scooter owner`s manual
SCOOTER OWNER'S MANUAL
THIS MANUAL CONTAINS IMPORTANT SAFETY, PERFORMANCE AND MAINTENANCE
INFORMATION. READ THE MANUAL BEFORE TAKING YOUR FIRST RIDE ON YOUR
NEW SCOOTER, AND KEEP THE MANUAL HANDY FOR FUTURE REFERENCE.
Contents
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
User Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Riding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Before You Ride Safety Checklist . . . . . . . . . . . . . . . . . . . . . 9
2 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Attach the Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Attach the Front Brake Cable . . . . . . . . . . . . . . . . . . . . . . 15
Cable Detangler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Attach the Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Attach the Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Attach the Pegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjusting the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjusting the Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hand Operated Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parts Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hub Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Inflating the Tire Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Repairing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Purchase Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Congratulations
About This Manual
Toll free: 1-800-626-2811.
Customer Service hours: Monday - Friday 8 AM- 5 PM Central
Standard Time (CST)
This manual contains important information regarding safety,
assembly, use, and maintenance of the scooter but is not
intended to be a complete or comprehensive manual covering all
aspects concerning scooter ownership. We recommend
consulting a bicycle mechanic if you have any doubts or concerns
regarding your experience or ability to properly assemble and
maintain the scooter.
on your new scooter! Proper assembly and operation of your
scooter is important for your safety and enjoyment. Our
customer service department is dedicated to your satisfaction
with Pacific Cycle and its products. If you have questions or need
advice regarding assembly, parts, performance, or returns,
please contact the experts at Pacific Cycle. Enjoy the ride!
You may also reach us at:
Web: www.pacific-cycle.com
Email:customerservice@pacific-cycle.com
Mail: P. O. Box 344
4730 E. Radio Tower Lane
Olney, IL 62450
Do not return this item to the store. Please call Pacific Cycle
customer service if you need assistance. You will need your
model number and date code located on the service sticker.
2
It is important for you to understand your new scooter.
By reading this manual before you go out on your first ride, you’ll
know how to get better performance, comfort, and enjoyment
from your new scooter. It is also important that your first ride on
your new scooter is taken in a controlled environment, away
from cars, obstacles and cyclists.
A Special Note For Parents and Guardians
It is a tragic fact that most scooter accidents involve children.
As a parent or guardian, you bear the responsibility for the
activities and safety of your minor child. Among these
responsibilities are to make sure that the scooter which your
child is riding is properly fitted to the child; that it is in good
repair and safe operating condition; that you and your child
have learned, understand and obey not only the applicable local
motor vehicle, scooter, and traffic laws, but also the common
sense rules of safe and responsible bicycling. As a parent, you
should read this manual before letting your child ride the
scooter. Please make sure that your child always wears an
approved bicycle helmet when riding.
Helmets
Save
Lives!
Correct Fitting
Make sure your helmet covers your forehead
•ALWAYS WEAR A PROPERLY FITTED
HELMET WHEN RIDING YOUR SCOOTER
•DO NOT RIDE AT NIGHT
•AVOID RIDING IN WET CONDITIONS
Incorrect Fitting
Forehead is exposed and vulnerable to serious injury
3
1 Safety
❶ Safety
SAFETY SIGNAL WORDS
USER RESPONSIBILITY
The following safety signal words indicate a safety message.
The symbol alerts you to potential hazards. Failure to follow the
warning may result in damage to property, injury, or death.
All persons assembling, using, and maintaining the scooter must
read and understand the safety warnings and operating
instructions in this manual before using the scooter.
This manual contains many Warnings and Cautions concerning
the consequences of failure to follow safety warnings. Because
any fall can result in serious injury or even death, we do not
repeat the warning of possible injury or death whenever the risk
of falling is mentioned.
It is the responsibility of the user, or in the case of a child rider,
an adult, to ensure the scooter is properly maintained and in
proper operating condition. Doing so will reduce the risk of
injury. Always conduct regular maintenance and inspection of
your scooter. Complete the Safety Checklist at the end of this
section before each use.
A responsible adult must always supervise the use of the scooter
by a child. You must ensure:
WARNING!
Indicates a hazard or unsafe practice that will result in severe
injury or death. Failure to read, understand and follow the safety
information in this manual may result in serious injury or death.
CAUTION!
Indicates a hazard or unsafe practice that could result in
minor injury.
NOTICE
Indicates a hazard unrelated to personal injury, such as
property damage.
4
• The child is wearing the proper protective attire and approved
bicycle helmet.
• The scooter is properly fitted to the child.
• The child understands applicable laws and common sense
rules of safe responsible scooter riding.
• Rider must be at least 48” tall.
Safety 1
PERSONAL SAFETY
WARNING!
Riding a scooter without protective gear, clothing, or a helmet
may result in serious injury or death. Always wear protective
gear, clothing, and helmet when riding the scooter. Ensure
protective gear does not interfere with steering, braking, and
pushing.
Protective Gear and Clothing
Always wear: Figure 1.1
• Colors that are easily seen and, if possible, reflective clothing
• Closed toe shoes
Properly fitted helmet
Easily seen or
reflective clothing
Elbow pads
• Clothing appropriate for the weather conditions
• Use of protective gear such as pads for the knees and elbows
is highly recommended for children
• A properly fitted, ASTM or SNELL approved, bicycle helmet
shall be worn at all times by riders of the scooter. For
information regarding how to properly fit a helmet visit:
http://www.nhtsa.gov/people/injury/pedbimot/bike/
easystepsweb
Do not wear:
• Loose clothing parts, strings, jewelry that may become
entangled with moving parts on the scooter or interfere with
handling of the scooter.
