warning!
Contents
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
User Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bicycle Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Riding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Before You Ride Safety Checklist . . . . . . . . . . . . . . . . . . . 13
2 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Attach the Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Attach the Front Brake Cable . . . . . . . . . . . . . . . . . . . . . . 21
Attach the Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Attach the Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Attach the Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Attach the Training Wheels . . . . . . . . . . . . . . . . . . . . . . . 25
Attach the Pegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjusting the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Adjusting the Seat Height . . . . . . . . . . . . . . . . . . . . . . . . . 37
Adjusting the Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Adjusting the Headset . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Adjusting the Bottom Bracket . . . . . . . . . . . . . . . . . . . . . . 41
5 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Parts Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hub Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Inflating the Tire Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Repairing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Purchase Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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 bicycle but is not
intended to be a complete or comprehensive manual covering all
aspects concerning bicycle ownership. We recommend
consulting a bicycle specialist if you have any doubts or concerns
regarding your experience or ability to properly assemble and
maintain the bicycle.
on your new bicycle! Proper assembly and operation of your
bicycle 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:[email protected]
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 near
the bottom bracket area. See Section 7: Purchase Record for the
location of the model number on your bicycle.
2
It is important for you to understand your new bicycle.
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 bicycle. It is also important that your first ride on
your new bicycle is taken in a controlled environment, away from
cars, obstacles and other cyclists.
A Special Note For Parents and Guardians
It is a tragic fact that most bicycle 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 bicycle 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, bicycle, 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
bicycle. 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 BICYCLE
•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
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.
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.
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
USER RESPONSIBILITY
WARNING!
Do not install any kind of power plant or internal combustion
engine to a bicycle. Adapting a bicycle in this manner poses an
extreme safety risk to rider and could result in loss of control
or death.
All persons assembling, using, and maintaining the bicycle must
read and understand the safety warnings and operating
instructions in this manual before using the bicycle.
It is the responsibility of the user, or in the case of a child rider,
an adult, to ensure the bicycle is properly maintained and in
proper operating condition. Doing so will reduce the risk of
injury. Always conduct regular maintenance and inspection of
your bicycle. Complete the Safety Checklist at the end of this
section before each use.
A responsible adult must always supervise the use of the bicycle
by a child. You must ensure:
• The child is wearing the proper protective attire and approved
bicycle helmet.
• The child is seated securely and the bicycle is properly fitted
to the child.
• The child understands applicable laws and common sense
rules of safe responsible bicycling.
Safety 1
BICYCLE SETUP
WARNING!
Inability to safely reach the handlebars and dismount the
bicycle may result in loss of control of the bicycle. If the
bicycle has a top tube on the frame, ensure there is one to
three inches of clearance between the rider and the top tube.
Improper setup or maintenance of the bicycle may result in
an unexpected movement, loss of control, and serious injury
or death.
Wheel Size
Riders Approximate Height
12 inch
28 - 38 inches tall
16 inch
38 - 48 inches tall
18 inch
42 - 52 inches tall
20 inch
48 - 60 inches tall
24 inch
56 - 66 inches tall
26 inch, 27.5 inch,
29 inch, 700c
64 - 74 inches tall
Correct Bicycle Size
Riding a bicycle that is not correctly sized to the rider may result
in the rider’s feet not being able to touch the ground and
balance the bicycle, properly reach the handlebar for steering or
braking, and loss of control when pedaling.
Use the wheel size in the following table as a guide to match the
rider and bicycle. For example, bicycles with a wheel size of 12
inches fit a rider that is 28 to 38 inches tall. Note: Some bicycles
such as folding bicycles may have smaller wheels but still fit
adults.
1 to 3 inch
clearance
Top tube
If the bicycle has a top tube on the frame, check that there is
one to three inches of clearance between the rider and the top
tube. Figure 1.1
Figure 1.1
5
1 Safety
Seat Height and Handlebar Reach
WARNING!
Improperly adjusted seat height could affect the rider’s ability
to reach the handlebar and pedals may result in an unexpected
movement, loss of control, and serious injury or death. Follow
these guidelines when adjusting the seat height. Always
ensure the seat post minimum insertion marks are below the
seat clamp and cannot be seen. Ensure the seat clamp is
locked and the seat cannot move.
2
❶ Your legs should be almost completely straight when the
pedal is in the down most position, just a slight bend in
the knee. Figure 1.2
Note: The rider’s feet may not touch the ground easily. If
this is the case the rider can simply move forward off the
seat to mount and dismount the bicycle or the seat can be
adjusted lower if the rider is uncomfortable with the height,
but note that riding is more difficult with the seat too low,
as the legs are in an unnatural position.
Do not raise the seat so much the knees lock straight when
pedaling or you have to move forward off the seat to pedal.
This is unsafe and the bicycle cannot be controlled in this
condition.
❷ You should be able to safely reach the handlebar with
your arms bent slightly (approximately 10 degrees) at
the elbow.
6
1
Adjust the seat
height
Figure 1.2
Safety 1
Quick-release Lever
WARNING!
Improper setup or maintenance of the quick-release levers
may result in an unexpected movement, loss of control, and
serious injury or death. Before riding always check that the
quick-release lever is firmly locked in place and the seat does
not move.
Seat Post
❷ Ensure the seat post’s minimum insertion marks are not
visible above the seat clamp and the clamp is locked in
place. Figure 1.3
Note: See Section 4: Adjusting the Seat Height if
adjustments are needed.
Seat post
Seat tube
Minimum insertion
marks are located
on the seat post
Quick-release
seat clamp
2
Figure 1.3
7
1 Safety
PERSONAL SAFETY
WARNING!
Riding a bicycle without protective gear, clothing, or a helmet
may result in serious injury or death. Always wear protective
gear, clothing, and helmet when riding the bicycle. Ensure
protective gear does not interfere with steering, braking, and
pedaling.
• Pants with loose pant legs. If necessary, always tuck pant legs
into a sock or use a leg band to avoid the clothing becoming
caught in the drive chain.
• Shoes with untied shoe laces.
Properly fitted helmet
Protective Gear and Clothing
Always wear: Figure 1.4
• Colors that are easily seen and, if possible, reflective clothing.
