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BICYCLEOWNER'S MAHUAL
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CORRECT FITTING-MAKE
SURE YOUR HELMET COVERS
YOUR FOREHEAD.
INCORRECT FITTING. FOREHEAD
IS EXPOSED AND VULNERABLE
TO SERIOUS INJURY.
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Copyright 2000 Pacific
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7
{800) 283-3303
Congratulations
on your
Our Service Department
to your satisfactioTz
We want
new
bike!
is dedicated
with Pacific
Cycle.
to help with any questions
or comments you may have.
You can also reach us by email at:
seraice @pacific-cycle.
com.
DO NOT Return this Product to the Store:
Please Call Pacific Cyc!e tbr AssNmrtce,
_
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The following manual is only a guide to assist you and is not a complete
maintaining and repairing your bicycle. The bicycle you have purchased
that you consult a bicycle specialist if you have doubts or concerns as to
repair, or maintain your bicycle. You will save time and the inconvenience
to write or call us concerning missing parts, service questions, operating
or comprehensive manual of all aspects of
is a complex object. Pacific Cycle recommends
your experience or ability to properly assemble,
of having to go back to the store if you choose
advice, and/or assembly questions.
PACIFIC SERVICE
CALL TOLL FREE 1-800-283-3303
Monday - Friday 8:00 a.m. to 4:30 p.m. Central Time
Serial Number Location
Bottom View
PACIFIC CYCLE LLC
4902 Hammersley Road
Madison, Wl 53711
Phone 608/268-2456
Fax 608/268-2455
Customer Service 1-800-283-3303
E-mail: service @pacific-cycle.corn
Web Address: www.pacific-cycle.com
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Serial Number
Purchase
Record
................................................86
Warning
/ Important
Take notice of this symbol throughout this manual and pay particular
attention to the instructions blocked off and preceded by this symbol.
(_) Copyright 2000 Pacific Cy
1. PARTS IDENTIFICATION
Mountain Bicycles
BMX Bicycles
Tools Required
2. BEFORE YOU RIDE
Correct Frame Size
Riding Position
-Saddle Height
-Reach
-Handlebar Height
Safety Checklist
-Brakes
-Wheels & Tires
-Steering
-Chain
-Bearings
-Cranks & Pedals
-Derailleurs
-Frame & Fork
-Accessories
1-2
t
2
3
3-17
4
5
5
5
6
7-8
7
7
7
8
8
8
8
8
8
Helmels
Riding Safely
-General Rules
-Wet Weather Riding
-Night Riding
-Pedaling Technique
-Hill Technique
Cornering Technique
Rules for Children
10-12
10
Gears - How to Operate
-Derailleur Gears
13-15
13
13
-Operating Principles
-Hand Grip Shifters
-Thumb Shifiers
-Below the Bar Shifters
Bicycle Care
-Basic Maintenance
-Storage
Security
3. ASSEMBLY
Derailleur Geared Bicycle
11
11
11
12
12
12
14
15
15
16-17
16
17
17
18-50
18-38
Handlebars
Forks
Seat and Seat Post
Pedals & Crank Set
Front Wheel
Quick Release Axle
18-20
21
22
23
24
Hub Bearing Adjustment
Flat Tire Repair
Handlebar Stem
Handlebars
24-25
Grip Shift Installation
60
Front Brake
-Cantilever with Link Wire
-Cantilever with Straddle Cable
25-32
25-26
27
Cables & Cable Housing
61
Headset
62
-V-Style
-Check your Brakes
-Disk Brakes
27-29
30
31-32
-Inspection
-Adjustment
62
62
Suspension Fork
-RST Maintenance
-RST Reassembly
-Check before each ride
63
63
63
63
Derailleur
-Rear Derailleur
*Front Derailleur
33-34
33
34
Dual Suspension
Rear Pivots
Accessories
Reflectors
Final Check
35
36
37
37
38
Single Speed & BMX
Handlebars
Seat
Pedals & Crank Set
Frontwheel
39-50
39
Front Brake
Side Pu_l Brake
Cantilever with Link Wire
V-Brake
Cantilever with Straddle Cable
Check your Brakes
Training Wheels
Rotors
Final Check
41
42
42-43
44-45
46
47
47
48-49
50
4. SERVICING
Schedule 1 - Lubrication
Schedule 2 - Service Checklist
Tools Required
51-53
51
52
53
6. DETAILED MAINTENANCE
Wheel inspection
Tire Inspection
Tire Pressures
54-85
54
55
55
40
40
41
56
56-57
58
59
-Freewheel
77-76
77
78
-Inspection
-Lubrication
78
-Coaster Hub
Saddle & Seat Post
*Inspection
-Lubrication
-Adjustment
64-65
64
64
65
Brakes
66-69
-Inspection
-Lubrication
66
67
-Adjustment Sidepull Calipers
-Adjustment Cantilever Calipers
67
68-69
Drivetrain
Pedals
-Inspection
-Lubrication & Adjustment
-Attachment
70-78
70-71
70
71
71
-Crank Set
72-75
-Inspection
-Lubrication
(one piece
-Lubrication
(coftedess
72
& Adjustment
cranks)
& Adjustment
cranks)
-Chain
-Inspection
-Lubrication
-Adjustment & Replacement
73
74-75
76-77
76
76
76-77
Oerailleur Systems
-Inspection
-Lubrication
-Adjustment (Rear)
*Adjustment (Front)
Quick Release Levers
Reflectors
Troubleshooting
6. PURCHASE
RECORD
7. WARRANTY
8, CONTACT ADDRESS
79-81
79
80
80
81
82
82
83-85
66
87
67, BACK
Mountain
handlebars
Bicycles.
Mountain
bicycles are designed
to give maximum
comfort over a wide variety of road surfaces. The wider
and convenient
shift lever position make them very easy to control. Wider rims and tires give them a softer ride with
more traction
on rough surfaces.
The frame and fork on mountain
style bicycles
are much sturdier than those on racing style bicycles,
Shift Lever
Handlebar
Top Tube
Brake Lever
Seat
Brake Control Cables
Seat Post
Handlebar Stem
Front Reflector
Quick Release
Head Set
Seat Stay
Rear Reflector
Rear Brake
Head Tube
\
Wheel Reflector
Wheel Reflector
Freewheel
_tBrake
\
Seat Tube
Front Hub
Down Tube
, Spokes
G
Front Derailleur
Bottom
Bracket Axle
Chain Wheel
Crank Arm
Pedal
1
Gear Control
Cable
Rear Derailleur
Chainstay
Tire Valve
Chain
1_ Copyright
2000 Pacific Cycles
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.
Brake Lever
Handlebar
Seat
Handlebar Grip
Seat Post
Handlebar Stem --
Seat Post Binder Bolt --
Head
Seat Stay
Rear Reflector __
Wheel Reflector
Brake Control Cable
Reflector
Head Tube
Front Brake
Top Tube
_
Brake Pad
_-_
Front Fork
Wheel Reflector
Front Hub
Spokes
Seat Tube
Down Tube-
Chain Wheel
Crank Arm
Pedal
Chain
, Rear Sprocket
Training Wheel
Rim
Tire
Tire Valve
Your new bicycle was assembled and tuned in the factory and then partially disassembled for shipping. You
may have purchased the bicycle already fully re-assembled and ready to ride QR in the shipping carton in the
partially disassembled form. The following instructions will enable you to prepare your bicycle for years of
enjoyable cycling. For more details on inspection, lubrication, maintenance and adjustment of any area please
refer to the relevant sections in this manual. If you need replacement parts or have questions pertaining to
assembly of your bicycle, call Pacific direct at:
PACIFIC SERVICE AND TECHNICAL
SUPPORT:
1-800-283-3303
Monday - Friday 8:00 a.m. - 4:30 p.m. Central Time.
I
3
6mm & 8mm Allen keys; adjustable
wrench or a 9mm, 10mm, 14mm & 15mm
open and box end wrenches; and a pliers
with cable cutting ability,
Phillips head
screw driver; 4mm, 5mm
Tools
Required:
©
Copyright 2000 Pacific Cycles
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 a clearance of between 25mm and 50mm between
the groin area of the intended rider and the top tube of the bicycle frame, while the rider straddles the
bicycle with both feet flat on the ground.
The ideal clearance will vary between types of bicycles and rider preference. This makes straddling the frame when off the
saddle easier and safer in situations such as sudden traffic stops. Women can use a men's style bicycle to determine the
correct size women's model.
The following chart and diagram will help you make the correct choice.
Frame Sizing Guide
Approximate Rider Leg
Length
Suggested Frame Size for
Racing/Touring Bicycle
Suggested Frame Size for
Mountain or Hybrid Bicycle
61-69cm / 24-27 inches
37cm / 14.5 inches
66-76cm / 26-30 inches
43cm / 17 inches
25-50mm
45cm / 18 inches
71-79cm / 28-31 inches
50cm / 19.5 inches
76-84cm / 30-33 inches
55cm / 21.5
inches
50cm / 19.5
inches
79-86cm / 31-34 inches
57cm / 22.5
inches
52cm / 20.5
inches
81-89cm / 32-35 Inches
60cm / 23.5 Inches
53-56cm / 21-22 Inches
86-94cm / 34-37 inches
63cm / 25 inches
58-60cm / 23-23.5 inches
4
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 while pedaling. While sitting on the bicycle
with 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 position, if the rider then places the heel of that foot on the
pedal, the leg should be almost straight.
Maximum Height / Minimum Insertion Mark
(Should not be visible)
Ensure that the seat pillar does not extend beyond the
minimum insertion mark,
Arms not overextended
(Refer to p. 65 on how to adjust seat height,)
Handlebar stern
height about the
j
seat
height
same
as
Reach
To obtain maximum comfort, the rider should not overextend
reach when riding.
his or her
To adjust this distance, the position of the seat can be altered in
relation to the seat pillar. (Refer to p. 65 on how to adjust the seat
clamp.)
Pedal at
bottom position
5
(_) Copyright 2000 Pacific Cycles
Handlebar
Height
Maximum comfort is usually obtained when the handlebar height is
equal to the height of the seat. You may wish to try different heights
to find the most comfortable position.
Stem Wedge Bolt
Handlebar Binder Bolt
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grthio_n
Exceeds 2 1/2"
(64ram)
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i_ark
Ensure that the handlebar stem does not extend beyond the minimum insertion
mark. Failure to do this may cause serious bodily injury or damage to the bicycle.
Ensure both the Stem Wedge Bolt and the Handlebar Binder Bolt are tightened
securely. Failure to do this may cause loss of steering control. (Refer to p. 59 on
how to adjust handlebars).
Warning: Overtightening the stem bolt or headset assembly
the bicycle and/or injury to the rider.
may cause damage to
6
SAFETY CHECKLIST
Before every ride, it is important
to carry out the following safety checks:
1. Brakes
-
Ensure
Ensure
Ensure
Ensure
front and rear brakes work properly.
brake shoe pads are not over worn and are correctly positioned in relation to the rims.
brake control cables are lubricated, correctly adjusted, and display no obvious wear.
brake control levers are lubricated and tightly secured to the handlebar.
2. Wheels
-
and Tires
Ensure tires are inflated to within the maximum recommended limit as displayed on the tire sidewall.
Ensure tires 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 tight and not broken.
Check that axle nuts are tight. If your bicycle is fitted with quick release axles, make sure locking levers
are correctly tensioned and in the closed position.
3. Steering
-
7
Ensure handlebar and stem are correctly adjusted and tightened, and allow proper steering.
Ensure that the handlebars are set correctly in relation to the forks and the direction of travel,
Check that the head set locking mechanism is properly adjusted and tightened,
If the bicycle is fitted with handlebar end extensions, ensure they are properly positioned and tightened.
(_) Copyright 2000 Pacific Cycles
4. Chain
o Ensure chain is oiled, clean and runs smoothly.
- Extra care is required in wet or dusty conditions.
