Vintage_Bike_Galore.pdf

8/17/2019 Vintage_Bike_Galore.pdf

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CORRECT FITTINGMake sure your helmet covers your forehead

INCORRECT FITTINGForehead is exposed and vulnerable to serious injury

©2010


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Congratulaons on your new purchase!Our Service Department is dedicated to

your sasfacon with Cycling Sports Group andits products. For quesons regarding

performance, assembly, operaon,

parts or returns, contact the experts at

Cycling Sports Group directly by calling toll free

[email protected]

©20102


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

the inconvenience of having to go back to the store if you choose to write or call us concerning missing parts, service quesons,operang advice, and/or assembly quesons.

16 Trowbridge DriveBethel, CT 06801 USA

www.schwinnbikes.com

Serial number locaon(Bike shown upside down)

Service scker locaon(Opposite side of the serial number)


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ABOUT THIS MANUAL

It is important for you to understand your new bicycle. By reading this manual before you go out on your rst ride, you’ll know how to getbeer performance, comfort, and enjoyment from your new bicycle. It is also important that your rst ride on your new bicycle is taken ina controlled environment, away from cars, obstacles, and other cyclists.

GENERAL WARNING

Bicycling can be a hazardous acvity even under the best of circumstances. Proper maintenance of your bicycle is your responsibility as ithelps reduce the risk of injury. This manual contains many “Warnings” and “Cauons” concerning the consequences of failure to maintainor inspect your bicycle. Many of the warnings and cauons say “you may lose control and fall.” Because any fall can result in serious injuryor even death, we do not repeat the warning of possible injury or death whenever the risk of falling is menoned.

A SPECIAL NOTE FOR PARENTS

It is a tragic fact that most bicycle accidents involve children. As a parent or guardian, you bear the responsibility for the acvies andsafety of your minor child. Among these responsibilies are to make sure that the bicycle which your child is riding is properly ed tothe child; that it is in good repair and safe operang condion; that you and your child have learned, understand and obey not only theapplicable local motor vehicle, bicycle, and trac laws, but also the common sense rules of safe and responsible bicycling. As a parent,

you should read this manual before leng your child ride the bicycle. Please make sure that your child always wears an approved bicyclehelmet when riding.

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©2010

4 MAINTENANCE

Scheduled • Inspecon • How to x a at re • Troubleshoong

3 ASSEMBLY

Tools • Handlebar • Front Wheel • Saddle • Pedals • Adjustments • Final Check

2 BEFORE YOU RIDE

Warning, Note to parents • Fit • Helmets, Protecve Gear & Clothing • Safety Checklist • Riding Safety • Operaon • Security • Maintenance • Storage

1 PARTS IDENTIFICATION

Single Speed Bicycle • Mul Speed Bicycle

.................................................................................................6-7

.......................................................................................................8-25

..................................................................................................................26-49

.........................................................................................................50-65

...............................................................................................................66-675 WARRANTY

Take noce of this symbol throughout this manual and pay parcularaenon to the instrucons blocked o and preceded by this symbol.

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©2010

P A R T S I D E N T I F I C A T I O N

SINGLE SPEED BICYCLE

Get to know the parts of your bicycle. This will help with assembly, maintenance, and troubleshoong. Single speed bicycles vary greatly. Yourmodel may have addional accessories such as fenders, bags, carriers, etc. Note that smaller children’s bicycles also contain training wheels.

Handlebar stem

Front brake

Brake pad

Front fork

Front hub

Wheelreflector

Rear brake lever

Handle bar

Front reflector

Seat

Rear reflector

Seat stay

Training wheel bracket

Rear sprocket

Spokes

Handlebar grip

Brake control cable

Head set

Head tube

Top tube

Down tube

Seat post

Pedal

Tire valve

Training wheel

Chain wheel

Chain

Crank arm

Chain stay

Rim

Tire

Seat tube

Seat post binder boltor quick-release skewer

1.1

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©2010

MULTI SPEED BICYCLE

Get to know the parts of your bicycle. This will help with assembly, maintenance, and troubleshoong.Mul speed bicycles vary greatly. Your model may have addional accessories such as fenders, bags, carriers, etc.

Seat

Rear reflector

Seat post

Quick release

Rear Brake

Gearcontrol cable

Shi lever

Handlebar stem

Head set

Head tube

Top tube

Down tube

Seat tube

Seat stay

Front derailleur

Chain wheel

Boom Bracket Axle

Crank arm

Tire valve

Front hub

Chain stay

Chain

Rear derailleur

Pedal

Freewheel

Wheel reflector

Rim

Spokes

Tire

Handlebar

Brake lever

Brake control cables

Front reflector

Front brake

Front fork

1.2

P A R T S

I DE N T I F I C A T I O N

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SIZING GUIDE & CHART

When choosing the correct size bicycle, there are some guidelines that will helpyou determine the correct t. It is important that you are able to safely mount anddismount the bicycle, and that while riding you are comfortable and can operate thebrakes, steering and pedal without any added diculty.

The rst rule is when standing over the bicycle, in front of the seat, straddlingthe top tube of the bicycle, you should have a minimum of 1-3 inches of clearance.

For ladies frames, pretend there is a top tube, because although you may be able tostraddle the frame, you must also be able to reach the handlebars. Bicycles get longeras well as taller as you go up in size.

Wheel size is a good starng point, but bicycles vary, so only use wheel size to getstarted, aer that, check that the rider can safely reach the handlebars while sllbending the elbows at least 10 degrees. The saddle height is adjustable, so there isa range of riders that will t each bicycle. Note that the correct height for the saddleis not determined by foot – to – oor, but by foot – to pedal. The leg should be almostcompletely straight when the pedal is in the down most posion. Just a slight bend in

the knee. This may put the rider in a posion where their feet can not touch the groundeasily. The rider can simply move forward of the saddle while mounng and dismounngthe bicycle. The saddle can be adjusted lower if the rider is uncomfortable this high, butnote that riding is more dicult with the saddle too low, as the legs are in an unnaturalposion. It is common for younger riders who want to feel secure to be able to touchthe ground easily, or any rider who is not comfortable with not being able to touch theground. In this case start o with the saddle lower, and raise the seat as condencein riding is gained. Do not raise the seat so much that the knees lock straight whenpedaling or you have to move forward of the saddle to pedal. This is unsafe and thebicycle can not be controlled in this condion.

Make sure that while riding you can see ahead of you clearly, steer and brake withno diculty reaching the brake levers or operang foot brakes. Also be sure you canmount and dismount the bicycle quickly if the need arises.

Please refer to the separate adjustment areas of this manual for seat and handlebaradjustments (p. 26 and p. 30)

*Note that some bicycles such as folding bicycles may have smaller wheels but sll t adults.

1-3 inches

2.1 B E F O R E Y O U R I D E

Bike Wheel Size

12 inch wheel

16 inch wheel

18 inch wheel

20 inch wheel

24 inch wheel

26 inch wheel

700c

Your Approx. Height

28 - 38 inches tall

38 - 48 inches tall

42 - 52 inches tall

48 - 60 inches tall

56 - 66 inches tall

64 - 74 inches tall

64 - 74 inches tall

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RIDING POSITION

Saddle Height In order to obtain the most comfortable riding posion and oer the best possible

pedaling eciency, the seat height should be set correctly in relaon to the rider ’s leglength. The correct saddle height should not cause leg strain from over-extension, andthe hips should not rock from side to side when pedaling. While sing on the bicyclewith one pedal at its lowest point, place the ball of your foot on that pedal. The correct

saddle height will allow the knee to be slightly bent in this posion. If the rider thenplaces the heel of that foot on the pedal, the leg should be almost straight. (Fig. 2.2)

Under no circumstances should the seat post extend from the frame beyondits “Minimum Inseron” or “Maximum Extension” mark. If your seat postextends from the frame beyond these markings, the seat post or frame maybreak, which could cause you to lose control and fall. Prior to your rst ride,be sure to ghten the saddle adjusng mechanism properly. A loose saddleclamp or seat post binder can cause damage to the bicycle or can cause youto lose control and fall. Periodically check to make sure that the saddleadjusng mechanism is properly ghtened.

Reach To obtain maximum comfort, the rider should not overextend his or her reach when

riding. To adjust this distance, the posion of the seat can be altered in relaon to theseat post. (Refer to p.30 on how to adjust the seat clamp.) (Fig. 2.3, 2.4)

BE F O RE Y O U R I DE

Arms notoverextended

Handlebarstem heightabout thesame as

seat height

2.2

Kneeslightly bent

Pedal atboom

posion

2.3

2.4

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B E F O R E Y O U R I D E

ASTM CONDITION 12“This is a set of conditions for the operation of a bicycle on a regular paved or smooth surface where

tires may unitentionally lose ground contact.”

