Schwinn Bicycles Tandem Bicycle Owner's manual

Schwinn Bicycles Tandem Bicycle Owner's manual
Owner’s Manual
Tandem 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
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bicycle Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Riding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bicycle Safety Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Attach the Front Handlebar . . . . . . . . . . . . . . . . . . . . . . . 18
Attach the Rear Handlebar to the Front Saddle . . . . . . . 20
Attach the Lockon Grips . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Attach the Brake Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Attach the Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Attach the Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Attach the Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Adjusting the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Adjusting the Cable Tension . . . . . . . . . . . . . . . . . . . . . . . . 41
Adjusting the DERAILLEUR . . . . . . . . . . . . . . . . . . . . . . . . . 42
Adjusting the Seat Height . . . . . . . . . . . . . . . . . . . . . . . . . 44
Adjusting the Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . 46
Adjusting the Headset . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Adjusting a Threaded Headset . . . . . . . . . . . . . . . . . . . . . 49
Adjust the Bottom Bracket . . . . . . . . . . . . . . . . . . . . . . . . 53
Adjusting the Bottom Bracket . . . . . . . . . . . . . . . . . . . . . 54
Adjust the Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . 55
5 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Gear Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Parts Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Hub Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Inflating the Tire Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Repairing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Purchase Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
i
Thank You
for purchasing your tandem bicycle. Before using your bicycle,
please practice riding and safety procedures. Be sure to follow
the sequence of steps carefully. Proper operation of your bicycle
is important for your safety and enjoyment.
Enjoy the ride!
About This Manual
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.
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.
You may also reach us at:
Web: www.pacific-cycle.com
Email: [email protected]
Mail: P. O. Box 344
4730 E. Radio Tower Lane
Olney, IL 62450
Do not return this item to the store. Please call Pacific Cycle
customer service if you need assistance. You will need your
model number when calling customer service. See Section 7:
Purchase Record for the location of the model number on
your bicycle.
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
Our customer service department is dedicated to your
sense rules of safe and responsible bicycling. As a parent, you
satisfaction with Pacific Cycle and its products. If you have
should read this manual before letting your child ride the
questions or need advice regarding assembly, parts, performance, bicycle. Please make sure that your child always wears an
or returns, please contact the experts at Pacific Cycle.
approved bicycle helmet when riding.
Toll free: 1-800-626-2811.
Customer Service hours: Monday - Friday 8:00 am to 5:00 pm
Central Standard Time (CST).
ii
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
iii
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
2
1
Adjust the seat
height
Note: The rider’s feet may not touch the ground easily. If
this is the case the rider can simply move forward off the
seat to mount and dismount the bicycle or the seat can be
adjusted lower if the rider is uncomfortable with the height,
but note that riding is more difficult with the seat too low,
as the legs are in an unnatural position.
Do not raise the seat so much the knees lock straight when
pedaling or you have to move forward off the seat to pedal.
This is unsafe and the bicycle cannot be controlled in this
condition.
❷ You should be able to safely reach the handlebar with
your arms bent slightly (approximately 10 degrees) at
the elbow.
6
Figure 1.2
Safety 1
Quick-release Levers
WARNING!
Seat post
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 tube
Minimum insertion
marks are located on
the seat post
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
wheel
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.
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
Rear (red)
plus or minus
5 degrees of
vertical
Front (white)
Rear wheel
(white)
Front wheel
(white)
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
Tandem Bicycle
Get to know the parts of your bicycle. This will help with assembly, maintenance, and troubleshooting. Models vary in color and style.
