Worksman MG/MGR Unisex Bicycle Owner’s Manual Worksman Trading Corporation – 94-15 100th Street – Ozone Park, NY 11416 – (718) 322-2000 www.worksmancycles.com Parts list UNISEXBIKE12 Congratulations! You have purchased an American-made Worksman Unisex bicycle. Worksman bicycles are considered the most durable bicycles available. This manual covers the MG and MGR Unisex Comfort Step-Through 24” Cruisers. Before assembling and riding, be sure to read this manual thoroughly. Always follow the rules of safe riding. Always keep your Worksman in tip-top shape by replacing worn parts as needed with genuine Worksman Cycles parts. (Do not use generic bicycle parts.) With simple maintenance, your Worksman will perform reliably day after day, year after year. Your bicycle has been handmade in the USA by our American craftspeople. Our reputation rides along with you, so your ultimate satisfaction is our goal. Worksman MG/MGR Bicycle Parts List (Subject to change without notice as we are constantly seeking ways to improve our products.) Frame, Fork and Headset Parts (Specify color of frames and forks when ordering.) Part # 3900R F818 Description Frame: Unisex reinforced Strap for fork (Drum brake only) Part # 154 55A Description Fork (24”, Silver) Stem for Handlebar 5031 49 51 53 55B Front Reflector Bracket Headset Bearings (pair) Bottom Cone (Presses on fork) Key Washer Handgrips (pair) Part # 1265BMXS 4915 1269 1272 1274 7217 Description Deluxe Sealed Crank Set (Upgrade) Chain Adjusters (for coaster brake) Stationary Washer (inside) Adjusting Cone (threaded, outside) Crank Locknut Pedal Set (pair) Headset and Other Parts 55F 48 50A 52 54 Handlebar Headset Cups (pair) Headset Complete (48,49,52,53,54) Top Adjusting Cone (threaded) Fork Top Locknut Crank Parts (Pedal Section) and Chains Part # 1265 1266 1268 1271 1273 3275 4910A Description Crank Parts (1266,1268,1269,1271,1272,1273,1274) Crank Bearings (pair) Cups for Crank Housing (pair) Key Washer (outside) Stationary Cone (inside) Crank (One piece, forged, 5.5”) Chainguard MGR Specific Parts (Below) MG Specific Parts (Below) 1380 1380D 4914A 4914R 4914AA 4914BB 1380B 1380C 4914M 4914R1 4914W 4914H Sprocket 44 Tooth (1/8”) (Standard) Sprocket 36 Tooth (1/8”) (Optional) Chain Connecting Link (1/2”x1/8”) Chain Half-Link (1/8”) Chain (1/8”x103 links – 44T sprocket) Chain (1/8”x97 links – 36T sprocket) Part # 139 Description Front Wire Basket (18”x13”x6”) Part # 6910V 4908D 7229I Description Saddle (13” w/o springs) Seatpost (1”) Kickstand Sprocket 44 Tooth (3/16”) (Standard) Sprocket 36 Tooth (3/16”) (Optional) Chain Connecting Link (1/2”x3/16”) Chain Half-Link (3/16”) Chain (3/16”x103 links – 44T sprocket) Chain (3/16”x97 links – 36T sprocket) Baskets (Optional) Part # 133WH Description Removable Front Basket (14.5”x9.5”x9”) Seats, Seatpost, Kickstand Part # 4912V 6911V 4911D Description Saddle (10” w/ springs) Saddle (13” extra-wide w/ springs) Seatpost Clamp (Post to frame) Wheels, Tires, and Tubes Part # Description MGR (24” x 2.125”) Wheels and Parts Part # (Below) Description MG (24” x 1.75”) Wheels and Parts (Below) 4135QA 7724A 4135A SMX243CB 4922E 4922EKV 4922EWSW 4923E 6023B 1014C 24” Front Wheel w/o Tire (No drum brake) 24” Front Drum Brake Wheel w/o Tire 24” x 2.125” Rear Wheel w/o Tire 24” x 2.125” Rear 3 SPEED Wheel w/o Tire 24” x 2.125” Blackwall Tire 24” x 2.125” Kevlar Blackwall Tire 24” x 2.125” Whitewall Tire 24” x 2.125” Tube (Standard) 24” x 2.125” Tube (Puncture Resistant) Spokes & Nipples (.120”) for 