How to assemble your Rhino

Your Rhino is already 95% assembled and only needs a few simple steps to be fully functional. Just watch the assembly video below ( 8 minutes) or follow the step-by-step instructions. 

What you'll need 

• A friend to help carefully lift the bike out of the box
• A knife or scissors to open the top of the box and cut the zip-ties
• Your Rhino parts box, which contains:
• Pedals
• Charger and cord
• Toolkit (contains all the tools you need for assembly)
• Touch-up paint
• Footpegs
• Miscellaneous screws

Assembling your Rhino

While assembling your Rhino should take no longer than 30 minutes, please take your time with each step. Remember to carefully open the top of the box (don’t rip it) to lift the bike out and clear away any packaging and trash as you go so you don’t lose any important parts. We want to make sure your Rhino is ready to ride as soon as you’ve assembled it!

If you don't want to assemble your bike yourself, you can also take it to a local bike shop where they can easily assemble it for a small fee.

Assembly Video

Step-by-step instructions

• Unpack your Rhino
• Install the handlebars
• Install the front fender
• Install the front wheel
• Install the front brake caliper
• Install the pedals
• Install the passenger footpegs
• Install your headlight
• Install your rear rack
• Get your Rhino ready to ride 

Unpacking Rhino

1. Place the box upright and cut the box open along the seams. Be careful not to rip the box
2. Remove any of the foam packaging and carefully lift the bike out of the box and gently place it on the ground
3. Cut all of the zip-ties attached to the handlebars and set the handlebars aside
4. Cut the remaining zip-ties and set the parts box (cardboard) and wheels aside in a safe place
5. Remove any cardboard and foam packaging with your hands to avoid scratching your frame

Installing the handlebars

1. Pick up the handlebars and find the minimum insertion line

   

2. Slide your handlebars into your two forks until the  minimum insertion line is just covered. Set your bike aside.

   

3. Open up your parts box (cardboard) to make sure everything is there (listed at the top of this article)
4. With an allen key tighten the two allen key screws on the side of the fork. To tighten, turn each screw 1-2 circles to the right, alternating screws, until the screws are snug, but not over-tight. Repeat on the other fork.

   

5. Check your handlebars are in and tight. Tighten again if you need!

Installing the front fender

1. Unscrew and remove the small bolt, washer, and nut that sit at the top of the wheel fork. Keep the bolt, washer, and nut in a safe place

   

2. Orient the fender so the larger side of the fender is towards the back of the bike and the shorter side is towards the front of the bike

   

3. Lift the fender up to align the fender holes with the bolt holes you just removed
   

   

4. Push the bolt (with the washer closest to the bolt head) through all of the holes and hand screw on the nut on the other side.
5. Tighten the bolt with an allen key while you hold the nut with your hand until it is snug, not over-tight.
   

Installing the front wheel

Note: these instructions are for a quick release wheel. The latest Rhino models have regular bolts instead of quick releases. For the purpose of these instructions, they are one and the same

1. Find your quick release bolt in the packaging (sometimes it is clipped or taped to the front wheel, the disc protector, or the bike’s axle)
2. Unscrew the end off the quick release bolt to remove the end and the cone-shaped spring

   

3. On the non-disc side of the wheel, slide the quick release bolt through the middle of the wheel
   

   

4. Turn the wheel around, and on the non-disc side, slide the cone-shaped spring onto the bolt so the cone faces the wheel
   

   

5. Screw the end on the bolt a couple of turns (it should be loose)
6. Remove the piece of protective plastic from the end of the bike forks. It’s just there for shipping
   

   

7. Orient the wheel in between the forks so the brake disc is on the disc side (the left fork, which has a protruding part with screw holes)
   

   

8. Slide the wheel between the front forks and hook the forks onto the quick release bolt on either side of the wheel
   

   

9. With the bike on the ground, hold the quick release end with one hand and slowly screw the quick release arm to the right with the other hand. Tighten the bolt until it is snug, not over-tight

   

Attaching the front brake caliper

1. Set the bike up on its kickstand
2. Remove any packaging from the hanging disc brake (here's a video on how to remove the protective piece of plastic)
3. Locate the two main bolts, remove them, and set them aside
   

   

4. Slide the caliper over the disc just behind the front fork. Line up the bolt holes and reinsert the bolts that you just removed. Tighten until snug.
   

