PACIFIC CYCLE none manual

CORRECT FITTING - MAKE SURE YOUR HELMET COVERS YOUR FOREHEAD. INCORRECT FITTING. FOREHEAD IS EXPOSED AND VULNERABLE TO SERIOUS INJUR Y. AL WA YS WEAR A PROPERL Y FITTED HELMET WHEN YOU RIDE YOUR BICYCLE. DO NOT RIDE AT NIGHT . A VOID RIDING IN WET CONDITIONS. HELME TS SA VE LIVES !!![...]

P P ersonal ersonal C C are are from Pacific Cycle 1.800.626.2811 Congratulations on your new bike! Congratulations on your new bike! Our Service Department is dedicated to your satisfaction with Pacific Cycle . We want to help with any questions or comments you may have. You can also reach us by email at: service@pacific-cycle.com. DO NOT Return t[...]

14 RIDING SAFELY General Rules When riding obey the same road laws as all other road vehicles, including giving way to pedestrians, and stopping at red lights and stop signs. For further information, contact the Road Traf fic Authority in your State. Ride predictably and in a straight line. Never ride against traffic. Use correct hand signals to in[...]

15 Wet Weather DO NOT RIDE IN WET WEA THER - In wet weather you need to take extra care. - Brake earlie r, you will take a longer distance to stop. - Decrease your riding speed, avoid sudden braking, and take corners with additional caution. - Be more visible on the road. - Wear reflective clothing and use safety lights. - Pot holes and slippery su[...]

16 Hill Technique - Gear down before a climb and continue gearing down as required to maintain pedaling speed. - If you reach the lowest gear and are struggling, stand up on your pedals. Y ou will then obtain more power from each pedal revolution. - On the descent, use the high gears to avoid rapid pedaling. - Do not exceed a comfortable speed, mai[...]

17 GEARS - HOW TO OPERATE Derailleur Gears Most multi-speed bicycles today are equipped with what are known as derailleur gears. They operate using a system of l evers and mecha nisms to move the drive chain between different sized driving gears or cogs. The purpose of gears is to let you maintain a constant, steady pedal ing pace under varying con[...]

18 6 5 4 3 2 1 6 5 4 3 2 1 Recommended Chainwheel/Rear Sprocket Gear Combinations Hand Grip Shifters Some bicycles are now being equipped with a shifting mechanism called Grip Shift, which is built into the handlebar grips and does not make use of separate levers. The actuating mechanism is built into the inside part of the grip that the web of the[...]

Please Retain your Sales Receipt as Proof of Purchase. Notes: _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ [...]

The following manual is only a guide to assist you and is not a complete or comprehensive manual of all aspects of maintaining and repairing your bicycle. The bicycle you have purchased is a complex object. We recommend that you consult a bicycle specialist if you have doubts or concerns as to your experience or ability to properly assemble, repair[...]

Thank Y ou for purchasing your bicycle. Please take a moment to fill out this reply card, and mail it back to us. We value your business and appreciate your feedback. Name: ______________________________________________ Birthdate: ____________________ Address: __________________________________________________________________________ ______________[...]

BICYCLE REGISTRA TION 4902 HAMMERSLEY ROAD MADISON, WI 5371 1 PLACE ST AMP HERE Cut along dotted line before mailing Cut along dotted line before mailing[...]

DIRECTORY PART 1 PART 2 PART 3 PART 4 PART 5 PART 7 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-05 Before You Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-21 Assembly . . . . . . . . . . . . . . . . . . . . [...]

01 1. P ARTS IDENTIFICA TION 2-5 Mountain Bicycles 2 BMX Bicycles 3 T ools Require d4 2. BEFORE YOU RIDE 6-21 Correct Frame Size 6 Riding Positio n7 -Saddle Height 7 -Reach 7 -Handlebar Height 8 Safety Checklist 9-10 -Brakes 9 -Wheels & Tires 9 -Steerin g9 -Chai n1 0 -Bearings 10 -Cranks & Pedal s1 0 -Derailleurs 10 -Frame & Fork 10 -Ac[...]

02 Gear Control Cable Rear Derailleur PART 1 - PARTS IDENTIFICATION Mountain Bicycles . Mountain bicycles are designed to give maximum comfort over a wide variety of road surfaces. The wider handlebars and convenient shift lever position make them very easy to control. Wider rims and tires give them a softer ride with more traction on r ough surfac[...]