• Shoes with untied shoe laces.
Knee pads
Laces tied
Figure 1.1
5
1 Safety
Helmet Use
Important! Many states have passed helmet laws regarding
children. Make sure you know your states helmet laws. It is your
job to enforce these rules with your children. Even if your state
does not have a children’s helmet law, it is recommended that
everyone wear a helmet.
It is strongly advised that a properly fitting, ASTM or SNELL
approved, bicycle helmet be worn at all times when riding your
scooter.
The correct helmet should: Figure 1.2
• Be comfortable
• Have good ventilation
• Fit correctly
Figure 1.2
• Cover forehead
Incorrect helmet position: Figure 1.3
• Helmet does not cover the forehead
Figure 1.3
6
Safety 1
RIDING SAFETY
WARNING!
Riding the scooter in unsafe conditions (i.e.: at night), in an
unsafe manner, or disregarding traffic laws may result in an
unexpected movement, loss of control, and serious injury or
death.
General Safety
• Familiarize yourself with all the scooter’s features before
riding. Practice braking.
• Always ride defensively in a predictable, straight line. Never
ride against traffic.
• Expect the unexpected (e.g., opening car doors or cars
backing out of concealed driveways).
• Take extra care at intersections and when preparing to pass
other vehicles.
• Maintain a comfortable stopping distance from all other
riders, vehicles and objects. Safe braking distances and forces
are subject to the prevailing weather conditions. Do not lock
up the brakes. When braking, always apply the rear brake
first, then the front. The front brake is more powerful and if it
is not correctly applied, you may lose control and fall.
• Always use the correct hand signals to indicate turning
or stopping.
• Obey the traffic laws (e.g., stopping at a red light or stop sign,
giving way to pedestrians).
• Use original spare parts only. Do Not make structural changes
or modifications to the scooter.
• Wear proper riding attire, reflective if possible, and avoid
open toe shoes.
• Do not use items that may restrict your hearing and vision.
• Do not carry packages or passengers that will interfere with
your visibility or control of the scooter.
Road Conditions
• Be aware of road conditions. Concentrate on the path ahead.
Avoid pot holes, gravel, wet road markings, oil, curbs, speed
bumps, drain grates and other obstacles.
• Cross train tracks at a 90 degree angle or walk your scooter
across.
• Keep away from motor vehicles and other traffic.
Wet Weather
• When riding in wet weather always wear reflective clothing
and use safety lights to enhance visibility.
• Exercise extreme caution when riding in wet conditions.
• Ride at a slower speed. Turn corners gradually and avoid
sudden braking.
• Brake earlier, it will take a longer distance to stop.
• Pot holes and slippery surfaces such as line markings and train
tracks all become more hazardous when wet.
7
1 Safety
Night Riding
Safe Riding Rules for Children
• Important! Riding a scooter at night is not recommended.
Check your local laws regarding night riding.
• Many states require that children wear a helmet while riding.
Always wear a properly fitted helmet.
• Wear reflective and light colored clothing. Wear reflective
clothing and use safety lights for increased visibility.
• Do not play in driveways or the road.
• Ride at night only if necessary. Slow down and use familiar
roads with street lighting.
Hill Technique
• Do not exceed a comfortable speed; maintain control and
take additional care.
• Braking will require additional distance. Initiate braking slowly
and earlier than usual.
Cornering Technique
• Brake slightly before cornering and prepare to lean your body
into the corner.
• Decrease your riding speed, avoid sudden braking and
sharp turns.
8
• 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 left, right, and left again
for traffic. If there’s no traffic, proceed into the roadway.
• If riding downhill, be extra careful. Slow down using the
brakes and maintain control of the steering.
• Never take your hands off the handlebars.
Safety 1
BEFORE YOU RIDE SAFETY CHECKLIST
Before every ride, it is important to carry out the following
safety checks. Do not ride a scooter that is not in proper
working condition! Replace any worn or broken parts as
needed.
Accessories
□
□
□
The frame and fork are not bent or broken.
Steering
□
The handlebar and post are correctly adjusted and
tightened, and allow proper steering.
□
All other fittings on the scooter are properly and securely
fastened, and functioning.
□
The rider is wearing a properly fitted helmet (protective gear
if necessary) and that clothing and loose items are properly
constrained.
□ The rims do not have dirt or grease on them.
□ The wheels are properly attached to the scooter and axle.
□ The tires are properly inflated within the recommended
All bearings are lubricated, run freely and display no excess
movement, grinding or rattling.
Brakes
□
□
The front and rear brakes work properly.
□
The brake control cables are lubricated, correctly adjusted
and display no obvious wear.
□
□
Check all parts are secured and functioning correctly before
each ride.
Bearings
□
Frame and Fork
The handlebars are set correctly in relation to the forks and
the direction of travel.
The handlebar binder bolt is tightened.
Wheels and Tires
□
pressures displayed on the tires sidewall.
The tires have the proper amount of tread, no bulges or
excessive wear.
The brake shoe pads are not overly worn and are correctly
positioned in relation to the rims.
The brake control levers are lubricated and tightly secured
to the handlebar.
