Contents 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 User Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bicycle Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Congratulations About This Manual Toll free: 1-800-626-2811. Customer Service hours: Monday - Friday 8 AM- 5 PM Central Standard Time (CST) This manual contains important information regarding safety, assembly, use, and maintenance of the bicycle but is not intended to be a complete or comprehensive manual covering all aspects concerning bicycle ownership.
Helmets Save Lives! Correct Fitting Make sure your helmet covers your forehead • ALWAYS WEAR A PROPERLY FITTED HELMET WHEN RIDING YOUR BICYCLE • DO NOT RIDE AT NIGHT • AVOID RIDING IN WET CONDITIONS Incorrect Fitting Forehead is exposed and vulnerable to serious injury 3
1 Safety ❶ Safety SAFETY SIGNAL WORDS The following safety signal words indicate a safety message. The symbol alerts you to potential hazards. Failure to follow the warning may result in damage to property, injury, or death. This manual contains many Warnings and Cautions concerning the consequences of failure to follow safety warnings. Because any fall can result in serious injury or even death, we do not repeat the warning of possible injury or death whenever the risk of falling is mentioned.
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.
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.
Safety 1 Quick-release Lever WARNING! Improper setup or maintenance of the quick-release levers may result in an unexpected movement, loss of control, and serious injury or death. Before riding always check that the quick-release lever is firmly locked in place and the seat does not move. Seat Post ❷ Ensure the seat post’s minimum insertion marks are not visible above the seat clamp and the clamp is locked in place. Figure 1.3 Note: See Section 4: Adjusting the Seat Height if adjustments are needed.
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.
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.
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.
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.
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.
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! Chains 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.
❷ Parts Identification Juvenile 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 grip Torque (in.-lb) Part name Torque (in.
Parts Identification 2 1 2 27A 5 6 7 25 27E 9A 8 24 27D 27C 3 4 9 27B 9B 23 27 9C 26 27E 10 12 17 22 11A 28 20 21 11 12 13 14 16 19, 19A 18 15 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.
Assembly 3 GETTING STARTED ❶ Open the carton from the top and remove the bicycle. Figure 3.2 ❷ Remove the straps and protective packaging from the bicycle. Important! Do not discard packing materials until assembly is complete to ensure that no required parts are accidentally discarded. Seat Handlebar assembly Seat post ❸ Inspect the bicycle and all accessories and parts for possible shortages.
3 Assembly ATTACH THE HANDLEBAR WARNING! • Improper attachment 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. Important! Be sure the minimum insertion marks do not go above the top of the headset and are not visible. ❸ Using a 6 mm Allen wrench tighten the stem binder bolt at the top of the stem post.
Assembly 3 Attaching a Threadless Stem Important! Do not disassemble the headset or lose any parts. Be sure the end of the fork is on the ground or being held with your free hand, because once you loosen the top cap the fork assembly may fall out of the frame. ❶ Turn the front fork to face forward (ie: the fork dropout is in the furthest forward position). Figure 3.3 ❷ Using a 5 mm Allen wrench loosen the top cap bolt on the steerer tube and remove the top cap and bolt.
3 Assembly ATTACH THE FRONT BRAKE CABLE 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 If the brakes are not attached follow these steps: Brake lever Figure 3.
Assembly 3 ATTACH THE FRONT WHEEL There are two types of front wheel assemblies; nutted with step retaining washer, and nutted with clip retaining washer. 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. 2 Protrusion on step retaining washer fits into the fork dropout Figure 3.
3 Assembly Nutted with Clip Retaining Washer ❶ Loosen the axle nuts on the front wheel. If there is a washer inside of the axle nut, it belongs outside of the fork dropouts. Figure 3.12 3 ❷ Position the front wheel between the front fork legs with the axle resting inside the fork drop out. Important! Be sure the wheel is as centered as possible between the fork legs. Clip retaining washer inserted into dropout hole Figure 3.
Assembly 3 ATTACH THE SEAT WARNING! Improperly adjusted seat height could affect the rider’s ability to reach the handlebar and pedals resulting in unexpected movement, loss of control, and serious injury or death. Follow these guidelines when adjusting the seat height. Always ensure the seat post minimum insertion marks are below the seat clamp and cannot be seen. Ensure the seat clamp is locked and the seat cannot move. ❹ Try to close the quick-release lever.
3 Assembly ATTACH THE PEDALS WARNING! • Attachment of an incorrect pedal into a crank arm can strip pedal threads and cause irreparable damage. Visually match the R and L stickers on the pedal and crank arm before attaching the pedals. Before your first ride, please check to ensure your pedals are attached correctly. 3 1 2 • It is very important that you check the crank set for correct adjustment and tightness before riding your bicycle.
