Assembly Instructions

Assembly Instructions
SERVICE
CALL TOLL FREE 800-222-5527
Monday - Friday 8:00 a.m. to 5:00 p.m. Pacific Standard Time
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Congratulations on the purchase of your new Raleigh bicycle!
With proper assembly and maintenance it will offer you years of enjoyment.
We at Raleigh are concerned with your safety and well being. We ask you to carefully read and follow
the owner's manual and the assembly guide before riding your bicycle. If you have any questions or do
not understand something, it is your responsibility to consult with your local authorized Raleigh dealer or
place of purchase before riding your bicycle.
The following guide is provided to assist you and is not intended to be a complete or comprehensive
manual covering all aspects of maintaining and repairing your bicycle. The bicycle you have purchased
is a complex piece of equipment that must be properly assembled and maintained in order to be ridden
safely. If you have any doubts about your ability to properly assemble your bicycle, you must have it
assembled by a professional bicycle mechanic.
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TABLE OF CONTENTS
Parts Identification Graphics .................................. 04-07
Before Riding ......................................................... 08-21
Assembly Instructions ............................................ 22-56
WARNING / CAUTION
Take notice of this symbol throughout this guide and pay particular attention
to the instructions blocked off and preceded by this symbol.
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PARTS IDENTIFICATION GRAPHICS
MOUNTAIN BICYCLES:
Mountain bicycles are designed to give maximum comfort over a wide variety of road surfaces. The
wider handlebars and convenient shift lever position make them very easy to control. Wider rims and
tires give them a softer ride with more traction on rough surfaces. The frame and fork on mountain style
bicycles are generally much sturdier than those on racing style bicycles.
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PARTS IDENTIFICATION GRAPHICS
YOUTH BICYCLES:
This style of bicycle is a popular general purpose type most suited for young riders. They are valued
because of their sturdy, simple construction and low maintenance.
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PARTS IDENTIFICATION GRAPHICS
ROAD BICYCLES:
Road bicycles are designed to be ridden on roads or paved paths. The drop handlebars, convenient
shift lever position and narrow tires make them very easy to control at speed.
Handlebar
Hood
Seat/Saddle
Stem
Seat Post
Headset
Seat Post Clamp
Head Tube
Rear Reflector
Top Tube
Brake Lever/Shifter
Brake Cable
Front Reflector
Front Brake
Seat Stay
Rear Brake
Tire
Wheel Reflector
Rim
Seat Tube
Cassette
Nipple
Down Tube
Spoke
Gear Control Cable
Front Hub
Front Derailleur
Pedal
Crank Arm
Gear Control Cable
Bottom Bracket Axle
Rear Derailleur
Crank Wheel
Chain Stay
Chain
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Tire Valve
PARTS IDENTIFICATION GRAPHICS
FULL SUSPENSION BICYCLES:
Full Suspension bicycles are designed to be ridden over fairly to moderately aggressive terrain. Their
combined suspension and wider rims and tires allow them to easily roll over obstacles.
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BEFORE RIDING:
Your new bicycle was assembled and tuned in the factory and then partially disassembled for shipping.
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
bicycle, please consult a qualified bicycle mechanic before riding.
SERVICE
CALL TOLL FREE 800-222-5527
Monday - Friday 8:00 a.m. to 5:00 p.m. Pacific Standard Time
TO AVOID INJURY, THIS PRODUCT MUST BE PROPERLY ASSEMBLED
BEFORE USE. WE STRONGLY RECOMMEND THAT YOU REVIEW THE
COMPLETE ASSEMBLY GUIDE AND PERFORM CHECKS SPECIFIED IN
THE OWNER'S MANUAL BEFORE RIDING.
Tools Included:
* 4mm, 5mm & 6mm Hex wrenches
* 25 torx wrench
* 13mm and 15mm open end wrench
Other Tools Required:
* Adjustable Wrench
* Phillips head screwdriver
* A pair of pliers with cable cutting ability
####
Serial Number Location
Bike Shown Upside Down
Serial Number
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ABOUT THIS GUIDE
It is important for you to understand your new bicycle. By reading this guide 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, other cyclists and other distractions.
A SPECIAL NOTE FOR PARENTS:
As a parent or guardian, you are responsible for the activities and safety of your minor child, and that
includes making sure that the bicycle is properly fitted to the child; that it is in good repair and safe
operating condition; that you and your child have learned and understand the safe operation of the
bicycle; and 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 guide, the owners manual, as well as review the warnings and the
bicycle’s functions and operating procedures with your child, before letting your child ride the bicycle.
WARNING: MAKE SURE THAT YOUR CHILD ALWAYS WEARS AN APPROVED
BICYCLE HELMET WHEN RIDING; BUT ALSO MAKE SURE THAT YOUR CHILD
UNDERSTANDS THAT A BICYCLE HELMET IS FOR BICYCLING ONLY, AND MUST BE
REMOVED WHEN NOT RIDING. A HELMET MUST NOT BE WORN WHILE PLAYING, IN
PLAY AREAS, ON PLAYGROUND EQUIPMENT, WHILE CLIMBING TREES, OR AT ANY
TIME WHILE NOT RIDING A BICYCLE. FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY OR DEATH.
GENERAL WARNING
Like any sport, bicycling involves risk of injury and damage. By choosing to ride a bicycle, you assume
the responsibility for that risk, so you need to know - and to practice - the rules of safe and responsible
riding and of proper use and maintenance. Proper use and maintenance of your bicycle reduces the
risk of injury. Like any sport, bicycling involves risk of injury and damage. By choosing to ride a bicycle,
you assume the responsibility for that risk, so you need to know — and to practice — the rules of safe
and responsible riding and of proper use and maintenance. Proper use and maintenance of your bicycle
reduces risk of injury.
This guide contains many “Warnings” and “Cautions” concerning the consequences of failure to
maintain or inspect your bicycle and of failure to follow safe cycling practices.
•
The combination of the
safety alert symbol and the word WARNING indicates a
potentially hazardous situation which, if not avoided, could result in serious injury or death.
•
The combination of the
safety alert symbol and the word CAUTION indicates a
potentially hazardous situation which, if not avoided, may result in minor or moderate injury,
or is an alert against unsafe practices.
•
The word CAUTION used without the safety alert symbol indicates a situation which, if not
avoided, could result in serious damage to the bicycle or the voiding of your warranty.
Many of the Warnings and Cautions say “you may lose control and fall.” Because any fall can result
in serious injury or even death, we do not always repeat the warning of possible injury or death.
Because it is impossible to anticipate every situation or condition which can occur while riding, this
guide makes no representation about the safe use of the bicycle under all conditions. There are
risks associated with the use of any bicycle which cannot be predicted or avoided, and which are
the sole responsibility of the rider.
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CORRECT FRAME SIZE
When selecting a new bicycle, the correct choice of frame size is a very important safety consideration.
Most full sized bicycles come in a range of frame sizes. These sizes usually refer to the distance
between the center of the bottom bracket and the top of the frame seat tube.
The ideal clearance will vary between types of bicycles and rider preference. This makes straddling the
frame when off the saddle easier and safer in situations such as sudden traffic stops. Women can use a
men’s style bicycle to determine the correct size women’s model.
1-2in.
FOR SAFE AND COMFORTABLE RIDING THERE SHOULD BE
CLEARANCE OF NO LESS THAN 1 - 2 INCHES BETWEEN THE GROIN
AREA OF THE INTENDED RIDER AND THE TOP TUBE OF THE BICYCLE
FRAME, WHILE THE RIDER STRADDLES THE BICYCLE WITH BOTH
FEET FLAT ON THE GROUND.
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CHOOSING YOUR CORRECT FRAME SIZE
These are intended only as a guide:
MOUNTAIN BIKE / COMFORT BIKE / PERFORMANCE HYBRID BIKE CHART*
Rider
Height
(feet/inches)
Inseam
Length
(inches)
Bike
Frame Size
(inches)
Bike
Frame Size
(name)
4 ft. 11 in. – 5 ft. 3 in.
25 in. – 27 in.
13 - 15 in.
XS
5 ft. 3 in. – 5 ft. 7 in.
27 in. – 29 in.
15 - 17 in.
SM
5 ft. 7 in. – 5 ft. 11 in.