9
❷ Parts Identification
Expo Scooter
Get to know the parts of your scooter. This will help with assembly, maintenance, and troubleshooting. Models vary in color and style.
Part name
Torque (ft-lb)
Part name
Torque (ft-lb)
1
Handlebar grip
-
19
Front fork
2
Rear brake lever
55 - 70
20
Front caliper brake assembly
3
Brake cables
-
20A
Front brake pads
4
Stem binder bolt
100 - 120
20B
Front brake pads hardware
50 - 60
5
Stem
-
20C
Brake cable pinch bolt
50 - 70
6
Headset
175 - 260
21
Foot board
7
Handlebar binder bolt(s)
145 - 200
22
Rear caliper brake assembly
8
Handlebar
-
22A
Rear brake pads
9
Front brake lever
55 - 70
22B
Rear brake pads hardware
50 - 60
10
Frame
-
22C
Brake cable pinch bolt
50 - 70
11
Cable splitter
12
Front brake attaching nut
13
50 - 70
-
50 - 70
-
23
Rear fork
-
70-85
24
Rear fork dropout
-
Valve stem
-
25
Pegs
-
14
Spoke
-
26
Rear tire
-
15
Rim
-
16
Tire
17
Wheel axle nut (front and rear)
18
Front fork dropout
10
180 - 240
-
Parts Identification 2
1
2
9
3
8
4
5
6
7
20C
22C
20B
20A
10
22A
20
11
12
22B
19
18
17
16
15
14
23 24 25 26
22
21
13
11
3 Assembly
❸ Assembly
WARNING!
• Improper assembly of this product may result in serious
injury or death. Always follow the instructions in this
manual and check critical components (e.g. wheels, brakes,
tires) before each use.
• We recommend that you consult a bicycle mechanic if you
have doubts or concerns as to your experience or ability to
properly assembly, repair, or maintain your scooter. If your
scooter was obtained assembled, we recommend that you
read these instructions and perform checks specified in
this manual before riding.
If you need replacement parts or have questions pertaining to
the assembly of your scooter, call the service line direct at:
1-800-626-2811. Monday - Friday 8:00 am to 5:00 pm Central
Standard Time (CST).
TOOLS REQUIRED
• Phillips head screw driver
• 4 mm, 5 mm and 6 mm Allen wrench
• Adjustable wrench or a 9 mm, 10 mm, 14 mm and 15 mm
open and box end wrenches
• A pair of pliers with cable cutting ability
Your new scooter was assembled and tuned in the factory and
then partially disassembled for shipping. You may have
purchased the scooter already fully assembled and ready to ride
or in the shipping carton in the partially disassembled form. The
following instructions will enable you to prepare your scooter
for years of riding enjoyment.
For more details on inspection, lubrication, maintenance and
adjustment of any area please refer to the relevant sections in
this manual. If you have questions about your ability to properly
assemble this unit, please consult a qualified bicycle mechanic
before riding.
12
Figure 3.1
Assembly 3
GETTING STARTED
❶ Open the carton from the top and remove the scooter.
Figure 3.2
Handlebar assembly
❷ Remove the straps and protective packaging from the
scooter. Important! Do not discard packing materials until
assembly is complete to ensure that no required parts are
accidentally discarded.
❸ Inspect the scooter 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. Note: We recommend using a lithium based
grease on the parts before assembly.
Frame
Wheels (2)
Pegs (2)
Figure 3.2
13
13
3 Assembly
ATTACH THE HANDLEBAR
WARNING!
• Improper attachment of the handlebar may result in
damage to the stem post, steering tube and result in lose of
control, serious injury or death. Ensure the minimum
insertion marks on the stem post are not visible above the
top of the headset.
• Failure to properly tighten handlebar components may
result in lose of control, serious injury or death. Always
check the handlebar cannot move and is secured to the
frame before riding the scooter.
❻ Look at all the cables to be sure they run in a smooth arc
from the brake lever to the front brake or cable stop on the
frame. Important! If they are twisted or kinked, braking will
not work.
Note: See Section 4: Adjusting the Handlebar if adjustments
are needed.
Handlebar clamp
plate
Handlebar
binder bolts 4
3
2
Handlebar bracket
Stem binder bolt
5
❶ Turn the front fork to face forward. Figure 3.3
❷ Insert the handlebar assembly into the handlebar bracket
with the brake levers on the outside. Align the handlebar so
it is centered with the front wheel.
6
❸ Place the handlebar clamp plate over the handlebar,
aligning the holes in the plate with the holes in the
handlebar bracket.
❹ Insert the handlebar binder bolts (4 total) through the plate.
Using at 6 mm hex wrench, tighten the bolts.
❺ Using a 14 mm open-end wrench, tighten the stem binder
bolt at the top of the stem post. Check the handlebar binder
bolt(s) to be sure they are properly tightened and the
handlebar is clamped in place. 14
Front fork
facing forward
1
Figure 3.3
Assembly 3
ATTACH THE FRONT BRAKE CABLE
WARNING!
Failure to properly set the brakes may result in the inability to
stop the scooter movement and cause serious injury or death.
Be sure the brakes are functioning properly before using the
scooter.
Cable adjustment Cable nut slot
barrel slot
1
2
Brake cable slot
Brake lever
❶ Rotate the cable adjustment barrel and cable nut until the
slots are aligned with the slot on the brake lever body.
Figure 3.4
Figure 3.4
❷ Press the brake lever towards the grip.