Part name
1 Handlebar with grips
Torque
(in-lb)
-
Part name
14 Spoke
15 Wheel axle nut (front)
2 Brake levers
55 - 70
3 Handlebar binder bolt(s)
145-200 16 Fork dropout
Torque
(in-lb)
-
Part name
29 Rear Disc Brake (option)
180-240 30 Freewheel
-
31 Rear derailleur
300-360 32 Chain stay
4 Stem
17 Pedal
5 Brake cable
18 Crank arm (1-piece)
300
33 Front Chain
6 Headset
175-260 18A Crank arm (3-piece)
390
34 Rear Chainwheel
7 Stem binder bolt
100-120 19 Front Chainwheel
8 Wheel quick-release (option)
-
9 Disc Brake (option)
10A Brake cable pinch bolt
10B Brake pads
10C Brake pads hardware
50 - 70
50 - 60
20 Rear Stem binder bolt
-
35 Bottom bracket lockring
100-120 36 Rear Pedals
21 Front Seat Post
-
37 Frame
22 Front Seat
-
38 Rear Chain
23 Adjustable Tandem Stem
100-110 39 Front derailleur
24 Rear Handlebar Binder Bolt
145-200 40A Brake cable pinch bolt
11 Valve stem
-
25 Rear Handlebar with grips
12 Tire
-
26 Seat post quick-release
13 Rim
-
27 Rear Seat
60-80
-
40B Brake pad
40C Brake pad hardware
40D Brake spring
28 Seat post attaching hardware 130-170 40E Brake pivot bolt
14
Torque
(in-lb)
-
50-70
50-60
17-20
Parts Identification 2
40B 40A
40E
Linear Brake
Assembly (Option)
40D
40C
10A
10B
25
24
21
20
28
32
26
19
16
16
37
32 33 34 35
8
9
23
39
31
2
3
4
5
7
6
27
30 29
1
10C
22
Caliper Brake
Assembly (Option)
36
38
15
18, 18a
17
14
13
12
11
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.
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.
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).
16
Assembly 3
TOOLS REQUIRED
GETTING STARTED
• Phillips head screw driver
❶ 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.
• 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
5mm
❷ 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.
Figure 3.1
17
17
3 Assembly
ATTACH THE FRONT 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.
Important! Be sure the minimum insertion marks do not go
above the top of the headset and are not visible.
❹ Using a 6 mm Allen wrench tighten the stem binder bolt at
the top of the stem post. Check the handlebar binder bolt(s)
to be sure they are properly tightened and the handlebar is
clamped in place. Note: See Section 4: Adjusting the
Handlebar if adjustments are needed.
• Failure to properly tighten handlebar components may
result in loss of control, serious injury or death.
Always check the handlebar cannot move and is secured to
the frame before riding the bicycle.
1
Figure 3.2
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
❶ Turn the front fork to face forward. Figure 3.2
❷ Position the handlebar assembly over the steerer tube.
Look at all the cables to be sure they run in a smooth arc
from the shifter or brake lever to the front brake or cable
stop on the frame. Important! If they are twisted or kinked,
the shifting and braking will not work. Figure 3.3
❸ Insert the stem post into the steerer tube and adjust the
handlebar height until the rider feels they have control of
the bicycle and are comfortable. See Section 1, Fig. 1.2:
Seat Height and Handlebar Reach for guidelines.
18
Front fork
faces forward
Handlebar binder bolt(s)
3
Stem
binder
bolt
2
Minimum
insertion
marks
Stem post
Headset
Steerer tube
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.
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.
❶ Turn the front fork to face forward (ie: the fork dropout is in
the furthest forward position). Figure 3.4
• 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.
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
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.
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 5 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.
1/8" - 3/16"
(3 - 5 mm)
Top cap
and bolt
2
Stem
Stem pinch
bolts
5
4
Steerer tube
Spacers
Figure 3.5
3
Headset
Figure 3.4
19
19
3 Assembly
ATTACH THE REAR HANDLEBAR TO THE
FRONT SADDLE
❶ Insert the seat post through the center of the clamp on the
rear handlebar. Figure 3.6
❷ Position the handlebar on the front seat post at the height
you desire. Apply a light layer of grease to the seat post and
frame head tube.
1
Important! Be sure the minimum insertion marks do not go
above the top of the headset and are not visible.
2
❸ Using a 5 mm allen wrench tighten the two pinch bolts on
the handlebar clamp.
❹ Using a 5 mm allen wrench tighten the two seat post
clamp bolts. Figure 3.7
3
Figure 3.6
Important: Do not completely tighten the bolts until the
saddle is installed and adjusted to the proper height.
4
20
Figure 3.7
Assembly 3
ATTACH THE LOCKON GRIPS
Follow these steps if your bicycle is equipped with lockon grips.
❶ Clean the handlebar surface.
❷ Slide the lockon grip over the handlebar as far as it can go.
Note: Rotate the clamp so the clamp screws are on the
underside of the handlebar. Figure 3.8
❹ Using a 2.5 mm Allen wrench tighten the clamps on both
ends of the lockon grip. Check the grip is securely attached
and does not rotate or slip.
❺ Snap the lockon grip cap onto the end of the lockon grip.