29 in. – 31 in.
17 - 19 in.
MD
5 ft. 11 in. – 6 ft. 2 in.
31 in. – 33 in.
19 - 21 in.
LG
6 ft. 2 in. – 6 ft. 4 in.
33 in. – 35 in.
21 - 23 in.
XL
6 ft.4 in. +
35 in. +
23 in. +
XL**
* Applies to both our Men's and Ladies' Bicycles ** No Larger Size Available
ROAD BIKE SIZING CHART
Rider
Height
(feet/inches)
( COMPACT GEOMETRY )
Inseam
Length
(inches)
Bike
Frame Size
(centimeters)
4 ft.10 in. – 5 ft.1 in.
25 in. – 27 in.
42 cm
XS
5 ft. 1 in. – 5 ft.5 in.
27.5 in. – 28 in.
46 cm
SM
5 ft. 5 in. – 5 ft. 9 in.
28.5 in. – 31 in.
50 cm
MD
5 ft. 9 in. – 6 ft. 1 in.
31.5 in. – 33 in.
55 cm
LG
6 ft. 1 in. – 6 ft.3 in.
33.5 in. – 34 in.
59 cm
XL
6 ft. 3 in. +
34.5 in. +
59 cm
XL **
** No Larger Size Available
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Bike
Frame Size
(name)
RIDING POSITION
Saddle Height
In order to obtain the most comfortable riding
position and offer the best possible pedaling
efficiency, the seat height should be set correctly
in relation to the rider’s leg length. The correct
saddle height should not allow leg strain from
over-extension, and the hips should not rock from
side to side when pedaling. While sitting on the
bicycle with one pedal at its lowest point, place
the ball of your foot on that pedal. The correct
saddle height will allow the knee to be slightly
bent in this position.
UNDER NO CIRCUMSTANCES SHOULD THE SEAT POST PROJECT
“MAXIMUM EXTENSION” MARK. IF YOUR SEAT POST PROJECTS
FROM THE FRAME BEYOND THESE MARKINGS, THE SEAT POST OR
FRAME MAY BREAK, WHICH COULD CAUSE YOU TO LOSE CONTROL
AND FALL. PRIOR TO YOUR FIRST RIDE, BE SURE TO TIGHTEN THE
SADDLE ADJUSTING MECHANISM PROPERLY. A LOOSE SADDLE
CLAMP OR SEAT POST BINDER CAN CAUSE DAMAGE TO THE BICYCLE
OR CAN CAUSE YOU TO LOSE CONTROL AND FALL. PERIODICALLY
CHECK TO MAKE SURE THAT THE SADDLE ADJUSTING MECHANISM
IS PROPERLY TIGHTENED.
REACH
To obtain maximum comfort, the rider should not overextend his or her reach when riding. There should
be a slight bend in the rider's elbows.
Refer to the section regarding Seat and Seat Posts to learn how to adjust the seat clamp.
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HANDLEBAR HEIGHT
Maximum comfort is usually obtained when the handlebar height is equal to the height of the seat. You
may wish to adjust the height to find the most comfortable position.
Stem Wedge Bolt
Handlebar Binder Bolt
Maximum Height/
Minimum Insertion
Mark
THREADLESS HEADSETS AND CLAMP-ON STEMS ARE NOT ADJUSTABLE.
THE STEM’S “MINIMUM INSERTION” MARK MUST NOT BE VISIBLE
ABOVE THE TOP OF THE HEADSET. IF THE STEM IS EXTENDED
BEYOND THIS MARK, THE STEM MAY BREAK OR DAMAGE THE FORK’S
STEERER TUBE, WHICH COULD CAUSE YOU TO LOSE CONTROL AND
FALL. FAILURE TO PROPERLY TIGHTEN THE STEM BINDER BOLT, THE
HANDLEBAR BINDER BOLT, OR THE BAR END EXTENSION CLAMPING
BOLTS MAY COMPROMISE STEERING ACTION, WHICH COULD CAUSE
YOU TO LOSE CONTROL AND FALL. PLACE THE FRONT WHEEL OF
THE BICYCLE BETWEEN YOUR LEGS AND ATTEMPT TO TWIST THE
HANDLEBAR/STEM ASSEMBLY USING A REASONABLE AMOUNT OF
FORCE. IF YOU CAN TWIST THE STEM IN RELATION TO THE FRONT
WHEEL, TURN THE HANDLEBARS IN RELATION TO THE STEM, OR
TURN THE BAR END EXTENSIONS IN RELATION TO THE HANDLEBAR,
YOU MUST TIGHTEN THE APPROPRIATE BOLTS ACCORDINGLY.
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SAFETY CHECKLIST
Before every ride, it is important to carry out the following safety checks:
1. Brakes
• Ensure front and rear brakes work properly.
• Ensure brake shoe pads are not over worn and are correctly positioned in relation to the rims.
• Ensure brake control cables are lubricated, correctly adjusted and display no obvious wear.
• Ensure brake control levers are lubricated and tightly secured to the handlebar.
2. Wheels and Tires
• Ensure tires are inflated to within the recommended limit as displayed on the tire sidewall.
• Ensure tires have tread and have no bulges or excessive wear.
• Ensure rims run true and have no obvious wobbles or kinks.
• Ensure all wheel spokes are tight and not broken.
• Check that axle nuts are tight. If your bicycle is fitted with quick release axles, make sure
locking levers are correctly tensioned and in the closed position.
3. Steering
• Ensure handlebar and stem are correctly adjusted and tightened, and allow proper steering.
• Ensure that the handlebars are set correctly in relation to the forks and the direction of travel.
• Check that the headset locking mechanism is properly adjusted and tightened.
• If the bicycle is fitted with handlebar end extensions, ensure they are properly positioned and tightened.
4. Chain
• Ensure chain is oiled, clean and runs smoothly.
• Extra care is required in wet or dusty conditions.
5. Bearings
• Ensure all bearings are lubricated, run freely & display no excess movement, grinding or rattling.
• Check headset, wheel bearings, pedal bearings and bottom bracket bearings.
6. Cranks and Pedals
• Ensure pedals are securely tightened to the cranks.
• Ensure cranks are securely tightened to the axle and are not bent.
7. Derailleurs
• Check that front and rear mechanisms are adjusted and function properly.
• Ensure control levers are securely attached.
• Ensure derailleurs, shift levers and control cables are properly lubricated.
8. Frame and Fork
• Check that the frame and fork are not bent or broken.
• If either are bent or broken, they should be replaced.
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9. Accessories
• Ensure that all reflectors are properly fitted and not obscured.
• Ensure all other fittings on the bike are properly and securely fastened, and functioning.
• Ensure the rider is wearing a helmet.
HELMETS
It is strongly advised that a properly fitting, ANSI 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 wear a helmet.
The correct helmet should:
• be comfortable
• be lightweight
• have good ventilation
• fit correctly
• cover forehead
ALWAYS WEAR A PROPERLY FITTED HELMET WHICH COVERS THE
FOREHEAD WHEN RIDING A BICYCLE.
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REFLECTORS
Your bicycle is supplied with one front (white), one rear (red), two wheel (white), and pedal (orange)
reflectors. (Please Note: Sidewalk bikes, 12˝ and under, may not have reflectors.) These are an important
safety and legal requirement, and should remain securely fitted and in good, clean condition at all
times. Periodically, inspect all reflectors, brackets and mounting hardware for signs of wear or damage.
Replace immediately if damage is found. Some bicycles will require you to install your reflectors onto
your bicycle. Please refer to the following section for instructions on all the types of bicycle reflectors.
REFLECTORS ARE IMPORTANT SAFETY DEVICES WHICH ARE
DESIGNED AS AN INTEGRAL PART OF YOUR BICYCLE. FEDERAL
REGULATIONS REQUIRE EVERY BICYCLE TO BE EQUIPPED
WITH FRONT, REAR, WHEEL, AND PEDAL REFLECTORS. THESE
REFLECTORS ARE DESIGNED TO PICK UP AND REFLECT STREET
LIGHTS AND CAR LIGHTS IN A WAY THAT HELPS YOU TO BE SEEN
AND RECOGNIZED AS A MOVING BICYCLIST. CHECK REFLECTORS
AND THEIR MOUNTING BRACKETS REGULARLY TO MAKE SURE THEY
ARE CLEAN, STRAIGHT, UNBROKEN AND SECURELY MOUNTED. HAVE
YOUR DEALER REPLACE DAMAGED REFLECTORS AND STRAIGHTEN
OR TIGHTEN ANY THAT ARE BENT OR LOOSE.