❸ Bring the brake cable from the stem over the handlebar and
Slide the brake cable through the slots and place the cable
head into the brake lever. Figure 3.5
3
Brake cable
Cable head
Figure 3.5
❹ Release the brake lever. Figure 3.6
❺ Lightly pull on the cable and rotate the cable nut and cable
barrel so they are no longer aligned.
Note: See Section 4: Adjusting the Brakes if adjustments
are needed.
4
5
Figure 3.6
15
15
3 Assembly
CABLE DETANGLER
c. Check to see if the bearing unit bottoms out on the
lower detangler plate. If so, unscrew the adjust barrel
further until the bearing unit sits about 1 mm above
the lower plate. This is the correct position for the
bearing unit.
Some scooters are equipped with a cable detangler for the rear
brake. Follow these steps to attach the upper cable to the rear
brake lever. Figure 3.7
❶ Loop the upper cables through the opening on the
handlebar. Note: One of the upper cable casings is shorter
than the other. The shorter side should be on the right. This
is the shorter distance between the brake lever and the
upper detangler plate.
❷ On both sides, place the cable through the upper plate and
thread the adjusting barrels into it.
❸ Insert the cables into the slots on the bearing plate. Note:
The lower cables should already be attached to the tabs on
the bearing unit.
❹ Squeeze the brake lever several times to be sure all the
cables are seated in the adjustment barrels. If there is
excess play before the brake cable starts to move, this can
be adjusted by turning the adjustment barrels.
a. First adjust the barrel adjuster at the mid point of the
upper cable until the brake lever does not have any
free play.
b. Next squeeze the brake lever and allow it to return.
16
❺ Rotate the handlebars back and forth and then turn them
completely around 360 degrees. Observe if the bearing unit
spins quietly, or if it “flops” back and forth. If it has any flop,
this can be fine-tuned with the four adjustment barrels in
the upper and lower plates. The goal is to reduce or
eliminate as much of the flop as possible, while keeping the
brake function consistent.
❻ Turn the handlebars 360 degrees and note whether the plate
flops forward and back, or if it flops the same way. If it flops
forward and back, adjust the upper cable barrel adjusters
until the flop is reduced. If the flop is the same way, then
adjust the lower cables until the flop is reduced. Sometimes
both need to be adjusted. The best thing to do is to adjust the
lower cables first until the bearing unit has an equal gap on
the left and right sides, then adjust the upper barrel
adjusters until the flop is minimal or none at all.
Note: See Section 4: Adjusting the Brakes for further
adjustment of the caliper brakes.
Assembly 3
Front View of Scooter
Cable
adjuster
Cable
splitter
Front brake
cable
Single cable
casing
Rear brake
lever
Upper cable
(short casing)
Cable adjusting
barrel
1
Front brake
lever
Upper cable
(long casing)
4
1 mm
(1/32")
2
3
1 mm
(1/32")
4
Upper cable adjusting barrels
Locknut
Upper plate
Lower plate
Bearing unit
Locknut
Lower cable adjusting barrels
Lower cable
Lower cable
Important! The gap between the plates and
bearing unit should be a minimum 1 mm (1/32”)
when the brake is engaged or disengaged.
Figure 3.7
17
17
3 Assembly
ATTACH THE FRONT WHEEL
❶ Loosen the axle nuts on the front wheel. If there is a washer
inside of the axle nut, it belongs outside of the fork
dropouts.
3
❷ Position the front wheel between the front fork legs with
the axle resting inside the fork drop out. Figure 3.8
Important! Be sure the wheel is as centered as possible
between the fork legs.
❸ Place the clip retaining washer on the axle and slide it up
against the fork drop out. Make sure the hooked end is
inside the small hole of the fork dropout. Figure 3.9
❹ Place the two outer axle nuts on and tighten evenly. Tighten
one side part way, then tighten the other side and repeat
until both sides are tightened securely. Be sure that the
wheel remained centered between the fork legs.
❺ If it is off center, loosen the axle nut on the side that has a
smaller gap between tire and fork leg and use your hand to
push the wheel to a centered position; hold the wheel with
one hand and tighten the axle nut and check again. Repeat if
needed to be sure the wheel is centered and securely
tightened.
Clip retaining
washer inserted
into dropout hole
Fork dropout
Figure 3.9
3
4
Dropout hole
2
Axle
Clip retaining
washer
3
4
Axle nut
18
Figure 3.8
Assembly 3
ATTACH THE REAR WHEEL
❶ Loosen the axle nuts on the rear wheel. If there is a washer
inside of the axle nut, it belongs outside of the fork
dropouts.
3
❷ Position the rear wheel between the rear fork legs with the
axle resting inside the fork drop out. Figure 3.10
Clip retaining
washer inserted
into dropout hole
Figure 3.11
Important! Be sure the wheel is as centered as possible
between the fork legs.
❸ Place the clip retaining washer on the axle and slide it up
against the fork drop out. Make sure the hooked end is
inside the small hole of the fork dropout. Figure 3.11
❹ Place the two outer axle nuts on and tighten evenly. Tighten
one side part way, then tighten the other side and repeat
until both sides are tightened securely. Be sure that the
wheel remained centered between the fork legs.
❺ If it is off center, loosen the axle nut on the side that has a
smaller gap between tire and fork leg and use your hand to
push the wheel to a centered position; hold the wheel with
one hand and tighten the axle nut and check again. Repeat if
needed to be sure the wheel is centered and securely
tightened.
