Schwinn Bicycles | electric bicycle | Owner Manual | Schwinn Bicycles Electric Bicycle Owner manual

Schwinn Bicycles Electric Bicycle Owner manual
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: customerservice@pacific-cycle.com
Mail: P. O. Box 344
4730 E. Radio Tower Lane
Olney, IL 62450
Do not return this item to the store. Please call Pacific Cycle
customer service if you need assistance. You will need your
model number and date code located on the service sticker 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
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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
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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
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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
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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
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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
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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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