03 BMX Bicycles . BMX style bicycles are a popular general purpose type most suited for young riders. They are valued because of their sturdy and simple construction, and low maintenance. Seat Seat Post Seat Post Binder Bolt Seat Stay Rear Reflector Wheel Reflector Chain Wheel Crank Arm Pedal Rim T ire Tire Va lve Chain Rear Sprocket Training Wheel[...]

04 Y our new bicycle was assembled and tuned in the factory and then partially disassembled for shipping. Yo u may have purchased the bicycle already fully re-assembled and ready to ride OR in the shipping carton in the partially disassembled form. The following instructions will enable you to prepare your bicycle for years of enjoyable cycling. Fo[...]

05 ABOUT THIS MANUAL This manual was written to help you get the most performance, comfort, enjoyment and safety when riding your new bicycle. It is important for you to understand your new bike. By reading this manual before you go out on your first ride, you’ll know how to get the most from your new bicycle. It is also important that your first[...]

06 CORRECT FRAME SIZE When selecting a new bicycle, the correct choice of frame size is a very important safety consideration. Most full sized bicycles come in a range of frame sizes. These sizes usually refer to the distance between the center of the bottom bracket and the top of the frame seat tube. For safe and comfortable riding there should be[...]

07 RIDING POSITION Saddle Height In order to obtain the most comfortable riding position and offer the best possible pedaling efficiency , the seat height should be set correctly in relation to the rider ’s leg length. The correct saddle height should not allow leg strain from over-extension, and the hips should not rock from side to side when pe[...]

08 Handlebar Height Maximum comfort is usually obtained when the handlebar height is equal to the height of the seat. Y ou may wish to try different heights to find the most comfortable position. Threadless headsets and clamp-on stems are not adjustable and are outside the scope of this manual. Please consult a qualified bicycle technician for deta[...]

09 SAFETY CHECKLIST Before every ride, it is important to carry out the following safety checks: 1. Brakes - Ensure front and rear brakes work properly . - Ensure brake shoe pads are not over worn and are correctly positioned in relation to the rims. - Ensure brake control cables are lubricated, correctly adjusted, and display no obvious wear . - E[...]

10 4. Chain - Ensure chain is oiled, clean and runs smoothl y. - Extra care is required in wet or dusty conditions. 5. Bearings - Ensure all bearings are lubricated, run freely and display no excess movement, grinding or rattling. - Check headset, wheel bearings, pedal bearings and bottom bracket bearings. 6. Cranks and Pedals - Ensure pedals are s[...]

11 Helmets It is strongly advised that a properly fitting, ANSI or SNELL approved, bicycle safety helmet be worn at all times when riding your bicycle. In addition, if you are carrying a passenger in a child safety seat, they must also be wearing a helmet. The correct helmet should: - be comfortable - be lightweight - have good ventilation - fit co[...]

12 Reflectors Y our bicycle is supplied with one front (white), one rear (red), two wheel (white), and two pedal (orange) reflectors. These are an important safety and legal requirement, and should remain securely fitted and in good, clean condi- tions at all times. Periodically , inspect all reflectors, brackets and mounting hardware for signs of [...]

13 Seat and Handlebar Mounting Reflectors First attach the reflector to the reflector bracket with the reflector screw, see the top diagram. Next, remove the clamp screw and open the clamping reflector bracket. Place clamping reflector bracket around the handlebar or seatpost. If the clamp is too loose, insert the shim inside of the clamp. Ti ghten[...]

19 Thumb Shifters (Top Mounted) Most mountain style bicycles are equipped with shifters mounted on the top of the handlebars and operated by the thumbs. To select a lower , easier gear , shift to a bigger rear cog and a small chainwheel. Pull the left shifter back to operate the front derailleur , and push the right shifter forward to operate the r[...]

20 BICYCLE CARE Basic Maintenance The following procedures will help you maintain your bicycle for years of enjoyable riding. For painted frames, dust the surface and remove any loose dirt with a dry cloth. To clean, wipe with a damp cloth soaked in a mild detergent mixture. Dry with a cloth and polish with car or furniture wax. Use soap and water [...]

21 Storage Keep your bicycle in a dry location away from the weather and the sun. Ultraviolet rays may cause paint to fade or rubber and plastic parts to crack.Before storing your bicycle for a long period of time, clean and lubricate all components and wax the frame. Deflate the tires to half pressure and hang the bicycle off the ground. Don'[...]

