Owner’s Manual Hybrid Electric Bicycle This manual contains important safety, performance and maintenance information. Read the manual before taking your first ride on your new bicycle, and keep the manual handy for future reference. To register your bike visit www.schwinnbikes.com/registerbike 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 Brake Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Attach the Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Attaching the Front Fender and Headlight . . . . . . . . . . . 22 Attach the Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Attach the Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Adjusting the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Adjusting the Cable Tension . . . . . . . . . . . . . . . . . . . . . . . 39 Adjusting the Derailleur . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Adjusting the Seat Height . . . . . . . . . . . . . . . . . . . . . . . . . 42 Adjusting the Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Adjusting the Headset . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Adjusting a Threaded Headset . . . . . . . . . . . . . . . . . . . . . 47 Adjust the Bottom Bracket . . . . . . . . . . . . . . . . . . . . . . . . 51 5 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Gear Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Parts Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Hub Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Inflating the Tire Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Repairing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 7 Pedal Assist Electric Bike . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 e-bike Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 The e-bike Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 The e-bike Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Check the Speed Sensor Alignment . . . . . . . . . . . . . . . . 82 e-bike General Maintenance and Care . . . . . . . . . . . . . . 83 Customer Service Information . . . . . . . . . . . . . . . . . . . . . 83 8 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Purchase Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 i 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@example.com Mail: P. O. Box 344 4730 E. Radio Tower Lane Olney, IL 62450 Do not return this item to the store. Please call Pacific Cycle customer service if you need assistance. You will need your model number and date code located on the service sticker 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. 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. 2 Adjust the seat height 1 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 Figure 1.2 Safety 1 Quick-release Levers 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 Seat tube Minimum insertion marks are located on the seat post Quick-release wheel Wheels ❶ Some bicycles will come equipped with quick-release levers for the front wheel. The wheels must be securely locked. Ensure the wheel quick-release lever is firmly locked in place. Figure 1.3 Quick-release seat clamp 2 1 Seat Post ❷ Ensure the seat post’s minimum insertion marks are not visible above the quick-release seat clamp and the clamp is locked in place. Note: See Section 4: Adjusting the Seat Height if adjustments are needed. 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! Chain 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 tires have the proper amount of tread, no bulges or excessive wear. The wheels are properly attached to the bicycle and axle. The tires are properly inflated within the recommended pressures displayed on the tires sidewall. 13 ❷ Parts Identification City Hybrid Bicycle Get to know the parts of your bicycle. This will help with assembly, maintenance, and troubleshooting. Color, style and parts may vary. 1 Handlebar grip Torque (in.-lb) - 2 Rear brake lever 55 -70 3 Shifter cable - 4 Brake cable - 5 Handlebar - 6 Star fangled nut 100-120 18 Tire - 31 Saddle (seat) 7 Stem Binder bolts 145-200 19 Rim - 32 Seat post attaching hardware 130-170 8 Stem spacers 20 Spoke - 33 Seat post - 9 Headset - 34 Seat quick-release (option) - Part name 10 Handle bar adjustment bolt 175-260 - 11 Headlight 15 Front Fender Torque Part name (in.-lb) 30A Brake cable pinch bolt 16 Disk brake (option) 70-85 Part name 17 Wheel axle nut (front) 180-240 30C Brake pad hardware 17A Wheel quick-release (option) 30D Brake spring 17B Wheel axle nut (rear) 240-300 30E Brake pivot bolt 21 Valve Stem 22 Bottom bracket lockring 300 23 Chain guard 12 Caliper brake attaching nut 70-85 24 Crank arm 12 Caliper brake assembly 50-70 25 Pedal 12A Brake cable pinch bolt 50-70 26 Chain wheel - 27 Chain - 28 Rear derailleur - 12B Brake pads 12C Brake pads hardware 50-60 300 300-360 13 Fork - 29 Freewheel - 14 Fork dropout - 30 Linear brake assembly - 14 30B Brake pad 34A Seat post clamp Torque (in.-lb) 50-70 50-60 17-20 60-80 Parts Identification 2 1 30B 30A 6 30E 7 8 9 30D 30C 11 12A 11B 12C 15B 30 33 34 12 13 14 15 23 20 27 26 16 34A 22 21 28 10 31 32 29 3 4 5 2 24 25 17A 17 19 18 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 Seat 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. Handlebar assembly Seat post Frame 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. Headlight Front Fender Pedals 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, steerer tube and result in loss of control, serious injury or death. Ensure the minimum insertion marks on the stem post are not visible above the top of the headset. • Failure to properly tighten handlebar components may result in loss of control, serious injury or death. Always check the handlebar cannot move and is secured to the frame before riding the bicycle. There are two types of stems that attach the handlebar to the steerer tube. It is either a quill or clamp (threadless) stem. Attaching a Quill Stem 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. 3 Handlebar binder bolt(s) Stem binder bolt Stem post 2 Headset Steerer tube Minimum insertion marks 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. ❷ 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 1 Front fork facing forward Figure 3.3 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 (i.e. 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 3.4 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. 2 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 3.5 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. Top cap and bolt 1/8" - 3/16" (3 - 5 mm) 3 Stem pinch bolts 4 5 Stem Figure 3.5 Steerer tube Spacers Headset Figure 3.4 19 19 3 Assembly ATTACH THE BRAKE CABLES 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 There are three brake options, Caliper, Linear Pull and Disc. Brake lever Figure 3.7 Follow these steps if the brake cables are not attached to the brake levers: 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 3 ❷ Press the brake lever towards the grip. Brake cable Cable head Figure 3.8 ❸ Slide the brake cable through the slots and place the cable head into the brake lever. 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 and quick-release. 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. Disc rotor Nut Disc brake caliper body Nutted Front Wheel ❶ Position the front wheel between the front fork legs with the axle resting inside the fork drop outs. Note: If the front wheel has a disc brake insert the disc rotor into the slot on the caliper body as you insert the wheel axle into the fork drop out. Important! Be sure the wheel is as centered as possible between the fork legs. Figure 3.10 Figure 3.11 3 2 ❷ Place the axle washers on the axle and slide it up against 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. 