Easily seen or
reflective clothing
• Clothing appropriate for the weather conditions.
Elbow pads
• 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 bicycle. 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, or jewelry that may become
entangled with moving parts on the bicycle or interfere with
handling of the bicycle.
Knee pads
Leg band
Shoes fastened
or tied
Figure 1.4
8
Safety 1
Helmet Use
Important! Many states have passed helmet laws regarding
children. Make sure you know your state’s 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 when cycling. When riding with a child
carrier seat or trailer, children must wear a helmet.
It is strongly advised that a properly fitting, ASTM 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: Figure 1.5
• Be comfortable
Figure 1.5
• Have good ventilation
• Fit correctly
• Cover forehead
Incorrect helmet position: Figure 1.6
• Helmet does not cover the forehead
Figure 1.6
9
1 Safety
Reflectors
WARNING!
Missing, damaged, or dirty reflectors will affect the ability of
others to see and recognize you as a moving bicyclist, increasing
the risk of being hit, serious injury or death. Always check the
reflectors are in place and make sure they are clean, straight,
unbroken and securely mounted before riding the bicycle.
Important! Federal regulations require every bicycle over 16
inches to be equipped with front, rear, wheel, and pedal
reflectors. Many states require specific safety devices. It is your
responsibility to familiarize yourself with the laws of the state
where you ride and to comply with all applicable laws, including
properly equipping yourself and your bike as the law requires.
Bicycles under 16 inches are considered “sidewalk bicycles” and
may not be fitted with reflectors. These bicycles should not be
ridden on streets, at night or unsupervised by an adult.
Rear (red)
Plus or minus
5 degrees of
vertical
Front (white)
Rear wheel
(white)
Front wheel
(white)
Check and confirm the front and rear reflectors are in the
correct position: Figure 1.7
• Front Reflector: Should aim forward (when viewed from
above) and be mounted so it is within 5 degrees of vertical.
• Rear Reflector: Should aim straight back (when viewed from
above) and be mounted so it is within 5 degrees of vertical.
10
Pedal (orange)
Figure 1.7
Safety 1
RIDING SAFETY
WARNING!
Riding the bicycle 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.
• 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 bicycle.
General Safety
• Familiarize yourself with all the bicycle’s features before
riding. Practice gear shifts, braking, and the use of toe clips
and straps, if installed.
• 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.
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 bicycle
across.
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.
• Obey the traffic laws (e.g., stopping at a red light or stop sign,
giving way to pedestrians).
11
1 Safety
Night Riding
Cornering Technique
• Important! Riding a bicycle at night is not recommended.
Check your local laws regarding night riding.
• Brake slightly before cornering and prepare to lean your body
into the corner.
• Ensure bicycle is equipped with a full set of correctly
positioned and clean reflectors.
• Maintain the inside pedal at the 12 o’clock position and
slightly point the inside knee in the direction you are turning.
• Use a white light on the front and a red light on the rear.
Use lights with flashing capability for enhanced visibility.
• Keep the other leg straight, do not pedal through fast or tight
corners.
• If using battery powered lights, make sure batteries are
well charged.
• Decrease your riding speed, avoid sudden braking and
sharp turns.
• Wear reflective and light colored clothing. Wear reflective
clothing and use safety lights for increased visibility.
Safe Riding Rules for Children
• Ride at night only if necessary. Slow down and use familiar
roads with street lighting.
Hill Technique
• Many states require that children wear a helmet while cycling.
Always wear a properly fitted helmet.
• Do not play in driveways or the road.
• Do not ride on busy streets.
• Gear down before a climb and continue gearing down as
required to maintain pedaling speed.
• Do not ride at night.
• If you reach the lowest gear and are struggling, stand up on
your pedals. You will then obtain more power from each
pedal revolution.
• Be aware of other road vehicles behind and nearby.
• On the descent, use the high gears to avoid rapid pedaling.
• Do not exceed a comfortable speed; maintain control and
take additional care.
• Braking will require additional distance. Initiate braking slowly
and earlier than usual.
12
• Obey all the traffic laws, especially stop signs and red lights.
• 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, or your feet off the
pedals when riding downhill.
Safety 1
BEFORE YOU RIDE SAFETY CHECKLIST
Before every ride, it is important to carry out the following
safety checks. Do not ride a bicycle that is not in proper
working condition!
Chains
Accessories
□
□
□
□
□
The reflectors are properly placed and not obscured. Note:
Bicycles 16” and under may not be equipped with reflectors
since small children should not ride at night.
All other fittings on the bike 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.
Bearings
□
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.
□
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.
□
The chain is oiled, clean and runs smoothly.
Cranks and Pedals
The pedals are securely tightened to the crank arms.
The crank arms are secured to the axle and are not bent.
Frame and Fork
□
□
The frame and fork are not bent or broken.
The quick-release clamps are locked in place.
Steering
□
□
□
The handlebar and post are correctly adjusted and
tightened, and allow proper steering.
The handlebars are set correctly in relation to the forks and
the direction of travel.
The handlebar binder bolt is tightened.
Wheels and Tires
□ The rims do not have dirt or grease on them.
□ The wheels are properly attached to the bicycle and axle.
□ The tires are properly inflated within the recommended
□
pressures displayed on the tires sidewall.
The tires have the proper amount of tread, no bulges or
excessive wear.
13
❷ Parts Identification
Juvenile Bicycle
Get to know the parts of your bicycle. This will help with assembly, maintenance, and troubleshooting. Models vary in color and style.