INTENDED1 To be ridden on paved roads only.

NOT INTENDED1 For off-road, cyclocross, or touring with racks or panniers.

MAXIMUM WEIGHT LIMIT1, 3RIDER (lbs/kg) LUGGAGE (lbs/kg) TOTAL (lbs/kg)

275/125 10/4.5* 285/126

ASTM CONDITION 12

ROAD TANDEM

“This is a set of conditions for the operation of a bicycle on a regular paved or smooth surface where

tires may unitentionally lose ground contact.”

INTENDED1Road tandems are designed to be ridden on paved roads only. They are not designed for mountain

biking or off-road use. Road tandems are designed for touring with racks and panniers.

NOT INTENDED1 Road tandem should not be taken off-road or used as a mountain tandem.


500 / 227 75 / 34 575 / 261

ASTM F2043

Suitable forroad riding

(only)

CHILD BIKE

These bikes are designed for children riding where parental supervision isalways required. Riders

shall avoid areas used by automobiles, as well as inclines, curves, stairs, or areas near drop-offs

or pools.

• Maximum seat height of 68mm; generally, bicycles with16” or 20” wheels, and kids’ tricycles• No quick-release wheel fastening systems• Weight limit: 80 lbs (36 kg)

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ASTM CONDITION 22“This is a set of conditions for the operation of a bicycle that includes Con dition1 as well as unpaved

and gravel roads and trails withmoderate grades. Contact with irregular terrain and loss of tire

contact with the ground may occur. Jumps should be limited to 30cm (12in.) or less.”

INTENDED1 For paved roads, gravel or dirt roads that are in good condition, and bike paths.

NOT INTENDED1

For off-road or mountain bike use, or for any kind of jumping. Some of these bikes have suspension

features, but these features are designed to add comfort, not off-road capability. Some come with

relatively wide tires that are well suited to gravel or dirt paths. Some come with relatively narrow tires

that are best suited to faster riding on pavement. If you ride on gravel or dirt paths, carry heavier loads

or want more tire durability talk to your dealer about wider tires.


500 / 227 75 / 34 575 / 261

ASTM CONDITION 32“This is a set of conditions for the operation of a bicycle that includes Condition 1 and Condition 2 as

well as rough trails, rough un-paved roads, and rough technical areas and unimproved trails. Jumps of

60 cm (24 in.) or less are an ticipated.”

INTENDED1

For cross-country riding and racing which ranges from mild to aggressive over intermediate terrain

(e.g., hilly with small obstacles like roots, rocks, loose surfaces and hard pack and depressions). There

are no large “sick drop” or drop offs, jumps or launches (wooden structures, dirt embankments)

requiring long suspension travel or heavy duty components. Cross-country and marathon equipment

(tires, shocks, frames, drive trains) are light-weight, favoring nimble speed over brute force. Suspension

travel is relatively short since the bike is intended to move quickly on the ground and not spend time

in the air landing hard and hammering through things.

NOT INTENDED1For use in extreme forms of jumping/riding such as hardcore mountain, Freeriding, Downhill, North

Shore, Dirt Jumping, Hucking etc.


300 / 136 5 / 2.3* 305 / 138

ASTM F2043

For off-roadriding and

jumps less than12”(30cm)

ASTM F2043

For roughoff-road ridingand jumps less

than 24”(61 cm)

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Handlebar Height Maximum comfort is usually obtained when the handlebar height is equal to the height

of the seat. You may wish to try dierent heights to nd the most comfortable posion.

Threadless headsets and clamp-on stems are not adjustable. Please referto assembly-adjustments (p. 27) for instrucons on installaon.

The stem’s “Minimum Inseron” mark must not be visible above the top of theheadset. If the stem is extended beyond this mark, the stem may break or damage

the fork’s steer tube, which could cause you to lose control and fall.

Failure to properly ghten the stem binder bolt, the handlebar binder bolt, or thebar end extension clamping bolts may compromise steering acon, which couldcause you to lose control and fall. Place the front wheel of the bicycle betweenyour legs and aempt to twist the handlebar/stem assembly using a reasonableamount of force. If you can twist the stem in relaon to the front wheel, turn thehandlebars in relaon to the stem, or turn the bar end extensions in relaon tothe handlebar, you must ghten the appropriate bolts accordingly.


Stem wedge bolt

Maximum height/minimum

inseron mark

Handlebarbinder bolt

Exceeds2 1/2”(64mm)

Stem wedge

2.5

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HELMETS, PROTECTIVE GEAR & CLOTHING

Helmets A WORD TO PARENTS REGARDING CHILDREN AND HELMETS:

Many states have passed helmet laws regarding children. Make sure youknow your states helmet laws. It is your job to enforce these rules withyour children. Even if your state does not have a children’s helmet law, itis recommended that everyone wear a helmet when cycling. When riding

with a child carrier seat or trailer, children must wear a helmet.It is strongly advised that a properly ng, ASTM or SNELL approved, bicycle safetyhelmet be worn at all mes when riding your bicycle. In addion, if you are carryinga passenger in a child safety seat, they must also be wearing a helmet.

The correct helmet should:• be comfortable

• have good venlaon • t correctly • cover forehead

Always wear a properly ed helmet which covers the forehead whenriding a bicycle. Many states require specic safety devices. It is yourresponsibility to familiarize yourself with the laws of the state where youride and to comply with all applicable laws, including properly equippingyourself and your bike as the law requires. Reectors are important safetydevices which are designed as an integral part of your bicycle. Federalregulaons require every bicycle (over 16”) to be equipped with front, rear,wheel, and pedal reectors. These reectors are designed to pick up andreect street lights and car lights in a way that helps you to be seen andrecognized as a moving bicyclist. Check reectors and their mounngbrackets regularly to make sure they are clean, straight, unbroken and

securely mounted.


Correct

2.6

Incorrect

2.7

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Choosing Riding Clothing and Protecve Gear When choosing to ride a bicycle, the riders should always consider the clothing they

will wear. Any loose clothing parts or strings can get caught in a bicycles moving partsand cause an accident. Be sure there are no loose cords, strings, over sized cus or pantlegs. Loose pants should be ed or tucked into a sock. A leg band is oen used to keeppants from geng caught in the chain of the bicycle. Be sure shoelaces are ed ghtly,and do not hang out. (Fig. 2.8)

Dress for the weather keeping in mind that when cycling, the wind can be colder than just walking or standing. Reecve clothing is always recommended for cycling. Avoidwearing all black, or dark clothes. A brightly colored jacket or shirt is a great way tohelp motorists and others see you.

Choosing to wear protecve gear is the riders or parents responsibility and is highlyrecommended. Protecve gear is available to cover knees and elbows, backs andshoulders and more.

Use of protecve gear can greatly reduce injuries while riding. If protecvegear is worn, be sure that it does not interfere with steering, braking andpedaling. Know your own abilies, and do not ride beyond them. (Fig. 2.9) B

E F O R E Y O U R I D E

2.9

2.8

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SAFETY CHECKLIST

Before every ride, it is important to carry out the following safety checks:

Brakes • Ensure front and rear brakes work properly. • Ensure brake shoe pads are not overly worn and are correctly posioned in relaon to the rims.

• Ensure brake control cables are lubricated, correctly adjusted and display no obvious wear. • Ensure brake control levers are lubricated and ghtly secured to the handlebar.

Wheels and Tires • Ensure res are inated to within the recommended pressure as displayed on the re sidewall. • Ensure res have tread and have no bulges or excessive wear.

• Ensure rims run true and have no obvious wobbles or kinks.• Ensure all wheel spokes are ght and not broken.

• Check that axle nuts are ght. If your bicycle is ed with quick release axles,

make sure locking levers are correctly tensioned and in the fully closed posion.

Steering • Ensure handlebar and stem are correctly adjusted and ghtened, and allow proper steering.

• Ensure that the handlebars are set correctly in relaon to the forks and the direcon of travel. • Check that the headset locking mechanism is properly adjusted and ghtened. • If the bicycle is ed with handlebar end extensions, ensure they are properly posioned and ghtened.

Chain • Ensure chain is oiled, clean and runs smoothly. • Extra maintenance is required in wet or dusty condions.


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Bearings • Ensure all bearings are lubricated, run freely and display no excess movement, grinding or raling. • Check headset, wheel bearings, pedal bearings and boom bracket bearings.

Cranks and Pedals • Ensure pedals are securely ghtened to the cranks. • Ensure cranks are securely ghtened to the axle and are not bent.

Derailleurs • Check that front and rear derailleurs are adjusted and funcon properly. • Ensure shi levers are securely aached.

• Ensure derailleurs, shi levers and control cables are properly lubricated.

Frame and Fork • Check that the frame and fork are not bent or broken. • If either are bent or broken, they should be replaced.