1 Fork dropout Axle 2 Axle washer 3 Axle nut Figure 3.10 21 21 3 Assembly ATTACHING THE FRONT FENDER AND HEADLIGHT Nutted Front Wheel with Round Fender Brace Headlight ❶ Position the front fender so the fender bracket is on the inside of the frame. Align the hole in the bracket to the hole in the fork crown. Figure 3.12 2 3 ❷ Align the hole in the headlight base with the hole in the fork crown. Washer Screw ❸ Place a washer on the screw and insert the screw through the headlight, fork crown and fender bracket. ❹ Place a washer on the screw. 1 Fender bracket ❺ Place the hex nut on the screw and tighten. 4 ❻ Place the rounded fender braces over the small hole on the back of the fork dropout. ❼ Insert the small screws through the rounded fender brace and screw into the fork dropout. Washer 5 Hex nut 7 6 ❽ Attach the wheel and firmly fasten the fender in place. Round fender brace 7 Figure 3.12 22 Assembly 3 Quick-release Front Wheel WARNING! • All quick-release levers should be inspected before every ride to be sure they are fully closed and secure. Failure to properly close a quick-release lever can cause loss of control of the bicycle resulting in injury or death. • Make sure the wheel is properly seated and the quick-release lever is properly closed. ❶ 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. ❷ Locate the skewer from the small parts carton of your bicycle. Figure 3.13 ❻ Slide the wheel into the fork dropout slots. Note: If you have a wheel with disc brakes insert the disc rotor into the center of the disc brake at the same time you are inserting the wheel axle into the fork drop out. Figure 3.14 Important! Be sure the wheel is as centered as possible between the fork legs. Front fork Outer spring 4 3 Adjustment nut Skewer 6 2 Inner spring Quick-release lever Disc rotor ❸ Unscrew the adjustment nut from the skewer, remove outer spring and slide the skewer through the front wheel axle so the quick-release lever is on the side of the bike opposite the chain. ❹ Slide the outer spring over the end of the skewer. Note: The smaller end should be in towards the wheel. ❺ Begin to thread the adjustment nut back onto the skewer, but do not tighten too far. Allow enough play so you can place the axle into the fork drop out. Caliper body Figure 3.14 Figure 3.13 23 23 3 Assembly ❼ Move the quick-release lever into the open position. With one hand on the quick-release lever and one hand on the adjustment nut, start to hand tighten the adjustment nut until you start to feel some resistance against the fork. Figure 3.15 ❽ 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. 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 tension. 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 wheel is securely locked in place. ❾ Re-check that the handlebars are perpendicular to the front wheel. Adjust if needed. Quick-release lever in closed position 7 Important! Only tighten the quick-release with the adjustment nut. Quick-release lever in the open position Figure 3.15 24 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. ❸ Tighten the seat clamp bolt to lock the seat in place. ❹ Check the seat to be sure it does not move. There are two kinds of seat clamps; bolted and quick-release, and two kinds of seat posts standard and micro-adjust. The seat assembly should be adjusted with the seat centered on the rails and level. It is recommended to add some grease to all threads and binders on a bicycle, especially on the outside of the seat post. Otherwise it may corrode over time and not be able to be adjusted again. Seat tube 2 Bolted Seat Clamp ❶ Using a 5 mm Allen wrench, loosen the seat clamp bolt and insert the seat post into the seat tube. Figure 3.16 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. 1 Minimum insertion marks Use a 5 mm Allen wrench to loosen and tighten the seat clamp Figure 3.16 25 25 3 Assembly Quick-release Seat Clamp ❶ Unlock the quick-release lever and insert the seat post into the seat tube. Figure 3.17 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 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. Figure 3.18 2 Seat post Minimum insertion marks on the seat post Quick-release seat clamp Adjustment nut Quick-release lever 1 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. 26 Seat tube Figure 3.17 Minimum insertion marks 3 Figure 3.18 Assembly 3 Micro Adjust Seat with Pillar Seat Post 5 ❶ Place the bottom plate on the pillar seat post. Be sure the holes in the bottom plate and the holes in the seat post are aligned. Figure 3.19 Square nut 4 ❷ Place the washer on the hex bolt and insert the bolt through the bottom hole of the pillar seat post and bottom plate. Top plate ❸ Place the rails of seat into the grooves of the bottom plate. 1 ❹ Place the top plate over the top of the seat rails. The hex bolt should be inserted through the hole in the top plate. ❺ Insert the square nut onto the hex bolt and tighten completely. ❻ Insert the pillar seat post into the seat tube and adjust the seat height up or down until the rider feels they have control of the bicycle and is comfortable. 3 Bottom plate Seat rails 6 2 Pillar seat post 7 Quick-release seat clamp 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. ❼ Lock the seat in place. Note: Refer to the section that pertains to your seat clamping device (bolted or quickrelease) on the previous page for instructions. ❽ Check the seat to be sure it does not move. 6 Bolted seat clamp Figure 3.19 27 27 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 • 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 3.20 ❷ Place the threaded pedal into the threaded hole on the crank arm. 1 5 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. ❹ If the spindle is entering the hole cleanly then use a 15 mm wrench or pliers to tighten completely. ❺ Remove the dust caps and tighten the crank axle nuts using a 15 mm wrench. 28 The left pedal turns counter-clockwise and the right pedal turns clockwise. 2 3 Figure 3.20 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 • 2.5 mm, 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 Figure 4.2 The serial number is located below the bottom bracket Figure 4.1 29 29 4 Adjustments ADJUSTING THE BRAKES Adjusting the Brake Pads 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. Adjusting Linear Pull Brakes Attaching the Brake Cable to the Brake Carrier ❶ Squeeze the two brake arms together until the brake pads touch the wheel rim. Figure 4.3 ❷ With your other hand, pull on the brake cable and insert the end of the “noodle” into the brake carrier. End of “noodle” in the brake carrier Brake carrier 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. 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. ❻ Using the 5 mm Allen wrench, firmly tighten the cable anchor bolt completely. 3 2 Cable anchor bolt 4 Brake cable Brake arm 1 Brake arm 5 mm Allen wrench 5 1/8” gap (both pads) Wheel rim Figure 4.3 30 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 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 3 2 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 Disc Brake Realign the Caliper Body WARNING! • Disc brakes are sharp, keep fingers away from the brake caliper and rotor. If fingers contact the disc brake while the wheel is turning serious injury may occur. Important! Different types of disc brakes may require specific adjustments not covered in this section. If you are unsure of what needs to be done see a qualified bicycle mechanic. Misalignment of the disc brake may be due to the following: • The wheel is not centered. • The caliper body is misaligned. ❶ Using a 5 mm Allen wrench, loosen the two centering adjustment screws. Adjust the caliper body until the gap between the disc rotor and the brake pads in the caliper body is even (1/32" per side). Figure 4.17 ❷ Tighten the centering adjustment screws. 