❻ Repeat steps 1 - 5 for the second lockon grip.
❸ Adjust the grip to how you want it to feel.
4
Lockon grip cap
Lockon grips
2
5
Figure 3.8
21
21
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 four brake options, Caliper, Linear Pull, Disc and
Hydraulic Disc. If you have hydraulic disc brakes, see the manual
on hydraulic disc brakes that came with your bicycle.
Brake lever
Figure 3.9
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 3.9
3
Brake cable
Cable head
Figure 3.10
❷ Press the brake lever towards the grip.
❸ Slide the brake cable through the slots and place the cable
head into the brake lever. Figure 3.10
4
❹ Release the brake lever. Figure 3.11
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.
22
5
Figure 3.11
Assembly 3
ATTACH THE FRONT WHEEL
Disc rotor
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.
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 3.12
Figure 3.12
3
2
❷ Place the axle washers on the axle and slide it up against the
fork drop out. Figure 3.13
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
Axle
Fork
dropout
Axle
washer
2
3
Axle nut
Figure 3.13
23
23
3 Assembly
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 3.14
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 3.15
Important! Be sure the wheel is as centered as possible
between the fork legs.
Front fork
Outer
spring
4
Skewer
6
2
Inner
spring
Quick-release
lever
3
Adjustment
nut
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 3.15
24
Assembly 3
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 3.16
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 3.16
25
25
3 Assembly
ATTACH THE SEATS
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.
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.
26
Bolted Seat Clamp
❶ Using a 5 mm Allen wrench, loosen the seat clamp bolt.
Figure 3.17
❷ Insert the seat post without the handlebars into the rear
seat tube.
❸ Insert the seat post with the handlebars into the seat tube.
❹ 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.
❺ Tighten the seat clamp bolt to lock the seat in place.
❻ Check the seat to be sure it does not move.
Assembly 3
6
6
3
5
2
4
3
1
Figure 3.17
27
27
3 Assembly
Quick-release Seat Clamp
❶ Unlock the quick-release lever and insert the seat post into
the seat tube. Figure 3.18
❷ Adjust the seat height up or down until the rider feels they
have control of the bicycle and is comfortable.
Important! Be sure the minimum insertion marks do not go
past the top of the seat clamp and are not visible. See
Section 1, Fig. 1.2: Seat Height and Handlebar Reach.
❸ Close the quick-release lever and lock the seat in place.
If there is not enough pressure to hold the seat in place
open the quick-release lever. With one hand on the quickrelease lever and one hand on the adjustment nut, start to
hand tighten the adjustment nut until you start to feel some
resistance against the seat clamp post. 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 3.19
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.
28
2
Seat post
Minimum
insertion marks
on the seat post
Adjustment nut
Quick-release lever
Seat tube
Quick-release
seat clamp
1
Figure 3.18
Minimum
insertion
marks
3
Figure 3.19
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 3.20
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.
Seat rails
7
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
6
2
Quick-release
seat clamp
Pillar seat
post
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 3.20
29
29
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.
• It is very important that you check the crank set for correct
adjustment and tightness before riding your bicycle.
1
3
2
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 3.21
1
❷ Place the threaded pedal into the threaded hole on the
crank arm.
❸ By hand, slowly turn the spindle the correct direction.
Clockwise for right side pedal, counterclockwise for left side
pedal. Important! Stop if you feel resistance! This may be
an indication the spindle is entering the hole at an
angle. Remove the spindle and repeat step two.
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.
30
5
The left pedal turns
counter-clockwise and
the right pedal turns
clockwise.
3
Figure 3.21
Adjustments 4
❹ Adjustments
After your bicycle is assembled you will need to make
adjustments. If you need replacement parts or have questions
pertaining to the assembly of your bicycle, call the service line
direct at: 1-800-626-2811. Monday - Friday 8:00 am to 5:00 pm
Central Standard Time (CST).