24” Wheels M24F 466A M24CB M243CB 6032 6032W 6032A 1014K 24” x 1.75” Front Wheel w/o Tire 24” x 1.75” Front Drum Brake Wheel 24” x 1.75” Rear Wheel w/o Tire 24” x 1.75” Rear 3 SPEED Wheel 24” x 1.75” Blackwall Tire 24” x 1.75” Whitewall Tire 24” x 1.75” Tube (Standard) Spokes & Nipples (.080”) for 24” Wheels 1017B 24” Rimstrip (1.75” OR 2.125”) 1018 Valve Cap (Any tube) Fenders and Parts (MG Only) (Fenders are not available for Heavy-Duty MGR bicycles.) FSB24 4803 4803K Complete Fender Set (Front & Rear) Front Fender Front Fender Parts Kit (All hardware) 95 4804 4805 Fender L-Bracket Rear Fender Front or Rear Fender Brace Safety and Comfort Accessories Part # 3979 3973 4963 3978 101710 7217-41197 1006 2000 1001 6001 7217GS12 Description Part # Ding Dong Chime Bell 303 Mega-Horn (battery operated) 201 Rear View Mirror 5032 Safety Flag on Pole P19 Flashing Strobe Light (clear lens) 101714 Pedals with Velcro Foot Straps (pair) 3975 Air Foot Pump 1000 Chain Rivet Remover Tool 1265TW Pedal Wrench Patch Kit (50) 3976 “Glowspeck” Flashing Pedals – Flash without batteries! Description Squeeze Bulb Horn Cable and Lock set Reflector Kit (Does not include 5031) Bicycle Helmet Flashing Strobe Light (red lens) Generator Light Set Spoke Wrench Crank Cone Wrench Battery Operated Headlight ASSEMBLY INSTRUCTIONS Please read this manual carefully prior to performing the simple finishing assembly and prior to riding. We recommend that a qualified bicycle mechanic assemble any cycle. Carefully remove the bicycle from the carton. You will notice the bicycle is mostly pre-assembled at the factory. TO ATTACH FRONT FORK/WHEEL ASSEMBLY TO THE FRAME: Headset Assembly: 1) Grease headset cups (48) with Rustolene 200 (light grease) or equal. Bearings (49) are pre-greased at the factory, but it is wise to add lubrication before assembly. 2) Place one headset bearing (49) onto fork steerer tube with balls facing up. Slide steerer tube into frame. 3) Place the other bearing on top of fork tube with balls facing down towards the cup (#48), which is already pressed onto the frame. 4) Install top-adjusting cone (52) onto treaded fork steering tube. Hand-tighten, making sure bearings do not bind. Turn back ¼ turn. 5) Install fork key washer (53) and reflector bracket on top of the adjusting cone with tip of washer in slot on steering tube. 6) Install head lock nut (54) and securely tighten. Make sure that the fork rotates freely without being loose. Excess play or resistance must be adjusted. Failure to adjust properly can lead to improper steering response. 7) Install handlebar stem (55A) into the fork steering tube with the handlebar clamp facing forward. The stem must be inserted far enough to reach the minimum insertion line. Tighten the stem bolt slightly at this point. Loosen the handlebar clamp nut and slide the handlebar through the clamp, centering the knurled center section of the handlebar into the clamp. 8) Position the handlebar to the desired angle and tighten clamp securely. Recommended torque is 300 IN. LBS. Adjust the handlebar rotation so that it is straight with the front wheel. Tighten stem bolt securely. Recommended torque 240 IN. LBS. Be sure not to over tighten, as damage to the parts may occur causing steering failure. 9) If a drum brake was ordered, attach brake lever to handlebar Make sure brake cable is not tangled in any way. INSTALLING PEDALS AND KICKSTAND: 1)Install kickstand. 