1/32 inch clearance on each side of disc rotor 2 Centering adjustment screws 1 • The brake pads are not centered. Center the Wheel ❶ Rotate the wheel and look at the gap between the rim and fork. If the gap is uneven, loosen the axle nuts and adjust until the wheel and disc rotor are centered. Figure 4.16 Brake pad Wheel should be centered Even space between wheel and fork (both sides) Figure 4.16 Disc rotor Adjust caliper body so disc rotor is centered Figure 4.17 Centering adjustment screws 2 Figure 4.18 37 37 4 Adjustments Center the Brake Pads Attaching the Brake Cable to the Brake Arm ❶ Insert a 1/32" spacer gage between the disc rotor and brake pad. Figure 4.19 ❶ If the brake cable wire is not attached to the brake arm then loosen the cable anchor bolt until you can see a gap large enough for the brake cable wire. Figure 4.19 ❷ Using a 2.5 mm Allen wrench, loosen the set screw. ❸ Using a 5 mm Allen wrench, turn the brake pad adjustment screw to move the brake pad. Turning the pad clockwise moves it towards the disc rotor, counterclockwise moves the pad away from the disc rotor. ❷ Pull on the brake cable wire and place it under the cable anchor bolt. ❸ Tighten the cable anchor bolt. Note: The brake cable should not be "pulling" on the brake arm. ❹ Adjust the pad until the gap between the disc rotor and the brake pads are even (1/32" per side). ❺ Re-tighten the set screw. 1/32 inch clearance on each side of disc rotor 2 Set screw 3 1 4 Brake arm Brake pad adjustment screw 2 Figure 4.19 38 Brake cable wire 3 Cable anchor bolt Figure 4.20 Adjustments 4 Adjusting the Cable Tension ❶ Check that the brake cable tension allows the brake lever about 1/3 of the travel before the brake pads contact the disc rotor. If the cable has stretched or slipped, re-adjust the brake cable tension. Figure 4.21 1 1/3 distance to handlebar 3 2 ❷ At the caliper body, or brake lever, slightly loosen the jam nut that is next to the adjustment barrel. Figure 4.22 ❸ Turn the adjustment barrel to adjust the cable tension. Turning clockwise will loosen the brake cable tension, counter-clockwise will tighten the brake cable tension. ❹ Re-check that the brake cable tension allows the brake lever about 1/3 of the travel before the brake pads contact the disc rotor. When you have the brake tension you want then tighten the jam nut. Brake is correctly adjusted when: • The brake pads do not drag on the disc rotor. Figure 4.21 Caliper body Brake cable 3 Adjustment barrel 2 Jam nut • Both brake pads move away from the disc rotor equally when the brake is released. • When the brake is applied, the brake pads contact the disc rotor before the brake lever reaches about 1/3 of the way to the handlebar. After brake adjustment, squeeze the brake lever as hard as you can several times and re-inspect if the wheel and brake pads are centered. If necessary, repeat brake adjustments. Figure 4.22 39 39 4 Adjustments ADJUSTING THE DERAILLEUR WARNING! Ensure all bolts are secured tightly and the chain does not fall off in either direction. Although the front and rear derailleur is initially adjusted at the factory, you will need to inspect and re-adjust both before riding the bicycle. ❺ Adjust the low limit screw in quarter turn increments until the guide pulley and the largest cog are aligned vertically. ❻ 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. Rear shifter Front shifter 8 Adjust the Rear Derailleur 3 6 2 3 ❶ Begin by shifting the rear shifter to largest number indicated and place the chain on the smallest sprocket. Figure 4.23 Figure 4.23 ❷ Adjust the high limit screw so the guide pulley and the smallest sprocket are lined up vertically. Figure 4.24 ❸ 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. ❹ Shift the rear shifter to gear one and place the chain on the largest cog. High limit screw 2 1 Smallest sprocket 5 Largest sprocket Anchor bolt 6 3 Low limit Barrel screw adjuster Cable Guide pulley Figure 4.24 40 Adjustments 4 Adjust the Front Derailleur WARNING! 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 standing up, or under heavy load, nor pedal backwards after having moved the shifter. This could jam the chain and cause serious damage to the bicycle and/or rider. ❶ Shift both shifters to the smallest number indicated and place the chain on the corresponding cog and chainwheel. ❷ Disconnect the front derailleur cable from the cable anchor bolt. Figure 4.25 ❸ Check the position of the front derailleur; it should be parallel with the outer chainwheel and clear the largest chainwheel by 1-3 mm when fully engaged. ❹ 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. ❺ Reconnect the cable, pull any slack out and tighten the cable anchor bolt securely. ❻ 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. ❼ 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. Cable anchor bolt Barrel adjuster 2 7 1-3 mm clearance between chain wheel and chain guide 3 Chain guide Chain wheel Figure 4.25 41 41 4 Adjustments 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. Bolted Seat Clamp Seat tube ❶ Using a 5 mm Allen wrench, loosen the seat clamp bolt. Figure 4.26 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. 2 1 Minimum insertion marks Use a 5 mm Allen wrench to loosen and tighten the seat clamp ❸ Tighten the seat clamp bolt to lock the seat in place. ❹ Check the seat to be sure it does not move. 42 Figure 4.26 Adjustments 4 Quick-release Seat Clamp ❶ Unlock the quick-release lever. Figure 4.27 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. Figure 4.28 2 Seat post Minimum insertion marks on the seat post Quick-release seat clamp Adjustment nut Quick-release lever 1 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, 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. Seat tube Figure 4.27 Minimum insertion marks 3 Figure 4.28 43 43 4 Adjustments ADJUSTING THE HANDLEBAR Align the Handlebar (with quill stem) WARNING! • Improper adjustment of the handlebar may result in damage to the stem post, steerer tube and result in loss of control, serious injury or death. Ensure the minimum insertion marks on the stem post are not visible above the top of the headset. • Failure to properly tighten handlebar components may result in loss of control, serious injury or death. Always check the handlebar cannot move and is secured to the frame before riding the bicycle. 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 and move the handle bar left or right until it is aligned with the front wheel. Figure 4.31 ❸ Tighten the stem binder bolt and check the handlebar is securely attached and cannot move. Adjusting the Handlebar Height Instructions for adjusting the handlebar height depend on whether your bicycle has a quill or clamp (threadless) stem. Figure 4.29 and 4.30 Quill Stem Stem binder bolt Handlebar binder bolt(s) Steerer tube Figure 4.29 44 Stem binder bolt 2 Move the handlebar left or right until it is aligned with the front wheel Threadless Stem Handlebar binder bolt(s) Pinch binder bolts Figure 4.30 Figure 4.31 Adjustments 4 Align the Handlebar (with threadless stem) Adjust the Handlebar Angle (all stem types) ❶ Stand in front of the handlebar and hold the front wheel between your legs. ❶ Using a 6 mm Allen wrench loosen the handlebar binder bolt(s). Figure 4.33 ❷ Using a 6 mm Allen wrench, loosen the pinch binder bolts and move the handlebar left or right until it is aligned with the front wheel. Figure 4.32 ❷ Rotate the handlebar into the desired position. ❸ Tighten the stem binder bolt and check the handlebar is securely attached and cannot move. Move the handlebar left or right until it is aligned with the front wheel Pinch binder bolts 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, Fig. 1.2: Seat Height and Handlebar Reach for guidelines. ❹ Tighten the handlebar binder bolt(s) and check the handlebar is securely attached and cannot move. 2 2 1 Figure 4.32 Loosen handlebar binder bolt(s) Figure 4.33 45 45 4 Adjustments Adjust the Handlebar Angle (with adjustable handlebar) ❶ Using a 5 mm Allen wrench loosen the bolt at the front of the stem. Important: Do not loosen the bolts on the side of the stem. Figure 4.34 ❷ Grasp the stem of the handlebar and rotate to the desired angle. Figure 4.35 ❸ Re-tighten the handlebar bolt at the front of the stem, and check the handlebar is securely attached and cannot move. Do not loosen the side bolts ❹ Once you have adjusted the angle of the handlebar check the angle of the reflector (if mounted on the handlebar) and cables to be sure they are facing forward. Refer to Section 1, Fig. 1.2: Seat Height and Handlebar Reach for guidelines. 