Note: You will need your model number and date code located
on the service sticker near the bottom bracket area. Figure 4.1
TOOLS REQUIRED
• Phillips head screw driver
• 4 mm, 5 mm, 6 mm and 8 mm Allen wrench
• Adjustable wrench or a 9 mm, 10 mm, 14 mm and 15 mm
open and box end wrenches
• A pair of pliers with cable cutting ability
Service sticker is
located above the
bottom bracket
Figure 4.2
Serial number is
located below the
bottom bracket
Figure 4.1
31
31
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
1
Cable anchor bolt
4
Brake cable
5 mm Allen wrench
Brake arm
5
1/8” gap
(both pads)
Brake arm
Figure 4.3
32
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
Wheel rim
Figure 4.4
Adjustments 4
Important! Before riding the bicycle it is important to check the
brakes. If you squeeze the brake lever and one brake arm moves
more than the other (or not at all) the brake is not centered. You
will need to fine-tune the brake pads. Multiple adjustments may
be necessary to center the brake pads, correctly set the brake
pressure and set the gap between the brake pad and rim.
Center the Brake Pads
Adjust the Brake Pad Alignment
❶ If you see the gap between the fork and wheel is uneven
loosen the axle nuts and adjust the wheel until centered.
Figure 4.6
Check that all brake pads are aligned correctly. If not, use a
5 mm Allen wench 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
33
33
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 and two 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.
34
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.
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
Cable
adjustment
barrel
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
35
35
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 wench 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
36
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
37
37
4 Adjustments
Check the Brakes
❶ After adjusting the brake, squeeze the brake lever as hard as
you can several times and re-inspect the brake pads,
centering and brake lever travel. If the brake pads are no
longer square to the rim, repeat brake pad adjustments.
Figure 4.14
1
1/3 distance to
handlebar
❷ Be sure that brake pads return to a centered position by
spinning the wheel and listening for the brake pad rubbing
the rim on either side. Re-adjust as needed.
Figure 4.14
❸ Check that the brake cable tension allows the brake lever
about 1/3 of the travel before the brake pads contact the
rim. If the cable has stretched or slipped, re-adjust the brake
cable tension by loosening cable anchor bolt and pulling
more cable through the anchor or use brake adjustment
barrels for fine tuning brake cable tension.
Brake is correctly adjusted when:
• The brake pads do not drag on the rim when the brake is
open. Figure 4.15
• Both brake pads move away from the rim equally when the
brake is released.
• When the brake is applied, the brake pads contact the rim
before the brake lever reaches about 1/3 of the way to the
handlebar.
Equal space
between brake
pad and the rim
on both sides
Brake pads
Wheel rim
Figure 4.15
38
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
39
39
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 4.20
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
40
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 travel to handlebar before
brake pads contact disc rotor
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.
Figure 4.21
Caliper body
Brake cable
3
2
Adjustment
barrel
Jam nut
Brake is correctly adjusted when:
• The brake pads do not drag on the disc rotor.
• 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.
Figure 4.22
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.
41
41
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 derailleurs are initially adjusted at
the factory, you will need to inspect and re-adjust both before
riding the bicycle.
Adjust the Rear Derailleur
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.
Front shifter
Rear shifter
1
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
6
3
Low limit Barrel
screw adjuster
1
Smallest
sprocket
5
Largest
sprocket
Anchor bolt
Cable
Guide pulley
Figure 4.24
42
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
43
43
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
Minimum
insertion
marks
Use a 5 mm Allen
wrench to loosen and
1 the seat clamp
tighten
2
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.
❸ Tighten the seat clamp bolt to lock the seat in place.
❹ Check the seat to be sure it does not move.
44
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 clamp post. 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
Adjustment nut
1
Quick-release lever
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.
Quick-release
seat clamp
Figure 4.27
Minimum
insertion
marks
3
Figure 4.28
45
45
4 Adjustments
ADJUSTING THE HANDLEBARS
Align the Handlebar (with quill stem)
WARNING!
• Improper adjustment of the handlebar may result in
damage to the stem post, steering tube and result in loss of
control, serious injury or death. Ensure the minimum
insertion marks on the stem post are not visible above the
top of the headset.
• Failure to properly tighten handlebar components may
result in loss of control, serious injury or death. Always
check the handlebar cannot move and is secured to the
frame before riding the bicycle.
Instructions for adjusting the handlebar height depend on
whether your bicycle has a quill or clamp (threadless) stem.
Figure 4.29
Stem
binder bolt
❸ Tighten the stem binder bolt and check the handlebar is
securely attached and cannot move.