Part name
1
Handlebar grip
Torque (in.-lb)
Part name
Torque (in.-lb)
-
16
Fork dropout
-
55 - 70
17
Fork
-
18
Pedal
300-360
2
Rear brake lever
3
Brake cable
-
4
Handlebar
-
19
Crank arm (1-piece)
300
145 - 200
19A
Crank arm (3-piece)
390
-
20
Chain
-
21
Chainwheel
-
5
Handlebar binder bolt(s)
6
Stem
7
Stem binder bolt
100 - 120
8
Headset
175 - 260
22
Bottom bracket lockring
9
Caliper brake assembly
50 - 70
23
Seat post
9A
Brake cable pinch bolt
50 - 70
24
Seat post attaching hardware
9B
Brake pads
-
25
Saddle (seat)
9C
Brake pads hardware
50 - 60
26
Seat post clamp
10
Caliper brake attaching nut
70-85
27
Linear brake assembly
-
11
Wheel axle nut (front)
180-240
27A
Brake cable pinch bolt
50-70
240-300
27B
Brake pad
11A
Wheel axle nut (rear)
12
Tire
-
27C
Brake pad hardware
13
Rim
-
27D
Brake spring
Brake pivot bolt
Freewheel
14
Spoke
-
27E
15
Valve stem
-
28
14
300
130-170
60-80
50-60
17-20
-
Parts Identification 2
1
2
27A
5
6
7
25
27E
9A
8
24
27D
27C
3
4
9
27B
9B
23
27
9C
26
27E
10
12
17
22
11A
28
20 21
11
12
13
14
16
19, 19A
18
15
15
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, seat,
pedals, brakes, derailleurs, tires) before each use.
• We recommend that you consult a bicycle specialist if you
have doubts or concerns as to your experience or ability to
properly assemble, repair, or maintain your bicycle. If your
bicycle 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 bicycle, 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, 6 mm and 8 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 bicycle was assembled and tuned in the factory and
then partially disassembled for shipping. You may have
purchased the bicycle 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 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 have questions about your ability to
properly assemble this unit, please consult a qualified specialist
before riding.
16
Figure 3.1
Assembly 3
GETTING STARTED
❶ Open the carton from the top and remove the bicycle.
Figure 3.2
❷ Remove the straps and protective packaging from the
bicycle. Important! Do not discard packing materials until
assembly is complete to ensure that no required parts are
accidentally discarded.
Seat
Handlebar
assembly
Seat post
❸ 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.
Note: We recommend using a lithium based grease on the
parts before assembly.
Frame
Pedals
Training
wheels (2)
Front
wheel
Figure 3.2
17
17
3 Assembly
ATTACH THE HANDLEBAR
WARNING!
• Improper attachment 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.
Important! Be sure the minimum insertion marks do not go
above the top of the headset and are not visible.
❸ Using a 6 mm Allen 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. Note: See Section 4: Adjusting the
Handlebar if adjustments are needed.
• 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 bicycle.
1
There are two types of stems that attach the handlebar to the
steerer tube. It is either a quill or clamp (threadless) stem.
Figure 3.3
Attaching a Quill Stem
Handlebar binder bolt(s)
❶ Turn the front fork to face forward. Figure 3.3
Position the handlebar assembly over the steerer tube. Look
at all the cables to be sure they run in a smooth arc from
the shifter or brake lever to the front brake or cable stop on
the frame. Important! If they are twisted or kinked, the
shifting and braking will not work. Figure 3.4
❸ Insert the stem post into the steerer tube and adjust the
handlebar height until the rider feels they have control of
the bicycle and are comfortable. See Section 1, Fig. 1.2:
Seat Height and Handlebar Reach for guidelines.
18
Front fork
facing forward
Stem binder bolt
3
2
Stem post
Minimum insertion marks
Headset
Steerer
tube
Figure 3.4
Assembly 3
Attaching a Threadless Stem
Important! Do not disassemble the headset or lose any parts.
Be sure the end of the fork is on the ground or being held with
your free hand, because once you loosen the top cap the fork
assembly may fall out of the frame.
❶ Turn the front fork to face forward (ie: the fork dropout is in
the furthest forward position). Figure 3.3
❷ Using a 5 mm Allen wrench loosen the top cap bolt on the
steerer tube and remove the top cap and bolt. Important!
Do not remove the spacers. Figure 3.5
❸ Position the handlebar assembly over the steerer tube.
Look at all the cables to be sure they run in a smooth arc
from the shifter or brake lever to the front brake or cable
stop on the frame. Important! If they are twisted or kinked,
the shifting and braking will not work.
❹ While holding the fork assembly in place, use a 6 mm Allen
wrench and loosen the stem pinch bolts. Slide the handlebar
assembly onto the steerer tube.
❺ Align and center the stem to the fork and wheel. Tighten the
stem pinch bolts until there is no play between the stem and
stem tube. Note: There should be a 3 to 5 mm (1/8" - 3/16")
gap between the top of the stem and stem post. Figure 3.6
❻ Place the top cap onto the top of the steerer tube. Insert
and tighten the top cap bolt until it is snug. Do not over
tighten.
❼ Using a 5 mm Allen wrench tighten the top cap bolt. Do the
following checks to determine if the headset is properly set.
Tighten or loosen the top cap bolt if necessary.
• Lift up the front wheel of the bicycle, if the wheel does
not move freely left to right the headset is too tight.
• Hold the handlebar, close the brakes and rock the fork
back and forth. If you hear a knock or clunking sound the
headset is too loose.
Note: If needed, see Section 4: Adjusting the Headset for
more detailed information. See Section 4: Adjusting the
Handlebar for information on aligning the handlebar.
Top cap
and bolt
2
Stem pinch
bolts
5
3
1/8" - 3/16"
(3 - 5 mm)
5
Figure 3.6
Figure 3.5
19
19
3 Assembly
ATTACH THE FRONT BRAKE CABLE
WARNING!
Failure to properly set the brakes may result in the inability to
stop the bicycle movement and cause serious injury or death.
Be sure the brakes are functioning properly before using the
bicycle.
Cable adjustment Cable nut slot
barrel slot
1
2
Brake cable slot
If the brakes are not attached follow these steps:
Brake lever
Figure 3.7
❶ Rotate the cable adjustment barrel and cable nut until the
slots are aligned with the slot on the brake lever body.
Figure 3.7
❷ Press the brake lever towards the grip.
3
❸ Slide the brake cable through the slots and place the cable
head into the brake lever. Figure 3.8
Brake cable
Cable head
Figure 3.8
❹ Release the brake lever. Figure 3.9
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.
20
4
5
Figure 3.9
Assembly 3
ATTACH THE FRONT WHEEL
There are two types of front wheel assemblies; nutted with step
retaining washer, and nutted with clip retaining washer.