1 Figure 4.34 2 Grasp here and rotate to desired angle 3 Figure 4.35 46 Adjustments 4 ADJUSTING THE HEADSET The headset is an assembly of parts that connects the front fork and the head tube of the frame. It is the rotational interface that enables the fork to turn. There are two types of headsets: threaded and threadless. 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. Adjusting a Threaded Headset A typical threaded headset consists of two cups that are pressed into the top and bottom of the head tube. Inside the two cups are bearings which provide a low friction contact between the bearing cup and the steerer. The short tube through which the steerer of the fork passes is called the head tube. Adjustment of the headset is needed if the headset is too loose (shakiness), too tight (stiffness). Note: It is possible that the bearings have become worn or damaged and cause stiffness. Replacement of the parts may be necessary. 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. Important! Use care with suspension forks, because the legs may have play in sliders. Grab upper portion of fork. Figure 4.36 1 Headset 2 Figure 4.36 47 47 4 Adjustments ❸ With the front wheel resting on the ground, use an adjustable, or headset wrench and hold the upper threaded race in place. Figure 4.37 ❹ Loosen the locknut clockwise about 1/32nd of a turn. Note: The front wheel must be straight to gauge adjustment. ❺ By hand, screw the upper threaded race down until bearings begin to bind. Then back the race off about 1/8 turn. ❻ Tighten the locknut and test that there is no shakiness or stiffness (ie. play) in the headset. Repeat steps 3 - 6 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. Loosen top locknut Stem Locknut Upper threaded race Top tube Head tube Lower race 2 Hold upper threaded race in place Figure 4.37 48 Figure 4.38 Adjustments 4 Adjusting a Threadless 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. 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. Important! Use care with suspension forks, because the legs may have play in sliders. Grab upper portion of fork. Figure 4.39 1 Headset 2 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. Figure 4.39 49 49 4 Adjustments ❶ Loosen the top cap bolt and remove the top cap. Important! Do not disassemble the headset or loosen 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 4.40 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 4.41 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 Steerer tube Stem 1/8" - 3/16" (3 - 5 mm) 2 Spacers Figure 4.41 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 4.40 50 Adjustments 4 ADJUST THE BOTTOM BRACKET Three piece bottom bracket: Adjustable Typically the bottom bracket contains four major pieces: lockring, adjustable cup, spindle and fixed cup. The lockring has notched rings and the adjustable cup may have holes for a pin spanner, or notches for a wrench. The fixed cup will have wrench flats, but no lockring. Cups and the spindle may be removed and replaced separately. A set of round ball bearings are found in each cup, typically eleven balls per side of 1/4 inch diameter. This type of bracket may be cleaned, greased and adjusted. 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 4.42 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. ❹ Repeat process of checking for play and re-tightening cone a slight amount until no play is felt. Bottom bracket shown with crank arm removed Lockring Fixed cup Adjusting cup Bearings Spindle Bearings Figure 4.42 51 51 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 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. • Disc brake rotors become hot during use and can burn the skin if contacted. Do not touch or come in contact with the disc rotor when it is hot. Allow it to cool before touching. You may operate one brake at a time, or all together, however, be careful to pay close attention to front brakes locking up. To avoid this: • Apply both brakes simultaneously, while shifting your body weight back slightly to compensate for braking force. • As terrain changes, the rider must practice and learn how the 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. • 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. Left side brakes the front wheel Right side brakes the rear wheel 8 3 Hand operated brakes have a separate hand lever to operate front and rear brakes. Front hand brake levers are located on the left side of the handlebar, and rear hand brake levers are located on the right side of the handlebar. Figure 5.1 52 2 6 3 Figure 5.1 Use 5 GEAR OPERATION WARNING! Improper shifting can result in the chain jamming, or becoming derailed resulting in loss of control, serious injury or death Always be sure the chain is fully engaged in the desired gear before pedaling hard. Avoid shifting while standing up on the pedals or under load. Multi speed bicycles can have internal or derailleur gear systems. Important! Best practices for proper shifting: • Pedal the bicycle with little pressure on the pedals, and move the shifter one gear at a time, ensuring that the chain is fully engaged in that gear before applying more pressure on the pedals. • For bicycles with 3 front chain rings; avoid “Cross Chaining”, which is the position when the chain is in the smallest cog in the rear combined with the inner or smallest chain ring in the front, or the largest cog in the rear and the outer or largest chain ring in the front. These gear positions put the chain at the most extreme angle and can cause premature wear to the drivetrain. Bicycles with 3 front chain rings have enough gear “overlaps” that these gears are not needed. Figure 5.2 • It is OK to ride the whole time in only one gear if this is comfortable. • Once you have successfully shifted gears, it is OK to start to pedal hard if desired. • Pedaling hard while shifting can cause the chain to skip and not engage the appropriate gear. • Backpedaling should be avoided on derailleur bikes because the chain can jam and cause the bike to become unstable. See Assembly and Maintenance for further information on proper gear adjustment. Three chain rings Avoid these extreme angles of the chain Figure 5.2 • Shift only while pedaling forward and seated. When shifting, lessen the pressure exerted on the pedals during the shift. 