2
Move the handlebar
left or right until it is
aligned with the
front wheel
Threadless Stem
Handlebar
binder bolt(s)
Pinch
binder
bolts
Handlebar
binder
bolt(s)
Figure 4.29
46
❷ Using a 6 mm Allen wrench, loosen the stem binder bolt
and move the handlebar left or right until it is aligned with
the front wheel. Figure 4.30
Stem binder
bolt
Adjusting the Handlebar Height
Quill Stem
❶ Stand in front of the handlebar and hold the front wheel
between your legs.
Figure 4.30
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 4.32
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 4.31
❷ Rotate the handlebar into the desired position.
❸ Tighten the stem binder bolt and check the handlebar is
securely attached and cannot move.
Pinch binder
bolts
2
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.
Move the
handlebar left
or right until it
is aligned with
the front wheel
1
Loosen
handlebar
binder bolt(s)
2
Figure 4.31
Figure 4.32
47
47
4 Adjustments
Follow these steps to adjust rear handlebars and stems:
Figure 4.33
Adjusting the seat height:
❶ Using the 5 mm Allen wrench, loosen the two seat post
clamp pinch bolts on the rear stem.
❷ Adjust the height so the rider is in control and comfortable.
❸ Re-tighten the two pinch bolts.
Adjust the handlebar angle:
❹ Using the 5 mm Allen wrench, loosen the stem clamp bolts
on the front of the handlebars.
5
2
❺ Rotate the handlebars until the rider feels comfortable and
in control.
❻ Re-tighten the two stem clamp bolts.
Adjust the handlebar length:
❼ Using the 5 mm Allen wrench, loosen the two pinch bolts on
the side of the rear stem.
❽ Adjust the length so the rider is in control and comfortable.
❾ Tighten the two pinch bolts.
48
4
8
1
3
6
7
6
Figure 4.33
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.
1
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.
Headset
2
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 4.34
Figure 4.34
49
49
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 4.35
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 (i.e. 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 locknut
Upper
threaded race
Locknut
Spacers
Head
tube
Lower
race
4
3
Hold upper
threaded race
in place
Figure 4.35
50
Stem
Figure 4.36
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:
1
Headset
2
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 4.37
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 4.37
51
51
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 4.38
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 4.39
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.
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.
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.
Top cap
bolt
1
Top cap
Stem pinch
bolts
3
Star nut
Steerer tube
Stem
1/8" - 3/16"
(3 - 5 mm)
2
Spacers
Figure 4.38
Figure 4.39
52
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 4.40
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 crankarms 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. Note: The one-piece crank
systems do not use a polished bearing system. There will be
some roughness to a correctly adjusted bottom bracket.
Adjust as loose as possible but without play in the bearings.
Bottom bracket shown with
crank arm removed
Lockring
Fixed cup
Adjusting cup
Bearings
Spindle
Bearings
Figure 4.40
53
53
4 Adjustments
ADJUSTING THE BOTTOM BRACKET
Typically the bottom bracket contains four major pieces:
lockring, adjustable cone, bearings, and washers. The lockring
has notches. The adjustable cone will have notches for a
spanner wrench or bottom bracket tool. The cones can be
removed and replaced separately. A set of round ball bearings
are found in each adjustable cone. A typical ball bearing is 5/16"
in diameter and contains nine balls. This type of bottom bracket
may be cleaned, greased and adjusted.
❹ Repeat process of checking for play and re-tightening cone
a slight amount until no play is felt. Note: The one-piece
crank systems do not use a polished bearing system.
There will be some roughness to a correctly adjusted
bottom bracket. Adjust as loose as possible but without
play in the crank assembly.
Crank arm
Bearing Adjustment
The basic concept for bearing adjustments is to get the bearings
adjusted as loose as possible but without play. Start by
purposely beginning with play in the adjustment and then
tightening in small increments until play is gone. Note: Extended
use may cause the bearings, cups (or cones) to become worn
and pitted. In this case, bearing adjustment will not be possible.
If bottom bracket is correctly adjusted, but grinds when spun,
cups and/or cones are worn and should be replaced. Figure 4.41
❶ Loosen the locknut. Turn adjusting cone counter-clockwise
until it hits the ball bearing, then turn back clockwise to
loosen 1/4 turn.
Bottom bracket shown
with crank arm
removed
Crank arm
Ball bearings
Washers
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.
54
Locknut
Lockring
Adjustable cones
Chainwheel
Figure 4.41
Adjustments 4
ADJUST THE CHAIN TENSION
If the chain tension is loose on your tandem bicycle, perform the
follow steps.