@
5. Bearings
- Ensure all bearings are lubricated, run freely and display no excess movement,
- Check headset, wheel bearings, pedal bearings and bottom bracket bearings.
6. Cranks
grinding or rattling.
and Pedals
- Ensure pedals are securely tightened to the cranks.
- Ensure cranks are securely tightened to the axle and are not bent.
D
7. Derailleurs
- Check that front and rear mechanisms are adjusted and function properly.
- Ensure control levers are securely attached.
- Ensure derailleurs, shift levers and control cables are properly lubricated.
8. Frame and Fork
- Check that the frame and fork are not bent or broken.
- If either are bent or broken, they should be replaced.
9. Accessories
- Ensure that all reflectors are properly fitted and not obscured.
- Ensure all other fittings on the bike are properly and securely fastened,
- Ensure the rider is wearing a helmet.
and functioning.
8
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 correctly
Always wear a properly fitted
9
helmet
when riding a bicycle.
©
Copyright 2000 Pacific Cycles
RIDING SAFELY
General
Rules
When riding obey the same road laws as all other road vehicles,
pedestrians, and stopping at red lights and stop signs.
I
For further
information,
Ride predictably
contact the Road Traffic Authority
including giving way to
in your State.
and in a straight line. Never ride against traffic.
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, oit, 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
Be extra careful at intersections
driveways.
and when preparing to pass other vehicles.
Familiarize yourself with all the bicycle's features.
toe clips and straps, if fitted.
Practice gear shifts, braking, and the use of
If you are wearing loose pants, use leg clips or elastic bands to prevent them from being caught
in the chain.
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,
When braking, always apply the rear brake first, then the front.
and if it is not correctly applied, you may lose control and fall.
The front brake is more powerful
Maintain a comfortable stopping distance from all other riders, vehicles and objects.
Safe braking distances and forces are subject to the prevailing weather conditions.
10
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 additional
caution.
- Be more visible on the road.
- Wear reflective 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
Do not ride at night
- Ensure bicycle is equipped with a full set of correctly positioned and clean reflectors.
- Refer to p. 84 of this manual.
- Use a properly functioning lighting set comprising a white front lamp and a red rear lamp.
- If using battery powered lights, make sure batteries are well charged.
- Some rear lights available have a flashing mechanism which enhances visibility.
- Wear reflective and light colored clothing.
- Ride at night only if necessary. Slow down and use familiar roads with street lighting, if possible.
Pedaling
RGING
11
,_
-
Technique
Position the ball of your foot on the center of the pedal.
When pedaling, ensure your knees are parallel to the bicycle frame.
To absorb shock, keep your elbows slightly bent.
Learn to operate the gears properly. (Refer to p. 13-15)
Copyright
2000 Pacific Cycles
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. You 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, maintain control and take additional care,
Cornering Technique
Brake slightly before cornering and prepare to lean your body into the corner. Maintain the inside pedal at the 12 o'clock
position and slightly point the inside knee in the direction you are turning. Keep the other leg straight, don't pedal through
fast or tight corners.
Rules for Children
To avoid accidents, teach children good riding skills with an emphasis
on safety from an early age,
1.
2.
3.
4.
5.
6.
7
Always wear a properly fitted helmet.
Do not play in driveways or the road.
Do not ride on busy streets.
Do not ride at night.
Obey all the traffic laws, especially stop signs and red lights.
Be aware of other road vehicles behind and nearby.
Before entering a street: Stop, look right, left, and right again for traffic.
If there's no traffic, 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 off the handlebars, or your feet off the pedals when riding downhill.
The Consumer Protection Safety Commission advises that the riding of small wheel diameter
bicycles at 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.
12
Drivetrain
Freewheel
Derailleur Control
Cable
Front Derailleur
Derailleur
Front
Rear
Guide Pu'lley
Derailleur
V'Cr'a'nk C/_
Pedal
GEARS - HOW
_
TO OPERATE
Gears
Most multi-speed bicycles today are equipped with what are known as
derailleur gears. They operate using a system of levers and mechanisms
to move the drive chain between different sized driving gears or cogs.
The purpose of gears is to let you maintain a constant, steady pedaling
pace under varying conditions. This means your riding will be less
tiring without unnecessary straining up hills or fast pedaling down hill.
Bicycles come with a variety of gear configurations from 5 to 24
speeds. A 5-6 speed bicycle will have a single front chainwheel, a
rear derailleur, and 5 or 6 cogs on the rear hub. Bicycles with more
gears will also have a front derailleur, a front chainwheel with
2-3 cogs, and up to 8 cogs on the rear hub.
Operating
Principles
No matter how many gears, the operating principles are the same.
The front derailleur is operated by the left shift lever and the rear
derailleur by the right. To operate you must be pedaling forward. You
can not shift derailleur gears when you are stopped or when pedaling
backwards, Before shifting ease up on your pedaling pressure. On
approaching a hil!, shift to a lower gear before your pedaling speed
slows down too much for a smooth shift. When coming to a stop, shift
to a lower gear first so it will be easier when you start riding again. If,
after selecting a new gear position, you hear a slight
rubbing noise from the front or rear gears, gently adjust the appropriate
shifter until the noise goes away. For optimal performance and
extended chain life, it is recommended that you avoid using the
extreme combinations of gear positions (diagram p. 14) for extended
periods.
13
©
Copyright 2000 Pacific Cycles
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High
Middle
Recommended
For optimal performance,
NOT RECOMMENDED
Low
Chainwheel/Rear
Front Low Gear
2
High
Low
For optimal performance,
NOT RECOMMENDED
Sprocket Gear Combinations
Rear Low Gear
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 thumb and
index finger closes around. To select a lower gear, twist the right
shifter toward you to engage a larger rear cog. You can shift one gear
at a time by moving the Grip Shift one click, or through multiple gears
by continued twisting. By twisting the teft shifter forward or away from
you, a smaller chainwheel can be selected. To select a higher gear,
twist the right shifter forward or away from you to engage a smaller
rear cog. To engage a larger front chainwheel, twist the left shifter
towards you. Single shifts can be achieved by twisting one click at a
time and multiple shifts by larger twists.
Front High Gear
Rear High Gear
14
Left hand lever
Thumb
Right hand lever
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 rear derailleur. To
select a higher, harder gear, shift to a smaller rear cog and a larger
chainwheel.
Push the left shifter forward for the front, and pull the
right lever back for the rear.
Top Gear
(Harder)
Small rear sprocket
Large chainwheel
Bottom Gear
(Easier)
Large rear sprocket
Small chainwheel
Left hand lever forward
Right hand lever back
Right hand leverforward
Left hand lever back
Below the Bar Shifters
Left hand lever
15
Right hand lever
Many mountain style bicycles now use a shift lever arrangement
mounted on the underside of the handlebars, which use two levers
operated by the thumb and index finger. To select a lower gear push
the larger (lower) right shifter with your thumb to engage a larger rear
cog. One firm push shifts the chain one cog, continuing to push will
move the chain over multiple cogs. Pulling the smaller (upper) left
shifter with your index finger moves the chain from a larger to a smaller
chainwheel. To select a higher gear pull the smaller (upper) right
lever with your index finger to engage a smaller rear cog. Pushing the
larger (lower) left lever with your thumb will move the chain from a
smaller to a larger chainwheel.
©
Copyright 2000 Pacific Cycles
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 to clean
plastic parts and rubber tires. Chrome plated bikes should be wiped over with a rust preventative fluid.
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 or spray all unpainted parts with an anti-rust treatment. Make sure wheel rims are dry so braking
performance is not affected. After rain, dry your bicycle and apply anti-rust treatment.
If the hub and bottom bracket bearings of your bicycle have been submerged
re-greased. This will prevent accelerated bearing deterioration.
in water, they should be taken out and
If paint has become scratched or chipped to the metal, use touch up paint to prevent rust. Clear nail polish can also be
used as a preventative measure.
Regularly clean and lubricate all moving parts, tighten components and make adjustments as required. (Refer to Parts
4 and 5 of this manual for further details).
The use of alloy components and BED, SATIN, and TITANIUM surface treatments minimizes the number of places
where rust can surface.
16
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't store near electric
motors as ozone emissions may effect the rubber and paint. Don't
cover with plastic as "sweating" will result which may cause rusting.
Security
It is advisable that the following steps be taken to prepare for and help
prevent possible theft.
1. Maintain a record of the bicycle's serial number, generally located
on the frame underneath the bottom bracket.
2, Register the bicycle with the local police.
3. Invest in a high quality bicycle lock that will resist hack saws and
bolt cutters. Always lock your bicycle to an immovable object if it
is left unattended.
17
©
Copyright
2000 Pacific Cycles
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 is recommended
that the threads and all moving parts in the parts package be lubricated
prior to installation. Do not discard packing materials until assembly is
complete to insure that no required parts are accidentally discarded.
Assemble your bicycle following the steps that pertain to your model.
Note: Your bicycle may be equipped with different style components than the ones illustrated.
Handlebars
Binder Bolt
Stem Bolt
Remove the protective cap from the handlebar stem wedge and loosen
the Allen key bolt using the 6ram Allen key. Some models may use a
13mm hexagonal bolt instead of an Allen key bolt. Place the handlebar
stem into the top of the head tube, ensuring that all cables are free of
tangles. Tighten the stem bolt observing the minimum insertion mark and
checking that the forks and the handlebars are facing forward. Check
the headset for smooth rotation and that the top nut is secured tightly.
Loosen the 6mm Binder Bolt and rotate the handlebar forward so the
levers are at a 45 degree angle below the handlebar. Retighten the
Binder Bolt to ensure the handlebar does not rotate in the stem.
Top Nut
Minimum Insertion
Mark
Wedge
Warning: Overtightening
the stem bolt or headset
assembly may cause damage to the bicycle and/or
injury to the rider.
Head Tube
18
NOTE: Comfort Series (CS) bicycles may be equipped with a stem that has an adjustable angle.
In addition to the normal assembly, these stems will require angling the stem to the desired position,
and securely tightening the 6mm angle bolt located in front of the stem bolt.
Failure to do this may cause loss of steering control.
The stem must be inserted so that the
minimum insertion mark cannot be seen.
19
©
Copyright 2000 Pacific Cycles
Tighten 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 Shifter.
(Figure 2) Top mounted thumb shifter.
Shift binder
bolt (Phillips
head or 5mm
Allen key)
Failure to properly tighten clamping bolts may
cause sudden movement of the component
resulting in loss of steering control.
=
20
Forks
Steering Tube
Brake Boss
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 absorber with a specified
amount of travel that varies between models. Most Pacific
Cycle suspension forks are not adjustable and are very
difficult to disassemble. If service is needed on a suspension
fork, consult a professional bicycle repair technician.
Fork Leg
1
ii
Do not attempt to disassemble a suspension
fork yourself. Consult a professional bicycle
repair technician.
i
Brake Bridge
Brake Boss
Steering Tube
Check the tightness of the headset and the fork. Rotate the
fork checking for smoothness. If it feels like the fork is
binding, then an adjustment will need to be made to the
headset. Move the fork in a push/pull manner checking for
tightness. If any play is detected, loosen the top nut, adjust
the bearing cup, and retighten the top nut. Recheck the
rotation and tightness. If necessary, readjust until a smooth
rotation is achieved without backward or forward movement.
If your bike is equipped with a suspension fork, check that
the fork compresses and rebounds smoothly. To do this,
place the fork dropouts against the ground, push and
release the handlebar. The fork Will generally compress 1-2"
and rebound quickly. Most elastomer type forks will gradually
soften with use.
_) Copyright
2000 Pacific Cycles
Seat and Seat Post
Seat
Clamp
at
Post
Adtusting
Nut -----.---IP-t
_
_
Quick
Release
Attach
Seat Here_
Preload adjusting
screw on underside
NOTE: Comfort Series (CS) bicycles may be equipped with a suspension
seat post (See Diagram-bottom left), Some suspension posts can be adjusted for stiffness using the preload adjusting screw. Turning the 6mm Allen
screw Clockwise will decrease travel and make the suspension stiffer, while
turning the 6mm Allen screw Counter-clockwise
will increase travel and
make the suspension less rigid.