53 53 5 Use Using the Rear Shifter Trigger-style Shifter The rear shifter (right) will have an indicator that reads either low to high or a series of numbers from 1 and up. Low or “1” is the lowest gear. This is used for slower riding, hill climbing, or to allow for easier pedaling. It is recommended to start off in this gear and move through the gears as speed increases as needed, or comfortable. Note: Not all models have a front shifter. The front (left) shifter will have an indicator that reads either low to high or a series of numbers from 1 and up. Low or “1” is the lowest gear. The front shifter acts much like the rear shifter, but the change between gears is greater. This means that one shift at the rear derailleur will be a subtle change in pedaling speed, but one shift at the front derailleur will be a large change in pedaling speed. Think of the front shifter as a range; low and high or low, medium, and high. Low is used for slower riding, hill climbing, or to allow for easier pedaling. It is recommended to start off in this gear and move through the gears as speed increases as needed, or comfortable. Rear shifter 8 Using the Front Shifter Front shifter 6 1 3 2 Pull down with index finger to shift gears 3 Push in with thumb to shift gears Figure 5.3 Twist-style Shifter Front shifter Rear shifter 1 To Use the Trigger-style Shifter Rear shifter: Use your index finger to shift up to a higher gear, and your thumb to shift down to lower gear. Left shifter: Use your index finger to shift down to a lower gear, and your thumb to shift up to higher gear. Figure 5.3 To Use the Twist-style Shifter Turn the area of the handlebar grip closest to the gear numbers to the desired gear level. Figure 5.4 54 Twist to change gear level Figure 5.4 Use 5 SECURITY Service sticker is located above the bottom bracket 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 serial number, generally located on the frame underneath the bottom bracket. Figure 5.5 • 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. The serial number is located below the bottom bracket Figure 5.5 • 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 5.6 • 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 5.6 55 55 6 Maintenance 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 56 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. Maintenance 6 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 Light oil or grease All pivot points should be lubricated (more often in severely rainy or muddy conditions). Wipe off any excess oil. Lithium based grease Remove cable from casing. Grease entire length. Wipe off excess lubrication from other surfaces. Derailleur Systems Brake cables Brake lever and caliper pivot points Light oil Shifting cables Thin layer of grease Two to three drops from oil can Clean and 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®). 57 6 Maintenance PARTS MAINTENANCE Tires Frequency: Inspect and maintain at least each use. Inspect Tire Inflation Action Maintenance Check tire pressure. Inflate tire to the pressure indicated on the tire sidewall. 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. 58 Maintenance 6 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. 59 6 Maintenance 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. 60 Maintenance 6 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. ❶ Check to make sure neither locknut is loose. ❷ To 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. ❸ Rotate the adjusting cone as needed to eliminate free play. ❹ Re-tighten the locknut while holding the adjusting cone in position. ❺ Re-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: ❶ Remove the valve cap and add air. ❷ Check the tire is evenly seated on the rim, both sides. ❸ Spin the wheel and check for high and low areas. ❹ Complete inflation to the recommended psi found on the sidewall of the tire. ❺ Be sure the tire is evenly seated on the rim, both sides. If not, release some air and repeat steps three through six. ❻ Check for dirt in the valve cap or stem. Clean dirt from cap or stem. ❼ Securely replace the valve cap on the stem. 61 6 Maintenance 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: ❶ Match tube size and tire size (see tire sidewall for size). ❷ Remove the wheel from the bicycle. Deflate the tire tube completely. ❸ Squeeze the tire beads into the center of the rim. ❹ Opposite 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. ❺ Remove tube. Release second tire bead. ❻ Remove tire. ❼ Carefully inspect inside of the rim and tire for the cause of the flat. ❽ Inflate the tube ¼ full and place inside tire. 62 ❾ Insert the valve stem through valve stem hole in rim. ❿ Start 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). Maintenance 6 TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Gear shifts not working properly • Derailleur cables sticking/stretched/ damaged • Front or rear derailleur not adjusted properly • Indexed shifting not adjusted properly • Lubricate/tighten/replace cables • Adjust derailleurs • Adjust indexing Slipping chain • Excessively worn/chipped chain wheel or freewheel sprocket teeth • Chain worn/stretched • Stiff link in chain • Non compatible chain/chain wheel freewheel • Replace chain wheel, sprockets and chain • Replace chain • Lubricate or replace link • Seek advice at a bicycle shop Chain jumping off • Chain wheel out of true freewheel sprocket or • Chain wheel loose chain wheel • Chain wheel 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 chain wheel/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 63 6 Maintenance Problem Possible Cause Remedy Freewheel does not rotate • Freewheel internal pawl pins are jammed • Lubricate. If problem persists, replace freewheel 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 64 Maintenance 6 Problem Steering not accurate Frequent punctures Possible Cause Remedy • Wheels not aligned in frame • Align wheels correctly • Headset loose or binding • Adjust/tighten headset • Front forks or frame bent • Take bike to a bike shop for possible frame realignment • Inner tube old or faulty • Replace inner tube • Tire tread/casing worn • Replace tire • Tire unsuited to rim • Replace with correct tire • Tire not checked after previous puncture • Remove sharp object embedded in tire • Tire pressure too low • Correct tire pressure • Spoke protruding into rim • File down spoke 65 7 Pedal Assist Electric Bike ❼ Pedal Assist Electric Bicycle WARNING! Disregarding or misunderstanding of the following safety warnings, the safety warnings in the manuals associated with the e-bike parts, and safety labels on the e-bike could result in serious injury or death. • Anyone assembling, using, maintaining, transporting or storing this e-bike must read, understand, and follow these safety warnings before performing any of the actions stated. If you have any questions regarding the safety warnings and labels call Schwinn Customer Service at 1-800-626-2811 before performing any of the actions stated. WARNING! This product can expose you to chemicals including lead, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov OPERATION General • Only use the e-bike and the drive assist system for safe, recreational riding. Use of the e-bike for a purpose it was not intended for is dangerous and could result in property damage, serious injury or death. 66 • Refer to the drive assist system manufacturer’s manual for instructions regarding all the components of the drive assist system (e.g. Battery, Drive Charger, Display/e-bike Computer). Always follow the manufacturer’s instructions for intended use and limitations. Personal Restrictions • Use of this e-bike by persons (including children) with reduced physical, sensory or mental capabilities or persons lacking experience and knowledge in the use of the e-bike could result in serious injury or death. The owner of this e-bike must ensure this product is not used by people with the conditions described above. Always follow the rules, regulations and laws (including age limits) related to the use of an e-bike in its area of use. • A child may not realize or understand the e-bike has moving parts and components (e.g. battery). Never allow children to play or come into contact with the e-bike or its parts. Always follow all rules, regulations and laws regarding age limits and operation in the e-bike area of use. Drive Assist System • Turning the drive assist system ON before you are seated and have both hands on the handlebar could result in loss of control of the e-bike. Always have total control of the e-bike and be ready to ride before engaging the drive system. Pedal Assist Electric Bike 7 WARNING! • The e-bike's drive assist system will increase or decrease the acceleration of the bike. It is the rider’s responsibility to appropriately judge the riding conditions (e.g. road conditions, tight turns) and current speed of the e-bike before