Accessories • Ensure that all reectors are properly ed and not obscured. • Ensure all other ngs on the bike are properly and securely fastened, and funconing. • Ensure the rider is wearing a properly ed helmet.


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Reectors 16” and under bicycles are considered “sidewalk bicycles”, and may not be ed with

reectors. These bicycles should not be ridden on streets, at night or unaended by anadult. All other bicycles are supplied with one front (white), one rear (red), two wheel(white), and four pedal (orange) reectors. These are an important safety and legalrequirement, and should remain securely ed and in good, clean condion at all mes.Periodically, inspect all reectors, brackets and mounng hardware for signs of wear ordamage. Replace immediately if damage is found. Front & rear reectors should be

mounted so that they are within 5 degrees of vercal (when looking at them from theside of the bike, while the bike is on level ground). The front reector should aimforward (when viewed from above), and the rear reector should aim straight back(when viewed from above). Wheel reectors should be checked to be sure they areght, and should be kept clean.


+/–5 degreesof vercal

2.10

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©2010

RIDING SAFETY

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 informaon, contact the Road Trac Authority in your State.

• Ride predictably and in a straight line. Never ride against trac.

• Use correct hand signals to indicate turning or stopping.

• Ride defensively. To other road users, you may be hard to see.

• Concentrate on the path ahead. Avoid pot holes, gravel, wet road markings, oil, curbs, speed bumps,drain grates and other obstacles.

• Cross train tracks at a 90 degree angle or walk your bicycle across.

• Expect the unexpected such as opening car doors or cars backing out of concealed driveways.

• Be extra careful at intersecons and when preparing to pass other vehicles.

• Familiarize yourself with all the bicycle’s features. Pracce gear shis, braking, and the use of toe clipsand straps, if installed.

• If you are wearing loose pants, use leg clips or elasc bands to prevent them from being caught in the chain.

• Wear proper riding are and avoid open toe shoes.

• Don’t carry packages or passengers that will interfere with your visibility or control of the bicycle.

• Don’t use items that may restrict your hearing.

• Do not lock up the brakes. When braking, always apply the rear brake rst, then the front.The front brake is more powerful and if it is not correctly applied, you may lose control and fall.

• Maintain a comfortable stopping distance from all other riders, vehicles and objects.

• Safe braking distances and forces are subject to the prevailing weather condions.


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©2010

Wet Weather • In wet weather you need to take extra care.

• Brake earlier, you will take a longer distance to stop.

• Decrease your riding speed, avoid sudden braking and take corners with addional cauon.

• Be more visible on the road.

• Wear reecve clothing and use safety lights.

• Pot holes and slippery surfaces such as line markings and train tracks all become more hazardous when wet.

Night Riding IT IS RECOMMENDED TO NOT RIDE AT NIGHT

Check your local laws regarding night riding;Many areas require the use of lights for night riding in addion to a full set of CPSC compable reectors.

• Ensure bicycle is equipped with a full set of correctly posioned and clean reectors.

• Refer to p. 15 of this manual.

• Use a properly funconing lighng set comprising of a white front lamp and a red rear lamp.

• If using baery powered lights, make sure baeries are well charged.

• Some rear lights available have a ashing mechanism which enhances visibility.

• Wear reecve and light colored clothing.

• Ride at night only if necessary. Slow down and use familiar roads with street lighng, if possible.


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Rules for Children

To avoid accidents, teach children good riding skills with an emphasis on safety from an early age. Children should be supervised by an adult.

1. Many states require that children wear a helmet while cycling. Always wear a properly ed helmet.

2. Do not play in driveways or the road.

3. Do not ride on busy streets.

4. Do not ride at night.

5. Obey all the trac laws, especially stop signs and red lights.

6. Be aware of other road vehicles behind and nearby.

7. Before entering a street: Stop, look le, right, and le again for trac. If there’s no trac, proceed into the roadway.

8. If riding downhill, be extra careful. Slow down using the brakes and maintain control of the steering.

9. Never take your hands o the handlebars, or your feet o the pedals when riding downhill.

The Consumer Protecon Safety Commission advises that the riding of small wheel diameter bicyclesat excessive speeds can lead to instability and is not recommended.

Children should be made aware of all possible riding hazards and correct riding behavior before they take to the streets.Do not leave it up to trial and error.


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©2010

BRAKE OPERATION

There are 2 types of braking systems for bicycles; Foot operated and hand operated.

Foot Operated Brakes Foot operated brakes allow the rider to pedal forward to accelerate the bicycle, and

pedal backwards to brake. The harder you push back on the pedals, the more brakingforce is applied to the rear wheel. In most cases a foot operated brake is strong enough

to “lock up” (stop the wheel from turning) the rear wheel and cause the re to skid.While this will decelerate the bicycle quickly, it will also cause unnecessary wear onthe re, and terrain, and can cause a loss of steering control. It is recommended topracce braking so that you have control over how quickly the bicycle comes to a stop.It is also important to know the environment that you are riding on. For example, a drypaved road is very predictable when stopping. But if you add rain, gravel, snow or anything else, the rider needs to be extra careful, and allow extra stopping distance, andslow down before turning. The rider should also be careful as terrain changes to keepthe bicycle at a controllable speed.

Some models may have a combinaon of foot and hand operated brakes. It is OK to

operate them at the same me or independently. However, if the bicycle is equippedwith a front wheel hand brake, be careful to use front and rear brake simultaneously,and avoid locking up the front wheel, as this can cause a loss of steering control, andcause a crash. See hand operated brakes (p. 20) for more detail.

BE F O RE Y O U R I DE 2.11

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Hand Operated Brakes Hand operated brakes have a separate hand lever to operate front and rear brakes.

Front hand brake levers are located on the le side of the handlebar, and rear handbrake levers are located on the right side of the handlebar. Hand operated brakes maybe used alone or on some models in conjuncon with foot operated brakes. It is OK tooperate one brake at a me, or all together, depending on your style, comfort, andriding condions, however, be careful to pay close aenon to front brakes locking up;

If the front brake is applied too quickly or too hard, the front wheel can stopturning resulng in a front pitch over or cause the bicycle to lose steeringfuncon leading to a crash.

To best avoid this, apply the front and rear brakes simultaneously, while shiing yourbody weight back slightly to compensate for braking force. As terrain changes, therider must pracce and learn how each bicycle will respond in a new terrain or weatherchange. The same bicycle will react dierently if it is wet, or if there is gravel on theroad etc. Always test the brakes and be sure you feel comfortable with the reacon.If the riding condions are too steep (o road for example) and you are unsure,dismount the bicycle and walk past the quesonable terrain before riding again.Remember that as you apply the brakes your weight will want to shi forward,and the wheels will want to stop. See Assembly and Maintenance for furtherinformaon on brake adjustment. (Fig. 2.12)


2.12

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GEAR OPERATION

Mul speed bicycles can have internal or derailleur gear systems.

WARNING: Improper shiing can result in the chain jamming,or becoming derailed resulng in loss of control or a crash.

Always be sure the chain is fully engaged in the desired gearbefore pedaling hard.

Avoid shiing while standing up on the pedals or under load.

To shi properly, pedal the bicycle with lile pressure on the pedals, andmove the shier (1) gear at a me, ensuring that the chain is fully engagedin that gear before applying more pressure on the pedals. For bicycles with 3front chain rings; avoid “Cross Chaining”, which is the posion when the chainis in the smallest cog in the rear combined with the inner or smallest chainring in the front, or the largest cog in the rear and the outer or largest chainring in the front. These gear posions put the chain at the most extreme angle

and can cause premature wear to the drivetrain. Bicycles with 3 front chainrings have enough gear “overlaps” that these gears are not needed. (Fig. 2.13)

Internal Gears (no derailleur)An internal gear system is one where the gears are housed within the rear hub of thebicycle. With internally geared bicycles, it is recommended to STOP pedaling while youshi gears. The bike may be sing sll or rolling to shi. Shier designs vary, you willeither twist or operate a push buon to change gears. The shier will indicate either“low to “high” or a series of numbers from 1 up. Low or “1” is the lowest gear. This isused for slower riding, hill climbing, or to allow for easier pedaling. It is recommended

to start o in this gear and move through the gears as speed increases as needed,or comfortable. It is OK to ride the whole me in only one gear if this is comfortable.Backpedaling should have no eect on an internally geared bicycle (unless it is equippedwith foot acvated brakes), however, backpedaling should not be necessary whenriding, and invites the possibility of clothing being caught in the chain, and shouldbe avoided. See Assembly and Maintenance for further informaon on propergear adjustment. (Fig. 2.14)


AVOID THESE GEARS!