FORK MOUNT REFLECTOR BRACKET ASSEMBLY
First insert one washer onto the hex bolt and insert hex bolt through the reflector bracket and then
through the fork. Next, insert a second washer onto the bolt and thread a hex nut onto the bolt behind
the fork. Tighten bolts until snug, making sure the reflector is in an upright position. See diagram below.
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FRONT REFLECTOR MOUNT WITH CALIPER BRAKE ASSEMBLY
First remove the hex nut from the back of the fork and pull the brake from the fork. Insert a spacer,
washer and the reflector bracket on to the caliper bolt. Insert the caliper bolt back into the fork and
secure firmly with a concave spacer, washer and the hex nut. Finally, adjust the reflector such that it is
in an upright position. See diagram below.
SEAT AND HANDLEBAR MOUNTING REFLECTORS
First attach the reflector to the reflector bracket with the reflector screw, see the top diagram. Next,
remove the clamp screw and open the clamping reflector bracket. Place clamping reflector bracket
around the handlebar or seatpost. If the clamp is too loose, insert the shim inside of the clamp. Tighten
the clamp screw to hold reflector assembly in place, see the second diagram. Finally, adjust the reflector
assembly in place and ensure that it is upright and facing away from the bike. See diagram below.
SEATSTAY MOUNT REFLECTOR BRACKET ASSEMBLY
First insert one washer onto the hex bolt and insert hex bolt through the reflector bracket and then
through the seatstay bridge. Next, insert a second washer onto the bolt and thread a hex nut onto the bolt
behind the seatstay bridge. Tighten bolts until snug, making sure the reflector is in an upright position.
See diagram below.
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GEARS - HOW TO OPERATE
Derailleur Gears
Most multi-speed bicycles today are equipped with what are known as derailleur gears. They operate
using a system of levers and mechanisms to move the drive chain between different sized driving gears
or cogs. The purpose of gears is to let you maintain a constant, steady pedaling pace under varying
conditions. Bicycles come with a variety of gear configurations from 5 to 30 speeds.
Drivetrain
Freewheel
Cogs
Guide Pulley
Front Derailleur
Front Chainwheels
Crank Arm
Rear Derailleur
Pedal
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Derailleur Control
Cable
Operating Principles
The front derailleur is operated by the left shift lever and the rear derailleur by the right. To operate you
must be pedaling forward. You can not shift derailleur gears when you are stopped or when pedaling
backwards. Before shifting ease up on your pedaling pressure. For a smooth gear change when
approaching a hill, shift to a lower gear BEFORE your pedaling speed slows down too much. When
coming to a stop, shift to a lower gear first so it will be easier when you start riding again. If, after
selecting a new gear position, you hear a slight rubbing noise from the front or rear gears, gently adjust
the appropriate shifter using the barrel adjusters until the noise goes away. For optimal performance and
extended chain life, it is recommended that you avoid using the extreme combinations of gear positions
(diagram next page) for extended periods.
Recommended Chainwheel/Rear Sprocket Gear Combinations
4
6 5
1
3 2
3
High
2
1
Middle
Low
These combinations are
NOT RECOMMENDED
for optimal performance.
Triple Chainwheel
4
6 5
1
3 2
2
High
1
Low
These combinations are
NOT RECOMMENDED
for optimal performance.
Double Chainwheel
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HAND GRIP SHIFTERS
Some bicycles will have a shifting mechanism which is built into the handlebar grips and does not make
use of separate levers. To select a lower gear, twist the right shifter toward you to engage a larger rear
cog. You can shift one gear at a time or through multiple gears by continued twisting. By twisting the
left shifter forward or away from you, a smaller chainwheel can be selected. To select a higher gear,
twist the right shifter forward or away from you to engage a smaller rear cog. To engage a larger front
chainwheel, twist the left shifter towards you. Single shifts can be achieved by twisting one click at a
time and multiple shifts by larger twists.
Front Low Gear
Rear Low Gear
Front High Gear
Rear High Gear
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LEVERED SHIFTERS
Many mountain style bicycles now use a shift lever arrangement mounted on the underside of the
handlebars, which use two levers operated by the thumb and index finger. To select a lower gear push
the larger (lower) right shifter with your thumb to engage a larger rear cog. One firm push shifts the
chain one cog, continuing to push will move the chain over multiple cogs. Pulling the smaller (upper) left
shifter with your index finger moves the chain from a larger to a smaller chainwheel. To select a higher
gear pull the smaller (upper) right lever with your index finger to engage a smaller rear cog. Pushing
the larger (lower) left lever with your thumb will move the chain from a smaller to a larger chainwheel.
Left hand lever
Right hand lever
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ASSEMBLY INSTRUCTIONS
WE RECOMMEND THAT YOU CONSULT A PROFESSIONAL BICYCLE
MECHANIC IF YOU HAVE DOUBTS OR CONCERNS AS TO YOUR
EXPERIENCE OR ABILITY TO PROPERLY ASSEMBLY, REPAIR, OR
MAINTAIN YOUR BICYCLE.
DERAILLEUR GEARED BICYCLES
GETTING STARTED
Open the carton from the top and remove the bicycle. Remove the straps and protective wrapping from
the bicycle. Inspect the bicycle and all accessories and parts for possible shortages. It is recommended
that the threads and all moving parts in the parts package be lubricated prior to installation. Do not
discard packing materials until assembly is complete to insure that no required parts are accidentally
discarded. Assemble your bicycle following the steps that pertain to your model.
HANDLEBARS
Remove the protective cap from the handlebar stem wedge and loosen the hex key bolt using the
6mm hex key. Some models may use a 13mm hexagonal bolt instead of an hex key bolt. Place the
handlebar stem into the fork steerer tube, ensuring that all cables are free of tangles. Tighten the stem
bolt observing the minimum insertion mark and checking that the forks and the handlebars are facing
forward. Check the headset for smooth rotation and that the top nut is secured tightly. Loosen the 6mm
Binder Bolt and rotate the handlebar forward so the levers are at a 45 degree angle below the handlebar.
Retighten the Binder Bolt to ensure the handlebar does not rotate in the stem.
Binder Bolt
Stem Bolt
Top Nut
Minimum Insertion
Mark
Wedge
Head Tube
WARNING: OVER TIGHTENING THE STEM BOLT OR HEADSET
ASSEMBLY MAY CAUSE DAMAGE TO THE BICYCLE AND/OR
INJURY TO THE RIDER.
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ADJUSTABLE STEMS
Some bicycles may be equipped with a stem that has an adjustable angle. In addition to the normal
assembly, these stems will require angling the stem to the desired position, and securely tightening the
6mm angle bolt located in front of the stem bolt. Failure to do this may cause loss of steering control.
TIGHTENING/PRELOADING THREADLESS HEADSETS
Stem Installation (Should be assembled on the bike already)
1. Insert the compression bolt through the top cap and the stem. Begin threading into the star nut.
2. Tighten compression bolt so it removes all play from the fork, but allows the fork to rotate smoothly.
3. Align the stem with the front wheel. Tighten the stem clamp bolts to secure the stem to the steerer tube.
HANDLEBAR INSTALLATION
1. Remove the stem cap bolts and stem cap.
2. Insert handlebar into the stem cap.
3. Tighten the stem cap bolts equally. Note the distance between the stem and stem cap: It should be
equal on the top and bottom of the stem cap. "A" must be equal distance.