adjusting the drive assist system. Anticipating changes in speed and providing time to react appropriately is critical to using the drive assist system. Always check your surroundings and conditions before accelerating and set the assistance level to lowest assist, or off, when descending hills. • The drive assist system will not function properly without the display (e-bike computer) properly attached to the base. If the display (e-bike computer) becomes disconnected from the base during a ride, the speed of the e-bike will change. Unexpected deceleration may impact your riding conditions and other vehicles near you. Always be prepared to pull off to a safe area in case the display (e-bike computer) becomes disconnected from the base. Riding • Improper use of the drive assist system may result in riding at unsafe speeds and cause accidents resulting in serious injury or death. Do not accelerate using the drive assist system in situations where there is a possibility of causing harm to people, animals, or property. Always maintain control of the e-bike and operate at a safe speed. • Riding the e-bike through water could result in loss of control and damage to the drive assist system. Do not ride into, or attempt to ride through, water or sub-merge any part of the e-bike. • The e-bike is heavier than ordinary bikes and may result in tip-over, serious injury, or death if not parked properly. Always park the e-bike in a safe area away from children, animals, and property (e.g. vehicles). Always park the e-bike on a level surface so it cannot tip over. If the e-bike is equipped with a kickstand: • Riding with the kickstand in the down position may result in unexpected contact with the ground or other objects causing loss of control. Always ensure the kickstand is in the up position and securely locked in place before riding the e-bike. • Sitting on the e-bike with the kickstand down may result in the e-bike tipping over. Never sit on the e-bike when it is only supported and stabilized by the kickstand. The kickstand is not designed to support the weight of a person. • Riding with a bike trailer that is incompatible with the e-bike could create dangerous riding conditions. Always confirm with the bike trailer manufacturer the bike trailer is compatible with the e-bike before attaching a bike trailer and riding. • Overloading a rear rack could create dangerous riding conditions. Always observe the maximum weight limit stated by the rack's manufacturer. Never overload the rear rack. • An improperly secured load on a rear rack could create dangerous riding conditions. Always ensure the load on the rear rack is properly secured before riding. 67 67 7 Pedal Assist Electric Bike WARNING! BATTERY Failure to observe the following warnings could result in electrical fires, explosion, severe burns or electrocution. General • The battery and battery charger contain hazardous materials. Always keep the battery and battery charger away from children, animals, or persons incapable of understanding the potential hazards. • The battery and battery charger contain no serviceable parts. Do not open, disassemble, or modify the battery or charger. • Improper handling of the battery and battery charger may result in electrical fires, explosion, severe burns or electrocution. • Do not move the battery or battery charger during charging • Do not hold the battery charger during a thunder or lighting storm • Do not plug or unplug the battery charger with wet hands • Do not place any items on the battery charger • Do not place the battery charger in liquids or metals • Overcharging the battery could result in electrical fires, explosion, or severe burns. Always disconnect the battery from the battery charger when the battery is fully charged. Unplug the battery charger from the wall outlet when not in use. 68 • A damaged battery or battery charger (e.g. cable, plug or housing) may result in leakage of hazardous materials or be a potential source of sparking and fire. Always examine the battery and battery charger before each use. Never charge a damaged battery or use a damaged battery charger. Battery Charger Compatibility • Charging the battery with an incompatible battery charger may result in electrical fires, explosion, severe burns or electrocution. Ensure the battery charger and the A/C outlet are the same voltage before charging the battery. Only charge the battery using the battery charger specified by the manufacturer’s instructions. Never use the battery charger to charge any other batteries. Battery Charging Environment • Remove the battery from the e-bike before charging and locate both the battery and battery charger indoors, in a clean, dry area with good ventilation to charge. Always place the battery and battery charger on an even surface. Ensure the area is free from dust, moisture, combustibles and keep the battery charger ventilation openings unobstructed. If applicable, always turn the power switch on the battery Off before attaching. • Contact between the battery contacts and metal objects such as paper clips, coins, keys, nails, screws or other metal items could result in shorting out the battery and cause electrical fires, explosion, or severe burns. Pedal Assist Electric Bike 7 WARNING! • The battery should be charged, discharged and operated in the following conditions: • Charge (Temperature Range): 0 – 45º C (0 – 113º F) • Discharge (Temperature Range): -20 - 45º (-4 - 113º F) • Operation (Relative Humidity): <80% Battery Disposal • Battery and battery charger contain regulated materials and must be disposed/discarded in accordance with national and/or local laws. Do not discard the battery and battery charger into fire, water or ordinary household waste/ garbage. Always dispose the battery and battery charger at an approved waste facility/recycler. STORAGE • Unexpected activation of the drive assist system could result in serious injury or death. Always turn OFF the drive assist system, remove the key and display unit, and remove the battery from the e-bike when storing the bike. Place the parts in a secure location. • Overheating of the battery could result in electrical fires or explosion. Always store the battery and battery charger in a well ventilated area at moderate temperatures. TRANSPORTATION • The battery is subject to hazardous materials regulations when in transit. Always contact the proper authorities regarding the requirements to transport the battery. Do not transport the battery without insulating the battery contacts, properly packaging the battery, applying required safety labels, and use of an authorized shipping container. Never transport a damaged battery. • The battery must be removed from the e-bike before transporting the bike on an aircraft. Always contact the air carrier for specific requirements. MODIFICATIONS General • Dealers and owners MUST NOT change, alter, or modify in any way the original components of the bicycle or driveassist system (e.g. modifying the drive unit or software). Only use software updates authorized by Schwinn. Failure to do so may void the product warranty. • Attempts to “hot-rod” or “improve” the speed of the bike are dangerous to the rider. Only use specified Schwinn and/ or manufacturer drive-assist service and replacement parts. Failure to do so may void the product warranty. Kickstand • Improperly installing a kickstand could result in the e-bike being unstable when parked and tipping over. A kickstand must only be installed by a professional bike mechanic. The kickstand must be safely compatible with the e-bike frame. The e-bike frame must not be modified to fit the kickstand. 