1

2

2.13

2.14

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External Gears (derailleur equipped bicycles) Derailleur equipped bicycles all have a rear derailleur. Some may also have a front

derailleur oering more gear choices. The right side shier will operate the rearderailleur, and the le side (if equipped) will operate the front derailleur. On derailleurequipped bicycles, it is important to be pedaling forward when shiing gears. Thisallows the chain to “derail” from one gear to the next. Operang the shier whilesing sll or not pedaling can cause damage to the system, and can be dangerous,as the chain may jam and cause the bike to become unstable. (Fig. 2.15)

Avoid back pedaling on any bicycle with derailleurs. Backpedaling can derail thechain and cause it to jam or fall o the gears. When shiing gears, make sure you pedalforward unl the gear has completely changed. (At least one full rotaon of the pedals.)Failure to do so, may result in the chain not engaging properly the next me you pedalforward, or falling o altogether causing a possible danger when you aempt to pedalagain. Remember always pedal through the gear change on a derailleur equipped bicycle.

Rear ShierThe rear shier (right) will have an indicator that reads either “low to “high” or a series

of numbers from 1 up. Low or “1” is the lowest gear. This is used for slower riding, hillclimbing, or to allow for easier pedaling. It is recommended to start o in this gear andmove through the gears as speed increases as needed, or comfortable. It is OK to ridethe whole me in only one gear if this is comfortable. Shi only while pedaling forwardand seated. When shiing, lessen the pressure exerted on the pedals during the shi.Once you have successfully shied gears, it is OK to start to pedal hard if desired. Pedalinghard while shiing can cause the chain to skip and not engage the appropriate gear.Backpedaling should be avoided on derailleur bikes because the chain can jam andcause the bike to become unstable. See Assembly and Maintenance for furtherinformaon on proper gear adjustment. (Fig. 2.16)


2.16

Freewheelcogs

Frontderailleur

Rearderailleur

Guidepulley

Frontchainwheels

Crank armPedal

Derailleurcontrol cable

2.15

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Front Shier Note that not all models have a front shier. The front (le) shier will have an

indicator that reads either “low to “high” or a series of numbers from 1 up. Low or“1” is the lowest gear. The front shier acts much like the rear shier, but the changebetween gears is greater. This means that one shi at the rear derailleur will be a subtlechange in pedaling speed, but one shi at the front derailleur will be a large change inpedaling speed. Think of the front shier as a “range”, low and high or low, medium,and high. Low is used for slower riding, hill climbing, or to allow for easier pedaling. It

is recommended to start o in this gear and move through the gears as speed increasesas needed, or comfortable. It is OK to ride the whole me in only one gear if this iscomfortable. Shi only while pedaling forward. When shiing, lessen the pressureexerted on the pedals during the shi. Once you have successfully shied gears, it isOK to start to pedal hard if desired. Pedaling hard while shiing can cause the chain toskip and not engage the appropriate gear. Backpedaling should be avoided on derailleurbikes because the chain can jam and cause the bike to become unstable. (Fig. 2.17)

SECURITY

You just bought a new bicycle! Don’t lose it. It is advisable that thefollowing steps be taken to prepare for and help prevent possible the:

• Maintain a record of the bicycle’s serial number, generallylocated on the frame underneath the boom bracket.

• Register the bicycle with the local police and/or bicycle registry.

• Invest in a high quality bicycle lock that will resist hacksaws and bolt cuers. Alwayslock your bicycle to an immovable object if it is le unaended. Keep in mind thatindividual parts of a bicycle may be stolen. Most commonly, if you lock just a wheel or

just the frame, other parts may be removed from the bicycle. Although it is impossibleto lock all the parts, it is suggested to lock the major components if possible. Use alock that is long enough to lock the frame and both wheels if possible. Some modelswith quick release front wheels allow the front wheel to be placed beside the frameso a smaller lock can be used to lock all 3 components. Be aware that a quick releaseseatpost can be stolen. It is recommended to remove the seatpost and saddle andcarry it with you if you believe that this is a risk.

2.17


2.18

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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 milddetergent mixture. Dry with a cloth and polish with car or furniture wax. Use soap and water to clean plasc parts and rubber res.Chrome plated bikes should be wiped over with a rust preventave uid.

• Store your bicycle under shelter. Avoid leaving it in the rain or exposed to corrosive materials.

• Riding on the beach or in coastal areas exposes your bicycle to salt which is very corrosive. Wash your bicycle frequently and wipe orspray all unpainted parts with an an-rust treatment. Make sure wheel rims are dry so braking performance is not aected. Aer rain,dry your bicycle and apply an-rust treatment. If the hub and boom bracket bearings of your bicycle have been submerged in water,they should be taken out and re-greased. This will prevent accelerated bearing deterioraon.

• If paint has become scratched or chipped to the metal, use touch up paint to prevent rust. Clear nail polish can also be used asa preventave measure.

• Regularly clean and lubricate all moving parts, ghten components and make adjustments as required.(Refer to Parts 4 and 5 of this manual for further details).

STORAGE• Keep your bicycle in a dry locaon away from the weather and the sun.

Ultraviolet rays may cause paint to fade or rubber and plasc parts to crack.

• Before storing your bicycle for a long period of me, clean and lubricate all components and wax the frame.

• Deate the res to half pressure and hang the bicycle o the ground.

• Don’t store near electric motors as ozone emissions may eect the rubber and paint.

• Don’t cover with plasc as “sweang” will result which may cause rusng.

• Please noce that your bicycle warranty does not cover paint damage, rust, corrosion, dry rot or the.


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TOOLS FOR ASSEMBLY

Your new bicycle was assembled and tuned in the factory and then parally disassembled for shipping. You may have purchased the bicyclealready fully assembled and ready to ride OR in the shipping carton in the parally disassembled form. The following instrucons willenable you to prepare your bicycle for years of enjoyable cycling. For more details on inspecon, lubricaon, maintenance and adjustmentof any area please refer to the relevant secons in this manual. If you have quesons about your ability to properly assemble this unit,please consult a qualied specialist before riding. If you need replacement parts or have quesons pertaining to the assembly of yourbicycle, call the service line direct at:

Tools Required: • Phillips head screw driver

• 4mm, 5mm, 6mm and 8mm Allen keys

• Adjustable wrench or a 9mm, 10mm, 14mm and 15mm open and box end wrenches

• A pair of pliers with cable cung ability

To avoid injury, this product must be properly assembled before use. If your bicycle was obtained assembled, we strongly

recommend that you review the complete assembly instrucons and perform checks specied in this manual before riding.

We recommend that you consult a bicycle specialist if you have doubts or concerns as to your experience or ability to properlyassembly, repair, or maintain your bicycle.

A S S E M

BL Y

SERVICE & TECHNICAL SUPPORTCALL TOLL FREE 1-800-THE-BIKE

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GETTING STARTED

Open the carton from the top and remove the bicycle. Remove the straps and protecvewrapping from the bicycle. Inspect the bicycle and all accessories and parts for possibleshortages. It is recommended that the threads and all moving parts in the parts packagebe lubricated prior to installaon. Do not discard packing materials unl assembly iscomplete to ensure that no required parts are accidentally discarded. Assemble yourbicycle following the steps that pertain to your model. (Fig. 3.2)

NOTE: Your bicycle may be equipped with dierent style components than theones illustrated.

HANDLEBAR ASSEMBLY

Remove all protecve packaging from the handlebar assembly if not already done.Turn the fork of the bicycle to face forward. Note that “forward” means that the wheelmounng slots are in the furthest forward posion. So the wheel axle will be in front ofthe fork when assembled. (Fig. 3.3)

Check handlebar stem clamp bolts to be sure they are properly ghtened, and

handlebar can not move. The angle of the handlebar can be adjusted. To adjust; loosenall of the handlebar stem clamping bolts, and rotate the handlebar to the desired angle.Be sure that the handlebar stays centered in the stem. Reghten the bolts a LITTLE ata me being sure that the gap between the stem cap and stem stays even. Repeatghtening each bolt a lile bit unl handlebar is secure. (Fig. 3.4)

Models with gear and/or brake cables:Locate the handlebar assembly. If your model bicycle comes equipped with gearsand/or handbrakes, you will need to be sure that the brake cables and shi cables areproperly routed. Posion the handlebar assembly as if you were going to install it, andtake a look at the cables. They should run in a smooth arc from the shier or brake

lever to the front brake or cable stop on the frame. If they are twisted or kinked, theshiing and braking will not work. Rotate the handlebars around unl the cables aretaking the smoothest route. (Fig. 3.5)

A S

S E M B L Y

3.2

CorrectIncorrect

3.5

3.3 3.4

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There are 2 basic types of handlebar mounng; Quill and Threadless.