Axle nut
4
Clip retaining washer
Axle
Dropout hole
3
2
3
Fork dropout
4
Figure 3.10
19
19
3 Assembly
ATTACH THE PEGS
Important! Periodically check to make sure pegs are tight.
Some models may come equipped with 2 or 4 pegs.
Peg
3
To install pegs:
❶ Do not loosen or remove axle nuts.
2
❷ Check to make sure axle nuts are properly tightened before
installing pegs. Figure 3.12
3
❸ Thread the pegs on the axle over the axle nut.
❹ Insert a screwdriver or similar tool through the peg holes
and tighten by turning the peg with the tool. Figure 3.13
Clip
retaining
washer
Axle nut
Peg
Figure 3.12
4
Figure 3.13
20
Adjustments 4
❹ Adjustments
After your scooter is assembled you will need to make
adjustments. If you need replacement parts or have questions
pertaining to the assembly of your scooter, call the service line
direct at: 1-800-626-2811. Monday - Friday 8:00 am to 5:00 pm
Central Standard Time (CST).
Note: You will need your model number and date code located
on the service sticker.
TOOLS REQUIRED
• Phillips head screw driver
• 4 mm, 5 mm, 6 mm Allen wrench
• Adjustable wrench or a 9 mm, 10 mm, 14 mm and 15 mm
open and box end wrenches
• A pair of pliers with cable cutting ability
Figure 4.1
21
21
4 Adjustments
ADJUSTING THE BRAKES
Adjusting the Side-pull Caliper Brakes
Brake cable at
brake lever
4
❶ If the brake cable is disconnected at the caliper, thread the
brake wire through the adjustment barrel. Figure 4.2
3
Brake wire
Figure 4.3
❷ Using a 10 mm open end wrench, loosen the cable anchor
bolt until you can see a gap large enough for the cable wire.
2
❸ Thread the cable wire through the gap. By hand, screw the
cable anchor bolt snug enough to hold the cable wire.
Cable anchor
bolt
❹ Check the cable end is seated in the brake lever. Figure 4.3
❺ With one hand squeeze the caliper arms until both brake
pads contact the rim. Loosen the cable anchor bolt just
enough to allow the brake wire to move freely. Figure 4.2
❻ While holding the brake closed, use your other hand to pull
the brake wire tight (through the cable anchor bolt). Check
that the cable end is seated in the brake lever and the barrel
adjuster of the brake.
Cable
adjustment
barrel
Caliper arm
Brake pads
5
Caliper
arm
1
Brake cable
❼ Tighten the cable anchor bolt as much as you can by hand
and then while still squeezing the brake, tighten the cable
anchor bolt fully.
Note: Use the adjustment barrel to fine-tune the brake
cable tension. Turning the barrel clockwise will loosen the
brake cable tension, counter-clockwise will tighten the
brake cable tension.
22
Figure 4.2
Adjustments 4
Adjusting the Brake Pads
Center the Brake Pads
Important! Before riding the scooter it is important to check the
brakes. If you squeeze the brake lever and one brake arm moves
more than the other, (or not at all), the brake is not centered.
You will need to fine tune the brake pads. Multiple adjustments
may be necessary to center the brake pads, correctly set the
brake pressure, and set the gap between the brake pad and rim.
Rotate the wheel and look straight down at the gap between
the rim, brake pads, and fork. If you find the gap between these
are uneven it indicates the wheel, the brake pads, or both are
not centered.
❶ Check that all brake pads are aligned correctly. If not, use a
5 mm allen wench and loosen the bolt enough so you can
reposition the pad. Position the pad so it is evenly centered
on the rim. Retighten the bolt after positioning the pad
correctly. Figure 4.4
❶ If you see the gap between the fork and wheel is uneven
loosen the axle nuts and adjust the wheel until centered.
Figure 4.5
Incorrect Alignment
Wheel should
be centered
Correct Alignment
Axle nuts
Figure 4.4
Even space
between
wheel and fork
(both sides)
Figure 4.5
23
23
4 Adjustments
❷ If the gap between the brake pad and wheel is uneven,
adjust the position of the brake pad. Figure 4.6
• Loosen the nut on the back of the brake.
• Squeeze the brake and hold the brake lever closed, while
re-tightening the lock nut on the back of the brake.
Note: Watch the brake, if it begins to shift or rotate, then
release the brake lever, and use your hand to rotate the
brake caliper back until both sides of the brake move
equally. Sometimes it is necessary to over-rotate the brake
slightly, so that as you tighten the locknut, the brake will
end up centered.
❸ Pull and release the brake lever a few times and check if the
pads are centered.
❹ If necessary, repeat steps one and two until the brake pads
are centered and the gap between the pads and rim is close
to 1/8 inch. Figure 4.7
Distance from
brake pad to
wheel rim is
1/8 inch
Brake pad
lock nut
Locknut on
brake pad
Brake pad
Axle nut
Figure 4.6
24
Tire
Wheel rim
Figure 4.7
Adjustments 4
Check the Brakes
❶ After adjusting the brake, squeeze the brake lever as hard as
you can several times and re-inspect the brake pads,
centering and brake lever travel. If the brake pads are no
longer square to the rim, repeat brake pad adjustments.
Figure 4.8
❷ Be sure that brake pads return to a centered position by
spinning the wheel and listening for the brake pad rubbing
the rim on either side. Re-adjust as needed.