69 69 7 Pedal Assist Electric Bike WARNING! Rear Rack • Improperly installing a rear rack could result in the e-bike being unstable when carrying weight and create dangerous riding conditions. A rear rack must only be installed by a professional bike mechanic and must be compatible with the e-bike frame. The e-bike frame must not be modified to fit the rear rack. Drive Assist System • Modifying the e-bike and drive assist system could result in damage to the drive system, faulty or dangerous operating conditions, or violation of rules, regulations and laws related to the use of an e-bike. Never modify the e-bike or its parts for any reason. MAINTENANCE • There are no user serviceable elements incorporated into the motor, motor controller, battery, battery charger, throttle, or wiring harness of your e-bicycle. DO NOT ATTEMPT TO DISASSEMBLE OR ADJUST ANY OF THESE COMPONENTS. Doing so may cause extensive damage to these components, will void your warranty, and may cause a hazardous condition. If you cannot resolve a problem, contact Schwinn Customer Service at 1-800-626-2811 for all service questions. 70 • Performing maintenance on the e-bike with the drive assist system active could result accidental activation of the drive assist system. Always remove the battery from the e-bike before performing maintenance. • Cleaning ‘live’ electrical components may result in shock, sparks, physical personal injury and damage to the electrical component(s). Always de-energize the electrical components (e.g. battery, display) before cleaning. Pedal Assist Electric Bike 7 NOTICE Cleaning • Contact between fluids (e.g.: water, cleaning products) and electrical components may cause damage to the components. It is recommended that you use a non-static cloth with a minimal amount of cleaning fluid. Do not soak the cloth with cleaning fluid. • Cleaning and drying the bicycle with a pressure washer or compressed air may force contaminants into sealed areas, electrical connections, and components which may cause damage, corrosion, or result in accelerated wear. Do not use a pressure washer or compressed air to clean and dry the bicycle. • It is possible that an e-bike has a Vehicle Class Designation in its area of use (e.g.: California, USA). The Vehicle Class Designation may define the types of e-bikes, e-bike identification and areas for legal use. They may include any required additional equipment, registration, and applicable rider age restrictions. It is the responsibility of the owner and user to understand and follow all rules, regulations, and laws specified in the Vehicle Class Designation. • Do not rely on the kickstand to stabilize the bicycle during cleaning. Cleaning the bicycle in an unstable position may result in tip-over, unexpected movement and cause damage to the bicycle. Always secure the bicycle so it is in a stable, secured position during cleaning. Compliance / Regulation • It is beyond the scope of this manual to identify all rules, regulations and laws related to the use of an e-bike in its area of use. Failure to comply with all rules, regulations and laws may endanger the e-bike user and other people, animals, and property. It is the e-bike owner and user’s responsibility to identify, be aware of, and follow all rules, regulations and laws necessary for legal compliance in its area of use. 71 71 7 Pedal Assist Electric Bike E-BIKE PARTS The following components are exclusive to the Schwinn Pedal Assist Electric Bike. Please see pages 14 - 15 of the this Owner’s manual for any other parts identification. Note: Your e-bike parts will vary depending on your model. Part name 1 Power assist adjuster 2 Keypad 3 Display unit 4 Battery charger 5 e-bike battery 6 e-bike battery keys 7 Mid-drive motor Speed sensor and magnet unit Rear-hub motor 8 9 BAFANG 1 4 2 SERVICE MENU km/h mile/h 3 TRIP TOTALMAXSAVG TO GO km/hd mile/h WhAhV TempCharg RANGE V/cell WALK 1 8 3 4 SERVICE MENU BATT 9 2 5 km/h mile/h TRIP TOTALMAXSAVGRANGE km/h mile/h WhAhV V/cell Temp WALK 1 2 3 4 5 5 6 7 72 Figure 6.1 Pedal Assist Electric Bike 7 THE E-BIKE BATTERY Charging the Battery ❶ Insert the charger probe into the charger port on the e-bike battery. Figure 6.2 ❷ Insert the pronged end of the battery cord into the battery charger. e-bike battery Battery capacity level indicator ❸ Insert the AC plug into an AC outlet. 4 ❹ The red indicator light turns on and will remain red until it is fully charged. The indicator light turns green once the battery is fully charged. Note: Only use the battery charger that is provided with your e-bike to charge the battery. 1 Battery Charger Battery Capacity Levels The level indicator on the top of the battery shows the power level remaining in the battery. 5 Bars: 100% capacity, fully charge 4 Bars: 60-80% capacity 3 Bars: 40-60% capacity 2 Bars: 20-40% capacity 1 Bar: 20% capacity of battery. 2 3 Figure 6.2 73 73 7 Pedal Assist Electric Bike The Battery Keys • Do not ride the e-bike while the key is in the battery lock. • Always keep the battery compartment locked. • If a replacement battery key is needed, you will need to provide the number found on the key. Write the key number down and keep it in a safe place. Figure 6.3 • The battery lock can become dry and difficult to use after prolonged riding. • Tip! Whenever you lubricate your bike chain, place a few drops of chain oil on the key, insert the key and operate the lock, then remove and wipe the key clean. H272 Battery key number Figure 6.3 Battery Insertion and Removal To Insert the battery: Figure 6.4 ❶ Insert the bottom end of the battery into the bottom section of the battery bracket. 2 ❷ Rotate the top end of the battery into top section of the battery bracket until it snaps into place. 1 Figure 6.4 74 Pedal Assist Electric Bike 7 Battery Maintenance • Keep the battery away from severe vibrations, impact, extrusion, direct sunshine and water. • Examine the battery and charger for damage, especially the cable, plug and housing. Do not charge the battery if either is visibly damaged. Care Use a damp cloth to clean the battery and the plastic housing. Transporting and Storing the Battery Before storing for long periods: Fully discharge the battery, then charge the battery for 2 - 3 hours. • Store the battery in a well ventilated area. • During storage you should charge the battery every 2 months. • Store the battery in a clean, dry area. • Do not store the battery near corrosive materials. • Do not store the battery near heat sources. • Disconnect the battery from the power source before storing. • Store the battery in temperatures between 32º F - 131º F, with a relative humidity of 5 - 65% RH • The battery can be transported by sea, air, and automobile. • The battery should be packed into a carton when transporting FCC WARNING WARNING! Any changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment. Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: • Reorient or relocate the receiving antenna. • Increase the separation between the equipment and receiver. • Connect the equipment into an outlet on a circuit different from that to which the receiver is connected • Consult the dealer on an experienced radio/TV technician for help. 75 75 7 Pedal Assist Electric Bike Battery Troubleshooting Problem Cause Solution No output voltage Cable is disconnected from the battery. Connect the output cable/wire to the battery according to the manual Power indicator off Battery is out of power. Display unit is not fully docked. Charge the battery Check display unit is fully docked The battery cannot be charged The connections between the charger, battery Check the connections to the battery, and/or outlet are not totally connected. charger and outlet and make sure they are completely connected. Battery is already fully-charged. THE E-BIKE DISPLAY The e-bike comes equipped with different styles of computers. The following information may vary depending on your model. ❶ Attach the Display to the Bracket Note: Not all models come equipped with a computer display. ❶ Slide the display into the display bracket until it snaps into place. Figure 6.5 Figure 6.5 ❷ Adjust the