Note: Quick-release wheels may be on both the front and rear
wheels or just one. Also, some tire tread patterns have a
direction, so compare your front tire and rear tire of the bicycle
so that both tread patterns face the same way.
2
Protrusion on
step retaining
washer fits into
the fork dropout
Figure 3.11
Nutted with Step Retaining Washer
❶ Position the front wheel between the front fork legs with
the axle resting inside the fork drop outs. Important! Be
sure the wheel is as centered as possible between the fork
legs. Figure 3.10
❷ Place a step washer on each end of the axle. Note: The flat
side of the step washer must be facing out, and the
protrusion on the washer must fit into the fork drop out.
Figure 3.11
❸ Attach the two axle nuts on the axle. Tighten one nut part
way, then tighten the other nut. Repeat until both sides are
tightened securely. Be sure that the wheel is centered
between the fork legs.
❹ If the wheel 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.
3
Axle
nut
2
1
Fork
dropout
Axle
Step
retaining
washer
2
Step
retaining
washer
3
Axle
nut
Figure 3.10
21
21
3 Assembly
Nutted with Clip Retaining Washer
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. Figure 3.12
3
❷ Position the front wheel between the front fork legs with
the axle resting inside the fork drop out.
Important! Be sure the wheel is as centered as possible
between the fork legs.
Clip retaining
washer
inserted into
dropout hole
Figure 3.13
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 3.13
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.
Dropout
hole
4
Axle
nut
Fork
dropout
Axle
3
Clip
retaining
washer
3
Clip
retaining
washer
4
Axle
nut
Figure 3.12
22
Assembly 3
ATTACH THE SEAT
WARNING!
Improperly adjusted seat height could affect the rider’s ability
to reach the handlebar and pedals resulting in unexpected
movement, loss of control, and serious injury or death. Follow
these guidelines when adjusting the seat height. Always
ensure the seat post minimum insertion marks are below the
seat clamp and cannot be seen. Ensure the seat clamp is
locked and the seat cannot move.
❹ Try to close the quick-release lever. If it closes easily, open it
up and tighten the adjustment nut further. If it is too difficult
to close, open the quick-release lever up and loosen the
adjustment nut a little and try again.
Important! You should feel resistance when you close
the quick-release lever that should leave a temporary
impression on your fingers. Open and close the handle to
ensure the seat is securely locked in place.
❶ Unlock the quick-release lever and insert the seat post into
the seat tube. Figure 3.14
❷ Adjust the seat height up or down until the rider feels they
have control of the bicycle and is comfortable.
Important! Be sure the minimum insertion marks do not go
past the top of the seat clamp and are not visible. See
Section 1, Fig. 1.2: Seat Height and Handlebar Reach.
❸ Close the quick-release lever and lock the seat in place.
If there is not enough pressure to hold the seat in place
open the quick-release lever. With one hand on the quickrelease lever and one hand on the adjustment nut, start to
hand tighten the adjustment nut until you start to feel some
resistance against the post clamp. Do not attempt to tighten
by turning the quick-release lever. The quick-release lever is
for closing, the adjustment nut is for adjusting the pressure.
Seat post
2
Adjustment nut
Quick-release
lever
Minimum
insertion marks on
the seat post
1
Quick-release
seat clamp
3
Minimum
insertion
marks
Figure 3.14
23
23
3 Assembly
ATTACH THE PEDALS
WARNING!
• Attachment of an incorrect pedal into a crank arm can strip
pedal threads and cause irreparable damage. Visually
match the R and L stickers on the pedal and crank arm
before attaching the pedals. Before your first ride, please
check to ensure your pedals are attached correctly.
3
1
2
• It is very important that you check the crank set for correct
adjustment and tightness before riding your bicycle.
❶ Match the pedal marked R with the right-hand crank arm,
and match the pedal marked L with the left-hand crank arm.
Figure 3.15
1
❷ Place the threaded pedal into the threaded hole on the
crank arm.
❸ By hand, slowly turn the spindle the correct direction.
Clockwise for right side pedal, counterclockwise for left side
pedal. Important! Stop if you feel resistance! This may be
an indication the spindle is entering the hole at an
angle. Remove the spindle and repeat step two and three.
❹ If the spindle is entering the hole cleanly then use a 15 mm
wrench or pliers to tighten completely.
❺ Repeat steps 1- 4 for the remaining pedal.
24
The left pedal turns
counter-clockwise and
the right pedal turns
clockwise.
3
Figure 3.15
Assembly 3
ATTACH THE TRAINING WHEELS
WARNING!
Failure to properly assemble and set up the training wheels
may cause instability and tip over resulting in serious injury or
death. Always check the training wheels before using the
bicycle.
❹ Replace the washer and axle nut. Tighten the axle nut
securely, making sure that the wheel brace stays in the
proper vertical position.
❺ The elongated hole on the wheel brace allows the training
wheel height to be adjusted for proper fit. Note: Not all bicycles will accept training wheels. If your bicycle
did not come stock with training wheels, please call Pacific Cycle
to help determine if after-market training wheels can be
attached.
There are three different braces used to attach the training
wheels to the bicycle: the c-shape brace, the flat brace and the
flat brace with stabilizer. Determine which brace was included
with your bicycle and follow the instructions below.
C-Shape Brace
❶ Remove the outer axle nut and washer from the rear wheel
axle. Figure 3.16
❷ Place the brace stabilizer washer onto the axle and align the
washer so that the notch on the washer fits into the frame
drop out.
Inner axle nut
DO NOT REMOVE!
Rear wheel axle
Brace stabilizer washer
2
C-shaped wheel brace
3
Axle nut
Washer
Training wheel
4
5
❸ Place the C-shaped wheel brace onto the axle.
Figure 3.16
25
25
3 Assembly
Flat Brace
❶ Remove the outer axle nut and washer from the rear
wheel axle. Figure 3.17
❷ Place the flat wheel brace onto the axle.
❸ Place the brace stabilizer washer onto the axle and align it
so that the notch fits into the rear frame drop out.
❹ Replace the washer and axle nut.
