Cross CRF300 Alloy Folding 20in Bike User manual

Cross CRF300 Alloy Folding 20in Bike User manual
Challenge Holborn 20in Folding Bike
Cross CRF300 20in Folding Bike
Maintenance Manual 6016/4263
607/7271
Important — Please read these instructions fully before performing any maintenance activities on the bike
These instructions contain important information that will help you get the best from your bike,
ensuring safe and correct maintenance.
The image in the manualis for instruction reference only.
Contents
Safety Information .............-.—-.————======eererereeeeeeeeeeene ene n nene nan nan an annanana NANA ANANANNANANNNNENNENENANENNENENEEENENENENE EEE NENEEEENE, 3
Maintenance Instructions.................=—=—====e=e===—===eseiieieeeeeee ene nene rrr ranma sara reer rrr nn msm am sss ana n ener nn nnnmnmnnns 4
Adjusting the Rear ОегаШеиг..................нннноноеаоееенононенннннннненененонннннненнннененееененнннннннннннннененненннннннныноо... 4
Adjusting V-Brakes .........--—----=ee=emennnnnnnanananananna ANDAN NANA ANNANANNNNNNNNNANANANNN NENE ENE NNENENENEENENENEE men me me mmnnnenmnanananana 7
Inspecting and Maintaining the Wheels... inners nesses ses 10
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ВоийНтпе 1 P= =] T= go n anne nene eee enana ne NNNNENANNANANNANANEANE Ren nna na nmeNENNN NA RNA NANENNRNNNNANANAANANANARNT 13
Before and After Each Ride .......................e.eeeeeceeceecceneeneeeenennenenznnANTRRENTre nena ne nee ee eee Ne NANNANANNNNNNNANANANNANANNRNDe 13
Y= VY Uo | FS 13
Every Six Mont 3 menmnnnanANENENNENENEEmEmeennn Na 14
Every Twelve Months .......ccooi sires rrr snes sree rrr mss sess seen nn mn mmm as 14
0 o Tq T= 1 Te] 0 JT £0] 4 ¢ 1 = 11 Te) FAP 15
Recommended tightening information... rere errr ere eee 15
NEED ANY HELP?
CUSTOMER
CARE HELPLINE
01702 208187
[email protected]
WE CAN GIVE YOU GUIDANCE ON
ASSEMBLY,PARTS & TECHNICAL ADVICE
/N\ Safety Information
Important — Please read these instructions fully before installation
WARNING! This Bike has been designed, assembled and tested in accordance with the
EN ISO 4210 to ensure our safety. To make sure the bike remains safe, it should only be used
for recreational use. Under no circumstances should it be used for competitive cycling, stunting,
jumping or acrobatic manoeuvres. This may result in serious personal injury and damage to
the bike.
WARNING! This bike is only suitable for use by riders (including any panniers and/or luggage) with a
weight of less than 80 kg (176 lb).
WARNING! Under no circumstances should the bike be ridden with loose or torn clothing.
WARNING! Always take extra care when riding in wet, foggy, windy or icy conditions. The brakes
may not be as effective and the braking distances may be increased.
WARNING! When riding in the dark, always make sure that the bike is fitted with suitable reflectors
and front and rear lights.
WARNING! The front and rear tyres of the bike must be fully inflated before attempting to ride the
bike. Under no circumstances should the tyres be inflated above the maximum pressure stated on
the side of the tyres.
WARNING! If the wheel rim wear grove is no longer visible, the wheel rim should be replaced
immediately. Do not attempt to ride the bike until the rim is replaced as the braking performance
could be affected.
WARNING! Always wear a cycle helmet when riding the bike.
WARNING! Safety critical components should be replaced using genuine replacement parts.
This bicycle is not suited for extreme use such as competitions, jumping, drop-offs or stunting.
The rider must be aware that intensive use can result in damage to the frame, forks, wheels and
other components of the bicycle that may affect its safety.
WARNING! As with all mechanical components, the bicycle is subjected to wear and high
stresses. Different materials and components may react to wear or stress fatigue in different ways.