Quill Stems This is a handlebar assembly that has a wedge shaped part at the boom of the stem

that is inserted into the fork steer tube. Loosen the center bolt enough so that the wedgeand stem can slide into the fork steer tube. Lower the stem unl the mark that says“minimum inseron” is not visible. Tighten the stem center bolt so that the handlebarassembly is in line with the fork. If needed, you can re-check this aer the front wheel

is installed, and re-adjust. (Fig. 3.6)

Threadless Stems This is a handlebar assembly that has a open ended stem with 1 or more pinch bolts that

goes outside of the fork steer tube. For this system it is important not to disassemblethe headset and lose any parts. Be sure that the end of the fork is on the ground orbeing held with your free hand, because once you loosen the top cap, the fork assemblymay fall out of the frame. Loosen the top cap of the fork steer and remove any cardboardpacking, the top cap, and bolt. Set these aside so you can easily retrieve them. Whileholding the fork assembly in place, slide the handlebar assembly onto the fork tube.Replace the top cap and bolt. Tighten the top cap bolt only unl the handlebar assemblyand fork have no free play, but so that the handlebar assembly and fork can sll freelyturn le and right. Then ghten the pinch bolt(s) evenly with the handlebar assemblyfacing forward. If needed you can re-check this aer the front wheel in installed, andre-adjust. (Fig. 3.7)

NOTE: Comfort Series bicycles may be equipped with a stem that has an adjustable angle.In addion to the normal assembly, these stems will require angling the stem to thedesired posion, and securely ghtening the angle bolt located in front of the stembolt. Failure to do this may cause loss of steering control. (Fig. 3.8)

If the stem is not inserted at least the “Minimum Inseron” mark, it is possibleto over-ghten the stem bolt and damage the fork steerer tube. If theseinstrucons are not followed, it could cause an unsafe condion and riskinjury to the rider. Check steering ghtness prior to riding by straddling thefront wheel. Try turning the handlebar. If you can turn it without turningthe front wheel, the stem is too loose. Re-align the handlebar with thefront wheel and re-ghten the stem bolt.

A S S E M

BL Y

3.6

Top cap

Pinchbolt(s)

3.7

3.8

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FRONT WHEEL

There are two types of front wheel hubs; Nued and quick release.

Nued Front WheelsLoosen the axle nuts on the front wheel. If there is a washer inside of the axle nut, itbelongs outside of the fork dropouts. If the washer has a hook or a step, be sure thatit engages the fork before ghtening the axle nuts. Slide the front wheel between the

fork dropouts. If the wheel has a hook shaped washer, be sure that the hook is hookedinto the hole above the wheel slot. If there is a step washer, be sure the step ts intothe key hole at the top of the wheel slot. Tighten the two outer axle nuts evenly; Tightenone side part way, then ghten the other side and repeat unl both sides are ghtenedsecurely. Be sure that the wheel is centered between the fork legs. If it is o center, loosenthe axle nut on the side that has a smaller gap between re and fork leg, and use yourhand to push the wheel to a centered posion; hold the wheel with one hand, andghten the axle nut and check again. Repeat if needed to be sure the wheel iscentered and securely ghtened. (Fig. 3.9)

A S S E M B L Y

Axlenut

Forkdrop out

Conenuts

Retainingwasher

Stepretainingwasher

Axle Hub

3.9

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Quick Release Wheels 1. Locate the quick release skewer from the small parts carton of your bicycle. Some

re tread paerns have a direcon, so compare your front re and rear re of thebicycle so that both tread paerns face the same way. (Fig. 3.10)

2. Unscrew the lock nut from the quick release skewer, remove outer spring and slidethe skewer through the front wheel axle so that the handle is on the le side of thebike (the side opposite the chain). (Fig. 3.11)

3. Install spring and then start to thread the lock nut back onto the skewer, but do notghten too far.

4. Slide the wheel into the fork wheel slots and be sure that the wheel is centered.

5. Inspect the handle, note that there’s an “open” and a “closed” posion. Move thehandle so it is in the “open” posion. With one hand on the handle and one hand onthe lock nut, start to hand ghten the lock nut unl you start to feel some resistancewith the fork.

6. Try to close the handle. If it closes easily, open it up, and ghten the lock nut further.If it is too dicult to close, open the handle up, and loosen the lock nut a lile and

try again. 7. The quick release handle should be dicult to push closed with your palm, but should

be possible. Pracce opening and closing the handle unl you feel comfortable. DONOT aempt to ghten the wheel by turning the handle to ghten; the handle is forclosing, the lock nut (opposite side) is for adjusng the tension. (Fig. 3.12)

Next go back and check that the handlebars are perpendicular to the front wheel,go back to handlebar assembly and re-adjust if needed.

All quick release levers should be inspected before every ride to be surethey are fully closed and secure. Failure to properly close a quick release

lever can cause loss of control of the bicycle resulng in injury or death. Make sure the wheel is properly seated and the quick release is

properly closed.

A S S E M

BL Y

Close

3.10

3.11

3.12

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SADDLE ASSEMBLY

The seat post must be inserted so that the minimum inseron mark cannotbe seen. The quick release mechanism must be ghtened securely to preventa sudden shi of the seat when riding. Failure to do this may cause loss ofbicycle control.

The saddle assembly should be adjusted with the saddle centered on the rails andlevel. Locate the saddle assembly and insert into the frame. It is recommended to add

some grease to all threads and binders on a bicycle, especially on the outside of the seatpost. Otherwise it may corrode over me, and not be able to be adjusted again.

Bolted Seat ClampIf your bicycle has a seat clamp with a bolt, adjust seat to desired height, and ghtenthe clamp so that the saddle may not turn le or right, or move up or down. Be surethat the seat post is inserted far enough into the frame to hide the “Minimum inseron”mark on the seat post. Riding a bicycle with the seat post above this line is dangerousand can cause injury to the rider or damage to the bicycle or create an unstable ridingposion causing an accident. (Fig. 3.13)

Quick Release Seat ClampIf your bicycle has a seat clamp with a quick release, adjust seat to desired height, andghten the quick release clamp so that the saddle may not turn le or right, or moveup or down. If the saddle moves aer locking the quick release lever, open the lever,and ghten the adjusng nut further, then close the quick release lever again. Be surethat the seat post is inserted far enough into the frame to hide the “Minimum inseron”mark on the seat post. Riding a bicycle with the seat post above this line is dangerousand can cause injury to the rider or damage to the bicycle or create an unstable ridingposion causing an accident.

A S S E M B L Y

Seat clamp

Quick release

Seat post

Adjusng nut

Rails

3.13

3.14

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PEDALS AND CRANKS

Aachment of an incorrect pedal into a crank arm can strip pedal threads andcause irreparable damage. Before your rst ride, please check to ensure yourpedals are aached correctly.

Look for the leers “R” for right, and “L” for le, stamped on each pedal spindle.Start each pedal spindle by hand to avoid stripping the threads. (Note that theright hand pedal aaches to the chainwheel side crank arm with a right-hand

(clockwise) thread. The le pedal aaches to the other crank arm and has a le-hand (counter-clockwise thread). Tighten with a 15mm narrow open ended wrench.It is very important that you check the crank set for correct adjustment and ghtnessbefore riding your bicycle.

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Dustcap

3.15

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FRONT BRAKE

CAUTION: Improper use of the front brake may cause front wheel to lock upresulng in loss of direconal control or front pitch over.

Determine which type of brake your bike is equipped with and refer to the appropriateassembly instrucons below. *Addionally some freestyle models may be equippedwith a “cable detangler”. See assembly steps for cable detangler.

Caliper BrakeIf the brake cable is not connected at the brake lever, slide the head of the brake cableinto the brake lever per the diagram, and thread the cable through the slot in the brakelever so the cable end rests squarely in the adjustment barrel or cable end rests in therecess of the brake lever. (Fig. 3.16)

Brake adjustmentIf the brake cable is disconnected at the caliper, thread the brake wire through theadjustment barrel, loosen the cable anchor bolt unl you can see a hole through theanchor bolt for the cable wire to aach, thread the cable wire through the cable anchor

and snug the cable anchor by hand. (Fig. 3.17)Check to be sure the cable is seated in the brake lever. Loosen the cable anchor bolt

just enough to allow the cable wire to move freely. With your le hand squeeze thecaliper brake unl both brake pads contact the rim. While holding the brake closedwith your le hand, use your right hand to pull the brake cable ght (through thecable anchor) again inspecng that the cable end is seated in the brake lever, andthe barrel adjuster of the brake. Tighten the cable anchor as much as you can byhand, and then while sll squeezing the brake, ghten the cable anchor fully witha wrench. (Fig. 3.18)

A S S E M B L Y

Cable adjusng barrel

Cable head

Ferrule

Grip

Brake lever

Handlebar

Brakearm

Center bolt(fixing nut in back)

Cableadjusng

barrel

Cableanchor nut

Brake shoe

3.16

3.17

3.18

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Check the brake pads to be sure they are square to the rim, and do not contact the rewhen the brake is applied. Adjust brake pads if needed. Then squeeze and release thebrake several mes squeezing as hard as you can. Aer this the cable may “stretch”and need to be ghtened further. If so, repeat cable ghtening steps. (Fig. 3.19)

Centering brake If you squeeze the brake and one side moves more than the other, or one side does not

move at all, then the brake is not centered, or the wheel is not centered. First determineif the wheel is centered. Look at the gap between the re and the fork or frame on either

side. If it is not even, loosen wheel axle nuts and center the wheel, then proceed tocentering the brake. (Fig. 3.20)

If the brake is not centered; loosen the nut on the back of the brake. Squeeze the brakeand hold the brake lever closed, while re-ghtening the lock nut on the back of the brake.Watch the brake, if it begins to shi or rotate, then release the brake lever, and use yourhand to rotate the brake caliper back unl both sides of the brake move equally.Somemes it is necessary to over rotate the brake slightly, so that as you ghtenthe locknut, the brake will end up centered. Repeat the steps unl the brake is centered.