Note: In addition to normal assembly, please be aware that the preload
adjusting screw must be flush with the bottom of the post.
Failure to do this may cause irreparable damage.
Boot
Minimum
Insertion
Mark
Attach the seat to the seat post by inserting the smaller end of the seat
post into the seat clamp and tighten. Insert the larger end of the seat
post into the seat tube of the bicycle frame observing the minimum insertion
mark on the seat post. Turn the adjusting nut of the Quick Release seat
bolt to ensure the locking lever is moved to the closed position with a firm
action. Turn the bicycle upside down and rest it on the seat and handlebars.
Insert this
end into
frame
The seat post must be inserted so that the minimum insertion
mark cannot be seen.The quick release mechanism must be
tightened securely to prevent a sudden shift of the seat when
riding. Failure to do this may cause loss of bicycle control.
22
Pedals & Crank
Dust -Cap
Set
Look for the letters "R" for right, and "1_'for left, stamped on each pedal
spindle, Start each pedal spindle by hand to avoid stripping the threads.
Tighten with a 15mm narrow open ended wrench. Note that the right hand
pedal attaches to the chainwheel side crank arm with a right-hand (clockwise) thread. The left pedal attaches to the other crank arm and has a
left-hand (counter-clockwise)
thread. It is very important that you check
the crank set for correct adjustment and tightness before riding your
bicycle. New cranks may become loose with initial use, refer to p. 74-77
for proper crank set adjustment and maintenance, Once the pedals have
been installed, remove the dust caps from the center of each crank arm.
Using a 14mm socket wrench, tighten the spindle nuts securely (approx.
350 in. Ibs.) and replace the dust caps.
an
Attachment of
cause irreparable
23
incorrect
damage.
pedal
©
arm
a
into
crank
will
Copyright 2000 Pacific Cycles
Adjusting
Nut
Front Wheel
Quick
Release
Axle
Hub
Axle
Quick
Release
Lever
f
Hub
Closed Position
Check the wheel hub before attaching it to the fork by rotating the
threaded axle. It should be smooth with no lateral movement. Insert
Spring
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
Release (QR) mechanism. This allows easy wheel removal without
the need for tools. The mechanism uses a long bolt with an adjusting
nut on one end, and a lever operating a cam-action tensioner on the
other. If the wheel is fitted with a Quick Release type axle, turn the
adjusting nut so that the locking lever is moved to the closed position
with a firm action. At the halfway closed position of the quick release
lever, you should start to feel some resistance to this motion. Do not
tighten the quick release by using the quick release lever like a wing
nut. If the quick release lever is moved to the closed position with no
resistance, clamping strength is insufficient. Move the quick release
lever to the open position, tighten the quick release adjusting nut, and
return the quick release lever to the closed position.
Correct Quick
1.
2.
Open Position
3.
4.
Release Axle
Setting
To set, turn the lever to the open position so that the curved
part faces away from the bicycle.
While holding the lever in one hand, tighten the adjusting nut
until it stops.
Pivot the lever towards the closed position. When the lever is
halfway closed, there must be firm resistance to turn it
beyond that point. If resistance is not firm, open the lever and
tighten the adjusting nut in a clockwise direction.
Continue to pivot the lever all the way to the closed position
so that the curved part of the lever faces the bicycle.
24
5. The wheel is tightly secured when the serrated surfaces of the
quick release clamping parts actually begin to cut into the
bicycle frame/fork surfaces.
6. Note that the same procedure applies when operating a quick
release seat post binder mechanism.
7. Turn the bicycle upright using the kickstand to support it.
Warning - Correct adjustment of the quick release
is vitally important to avoid an accident caused by
loose wheels.
Cantilever
Brakes
Cable
End
2, Set the cable into
the straddle holder.
1. Install the cable into
the link wire
\
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 end into the slot of the left brake arm.
Loosen the anchor bolt on the right brake arm and slide the brake cable
under the tabbed washer. Squeeze both brake arms together so the
brake shoes hit the rim, pull all slack out of the brake cable, and tighten
the anchor bolt. With the cable fitted, the straddle holder should sit 1020mm above the reflector bracket. Adjust the brake shoes using a
10ram wrench so that they are parallel with the rim and are positioned
1-2mm away from the rim. Several adjustments
may be necessary to
achieve the correct brake position.
25
(_) Copyright 2000 Pacific Cycles
iiii
5. Secure one of the shoes at e 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. Ibs.)
3 Temporarily tighten the cable so
that the link wire is at the position in
the illustration.
Link Wire
10 mm wrench
5 mm Allen key
lble Anchor Bolt
Spring tension
adjustment screw
Cable Casing Holder
(DE=>
4. Turn the spring tension
adjustment screw so that the link
wire comes to a position directly
below the cable casing holder.
6. If balance adjustment is necessary,
adjust with the spring tension
adjustment screw.
Cut off any unnecessary
cable, allach an end cab,
and hook it onto the
notched part of the nut
which secures the shoe.
End cap
26
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, to adequately clear the tire (and any debris that
may stick to the tire) or to fit over the front reflector hanger. In the
event of brake cable failure, the front reflector hanger would prevent
the straddle cable from catching in the tire and locking up the front
wheel. The straddle cable length (when adjustable) is set to transfer
as much force to the brake pads as possible. For the most efficient
transfer of force, the straddle cable and the line between the
cantilever pivot and the cable anchor should form a right angle (90
degrees). If the force is not at a right angle, part of the force gets
wasted in pulling on the brake post, which has no effect on braking.
V-Style Brakes
Brake
Cable
Boot
Outer
Cable
Lead
Brake
Noodle
Bolt
Arm
P)vot
27
Brake
Shoe
Tension
Screw
Take the brake noodle from the parts box and slide the cable through
the larger opening. The cable housing will then seat into the end of the
noodle. Slide the cable through the cable lead on the end of the left
brake arm, this will cause the noodle to fit into the lead. Slip the brake
cable boot over the cable and position it between both brake arms.
Next, loosen the 5mm anchor bolt at the end of the right brake arm
and slide the cable under the retaining washer. Pull the slack out of
the cable making sure a distance of 39ram or more remains between
the end of the lead and the start of the anchor bolt. Once the cable is
secured to the brake arms, engage the brake lever several times,
checking the position of the brake shoes at the rim. The brake shoes
should be 1mm away from the rim when in a relaxed position. When
the brake lever is engaged, the brake shoe should hit the rim flush
(never the tire) with the front touching slightly before the rear. If this
position is not achieved, adjustments to the brake shoe are required.
Loosen the brake shoe hardware and reposition the brake shoe. It
may take several shoe and cable adjustments before the required
position is accomplished.
V - Brake
1. 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.
2. 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
dimension A is kept at 39 mm or more.
39 mm or more
A
o
(D
L
)
,-_I
5 mm Allen key
3 mm washer B
Spring
hole
Stopper pin
-
l
6 mm washer
B
l
Shoe fixing nut
/
Washer
Washer A
Washer A
Shoe fixin
link
,,
28
3. While holding the shoe against the
rim, tighten the shoe fixing nut.
5. Adjust the balance with the spring
tension adjustment screws.
shoe fixing nut
1 mm
5 mm Alien key
4. Pass the inner cable through the inner
cable lead. Set the cable with a clearance
of 1mm between each brake pad and the
rim, tighten the cable fixing bolt.
'_'_lb
Spring tension
adjustment screw
1 mm
Spring tension
adjustment screw
6. 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.
: :
Depress about
10 times
5 mm Alien key
29
(_) Copyright 2000 Pacific Cycles
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 be about 0.5 - 1.0 mm
farther from the rim than the front portion of the brake pad.
Brake pad aligned with the rim surface
Pad and rim should be parallel.
Direction of rim
rotation
1-2mm
0.5 - 1.0 mm
Do not ride the bicycle until the brakes are functioning
properly. To test, apply the brakes while trying to push
the bike forward to make sure they will stop the bicycle.
3O
Disk Brakes
It 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 ensuring that the disc fits into the brake mechanism
between the enclosed brake pads. Secure the front rim to the
bicycle by tightening the quick release mechanism and clamping
the lever to the closed position. Please refer to section 6 for
further instruction on quick release mechanisms.
"C" Clip
Mounting
Caliper
Bolt
with
Rotating Rod
Next, attach the cable to the brake lever by inserting the cable
end into the cable end holder after the barrel adjuster and lock
nut slots have been aligned with the cable end holder. After the
cable is secured to the lever, rotate the barrel adjuster and lock
nut so the slots no longer line up. Ensure the cable housing
seats appropriately into the end of the barrel adjuster and
check for any kinks or damage.
Slide the exposed brake cable through the rotating rod located
on the caliper body and seat the housing into the same stop.
Insert the cable into the spring and spring boot.
1
spacers
Actuating Arm
Next, slide the cable through the cable anchor and pull all the
slack out. Secure the cable in place by tightening the bolts that
comprise the anchor assembly. Some disc brakes will have a
centering devise while others are a free-floating mechanism. If
your caliper body is equipped with centering bolts, apply the
brake lever after the cable has been connected. While engaging
the lever, tighten the centering bolts securely. This will center
the caliper body on the disc.
Brake Pads
Caliper
Mounting
Bott with
spacers
31
Cable Anchor
Bolt
DISC GETS HOT! Severe injury could result from
contact with the hot disc! Mind your legs, as well
as your hands.
_) Copyright 2000 Pacific Cycles
Centering Bolt
Brake Cable
Housing
Rotating
Rod
Caliper
Body
Cable Boot
with Spring
inside
Centering Bolt (inside)
Cable Anchor
Bolt
Quick Release
lever
Caliper Mounting
Bolts with spacers
These brakes require breaking in! Ride and use the brakes gently for 13
miles before using the brakes in downhill conditions, for sudden stops, or
any other serious braking. Please be aware that your brake system will
change in performance throughout the wear-in process. The disc brake
should be cleaned before the first ride using rubbing alcohol. NEVER use oil
or similar products to clean your disc brake system.
32
Derailleur
Freewheel
j
Outer side of Top Gear
Pulley Adjustment
Screw
t
Guide Pulley
Adjustment
Screws
Tension Pulley
High Gear
LAC_Gema:ntS'_
Adjustment
Screw
/
SIS Cable Adjuster
,,_
_H _
_)_
"/OH,f""_
Although the front and rear derailleurs are initially adjusted at
the factory, you will need to inspect and readjust both prior to
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 sprocket.
Adjust the High limit screw so the guide pulley and the
smallest sprocket are lined up vertically. Reconnect the cable,
pull out any slack, and retighten the anchor bolt securely. Shift
through the gears, making sure each gear achieved is done
quietly and without hesitation. If necessary, use the barrel
adjuster to fine tune each gear by turning it the direction you
want the chain to go. For example, turning clockwise will
loosen the cable tension and move the chain away from the
wheel, while turning counter-clockwise
will tighten cable
tension and direct the chain towards the wheel. Shift the rear
shifter to the gear one and place the chain on the largest cog.
Adjust the Low limit screw in quarter turn increments until the
guide pulley and the largest cog are aligned vertically. Again,
shift through each gear several times, checking that each gear
is achieved smoothly. It may take several attempts before the
rear derailleur and cable is adjusted properly.
__
Ensure all bolts are secured tightly and the chain
does not fall off in either direction.
Barret
Adjuster
eur Side View
33
_)
Copyright 2000 Pacific Cycles
Front Derailleur
Low Adjusting Screw
Cable Anchor Bolt_
Outer Chainc
Inner Chainguard
High Adjusting
Screw
Chainguide
clearance of
1-3ram
Shift both shifters to the smallest number indicated and place
the chain on the corresponding cog and chainwheel. Disconnect the front derailleur cable from the cable anchor bolt.
