Final Assembly Instructions – Portside Cruiser

Final Assembly Instructions – Portside Cruiser
Final Assembly Instructions – Portside Cruiser
Thank you for buying your new bicycle from L.L.Bean. Read these instructions carefully before beginning the final
assembly. Prior to shipping, our expert cycling technicians completely assembled and tuned your bicycle to ensure that all
components are functioning properly. However, for shipping purposes we have to partially disassemble your bicycle.
Although this bicycle has been factory pre-assembled, some loosening may have occurred during shipping and handling.
WARNING: BEFORE ATTEMPTING TO RIDE THIS BICYCLE, read the enclosed Owner’s Manual thoroughly. The
Owner’s Manual includes important information on customizing your bike for an optimal fit.
Tools required for final assembly:
 Cutting-type pliers – for removal of packaging materials, including “zip-ties”
 6mm hex wrenches – for tightening stem bolt
 15mm wrench or adjustable wrench – for tightening pedals & installing front fender
 Phillips head screwdriver – for tightening the front reflector & front fender
 8mm wrench or adjustable wrench – for tightening front fender
BEFORE GETTING STARTED:
PLEASE REMOVE BICYCLE FROM BOX AND REMOVE PACKAGING MATERIAL. Recommended tool –
diagonal cutting pliers, wire cutter, heavy duty shears, or multi-tool wire cutter.
FYI - Your bicycle may appear different
from those in photos.
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 11/19/13
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern.
pg.1
1. INSTALL HANDLEBAR AND STEM
Required tool – 6mm hex wrench
The front wheel has been removed and the fork may have been reversed for shipping. If you find the brakes facing toward
the frame, spin the fork 180 degrees. Spin so the brake cable does not wrap around the head tube. In proper position,
brakes will face away from the frame (1-A).
Head tube
Correct brake
position
1-A
If there is a protective plastic cap on the end of the stem, remove
and discard it before inserting the stem into the head tube. Cables
should be in brackets and routed in smooth rounded paths (not
pinched or bent). Insert stem into head tube. You may need to
loosen the stem bolt slightly (1-B).
Snug the stem bolt. Instructions for proper alignment will be
given later.
Tighten and
loosen the stem
bolt with a 6mm
hex wrench.
Turn clockwise
to tighten,
counter
clockwise to
loosen
Stem bolt
head
Stem
Minimum
insertion
line
The stem
bolt works
by drawing
this wedged
piece up
until it locks
the stem in
place.
Head
tube
1-B
1-C
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 11/19/13
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern.
pg.2
2. ATTACHMENT OF FRONT FENDER
Tools required – 10mm & 8mm wrenches or adjustable wrench
Using a 10mm wrench or an adjustable wrench, remove the locknut from the front brake mounting bolt, this is the thicker
nut on the end (2-A). Insert the fender through the rear of the fork and the brake caliper. Position the fender with the brake
mounting bolt through the fender mount (2-B). Carefully thread the locknut onto the brake mounting bolt. While holding
the brake caliper in position, tighten the locknut.
Fender
mount
Locknut
Fender strut
Brake
caliper
Brake mounting
bolt mounting
bolt
2-A
2-B
Using an 8mm wrench or an adjustable wrench, remove the fender mounting bolts (3-A) on the fork and use them to
attach the fender struts.
3. FRONT WHEEL INSTALLATION
Tool required – 15mm wrench or adjustable wrench
Loosen the outer silver nuts on each side of the wheel axle enough for the fork to fit over the axle with a silver nut and
washer on the outside of the fork on each side (3-B). With the tire tread in the same direction as the rear wheel, center
the tire between the brake pads and push the tire through the brake. Position the wheel axle between the fork blades so
that the axle seats firmly at the top of the slots of the fork dropouts (3-A).
Fork dropout
3-A
Fender mounting
bolt
3-B
Silver nut and
washer on the
outside of the
fork
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 11/19/13
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern.
pg.3
With the front wheel held off of the ground, ensure that the wheel can spin freely and the wheel is centered between the
brake pads. If the tire is rubbing on the fender, you may need to raise the fender at the fender mount (3-C). The rim should
be centered between the brake pads. If the brake pads are not centered, grasp the brake caliper and rotate the brake to a
centered position (3-D). You may need to hold the fender in place as this is being done.
Fender mount
adjustment
3-C
3-D
4. HANDLEBAR AND STEM ALINGMENT
Tools required - 6mm and 5mm hex wrench
Brakes
are to the
front of
the fork.