22 DERAILLEUR GEARED BICYCLES Includes 20", 24” and 26" Wheel Mountain Bikes Assembly is the same for men’s and women’s bikes. . Getting Started Open the carton from the top and remove the bicycle. Remove the straps and protective wrapping from the bicycle. Inspect the bicycle and all accessories and parts for possible shortages. It[...]

23 NOTE: Comfort Series (CS) bicycles may be equipped w ith a stem t hat has an adjustable angle. In addition to the normal assembl y, t hese stems w ill require angling t he stem to t he desired position, and securely tightening t he 6mm angle bolt l ocated in front of t he stem bolt. Failure to do this may cause loss of steering control. If the s[...]

24 Ti ghten all bolts that clamp the shifters, brake levers, and bar ends to the handlebar using a 5mm Allen key or Phillips head screwdriver . (Figure 1) Handlebar with Grip Shifte r. (Figure 2) T op mounted thumb shifte r. Failure to properly tighten clamping bolts may cause sudden movement of the component resulting in loss of steering control. [...]

25 Forks There are two different types of forks that range in styles and dimensions. One type is a rigid fork (Figure 1) consisting of stationary tubing with curved blades. The other type is a suspension fork (Figure 2) consisting of stanchion tubes riding on elastomers or springs inside of a straight fork leg. This mechanism acts as a shock absorb[...]

26 Seat and Seat Post Attach the seat to the seat post by loosening the nuts on the seat clamp. Insert the tapered end of the seat post into the seat clamp until it is at the top of the clamp. Partially tighten the nuts on the seat clamp until the seat is snug, but can still be turned. I nsert the seat assembly into the frame of the bicycle and adj[...]

27 Attachment of an incorrect pedal into a crank arm will cause irreparable damage. Before your first ride, please check to insure your pedals are attached correctly . Pedals & Crank Set Look for the letters “R” for right, and “L” for left, stamped on each pedal spindle. Start each pedal spindle by hand to avoid stripping the threads. T[...]

28 Front Wheel Check the wheel hub before attaching it to the fork by rotating the threaded axle. It should be smooth with no lateral movement. Insert the front wheel into the fork dropouts. Tighten the wheel nuts using the appropriate 14mm or 15mm wrench. Spin the wheel checking for trueness. Some bicycles have wheel axles that incorporate a Quick[...]

29 Front Brake Determine which type of brake your bike is equipped with and refer to the appropriate assembly instructions. For more information on brake adjustment and maintenance, refer to p. 66-69. Cantilever Brakes - Utilizing a Link Wire If fitted with cantilever type brakes, insert the brake cable into the link wire lead, and notch the cable [...]

30 3. T emporarily tighten the cable so that the link wire is at the position in the illustration. 1 1 2 2 1 1 2 2 5. Secure one of the shoes at a time. The adjustment of the shoe clearance is not necessary at this time. Shoe fixing nut tightening torque: 7.84 - 8.82 Nm (70 - 78 in. lbs.) 6. If balance adjustment is necessary , adjust with the spri[...]

31 Cantilever Brakes - Utilizing a Straddle Cable The length of the straddle cable, the height of the straddle hanger , and the brake pad-to-caliper arm position all have an effect on braking power . Generally , the straddle cable bridge is set low and close to the tire for maximum braking force. The straddle cable should be high enough, however, t[...]

32 V - Brake If fitted with V -Brakes, insert the brake body into the center spring hole in the frame mounting boss, and then secure the brake body to the frame with the link fixing bolt. 1. While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging the position of the B washers (i.e. 6 mm and 3 mm) so that dimens[...]

33 While holding the shoe against the rim, tighten the shoe fixing nut. 3. Adjust the balance with the spring tension adjustment screws. 5. Depress the brake lever about 10 times as far as the grip to check that everything is operating correctly and that the shoe clearance is correct before using the brakes. 6. Pass the inner cable through the inne[...]

34 Check your Brakes Press each brake lever to make sure that there is no binding and that the brake pads press hard enough on the rims to stop the bike. The brake pads should be adjusted so they are 1 mm to 2 mm away from the rim when the brakes are not applied. Brake pads should be centered on the rim and the rear portion of each brake pad should[...]

35 Disk Brakes If fitted with a front disc brake, the components should already be attached. However , please check all connections before attempting to ride the bicycle. Secure tightly the 6 bolts that hold the disc to the front wheel hub and the 2 bolts that hold the brake mechanism to the fork. Insert the front rim into the fork dropouts ensurin[...]