Brake is correctly adjusted when:• The brake pads do not drag on the rim when the brake is open.

• Both brake pads move away from the rim equally when the brake is released.• When the brake is applied, the brake pads contact the rim before the brake lever

reaches about 1/3 of the way to the handlebar. (Fig. 3.21)

Aer adjusng brake, squeeze the brake lever as hard as you can several mes andre-inspect the brake pads, centering, and brake lever travel. If the brake pads are nolonger square to the rim, repeat brake pad adjustments. Be sure that brake pads returnto a centered posion by spinning the wheel and listening for the brake pad rubbingthe rim on either side. Readjust as needed. Check that the brake cable tension allowsthe brake lever about 1/3 of the travel before the brake pads contact the rim. If thecable has stretched or slipped, readjust brake cable tension by loosening cable anchor

bolt and pulling more cable through the anchor or use brake adjustment barrels forne tuning brake cable tension.

A S S E MBL Y

Rim

Equal spacebetweenthe brake

and the rim

3.21

3.22

Brake pad alignedwith the rim surface

Pad andrim shouldbe parallel

1-2 mm

Incorrect

Correct

3.19

3.20

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U-BrakeIf the brake cable is not connected at the brake lever, slide the head of the brake cableinto the brake lever per the diagram, and thread the cable through the slot in the brakelever so the cable end rests squarely in the adjustment barrel or cable end rests in therecess of the brake lever. (Fig. 3.16)

Brake adjustmentCheck to be sure the cable is seated in the brake lever. Loosen the cable anchor bolt

just enough to allow the cable wire to move freely. With your le hand squeeze the

caliper brake unl both brake pads contact the rim. While holding the brake closedwith your le hand, use your right hand to pull the brake cable ght (through the cableanchor) again inspecng that the cable end is seated in the brake lever, and the barreladjuster of the brake. Tighten the cable anchor as much as you can by hand, and thenwhile sll squeezing the brake, ghten the cable anchor fully with a wrench.

A S S E M B L Y

Brake cable

Brake pads

Cable end cap

Cable anchor bolt

5mm Allen bolt

Housing barrel

Spring tension nut

To tensionspring

To tensionspring

FRONT

Cable carrier

20mm

Hook cable end

Brake cable

Cable anchor

5mm Allen bolt

Straddle cable

Spring tension nut

To tensionspring

To tensionspring

REAR A

Frame housing stop

To tensionspring

Brake cable

5mm Allen bolt

Spring tension nut

To tensionspring

Cable anchor

Brake housing

Cable anchor

Frame housing stop

Brake housingSeatTube

REAR B

3.23

3.24

3.25

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Check the brake pads to be sure they are square to the rim, and do not contact the rewhen the brake is applied. Adjust brake pads if needed. Then squeeze and release thebrake several mes squeezing as hard as you can. Aer this the cable may “stretch”and need to be ghtened further. If so, repeat cable ghtening steps. (Fig. 3.27)

Centering brakeIf you squeeze the brake and one side moves more than the other, or one side does notmove at all, then the brake is not centered, or the wheel is not centered. First determineif the wheel is centered. Look at the gap between the re and the fork or frame on either

side. If it is not even, loosen wheel axle nuts and center the wheel, then proceed tocentering the brake. (Fig. 3.28)

If the brake is not centered; determine which side of the brake needs to move, and usea wrench and Allen wrench to adjust the spring tension on that side. To do this, holdthe outer nut of the spring tension assembly with a wrench and carefully loosen thecenter Allen bolt unl you can move the nut with the wrench. Turn the spring tensionnut with the wrench unl the brake pad starts to move away from the rim. Hold thenut sll at the place where both brake pads are an equal distance away from the rim.While keeping the nut sll, re-ghten the Allen bolt. Squeeze the brake lever a fewmes to be sure that the brake is centered. Repeat above centering steps if needed.

Brake is correctly adjusted when:• The brake pads do not drag on the rim when the brake is open.

• Both brake pads move away from the rim equally when the brake is released. • When the brake is applied, the brake pads contact the rim before the brake

lever reaches about 1/3 of the way to the handlebar. (Fig. 3.29)

Aer adjusng brake, squeeze the brake lever as hard as you can several mes andre-inspect the brake pads, centering, and brake lever travel. If the brake pads are nolonger square to the rim, repeat brake pad adjustments. Be sure that brake pads returnto a centered posion by spinning the wheel and listening for the brake pad rubbingthe rim on either side. Readjust as needed. Check that the brake cable tension allows

the brake lever about 1/3 of the travel before the brake pads contact the rim. If thecable has stretched or slipped, readjust brake cable tension by loosening cable anchorbolt and pulling more cable through the anchor or use brake adjustment barrels forne tuning brake cable tension.

A S S E MBL Y

3.28

3.29



1-2 mm

Incorrect

Correct

3.26 3.27

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Cable DetanglerSome freestyle bicycles are equipped with a cable detangler for the rear brake. See diagram of the cable roung. If the upper cable is notalready assembled, insert the cable barrel end into the right (rear) brake lever. Adjust the brake lever adjustment barrel so that the slotsline up with the brake lever and insert the upper cable through the brake barrel slots. Rotate the barrel so that the slots are no longer inline. Note that on the upper cable, one of the cable casings is shorter than the other. The shorter side should be on the right. This is theshorter distance between the brake lever and the upper detangler plate. Thread the adjusng barrels in on both sides, and hook thecable ends into the bearing unit. Note that the lower cable should already be hooked into the lower tabs of the bearing unit. (Fig. 3.28)

Next try squeezing the brake lever several mes to be sure all the cables are seated in the adjustment barrels. If there is excess play

before the brake cable starts to move, this can be adjusted by unscrewing one or more of the adjustment barrels.

First adjust the barrel adjuster at the mid point of the upper cable unl the brake lever does not have any free play. Next squeeze thebrake lever and allow it to return. Check to see if the bearing unit booms out on the lower detangler plate? If so, unscrew the adjustbarrel further unl the bearing unit sits about 1mm above the lower plate. This is the correct posion for the bearing unit.

Rotate the handlebars back and forth, and then turn them completely around 360 degrees. Note whether the bearing unit spins quietly, orif it “ops” back and forth? If it has any op, this can be ne tuned with the 4 adjustment barrels in the upper and lower detangler plates.

The goal is to reduce or eliminate as much of the op as possible, while keeping the brake funcon consistent. While turning the handlebars360 degrees, note whether the plate ops forward and back, or if it ops the same way. If it ops forward and back, adjust the upper cablebarrel adjusters unl the op is reduced. If the op is the same way, then adjust the lower cables unl the op is reduced. Somemes both

need to be adjusted. The best thing to do is to adjust the lower cables rst unl the bearing unit has an equal gap on the le and right sides,then adjust the upper barrel adjusters unl the op is minimal or none at all.

Now follow the brake adjustments for the type of brake the bike is equipped with (Caliper or U brake).

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A S S E MBL Y

Barrel end

Upper cable

(short casing)

Upper plate

Upper cable(long casing)

Single cable casing

Cable adjuster

Cable splier

BearingFootball ends

Lower plate

Lower cable Lower cable

Locknut

Locknut

Adjusng barrel

Set for maximum travel

Minimum 1mm (1/32”)

Minimum 1mm (1/32”) Keyed washer

3.30

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Linear Pull BrakesIf the brake cable is not connected at the brake lever, slide the head of the brake cableinto the brake lever per the diagram, and thread the cable through the slot in the brakelever so the cable end rests squarely in the adjustment barrel or cable end rests in therecess of the brake lever. (Fig. 3.31)

If the brake cable is disconnected at the brake arm, with le hand, squeeze the 2 brakehalves together unl the brake pads touch the rims. With your right hand pull thebrake cable so that the stepped end of the “noodle” can be inserted into the brake

carrier.