The handlebar should be aligned square to the tire, if not,
slightly loosen the stem bolt, adjust square and retighten
(4-A). Tighten stem bolt firmly. To check tightness, brace
front wheel between your knees, then try to turn the
handlebar left and right. The stem should not move.
4-B
Stem bolt
Stem bolt
NOTE: After completing Step 4, Handlebar and
Stem Alignment, your bike should look like this
(4-B) – handlebar and stem facing forward – with
front brakes located in front of fork.
4-A
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 11/19/13
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern.
pg.4
Handlebar
clamp bolt
The handlebar may have been rotated for shipping.
To adjust, use a 6mm hex wrench to loosen the
handlebar clamp bolt on the stem (4-C). Rotate to
desired position and tighten the bolt. The grips should
be parallel to the ground. The bolt should be tightened
enough that there is no movement when firmly pushing
against the handlebar.
4-C
REMEMBER, the handlebar stem may be raised or lowered for comfort, but it should never be raised above the
“Minimum insertion line” marked on the stem.
5. INSTALL PEDALS
Required tool – 15mm open-end wrench, or adjustable wrench.
CAUTION: The right pedal has right-hand threads and must be installed in the right crankarm, tightening in a
clockwise direction (5-B). The left pedal has left-hand threads and must be installed in the left crankarm,
tightening in a counter-clockwise direction (5-C). To avoid cross-threading, carefully start and tighten pedals by
hand. Then tighten securely with a 15mm wrench.
5-A
Pedals are marked “L” and
“R” on their spindles.
5-B
Insert right pedal into right
crankarm and turn
clockwise.
5-C
Insert left pedal into left
crankarm and turn counterclockwise.
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 11/19/13
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern.
pg.5
6. ATTACHMENT OF SADDLE TO SETPOST
Required tool- 13mm wrench or adjustable wrench
Use a 13mm or adjustable wrench to loosen the seat clamp nut (6-A) enough to slide the small end of the seat post into the
seat clamp. Ensure that the smaller end of the seat post is fully inserted into the seat clamp (6-B). Snug the clamp nut.
Seat clamp
6-A
6-B
Seat clamp nut
To install the seat post to the bike, open the quick release seat clamp or loosen clamp bolt if not a quick release (6-C).
Insert the seat post into the bike’s seat tube past the minimum insertion line, this line is embossed into the lower portion
on the seatpost (6-C). The saddle is adjustable forward and back along the saddle rails and can be angled up or down. The
best starting position is with the saddle horizontal and in the middle of the saddle rails (6-D). With the bike on the ground
find this position and tighten the seat post clamp nuts.
Saddle mounted correctly
Saddle set
horizontal
Minimum
insertion
line
6-C
6-D
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 11/19/13
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern.
pg.6
7. SADDLE HEIGHT ADJUSTMENT
If the seat and seat post are not already installed, insert the seat post into the seat post tube.
WARNING: The seatpost may be raised or lowered for comfort, but it should never be raised above the “minimum
insertion line” marked on the seatpost.
7-A
7-B
To raise or lower seatpost,
open the quick-release lever as
shown and close when
adjusted. If not equipped with
quick-release, loosen and
tighten hex head bolt.
To determine proper saddle
height, position right pedal at the
bottom of its revolution, aligned
with the seat tube. While sitting
on saddle, place your heel on right
pedal. Your leg should be fully
extended (7-B).
7-C
Adjust saddle height if
necessary and repeat. Now
place the ball of your foot
directly over the center of the
pedal (normal riding position).
This should result in the
correct bend at the knee (7-C).
Generally, you do not want to raise your saddle higher than determined by this method. If you have to rock your hips to
reach the bottom of the pedal stroke, then your saddle is too high. However, if while riding your bicycle, this position
doesn’t feel comfortable to you, adjust as necessary.
8. ATTACH REFLECTOR
Required tool – Phillips head screwdriver
The front reflector was not installed to prevent shipping damage. Your bike came with a handlebar-mounted front
reflector (white). Remove the reflector mounting screw and gently open the bracket enough to slide over the handlebar on
the left side of the stem. Position the reflector perpendicular to the ground and secure with the screw. Use care not to overtighten as the bracket may crack.
Reflector
mounting
screw
8-A
NOTE: For additional maintenance and safety tips, be sure to read your Owner’s Manual thoroughly.
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 11/19/13
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern.
pg.7
QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 11/19/13
specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. Eastern.
pg.8
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