Assembly 3 ATTACH THE TRAINING WHEELS WARNING! Failure to properly assemble and set up the training wheels may cause instability and tip over resulting in serious injury or death. Always check the training wheels before using the bicycle. ❹ Replace the washer and axle nut. Tighten the axle nut securely, making sure that the wheel brace stays in the proper vertical position. ❺ The elongated hole on the wheel brace allows the training wheel height to be adjusted for proper fit.
3 Assembly Flat Brace ❶ Remove the outer axle nut and washer from the rear wheel axle. Figure 3.17 ❷ Place the flat wheel brace onto the axle. ❸ Place the brace stabilizer washer onto the axle and align it so that the notch fits into the rear frame drop out. ❹ Replace the washer and axle nut. ❺ Tighten the axle nut securely, making sure that the wheel brace stays in the proper vertical position. The elongated hole on the wheel brace allows the training wheel height to be adjusted for proper fit.
Assembly 3 Training Wheel Stabilizer Bracket ❶ Remove the outer axle nut and washer from the rear wheel axle. Figure 3.18 ❷ Insert the training wheel brace into the stabilizer bracket so that the forked end of the stabilizer bracket faces in. ❸ Slide assembly onto the rear axle so that the forked end hooks around the chain stay of the bicycle. ❹ Replace the axle nut and washer, secure tightly. ❺ The elongated hole on the brace allows for raising and lowering the training wheel to the proper height.
3 Assembly ATTACH THE PEGS Important! Periodically check to make sure pegs are tight. Some models may come equipped with 2 or 4 pegs. To install: ❶ Do not loosen or remove axle nuts. Figure 3.19 ❷ Check to make sure axle nuts are properly tightened before installing pegs. Axle nut 2 3 ❸ Thread the pegs on the axle over the axle nut. ❹ Insert a screwdriver or similar tool through the peg holes and tighten by turning the peg with the tool. Figure 3.
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.
4 Adjustments ADJUSTING THE BRAKES WARNING! Adjusting the Brake Pads 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 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.
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.
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.
Adjustments 4 Adjusting the Side-pull Caliper Brake Attaching the Brake Cable to the Brake Carrier 1 ❶ If the brake cable is disconnected at the caliper, thread the brake wire through the adjustment barrel. Figure 4.8 Brake cable ❷ Loosen the cable anchor bolt until you can see a gap large enough for the cable wire. Cable adjustment barrel ❸ Thread the cable wire through the gap. By hand, screw the cable anchor bolt snug enough to hold the cable wire.
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.
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.
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.
Adjustments 4 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. ❹ Try to close the quick-release lever.
4 Adjustments ADJUSTING THE HANDLEBAR 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 is functioning properly and secured to the frame before riding the bicycle.
Adjustments 4 ADJUSTING THE 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.
4 Adjustments ❶ Loosen the top cap bolt and remove the top cap. 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. Figure 4.19 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 4.20 If the gap is not correct add or remove spacers until it is.
Adjustments 4 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.
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.
Use 5 Hand Operated Brakes 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. 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.
5 Use SECURITY 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 model number. Serial number is underneath the bottom bracket. Model number is above the bottom bracket. Figure 5.3 • 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.
Maintenance 6 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.
6 Maintenance 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.
Maintenance 6 PARTS MAINTENANCE Tires Inspect Tire Inflation Frequency: Inspect and maintain at least each use 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.
6 Maintenance Drivetrain (pedals, chains, chainwheel, crank set, freewheel) Inspect Pedals Action Every month, check each pedal is securely set and tighten into the crank arm. Frequency: as noted Maintenance If necessary, re-set and tighten. Before each ride, check each front and rear pedal reflectors are Clean or replace. clean and in place. Pedal Bearings Every ride, check the pedal bearings are properly adjusted. Move the pedal up and down, left and right.
Maintenance 6 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.
6 Maintenance 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.
Maintenance 6 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: 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).
6 Maintenance TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Slipping chain • Excessively worn/chipped chainring or freewheel sprocket teeth • Chain worn/stretched • Stiff link in chain • Non compatible chain/chainring freewheel • Replace chainring, sprockets and chain • Replace chain • Lubricate or replace link • Seek advice at a bicycle shop Chain jumping off freewheel sprocket or chainring • Chainring out of true • Chainring loose • Chainring teeth bent or broken • Rear or front
Maintenance 6 Problem Possible Cause Remedy 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
6 Maintenance Problem Steering not accurate Frequent punctures 54 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
Warranty 7 ❼ Warranty LIMITED LIFETIME WARRANTY AND POLICY ON REPLACEMENT PROCEDURES AND 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.
7 Warranty 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: Address: City: State: Service sticker is located above the bottom bracket area Date Purchased: Place of Purchase: Model & Brand Information: Wheel Size: Model Number: Color: The serial number is located below the bottom bracket Date Code: Serial Number: 56 Figure 7.