If the design life of a component has been exceeded, it may suddenly fail possibly causing injuries
to the rider. Any form of crack, scratches or change of colouring in highly stressed areas indicate
that the life of the component has been reached and it should be replaced.
WARNING! The saddle height and handlebars are secure, set to a comfortable riding position and
do not exceed the minimum insertion mark. The rider when seated should be able to reach the floor
with their tip toes and be able to reach the brakes and handlebars without over balancing.
WARNING! Please be aware of the specific risk of entrapment during normal use andmaintenance
on the front/rear wheel, chain and sprocket.
WARNING! This bike is not suitable to add bike trailer.
WARNING! The rider shall follow the national legal requirement when use on public
roads. (e.g. Lighting and reflectors)
/\
3-1
CAUTION! The safety and smooth running of the bike can only be preserved with regular
maintenance. Always ensure the bike is maintained in accordance with this maintenance manual.
CAUTION! Only use suitable tools to assemble the bike. The use of unsuitable tools may lead to
personal injury and damage to the bike.
CAUTION! If the gears make a grinding sound while riding the bike, STOP immediately.
The bike may be unsafe and prolonged use may lead to personal injury or damage to the bike.
Inspect and, if required, repair the bike before reusing.
CAUTION! Do not clean your bike with pressure washers. These high pressure cleaning devices
may remove lubricant and/or grease from bearings and internal bike parts. This may lead to poor
performance.
CAUTION! When lubricating the moving parts of the bike, take care not to get any lubricant on the
rms of the wheels or the brake pads.
CAUTION! Be careful not to trap the inner tube between the tyre levers and the wheel.
Maintenance Instructions
Ш NOTE! You will need a second person to help you adjust the front and rear derailleur.
Adjusting the Rear Derailleur
While riding the bike, if the rear gears fail to work correctly and/or become noisy, the rear derailleur
should be adjusted. The following are a few examples of when to do this:
e |f a grinding noise comes from the rear gears while peddling
e [f the chain fails to move between the rear gears or jumps gears
e If the chain routinely jumps off the highest (smaller) gear.
Adjusting the Rear Derailleur — Step 1
1a. Select the Lowest Gear
Ш NOTE! The lowest gear is always the largest.
While raising the rear of the bike and rotating the pedals by hand, use the right hand twist shifter to
select the lowest gear (number 1 on the indicator).
1b. Set the Position of the Lower Limit Screw
The lower limit screw O controls the position of the rear derailleur when the lowest gear is selected.
Using a suitable screwdriver, rotate the lower limit screw O until the small gears of the derailleur are
vertically aligned below the lowest gear.
e Turn the lower limit screw O clockwise to move the derailleur to the right (when viewed from the
back of the bike).
e Turn the lower limit screw O anti-clockwise to move the derailleur to the left (when viewed from
the back of the bike).
Maintenance Instructions
Adjusting the Rear Derailleur — Step 2
2a
2b
rec je
Ш
2a. Select the Highest Gear
NOTE! The highest gear is always the smallest.
While raising the rear of the bike and rotating the pedals by hand, use the right hand twist shifter to
select the lowest gear (number 1 on the indicator).
2b. Set the position of the Upper Limit Screw
The upper limit screw O controls the position of the rear derailleur when the highest gear is selected.
Using a suitable screwdriver, rotate the upper limit screw O until the small gears of the derailleur are
vertically aligned below the highest gear.
o Turn the lower limit screw O clockwise to move the derailleur to the left (when viewed from the
back of the bike).
e Turn the lower limit screw O anti-clockwise to move the derailleur to the right (when viewed from
the back of the bike).
Maintenance Instructions
Adjusting the Rear Derailleur — Step 3
3a & 3b
3a. Check the Gear Change
While raising the rear of the bike and rotating the pedals by hand, use the right hand twist shifter to
change from the highest (smallest) gear to the lowest (largest) gear one at time. If the rear derailleur is
tuned correctly, the gears should change quickly without any grinding noises.