❸ Check that the brake cable tension allows the brake lever
about 1/3 of the travel before the brake pads contact the
rim. If the cable has stretched or slipped, re-adjust the brake
cable tension by loosening cable anchor bolt and pulling
more cable through the anchor or use brake adjustment
barrels for fine tuning brake cable tension.
Brake is correctly adjusted when:
• The brake pads do not drag on the rim when the brake is
open. Figure 4.9
1/3 distance to
handlebar
1
Figure 4.8
Equal space
between brake
pad and the rim
on both sides
• Both brake pads move away from the rim equally when the
brake is released.
• When the brake is applied, the brake pads contact the rim
before the brake lever reaches about 1/3 of the way to the
handlebar.
Brake pads
Wheel rim
Figure 4.9
25
25
4 Adjustments
ADJUSTING THE HANDLEBAR
WARNING!
• Improper adjustment of the handlebar may result in
damage to the stem post, steering tube and result in loss of
control, serious injury or death. Ensure the minimum
insertion marks on the stem post are not visible above the
top of the headset.
• Failure to properly tighten handlebar components may
result in loss of control, serious injury or death. Always
check the handlebar cannot move and is secured to the
frame before riding the scooter.
Stem binder bolt
Handlebar binder
bolts
3
Stem post
2
Headset
Adjusting the Handlebar Height
Steerer tube
❶ Turn the front fork to face forward. Figure 4.10
❷ Using a 14 mm open-end wrench loosen the stem binder
bolt.
❸ Adjust the handlebar height until the rider feels they have
control of the scooter and are comfortable. Important! Be sure the minimum insertion marks do not go
above the top of the headset and are not visible.
❹ Tighten the stem binder bolt. Check the handlebar binder
bolts to be sure they are properly tightened and the
handlebar is clamped in place. 26
Front fork
facing forward
Minimum
insertion marks
1
Figure 4.10
Adjustments 4
Adjusting the Handlebar Alignment
❶ Using a 14 mm open-end wrench loosen the stem binder
bolt. Figure 4.11
5
❷ Move the handlebar left or right until it is aligned with the
front wheel.
❸ Tighten the stem binder bolt. Check the handlebar binder
bolts to be sure they are properly tightened and the
handlebar is clamped in place. Adjusting the Handlebar Angle
❹ Loosen all of the handlebar binder bolts to allow the
handlebar to move.
❺ Rotate the handlebar to the desired angle. Be sure that the
handlebar stays centered in the handlebar bracket.
2
Stem binder bolt
Handlebar
binder bolts
1
1
❻ Using a hex wrench, tighten the handlebar binder bolts a
little at a time. Ensure the gap between the stem cap and
stem stays even.
❼ Repeat tightening each handlebar binder bolt a little bit until
handlebar is secure.
Figure 4.11
27
27
5 Use
❺ Use
HAND OPERATED BRAKES
WARNING!
Failure to follow all local and state regulations and laws
pertaining to scooter use as well as the safety warnings in this
manual may result in serious injury or death. Always follow all
local and state regulations and laws pertaining to scooter use,
follow the safety warnings in this manual and use common
sense when riding the scooter. Always conduct a pre-ride
check of the scooter condition before riding.
If the front brake is applied too quickly or too hard, the front
wheel can stop turning resulting in a front pitch over or cause
the scooter to lose steering function leading to a crash.
Hand operated brakes have a separate hand lever to operate
front and rear brakes. Front hand brake levers are located on
the left side of the handlebar, and rear hand brake levers are
located on the right side of the handlebar. Figure 5.1
To best avoid this:
• Apply the front and rear brakes simultaneously, while shifting
your body weight back slightly to compensate for braking
force.
• As terrain changes, the rider must practice and learn how the
scooter will respond in a new terrain or weather change.
The same scooter will react differently if it is wet, or if there is
gravel on the road etc.
• Always test the brakes and be sure you feel comfortable with
the reaction. If the riding conditions are too steep (off road
for example) and you are unsure, dismount the scooter and
walk past the questionable terrain before riding again.
• Remember that as you apply the brakes your weight will want
to shift forward, and the wheels will want to stop.
Note: See Section 4: Adjusting the Brakes for information on
brake adjustment.
It is OK to operate one brake at a time, or all together,
depending on your style, comfort, and riding conditions,
however, be careful to pay close attention to front brakes
locking up.
Figure 5.1
28
Use 5
SECURITY
You just bought a new scooter! Don’t lose it. It is advisable that
the following steps be taken to prepare for and help prevent
possible theft:
• Invest in a bicycle lock that will resist hacksaws and bolt
cutters.
• Always lock your scooter to an immovable object if it is left
unattended. Figure 5.2
Figure 5.2
29
29
6 Maintenance
❻ Maintenance
WARNING!
• Failure to conduct maintenance on the scooter may result
in malfunction of a critical part and serious injury or death.
Proper maintenance is critical to the performance and safe
operation of the scooter.
• The recommended intervals and need for lubrication and
maintenance may vary depending on conditions the
scooter is exposed to. Always inspect the scooter and
conduct necessary maintenance before each use of the
scooter.
This section presents important information on maintenance
and will assist you in determining the proper course of action to
take if you do have a problem with the operation of the scooter.
If you have questions regarding maintenance please call our
customer service, toll free, at 1-800-626-2811 or see a qualified
bicycle mechanic. Do not call the store where the scooter was
purchased.