Compression Bolt
Handlebar
Top Cap
Stem Cap
Bolts
Stem Clamp Bolts
Spacer
Headset Wedge
Bearing Race
Bearing Dust Cover
Bearing Retainer
Installed
by
factory
Upper Headset Cup
Steerer Tube
Star Nut
(Inside Steerer Tube)
Headtube
Lower Headset Cup
Bearing Retainer
Bearing Dust Cover
Headset Crown Race
fork
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Stem Cap
SEAT AND SEAT POST
Attach the seat to the seat post if required by loosening the nuts on the seat clamp. Insert the tapered
end of the seat post into the seat clamp until it is at the top of the clamp. Partially tighten the nuts on
the seat clamp until the seat is snug, but can still be turned. Insert the seat assembly into the frame
of the bicycle and adjust the seat to the proper height. The seat post must be inserted to at least the
“Minimum Insertion” line marked on the seat post. If equipped with a quick release skewer; tighten
the adjusting nut by hand and move the quick release lever to the closed position. You should feel
considerable resistance while moving the lever. If not, re-open and re-tighten the lever, then move it to
the closed position so it is in line with the frame as pictured. If equipped with a binder clamp; Insure
the lip on the binder clamp is fitted completely against the top of the seat tube of the frame. With the
seat post inserted, tighten the binder bolt securely. Position the top of the seat parallel with the ground.
Push the front of the seat up and down to firmly mesh the serrations together. The serrations must mesh
completely together to insure a stabilized riding position. Securely tighten the nut on the seat clamp. If
there is a nut on both sides of the clamp, tighten each one by alternating from one to the other. Check
for tightness by twisting the seat from side to side, and from front to back. If the seat moves at the seat
clamp or quick release, reposition and re-tighten the appropriate clamping mechanism.
Seat
Clamp
Seat
Post
Quick
Release
Adjusting
Nut
THE SEAT POST MUST BE INSERTED SO THAT THE MINIMUM
INSERTION MARK CANNOT BE SEEN. THE QUICK RELEASE
MECHANISM MUST BE TIGHTENED SECURELY TO PREVENT A
SUDDEN SHIFT OF THE SEAT WHEN RIDING. FAILURE TO DO THIS
MAY CAUSE LOSS OF BICYCLE CONTROL.
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PEDALS
Look for the letters “R” for right, and “L” for left, stamped on each pedal spindle. Start each pedal spindle
by hand to avoid stripping the threads. Tighten with a 15mm narrow open ended wrench. Note that the
right hand pedal attaches to the chainwheel side crank arm with a right-hand (clockwise) thread. The
left pedal attaches to the other crank arm and has a left-hand (counter-clockwise) thread. It is very
important that you check the crank set for correct adjustment and tightness before riding your bicycle.
Dust
Cap
ATTACHMENT OF AN INCORRECT PEDAL INTO A CRANK ARM CAN
STRIP PEDAL THREADS AND CAUSE IRREPARABLE DAMAGE. BEFORE
YOUR FIRST RIDE, PLEASE CHECK TO INSURE YOUR PEDALS ARE
ATTACHED CORRECTLY.
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FRONT WHEEL
Insert the front wheel into the fork dropouts. Tighten the wheel nuts using the appropriate 14mm or
15mm wrench. Spin the wheel checking for trueness. Some bicycles have wheel axles that incorporate
a cam lever. This allows easy wheel removal without the need for tools. The cam lever uses a long bolt
with an adjusting nut on one end, and a lever operating a cam-action tensioner on the other. If the wheel
is fitted with this type of axle, turn the adjusting nut so that the locking lever is moved to the closed
position with a firm action. At the halfway closed position of the quick release lever, you should start
to feel some resistance to this motion. Do not tighten the cam lever by using it like a wing nut. If the
cam lever is moved to the closed position with no resistance, clamping strength is insufficient. Move the
cam lever to the open position, tighten the adjusting nut, and return the cam lever to the closed position.
Adjusting
Axle
Nut
Hub
Axle
Cam
Lever
Hub
Spring
CORRECT CAM LEVER AXLE SETTING
1. To set, turn the lever to the open position so that the curved part faces away from the bicycle.
2. While holding the lever in one hand, tighten the adjusting nut until it stops.
3. Pivot the lever towards the closed position. When the lever is halfway closed, there must be firm
resistance to turn it beyond that point. If resistance is not firm, open the lever and tighten the
adjusting nut in a clockwise direction.
4. Continue to pivot the lever all the way to the closed position so that the curved part of the lever
faces the bicycle.
5. The wheel is tightly secured when the serrated surfaces of the clamping parts actually begin to cut
into the bicycle frame/fork surfaces.
6. Note that the same procedure applies when operating a quick release seat post binder mechanism.
Closed Position
Open Position
IF YOU CAN FULLY CLOSE THE CAM LEVER WITHOUT WRAPPING YOUR
FINGERS AROUND THE FORK BLADE FOR LEVERAGE, AND THE LEVER
DOES NOT LEAVE A CLEAR IMPRINT IN THE PALM OF YOU HAND, THE
TENSION IS INSUFFICIENT. OPEN THE LEVER, TURN THE ADJUSTING NUT,
AND TRY AGAIN. CONTINUE UNTIL THE CAM LEVER CLOSES PROPERLY.
SECONDARY RETENTION DEVICES ARE NOT A SUBSTITUTE FOR A
CORRECT CAM LEVER ADJUSTMENT.
FAILURE TO PROPERLY ADJUST THE CAM LEVER MECHANISM CAN CAUSE
THE WHEEL TO WOBBLE OR DISENGAGE, WHICH COULD CAUSE YOU TO
LOSE CONTROL AND FALL, RESULTING IN SERIOUS INJURY OR DEATH.
27
BRAKES
V-Style Brakes
If not already assembled, take the brake noodle from the parts box and slide the cable through the
larger opening. The cable housing will then seat into the end of the noodle. Slide the cable through the
cable lead on the end of the left brake arm, this will cause the noodle to fit into the lead. Slip the brake
cable boot over the cable and position it between both brake arms. Next, loosen the 5mm anchor bolt
at the end of the right brake arm and slide the cable under the retaining washer. Pull the slack out of
the cable making sure a distance of 39mm or more remains between the end of the lead and the start
of the anchor bolt. Once the cable is secured to the brake arms, engage the brake lever several times,
checking the position of the brake shoes at the rim. The brake shoes should be 1mm away from the rim
when in a relaxed position. When the brake lever is engaged, the brake shoe should hit the rim flush
(never the tire) with the front brake pad touching the rim slightly before the rear. This is called “toeingin” your brake shoe. If this position is not achieved, adjustments to the brake shoe are required. Loosen
the brake shoe hardware and reposition the brake shoe. It may take several shoe and cable adjustments
before the required position is accomplished.
Brake
Cable
Boot
Outer
Cable
Lead
Brake
Noodle
Anchor
Bolt
Brake
Arm
Pivot
Bolt
Tension
Screw
Brake
Shoe
28
V-Style Brake
1. If fitted with V-Style Brakes, insert the brake body into the center spring hole in the frame mounting
boss, and then secure the brake body to the frame with the link fixing bolt.
5 mm hex key
Washer
Link
fixing
bolt
Spring
hole
Stopper pin
2. While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging the
position of the B washers (i.e. 6 mm and 3 mm) so that dimension A is kept at 39 mm or more.
39 mm or more
A
3 mm washer B
6 mm washer B
Shoe fixing nut
Washer
Washer A
Shoe fixing link
29
Washer A
3. While holding the shoe against the rim,
tighten the shoe fixing nut.
shoe fixing nut
5 mm hex key
1mm
4. Pass the inner cable through the inner cable
lead. Set the cable with a clearance of 1mm
between each brake pad and the rim, tighten
the cable fixing bolt.
5 mm hex key
1mm 1mm
5. Adjust the balance with the spring tension
adjustment screws.
1 mm
Spring tension
adjustment screw
6. Depress the brake lever about 10 times
as far as the grip to check that everything
is operating correctly and that the shoe
clearance is correct before using the brakes.
1 mm
Spring tension
adjustment screw
Depress about
10 times
30
DO NOT RIDE THE BICYCLE UNTIL THE BRAKES ARE FUNCTIONING
PROPERLY. TO TEST, APPLY THE BRAKES WHILE TRYING TO PUSH
THE BIKE FORWARD TO MAKE SURE THEY WILL STOP THE BICYCLE.
NEVER RIDE A BICYCLE THAT IS NOT FUNCTIONING PROPERLY.