❺ Tighten the axle nut securely, making sure that the wheel
brace stays in the proper vertical position. The elongated
hole on the wheel brace allows the training wheel height to
be adjusted for proper fit.
Inner axle nut
DO NOT REMOVE!
Rear wheel axle
Brace stabilizer washer
2
C-shaped wheel brace
3
Axle nut
Washer
Training wheel
4
5
4
Figure 3.17
26
Assembly 3
Training Wheel Stabilizer Bracket
❶ Remove the outer axle nut and washer from the rear
wheel axle. Figure 3.18
❷ Insert the training wheel brace into the stabilizer bracket so
that the forked end of the stabilizer bracket faces in.
❸ Slide assembly onto the rear axle so that the forked end
hooks around the chain stay of the bicycle.
❹ Replace the axle nut and washer, secure tightly.
❺ The elongated hole on the brace allows for raising and
lowering the training wheel to the proper height.
Stabilizer brace
3
Axle nut
Washer
4
Wheel brace
5
2
Figure 3.18
27
27
3 Assembly
ATTACH THE PEGS
Important! Periodically check to make sure pegs are tight.
Some models may come equipped with 2 or 4 pegs. To install:
❶ Do not loosen or remove axle nuts. Figure 3.19
❷ Check to make sure axle nuts are properly tightened before
installing pegs.
Axle nut
2
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 3.20
Peg
❺ Repeat steps three and four for the remaing pegs.
Figure 3.19
4
Figure 3.20
28
Adjustments 4
❹ Adjustments
After your bicycle is assembled you will need to make
adjustments. If you need replacement parts or have questions
pertaining to the assembly of your bicycle, 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 near the bottom bracket area. Figure 4.1
TOOLS REQUIRED
• Phillips head screw driver
• 4 mm, 5 mm, 6 mm and 8 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
Service sticker is
located above
the bottom
bracket area.
Figure 4.2
The serial number is
located under the
bottom bracket.
Figure 4.1
29
29
4 Adjustments
ADJUSTING THE BRAKES
WARNING!
Adjusting the Brake Pads
Failure to properly set the brakes may result in the inability
to stop the bicycle movement and cause serious injury or
death. Be sure the brakes are functioning properly before
using the bicycle.
Adjusting Linear Pull Brakes
Attaching the Brake Cable to the Brake Carrier
❸ Check the brake cable is seated in the brake lever. Using a 5
mm allen wrench loosen the cable anchor bolt enough so
the brake cable can move freely. Figure 4.4
❹ Pull the brake cable through the cable anchor so the
left brake arm moves towards the rim and there is
approximately a 1/8” (3 mm) gap between the brake
pad and rim.
❶ Squeeze the two brake arms together until the brake pads
touch the wheel rim. Figure 4.3
❺ Move the right brake arm towards the rim until there is
approximately a 1/8” (3 mm) gap between the brake pad
and rim.
❷ With your other hand, pull on the brake cable and insert the
end of the “noodle” into the brake carrier.
❻ Using the 5 mm allen wrench, firmly tighten the cable
anchor bolt completely.
End of “noodle” in
the brake carrier
Brake carrier
3
2
5 mm Allen wrench
Brake arm
5
1/8” gap
(both pads)
Brake arm
Figure 4.3
30
4
Brake cable
1
Cable anchor bolt
Wheel rim
Figure 4.4
Adjustments 4
Important! Before riding the bicycle 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.
Center the Brake Pads
Adjust the Brake Pad Alignment
❶ If you see the gap between the fork and wheel is uneven
loosen the axle nuts and adjust the wheel until centered.
Figure 4.6
Check that all brake pads are aligned correctly. If not, use a
5 mm allen wrench 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 4.5
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.
Incorrect Alignment
1
Correct Alignment
Even space
between
wheel and fork
(both sides)
Wheel should
be centered
Figure 4.5
Figure 4.6
31
31
4 Adjustments
❷ If the gap between the brake pad and wheel is uneven,
adjust the position of the brake pad.
• Using a phillips head screwdriver, adjust the brake arm
screws on either side of the brake arm. Note: Turning the
screw clockwise moves the pad away from the rim.
Turning the screw counterclockwise moves the pad
towards the rim. Figure 4.7
2
Even space between
brake pad and wheel
• Start with the side where the pad is closest to the rim or
is not moving properly. Turn the screw to move the pad
towards or away from the rim.
• Adjustments to these screws should be made in small
increments, one-quarter to one-half turn then checked
by activating the brake lever three to four times after
each adjustment. If you continue to adjust the screw until
you have noticeable movement you will run out of
adjustment.
❸ Pull and release the brake lever a few times and check if the
pads are centered.
❹ If necessary, repeat steps one through three until the brake
pads are centered and the gap between the pads and rim is
close to 1/8 inch.
Note: If you run out of adjustment capability on one side,
adjust the screw on the opposite side. If you run out of
adjustment capability on both screws do a minor
adjustment to the brake cable. Adjustments should be made
to each side as equally as possible to prevent running out of
adjustment capability.
32
Brake arm
screw
Brake arm screw
Figure 4.7
Adjustments 4
Adjusting the Side-pull Caliper Brake
Attaching the Brake Cable to the Brake Carrier
1
❶ If the brake cable is disconnected at the caliper, thread the
brake wire through the adjustment barrel. Figure 4.8
Brake cable
❷ Loosen the cable anchor bolt until you can see a gap large
enough for the cable wire.
Cable
adjustment
barrel
❸ Thread the cable wire through the gap. By hand, screw the
cable anchor bolt snug enough to hold the cable wire.
❹ Check the cable end is seated in the brake lever.
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 cable wire to move freely.
❻ While holding the caliper closed, use your other hand to pull
the brake cable tight (through the cable anchor bolt).
Check that the cable end is seated in the brake lever and the
barrel adjuster of the brake.