Tools: Two Phillips head screwdrivers.
❶ Using a phillips head screwdriver loosen the two screws
located under pedal crank bracket. Figure 4.38
❷ Insert a screwdriver into the hole located next to the
pedal crank. Figure 4.42
Tip!
Adjusting the chain
tension is easier to
perform with the
bicycle turned
upside down.
1
Figure 4.38
❸ Insert another screwdriver between the crank axel and the
first screwdriver. Pull this screwdriver toward the back of
the bicycle to increase the chain tension.
4
❹ Once you have acquired the correct chain tension, tighten
the two screws directly under the pedal crank.
2
3
Figure 4.42
55
55
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 rotor's 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
1
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
56
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 Section 4: Adjusting the Derailleur 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.
57
57
5 Use
Using the Rear Shifter
Using the Front Shifter
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.
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
58
Trigger-style Shifter
Front shifter
Rear shifter
8
6
1
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.
3
2
Pull down with
index finger to shift
up in gear level
Thumb
shifter
3
Thumb shifter
Push in with thumb to
shift down in gear level
Figure 5.3
Twist-style Shifter
Front shifter
Rear shifter
1
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.
• 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
The serial number is
located below the
bottom bracket
Figure 5.5
• 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
59
59
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
60
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
Derailleur Systems
Light oil or grease
All pivot points should be lubricated (more often in severely rainy
or muddy conditions). Wipe off any excess oil.
Brake cables
Lithium based grease
Remove cable from casing. Grease entire length. Wipe off excess
lubrication from other surfaces.
Brake lever and caliper pivot points Light oil
Two to three drops from oil can
Shifting cables
Clean and grease
Thin layer of grease
Yearly
Bottom bracket
Lithium based grease
Disassemble
Pedals
Lithium based grease
Disassemble
Wheel bearings
Lithium based grease
Disassemble
Headset
Lithium based grease
Disassemble
Seat stem
Lithium based grease
Disassemble
Pedals: that can be disassembled
See bicycle mechanic for maintenance.
Note: The frequency of maintenance should increase with use in wet or dusty conditions. Do not over lubricate. Remove excess
lubricant to prevent dirt build up. Never use a degreaser to lubricate your chains (WD-40®).
61
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. See
“Inflating a Tire Tube” for more detail. If the tire is flat see
“Fixing a Flat Tire” for more detail.
Check the bead is properly seated while inflating
or refitting the tire.
Reduce air pressure in the tube and re-seat the bead.
Spin wheel and check rotation / alignment
is smooth and even.
Loosen axle nut(s) and adjust until properly seated. If the hub
bearings need repair see a bicycle mechanic for repair.
Bead Seating
Check for broken or loose spokes.
See bicycle mechanic for repair.
Tread
Inspect for signs of excessive wear, flat spots or
cuts and damage.
Replace tire.
Valves
Check that valve caps are fitted and free of dirt.
Clean dirt from the valve.
Wheels
Inspect
Frequency: Inspect and maintain at least each use.
Action
Maintenance
Rims
Inspect for dirt and grease.
Use a clean rag or wash with soapy water, rinse, and air dry.
Wheels
Check the wheels are securely fastened to the
bicycle and axle nuts are tight.
Adjust if necessary and tighten axle nuts.
Spin wheel and check rotation / alignment is true See bicycle mechanic for repair.
Spokes
Check for broken or loose spokes.
Hub Bearings
Lift each wheel and see if there is movement side See bicycle mechanic for repair.
to side.
62
See bicycle mechanic for repair.
Maintenance 6
Drivetrain (pedals, chains, chainwheel, crank set, freewheel)
Inspect
Pedals
Frequency: as noted.
Action
Maintenance
Every month, check each pedal is securely set and tighten If necessary, re-set and tighten.
into the crank arm.
Before each ride, check each front and rear pedal
reflectors are clean and in place.
Clean or replace.
Pedal Bearings
Every month, 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 chains are clean, properly
Lubricate if necessary. Replace if rusted,
lubricated, rust free, and is not stretched, broken, or have stretched, or broken.
stiff links.
Loosen bolts holding the rear frame and move
Every week, check chain tension is correct on both chains: it until the chain is taut and moves less than 10
mm. Check the rear frame is “square” to the
1. Set a straightedge against the bottom of the front
main frame and firmly tighten the bolts holding
chainwheel and rear sprocket.
the rear frame.