36 Fork Leg Brake Cable Housing Rotating Rod Cable Boot with Spring inside Cable Anchor Bolt Caliper Body Actuating Arm Caliper Mounting Bolts with spacers Quick Release lever Fork Drop Out Disc Disc Mounting Bolts Hub Centering Bolt Centering Bolt (inside) These brakes require breaking in! Ride and use the brakes gently for 13 miles before using t[...]

37 Derailleur Although the front and rear derailleurs are initially adjusted at the factory , you will need to inspect and readjust both before riding the bicycle. Rear Derailleur Begin by shifting the rear shifter to largest number indicated, disconnect the cable from the rear derailleur cable anchor bolt, and place the chain on the smallest sproc[...]

38 Front Derailleur Shift both shifters to the smallest number indicated and place the chain on the corresponding cog and chainwheel. Discon- nect the front derailleur cable from the cable anchor bolt. Check t he position of t he front derailleur; it should be para llel with the outer chainwheel and clear the largest chainwheel by 3- 5mm when fully[...]

39 Dual Suspension Dual Suspension bikes (DS) are equipped with a front fork as well as a rear suspension generally located below the seat. The piston works in conjunction with a spring to allow the bike to rotate on a pivot point. Ensure all attaching hardware is secured and there is no lateral movement of the rear triangle. The amount of Rear Sus[...]

40 Rear Pivots The pivot assembly is a simple mechanism that allows the rear triangle to move up and down in combination with a rear suspension. Size, shape, and compounds will vary between models; however , operating principles are the same. A shaft will pivot inside of two bushings secured in place with bolts. Pivots should be kept clean and free[...]

41 Accessories If your bike is supplied with a water bottle and cage, attach the cage to the bicycle using the Allen bolts provided. Most bikes come equipped with a saddle bag or frame bag. The saddle bag installs under the seat with the zipper facing the rear wheel. Undo the straps that wrap around the bag, thread them through the rails underneath[...]

42 Final Check -A fter all adjustments have been made, shift through every gear several times at varying speeds. This will ensure all your adjustments are correct and w ill allow you to pinpoint any trou ble areas. If you encounter any problems, refer to t he appropriate section and make any necessary adjustments. - Check t he tire pressure and inf[...]

43 SINGLE SPEED & BMX Includes 16" and 20" BMX Bikes Assembly is the same for boy’s and girl ’s b ikes. Getting Started Open the carton from the top and remove the bicycle. Remove the straps and protective wrapping from the bicycle. Inspect the bicycle and all accessories and parts for possible shortages. It is recomm ended t hat [...]

44 Seat Loosen nut on t he seat clamp and add 3 or 4 drops of o il onto t he threads of the bolt. Place the smaller end of the seat post i nto the seat clamp until it stops w ith t he bolt to t he r ear of t he seat post. Thread t he nut on the seat clamp loosely . I nsert t he larger end of t he seat post into t he seat t ube of t he bicycle frame[...]

45 Front Wheel 1. Make sure the brakes are loose enough to allow the wheel to pass through the brake pads easily . 2. Place wheel into fork drop outs. 3. Install retaining washers with raised lip pointed towards the fork, and insert into the small hole of the fork blade. 4. Install axle nut and tighten. Make sure the wheel is centered between the f[...]

46 Side Pull Brake Loosen the cable anchor nut and thread the brake cable through it. T ighten the nut by hand until it holds the cable in place. Squeeze the brake arms together against the rim of the wheel. Loosen the nuts on the brake shoes and turn until they match the angle of the rim. T ight- en the nuts securel y. Pull down on the end of the [...]

47 3. T emporarily tighten the cable so that the link wire is at the position in the illustration. 1 1 2 2 1 1 2 2 5. Secure one of the shoes at a time. The adjustment of the shoe clearance is not necessary at this time. Shoe fixing nut tightening torque: 7.84 - 8.82 Nm (70 - 78 in. lbs.) 6. If balance adjustment is necessary , adjust with the spri[...]

48 V - Brake If fitted with V -Brakes, insert the brake body into the center spring hole in the frame mounting boss, and then secure the brake body to the frame with the link fixing bolt. 1. While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging the position of the B washers (i.e. 6 mm or 3 mm) so that dimensi[...]

49 While holding the shoe against the rim, tighten the shoe fixing nut. 3. Adjust the balance with the spring tension adjustment screws. 5. Depress the brake lever about 10 times as far as the grip and check that everything is operating correctly and that the shoe clear ance is correct before using the brakes. 6. Pass the inner cable through the in[...]