Check the position of the front deraiileur; it should be parallel with
the outer chainwheel and clear the largest chainwheel by 35mm when fully engaged,
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. Reconnect the cable, pull
any slack out, and tighten the anchor bolt securely. Shift the
front shifter to the largest chainwheel. If the chain does not go
onto the largest chainwheel, turn the high limit screw in 1/4 turn
increments counter-clockwise until the chain engages the largest
chainwheel. If the chain falls off the largest chainwheel, and
into the pedals, you will need to turn the High limit screw in 1/4
turn increments clockwise until the chain no longer falls off.
Shift through every gear, using the barrel adjusters to fine tune
each transition. The barrel adjuster for the front derailleur is
located on the front shifter where the cable comes out of the
shifter. Clockwise will loosen the cable tension and direct the
chain closer to the frame while counter-clockwise
will tighten
the cable tension and direct the chain away from the frame.
Do not ride a bicycle that is not shifting
properly. Overlooking proper adjustments
may cause irreparable damage to the bicycle
and/or bodily injury,
34
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 Suspension travel can be adjusted by
turning the adjusting plate. Clockwise will increase spring
tension and decrease travel, while turning counter-clockwise
will decrease spring tension and increase travel.
There must be enough tension on the spring
to hold the spring plate in place. Failure to do
this may cause the mechanism to fail.
Spring
Spring plate
Anchor bolt
35
J
©
Copyright 2000 Pacific Cycles
Rear Pivots
®®
®
®
I
1.
2.
3.
®
I
Attaching Bolt
Bushing
Shaft
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 from grime and should be disassembled and regreased at least once a riding season. Please note the
drive side crank arm must be removed from the spindle
before attempting to work on the pivot. Some models
have two, small (2.5mm) Allen bolts on the underside of
the bottom bracket shell. These must be removed before
attempting to disassemble the pivot. After disassembling
and cleaning, the shaft of the pivot assembly should be
lightly coated with lithium-based grease, as well as the
bushings and the threads of the attaching hardware.
Please remember: Never use WD-40 to grease components. It is a degreaser that will not provide required
lubrication and has a tendency to attract dust.
1.
2.
3.
Pivot Assembly
Bottom Bracket Cup & Lockring
Rear Triangle
36
Accessories
Saddle Bag
Flame Bag
_'_
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 the seat and secure
around the bag. The smaller strap wraps around the seat post,
Frame bags install at the apex of the top and seat tubes.
Secure the straps around each tube.
NOTE: The frame bag straps must not bind the cables. The
straps must go around the frame only.
eo,or
Reflector
Water bottle and cage
Other: Some 20" and 24/' model bicycles come with a rear
derailleur guard to protect the rear derailleur from damage. To
install, remove the the rear wheel axle nut on the drive side,
install the rear derailleur guard over the axle with the U-shaped
guard pointing down, and retighten the axle nut. The guard will
sit between the frame and the axle nut.
Reflectors
Tighten both rear wheel axle nuts or the
quick release mechanism securely. Failure to
do this may cause the rear wheel to
dislodge from the frame dropouts resulting
in serious damage or injury.
37
Attach the white reflector to
secure to the fork using the
reflector to the rear reflector
seat post, depending on the
provided.
the front reflector bracket and
hardware provided. Attach the red
bracket and secure to the frame or
bracket style, with the hardware
©
Copyright 2000 Pacific Cycles
Final Check
After all adjustments have been made, shift through every
gear several times at varying speeds. This will ensure all
your adjustments are correct and will allow you to pinpoint
any trouble areas. If you encounter any problems, refer to
the appropriate section and make any necessary adjustments.
Check the tire pressure and inflate each tube to the recommended
psi as stated on the sidewall of the tire.
Check that the kickstand operates
kickstand bolt is secured tightly.
smoothly and the
Finally, examine the bicycle. Make sure all accessories are
attached and all quick releases, nuts and bolts have been
tightened securely.
Correct maintenance of your bicycle will ensure many years
of happy riding. Service your bicycle regularly by referring
to the relevant sections of this manual, OR take it to a
professional bicycle shop.
Remember: Always wear a helmet and obey all
traffic laws.
Do not over-inflate
the tires,
38
SINGLE SPEED & BMX
ii
i
Includes 16" and 20" BMX Bikes
Assembly is the same for boy's and girl's bikes.
Foreword: Assembling a bicycle is an important responsibility. Proper
assembly not only gives the rider more enjoyment of the bicycle; it
also offers an important measure of safety.
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 recommended
that the threads and all moving parts in the parts package be lubricated
prior to installation.
Do not discard packing materials until assembly is complete to insure
that no required parts are accidentally discarded. Assemble your
bicycle following the steps that pertain to your model,
Note: Your bicycle may be equipped with different style components
than the ones illustrated.
Stem Cap Binder Bolts
Stem
Bolt
Minimum Insertion Mark
Stem Wedge
Head
Tube
39
Handlebars
Remove the protective cap from the stem wedge and loosen the stem
bolt using the 6mm Allen key. Some models may use a 13mm
hexagonal bolt instead of an Allen key bolt, Place the handlebar stem
into the head tube, observing the minimum insertion mark on the
handlebar stem and ensuring that all cables are free of tangles.
Check that the fork and the handlebar are facing forward, and that
they are properly aligned with the front wheel. Tighten the stem bolt.
Rotate the handlebar to the desired position and tighten the Stem
Cap Binder Bolts securely using a 5mm Allen key.
The handlebar must be inserted so that the minimum insertion
mark cannot be seen.
Warning:
Overtightening the stem bolt or headset assembly may
cause damage to the bicycle and/or injury to the rider.
1_ Copyright 2000 Pacific Cycles
Seat
Loosen nut on the seat clamp and add 3 or 4 drops of oil onto the threads
of the bolt. Place the smaller end of the seat post into the seat clamp
until it stops with the bolt to the rear of the seat post. Thread the nut on
the seat clamp loosely. Insert the larger end of the seat post into the seat
tube of the bicycle frame observing the minimum insertion mark on the
seat post. Position the top surface of the seat parallel with the ground.
The serrations on the seat clamp must mesh completely with the seat
frame serrations, push the front of the seat up and down to align the serrations.
Securely tighten the seat clamp. Securely tighten the bolts on the seat
post clamp. Turn the bicycle upside down and rest it on the seat and handlebars. If your bicycle is equipped with a quick release mechanism,
please refer to page 24-25.
The seat pillar must be inserted
insertion mark cannot be seen.
Pedals & Crank
so that the minimum
Set
Look for the letters "R" for right, and 'I" for left, stamped on each pedal spindle.
Start each pedal spindle by hand to avoid stripping the threads. Tighten with a
15mm narrow open ended wrench. Note that the right hand pedal attaches to
the chainwheel side crank arm with a right-hand (clockwise) thread. The left
pedal attaches to the other crank arm and has a left-hand (counter-clockwise)
thread. It is very important that you check the crank set for correct adjustment
and tightness before riding your bicycle. New cranks may become loose with
initial use, refer to p. 74-77 for proper crank set adjustment and maintenance.
Once the pedals have been attached, check that the crank arm rotates
smoothly and that there is no lateral movement.
Attachment of an incorrect
cause irreparable damage.
pedal into a crank arm will
40
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 fork blades.
5. Spin the wheel to make sure that it is centered and clears the
brake shoes. Tighten the brakes if necessary.
6. Turn the bicycle upright using the kickstand to support it.
Axle Nut
Axle
Hub
t
'_
Retaining
Washer
"_
'Cone Nuts
Fork Drop Out
It is very important to check the front wheel
connection to the bicycle. Failure to properly tighten
may cause the front wheel to dislodge.
Front Brake
Brake Lever
Nipple
1
C
C
)
)
/
Grip
41
Ferrule
t
Handlebar
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. 68-71. A greater force is
required to activate the rear brake due to longer cable length. It is
advisable to mount the rear brake on the side of the stronger hand. It
is important to become familiar with the use of hand brakes. When
properly adjusted, hand brakes are an efficient braking system. Keep
the rim and brake shoes clean and free from wax, lubricants and dirt
at all times. Keep brakes properly adjusted and in good working
condition at all times,
O. ,e
Adjusting
Barrel
Open the brake lever and place the nipple end of the short brake
cable into the lever, then close the lever. Secure the ferrule against
the lever using the cable adjusting barrel.
Copyright 2000 Pacific Cycles
Side Pull
Brakes
"_"_
d Cable
justing
Barrel
Center Bolt
Brake
Arm
_),,_
Cable
Aolo
Fixing Nut j
in Back
Zb
Brake Shoe
Cantilever
Brakes
Cable
End
\
2. Set the cable onto
the straddle holder.
1. Install the cable into
the cable carrier.
Side Pull Brake
Loosen the cable anchor nut and thread the brake cable through it.
Tighten 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. Tighten the nuts securely. Pull down on the end of the brake cable with pliers, hold taut and securely tighten the cable anchor nut.
Spin the wheel, the brake shoes should not contact the rim at any
point and should be an equal distance from the rim on both sides.
Make sure all nuts and bolts are securely tightened. Test the brake
levers 20-25 times to take care of any initial cable stretch. Be sure to
tightly secure the brake fixing nut behind the fork.
When assembling or adjusting the brakes, make
sure the cable anchor is tight. Failure to securely
tighten the nut could result in brake failure and
personal injury.
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 end into the slot of the left brake arm.
Loosen the anchor bolt on the right brake arm and slide the brake
cable under the tabbed washer. Squeeze both brake arms together so
the brake shoes hit the rim, pull all slack out of the brake cable, and
tighten the anchor bolt. With the cable fitted, the straddle holder
should sit 10-20mm above the reflector bracket. Adjust the brake
shoes using a 10mm wrench so that they are parallel with the rim and
are positioned 1-2mm away from the rim. Several adjustments
may
be necessary to achieve the correct brake position.
42
3. Temporarily tighten the cable so
that the link wire is at the position in
II
the illustration.
_3,
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. Ibs.)
°
Link Wire_
t0 mm wrench
5 mm Allen key
_
O__i__m_-_
Cable Anchor Bolt
@
_
aSdPruntgmt:_is°nrew
6. if balance adjustment is necessary.
adjust with the spring tension
adjustment screw.
Cabte Casing Holder
Q=>
+,,Q
Cut off any unnecessary
cable, attach an end cap,
and hook it onto the
notched part of the nut
which secures the shoe.
4. Turn the spring tension
adjustment screw so that the link
wire comes to a position directly
below the cable casing holder.
End cap
®
43
®
(_ Copyright 2000 Pacific Cycles
V-
Brake
1. 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.
2. 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
dimension A is kept at 39 mm or more.
39 mm or more
A
o
o
/
)
5 mm Allen key
3 mm washer B
6 mm washer B
_
Sho_ing
nut
Washer
Link
fixing
Spring
hole
Washer€
b0,,
Stopper pin
r
_
_Washer
WaSheshoe fixin,
Washer A
I link
44
i
ii
3. While holding the shoe against
the rim, tighten the shoe fixing nut.
5 mm Allen key
ii
5, Adjust the balance with the spring
tension adjustment screws.
q)
1 mm
Spring tension
adjustment screw
4. Pass the inner cable through the inner
cable lead. Set the cable with a clearance
\
of 1ram between each brake pad and the
rim, tighten the cable fixing bolt.
iii
®
tmm
Spring tension
adjustment screw
6. Depress the brake lever about 10 times as
far as the grip and check that everything is
operating correctly and that the shoe clearance
is correct before using the brakes.