angle of the display so it can be easily viewed while riding. Figure 6.6 ❷ Figure 6.6 76 Pedal Assist Electric Bike 7 Turning the e-bike On and Off e-bike Display with Keypad ❶ Press and hold the power button for 2 seconds to power on the display. Figure 6.7 ❷ Press and hold the power button again for two seconds to power off the display. Note: If the bike is not used, after 5 minutes the display will automatically turn off. ❶ Hold for 2 seconds e-bike with Power Assist Adjuster ❶ Press the power button to power on the computer on. Figure 6.8 Figure 6.7 ❷ Press the power button to turn the computer off. BAFANG ❶ Figure 6.8 77 77 7 Pedal Assist Electric Bike e-bike Display Overview Figure 6.9 For detailed information on your e-bike display please see the e-bike display manual that is shipped with your e-bike. Note: Display styles and menu modes will vary depending on your model. ❶ Battery level indicator: The indicator has a 10-bar level indicator. ❷ USB charge ❸ Headlight indication: There are multiple levels of backlighting that show when the headlight or backlight are on. Automatic light-sensitive lights: If equipped the headlight, taillight and display light will be automatically turned on/off depending on lighting conditions. ❹ Error Display: The wrench service is needed. icon will be appear when ❺ Menu: Sets the various parameter settings. See your e-bike display manual for detailed information on your model. ❻ Speed display: Indicates the speed in km/h or mph. Displays the real-time speed as SPEED, ❼ Max and Avg: The maximum speed as the MAX and the average speed as AVG. ❽ Remaining mileage: Range remaining with current battery level. 78 ❾ Level Indication: Sets power levels between 1 to 5. The chosen level will be displayed. Note: If there is no numeric display, it means that there is no assistance by the motor. ❿ Walk assistance: When the rider is walking and pushing the e-bike will be displayed. ⓫ Distance Indication: Displays the distance depending on the setting. ⓬ Distance Mode: The maximum distance displayed is 99999. Single-trip distances TRIP or the total distance TOTAL can be displayed. ⓭ Speed Mode: Max speed: maximum speed (MAX mph). Average speed (AVG/mph), ⓮ Service: When there is a need for maintenance SERVICE will be displayed. Computer Keypad ⓯ Plus button: Scrolls up and down. Increases assist. ⓰ Minus button: Scrolls left to right. Decreases assist. ⓱ Headlight button: Turns backlight feature on/off ⓲ Power button: Turns the display on and off. ⓳ Information button: Press to move through modes. Pedal Assist Electric Bike 7 ❶ ❷❸❹ ❶ ⓮ ❺ SERVICE MENU BATT ⓮ SERVICE MENU km/h mile/h ⓭ ⓬ ⓫ ❿ TRIP TOTALMAXSAVG TO GO km/hd mile/h WhAhV TempCharg RANGE V/cell WALK 1 2 3 4 5 ❺ ❻ ❼ ⓭ ⓬ ❸ ⓫ ❿ km/h mile/h ❻ ❹ TRIP TOTALMAXSAVGRANGE km/h mile/h WhAhV V/cell Temp WALK 1 2 3 4 ❼ ❾ 5 ❽ ❾ ⓯ ⓰ ⓱ ⓲ ⓳ Figure 6.9 79 79 7 Pedal Assist Electric Bike Using the Motor Assist Levels Note: Display screens may vary in style. e-bike Display with Keypad In the manual gearshift mode, press the plus button or minus button to choose the desired level of support by the motor. The lowest level is level 1, the highest level is 5. When the display in on, the default mode is level 1. When there is no numeric mode display, there in no power assistance. Figure 6.10 e-bike with Power Assist Adjuster In the manual gearshift mode, press the Up button or Down button to choose the desired level of support by the motor. The lowest level is level 1, the highest level is 5. When the display in on, the default mode is level 1. When the display is on, the default model has the first bar illuminated. When no bars are illuminated, there is no power assistance. Figure 6.11 km/h TRIP km/h TRIP km km/h TRIP km km WALK 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 Figure 6.10 BAFANG Figure 6.11 80 Pedal Assist Electric Bike 7 Switching Between Modes Briefly press the mode button to switch between distance and speed Single-trip distance (TRIP km) > total distance (TOTAL km) > maximum speed (MAX mph) > average riding speed (AVG mph) > remaining range (TO GO km) > Power (w) > Calorie (c) are displayed in successive order. Note: Display screens may vary in style and modes available. Figure 6.12 km/h TRIP km/h TOTAL km km/h MAXS km km/h km/h TO GO TO GO km km/h km km/h W 1 2 3 4 5 Single-trip distance 1 2 3 4 5 1 Total distance 2 3 4 5 1 Maximum speed 3 4 5 Remaining range 4 5 1 2 3 4 5 Calorie km/h AVG 2 3 Power km/h 1 2 1 2 3 4 km/h km 5 Average riding speed Figure 6.12 81 81 7 Pedal Assist Electric Bike CHECK THE SPEED SENSOR ALIGNMENT If your e-bike is equipped with a speed sensor you may need to adjust the alignment of the speed sensor to the magnet unit before using your e-bike. The speed sensor is located on the inside of your chain stay. Figure 6.13 To make this adjustment: ❶ Slide the magnet along the spoke until the center of the magnet is aligned with the center of the speed sensor’s induction zone. ❷ Be sure the space between speed sensor and the magnet is between 5 mm and 25 mm. ❸ Check that the magnet is secured firmly to the spoke. Tighten if necessary. Inside of chain stay ❷5 - 25 mm ❸ ❶ Magnet 82 Spoke Figure 6.13 Pedal Assist Electric Bike 7 E-BIKE GENERAL MAINTENANCE AND CARE CUSTOMER SERVICE INFORMATION • The e-bike is designed to be totally waterproof to and to withstand wet riding conditions. However, do not deliberately immerse the ebike in water. Servicing Information • Handle the e-bike carefully. Avoid subjecting it to any strong shocks. The label on the battery and motor contain information you may need if servicing is needed. Figure 6.14 Battery Label • Do not modify the system. Doing so may lead to a malfunction of the system. Contact Schwinn Customer Service at 1-800-626-2811 regarding: Model Number • Information related to product installation and adjustments. Serial Number • Problems with this product • Maintenance and use of the product • Software updates Motor Label RM G020.350DC Model Number 14010001 36V 350W Serial Number Figure 6.14 Note: The label shown in Figure 6.14 is for visual reference only. The label on the battery equipped with your e-bike may differ. 83 83 8 Warranty ❽ Warranty Parts All other parts of the bicycle, except Pedal Assist Components and Normal Wear Parts, are warranted against defective materials and workmanship for as long as the initial consumer purchaser has the bicycle, subject to the Terms and Conditions of this Limited Warranty. Pedal Assist Components (battery, motor and head module) are warranted against defective materials and workmanship for 2 years from original date of purchase. 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. 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. Pacific Cycle · PO Box 344 Olney, IL 62450 84 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. This 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, theft, or failing to follow the instructions and warnings in the Owner’s Manual. Claims involving these issues will not be honored. 4. 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. 5. This warranty does not apply to damage due to improper installation of parts, installation of any kind of unauthorized 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. Warranty 8 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: Service sticker is located above the bottom bracket Address: City: State: Date Purchased: Place of Purchase: Model and Brand Information: Wheel Size: Model Number: Date Code: Serial Number: Color: Serial number is located below the bottom bracket Figure 7.1 85 WWW.SCHWINNBIKES.COM 4902 Hammersley Road Madison, WI 53711 Service: 1-800-626-2811 www.pacific-cycle.com WARNING: This product can expose you to chemicals including lead, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov. OMSCE ©2017 Pacific Cycle, Inc.
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