PRESS EACH BRAKE LEVER TO MAKE SURE THAT THERE IS NO
BINDING AND THAT THE BRAKE PADS PRESS HARD ENOUGH ON THE
RIMS TO STOP THE BIKE. THE BRAKE PADS SHOULD BE ADJUSTED
SO THEY ARE 1 MM TO 2 MM AWAY FROM THE RIM WHEN THE
BRAKES ARE NOT APPLIED. BRAKE PADS SHOULD BE CENTERED ON
THE RIM AND “TOED-IN” SO THE REAR PORTION OF EACH BRAKE PAD
IS ABOUT 0.5 - 1.0 MM FARTHER FROM THE RIM THAN THE FRONT
PORTION OF THE BRAKE PAD.
DO NOT LOCK UP BRAKES. SUDDEN OR EXCESSIVE APPLICATION OF
THE FRONT BRAKE MAY PITCH THE RIDER OVER THE HANDLEBARS,
CAUSING SERIOUS INJURY OR DEATH. WHEN BRAKING, ALWAYS
APPLY THE REAR BRAKE FIRST, THEN THE FRONT.
31
DISC BRAKES
If fitted with a front disc brake, the components should already be attached. However, please check all
connections before attempting to ride the bicycle. Secure tightly the 6 bolts that hold the disc to the front
wheel hub and the 2 bolts that hold the brake mechanism to the bicycle. Insert the front wheel into the fork
dropouts ensuring that the disc fits into the brake mechanism between the enclosed brake pads. Secure
the front wheel to the bicycle by tightening the cam lever mechanism and clamping the lever to the closed
position.
Next, attach the cable to the brake lever by inserting the cable end into the cable end holder after the barrel
adjuster and lock nut slots have been aligned with the cable end holder. After the cable is secured to the
lever, rotate the barrel adjuster and lock nut so the slots no longer line up. Ensure the cable housing
seats appropriately into the end of the barrel adjuster and check for any kinks or damage.
Slide the exposed brake cable through the rotating rod located on the caliper body and seat the housing
into the same stop. Insert the cable into the spring and spring boot.
Next, slide the cable through the cable anchor and pull all the slack out. Secure the cable in place by
tightening the bolts of the anchor assembly. Some disc brakes will have a centering devise while others
are a free-floating mechanism. If your caliper body is equipped with centering bolts, apply the brake lever
after the cable has been connected. While engaging the lever, tighten the centering bolts securely. This will
center the caliper body on the disc.
“C” Clip
Brake Cable
Housing
Rotating Rod
Caliper
Mounting
Bolt with
spacers
Barrel Adjuster
Lock Nut
Actuating Arm
Brake Lever
Cable
Insertion
Slot
Brake Pads
Brake Cable
Cable End
Holder
Brake Type
Selector
Caliper
Mounting
Bolt with
spacers
Cable Anchor
Bolt
BRAKE DISC GETS HOT! SEVERE INJURY COULD RESULT FROM
CONTACT WITH THE HOT DISC! MIND YOUR LEGS, AS WELL AS YOUR
HANDS.
32
DISC BRAKES
Hub
Fork Leg
Centering Bolt
Disc Mounting
Bolts
Brake Cable
Housing
Rotating
Rod
Caliper
Body
Disc
Cable Boot
with Spring
inside
Centering Bolt
(inside)
Actuating
Arm
Cable Anchor
Bolt
Fork Drop Out
Caliper Mounting
Bolts with spacers
Cam Lever
DISC BRAKES REQUIRE A BREAK IN PERIOD! RIDE AND USE THE
BRAKES GENTLY FOR 15 MILES BEFORE USING THE BRAKES IN
DOWNHILL CONDITIONS, FOR SUDDEN STOPS, OR ANY OTHER
SERIOUS BRAKING. PLEASE BE AWARE THAT YOUR BRAKE SYSTEM
WILL CHANGE IN PERFORMANCE THROUGHOUT THE WEAR-IN
PROCESS. THE DISC BRAKE SHOULD BE CLEANED BEFORE THE
FIRST RIDE USING RUBBING ALCOHOL. NEVER USE OIL OR SIMILAR
PRODUCTS TO CLEAN YOUR DISC BRAKE SYSTEM.
33
DERAILLEUR
Although the front and rear derailleurs are initially
adjusted at the factory, you will need to inspect
and readjust both before riding the bicycle.
Cassette
Outer side of Top Gear
Pulley Adjustment
Screw
Rear Derailleur
Begin by shifting the rear shifter to largest number
indicated, disconnect the cable from the rear
derailleur cable anchor bolt, and place the chain
on the smallest sprocket.
Guide Pulley
Adjustment
Screws
Tension Pulley
Adjust the High limit screw so the guide pulley
and the smallest sprocket are lined up vertically.
Reconnect the cable, pull out any slack, and
retighten the anchor bolt securely. Shift through
the gears, making sure each gear achieved is
done quietly and without hesitation. If necessary,
use the barrel adjuster to fine tune each gear by
turning it the direction you want the chain to go.
For example, turning clockwise will loosen the
cable tension and move the chain away from
the wheel, while turning counter-clockwise will
tighten cable tension and direct the chain towards
the wheel. Shift the rear shifter to the gear one
and place the chain on the largest cog. Adjust the
Low limit screw in quarter turn increments until
the guide pulley and the largest cog are aligned
vertically. Again, shift through each gear several
times, checking that each gear is achieved
smoothly. It may take several attempts before the
rear derailleur and cable is adjusted properly.
SIS Cable Adjuster
High Gear
Adjustment Screw
Low Gear
Adjustment
Screw
H
L
Barrel
Adjuster
Rear Derailleur Side View
ENSURE ALL BOLTS ARE SECURED TIGHTLY AND THE CHAIN DOES
NOT FALL OFF IN EITHER DIRECTION.
34
Front Derailleur
Shift both shifters to the smallest number indicated and place the chain on the corresponding cog and
chainwheel. Disconnect the front derailleur cable from the cable anchor bolt. Check the position of the
front derailleur; it should be parallel with the outer chainwheel and clear the largest chainwheel by
1-3mm when fully engaged.
With the chain on the smallest chainwheel in front and the largest cog in back, adjust the Low limit
screw so the chain is centered in the front derailleur cage. Reconnect the cable, pull any slack out,
and tighten the anchor bolt securely. Shift the front shifter to the largest chainwheel. If the chain does
not go onto the largest chainwheel, turn the high limit screw in 1/4 turn increments counter-clockwise
until the chain engages the largest chainwheel. If the chain falls off the largest chainwheel, and into the
pedals, you will need to turn the High limit screw in 1/4 turn increments clockwise until the chain no
longer falls off.
Shift through every gear, using the barrel adjusters to fine tune each transition. The barrel adjuster for
the front derailleur is located on the front shifter where the cable comes out of the shifter. Clockwise will
loosen the cable tension and direct the chain closer to the frame while counter-clockwise will tighten the
cable tension and direct the chain away from the frame.
Low Adjusting Screw
High Adjusting
Screw
Cable Anchor Bolt
Chainguide
clearance of
1-3mm
Outer Chainguide
Inner Chainguard
DO NOT RIDE A BICYCLE THAT IS NOT SHIFTING PROPERLY.
OVERLOOKING PROPER ADJUSTMENTS MAY CAUSE IRREPARABLE
DAMAGE TO THE BICYCLE AND/OR BODILY INJURY. NEVER MOVE THE
SHIFTER WHILE PEDALING BACKWARD, NOR PEDAL BACKWARDS
AFTER HAVING MOVED THE SHIFTER. THIS COULD JAM THE CHAIN
AND CAUSE SERIOUS DAMAGE TO THE BICYCLE AND/OR RIDER.
35
FULL SUSPENSION
Full Suspension bikes are equipped with a front fork as well as a rear suspension generally located
below the seat. The piston works in conjunction with a spring to allow the bike to rotate on a pivot
point. Ensure all attaching hardware is secured and there is no lateral movement of the rear triangle.
On some bicycles the amount of rear suspension travel may be adjustable by turning the adjusting
plate. Clockwise will increase spring tension and decrease travel, while turning counter-clockwise will
decrease spring tension and increase travel.