Depress about
10 times
5 mm Allen key
"
L
B+C=2mm
45
(_) Copyright 2000 Pacific Cycles
Straddle
Cable
Brake
Cantilever
Brake Cable
Straddle Hanger
Pinch Bolt
Straddle Cable
Cable
Anchor
Pivot
Caliper Arm
Brake pad aligned with the rim surface
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, to adequately clear the tire (and any debris that may
stick to the tire) or to fit over the front reflector hanger. In the event of
brake cable failure, the front reflector hanger would prevent the straddle cable from catching in the tire and locking up the front wheel. The
straddle cable length (when adjustable) is set to transfer as much
force to the brake pads as possible. For the most efficient transfer of
force, the straddle cable and the line between the
cantilever pivot and the cable anchor should form a right angle (90
degrees). If the force is not at a right angle, part of the force gets
wasted in pulling on the brake post, which has no effect on braking.
Pad and rim should be parallel.
Direction of rim
rotation
1-2mm
0.5 - 1.0 mm
,
46
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 lmm 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 be about 0.5 - 1.0 mm farther from
the rim than the front portion of the brake pad.
Do not ride the bicycle until the brakes are functioning properly. To
test, apply the brakes v_hile trying to push the bike forward to make
sure they will stop the bicycle.
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.
Stabilizer
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.
.
Shoulder Washer
Bo{t
l
l
Nut
Remove the nut and washer from the rear wheel axle.
Align stabilizer bracket onto the brace. Align brace and
stabilizer bracket on the wheel axle. Replace the axle
nut and washer, secure tightly. The elongated hole on
the brace allows for raising or lowering the training
wheel to the proper height.
Star Washer
47
©
Copyright 2000 Pacific Cycles
Rotors
Some freestyle BMX bicycles come equipped with a detangler
system that will allow the handlebar to spin 360-degrees
without binding the cables. It is very important that this system
is adjusted correctly. Installation should only be done by a
qualified bicycle mechanic with the correct tools.
Upper Cable
1. First connect the barrel end of the upper cable to the
rear brake lever. Make sure the long cable casing is on
top of the short cable casing; otherwise, the upper cable
will have a twist in it.
2. Route the upper cable through the handlebars (below
the crossbar) with the short cable casing on the same
side as the rear brake lever.
3. Connect the upper cable to the upper plate by passing
the football ends of the upper cable through the threaded
holes in the upper plate and connecting them to the bearing.
4. Screw the adjusting barrels into the upper plate. Don't
tighten the Iocknuts at this time.
Lower Cable
1. Slide the cable casing through the cable guide on the frame.
2. Connect the lower cable to the lower plate by passing
the football ends of the lower cable through the threaded
holes in the lower plate and connecting them to the bearing.
3. Screw the adjusting barrels into the lower plate. Don't
tighten the Iocknuts at this time.
4. Connect the lower cable to the rear brake. Don't adjust
the rear brake at this time.
NOTE: Check to make sure all 11 cable casing ends on
the upper and lower cables are seated correctly, and that
the spring tension of the rear brake is pulling the bearing down.
Adjustment
1. Screw the cable adjusters on the rear brake lever and the
upper cable splitter all the way in.
2. Screw the adjusting barrels in the upper plate in (or out)
3.
4.
5.
6.
7.
to set the bearing for maximum travel. The bearing should
be as far down as it can go without resting on the lower
plate or the adjusting barrels screwed into the lower plate.
Use the adjusting barrels that are screwed into the
upper plate to make the bearing parallel to the upper
plate. Use a 10mm wrench to tighten the Iocknut on the
left adjusting barrel of the upper cable. Leave the right
adjusting barrel loose.
Screw the lower cable adjusting barrel into (or out of)
the lower plate until they are as close to the bearing as
they can get without touching it.
Screw the cable adjuster on the upper cable splitter out
until all slack is removed from the upper cable. Then
screw the cable adjuster out one more turn to raise the
bearing an additional 1mm away from the lower cable
adjusting barrels.
CAUTION: Don't screw the cable adjuster on the upper
cable splitter out more than 8mm. Use the cable adjuster
on the rear brake lever if more adjustment is needed.
Check for bearing flop by placing the handlebars in the
normal riding position, then quickly rotate the handlebars
back and forth. Perform the following steps to eliminate
bearing flop.
NOTE: The bearing should never be allowed to rest on
the lower plate or lower cable adjusting barrels.
a) Screw the lower cable adjusting barrels out of (or
into) the lower plate until all bearing flop is eliminated.
b) Tighten the locknut of the right adjusting barrel on the
lower cable.
c) Rotate the handlebars 180 degrees and recheck for
bearing flop. If there is any bearing flop, use the"loose"
adjusting barrels on the upper and lower cable to remove it.
d) Repeat steps (6a) and (6c) until the handlebars can be
rotated 360 degrees without any bearing flop.
Finish adjusting the rear brakes.
48
Failure to adjust correctly may result in
loss of braking power and personal injury.
Single Cable Casing
Cable Adjuster
Cable Splitter
Upper Cable
Barrel End
(long casing)
Upper Cable
(short casing)
Barrel
Locknut
Upper Plate
37ram
Set for Max. Travel
Keyed Washer
+ 0r - 1ram
Bearing
Minimum 1ram (1/32")
Football Ends
t
Lower Plate
_._
Lower Cable
49
Locknut
Adjusting Barrel
(_) Copyright 2000 Pacific Cycles
Final Check
Install any additional parts that are supplied with your bike.
NOTE: Your 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 the bicycle
using the hardware provided. For some models, the front reflector
bracket will be mounted on the front brake assembly bolt that
fits through the fork. It is important to make sure all connections
are tightened securely and that the reflectors are properly
angled.
Pads: If your bike is supplied with pads, wrap the foam inner
cushion around the appropriate bar. Place the outer cover over
the inner cushion and press the velcro together securely. Turn
the pad so the velcro faces the ground.
Chainguards:
If not already attached, attach the chainguard to
the bicycle frame using the clamps provided. Secure in place
making sure the guard does not bind or get caught on the
chain.
(Red)
(White)
e%tor
Tire Pressure: Check tire pressure, inflate to the range
recommended on the tire sidewalls.
Re" r'%1
Before riding, ensure all nuts, bolts and fittings
on the bicycle have been correctly tightened.
Chainguard
5O
Correct routine maintenance
Smooth running
of your new bike will ensure:
- 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 schedules are a useful guide
and by referring to Part 5 of this manual, you should be able to accomplish most tasks. If you require assistance, we
recommend you see a bicycle specialist.
Schedule
1 - Lubrication
Component
Lubricant
How
chain
derailleur wheels
chain lube or light oil
brush on or squirt
chain lube or light oil
oil
brush on or squirt
oil can
brake calipers
brake levers
oil
3 drops from oil can
oil
Monthly
shift levers
lithium based grease
2 drops from oil can
disassemble
Every Six Months
freewheel
oil
brake cables
lithium based grease
2 squirts from oil can
disassemble
bottom bracket
lithium based grease
disassemble
pedals
derailleur cables
lithium based grease
disassemble
lithium based grease
disassemble
wheel bearings
headset
lithium based grease
disassemble
lithium based grease
disassemble
seat pillar
lithium based grease
disassemble
Frequency
to Lubricate
i
Weekly
derailleurs
Yearly
Note: The frequency of maintenance should increase with lots of usage and use in wet or dusty conditions. Do not over
lubricate - remove excess lubricant to prevent dirt build up. Never use a degreaser to lubricate your chain (WD-40)
51
(_ Copyright 2000 Pacific Cycles
Schedule
2 - Service Checklist
Frequency
Task
Before every ride
Check tire pressure
Page Reference
55
66-69
Check brake operation
Check wheels for loose spokes
54
Make sure nothing is loose
54
16-17
After every ride
Quick wipe down with damp cloth
Weekly
Lubrication
as per schedule 1
51
Monthly
Lubrication
as per schedule 1
51
Check derailleur adjustment
79-81
Check brake adjustment
66-69
Check brake and gear cable adjustment
61,66
Check tire wear and pressure
55
Check wheels are true and spokes tight
54
Check hub, head set and crank bearings for looseness
Check pedals are tight
Check handlebars
58-59
are tight
Check seat and seat post are tight and comfortably
Check frame and fork for trueness
56,62,73
70
adjusted
64
63
Check all nuts and bolts are tight
Every
Yearly
Six Months
Lubrication
as per schedule 1
51
Check all points as per monthly service
52
Check and replace brake pads, if required
69
Check chain for excess play or wear
76
Lubrication
51
as per schedule 1
52
Tools
1.
Required
4.
5.
Open ended wrench or ring
wrenches: 8mm, 9mm, 10mm,
12ram, 13mm, 14mrn, 15mm
Open end or pedal wrench 15mm
Allen key wrenches: 4mm, 5ram,
6mm, 8ram
Adjustable wrench
Standard flat head screwdriver
6.
7.
8.
9
10.
Standard Phillips head screwdriver
Standard slip joint pliers
Tire pump
Tube repair kit
Tire levers
2.
3.
Travel Tools
1. Spare Tube
2. Patch kit
3. Pump
4. Tire levers
5. Multi-tool
6.
53
Change (phone call)
©
Copyright 2000 Pacific Cycles
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 oily or greasy materials.
cleaning, use a clean rag or wash with soapy water, rinse and air dry. Don't ride while they're wet.
When lubricating your bicycle, don't get oil on the rim braking surfaces.
•Wheels
When
not straight:
Lift each wheel
off the ground
will need to be adjusted.
and spin them to see if they are crooked
This is quite
difficult
and is best left to a bicycle
or out of round.
If wheels
are not straight,
they
specialist.
•Broken or loose spokes:
Check that all spokes are tight and that none are missing or damaged.
Caution: Such damage can result in severe instability and possibly an accident if not corrected.
Again, spoke repairs are best handled by a specialist.
•Loose hub bearings:
Lift each wheel off the ground and try to move the wheel from side to side.
Caution: If there is movement between the axle and the hub, do not ride the bicycle.
Adjustment
is required.
•Axle nuts:
Check that these are tight before each ride.
•Quick release:
Check that these are set to the closed position and are properly tensioned before each ride.
Caution: Maintain the closed position and the correct adjustment.
Failure to do so may result in serious injury.
54
Tire Inspection
Tires must be maintained
Inflation:
Bead
Seating:
properly to ensure road holding and stability.
Check the following areas:
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.
Caution: If inflating tires with a service station pump, take care that sudden over inflation does not cause
tire to blow up.
When inflating or refitting tire, make sure that the bead is properly seated in the rim.
Tread:
Check that the tread shows no signs of excessive wear or flat spots, and that there are no cuts or other damage.
Caution: Excessively worn or damaged tires should be replaced.
Valves:
Make sure valve caps are fitted and that valves are free from dirt. A slow leak caused by the entry of the dirt can
lead to a flat tire, and possibly a dangerous situation.
Recommended Tire pressures:
The recommended
pressure
molded on the sidewall of your bicycle tires should match the following chart.
Use this as a general guide.
BMX
35-50 p.s.i.
MTB
40-65 p.s.i.
Road Touring
70-90 p.s.i.
Road Racing
110-125 p.s.i.
Hybrid/Crossbike
55
60-1 O0 p.s.i.
_) Copyright 2000 Pacific Cycles
Bali Bearings
Lock
Washer
Bearin 9
Cone
Hub Body
Axle
Lock Nut
Washer
Axle Nut
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 Iocknut is loose.
2. To adjust, remove wheel from bicycle and loosen the Iocknut on
one side of the hub while holding the bearing cone on the same
side with a flat open end wrench.
3. Rotate the adjusting cone as needed to eliminate free play.
4. Re-tighten the Iocknut while holding the adjusting cone in position.
5. Re-check that the wheel can turn freely without excessive side play.
How To Fix a Flat Tire
If you need to repair a tire, follow these steps:
Push tire bead
into the center
of the rim.
1. Remove the wheel from the bicycle.
2. Deflate the tire completely via the valve,
Loosen the tire bead by pushing it inward all the way around.
3. Press one side of the tire bead up over the edge of the rim.
Note: Use tire levers, not a screwdriver, otherwise you may
damage the rim.
4. Remove the tube, leaving the tire on the rim.
5. Locate the leaks and patch using a tube repair kit, carefully
following the instructions, or replace the tube.