50 Brake pad aligned with the rim surface Pad and rim should be parallel. Direction of rim rotation 1- 2 mm Cantilever Brakes - Utilizing a Straddle Cabl e The length of the straddle cable, the height of the straddle hanger , and the brake pad-to-caliper arm position all have an effect on braking power . G enerally , the straddle cable bridge is se[...]

51 Training Wheels 1. Position a washer on the shoulder bolt. Insert the shoulder bolt through the wheel. Follow with another flat washer then completely thread a nut on the shoulder bolt. 2. Insert the shoulder bolt through the brace. Set the “star” washer on the shoulder bolt. Lock into place by screwing another nut onto the shoulder bolt. 3.[...]

52 Rotors Some f reestyle BMX bicycles come equipped w ith a detan gler system that will allow the handlebar to spin 360-degrees w ithout binding t he cables. It is very i mportant t hat this sys tem is adjusted correctly . Installation should only be done by a qualified bicycle mechanic with the correct tools. Upper Cable 1. First connect the barr[...]

53 Failure to adjust correctly may result in loss of braking power and personal injury . Barrel End Single Cable Casing Cable Adjuster Cable Splitter Upper Cable (short casing) Upper Cable (long casing) Upper Plate Bearing Football Ends Lower Plate Lower Cable Adjusting Barrel Locknut Keyed Washer Locknut Adjusting Barrel 37mm + or - 1mm Set for Ma[...]

54 Final Check Install any additional parts that are supplied with your bike. NOTE: Y our bicycle may be equipped with different style components than the ones illustrated. Reflectors: Attach the white reflector to the front bracket and the red reflector to the rear bracket using an 8mm wrench or a Phillips head screwdriver . Attach the brackets to[...]

55 Correct routine maintenance of your new bike will ensure: Smooth running - Longer lasting components - Safer riding - Lower running costs Every time you ride your bicycle, its condition changes. The more you ride, the more frequently maintenance will be required. We recommend you spend a little time on regular maintenance tasks. The following sc[...]

56 T ask Check tire pressure Check brake operation Check wheels for loose spokes Make sure nothing is loose Quick wipe down with damp cloth Lubrication as per schedule 1 Lubrication as per schedule 1 Check derailleur adjustment Check brake adjustment Check brake and gear cable adjustment Check tire wear and pressure Check wheels are true and spokes[...]

57 Tools Required 1. Open ended wrench or ring wrenches: 8mm, 9mm, 10mm, 12mm, 13mm, 14mm, 15mm 2. Open end or pedal wrench 15mm 3. Allen key wrenches: 4mm, 5mm, 6mm, 8mm 4. Adjustable wrench 5. Standard flat head screwdriver 6. Standard Phillips head screwdriver 7. Standard slip joint pliers 8. T ire pump 9T ube repair kit 10. T ire levers Travel [...]

58 WHEELS AND TIRES Wheel Inspection It is most important that wheels are kept in top condition. Properly maintaining your bicycle's wheels will help braking performance and stability when riding. Be aware of the following potential problems: •Dirty or greasy rims: Caution: These can render your brakes ineffective. Do not clean them with oil[...]

59 Tire Inspection T ires must be maintained properly to ensure road holding and stability . Check the following areas: Inflation: Ensure tires are inflated to the pressure indicated on the tire sidewalls. It is better to use a tire gauge and a hand pump than a service station pump. C aution: If inflating tires w ith a service station pump, t ake c[...]

60 Hub Bearing Adjustment When checked, the hub bearings of either wheel will require adjustment if there is any more than slight side play . 1. Check to make sure neither locknut is loose. 2. To adjust, remove wheel from bicycle and loosen the locknut on one side of the hub while holding the bearing cone on the same side with a flat open end wrenc[...]

61 Remove tire bead from the rim. Pull tire back onto the rim. 6. Match the position of the leak in the tube with the tire to locate the possible cause and mark the location on the tire. 7. Remove the tire completely and inspect for a nail, glass, etc. and remove if located. Also inspect the inside of the rim to ensure there are no protruding spoke[...]

62 HANDLEBARS AND STE M Handlebar Stem The handlebar stem fits into the steering column and is held firm by the action of a binder bolt and expander wedge which, when tightened, binds with the inside of the fork steerer tube. When removing the stem, loosen the stem bolt two or three turns, then give it a tap to loosen the wedge inside. Lubricate by[...]