Spring plate
Spring
Anchor bolt
Adjusting plate
Piston
THERE MUST BE ENOUGH TENSION ON THE SPRING TO HOLD
THE SPRING PLATE IN PLACE. FAILURE TO DO THIS MAY CAUSE
THE MECHANISM TO FAIL. FAILURE TO MAINTAIN, CHECK AND
PROPERLY ADJUST THE SUSPENSION SYSTEM MAY RESULT IN
SUSPENSION MALFUNCTION, WHICH CAN CAUSE YOU TO LOSE
CONTROL AND FALL. CHANGING SUSPENSION ADJUSTMENT CAN
CHANGE THE HANDLING AND BRAKING CHARACTERISTICS OF YOU
BICYCLE. NEVER CHANGE SUSPENSION ADJUSTMENT UNLESS
YOU ARE THOROUGHLY FAMILIAR WITH THE SUSPENSION SYSTEM,
MANUFACTURER’S INSTRUCTIONS AND RECOMMENDATIONS, AND
ALWAYS CHECK FOR CHANGES IN THE PERFORMANCE OF YOUR
BICYCLE BY TAKING A CAREFUL TEST RIDE IN A HAZARD FREE AREA.
IF YOUR BIKE HAS SUSPENSION EQUIPMENT, THE INCREASED SPEED
YOU MAY DEVELOP ALSO INCREASES YOUR RISK. WHEN BRAKING,
THE FRONT OF A SUSPENDED BIKE DIPS. YOU COULD LOSE CONTROL
OF HE BICYCLE AND FALL. GET TO KNOW HOW TO HANDLE YOUR
SUSPENSION SYSTEM SAFELY BEFORE TRYING ANY DOWNHILL OR
VERY FAST BIKING.
36
ACCESSORIES
If your bike is supplied with a water bottle and cage, attach the cage to the bicycle using the hex bolts
provided.
Some 20˝ and 24˝ model bicycles come with a rear derailleur guard to protect the rear derailleur from
damage. To install, remove the rear wheel axle nut on the drive side, install the rear derailleur guard over
the axle with the U-shaped guard pointing down, and retighten the axle nut. The guard will sit between
the frame and the axle nut.
TIGHTEN BOTH REAR WHEEL AXLE NUTS OR THE CAM LEVER
MECHANISM SECURELY. FAILURE TO DO THIS MAY CAUSE THE REAR
WHEEL TO DISLODGE FROM THE FRAME DROPOUTS RESULTING IN
SERIOUS DAMAGE OR INJURY.
37
FENDERS
Front Fender
The front fender is mounted at the fork crown. There are two ways in which to mount your front fender.
The first is the caliper brake mounting system (see figure 1), and the second is the 10mm nut and
bolt system (see figure 2). Identify the mounting system used on your bicycle and follow the given
instructions for that particular type of mounting system.
1. Caliper Brake Mounting System
First remove the front wheel from your bicycle. Remove the hex nut from the caliper brake bolt on the
rear of the fork, and slide the brake assembly from the fork. Place the fender assembly onto the fork
making sure the attachment holes and fender bracket holes line up. Reattach the caliper brake making
sure that the brake arms are on each side of the fender. Tighten the bolt until secure.
2. 10mm Nut and Bolt Mounting System
First remove the front wheel from your bicycle. Place the fender assembly onto the fork making sure the
attachment holes and fender bracket holes line up. Attach the fender with the 10mm hex bolt and nut.
Tighten the bolt until secure.
figure 2
figure 1
38
FENDERS
Rear Fender
The rear fender is mounted at the seatstay brace. There are two ways in which to mount your rear
fender. The first is the screw mounting system (see figure 3), and the second is the 10mm bolt and
screw system (see figure 4). Identify the mounting system used on your bicycle and follow the given
instructions for that particular type of mounting system.
1. Screw Mounting System
First remove the rear wheel. Place the fender assembly between the stays, making sure the fender
bracket holes line up with those in the frame. Attach the fender by using two screws to directly mount
the fender onto the frame. The mounts are located below the seat post and near the rear of the crank.
Tighten all screws until snug.
2. 10mm Bolt and Screw System
First remove the rear wheel. Place the fender assembly between the stays, making sure the fender
bracket holes line up with those in the frame. Attach the fender by using one screw to directly mount the
fender onto the frame near the crank. Next, use the 10mm hex bolt and nut to attach the fender to the
brace between the seat stays, near the seat post. Tighten all bolts and screws until snug.
figure 3
figure 4
39
FINAL CHECK
• After all adjustments have been made, shift through every gear several times at varying speeds.
This will ensure all your adjustments are correct and will allow you to pinpoint any trouble areas. If
you encounter any problems, refer to the appropriate section and make any necessary adjustments.
• Check the tire pressure and inflate each tube to the recommended psi as stated on the sidewall of
the tire.
• If your bicycle is equipped with a kickstand, check that the kickstand operates smoothly and the
kickstand bolt is tightly secured.
• Finally, examine the bicycle. Make sure all accessories are attached and all quick releases, cam
levers, nuts and bolts have been tightened securely.
Remember: Always wear a helmet and obey all traffic laws.
40
SINGLE-SPEED AND BMX BICYCLES
WE RECOMMEND THAT YOU CONSULT A PROFESSIONAL BICYCLE
MECHANIC IF YOU HAVE DOUBTS OR CONCERNS AS TO YOUR
EXPERIENCE OR ABILITY TO PROPERLY ASSEMBLY, REPAIR, OR
MAINTAIN YOUR BICYCLE.
GETTING STARTED
Open the carton from the top and remove the bicycle. Remove the straps and protective wrapping from
the bicycle. Inspect the bicycle and all accessories and parts for possible shortages. It is recommended
that the threads and all moving parts in the parts package be lubricated prior to installation. Do not
discard packing materials until assembly is complete to insure that no required parts are accidentally
discarded. Assemble your bicycle following the steps that pertain to your model.
HANDLEBARS
Remove the protective cap from the stem wedge and loosen the stem bolt using the 6mm hex key. Some
models may use a 13mm hexagonal bolt instead of an Hex key bolt. Place the handlebar stem into the
head tube, observing the minimum insertion mark on the handlebar stem and ensuring that all cables
are free of tangles. Check that the fork and the handlebar are facing forward, and that they are properly
aligned with the front wheel. Tighten the stem bolt. Rotate the handlebar to the desired position. Tighten
stem cap bolt 1 (see picture) two turns, tighten stem cap bolt 2 two turns and so on. Repeat until handle
bar is secure to the stem. See picture for a 4-bolt system. Also check that the stem binder bolts are
tightened equally and securely.
Stem Cap Binder Bolts
Stem
Bolt
4-Bolt
Face
Plate
Minimum
Insertion Mark
Stem Wedge
Head
Tube
THE HANDLEBAR MUST BE INSERTED SO THAT THE MINIMUM
INSERTION MARK CANNOT BE SEEN. WARNING: OVER TIGHTENING
THE STEM BOLT OR HEADSET ASSEMBLY MAY CAUSE DAMAGE TO
THE BICYCLE AND/OR INJURY TO THE RIDER.
41
SEAT AND SEAT POST
Attach the seat to the seat post if required by loosening the nuts on the seat clamp. Insert the tapered
end of the seat post into the seat clamp until it is at the top of the clamp. Partially tighten the nuts on
the seat clamp until the seat is snug, but can still be turned. Insert the seat assembly into the frame
of the bicycle and adjust the seat to the proper height. The seat post must be inserted to at least the
“Minimum Insertion” line marked on the seat post. If equipped with a quick release skewer; tighten
the adjusting nut by hand and move the quick release lever to the closed position. You should feel
considerable resistance while moving the lever. If not, re-open and re-tighten the lever, then move it to
the closed position so it is in line with the frame as pictured. If equipped with a binder clamp; Insure
the lip on the binder clamp is fitted completely against the top of the seat tube of the frame. With the
seat post inserted, tighten the binder bolt securely. Position the top of the seat parallel with the ground.
Push the front of the seat up and down to firmly mesh the serrations together. The serrations must mesh
completely together to insure a stabilized riding position. Securely tighten the nut on the seat clamp. If
there is a nut on both sides of the clamp, tighten each one by alternating from one to the other. Check
for tightness by twisting the seat from side to side, and from front to back. If the seat moves at the seat
clamp or quick release, reposition and re-tighten the appropriate clamping mechanism.