❼ Tighten the cable anchor bolt as much as you can by hand
and then while still squeezing the caliper arms until both
brake pads contact the rim, tighten the cable anchor bolt
fully with a 10 mm box wrench. Note: Use the adjustment
barrel(s) to fine-tune the brake cable tension. Turning the
barrel clockwise will loosen the brake cable tension, counterclockwise will tighten the brake cable tension. Figure 4.9
Side-pull
caliper brake
2
Cable
anchor bolt
Caliper
arms
3
5
Cable wire
Brake pad
Wheel rim
Brake cable end at
brake lever
4
Figure 4.9
Figure 4.8
33
33
4 Adjustments
Adjusting the Brake Pads
Center the Brake Pads
Important! Before riding the bicycle 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 wrench 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 4.10
❶ If you see the gap between the fork and wheel is uneven
loosen the axle nuts and adjust the wheel until centered.
Figure 4.11
Incorrect Alignment
Wheel should
be centered
Correct Alignment
Axle nut
Figure 4.10
34
Even space
between
wheel and fork
(both sides)
1
Figure 4.11
Adjustments 4
❷ If the gap between the brake pad and wheel is uneven,
adjust the cable tension. Figure 4.13
2a Loosen the cable anchor nut.
2b Using one hand, squeeze the brake pads against
the rim. 2c Pull the slack out of the cable.
2d While holding tension on the cable, tighten the cable anchor nut.
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 caliper locknut, the brake
will end up centered. Figure 4.12
3
1
Distance from
brake pad to
wheel rim 1/8”
4
❸ Pull and release the brake lever a few times and check if the
pads are centered.
❹ If necessary, repeat steps one through three until the brake
pads are centered and the gap between the pads and rim is
close to 1/8 inch.
Brake pad
locknut
2a Cable
anchor
nut
2c Cable
Brake pads
Tire
Caliper
locknut
Wheel rim
Figure 4.12
Figure 4.13
35
35
4 Adjustments
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 4.14
1
1/3 distance to
handlebar
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.
Figure 4.14
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 4.15
• 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.
Equal space
between brake
pad and the rim
on both sides
Brake pads
Wheel rim
Figure 4.15
36
Adjustments 4
ADJUSTING THE SEAT HEIGHT
WARNING!
Improperly adjusted seat height could affect the rider’s ability
to reach the handlebar and pedals resulting in unexpected
movement, loss of control, and serious injury or death. Follow
these guidelines when adjusting the seat height. Always
ensure the seat post minimum insertion marks are below the
seat clamp and cannot be seen. Ensure the seat clamp is
locked and the seat cannot move.
❹ Try to close the quick-release lever. If it closes easily, open it
up, and tighten the adjustment nut further. If it is too
difficult to close, open the quick-release lever up, and loosen
the adjustment nut a little and try again.
Important! You should feel resistance when you close
the quick-release lever that should leave a temporary
impression on your fingers. Open and close the handle to
ensure the seat is securely locked in place.
❶ Unlock the quick-release lever. Figure 4.16
❷ Adjust the seat height up or down until the rider feels they
have control of the bicycle and are comfortable.
Important! Be sure the minimum insertion marks do not go
past the top of the seat clamp and are not visible. See
Section 1, Fig. 1.2: Seat Height and Handlebar Reach.
❸ Close the quick-release lever and lock the seat in place.
If there is not enough pressure to hold the seat in place
open the quick-release lever. With one hand on the quickrelease lever and one hand on the adjustment nut, start to
hand tighten the adjustment nut until you start to feel some
resistance against the seat clamp. Do not attempt to tighten
by turning the quick-release lever. The quick-release lever is
for closing, the adjustment nut is for adjusting the pressure.
Seat post
2
Adjustment nut
Quick-release
lever
Minimum
insertion marks on
the seat post
1
Quick-release
seat clamp
3
Minimum
insertion
marks
Figure 4.16
37
37
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 is functioning properly and secured to
the frame before riding the bicycle.
Adjusting the Handlebar Height
Instructions for adjusting the handlebar height depend on
whether your bicycle has a quill or clamp (threadless) stem.
Refer to Section 3: Attach the Handlebar for instructions on
adjusting the handlebar height.
❸ Tighten the stem binder bolt and check the handlebar is
securely attached and functioning properly.
Adjust the Handlebar Angle
❶ Using a 6 mm Allen wrench loosen the handlebar binder
bolt(s). Figure 4.17
❷ Rotate the handlebar into the desired position.
❸ Check that the handlebar is centered to the frame and front
wheel. Sit on the seat and check your reach to grips,
shifters, and brakes. Refer to Section 1: Seat Height and
Handlebar Reach for guidelines.
❹ Tighten the handlebar binder bolt(s) and check the
handlebar is securely attached and functioning properly.
4
Align the Handlebar
❶ Stand in front of the handlebar and hold the front wheel
between your legs.
❷ Using a 6 mm Allen wrench, loosen the stem binder bolt, or
pinch binder bolts, and move the handlebar left or right
until it is aligned with the front wheel. Figure 4.17
Stem binder bolt
Note: The clamp
on threadless
stems have two
pinch binder bolts.
Handlebar binder bolt(s)
Stem post
Figure 4.17
38
Adjustments 4
ADJUSTING THE HEADSET
Threadless headsets are similar to threaded headsets, they use
two sets of bearings and bearing cups. Unlike a threaded
headset, a threadless headset does not have an upper threaded
race or use a threaded steerer tube. Instead the steerer tube
extends from the fork all the way through the head tube and
above the headset and is held in place by the stem clamped
on top.
1
Conduct the following checks to determine if there is play in the
headset:
❶ Shakiness: Apply the front brake and push the handlebars
back and forth, front to back. Or if the bicycle is on a
workstand and the front wheel removed, push and pull on
the forks. If you feel a knocking sensation or "clunk" it
means the headset is too loose.
❷ Stiffness: Lift the front of the frame so the front wheel is
off the ground. The handlebar and wheel should flop to
one side or another. If there is drag or binding the headset
is too tight.
Headset
2
Figure 4.18
39
39
4 Adjustments
❶ Loosen the top cap bolt and remove the top cap.
Important! Do not disassemble the headset or lose any
parts. Be sure the end of the fork is on the ground or being
held with your free hand, because once you loosen the top
cap the fork assembly may fall out of the frame. Figure 4.19
❷ Check that the gap between the top of the steerer tube and
top of the stem is between 3 - 5 mm (1/8" - 3/16").
