay hole all the way to the headtube, using the recommended length from Section 4.2.
• 5.6.4 Front Derailleur Cable Routing: Route the front derailleur cable housing from the front derailleur cable hole, upper bottom bracket, all the way to the headtube, using the recommended length from Section 4.2.
• 5.6.5 BB386 Press Fit Installation: Install the BB386 press fit bottom bracket, ensuring all three cables are routed on top of the BB sleeve cylinder.
• 5.6.6 Foam House Installation: Install the foam housing from the headtube opening and slide it until it sits in the middle of the downtube.

5.7: Steerer Tube and Headset Installation

• Push the steerer tube up into the head tube, guiding the front brake hose through the bearing and up through the head tube. Use a proper support for the fork to prevent it from dropping. All four cables should now be visible at the head tube.
• Install the upper bearing (Black bearing) into its frame seat. Ensure the rear and front brake hoses are positioned between the bearing and the steerer tube. Apply grease around the bearing frame seat.
• Install the compression ring (C-ring), ensuring the cut faces forward. Install the headset top cap, keeping all cables tidy and in front of the frame.

5.8: Handlebar Installation Guideline

• 5.8.1 Shift Lever Installation: Install shift levers on the H9v2 handlebar according to OEM specifications.
• 5.8.2 Handlebar Cable Routing:
  • Route rear derailleur housing from the front stem exit hole, through the handlebar, and out the right lever exit hole.
  • Route front derailleur housing from the right stem exit hole, through the handlebar, and out the left lever exit hole.
  • Route front brake hose from the front stem exit hole, through the handlebar, and out the left lever exit hole.
  • Route rear brake hose from the front stem exit hole, through the handlebar, and out the right lever exit hole.

5.9: Headset Adjusting

• Handlebar stack height can be adjusted using split spacers (10mm, 3mm, 5mm).
• Interlock the required number of spacers between the top cap and handlebar. Ensure spacers and top cap alignment pins are correctly seated and cables are not twisted.
• Install the planned spacers between the handlebar and top cap. Slide the handlebar down the steerer tube until the spacer is seated on the top cap. Lightly tighten the handlebar to secure headset components.
• Mark a line on the steerer tube aligned with the top edge of the stem. For uncertain final stem positions, add round spacers on top of the stem before marking.
• Disassemble the handlebar from the steerer tube to cut the steerer tube. The actual cutting line should be 5mm below the marked line.
• Slide the handlebar down the steerer tube to the top of the last spacer. Ensure housings are pushed back into the frame to prevent kinks. Firmly tighten the headset using the expander and top cover, referring to Section 3 for correct torques. The correctly assembled headset should appear as illustrated.

6. Final Check

• 6.1 Brake Tightening: Perform final tightening of the brakes, checking their centering according to OEM instructions. Ensure disc brake calipers are tightened to OEM specs and properly bled before the first ride.
• 6.2 Drivetrain Tuning: Fine-tune the drivetrain (rear and front derailleur) according to OEM specifications.
• Pre-Ride Check: Before the first ride, carefully check the correct assembly and operation of all components. Repeat these checks periodically.

Contact Us

For inquiries and support, please contact YOELEO through the following regional websites and emails:

• Website: https://www.yoeleobike.com/
  Email: info@yoeleobike.com
• Website: https://www.yoeleospain.com/
  Email: info@yoeleospain.com
• Website: https://www.yoeleofrance.com/
  Email: info@yoeleofrance.com
• Website: https://www.yoeleogermany.com/
  Email: info@yoeleogermany.com
• Website: https://www.yoeleojapanshop.com/
  Email: info@yoeleojapanshop.com
• Website: http://www.yoeleoindonesia.com/
  Email: info@yoeleoindonesia.com
• Website: https://www.yoeleoitaly.com/
  Email: info@yoeleoitaly.com