Seat
Clamp
Seat
Post
Quick
Release
Adjusting
Nut
THE SEAT POST MUST BE INSERTED SO THAT THE MINIMUM
INSERTION MARK CANNOT BE SEEN. THE QUICK RELEASE
MECHANISM MUST BE TIGHTENED SECURELY TO PREVENT A
SUDDEN SHIFT OF THE SEAT WHEN RIDING. FAILURE TO DO THIS
MAY CAUSE LOSS OF BICYCLE CONTROL.
42
PEDALS
Look for the letters “R” for right, and “L” for left, stamped on each pedal spindle. Start each pedal spindle
by hand to avoid stripping the threads. Tighten with a 15mm narrow open ended wrench. Note that the
right hand pedal attaches to the chainwheel side crank arm with a right-hand (clockwise) thread. The
left pedal attaches to the other crank arm and has a left-hand (counter-clockwise) thread. It is very
important that you check the crank set for correct adjustment and tightness before riding your bicycle.
Dust
Cap
ATTACHMENT OF AN INCORRECT PEDAL INTO A CRANK ARM CAN
STRIP PEDAL THREADS AND CAUSE IRREPARABLE DAMAGE. BEFORE
YOUR FIRST RIDE, PLEASE CHECK TO INSURE YOUR PEDALS ARE
ATTACHED CORRECTLY.
43
FRONT WHEEL
1. Make sure the brakes are loose enough to allow the wheel to pass through the brake pads easily.
2. Place wheel into fork drop outs.
3. Install retaining washers with raised lip pointed towards the fork, and insert into the small hole
of the fork blade. NOTE: Some bikes may have step retaining washers in place of the retaining
washer (shown in dotted box). If so, install the step retaining washer, raised portion sliding in to
the fork dropouts.
4. Install axle nut and tighten. Make sure the wheel is centered between the fork blades.
5. Spin the wheel to make sure that it is centered and clears the brake shoes. Tighten the brakes
if necessary.
6. Turn the bicycle upright using the kickstand to support it, if your bicycle is equipped with one.
Axle Nut
Retaining
Washer
Axle
Hub
Cone Nuts
Fork Drop Out
Step
Retaining
Washer
IT IS VERY IMPORTANT TO CHECK THE FRONT WHEEL
CONNECTION TO THE BICYCLE. FAILURE TO PROPERLY TIGHTEN MAY
CAUSE THE FRONT WHEEL TO DISLODGE.
BRAKES
Determine which type of brake your bike is equipped with and refer to the appropriate assembly
instructions. A greater force is required to activate the rear brake due to longer cable length. It is
advisable to mount the rear brake on the side of the stronger hand. It is important to become familiar
with the use of hand brakes. When properly adjusted, hand brakes are an efficient braking system. Keep
the rim and brake shoes clean and free from wax, lubricants and dirt at all times. Keep brakes properly
adjusted and in good working condition at all times.
Open the brake lever and place the cable end of the short brake cable into the lever, then close the lever.
Secure the ferrule against the lever using the cable adjusting barrel.
Brake Lever
Grip
Cable End
Handlebar
44
Ferrule
Cable
Adjusting
Barrel
V-Style Brake
1. If fitted with V-Style Brakes, insert the brake body into the center spring hole in the frame mounting
boss, and then secure the brake body to the frame with the link fixing bolt.
5 mm hex key
Washer
Link
fixing
bolt
Spring
hole
Stopper pin
2. While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging the
position of the B washers (i.e. 6 mm and 3 mm) so that dimension A is kept at 39 mm or more.
39 mm or more
A
3 mm washer B
6 mm washer B
Shoe fixing nut
Washer
Washer A
Shoe fixing link
45
Washer A
3. While holding the shoe against the rim,
tighten the shoe fixing nut.
shoe fixing nut
5 mm hex key
1mm
4. Pass the inner cable through the inner cable
lead. Set the cable with a clearance of 1mm
between each brake pad and the rim, tighten
the cable fixing bolt.
5 mm hex key
1mm 1mm
5. Adjust the balance with the spring tension
adjustment screws.
1 mm
Spring tension
adjustment screw
6. Depress the brake lever about 10 times
as far as the grip to check that everything
is operating correctly and that the shoe
clearance is correct before using the brakes.
1 mm
Spring tension
adjustment screw
Depress about
10 times
46
U-BRAKES
Begin by adjusting the pads of the U-brakes using a 10mm wrench. Make sure the pad is hitting the rim
and not the tire. Ideally the front of the pad should hit the rim approximately 1mm before the rear pad.
Front U-Brake
Slide the brake cable and housing through the Housing Barrel and through the cable anchor bolt. Set
the cable clearance of 1mm between the brake pads and the rim. Tighten the cable anchor bolt. All
instructions shown are if you are looking at the bike from the front. For brake adjustments, use a 13mm
box end wrench and a 5mm hex wrench. Loosen the 5mm hex bolt. For the drive side (left) of the bike
turn the spring tension nut with a 13mm box end wrench counter-clockwise to increase tension on
the spring. For the non-drive side (right), turn spring tension nut with a box end wrench clockwise to
increase tension on the spring. When the desired tension is achieved hold the tension nut with the 13mm
wrench and tighten the 5mm hex bolt. The tension on each side should be equal so that the brake arms
move the same distance when the brake is activated.
Front U-Brake
increase
increase
hex
47
increase
Rear U-Brake
Option 1: Next, tighten the Cable Carrier to the brake cable approximately 20mm from the brake arms
when they are closed against the rim. Attach the Straddle cable to the carrier. Hook cable end into the
brake slot, pull excess straddle cable through the cable anchor and tighten the cable anchor. Continue
with “For Both Options” below.
Rear U-Brake
Option 1
increase
increase
hex
Option 2: Place brake housing into the frame housing stops. Pull brake cable tightly and thread across
through the opposite cable anchor bolt. Tighten cable. Repeat for other side. Continue with “For Both
Options” below.
Rear U-Brake
Option 2
increase
increase
hex
For Both Options: For brake adjustments, use a 13mm open end wrench and a 5mm hex wrench and
loosen the 5mm hex bolt. For the drive side (right) of the bike turn the spring tension nut with a 13mm
open end wrench counter clockwise to increase tension on the spring. For the non-drive side (left), turn
the spring tension nut with a box end wrench clockwise to increase tension on the spring. When the
desired tension is achieved, hold the tension nut with the 13mm wrench and tighten the 5mm hex bolt.
The tension on each side should be equal so that the brake arms move the same distance when the
brake is activated.
PLEASE NOTE: that some BMX frames have the U-Brake flipped and mounted below the seatstays. The
direction to tension the springs will still be oriented to how the picture is oriented.
48
ROTORS
Some freestyle BMX bicycles come equipped with a detangler system that will allow the handlebar to
spin 360-degrees without binding the cables. It is very important that this system is adjusted correctly.
Installation should only be done by a qualified bicycle mechanic with the correct tools.
Upper Cable
1. First connect the cable end of the upper cable to the rear brake lever. Make sure the long cable casing
is on top of the short cable casing; otherwise, the upper cable will have a twist in it.
2. Route the upper cable through the handlebars (below the crossbar) with the short cable casing on the
same side as the rear brake lever.
3. Connect the upper cable to the upper plate by passing the football ends of the upper cable through
the threaded holes in the upper plate and connecting them to the bearing.
4. Screw the adjusting barrels into the upper plate. Don’t tighten the locknuts at this time.
Lower Cable
1. Slide the cable casing through the cable guide on the frame.
2. Connect the lower cable to the lower plate by passing the football ends of the lower cable through the
threaded holes in the lower plate and connecting them to the bearing.
3. Screw the adjusting barrels into the lower plate. Don’t tighten the locknuts at this time.
4. Connect the lower cable to the rear brake. Don’t adjust the rear brake at this time.
NOTE: Check to make sure all 11 cable casing ends on the upper and lower cables are seated correctly,
and that the spring tension of the rear brake is pulling the bearing down.
Adjustment
1. Screw the cable adjusters on the rear brake lever and the upper cable splitter all the way in.
2. Screw the adjusting barrels in the upper plate in (or out) to set the bearing for maximum travel. The
bearing should be as far down as it can go without resting on the lower plate or the adjusting barrels
screwed into the lower plate.
3. Use the adjusting barrels that are screwed into the upper plate to make the bearing parallel to the
upper plate. Use a 10mm wrench to tighten the locknut on the left adjusting barrel of the upper cable.