Figure 4.20
If the gap is not correct add or remove spacers until it is.
The stem needs to press down on the spacers in order to
adjust the bearings. If the gap is correct then re-install the
top cap and tighten the top cap bolt until it is snug. Do not
over tighten.
❸ Slightly loosen the stem pinch bolts. The stem probably
won't move but make sure the stem remains aligned with
the fork and wheel.
❹ Re-install and tighten the top cap down with a 1/4 to 1/2
turn of the top cap screw and test for shakiness in the
headset. If there is still play in the headset then turn the top
cap bolt another 1/4 to 1/2 turn. Repeat this process until
the shakiness is gone.
❻ Repeat steps 3 and 4 until there is no play in the headset. If
the play in the headset cannot be rectified with these
adjustments see a qualified bicycle mechanic for these
repairs.
1
Top cap
bolt
Top cap
Stem pinch
bolts
3
Star nut
Stem
1/8" - 3/16"
(3 - 5 mm)
Steerer tube
Spacers
2
Figure 4.19
❺ Lift up the front wheel of the bicycle, if the wheel does not
move freely left to right the top cap bolt is too tight. If this is
the case turn the top cap bolt back some.
Figure 4.20
40
Adjustments 4
ADJUSTING THE BOTTOM BRACKET
Typically the bottom bracket contains four major pieces:
lockring, adjustable cone, bearings, and washers. The lockring
has notches. The adjustable cone will have notches for a
spanner wrench or bottom bracket tool. The cones can be
removed and replaced separately. A set of round ball bearings
are found in each adjustable cone. A typical ball bearing is 5/16"
in diameter and contains nine balls. This type of bottom bracket
may be cleaned, greased and adjusted.
❹ Repeat process of checking for play and re-tightening cone a
slight amount until no play is felt. Note: The one-piece crank
systems do not use a polished bearing system. There will be
some roughness to a correctly adjusted bottom bracket.
Adjust as loose as possible but without play in the crank
assembly.
Crank arm
Bearing Adjustment
The basic concept for bearing adjustments is to get the bearings
adjusted as loose as possible but without play. Start by
purposely beginning with play in the adjustment and then
tightening in small increments until play is gone. Note: Extended
use may cause the bearings, cups (or cones) to become worn
and pitted. In this case, bearing adjustment will not be possible.
If bottom bracket is correctly adjusted, but grinds when spun,
cups and/or cones are worn and should be replaced. Figure 4.21
❶ Loosen the locknut. Turn adjusting cone counter-clockwise
until it hits the ball bearing, then turn back clockwise to
loosen 1/4 turn.
❷ Secure the locknut.
❸ Grab the end of the crank arms and rock it sideways to
check for play. If play is present, loosen locknut and turn
adjusting cone counter-clockwise slightly to tighten.
Re-secure locknut and check again.
Bottom bracket shown
with crank arm
removed
Crank arm
Ball bearings
Washers
Locknut
Lockring
Adjustable cones
Chainwheel
Figure 4.21
41
41
5 Use
❺ Use
WARNING!
Failure to follow all local and state regulations and laws
pertaining to bicycle 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 bicycle use,
follow the safety warnings in this manual and use common
sense when riding the bicycle. Always conduct a pre-ride
check of the bicycle condition before riding.
BRAKE OPERATION
There are two types of braking systems for bicycles; foot
operated and hand operated.
to know the environment that you are riding on. For example, a
dry paved road is very predictable when stopping. But if you add
rain, gravel, snow or anything else, the rider needs to be extra
careful, and allow extra stopping distance, and slow down
before turning. The rider should also be careful as terrain
changes to keep the bicycle at a controllable speed.
Some models may have a combination of foot and hand
operated brakes. It is OK to operate them at the same time or
independently. However, if the bicycle is equipped with a front
wheel hand brake, be careful to use front and rear brake
simultaneously, and avoid locking up the front wheel, as this can
cause a loss of steering control, and cause a crash. See hand
operated brakes on the next page for more detail.
Foot Operated Brakes
Foot operated brakes allow the rider to pedal forward to
accelerate the bicycle, and pedal backwards to brake. The
harder you push back on the pedals, the more braking force is
applied to the rear wheel. Figure 5.1
In most cases a foot operated brake is strong enough to lock up
(stop the wheel from turning) the rear wheel and cause the tire
to skid. While this will decelerate the bicycle quickly, it will also
cause unnecessary wear on the tire, and terrain, and can cause a
loss of steering control.
It is recommended to practice braking so that you have control
over how quickly the bicycle comes to a stop. It is also important
42
Push backwards
to brake
Figure 5.1
Use 5
Hand Operated Brakes
WARNING!
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 bicycle 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 5.2
• 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 bicycle 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.
Pull to engage brakes
Hand operated brakes may be used alone or on some models in
conjunction with foot operated brakes. 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.
To best avoid this:
• Apply the front and rear brakes simultaneously, while shifting
your body weight back slightly to compensate for braking
force.
Figure 5.2
• As terrain changes, the rider must practice and learn how the
bicycle will respond in a new terrain or weather change. The
same bicycle will react differently if it is wet, or if there is
gravel on the road etc.
43
43
5 Use
SECURITY
You just bought a new bicycle! Don’t lose it. It is advisable that
the following steps be taken to prepare for and help prevent
possible theft:
• Maintain a record of the bicycle’s model number. Serial
number is underneath the bottom bracket. Model number is
above the bottom bracket. Figure 5.3
• Register the bicycle with the local police and/or bicycle
registry.
• Invest in a high quality bicycle lock that will resist hacksaws
and bolt cutters.
• Always lock your bicycle to an immovable object if it is left
unattended. Keep in mind that individual parts of a bicycle
may be stolen. Most commonly, if you lock just a wheel or just
the frame, other parts may be removed from the bicycle.
Although it is impossible to lock all the parts, it is suggested
to lock the major components if possible. Figure 5.4
Service sticker
and model
number is located
above the bottom
bracket area.
The serial number
is located under the
bottom bracket.