Correct routine maintenance of your new scooter
will ensure:
• Smooth running
• Longer lasting components
• Safer riding
• Lower running costs
30
BASIC MAINTENANCE
The following procedures will help you maintain your scooter 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 scooter under shelter. Avoid leaving it in the rain
or exposed to corrosive materials.
• Riding on the beach or in coastal areas exposes your scooter
to salt which is very corrosive. Wash your scooter 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 scooter and
apply anti-rust treatment. If the hub bearings of your scooter
have been submerged in water, they should be taken out and
re-greased. This will prevent accelerated bearing
deterioration.
• 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.
Maintenance 6
LUBRICATION SCHEDULE
Component
Lubricant
Method
Weekly
Brake calipers
Oil
Three drops from oil can
Brake levers
Oil
Two drops from oil can
Brake cables
Lithium based grease
Remove cable from casing. Grease entire length. Wipe off excess
lubrication from other surfaces.
Brake lever and caliper pivot points Light oil
Two to three drops from oil can
Yearly
Wheel bearings
Lithium based grease
Disassemble
Headset
Lithium based grease
Disassemble
Note: The frequency of maintenance should increase with use in wet or dusty conditions. Do not over lubricate. Remove excess
lubricant to prevent dirt build up.
31
6 Maintenance
PARTS MAINTENANCE
Brakes
Frequency: Inspect and maintain before each use
Inspect
Action
Maintenance
Levers
Check the levers are securely fastened to the handlebar.
Position the levers to fit the rider’s grip and
screw tight to handlebar.
Pads
Check pad position, gap and pressure.
See Section 4: Adjusting the Brakes
Cables
Check the outer casing for kinks, stretched coils and damage.
Check cables for kinks, rust, broken strands or frayed ends.
Check the outer casing for kinks, stretched coils and damage.
Replace cable.
Check the housing is seated properly into each cable stop of
the scooter.
It is recommended that the cables and
housing be replaced every riding season.
Wheels
Inspect
Frequency: Inspect and maintain at least each use.
Action
Maintenance
Rims
Inspect for dirt and grease.
Use a clean rag or wash with soapy water, rinse, and air dry.
Wheels
Check the wheels are securely fastened to the
scooter and axle nuts are tight.
Adjust if necessary and tighten axle nuts.
Spin wheel and check rotation / alignment is true See bicycle mechanic for repair.
Spokes
Check for broken or loose spokes.
Hub Bearings
Lift each wheel and see if there is movement side See bicycle mechanic for repair.
to side.
32
See bicycle mechanic for repair.
Maintenance 6
Tires
Frequency: Inspect and maintain at least each use.
Inspect
Tire Inflation
Action
Maintenance
Check tire pressure.
Inflate tire to the pressure indicated on the tire sidewall. See
“Inflating a Tire Tube” for more detail. If the tire is flat see
“Fixing a Flat Tire” for more detail.
Check the bead is properly seated while inflating
or refitting the tire.
Reduce air pressure in the tube and re-seat the bead.
Spin wheel and check rotation / alignment
is smooth and even.
Loosen axle nut(s) and adjust until properly seated. If the hub
bearings need repair see a scooter mechanic for repair.
Bead Seating
Check for broken or loose spokes.
See bicycle mechanic for repair.
Tread
Inspect for signs of excessive wear, flat spots or
cuts and damage.
Replace tire.
Valves
Check that valve caps are fitted and free of dirt.
Clean dirt from the valve.
33
6 Maintenance
HUB BEARINGS
Hub bearings require special thin wrenches called cone
wrenches. If you do not own these tools, do not attempt hub
bearing adjustments. Have a qualified bicycle mechanic perform
the adjustment if you have any doubts.
❶Check to make sure neither locknut is loose.
❷To adjust, remove wheel from scooter and loosen the
locknut on one side of the hub while holding the bearing
cone on the same side with a cone wrench.
❸Rotate the adjusting cone as needed to eliminate free play.
❹Re-tighten the locknut while holding the adjusting cone in
position.
❺Re-check that the wheel can turn freely without excessive
side play.
INFLATING THE TIRE TUBE
WARNING!
• An unseated tire can rupture unexpectedly and cause
serious injury or death. Be sure the tire is properly seated
when inflating the tube.
• Over inflation or inflating the tube too quickly may result
in the tire blowing off the rim and damaging the scooter or
causing injury to the rider. Always use a hand pump to
inflate the tube. Do not use a gas station service pump to
inflate the tube.
Follow these steps to inflate a tire:
❶Remove the valve cap and add air.
❷Be sure the tire is evenly seated on the rim, both sides.
❸Spin the wheel and check for high and low areas.
❹Complete inflation to the recommended psi found on the
sidewall of the tire.
❺Be sure the tire is evenly seated on the rim, both sides. If
not, release some air and repeat steps three through six.
❻Check for dirt in the valve cap or stem. Clean dirt from cap
or stem.
❼Securely replace the valve cap on the stem.
34
Maintenance 6
REPAIRING A FLAT TIRE
WARNING!
An unseated tire can rupture unexpectedly and cause serious
injury or death. Be sure the tire is properly seated when
inflating the tube.
Follow these steps to fix a flat tire:
❿Start at the valve stem and install the first bead onto the
rim. Repeat for the second bead.
⓫ Slowly inflate the tire, checking the tire is seated properly
and not pinched as the tire is inflated.