63 When re-fitting the stem, make sure the handlebars are correctly aligned and tightened using the appropriate hex wrench or allen key . Do not over tighten. T est the security of the handlebar within the stem, and the stem within the fork steerer tube, by clamping the front wheel between your knees and trying to move the handlebar up and down, an[...]

64 GRIP SHIFTERS Grip Shift - Installation 1. Slide front Grip Shift assembly over left side of handlebar leaving proper clearance for handlebar grip. If necessary , move the brake lever to accommodate Grip Shift and handlebar grip. 2. Rotate assembly until cable exits beneath brake lever with adequate clearance for brake lever movement. 3. Firmly [...]

65 Cables and Cable Housing Cables and housing are one of the most overlooked parts on the bicycle. The first indication that your cables and housing need to be replaced is an increased amount of pressure needed to operate the brakes or shifters. Before every ride, check that there are no kinks or frays in the cables and housing. Also check that th[...]

66 HEADSET Inspection The headset bearing adjustment should be checked every month. This is important as it is the headset which locks the fork into the frame, and if loose, can cause damage or result in an accident. While standing over the frame top tube with both feet on the ground, apply the front brake firmly and rock the bicycle back and forth[...]

67 Sleeves Seal Slider Elastomer T op-out Bottom-out Elastomer Skewer Through-Shaft Drop-Out Suspension Fork SUSPENSION FORK Some fork models di ff er from the one illustrated. Those models are not adjustable and require no maintenance other than keeping it free from dirt and grime. RST - Regular Maintenance The following maintenance should be perf[...]

68 SADDLE AND SEAT POST Inspection The seat fixing bolt and the seat post binder bolt should be checked for tightness and adjustment every month. On removing the seat post from the frame, you will notice a mark about 65mm up from the bottom with the words “max. height” or “minimum insertion”. To avoid damage to either the seat post, the fra[...]

69 Adjustment As mentioned in Part 2, the seat can be adjusted in height, angle and distance from the handlebars to suit the individual rider. Saddle angle is a matter of personal preference but the most comfortable position will usually be found when the top of the seat is almost parallel to the ground, or slightly raised at the front. The saddle [...]

70 BRAKES The correct adjustment and operation of your bicycle's brakes is extremely important for safe operation. Brakes should be checked for effective operation before every ride. Frequent checking of adjustment is necessary as the control cables will stretch and the brake pads will become worn with use. Never ride a bicycle unless the brak[...]

71 Some brakes have a quick release mechanism to allow easier wheel removal. W henever you adjust the brakes, make sure the quick release mechanism is in the closed position. Never ride unless the quick release is firmly locked in the closed position. Lubrication The brake lever and brake caliper pivot points should be oiled with 2-3 drops of light[...]

72 Some brakes have a special mechanism which enables you to set the clearance on either side of the rim using a screwdriver . Brake pads should finally be adjusted so that the leading edge of the pad makes first contact with the rim. Some brakes have special curved washers to allow this, but on less complex models it will be necessary to apply a l[...]

94 4. Removing and Installing Bolt-On Wheels a. Removing a Bolt-On Front Wheel (1) Open up the brake shoes. (2) With a 15mm box wrench or a six inch adjustable wrench, loosen the two axle nuts. (3) If your front fork has a clip-on type secondary retention device, disengage it and go to step (4). If your front fork has an integral seondary retention[...]

95 B. Seatpost Quick Release Many mountain bikes are equipped with quick-release seat post binders. The seatpost quick-release binder works exactly like the wheel quick-release. While a quick release looks like a long bolt with a lever on one end and a nut on the other , the quick release uses a cam action to firmly clamp the seat post. W ARNING: R[...]

96 C. Brakes NOTE: For most effective braking, use both brakes and apply them simultaneously . W ARNING: Sudden or excessive application of the front brake may pitch the rider over the handlebars, causing serious injury or death. 1. How brakes work It’s important to your safety that you instinctively know which brake lever controls which brake on[...]

97 When you apply one or both brakes, the bike begins to slow , but your body wants to continue at the speed at which it was going. This causes a transfer of weight to the front wheel (or , under heavy braking, around the front wheel hub, which could send you flying over the handlebars). A wheel with more weight on it will accept greater brake pres[...]

98 2. Shifting a derailleur drivetrain If your bicycle has a derailleur drivetrain, the gear-changing mechanism will consist of: • a rear sprocket cluster , called a freewheel or freewheel cassette • a rear derailleur • usually a front derailleur • one or two shifters • one or two control cables • one, two or three front sprockets calle[...]