2)Pedals are marked on the shaft with either an “L” or “R” denoting left or right. The “R” pedal fits on the right (sprocket side) of the crank arm. Tighten clockwise. The “L” pedal fits on the left side of the crank arm. Tighten counter-clockwise (left-hand thread). Securely tighten. Recommended torque 275 IN. LBS. CAUTION: Tightening in the wrong direction will damage the crank threads, and will not be covered under warranty. SEAT ADJUSTMENTS: Adjust the seat height to your desired level by loosening the seat clamp nut at the top of the frame’s seat tube. Re-tighten at desired height. Make sure a minimum of 3 1/2” of the post remains in the frame tube. Never adjust post above this level. Adjust angle of seat with nose raised slightly. Tighten seat clamp securely. (240 IN. LBS.) MAINTENANCE TIPS: Always inspect your Worksman Cycle to ensure that all nuts, bolts, screws and hardware are tight and that no parts are worn or damaged. Do not attempt to straighten bent forks or frames. Chain: Lubricate chain once a month or as needed with light oil. Replace sprockets when teeth become worn, bent or broken. Keep chain adjusted so there is no more than 3/8” slack. Note that we make the chains tight at the factory, as we do know they will stretch during the break-in period. Lubricate crank parts every six months. Replace pedals when the surface is worn or if axle becomes “tight” or frozen. Drum Brake: Some Worksman bicycles are equipped with a front drum brake. It is engaged by squeezing the hand lever on the handlebar. To use “Park” feature, when cycle is completely stopped, squeeze hand lever and push in parking plunger button on lever. To disengage, simply squeeze lever until parking plunger button releases. Drum brakes are pre-adjusted at the factory. Readjust the cable tension as necessary using the adjusting barrel so that wheel spins freely and stops when brake is applied. Always replace worn brake cables and damaged hand levers. Coaster Brake (if applicable): Foot activated coaster brakes are easy to use and reliable. To activate this internal brake, reverse the pedaling motion until the brake engages. To avoid skidding and maintain control, apply care when braking. This is especially true on wet surfaces. Apply brakes gently, gradually increasing pressure. Replace coaster brakes when they become worn. Check chain tension regularly. Coaster brake hubs may make a vibrating noise under braking until they are broken in. Tires: Always check for wear or damage. We recommend 40PSI as proper level of inflation. Replace worn or cut tires and leaking tubes immediately. LIMITED WARRANTY: THIS CYCLE IS WARRANTIED AGAINST FAULTY PARTS UNDER THE FOLLOWING CONDITIONS: THIS WARRANTY DOES NOT COVER ANY FAILURE DUE TO ACCIDENT, ABUSE, MISUSE, NEGLECT OR AS THE RESULT OF NORMAL WEAR AND TEAR, OR IMPROPER ASSEMBLY. THE ENTIRE FRAME, INCLUDING ALL WELDED JOINTS, IS WARRANTED TO BE FREE FROM DEFECTS AND MATERIAL FOR ONE YEAR WHILE IN POSSESSION OF THE ORIGINAL PURCHASER. ALL OTHER PARTS ON THIS CYCLE, EXCEPT TIRES AND TUBES, ARE WARRANTIED FOR 90 DAYS FROM THE DATE OF PURCHASE. REPAIR AND REPLACEMENT OF THESE PARTS IS TO BE ACCORDING TO THE W ORKSMAN CYCLES PARTS AND SERVICE PROCEDURES AND MUST BE HANDLED DIRECTLY THROUGH THE SOURCE WHERE THE CYCLE WAS PURCHASED. IF UPON EXAMINATION OF THE PARTS IN QUESTION, THE WORKSMAN CYCLE DEALER DETERMINES THAT IT IS DEFECTIVE, EITHER REPAIR OR REPLACEMENT WILL BE MADE AT NO COST EXCEPT THE COST OF TRANSPORTATION AND LABOR CHARGES (IF ANY). UNAUTHORIZED REPAIRS OR REPLACEMENT AUTOMATICALLY VOIDS W ARRANTY. PROPER MAINTENANCE