Note: Ensure that the replacement tube size matches the size
stated on the tire sidewall and that the valve is the correct type
for your bicycle.
56
.
,
.
\
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
spokes, rust or other potential causes. Replace the rim tape which covers the
spoke ends, if damaged.
Remount one side of the tire onto the rim.
f
Remove tire bead from the rim.
9.
Using a hand pump, inflate the tube just enough to give it some shape.
10.
Place the valve stem through the hole in the rim and work the tube into the
tire. Note: Do net let it twist.
11.
Using your hands only, remount the other side of the tire by pushing the edge
toward the center of the rim. Start on either side of the valve and work around
the rim.
12.
Before the tire is completely mounted, push the valve up into the rim to make
sure the tire can sit squarely in position.
13.
Fit the rest of the tire, rolling the last, most difficult part on using your thumbs.
Note: Avoid using tire levers as these can easily puncture the tube or damage
the tire.
14.
Check that the tube is not caught between the rim and the tire bead at any point.
15.
Using a hand pump, inflate the tube until the tire begins to take shape, and check
that the tire bead is evenly seated all the way around the rim. When properly
seated, fully inflate the tire to the pressure marked on the sidewall. Use a tire air
pressure gauge to check.
16.
Replace the wheel into the frame checking that all gears, brakes and quick
Pull tLre back onto the rim.
57
Match the position of the leak in the tube with the tire to locate the possible
cause and mark the location on the tire.
release levers are properly adjusted.
(_) Copyright 2000 Pacific Cycles
HANDLEBARS
Handlebar
Max. Height/
Minimum Insertion
Mark
AND STEM
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 first wiping off any old grease and grime, then applying a
thin film of grease to the part, including the wedge, that will be inserted
into the frame.
The height ef the handlebar can be adjusted to suit your
comfort preference.
If the stem is removed from the steering column, you will notice a
mark about 65mm up from the bottom with the words "max. height" or
"minimum insertion".
Handlebar Binder Bolt
Handlebar Clamp Bolts
Max. Height/
Never ride a bicycle if the stem has
been raised so that the max. height/
minimum insertion line can be seen.
Warning: Overtightening the stem
bolt or headset assembly may cause
damage to the bicycle and/or injury
to the rider.
Stem Bolt Wedge
58
When re-fitting the stem, make sure the handlebars are correctly
aligned and tightened using the appropriate hex wrench or allen key.
Grip
Do not over tighten.
- Stem Bolt
Handlebar
Handlebar Stem
MTB Handlebar Assembly
Test 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, and from side
to side. The handlebar should not move when applying turning pressure.
Handlebars
The exact positioning of the handlebar is a matter of personal
comfort. For MTB bicycles, the bar should be approximately
horizontal, with the ends pointing back and slightly up. On BMX
bicycles, the handlebar should remain in an approximately upright
position but can be angled back or forward slightly for comfort. On
MTB and racing style bicycles, the handlebar is usually tightened in
the stem by a single allen key bolt or hexagonal bolt. On BMX style
bicycles there may be four clamping bolts.
Make sure, when setting the handlebars in the fork, that the curved
rake of the fork is angled to the front of the bicycle.
Please note that if you need to replace the forks in your bicycle at any
time, the replacement forks must have the same rake and the same
tube inner diameter as those originally fitted to the bicycle.
Never ride unless the handlebar clamping
mechanism has been securely tightened.
59
©
Copyright 2000 Pacific Cycles
Grip
7/8" Plastic Washers
\
Barrel Adjuster
Cable
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 tighten recessed clamp screw. Installation torque should be 20 in.-Ibs.
4. Slide the two 7/8" plastic washers over handlebar. The washers prevent the grip from interfering with Grip Shift rotation.
5. Slide handlebar grip over handlebar. Thread the cable inner wire through cable housings and frame, and attach to
derailleur. Make sure that the cable is in the V groove at the derailleur attachment bolt. If trimming the cable housing is
necessary, be sure to replace the housing end cap.
6. Adjust indexing.
7. Slide rear Grip Shift over right side of handlebar and repeat steps 2 - 6.
8. Actuate front and rear brake levers to be certain of proper operation, if Grip Shift interferes with brake lever movement,
rotate brake lever or Grip Shift. Check for proper brake lever operation
again.
6O
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 the housing is seated properly into each
cable stop of the bicycle. It is recommended
that the cables and housing are replaced at least
every riding season to prolong the life of your bike.
Do not ride a bicycle
operating properly.
6"_
that is not
(_ Copyright
2000 Pacific Cycles
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; if you
detect any looseness in the headset, it will need adjustment.
Check
that the headset is not over tight by slowly rotating the fork to the right
and left. If _he fork tends to stick or bind at any point, the bearings
are too tight.
Lock Nut
Lock Washer
Adjusting Cup/Cone
Ball Retainer
Adjustment
Loosen the headset top Iocknut or remove it completely along with the
reflector bracket, if fitted. Turn the adjusting cup clockwise until finger
tight. Replace the lock washer or reflector bracket and re-tighten the
lock nut using a suitable wrench.
Note: Do not over tighten or bearing damage will occur.
Top Head Cup
BoSom Head Cup
Always make sure that the headset is properly
adjusted and that the headset Iocknut is fully
tightened before riding.
Bali Retainer
Crown Race
Warning: Overtightening
the stem bolt or headset
assembly may cause damage to the bicycle and/or
injury to the rider.
62
SUSPENSION
Suspension
Fork
FORK
Some fork models differ from the one illustrated. Those models are
not adjustable and require no maintenance
from dirt and grime.
RST - Regular
"_"""""-_ Slider
Elast(
Skewer
er
other than keeping it free
Maintenance
The following maintenance should be performed every month (if riding
off-road), or whenever you feel performance is
deteriorating.
1. With the fork apart, thoroughly clean all parts.
2. Apply a thin coat of grease to the upper tubes, coil springs, and all
internal bushings.
Top-out
RST - Reassembly
DroF
1.
2.
3.
4.
Slide upper tubes into lower tubes.
Firmly hold lower tube and turn clockwise until it wilt not turn anymore.
Align the brake arch mounts on both lower tubes and install brake arch.
Tighten brake arch bolts to 70-80 in.-Ibs (8-9.2 Nm).
Check before
each ride:
1.
2.
3.
4.
Make sure the headset is properly secured.
Make sure the exposed portions of the upper tubes are clean.
Make sure the quick releases are properly secured.
Make sure the front brake cable housing is properly seated into the
brake cable stop.
5. Check tire clearance and clearance between the top of the front
brake straddle cable carrier and the bottom of the cable stop.
Make sure the front brake cable is routed to the brake cable stop
located on the brake arch. Do not route the cable through the
stem or any other mounts or cable stops.
63
©
Copyright 2000 Pacific Cycles
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".
Seat Fixing Bolt
Micro Adjustable
Seat Post
Seat Post
Binder Bolt
To avoid damage to either the seat post, the frame or
possibly the rider, a minimum of 65mm of the seat
post must always remain in the frame,
Lubrication
Remove the seat post from the frame and wipe off any grease, rust or
dirt. Then apply a thin film of new grease to the part that will be inserted
into the frame. Re-insert, adjust and tighten the seat post in the frame.
Seat CIamp Nut
Standard
Seat Post
64
Adjustment
As mentioned in Part 2, the seat can be adjusted in height, angle and distance from the handlebars
individual rider.
Saddle angle is a matter of personal preference but the most comfortable
of the seat is almost parallel to the ground, or slightly raised at the front.
to suit the
position will usually be found when the top
The saddle can also be adjusted by sliding it forward or back along the mounting rails to obtain the most
comfortable reach to the handlebars.
When fitting, position the seat post into the clamp under the seat and place it in the frame without
tightening. Adjust it to the desired angle and position, and tighten the clamping mechanism.
There are two types of seat clamps commonly in use. The most common employs a steel clamp with hexagonal
nuts on either side to tighten. The other type, known as a micro-adjustable clamp, uses a single vertically mounted
Allen head fixing bolt to tighten. After fixing the seat to the desired position on the post, adjust the height to the
required level and tighten the binder bolt.
Note that the type of binder bolt may be either a hexagonal bolt, an Allen head bolt, or a quick release mechanism.
The operation of a seat post quick release mechanism is the same as for quick release hubs.
Refer to p.22.
Test the security by grasping the seat and trying to turn it sideways.
binder bolt.
Note: Remember
65
that the minimum insertion
If it moves, you will need to further tighten the
mark must remain inside the frame assembly.
©
Copyright
2000 Pacific Cycles
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 brakes are functioning
properly.
There are two types of hand operated bicycle brakes in common use: sidepull calipers and cantilever calipers. Both utilize
a handlebar mounted lever which controls a cable to operate the brake. Sidepull brakes are mounted to the frame or fork
via a single pivot point. Cantilever brakes use two brake pivot arms, each mounted on separate pivots on either side of the
frame/fork.
Inspection
Brake Cable
Brake Arm
Straddle Cable
/
Cantilever
Brakes
Brake levers should be checked for tightness at least every three
months. They should be set in a comfortable position within easy
reach of the rider's hands, and must not be able to move on the
handlebar. Some brake levers make use of a reach adjustment screw,
which can be altered to the distance between the handlebar grip and
the lever, as required. The brake pads should be checked for correct
positioning and tightness before every ride, and the various bolts and
nuts at least every three months. Squeeze each brake lever to make
sure they operate freely and that the brake pads press hard enough
on the rims to stop the bike. There should be about lmm - 2mm
clearance between each pad and the rim when the brakes are not
applied. The brake pads must be properly centered for maximum
contact with the rim. Replace the brake pads if they are over worn so
that the grooves or pattern cannot be seen. The brake cable wires
should be checked for kinks, rust, broken strands or frayed ends. The
outer casing should also be checked for kinks, stretched coils and
other damage. If the cables are damaged, they should be replaced.
66
Some
brakes
make
sure the quick
have a quick release
release
mechanism
mechanism
to allow
easier
is in the closed
Never ride unless the quick release
is firmly
wheel
removal.
Whenever
you adjust
the brakes,
position.
locked in the closed position.
Lubrication
The brake lever and brake caliper pivot points should be oiled with
2-3 drops of light oil at least every three months to ensure smooth
operation and to reduce wear. Cables should be greased along
their entire length, after removing them from their casings, at least
every six months. Always grease new cables before fitting.
Adjustment
Cable Adjusting Barrel
Center Bolt
Brake Shoe
Cable
Anchor
Bolt
Side-Pull
67
Brakes
- Sidepull
Calipers
Minor brake adjustment can be made via the cable
adjusting barrel, usually located at the upper cable arm. To adjust,
squeeze the brake pads against the rim, loosen the lock nut and
turn the adjuster Brake pad clearance should be a maximum 2mm
from the rim. When correct, re-tighten the lock nut. If the peds cannot be set close enough to the rim in this manner, you may have to
adjust the cable length. Screw the barrel adjuster 3/4 of the way in,
squeeze the pads against the rim, undo the cable anchor bolt and
pull the cable through with pliers. Re-tighten the cable anchor bolt
and apply full force to the brake lever to test, then fine tune using
the barrel adjuster. If one pad is closer to the rim than the other,
loosen the fixing nut at the back of the brake, apply the brake to
hold it centered, and re-tighten the fixing nut.
Ensure the Brake fixing nut is secured tightly.
Failure to do this may cause the Brake assembly
to dislodge from the fork.
_) Copyright 2000 Pacific Cycles
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 little force to the pad and its mounting.
Adjustment
Fully Adjustable Brake Shoes
Curved
?_(Adjustment
Washh_
Curved
_
Adjustment
- Cantilever Calipers
Minor brake adjustment can be made via the barrel cable adjusters
which are located on each brake lever. To adjust, squeeze the brake
pads against the rim, loosen the lock nut, and turn the adjuster to pull
the brake pads closer to, or spread them away from the rim as required.
Brake pad clearance should be a maximum 2mm from the rim.