If the gears still do not operate correctly, carry out step 3b.
3b. Check the Cable Tension
If the gears change correctly between the highest and lowest gears but not between the lowest and
highest gears, the cable tension should be increased.
Rotate the barrel adjuster O a quarter of a turn anti-clockwise.
Check the gear change by repeating step 3a.
Keep checking the gear change and slowly increasing the cable tension a quarter of a tum at a time
until they operate correctly.
Maintenance Instructions
Throughout the life of your bike, the front and rear v-brakes may need adjusting if the brake cable
has stretched or the brake arms have been knocked during use.
Adjusting the V-Brake Cable Tension
AO)
on
1a. Adjust the Brake Cable
The brake cable must be adjusted to ensure that the brakes are as close as possible to the wheel
rim when no pressure is applied to the brake lever. But must not touch the rim and have some
clearance.
Using a suitable spanner or socket, loosen the cable pinch bolt Y until the brake cable (O IS
free to move.
Pull the brake cable until the brake pads are approximately 3 to 4 mm from the wheel rim.
Retighten the cable pinch bolt ©@ while holding the brake cable in position.
Maintenance Instructions
Adjusting the V-Brake Cable Tension (continued)
1b. Fine Tune the Cable Tension
If the brake pads are too close or too far away from the wheel rim once the brake cable has been
adjusted in step 1a, fine tune the cable tension as described below.
Anti-clockwise is only if the brake shoes are to far away from the rim O
Turn the barrel adjuster bolt to increase or decrease the cable tension. This will fine tune the position
of the brakes.
e To increase the tension on the brake cable @ and move the brakes towards the wheel rim, turn
the barrel adjuster bolt Q anti-clockwise.
e To decrease the tension on the brake cable O and move the brakes away from the wheel rim,
turn the barrel adjuster bolt UY clockwise.
Once the cable tension is correct, retighten the barrel adjuster locking nut O.
Maintenance Instructions
Adjusting the V-Brake Spring Tension
1a & 1b
on
Over time, the brake arms can begin to lean to one side or another making the distance between
the brake pads and the wheel rim uneven. This can be corrected by adjusting the spring tension of
the individual brake arm.
NOTE!: When adjusting the spring tension, even adjustments should be made to both brake arms
@ until they are positioned evenly on either side of the wheel and rim.
1a. Adjusting the Spring Tension on the Right Hand Brake Arm.
If the brake arms 0 lean to the right (when viewed from the front of the bike), the right hand brake
arm spring tension should be reduced. This can be achieved by turning the right spring tension
screw © anti-clockwise.
If the brake arms @ lean to the left (when viewed from the front of the bike), the right hand brake
arm spring tension should be increased. This can be achieved by turning the right spring tension
screw O clockwise.
1b. Adjusting the Spring Tension on the Left Hand Brake Arm.
If the brake arms @ lean to the right (when viewed from the front of the bike), the left hand brake
arm spring tension should be increased. This can be achieved by turning the left spring tension
screw O clockwise.
If the brake arms 0 lean to the left (when viewed from the front of the bike), the left hand brake arm
spring tension should be decreased. This can be achieved by turning the left spring tension screw
O anti-clockwise.
Maintenance Instructions
Inspecting and Maintaining the Wheels
It is essential that you regularly inspect and maintain your wheels, especially if your bike becomes
unstable or vibrates while riding.
1a. Inspect the Trueness of the Wheels
Over the life of the bike, the wheels may begin to run out of true. This is when the wheel buckles from
side to side.
To check the trueness of a wheel, lift the bike up and spin the wheel. If the wheel wobbles, it is out of
true and will need repairing.
Repairing wheels requires special tools. It is recommended that all wheels are trued by qualified bike
repair technicians. Contact your local retailer for more information on wheel repairs.
1b
10
1b. Inspect the Rim Wear
WARNING! If the wheel rim wear grove is no longer visible, the wheel rim should be replaced
Immediately. Do not attempt to ride the bike until the rim is replaced as the braking performance could
be affected.