   

5. Lift the bike off the ground and spin the wheel freely. If it sounds like the wheel is rubbing somewhere, place the bike back on the ground and locate the two caliper screws (note: these are different to the two bolts you used to attach the caliper to the disc)
   

   

6. Loosen both caliper screws until the caliper can wiggle a little
7. Squeeze the front brake lever on the handlebars and hold it in to center the caliper
   
8. Place a white piece of paper beneath the wheel and look down towards the ground from above the disc to make sure it is centered. If not, gently push the caliper over with your thumb or finger and keep looking down to make sure the caliper is centered over the rotor
   

   

9. Lift the front wheel and spin the wheel freely. Continue to make adjustments if necessary
   
10. Tighten your caliper screws so they are snug, not over-tight
    

Installing your pedals

1. There is a left pedal and a right pedal. To determine which pedal is for which side, if you’re sitting on the bike, you should be able to read the pedal manufacturer’s brand “wellgo” on the pedal

   

2. With your fingers, gently screw in the pedal to the axle. If you encounter any resistance, stop and make sure you’re screwing the pedal into the correct side
3. Take your 15mm wrench and gently tighten the pedal (for both pedals, push the wrench handle towards the front of the bike). Tighten until they are snug
   

   

Installing the passenger footpegs (optional)

1. Locate the loose screw on the frame that sits just above the kickstand screws. Unscrew the bolt and the nut and set them aside

   

2. Pick up your footpeg and insert the bolt and washer through the small hole on the footpeg
   

   

3. Insert the bolt into the hole that is closest to the rear of the bike and screw the nut onto the bolt

   

4. Orient the pedal so it points upwards, then take your 8mm wrench and hold onto the nut, while you use an allen key to tighten the bolt until it is tight
   

   

5. Repeat on the other side of the bike with the other footpeg
   

Installing your headlight

Note: Make sure your Rhino is turned off before starting this step

1. Remove the two screws, washers, and nuts from the bracket part of the headlight and set aside

   

2. Locate the headlight bracket on the bike frame and your headlight plug (marked with a reddish/orange plug insert)
   

   

3. Hold onto the headlight with the brackets away from you and the plug oriented towards the bottom of the headlight
   
4. Gently slide the headlight between the mounting bracket on the frame, lining up the bolt holes. Attach the screws on both sides of the bracket. Tighten enough so you can still adjust the angle of the headlight
   

   

5. Attach the plug on the headlight to the plug on the bike. Make sure the pins are aligned before pushing the two sides together. It only goes on one way

   

6. Take the protective film off the front of the headlight
7. To turn the headlight on and off, just follow the instructions in our article How to turn the headlight on. Note: Unlike the model in the assembly video, the latest headlights are designed to stay on low beams in order to minimize glare for motorists, riders, and pedestrians. It will still give you sufficient light to see the road or trail ahead of you.
   

Installing the rear rack (optional)

1. Open up the box and remove any of the packaging. Make sure you don’t throw out the bag with the bolts and washers
2. Unlock and remove your battery 
3. Line up the rear rack with the hole that is just under the back of the seat

   

4. Insert the longest screw and washer through the top slot of the rear rack and the hole. Finger tighten the nut on the end of the screw. You can tighten it later after you line up the rear rack
   

   

5. Then line up the rear rack sides with the holes on the frame. Use the short screws to attach the rack to the frame. Repeat on the other side
   

   

6. Tighten the two side screws and then the main long screw (you’ll need to hold the nut on the back while you tighten it)
7. Slide your battery back in
   

Getting your Rhino ready to ride

1. Turn your battery switch on
2. Remove the safety film off your display
   
3. Check out our before your first ride and tips for riding safely information and ZuGo’s Pre-Ride Safety Checklist
   

If you still need help with assembly

You may refer to our Zugo Bike User manual which you may download here.

If you need any help, please email us at [e-mail] or call us at 1-888-375-0041, Monday-Friday, 10AM to 5PM (Central). Remember it's always good to include videos or pictures with any inquiry!