Brake adjustmentCheck to be sure the cable is seated in the brake lever. Loosen the cable anchor bolt justenough to allow the cable wire to move freely. With your le hand squeeze the caliperbrake unl both brake pads contact the rim. While holding the brake closed with yourle hand, use your right hand to pull the brake cable ght (through the cable anchor.Again inspecng that the cable end is seated in the brake lever, and the barrel adjusterof the brake. Tighten the cable anchor as much as you can by hand, and then while sllsqueezing the brake, ghten the cable anchor fully with a wrench. (Fig. 3.32)

A S S E M B L Y

Noodle

3.32


Cable head

Ferrule

Grip

Brake lever

Handlebar

3.31

40

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Check the brake pads to be sure they are aligned with the rim, and that they donot contact the re when the brake is applied. Adjust brake pads if needed. Thensqueeze and release the brake several mes squeezing as hard as you can. Aer thisthe cable may “stretch” and need to be ghtened further. If so, repeat cable ghteningsteps. (Fig. 3.34)


move at all, then the brake is not centered, or the wheel is not centered. First determine

if the wheel is centered. Look at the gap between the re and the fork or frame on eitherside. If it is not even, loosen wheel axle nuts and center the wheel, then proceed tocentering the brake.

If the brake is not centered; use a Phillips screwdriver to ghten or loosen the screwson either side of the linear pull brake where they mount to the frame or fork. If youturn the screw clockwise it will increase spring tension on that side, counter clockwiseto decrease spring tension. Start by increasing tension on the side that is not moving ornot moving enough. Turn only about ½ turn at a me, and try squeezing and releasingthe brake lever a few mes to see the dierence. Repeat unl the brake is centered. Ifyou run out of adjustment, you can go to the other side and loosen the screw slightly

to connue adjusng the brake. When the brake is correctly adjusted, both sides shouldmove evenly when the brake lever is squeezed, and when released, the wheel shouldrotate with no brake shoe contact. (Fig. 3.35)

Brake is correctly adjusted when: • Both brake pads move away from the rim equally when the brake is released.

• The brake pads do not drag on the rim when the brake is open.• When the brake is applied, the brake pads contact the rim before the brake

lever reaches about 1/3 of the way to the handlebar (Fig. 3.36)

Aer adjusng brake, squeeze the brake lever as hard as you can several mes andre-inspect the brake pads, centering, and brake lever travel. If the brake pads are no

longer square to the rim, repeat brake pad adjustments. Be sure that brake pads returnto a centered posion by spinning the wheel and listening for the brake pad rubbingthe rim on either side. Readjust as needed. Check that the brake cable tension allowsthe brake lever about 1/3 of the travel before the brake pads contact the rim. If thecable has stretched or slipped, readjust brake cable tension by loosening cable anchorbolt and pulling more cable through the anchor or use brake adjustment barrels forne tuning brake cable tension.

A S S E MBL Y

3.35

3.36



1-2 mm

Incorrect

Correct

3.33 3.34

41

Di B k


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Disc BrakeIf the brake cable is not connected at the brake lever, line up brake barrel slots withbrake lever slot before installing the cable. Then slide the head of the brake cable intothe brake lever per the diagram, and thread the cable through the slot in the brake leverso the cable end rests squarely in the adjustment barrel or cable end rests in the recessof the brake lever. (Fig. 3.37)

If the brake cable is disconnected at the disc caliper, thread the brake wire through theadjustment barrel, loosen the cable anchor bolt unl you can see a hole through the

anchor bolt for the cable wire to aach, thread the cable wire through the cableanchor and snug the cable anchor by hand. (Fig. 3.38)


Cable head

Ferrule

Grip

Brake lever

Handlebar

3.37

A S S E M B L Y

Cableanchor bolt

Fork leg

3.38

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Centering brake


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move at all, then the brake is not centered, or the wheel is not centered. First determineif the wheel is centered. Look at the gap between the re and the fork or frame on eitherside. If it is not even, loosen wheel axle nuts and center the wheel, then proceed tocentering the brake. (Fig. 3.39, 3.40)

If the brake is not centered, look at the disc brake caliper for centering adjustment screwsat the center of the brake pad on either side. (Fig. 3.39) Looking down into the brake where

the brake pads contact the disc rotor, determine which side needs to move away or towardsthe disc. Turn the centering adjustment screws so that there is about 1/32 of an inch ofclearance on either side of the disc rotor. Spin the front wheel and listen for any rubbingnoise or excess fricon. Repeat the steps unl the brake is centered.

Brake is correctly adjusted when:• The brake pads do not drag on the rotor when the brake is open.

• Both brake pads move away from the rotor equally when the brake is released. • When the brake is applied, the brake pads contact the rim before the brake

lever reaches about 1/3 of the way to the handlebar. (Fig. 3.41)

DISC GETS HOT! Severe injury could result from contact with the hot disc!

Mind your legs, as well as your hands.

These brakes require breaking in! Ride and use the brakes gently for 13 miles beforeusing the brakes in downhill condions, for sudden stops, or any other serious braking.Please be aware that your brake system will change in performance throughout thewear-in process. The disc brake should be cleaned before the rst ride using rubbingalcohol. NEVER use oil or similar products to clean your disc brake system.

WARNING: Disc brakes are sharp, keep ngers away from brake caliper androtor. If ngers contact brake while wheel is turning injury can occur.

Aer adjusng brake, squeeze the brake lever as hard as you can several mes and re-

inspect the brake pads, centering, and brake lever travel. If the brake pads are no longersquare to the rim, repeat brake pad adjustments. Be sure that brake pads return to acentered posion by spinning the wheel and listening for the brake pad rubbing the rotor oneither side. Readjust as needed. Check that the brake cable tension allows the brake leverabout 1/3 of the travel before the brake pads contact the rotor. If the cable has stretched orslipped, readjust brake cable tension by loosening cable anchor bolt and pulling more cablethrough the anchor or use brake adjustment barrels for ne tuning brake cable tension.3.41

A S S E MBL Y

Adjust brakecaliper so discis centered

betweenbrake pads

3.39

3.40

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DERAILLEUR


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DERAILLEUR

Although the front and rear derailleurs are inially adjusted at the factory, you willneed to inspect and readjust both before riding the bicycle.

Rear DerailleurBegin by shiing the rear shier to largest number indicated and place the chain onthe smallest sprocket. Adjust the High limit screw so the guide pulley and the smallest

sprocket are lined up vercally. Reconnect the cable, pull out any slack, and reghtenthe anchor bolt securely. Shi through the gears, making sure each gear achieved is donequietly and without hesitaon. If necessary, use the barrel adjuster to ne tune eachgear by turning it the direcon you want the chain to go. For example, turning clockwisewill loosen the cable tension and move the chain away from the wheel, while turningcounter-clockwise will ghten cable tension and direct the chain towards the wheel.Shi the rear shier to the gear one and place the chain on the largest cog. Adjust theLow limit screw in quarter turn increments unl the guide pulley and the largest cogare aligned vercally. Again, shi through each gear several mes, checking that eachgear is achieved smoothly. It may take several aempts before the rear derailleur andcable is adjusted properly. (Fig. 3.42, 3.43)

Ensure all bolts are secured ghtly and the chain does not fall o ineither direcon.

A S S E M B L Y

Freewheel Outer side of top gear

Pulleyadjustment

screw

Adjustmentscrews

SIS cableadjuster

TensionPulley

GuidePulley

3.42

High gearadjustment

screw

Low gearadjustment

screw

Barreladjuster

3.42

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Front Derailleur


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Front Derailleur (Fig. 3.44) Shi both shiers to the smallest number indicated and place the chain

on the corresponding cog and chainwheel. Disconnect the front derailleur cable fromthe cable anchor bolt. Check the posion of the front derailleur; it should be parallelwith the outer chainwheel and clear the largest chainwheel by 1-3mm when fullyengaged. With the chain on the smallest chainwheel in front and the largest cog in back,adjust the Low limit screw so the chain is centered in the front derailleur cage. Reconnectthe cable, pull any slack out, and ghten the anchor bolt securely. Shi the front shier

to the largest chainwheel. If the chain does not go onto the largest chainwheel, turn thehigh limit screw in 1/4 turn increments counter-clockwise unl the chain engages thelargest chainwheel. If the chain falls o the largest chainwheel, and into the pedals, youwill need to turn the High limit screw in 1/4 turn increments clockwise unl the chainno longer falls o. Shi through every gear, using the barrel adjusters to ne tune eachtransion. The barrel adjuster for the front derailleur is located on the front shier wherethe cable comes out of the shier. Clockwise will loosen the cable tension and direct thechain closer to the frame while counter-clockwise will ghten the cable tension anddirect the chain away from the frame.