2. Pull up on the bottom of the chain.
3. If movement is more than 10 mm adjust the position
of the rear frame.
Crank Set
Every month, check the crank set (crank arms, chain
rings, and bottom bracket axle and bearings) is correctly
adjusted and tight. Remove the primary chain
Replace cable.
63
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.
64
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 Be sure 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.
65
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.
❾ Insert the valve stem through valve stem hole in rim.
66
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
67
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
68
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
69
7 Warranty
❼ Warranty
LIMITED WARRANTY AND POLICY ON REPLACEMENT PROCEDURES & RESPONSIBILITIES
Your purchase includes the following warranty which is in lieu of all other express warranties. This warranty is extended only to the initial consumer purchaser.
No warranty registration is required. This warranty gives you specific legal rights and you may have other rights which vary from state to state.
FRAME
Steel frames are guaranteed against faulty materials and workmanship for as long as the initial consumer purchaser has the bicycle, subject to the condition of the
warranty listed below. Aluminum and dual suspension frames are guaranteed against manufacturing defects for a period of 5 years. If frame failure should occur due to
faulty materials or workmanship during the guarantee period, the frame will be replaced. For frame replacement under this Pacific Limited Warranty, contact us, stating
the nature of the failure, model number, date received and the name of the store from which the bike was received, at the address given on this page. Frame must be
returned for inspection at customer’s expense. Please note: the fork is not part of the frame. A lifetime warranty on your frame does not guarantee that the product will
last forever. The length of the useful life cycle will vary depending on the type of bike, riding conditions and care the bicycle receives. Competition, jumping, downhill
racing, trick riding, trial riding, riding in severe conditions or climates, riding with heavy loads or any other non-standard use can substantially shorten the useful product
life cycle. Any one or a combination of these conditions may result in an unpredictable failure that is not covered by this warranty. All bicycles and frame sets should be
periodically checked by an authorized dealer for indications of potential problems, inappropriate use or abuse. These are important safety checks and are very important
to help prevent accidents, bodily injury to the rider and shortened useful product life cycle.
PARTS
All other parts of the unit except Normal Wear Parts are warranted against defective materials and workmanship for a period of 1 year from the date of purchase by the
initial consumer purchaser, subject to the Terms and Conditions of the warranty listed below. If failure of any part should occur due to faulty materials or workmanship
during the warranty period, the part will be replaced. All warranty claims must be submitted to the address below and must be shipped prepaid and accompanied by
proof of purchase. Any other warranty claims not included in this statement are void. This especially includes installation, assembly, and disassembly costs. This warranty
does not cover paint damage, rust, or any modifications made to the bicycle. Normal Wear Parts are defined as grips, tires, tubes, cables, brake shoes and saddle
covering. These parts are warranted to be free from defects in material and workmanship as delivered with the product. Any claim for repair or replacement of Normal
Wear Parts (grips, tubes, tires, cables, brake shoes and saddle covering) and missing parts must be made within thirty (30) days of the date of purchase. The warranty
does not cover normal wear and tear, improper assembly or maintenance, or installation of parts or accessories not originally intended or compatible with the bicycle as
sold. The warranty does not apply to damage or failure due to accident, abuse, misuse, neglect, or theft. Claims involving these issues will not be honored.
CONDITIONS OF WARRANTY
1. Your bicycle has been designed for general transportation and recreational use, but has not been designed to withstand abuse associated with stunting and jumping.
This warranty ceases when you rent, sell, or give away the bicycle, ride with more than one person, or use the bicycle for stunting or jumping.
2. This warranty does not cover ordinary wear and tear or anything you break accidentally or deliberately.
3. It is the responsibility of the individual consumer purchaser to assure that all parts included in the factory-sealed carton are properly installed, all functional
parts are initially adjusted properly, and subsequent normal maintenance services and adjustments necessary to keep the bicycle in good operating condition are
properly made. This warranty does not apply to damage due to improper installation of parts, installation of any kind of power plant or internal combustion engine,
modification or alteration of the brakes, drive train, or frame in any way, or failure to properly maintain or adjust the bicycle. NOTICE: Bicycle specifications subject to
change without notice.
70
Pacific Cycle · PO Box 344 Olney, IL 62450
Warranty 7
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
71
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.
OMSCTDM
©2017 Pacific Cycle, Inc.
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