Leave the right adjusting barrel loose.
4. Screw the lower cable adjusting barrel into (or out of) the lower plate until they are as close to the
bearing as they can get without touching it.
5. Screw the cable adjuster on the upper cable splitter out until all slack is removed from the upper
cable. Then screw the cable adjuster out one more turn to raise the bearing an additional 1mm away
from the lower cable adjusting barrels.
CAUTION: Don’t screw the cable adjuster on the upper cable splitter out more than 8mm. Use the
cable adjuster on the rear brake lever if more adjustment is needed.
DO NOT LOCK UP BRAKES. SUDDEN OR EXCESSIVE APPLICATION OF
THE FRONT BRAKE MAY PITCH THE RIDER OVER THE HANDLEBARS,
CAUSING SERIOUS INJURY OR DEATH. WHEN BRAKING, ALWAYS
APPLY THE REAR BRAKE FIRST, THEN THE FRONT.
49
6. Check for bearing flop by placing the handlebars in the normal riding position, then quickly rotate the
handlebars back and forth. Perform the following steps to eliminate bearing flop.
NOTE: The bearing should never be allowed to rest on the lower plate or lower cable adjusting barrels.
a) Screw the lower cable adjusting barrels out of (or into) the lower plate until all bearing flop
is eliminated.
b) Tighten the locknut of the right adjusting barrel on the lower cable.
c) Rotate the handlebars 180 degrees and recheck for bearing flop. If there is any bearing flop, use
the “loose” adjusting barrels on the upper and lower cable to remove it.
d) Repeat steps (6a) and (6c) until the handlebars can be rotated 360 degrees without any
bearing flop.
7. Finish adjusting the rear brakes.
Single Cable Casing
Cable Adjuster
Cable Splitter
Upper Cable
(long casing)
Cable End
Upper Cable
(short casing)
Adjusting Barrel
Locknut
Upper Plate
Set for Max. Travel
Keyed Washer
37mm + or - 1mm
Bearing
Football Ends
Minimum 1mm (1/32”)
Lower Plate
Locknut
Adjusting Barrel
Lower Cable
DO NOT RIDE THE BICYCLE UNTIL THE BRAKES ARE FUNCTIONING
PROPERLY. TO TEST, APPLY THE BRAKES WHILE TRYING TO PUSH
THE BIKE FORWARD TO MAKE SURE THEY WILL STOP THE BICYCLE.
NEVER RIDE A BICYCLE THAT IS NOT FUNCTIONING PROPERLY.
PRESS EACH BRAKE LEVER TO MAKE SURE THAT THERE IS NO
BINDING AND THAT THE BRAKE PADS PRESS HARD ENOUGH ON THE
RIMS TO STOP THE BIKE. THE BRAKE PADS SHOULD BE ADJUSTED
SO THEY ARE 1 MM TO 2 MM AWAY FROM THE RIM WHEN THE
BRAKES ARE NOT APPLIED. BRAKE PADS SHOULD BE CENTERED ON
THE RIM AND “TOED-IN” SO THE REAR PORTION OF EACH BRAKE PAD
IS ABOUT 0.5 - 1.0 MM FARTHER FROM THE RIM THAN THE FRONT
PORTION OF THE BRAKE PAD.
50
ACCESSORIES
AXLE PEG ASSEMBLY INSTRUCTIONS
Non-Threaded
First remove the axle nut from the wheel. There will be either a retaining washer or a step retaining
washer included. Place this washer between the peg and the frame of the bicycle. Slide the peg onto the
axle, followed by a flat washer and lastly the axle nut. Tighten the axle nut clockwise until the peg fits
snugly against the frame or fork. Repeat for all the remaining pegs.
Non-Threaded
Threaded
This style of peg is threaded to fit the axle. Make sure the axle nut is tight with a 15mm wrench. Place a
screw driver through the mounting holes of the peg and attach the peg to the axle by turning clockwise.
Tighten against the frame or fork for a snug fit. Repeat for all the remaining pegs.
Threaded
PLEASE NOTE: Not all axles are able to accept axle pegs. Please consult an authorized Raleigh dealer
if you have any questions.
51
TRAINING WHEELS
There are two options when attaching the training wheels to the wheel brace. Determine which option
is used on your bicycle and follow the given instructions for that option.
Option 1
First attach the training wheels to the wheel brace. Position a washer on the shoulder bolt. Next, insert
the shoulder bolt through the wheel. Follow with another flat washer then completely thread a hex nut
onto the shoulder bolt. Insert the shoulder bolt through the wheel brace and set the washer on the
shoulder bolt. Lock the training wheel into place by screwing another hex nut onto the shoulder bolt.
Repeat for both training wheels.
Option 1
Option 2
First attach the training wheels to the wheel brace. Insert the shoulder bolt through the wheel. Follow
with a flat washer. Insert the shoulder bolt through the wheel brace and set the washer on the shoulder
bolt. Lock the training wheel into place by screwing another hex nut onto the shoulder bolt. Repeat for
both training wheels.
Option 2
52
ATTACHING TRAINING WHEEL BRACE TO BICYCLE
There are two different braces used to attach the training wheels to the bicycle: the C-Shape Brace and
the Flat Brace. Determine which brace was included with your bicycle and follow
the given instructions for that particular brace.
C-Shape Brace
Remove the axle nut and washer from the rear wheel axle. Place the brace stabilizer washer onto the
axle and align the washer so that the notch on the washer fits into the rear frame drop out. Next, place
the C-shaped wheel brace onto the axle and replace the washer and axle nut. 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.
C-Shape
53
Flat Brace
Remove the axle nut and washer from the rear wheel axle. Place the flat wheel brace onto the axle. Next
place the brace stabilizer washer onto the axle and align it so that the notch fits into the rear frame drop
out. Replace the washer and axle nut. 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.
Flat
54
TRAINING WHEEL STABILIZER BRACKET
Your bicycle may include a stabilizer bracket to attach the training wheel to the bicycle.
First remove the nut and washer from the rear wheel axle. Align the stabilizer bracket onto the brace.
Align the brace and stabilizer bracket on the wheel axle. Replace the axle nut and washer, secure
tightly. The elongated hole on the brace allows for raising and lowering the training wheel to the
proper height.
NOTICE: Not all bicycles will accept training wheels. If your bike did not come with training wheels,
please consult an authorized Raleigh dealer to determine if you can install any.
IT IS VERY IMPORTANT TO CHECK THE TRAINING WHEEL CONNECTION
TO THE BICYCLE. FAILURE TO PROPERLY TIGHTEN MAY CAUSE THE
TRAINING WHEEL TO DISLODGE. PLEASE CONTACT AN AUTHORIZED
RALEIGH DEALER WITH ANY QUESTIONS.
55
PADS
If your bike is supplied with pads, wrap the foam inner cushion around the appropriate bar. Place the
outer cover over the inner cushion and press the hook & loop closure together securely. Turn the pad
so the closure faces the ground.
Pads
56
FINAL CHECK
Install any additional parts that are supplied with your bike.
NOTE: Your bicycle may be equipped with different style components than the ones illustrated.
Reflectors: Attach the white reflector to the front bracket and the red reflector to the rear bracket
using an 8mm wrench or a Phillips head screwdriver. Attach the brackets to the bicycle using the
hardware provided. For some models, the front reflector bracket will be mounted on the front brake
assembly bolt that fits through the fork. It is important to make sure all connections are tightened
securely and that the reflectors are properly angled.
Chainguards: If not already attached, attach the chainguard to the bicycle frame using the clamps
provided. Secure in place making sure the guard does not bind or get caught on the chain.
Tire Pressure: Check tire pressure, inflate to the recommended PSI as stated on the sidewall of the tire.
Kickstand: If your bicycle is equipped with a kickstand, check that the kickstand operates smoothly
and the kickstand bolt is tightly secured.
Front
Reflector
(White)
Rear
Reflector
(Red)
Chainguard
BEFORE RIDING, ENSURE ALL NUTS, BOLTS AND FITTINGS ON THE
BICYCLE HAVE BEEN CORRECTLY TIGHTENED AND ALL ACCESSORIES
ARE SECURED.
57
raleighusa.com
6004 S 190th ST, Suite 101, Kent, WA 98032
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