When correct, re-tighten the lock nut.
If the pads cannot be set close enough to the rim in this manner, you
may have to adjust either the length of the straddle cable or the length
of the brake cable.
If the brakes use a separate brake cable and straddle cable, adjust
the straddle length by first screwing the barrel adjuster 3/4 of the way
in, then loosening the straddle cable fixing bolt, then pulling or pushing
the cable through the fixing bolt to adjust the length, and finally
re-tightening the fixing bolt.
Check that the straddle bridge is in the middle of the cable to ensure
even brake pad contact. Apply full force to the brake lever to test, then
fine tune using the barrel adjuster.
Washer_
To adjust
the brake
cable
length,
loosen
the brake
cable
fixing
bolt on
the cable straddle bridge, adjust the length until the brake shoes
the correct distance from the rim, then re-tighten
and test.
are
Parallel
68
Tread Worn Off
Tread
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.
Usable Brake Shoe
Worn Out Brake Shoe (Replace)
Adjust the brake pad position so that it is parallel to the wheel rim
and so that the leading edge makes first contact.
To do this, fit an Allen key into the brake pad holding bolt, loosen
the fixing nut and adjust. Move the brake pad along its mounting
post to alter the distance from the rim, and move the curved adjustment
washer to alter the angle of the pad.
On some models there is a spring-force adjustment screw on the
brake arm which allows further fine tuning of the brake shoe position.
Align brake shoe with rim surface
Direction of rim
rotation
Brake Shoe Holding Nut
!
,/
Bicycles with cantilever brakes must be fitted with safety devices to
prevent a possible accident in the event of the brake control cable
or the straddle bridge becoming loose or breaking while riding.
These are usually the reflector brackets, and must be fitted in the
front and rear. The bracket will prevent the straddle cable from interfering with the wheel should the cable become disconnected from
the control cable. If the reflector brackets are not fitted in this position, then alternative emergency cable safety stops must still be fitted.
0.5 - 1.0 mm
69
©
Copyright 2000 Pacific Cycles
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. These help to keep the feet correctly positioned and allow the rider to exert pulling force, as well as
downward pressure, on the pedals. Use of toe clips with straps
requires practice to acquire the necessary skill to operate them safely.
Inspection
Pedals should be inspected every month, taking note of the
following areas:
Check correct tightness into the crank arms. If pedals are allowed
to become loose, they will not only be dangerous but will also
cause irreparable damage to the cranks.
Check that pedal bearings are properly adjusted. Move the pedals
up and down, and right to left, and also rotate them by hand. If
you detect any looseness or roughness in the pedal bearings then
adjustment, lubrication or replacement is required.
Ensure that the front and rear pedal reflectors are clean and
securely fitted.
Also ensure that the toe clips, if fitted, are securely tightened
to the pedals.
L = Left
Turn counter-clockwise
to tighten.
;
I
R = Right
Turn clockwise
to tighten.
Never ride with loose pedals.
70
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
greased every six to twelve months. Because of the wide variety
of pedal types and their internal complexity, disassembly procedures
are beyond the scope of this manual and further assistance
should be sought from a specialist.
Never ride in traffic with fully tightened
toe straps.
Pedal with toe clip and strap attached
Attachment
Note: The right and left pedals of a bicycle each have a different thread and are not interchangeable.
Never force a pedal into the incorrect crank arm.
The right pedal, which attaches to the chainwheel side, is marked 'R' on the end of the axle, and screws in with a clockwise thread. The left pedal, which attaches to the other crank arm, is marked 'L' on the axle, and screws in with a
counter-clockwise thread.
Insert the correct pedal into the crank arm and begin to turn the thread with your fingers only. When the axle is screwed
all the way in, securely tighten using a 15ram wrench.
If removing a pedal, remember that the right pedal axle must be turned counter clockwise, i.e. the reverse of when fitting.
If replacing the original pedals with a new set, make sure the size and the axle thread is compatible with the cranks on
your bicycle. Bicycles use one of two types of cranks and these use different axle threads. Your bike may be equipped
with cranks that are a one piece design with no separate axle. These operate with pedals that have a 1/2"(12.7mm)
thread. Bikes equipped with three piece crank sets with a separate axle, left crank and right crank, use a slightly larger
9/16"(14mm) thread.
Note: Never try and force a pedal with the wrong thread size into a bicycle crank.
71
_ Col3vriqht 2000 Pac tic Cycles
CRANK SET
t
¢'1
l
Cotterleas
The crank set refers to the bottom bracket axle and bearings, the
crank arms, and chainrings.
Your 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. The one piece system is simpler and
requires less maintenance, while the cotterless system requires a little
extra care.
i
Never ride your bike if the cotterless cranks are loose.
This may be dangerous and will damage the crank
arms beyond repair.
Crank
Inspection
Ball Bearing
\
\'_'
_-'_N
_',._F__..
ken teeth on the chainrings,
may have built up on them.
AdjuStc_ _ -'-__
Standard
The crank set should be checked for correct adjustment and tightness
every month. Cotterless crank axle nuts must be kept tight, and the
bottom bracket bearings must be properly adjusted.
Remove the chain and try to move the cranks from side to side with
your hands. The cranks should not move on the axle, and there
should be only very slight movement in the bottom bracket. Next, spin
the cranks. If they don't spin freely without grinding noise, then adjustment or lubrication will be needed. Also check that there are no bro-
Bottom Bracket Assembly
and wipe off excess dirt and grease that
(Cotterless)
72
Lubrication and Adjustment
- One Piece Cranks
To adjust the free play in a one piece type bottom bracket, loosen the Iocknut on the left side by turning it clockwise
and tighten the adjusting cone counter-clockwise
using a screwdriver in the slot. When correctly adjusted, re-tighten
the !ocknut counter-clockwise.
To disassemble:
1. Remove the chain from the chainwheel.
2.
3.
4.
5.
Remove the left pedal by turning the spindle clockwise.
Remove the left side Iocknut by turning it clockwise and remove the keyed Iockwasher.
Remove the adjusting cone by turning it clockwise with a screwdriver.
Remove the left ball retainer, slide the crank assembly out of the frame to the right, and remove the right ball retainer.
Clean and inspect all bearing surfaces and ball retainers, and replace any damaged parts. Pack the ball bearing
retainers with grease, then re-assemble in the reverse of the above procedure.
Bearing Cup
Locknut
÷
Fixed Cone
\
_
_
l
Bearing Cup
0"_Loekwasher
Adjusting Cone
Ball Retainer
Ball Retainer
Crank
Chainwheel
73
One Piece Crank Assembly
Copvriclht 2000 Pacific Cycles
Bottom Bracket
Lubrication and Adjustment
- Cotterless Cranks
To adjust the free play in a three piece type bottom bracket, loosen
the Iockring on the left side by turning it counter-clockwise,
then turn
the adjusting cup as required. Re-tighten the Iockring taking care not
to alter the cup adjustment.
Fixed Cup
Cottefless Crank removing tool
__"_
_
Bottom Bracket
_/
/"
Ball Retainer
AdiustingCup
_"
Lockring
To
1.
2.
3.
4.
disassemble:
Remove the cranks from the axle.
Remove the left side ]ockring by turning it counter-clockwise.
Remove the adjusting cup by turning it counter-clockwise.
Remove the left bail retainer and slide the axle out of the frame to
the left.
5. Remove the right side fixed cup by turning it counter-clockwise
and
remove the right ball retainer. Clean and inspect all bearing surfaces
and ball retainers, and replace any damaged parts. Pack the ball
bearing retainers with grease, then re-assemble in reverse of
the above procedure.
Remove the dust cap
Cotterless
Loosen and remove
the flange nut.
Crank
Removal
To remove cotterless cranks use the following procedure.
Note that a special tool will be required.
1. Remove the dust cap with a coin or screwdriver.
2. Loosen the flange nut or bolt and washer, and remove.
74
Screw in the removal tool.
i
3. Screw the removing tool into the crank and tighten.
4. Turn the screw bolt down until the crank comes away from
the axle.
Turn the screw
bolt
clockwise.
Cotterless
Crank Replacement:
1. Replace the crank arm onto the axle.
2. Tap 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
Position the crank on the axle.
Lightly tap the crank
onto the axle.
Adjustment
After Use:
1. Remove dust cap.
2. Tap the crank arm lightly with a mallet.
3. Re-tighten the flange nuts, and refit the dust caps.
New cotterless cranks may become loose with initial
use. Perform the following task after several hours of
riding, and repeat it two or three times after further
use. Cranks should then remain tight.
Tighten the flange nut.
Replace the dust cap.
O
75
(_) Copyright 2000 Pacific Cycles
Rear Sprocket
Front Chainwheel
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. Make sure
that there are no stiff links, they must all move freely.
Straightedge
Lubrication
The chain should be lubricated with light oil at least every month, or after use in wet, muddy, or dusty conditions.
Take care to wipe off excess oil, and not to get oil on the tires or rim braking surfaces.
Adjustment
and Replacement
On derailleur geared bicycles the rear derailleur automatically tensions the chain.
To adjust the chain on single speed freewheel, coaster hub braked or 3-speed hub geared bicycles:
1. Loosen the rear axle nuts (and coaster brake arm clip if fitted) and move the wheel forward to loosen, or backward to
tighten, in the frame.
2. When correctly adjusted, the chain should have approximately lOmm of vertical movement when checked in the center
between the chainwheel and rear sprocket. Center the wheel in the frame and re-tighten the axle nuts after any
adjustment. Bicycles which have a single speed freewheel, coaster hub brake or 3-speed hub, generally use a wider
type chain than derailleur geared bicycles. These chains can be disconnected by way of a special U-shape joining link,
that can be pried off of the master link with a screwdriver. To replace, feed the chain around the chainwheel and rear
sprocket, fit the master link into the rollers into each end of the chain, position the master link side plate, and slip on the
U-shaped snap-on plate. Make sure the open end of the U-shaped plate is trailing as the link approaches the
chainwheel when pedaling forward.
76
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 the punched rivet, bend it slightly to release link
from the dvet. To install, feed chain around chainwheel, rear
sprocket and derailleur cage with rivet facing away from the bicycle.
Bring the two ends together within the special tool and punch the
rivet into place. Be sure not to push rivet tee far through side plate.
Chain RivetTool
FREEWHEEL
Inspection
Like the chain, the freewheel must be kept clean and well
lubricated. If the chain has become worn and needs replacing,
then it is likely that the freewheel will also have become worn and
should also be replaced. Take the chain off the freewheel and
rotate it with your hand. if you hear a grinding noise or the
freewheel stops suddenly after spinning it, it may need adjustment
or replacement.
Such action is beyond the scope of this manual
and you should consult a specialist.
(_ Copyright 2000 Pacific Cycles
Lubrication
Brake Arm Clip
Brake Arm
_'_Sprocke_
Remove any accumulated dirt from the freewheel with a brush
and a degreaser. Disassembly of the free wheel is a complicated
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 children's bicycles are fitted with a
coaster hub brake in the rear wheel. This type of brake offers
the advantages of reliability and easy operation. The brake is
operated by applying back pedal pressure and allows the rider
to 'coast' without pedaling, if desired. There are several models
of coaster hubs available, and the internal mechanisms are very
complex. They require infrequent attention as far as lubrication,
adjustment or replacement of internal parts; if needed, this
should be left to a specialist.
Keep the coaster hub sprocket clean and oil it along with the chain.
Make sure the brake arm is correctly attached to
the chainstay with the brake arm clip. The brake
will not operate otherwise.
78
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. Your new bicycle may be fitted with a standard 'friction' type system where you will need
to feel each gear shift into position, It may be fitted with an 'index' system (e.g. SIS) which links each different gear position
to a positive click mechanism in the shifter, and makes shifting very simple and precise. A further development of SIS is
the fully integrated system (e.g. STI) where the shift lever and brake lever mechanisms form an integrated unit with the
system allowing both gear shifting and braking to occur at the same time.