IS REQUIRED FOR WARRANTY TO BE VALID. IN THE EVENT THAT IT WAS DETERMINED THAT THE WARRANTY CLAIM IS THE RESULT OF MISUSE, ABUSE, IMPROPER MAINTENANCE OR SIMPLY NOT DEFECTIVE OR BEYOND THE WARRANTY PERIOD, WORKSMAN CYCLES OR THE DEALER WILL ADVISE YOU AS TO THE COST OF REPAIR, REPLACEMENT OR LABOR PRIOR TO PERFORMING ANY W ORK OR REPLACING ANY PARTS. IF YOU CHOOSE NOT TO HAVE THE DEALER OR WORKSMAN CYCLES PERFORM THE WORK, THE PARTS WILL BE RETURNED TO YOU AT YOUR EXPENSE OR DISCARDED IF NO REPLY IS RECEIVED WITHIN 2 WEEKS OF NOTIFICATION. THE SOLE RESPONSIBILITY OF THE MANUFACTURER TO THE TERMS OF THIS WARRANTY, IF ANY, SHALL BE THE REPAIR AND/OR REPLACEMENT OF THE PARTS AS INDICATED ABOVE. THE LIABILITY OF THE MANUFACTURER SHALL IN NO EVENT EXCEED THE ORIGINAL PURCHASE PRICE OF THE PRODUCT, AND THE MANUFACTURER SHALL NOT BE RESPONSIBLE FOR ANY CONSEQUENTIAL DAMAGES OF ANY NATURE, INCLUDING, BUT NOT BY WAY OF LIMITATION, DAMAGES FOR PERSONAL INJURY OR PROPERTY. THIS STATEMENT CONSTITUTES THE EXCLUSIVE EXPRESSION OF WARRANTIES BY THE MANUFACTURER AND IS IN LIEU OF ANY OR ALL OTHER WARRANTIES SUCH AS EXPRESSED WARRANTIES, IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY, AND FITNESS OR PURPOSE, ARE LIMITED IN DURATION FOR ONE YEAR FROM THE DATE OF PURCHASE OF THE FRAME ONLY AND 90 DAYS FOR ALL OTHER PARTS, EXCEPT TIRES AND TUBES WHICH ARE NOT WARRANTIED. WORKSMAN TRADING CORPORATION IS THE MANUFACTURER. MISUSE OF THE CYCLES INCLUDING OFF ROAD RIDING, INSTALLATION OF MOTORS OR POWER ASSISTS, ALTERATIONS, REPAIRS USING PARTS OTHER THAN WORKSMAN CYCLE PARTS VOIDS WARRANTY. WORKSMAN TRADING CORPORATION IS NOT RESPONSIBLE FOR MAINTAINING RECORDS OF SERIAL NUMBERS. VOID WHERE PROHIBITED BY STATE LAW. RULES FOR SAFE RIDING AND RESPONSIBLE OPERATION: Carefully read this manual before operating the cycle. · It is the responsibility of the assembler to properly install all parts included and to inspect the cycle prior to riding to insure proper operation. · Wear a helmet! · Operator is responsible for required maintenance and for observing all traffic regulations in the operating environment. (Stop signs, etc.) · Keep to the right and in a straight line. Ride in single file. Operate cycle at slow speeds, particularly in high traffic areas. · Do not ride outdoors at night, and use appropriate signaling methods as needed. (We recommend the 3973 Mega Horn and P122 light kit.) · Give pedestrians the Right of Way. Always look around you to understand the riding environment and hazards. · Do not carry passengers, and check brakes prior to riding. Never ride the cycle if there are known repairs required. · Slow down when approaching turns or intersections. · Recommended safety options include, but are not limited to, an approved helmet, audible warning device, front/rear lights and/or reflectors. · Do not exceed the recommended weight capacity. (MG: 210 lbs. / MGR: 350 lbs.) Always secure cargo with appropriate tie down straps. · Wipe surface of cycle clean and dry when exposed to corrosive substances or environment. · Operators of cycles should be in good physical condition. Ride at your own risk. · Wear proper riding attire. Check shoelaces and pant legs prior to riding so they do not become engaged in the chain and sprocket. · Ride only on smooth, paved surfaces. Do not use off road. Always keep both hands on the handlebars. · Always replace worn parts with genuine Worksman Cycle Repair Parts. Visit us online at www.worksmancycles.com or call us at 888-3WHEELER!