99 1) Shifting the Rear Derailleur The rear derailleur is controlled by the right shifte r. The function of the rear derailleur is to move the drive chain from one gear to another on the rear gear cluster , thereby changing gear drive ratios. The smaller sprockets on the gear cluster produce higher gear ratios. Pedal- ing in the higher gears requir[...]

100 3. Shifting an internal gear hub drivetrain If your bicycle has an internal gear hub drivetrain, the gear changing mechanism will consist of: • a 3, 5, 7 or possibly 12 speed internal gear hub • one, or sometimes two shifters • one or two control cables • one front sprockets called chainrings • a drive chain a) Shifting internal gear [...]

101 F. C lipless (“step-in”) pedals Clipless pedals (sometimes called “step-in pedals”) are the means most racers use to keep their feet securely in the correct position for maximum pedaling efficiency . They work like ski bindings ... a plate on the sole of the shoe clicks into a spring-loaded fixture on the pedal. Clipless pedals require [...]

102 Ti re pressure is given either as maximum pressure or as a pressure range. How a tire performs under di ff erent terrain or weather condi- tions depends largely on tire pressure. Inflating the tire to near its maximum recommended pressure gives the lowest rolling resistance; but also produces the harshest ride. High pressures work best on smoot[...]

103 H. Bicycle Suspension Some Mountain Bikes come equipped with suspension systems which are designed to smooth out some of the shocks encountered in of f-road riding. There are many different types of suspension systems — too many to deal with individually in this Manual. If your bicycle has a suspension system of any kind, ask your dealer to p[...]

104 Purchase Record Card Fill in Immediately and retain as a record of your purchase. Y our Name: __________________________________________________ Address: ____________________________________________________ Date Purchased: ________________ Place of Purchase: ____________ Model & Brand Information: ____________________________________ Wheel [...]

105 LIMITED WARRANTY AND POLICY ON REPLACEMENT PROCEDURES AND RESPONSIBILITIES Y our purchase includes the following warranty which is in lieu of all other express warranties. This warranty is extended only to the initial consumer purchaser. No warranty registration is required. This warranty gives you specific legal rights and you may have other r[...]

73 On some newer type cantilever brakes, the main brake cable continues through the central cable carrier to an anchor bolt on one of the brake arms. A shorter link cable reaches from the carrier and the hook on the other brake arm. Adjustment of the cable length is made after loosening the anchor bolt on the brake arm. Adjust the brake pad positio[...]

74 DRIVETRAIN The drivetrain of a bicycle refers to all parts that transmit power to the rear wheel including the pedals, chain, chainwheel, crank set, and freewheel. PEDALS Pedals are available in a variety of shapes, sizes and materials, and each are designed with a particular purpose in mind. Some pedals can be fitted with toe clips and straps. [...]

75 Lubrication and Adjustment Many pedals cannot be disassembled to allow access to the internal bearings and axle. However , it is usually possible to inject a little oil onto the inside bearings, and this should be done every six months. If the pedal is the type that can be fully disassembled, then the bearings should be removed, cleaned and grea[...]

76 CRANK SE T The crank set refers to the bottom bracket axle and bearings, the crank arms, and chainrings. Y our bike may be fitted with either a one piece crank, where the crank arms and bottom bracket are a single component, or cotterless cranks, where the crank arms bolt onto the bottom bracket axle without using old fashioned type cotterpins. [...]

77 Lubrication and Adjustment - One Piece Cranks To adjust the free play in a one piece type bottom bracket, loosen the locknut on the left side by turning it clockwise and tighten the adjusting cone counter-clockwise using a screwdriver in the slot. W hen correctly adjusted, re-tighten the locknut counter-clockwise. To disassemble: 1. Remove the c[...]

78 Lubrication and Adjustment - Cotterless Cranks To adjust the free play in a three piece type bottom bracket, loosen the lockring on the left side by turning it counter-clockwise, then turn the adjusting cup as required. Re-tighten the lockring taking care not to alter the cup adjustment. To disassemble: 1. Remove the cranks from the axle. 2. Rem[...]

79 3. Screw the removing tool into the crank and tighten. 4. T urn the screw bolt down until the crank comes away from the axle. Cotterless Crank Replacement: 1. Replace the crank arm onto the axle. 2. T ap the crank arm lightly with a mallet. 3. Refit the washer and tighten flange nut or bolt securely to a torque of 27Nm. 4. Replace the dust cover[...]