Inspection
Pre-stretch the derailleur
cables to remove slack
Stretch
79
The operation of the derailleur system should be checked at
least every month. Check the operation of the rear derailleur
first, then the front. The rear derailleur should shift the chain
cleanly from one cog to the next without hesitation. On SIS
equipped bicycles, each notched position in the shifter must
equate to a new gear position. After shifting, the rear derailleur
should not rub on the chain. The derailleur should never cause
the chain to fall off the inner or outer freewheel cogs.
The front derailleur should also shift the chain cleanly and
without hesitation between each chainring. If your bicycle is
equipped with front SIS, then each click or stop in the shifter
should equate exactly to a new gear position. When the chain
has been positioned onto a new chainring, it should not rub on
the front derailleur. The chain should not fall off a chainring at
any time. Derailleur control cables are a critical component that
must be well maintained for accurate shifting performance.
Check them for any sign of rust, fraying, kinks, broken strands,
and any damage to the cable housing. If you find any
problems, the cables may need replacing before you ride.
Lubrication
Freewheel
j
Outer side of Top Gear
PulJey Adjustment
Screw
t Adjustment
Screws
SiS Cable Adjuster
Guide Pulley
Tension Pulley
Rear Derailleur Rear View
High Gear
Adjustment Screw
Low Gear
Adjustment Screv
/
SIS Cable
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 installed.
Adjustment
- Rear Derailleur
The Low limit screw determines
how far the rear derailleur
will travel
toward the wheel of the bicycle, while the High limit screw determines
how far the cage will travel toward the frame.
1. Shift the rear shifter to the largest number indicated, disconnect the
rear derailleur cable from the cable anchor bolt and place the chain
on the smallest sprocket.
2. Adjust the High limit screw so the chain and the smallest sprocket
are lined up vertically. Remove any slack in the cable by pulling it
taut, then re-connect the cable and tighten the cable anchor bolt securely.
3. Shift up through the gears making sure that each gear is achieved quietly
and without hesitation.
If noise occurs, use the barrel adjuster to fine-tune the cable tension.
Turning the barrel adjuster clockwise will decrease cable tension and
allow the derailleur cage to move farther away from the bicycle in small
increments. Turning counter-clockwise
will increase cable tension and
bring the cage closer to the bicycle. This will micro-adjust the positioning
of the derailleur cage in relation to the freewheel. Simply put; turn the
barrel adjuster the direction you want the chain to go.
4. Shift the chain onto the largest sprocket; adjust the low limit screw so the
chain and the largest cog are fined up vertically. If you are unable to get
the chain to the largest cog, turning the Low limit screw counter-clockwise
will enable the chain to move towards the wheel.
5. Shift through the gears ensuring each gear is achieved quietly and without
hesitation.
Adjuster
Rear Derailleur Side View
NOTE: It may take several adjustments to achieve the desired positioning.
Please refer to the troubleshooting section for more assistance.
8O
Low Adjusting Screw
/
Cable Fixing Bolt
/
High AdJs_tring
_L_
Chainguide
Outer Chainguide X
InnerChainguide\
_
_
_
i__
clearln3e°mf
/'
_Z_
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 the crankset. There must be a 3-5mm gap between
the bottom of the derailleur cage and the top of the outer chainwheel
teeth to ensure the derailleur will clear the chainwheel when shifting.
3. Adjust the low limit screw so the chain is centered in the middle of
derailleur cage. Pull all slack out of the cable by pulling it taut, then
reconnect the cable and tighten the cable anchor bolt securely.
4. Shift the front shifter into the largest gear and pedal the bike so the
chain jumps to the largest chainwheel. If the chain does not shift
onto the largest chainwheel, you will need to turn the High limit
screw counter-clockwise until the chain moves to the largest
chainwheel. If the chain falls into the pedals, the High limit screw has
been turned too far. You will need to readjust the High screw
clockwise in 1/4 turn increments until the chain no longer falls off.
5. Shift through each gear ensuring all are achieved quietly and without
hesitation.
6. The barrel adjuster for the front deraitleur is located on the shift
mechanism. Turning clockwise will decrease cable tension and
allow the front derailleur cage to move away from the bike, while
turning counter-clockwise will increase tension and bring the cage
closer to the bike. If you are experiencing problems shifting between
gears, use the barrel adjuster to fine-tune the cable tension.
NOTE: tt may take several adjustments to achieve the desired positioning.
81
(_) Copyright 2000 Pacific Cycles
QUICK RELEASE LEVERS
It is important to check the quick release levers before every ride to ensure all connections are made properly
and securely. 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 properly. Please
refer to page 21 and 22 for the appropriate assembly instructions.
REFLECTORS
Your 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 conditions at all times. Periodically, inspect all reflectors, brackets and mounting hardware for signs of wear
or damage. Replace immediately if damage is found.
Wear reflective clothing
when riding.
Reflectors _'
_Reflectors
Attach a light to your
bike if you ride at night.
82
Problem
Gear shifts not working properly
Possible Cause
Derailleur cables
Lubricate/tighten/replace
sticking/stretched/damaged
Front or rear derailleur not adjusted
properly
Indexed shifting not adjusted properly
Slipping chain
Excessively worn/chipped chainring
or freewheel sprocket teeth
Chain worn/stretched
Stiff link in chain
Non compatible
freewheel
Chain jumping off freewheel
sprocket or chainring
Remedy
chain/chainring/
Chainring out of true
Chainring loose
Chainring teeth bent or broken
Rear or front derailleur side-to-side
cables
Adjust derailleurs
Adjust indexing
Replace chainring, sprockets and
chain
Replace chain
Lubricate or replace link
Seek advice at a bicycle shop
Re-true if possible, or replace
Tighten mounting bolts
Repair or replace chainring/set
Adjust derailleur travel
travel out of adjustment
Constant clicking noises when
pedaling
Stiff chain link
Loose pedal axle/bearings
Loose bottom bracket axle/bearings
Bent bottom bracket or pedal axle
Loose crankset
Grinding
83
noise when pedaling
Pedal bearings too tight
Bottom bracket bearings too tight
Chain fouling derailleurs
Derailleur jockey wheels
dirty/binding
Lubricate chain / Adjust chain link
Adjust bearings/axle nut
Adjust bottom bracket
Replace bottom bracket axle or
pedals
Tighten crank bolts
Adjust
Adjust
Adjust
Clean
bearings
bearings
chain line
and lubricate
jockey wheels
CO")Copyright 2000 Pacific Cycles
Problem
Possible Cause
Remedy
Freewheel does not rotate
Freewheel internal pawl pins are
jammed
Lubricate. If problem persists,
replace freewheel
Brakes
Brake blocks worn down
Replace brake blocks
Clean blocks and rim
not working
effectively
Brake blocks/rim greasy, wet or dirty
Brake cables are
When applying the brakes
they squeal/squeak
binding/stretched/damaged
Brake levers are binding
Brakes out of adjustment
Clean/adjust/replace
- Adjust brake levers
- Center brakes
Brake blocks worn down
Brake block toe-in incorrect
Replace blocks
- Correct block toe-in
- Clean blocks and rim
Brake blocks/rim dirty or wet
Brake arms loose
Knocking or shuddering
applying brakes
when
Bulge in the rim or rim out of true
Brake mounting bolts loose
Brakes out of adjustment
Wobbling
wheel
- Tighten mounting
cables
bolts
- True wheel or take to a bike shop
for repair
o Tighten bolts
- Center brakes and/or adjust brake
block toe-in
Fork loose in head tube
- Tighten headset
Axle broken
Wheel out of true
Hub comes loose
Headset binding
Hub bearings collapsed
-
Replace axle
True wheel
Adjust hub bearings
Adjust headset
Replace bearings
84
Problem
Possible Cause
Steering not accurate
Wheels not aligned in frame
Headset loose or binding
Front forks or frame bent
Align wheels correctly
Adjust/tighten headset
Take bike to a bike shop for possible
frame realignment
Frequent
Inner tube old or faulty
Tire tread/casing worn
Tire unsuited to rim
Replace Inner tube
Replace tire
Replace with correct tire
Remove sharp object embedded
in tire
Correct tire pressure
File down spoke
punctures
Tire not checked after previous
puncture
Tire pressure too low
Spoke protruding into rim
85
Remedy
(_) Copyright 2000 Pacific Cycles
Purchase Record Card
Fill in Immediately and retain as a record of your purchase.
*Please retain your sales receipt for any possible
warranty
claims.
Your Name:
Address:
Date Purchased:
Place of Purchase:
Model Name:
Wheel Size:
Color:
Serial Number:
Serial Number
Location
86
PACIFIC LIMITED WARRANTY
AND POLICY ON REPLACEMENT PROCEDURES AND RESPONSIBILITIES
Your purchase includes the following warranty which is in lieu of all other express warranties. This warranty is extended only to the initial consumer
warranty registration is required This warranty gives you specific legal rights and you may have other rights which vary from state to state.
purchaser.
No
FRAME
The entire frame is guaranteed against faulty materials and workmanship for as long as the initial consumer purchaser has the bicycle, subject to the condition of the
warranty listed below If frame failure should occur due to faulty materials or workmanship during the guarantee period, the frame will be replaced. For frame replacement under this
Pacific Limited Warranty, contact us, stating the nature of the failure, model number, date received and the name of the store from which the bike was received, at the address given
oil this page Frame must be returned for inspection at customer's expense. Please note: the fork is not part of the frame.
PARTS
All other parts of the unit except Normal Wear Paris are warranted against defective materials and workmanship for a period of 1 year from the date of purchase by the initial consumer purchaser subiect to the Terms and Conditions of the warranty listed below. If failure of any part should occur during the warranty period, the part will be replaced for you if
the failure was due to faulty materials or workmanship All warranty claims must be submitted to the address below and must be shipped prepaid and accompanied by proof of purchase. Any other warranty claims not included in this statement are void. This especially includes installation, assembly, and disassembly costs. This warranty does not cover paint
damage, rust or any modifications made to the bicycle. Normal Wear Parts are defined as grips, tires, tubes, cables and saddle covering. These parts are warranted to be free from
defects in material and workmanship as delivered with the product. Any claim for repair or replacement of Normal Wear Parts (grips, tubes, tires, cables, brake shoes, and saddle
covering) and m_ssmg paris must be made within thirty (30) days of the date of purchase. The warranty does not cover normal wear and tear, improper
assembly or maintenance or installation of parts or accessories not originally intended or compatible with the bicycle as sold. The warranty does not apply to damage or failure due
to accident abuse m_suse, neglect, or theft Claims involving these issues wil! not be honored.
CONDITIONS
1
2
3.
OF WARRANTY
Your bicycle has been designed for general transportation and recreational use, but has not been designed to withstand abuse associated with stunting and jumping.
This warranty ceases when you rent. sell, or give away the bicycle, ride with more than one person, or use the bicycle for stunting or jumping.
This warranty does not cover ordinary wear and tear or anything you break accidentally or deliberately.
It is the responsibility of the individual consumer purchaser to assure that all parts included in the factory-sealed carton are properly installed, all functional parts are
initially adjusted properly and subsequent normat maintenance services and adjustments necessary to keep the bicycle in good operating condition are properly made.
This warranty does not apply to damage due to _mproper installation of parts or failure to properly maintain or adjust the bicycle. NOTICE: Bicycle specifications
subject to change wpthout notice
PACIFIC
CYCLE
LLC
4902 Hammersley
Road
Madison, W153711
Call Toll Free 1-800-283-3303
Monday
87
-Friday
8:00 a.m. to 4:30 p.m. Central
Time
_) Copyright 2000 Pacific Cycles
PACIFIC CYCLE LLC
4902 Hammersley Road
Madison, WI 53711
Phone 608/268-2456
Fax 608/268-2455
Customer Service .1-800-283-3303
E-mail: service @pacific-cycle:corn
Web Address: www.pacific-cyclelcom
(_ Copyright 2000 Pacific Cycles
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