⓬ Inflate to recommended pressure (see tire sidewall).
❶Match tube size and tire size (see tire sidewall for size).
❷Remove the wheel from the scooter. Deflate tire completely.
❸Squeeze the tire beads into the center of the rim.
❹Opposite the valve, use a scooter tire lever to pry the tire
bead up and out of the rim. Repeat around the wheel until
one bead is off the rim.
❺Remove tube. Release second tire bead.
❻Remove tire.
❼Carefully inspect inside of the rim and tire for the cause of
the flat.
❽Inflate the tube ¼ full and place inside tire.
❾Insert the valve stem through valve stem hole in rim.
35
6 Maintenance
TROUBLESHOOTING GUIDE
Problem
Possible Cause
Remedy
Brakes not working
effectively
•
•
•
•
•
Brake pads worn down
Brake pads/rim greasy, wet or dirty
Brake cables are binding/stretched/damaged
Brake levers are binding
Brakes out of adjustment
•
•
•
•
•
Replace brake pads
Clean pads and rim
Clean/adjust/replace cables
Adjust brake levers
Center brakes
When applying the
brakes they squeal/
squeak
•
•
•
•
Brake pads worn down
Brake pads toe-in incorrect
Brake pads/rim dirty or wet
Brake arms loose
•
•
•
•
Replace pads
Correct pads toe-in
Clean pads and rim
Tighten mounting bolts
Knocking or shuddering
when applying brakes
•
•
•
•
Bulge in the rim or rim out of true
Brake mounting bolts loose
Brakes out of adjustment
Fork loose in head tube
•
•
•
•
True wheel or take to a bike shop for repair
Tighten bolts
Center brakes and/or adjust brake pads toe-in
Tighten headset
Wobbling wheel
•
•
•
•
•
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
36
Maintenance 6
Problem
Steering not
accurate
Frequent
punctures
Possible Cause
Remedy
• Wheels not aligned in frame
• Align wheels correctly
• Headset loose or binding
• Adjust/tighten headset
• Front forks or frame bent
• Take bike to a bike shop for possible frame realignment
• Inner tube old or faulty
• Replace inner tube
• Tire tread/casing worn
• Replace tire
• Tire unsuited to rim
• Replace with correct tire
• Tire not checked after previous puncture
• Remove sharp object embedded in tire
• Tire pressure too low
• Correct tire pressure
• Spoke protruding into rim
• File down spoke
37
7 Warranty
❼ Warranty
LIMITED WARRANTY AND POLICY ON REPLACEMENT PROCEDURES & 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 purchaser.
No warranty registration is required. This warranty gives you specific legal rights and you may have other rights which vary from state to state.
FRAME
Steel frames are guaranteed against faulty materials and workmanship for as long as the initial consumer purchaser has the scooter, subject to the condition of the
warranty listed below. Aluminum frames are guaranteed against manufacturing defects for a period of 5 years. 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 scooter was received, at the address given on this page. Frame must be returned for
inspection at customer’s expense. Please note: the fork is not part of the frame. A lifetime warranty on your frame does not guarantee that the product will last
forever. The length of the useful life cycle will vary depending on the type of scooter, riding conditions and care the scooter receives. Competition, jumping, downhill
racing, trick riding, trial riding, riding in severe conditions or climates, riding with heavy loads or any other non-standard use can substantially shorten the useful
product life cycle. Any one or a combination of these conditions may result in an unpredictable failure that is not covered by this warranty. All scooters and frame sets
should be periodically checked by an authorized dealer for indications of potential problems, inappropriate use or abuse. These are important safety checks and are
very important to help prevent accidents, bodily injury to the rider and shortened useful product life cycle.
PARTS
All other parts of the unit except Normal Wear Parts are warranted against defective materials and workmanship for a period of 1 year from the date of purchase by
the initial consumer purchaser, subject to the Terms and Conditions of the warranty listed below. If failure of any part should occur due to faulty materials or
workmanship during the warranty period, the part will be replaced. 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 scooter. Normal Wear Parts are defined as grips, tires, tubes, cables, brake
shoes. 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 missing parts 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 scooter as sold. The
warranty does not apply to damage or failure due to accident, abuse, misuse, neglect, or theft. Claims involving these issues will not be honored.
CONDITIONS OF WARRANTY
1.Your scooter 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 scooter, ride with more than one person, or use the scooter for stunting or jumping.
2.This warranty does not cover ordinary wear and tear or anything you break accidentally or deliberately.
3. 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 normal maintenance services and adjustments necessary to keep the scooter in good operating condition are
properly made. This warranty does not apply to damage due to improper installation of parts, installation of any kind of power plant or internal combustion engine,
modification or alteration of the brakes, or frame in any way, or failure to properly maintain or adjust the scooter. NOTICE: Scooter specifications subject to change
without notice.
38
Pacific Cycle · 4902 Hammersley Road · Madison, WI 53711
Warranty 7
PURCHASE RECORD
Fill in immediately and retain as a record of your purchase.
Please retain your sales receipt for any possible warranty claims.
Your Name:
Address:
City:
State:
Date Purchased:
Place of Purchase:
Model & Brand Information:
Wheel Size:
Color:
Model Number:
Model Number: Date Code:
39
4902 Hammersley Road
Madison, WI 53711
Service: 1-800-626-2811
www.pacific-cycle.com
©2013
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