Do not ride a bicycle that is not shiing properly. Overlooking proper

adjustments may cause irreparable damage to the bicycle and/or bodilyinjury. Never move the shier while pedaling standing up, or under heavyload, nor pedal backwards aer having moved the shier. This could jamthe chain and cause serious damage to the bicycle and/or rider.

High adjusngscrew

Chainguide clearance

of 1-3mmOuter chainguide

Innerchainguide

Cableanchor bolt

Low adjusng screw

3.44

A S S E MBL Y

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FRONT FENDER if equipped


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FRONT FENDER - if equipped

The front fender is mounted at the fork crown. There are two ways in which to mountyour front fender. The rst is the caliper brake mounng system (see Fig. 3.45), and thesecond is the 10mm nut and bolt system (see Fig. 3.46). Idenfy the mounng systemused on your bicycle and follow the given instrucons for that parcular type ofmounng system.

(Fig. 3.45) Caliper Brake Mounng System

First remove the front wheel from your bicycle. Remove the hex nut from the caliperbrake bolt on the rear of the fork, and slide the brake assembly from the fork. Placethe fender assembly onto the fork making sure the aachment holes and fenderbracket holes line up. Reaach the caliper brake making sure that the brake armsare on each side of the fender. Tighten the bolt unl secure.

(Fig. 3.46) 10mm Nut and Bolt Mounng System First remove the front wheel from your bicycle. Place the fender assembly onto thefork making sure the aachment holes and fender bracket holes line up. Aach thefender with the 10mm hex bolt and nut. Tighten the bolt unl secure.

A S S E M B L Y

3.45

3.46

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PEGS


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PEGS

Some models may come equipped with 2 or 4 pegs. To install pegs, DO NOT loosen orremove axle nuts. Check to make sure axle nuts are properly ghtened before installingpegs. Thread the pegs on the axle over the axle nut, and insert a screwdriver or similartool through the peg holes and ghten by turning the peg with the tool. (Fig. 3.47)

Periodically check to make sure pegs are ght.

TRAINING WHEELS

Aaching training wheel brace to bicycleThere are three dierent braces used to aach the training wheels to the bicycle:the c-shape brace, the at brace and the at brace with stabilizer. Determine whichbrace was included with your bicycle and follow the given instrucons for thatparcular brace.

C-Shape Brace

Remove the outer axle nut and washer from the rear wheel axle. Place the bracestabilizer washer onto the axle and align the washer so that the notch on the washerts into the rear frame drop out. Next, place the C-shaped wheel brace onto the axleand replace the washer and axle nut. Tighten the axle nut securely, making sure thatthe wheel brace stays in the proper vercal posion. The elongated hole on the wheelbrace allows the training wheel height to be adjusted for proper t. (Fig. 3.48)

A S S E MBL Y

Front/rearhub

Front/reardrop outs

Retainingwasher

Step retainingwasher

Axle nut

3.47

Bracestabilizerwasher

Trainingwheel

C-Shapedwheelbrace

Axle nut

Inner axle

Inner axle nutDO NOT REMOVE

3.48

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Flat Brace


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Flat BraceIt is very important to check the training wheel connecon to the bicycle.Failure to properly ghten may cause the training wheel to dislodge. Pleasecontact Cycling Sports Group Service with any quesons.

Remove the outer axle nut and washer from the rear wheel axle. Place the at wheelbrace onto the axle. Next place the brace stabilizer washer onto the axle and align itso that the notch ts into the rear frame drop out. Replace the washer and axle nut.Tighten the axle nut securely, making sure that the wheel brace stays in the proper

vercal posion. The elongated hole on the wheel brace allows the training wheelheight to be adjusted for proper t. (Fig. 3.49)

Training Wheel Stabilizer BracketRemove the outer axle nut and washer from the rear wheel axle. Insert the wheel braceinto the stabilizer bracket so that the forked end of the stabilizer bracket faces in. Slideassembly onto the rear axle so that the forked end hooks around the chain stay of thebicycle. Replace the axle nut and washer, secure ghtly. The elongated hole on the braceallows for raising and lowering the training wheel to the proper height. (Fig. 3.50)

NOTICE: Not all bicycles will accept training wheels. If your bike did not come stock withtraining wheels, please call Cycling Sports Group to help determine if aer-markettraining wheels

can be aached.

A S S E M B L Y

Flat wheel brace

Trainingwheel

Bracestabilizerwasher

Axle nut

Inner axle

Inner axle nutDO NOT REMOVE

3.49

Trainingwheel

Wheelbrace

Axle nut

Washer

Stabilizer bracket

3.50

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FINAL CHECK


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FINAL CHECK

Never inate a re beyond the maximum pressure marked on the re’s sidewall. Exceeding the recommended pressuremay blow the re o the rim, which could cause damage to the bicycle and injury to the rider and bystanders.

Tighten both front/rear wheel axle nuts or the quick release mechanism securely. Failure to do this may cause thefront/rear wheel to dislodge from the frame dropouts resulng in serious damage or injury.

• Aer all adjustments have been made, shi through every gear several mes at varying speeds. This will ensure all your adjustmentsare correct and will allow you to pinpoint any trouble areas. If you encounter any problems, refer to the appropriate secon and make

any necessary adjustments.

• Check the re pressure and inate each tube to the recommended psi as stated on the sidewall of the re.

• Check that the kickstand operates smoothly and the kickstand bolt is secured ghtly.

• Finally, examine the bicycle. Make sure all accessories are aached and all quick releases, nuts and bolts have been ghtened securely.

• Correct maintenance of your bicycle will ensure many years of happy riding. Service your bicycle regularly by referring to the relevantsecons of this manual, OR take it to a professional bicycle shop. Remember: Always wear a helmet and obey all trac laws.

A S S E MBL Y

49

Correct roune maintenance of your new bike will ensure:


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Correct roune maintenance of your new bike will ensure:Smooth running - Longer lasng components - Safer riding - Lower running costs

Every me you ride your bicycle, its condion changes. The more you ride, the more frequently maintenance will be required. Werecommend you spend a lile me on regular maintenance tasks. The following schedules are a useful guide and by referring to Part 5of this manual, you should be able to accomplish most tasks. If you require assistance, we recommend you see a bicycle specialist.

WARNING: Do not over lubricate. If lubricant gets on rims, res or brake shoes, it will reduce control and braking performanceand may require a longer stopping distance. Injury to the rider can occur. Avoid geng any excess lubricaon on these areaby wiping o excess lubricant, and keeping these areas clean and dry.

LUBRICATION

NOTE: The frequency of maintenance should increase with use in wet or dusty condions. Do not over lubricate - remove excess lubricantto prevent dirt build up. Never use a degreaser to lubricate your chain (WD-40™).

M A I N T E N A N C E

Frequency Component Lubricant How to Lubricate

Weekly Chain Chain lube or light oil Brush on or squirtDerailleur wheels Chain lube or light oil Brush on or squirtDerailleurs Oil Oil can

Brake calipers Oil 3 drops from oil canBrake levers Oil 2 drops from oil can

Monthly Shi levers Lithium based grease Disassemble

Every Six Months Freewheel Oil 2 squirts from oil canBrake cables Lithium based grease Disassemble

Yearly Boom bracket Lithium based grease DisassemblePedals Lithium based grease DisassembleDerailleur cables Lithium based grease Disassemble

Wheel bearings Lithium based grease DisassembleHeadset Lithium based grease DisassembleSeat pillar Lithium based grease Disassemble

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WHEELS


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WHEELS

Quick release: Check that these are set to the closed posion and are properly tensioned before each ride.CAUTION: Maintain the closed posion and the correct adjustment. Failure to do so may result in serious injury.

Axle nuts: Check that these are ght before each ride.

It is most important that wheels are kept in top condion. Properly maintaining your bicycle’s wheels will help braking performance andstability when riding. Be aware of the following potenal problems:

• Dirty or greasy rims. CAUTION: These can render your brakes ineecve. Do not clean rims with oily or greasy materials. When cleaning,use a clean rag or wash with soapy water, rinse and air dry. Don’t ride while they’re wet. When lubricang your bicycle, don’t get oil onthe rim braking surfaces.

• Wheels not straight: Li each wheel o the ground and spin them to see if they are crooked or out of true. If wheels are not straight,they will need to be adjusted. This is quite dicult and is best le to a bicycle specialist.

• Broken or loose spokes: Check that all spokes are ght and that none are missing or damaged. CAUTION: Such damage can resultin severe instability and p

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