Each wheel features a wear grove O machined into the side of the rim. If the wear grove O IS no
longer visible, the wheel rim is worn and should be replaced immediately.
1c. Inspect the Wheel Bearings
Over the life of the bike, the wheel bearings may become worn and will need servicing.
To check the condition of the wheel bearing, grab the tyre of either the front or rear wheel while holding
the bike securely. Vigorously move the tyre from side to side. If the wheel moves at the wheel hub (the
centre of the wheel), the bearings may be worn.
Repairing bearings requires special tools. It is recommended that all bearings are repaired by
qualified bike repair technicians. Gontact your local retailer for more information on bearing repairs.
Maintenance Instructions
1a
NOTE
on
If you have a puncture, you will need to remove and repair the inner tube.
NOTE! To remove the inner tube you will need a set of tyre levers.
1a. Removing the Tyre from the Wheel Rim
Unscrew the valve nut O from the inner tube valve. If required, deflate the tyre fully.
Using the thumb of one hand, depress the tyre opposite to the inner tube valve.
CAUTION! Be careful not to trap the inner tube between the tyre levers and the wheel.
Insert a tyre lever O between the wheel rim and the tyre walll.
Pull downwards on the tyre lever O and hook onto the nearest spoke.
Insert and secure the remaining two tyre levers at suitable points around the wheel rim.
NOTE! Do not leave too much space between tyre levers as the tyre may prove difficult to remove.
If it is not possible to fully remove the tyre from one side of the wheel rim, use the tyre levers as
described above on another section of the wheel.
11
Maintenance Instructions
Changing an Inner Tube (continued)
12
1b. Remove the Inner Tube from the Tyre
Once the tyre is removed from one side of the wheel rim, carefully remove the inner tube starting with
the valve.
1c. Replace the Inner Tube into the Tyre
Check the inner surfaces of the tyre for any signs of damage or foreign matter i.e. thorns or small
stones.To check the rim tape make sure its in place and covering the spoke nipple heads.
Partially inflate the inner tube using a bicycle pump.
Carefully feed the inner tube into the tyre, starting with the valve. The valve must be repositioned
through the appropriate hole in the wheel rim.
1d. Refit the Tyre to the Wheel Rim
Using the thumb of one hand, refit the tyre to the wheel rim a small section at a time. When the tyre is
too tight to fit by hand, use the tyre levers to refit the last section.
Routine Maintenance
Before and After Each Ride
You should perform the following checks before riding your bike to ensure it is safe to use and
operating correctly.
1. Is the Saddle Secure?
While standing next to the bike, try to move the saddle from side to side. If the saddle moves, you
should retighten the seat post bolt or the saddle clamp bolts.
2. Are the Front and Rear Tyres Inflated Correctly?
Squeeze the sides of the front and rear tyres. If they are soft they will need inflating. Re-inflate to the
pressure indicated on the sides of the tyres using an approved bicycle pump.
3. Are the Pedals Tight?
Using the supplied multi-tool, ensure both the left and right pedals are fully tight. Remember that the
threaded shafts of the left and right pedals tighten in different directions.Right is clockwise and left
side anti-clockwise.
4. Do the Brakes Work?
Stand next to the bike and apply the front brake and push forwards. If the wheels move, the front
brake may not be working correctly. If required, adjust the front brake as described on pages 7-9.
Repeat the above check for the rear brake.
5. Do the Handlebars Move?
Hold the front wheel between your legs and move handlebars left to right to see if moves? If the
handlebars move, the stem bolt may have become loose. Re-tighten the stem bolt.
6. Is the Bike Clean?
The bike should be cleaned and re-olled regularly to ensure it operates correctly.
Every Month
You should perform the following checks once a month or after long rides.
1. Check that the bike is Clean and Suitably Lubricated.
Thoroughly clean and degrease your bike. Ensure the chain, gears, front derailleur and rear derailleur
are adequately lubricated using a suitable bicycle lubricant.