Figure 5.3
• Use a lock that is long enough to lock the frame and both
wheels if possible. Some models with quick-release front
wheels allow the front wheel to be placed beside the frame
so a smaller lock can be used to lock all 3 components.
• Be aware that a quick-release seat post can be stolen. It is
recommended to remove the seat post and saddle and carry
it with you if you believe that this is a risk.
Figure 5.4
44
Maintenance 6
❻ Maintenance
WARNING!
• Failure to conduct maintenance on the bicycle 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 bicycle.
• The recommended intervals and need for lubrication and
maintenance may vary depending on conditions the bicycle
is exposed to. Always inspect the bicycle and conduct
necessary maintenance before each use of the bicycle.
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 bicycle.
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 bicycle was
purchased.
Correct routine maintenance of your new bike
will ensure:
• Smooth running
• Longer lasting components
• Safer riding
• Lower running costs
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 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.
45
6 Maintenance
LUBRICATION SCHEDULE
Component
Lubricant
Method
Weekly
Chains
Chain lube or light oil
Brush on or squirt
Brake calipers
Oil
Three drops from oil can
Brake levers
Oil
Two drops from oil can
Freewheel
Oil
Two drops from oil can
Derailleur Systems
Light oil or grease
All pivot points should be lubricated (more often in severely rainy
or muddy conditions). Wipe off any excess oil.
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
Shifting cables
Clean and grease
Thin layer of grease
Yearly
Bottom bracket
Lithium based grease
Disassemble
Pedals
Lithium based grease
Disassemble
Wheel bearings
Lithium based grease
Disassemble
Headset
Lithium based grease
Disassemble
Seat stem
Lithium based grease
Disassemble
Pedals: that can be disassembled
See bicycle mechanic for maintenance.
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. Never use a degreaser to lubricate your chains (WD-40®).
46
Maintenance 6
PARTS MAINTENANCE
Tires
Inspect
Tire Inflation
Frequency: Inspect and maintain at least each use
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 bicycle 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.
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
bicycle 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.
See bicycle mechanic for repair.
Hub Bearings
Lift each wheel and see if there is movement side See bicycle mechanic for repair.
to side.
47
6 Maintenance
Drivetrain (pedals, chains, chainwheel, crank set, freewheel)
Inspect
Pedals
Action
Every month, check each pedal is securely set and tighten into
the crank arm.
Frequency: as noted
Maintenance
If necessary, re-set and tighten.
Before each ride, check each front and rear pedal reflectors are Clean or replace.
clean and in place.
Pedal Bearings
Every ride, check the pedal bearings are properly adjusted.
Move the pedal up and down, left and right. If looseness or
roughness is detected adjustment, lubrication or replacement
is required.
See bicycle mechanic for repair.
Chains
Every week, check the chain is clean, properly lubricated,
rust-free, and is not stretched, broken, or has stiff links.
Lubricate if necessary. Replace if rusted,
stretched, or broken.
Crank Set
Every month, check the crank set (crank arms, chain rings, and
bottom bracket axle and bearings) is correctly adjusted and
tight.
See bicycle mechanic for repair.
48
Maintenance 6
Brakes
Inspect
Frequency: Inspect and maintain before each use
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 bicycle.
It is recommended that the cables and
housing be replaced every riding season.
49
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 bicycle 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 bicycle 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.
50
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 tube, checking the tire is seated
properly and not pinched as the tire tube 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 bicycle. Deflate the tire tube
completely.
❸Squeeze the tire beads into the center of the rim.
❹Opposite the valve, use a bicycle 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.
51
6 Maintenance
TROUBLESHOOTING GUIDE
Problem
Possible Cause
Remedy
Slipping chain
• Excessively worn/chipped chainring or freewheel sprocket
teeth
• Chain worn/stretched
• Stiff link in chain
• Non compatible chain/chainring freewheel
• Replace chainring, sprockets and chain
• Replace chain
• Lubricate or replace link
• Seek advice at a bicycle shop
Chain jumping off
freewheel sprocket
or chainring
• Chainring out of true
• Chainring loose
• Chainring teeth bent or broken
• Rear or front derailleur side-to-side travel out of adjustment
• Cross chaining and shifting under load
• Re-true if possible, or replace
• Tighten mounting bolts
• Repair or replace chainring/set
• Adjust derailleur travel
Constant clicking
noises when
pedaling
• Stiff chain link
• Loose pedal axle/bearing
• Loose bottom bracket axle/bearings
• Bent bottom bracket or pedal axle
• Loose crankset
• Lubricate chain/adjust chain link
• Adjust bearings/axle nut
• Adjust bottom bracket
• Replace bottom bracket axle or pedals
• Tighten crank bolts
Grinding noise when
pedaling
• Pedal bearings too tight
• Bottom bracket bearings too tight
• Chain fouling derailleurs
• Derailleur jockey wheels dirty/binding
• Adjust bearings
• Adjust bearings
• Adjust chain line
• Clean and lubricate jockey wheels
Freewheel does not
rotate
• Freewheel internal pawl pins are jammed
• Lubricate. If problem persists, replace freewheel
52
Maintenance 6
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
Quick-release mechanism loose
•
•
•
•
•
•
Replace axle
True wheel
Adjust hub bearings
Adjust headset
Replace bearings
Adjust quick-release mechanism
53
6 Maintenance
Problem
Steering not
accurate
Frequent punctures
54
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
Warranty 7
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 bicycle, subject to the condition of the
warranty listed below. Aluminum and dual suspension 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 bike 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 bike, riding conditions and care the bicycle 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 bicycles 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 bicycle. Normal Wear Parts are defined as grips, tires, tubes, cables, brake shoes 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 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 bicycle 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 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.
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 bicycle 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, drive train, or frame in any way, or failure to properly maintain or adjust the bicycle. NOTICE: Bicycle specifications subject to
change without notice.
Pacific Cycle · PO Box 344 Olney, IL 62450
55
7 Warranty
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:
Service sticker
is located above
the bottom
bracket area
Date Purchased:
Place of Purchase:
Model & Brand Information:
Wheel Size:
Model Number:
Color:
The serial number is
located below the
bottom bracket
Date Code:
Serial Number:
56
Figure 7.1
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