80 CHAIN Inspection The chain must be kept clean, rust free and frequently lubricated in order to extend its life as long as possible. It will require replacement if it stretches, breaks, or causes inefficient gear shifting. M ake sure that there are no stiff links, they must all move freely . Lubrication The chain should be lubricated with light o[...]

81 Derailleur geared bicycles use narrower chains and require a special tool to fit and remove chain links, or to change the length. To remove, fit the rivet tool so that the punch pin is centered over any one of the chain rivets. Push the rivet almost all the way out, then back out the punch and remove the tool. Holding the chain on both sides of [...]

82 Lubrication Remove any accumulated dirt from the freewheel with a brush and a degreaser. Disassembly of t he freewheel is a compl icated procedure requiring special tools, and should be left to a specialist. Apply oil to the freewheel whenever you lubricate the chain, taking care to wipe off any excess. COASTER HUB Many BMX style and other child[...]

83 DERAILLEUR SYSTEMS The derailleur system includes the front and rear derailleurs, the shift levers, and the derailleur control cables, all of which must function correctly for smooth gear shifting to occur . There are several different types of derailleur systems but all operate using similar principles. Y our new bicycle may be fitted with a st[...]

84 Lubrication All the pivoting points of the front and rear derailleurs should be lubricated with light oil at least every month. Be sure to wipe off any excess oil to prevent attraction of dirt into the mechanisms. The shifting cables should be cleaned and re-coated with a thin layer of grease every six months, or whenever new cables are being in[...]

85 Adjustment - Front Derailleur 1. Shift the rear shifter to the smallest number indicated, then shift the front shifter to the smallest number indicated. Disconnect the front derailleur cable from the cable anchor bolt and place the chain on the smallest chainwheel. 2. Make sure the front derailleur cage is parallel with the outer chainwheel on t[...]

86 QUICK RELEASE LEVERS It is important to check the quick release levers before every ride to ensure all connections are made properly and securel y. Periodically , disassemble the mechanism from the bicycle and inspect for any wear or damage and replace if necessary . When re-installing, it is very important to ensure the connections are made pro[...]

87 Basket Assembly Y our bicycle may be supplied with an attachable front basket. Yo u must make sure that the basket is attached properl y. First insert on washer onto the 10mm hex head bolt and insert hex head bolt through the basket an then through the basket bracket assembly (on bike). Next, insert a second washer onto the bolt and thread a 10m[...]

88 Problem Gear shifts not working properly Slipping chain Chain jumping off freewheel sprocket or chainring Constant clicking noises when pedaling Grinding noise when pedaling Possible Cause - Derailleur cables sticking/stretched/damaged -F ront or rear derailleur not adjusted properly - Indexed shifting not adjusted properly - Excessively worn/ch[...]

89 Problem Freewheel does not rotate Brakes not working effectively When applying the brakes they squeal/squeak Knocking or shuddering when applying brakes Wobbling wheel Possible Cause -F reewheel internal pawl pins are jammed -B rake blocks worn down - Brake blocks/rim greasy , wet or dirty -B rake cables are binding/stretched/damaged - Brake lev[...]

90 Remedy - Align wheels correctly -A djust/tighten headset -T ake bike to a bike shop for possible frame realignment - Replace Inner tube - Replace tire - Replace with correct tire - Remove sharp object embedded in tire - Correct tire pressure -F ile down spoke Problem Steering not accurate Frequent punctures Possible Cause -W heels not aligned in[...]

91 6. How Things Work It’s important to your performance, enjoyment and safety to understand how things work on your bicycle. Even if you’re an experienced bicyclist, don’t assume that the way things work on your new bike is the same as how they work on older bikes. Be sure to read and to understand this section of the Manual. If you have eve[...]

92 Secondary retention devices fall into two basic categories: a) The clip-on type is an accessory part which the manufacturer adds to the front wheel hub or front fork. b) The integral type is molded, cast or machined into the outer faces of the front fork dropouts. Ask your dealer to explain the particular secondary retention device on your bike.[...]

93 (6) Close the brake shoes; then spin the wheel to make sure that it is centered in the frame and clears the brake shoes. W ARNING: Secondary retention devices are not a substitute for correct quick release adjustment. Failure to properly adjust the quick release mechanism can cause the wheel to wobble or disengage, which could cause you to lose [...]