It is important to wipe off any excess lubricant as this will attract dirt and may prevent the bike from
operating correctly. Note:lubricant in wrong places and too much will be a disaster.
2. Check that all Parts of the Bike are Securely Fitted.
It is essential for your safety that the securing nuts and bolts are fully tightened and have not become
loose. Pay particular attention to the pedals, wheel nuts, seat post bolt and the stem bolt.
While holding the bike with one hand, vigorously rock the crank arms and wheels. If you notice any
movement, the bearings may be worn.
Repairing bearings requires special tools. It is recommended that all bearings are repaired by
qualified bike repair technicians. Contact your local retailer for more information on bearing repairs.
13
Routine Maintenance
Every Month (continued)
3. Check that the Tyres are in Good Condition.
Check the outside of each tyre for signs of damage including cuts, deformation, excessive wear
or bald spots.
If your tyre shows any signs of damage, it must be replaced immediately. Do not attempt to ride the
bike with damaged tyres.
4. Check that the Wheel Spokes are Tight.
On each wheel check the tightness of the spokes. This can be done by gently squeezing two together
at time. If you notice any movement, the spokes may need tightening.
Repairing wheels and tightening spokes requires specialist tools. It is recommended that all wheel
spokes are tightened by qualified bike repair technicians. Contact your local retailer for more
information on wheel repairs.
Every Six Months
1. Check the Frame and Forks for Signs of Damage.
Thoroughly check all the external surfaces of the frame and suspension forks for signs of damage.
This may include cracks, dents or bent mounting points.
If the frame or suspension forks are damaged, do not attempt to ride the bike until it has been
inspected by a qualified bicycle technician.
2. Check that the Wheels are Running True.
Check the trueness of both the front and rear wheels as described on page 10.
3. Check the Condition of the Brake Pads.
Check all brake pads for signs of limit wear lines. Replace badly worn brake pads immediately.
4. Check the Front and Rear Gears for Signs of Damage.
Check the front and rear gears for signs of damage and/or limit wear lines. If any of the teeth on
a gear are chipped or missing, the chain may be prone to slipping. Replace the gear as soon as
possible.
Every Twelve Months
It is recommended that the bike is serviced by a suitably qualified bike technician every 12 months.
Make the replacement of the inner tube, tyre and brake pads which are the most vulnerable
components of a bicycle or contact Customer Care for help.
Routine Maintenance
Lubrication Information
Frequency Component
Weekly Chain
Deraileur wheels
Deraileurs
Brake calipers
Brake levers
Monthl Shift levers
y
Freewheel
Brake cables
Every Six Months
Yearly
Pedals
Bottom bracket
Deraileur cables
Wheel bearings
Headset
Seat pillar
Lubricant
Chain lube or light oil
Chain lube or light oil
Oil
Oil
Oil
Lithium based grease
Oil
Lithium based greas
Lithium based greas
Lithium based greas
Lithium based greas
Lithium based greas
Lithium based greas
Lithium based greas
How to Lubricate
Brush on or squirt
Brush on or squirt
Oil can
3 drops from oil can
2 drops from oil can
2 squirts from oil can
Disassemble
Disassemble
Disassemble
Disassemble
Disassemble
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 chain(WD-40™).
[ performance and may require a longer stopping distance.Injury to the rider can occur. Avoid getting any excess
lubrication on these area by wiping off excess lubricant,and keeping these areas clean and dry.
Recommended tightening information
Part Torque (Nm)
Front Wheel Nuts 22-25 Nm
Rear Wheel Nuts 25-29 Nm
Handlebar Clamp Nuts 16-18 Nm
Stem Bolt 18-20 Nm
Seat Clamp Bolt or Nuts 16-18 Nm
Seat Post Clamp Allen Bolt 8-10 Nm
Brake Cable Pinch Bolt 6-8 Nm
Crank Bolt or Nut 45 Nm
Pedals 40-45 Nm
Quick Release
Tight Enough to Secure (150-200N)
V-Brake Brake Blocks
8-10 Nm
15
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