, Inc. OWNERS MANUAL FOR SINGLE SPEED AND MULTI-SPEED BICYCLES 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.
HELMETS SAVE LIVES !!! ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE. DO NOT RIDE AT NIGHT. AVOID RIDING IN WET CONDITIONS. CORRECT FITTING - MAKE SURE YOUR HELMET COVERS YOUR FOREHEAD. INCORRECT FITTING. FOREHEAD IS EXPOSED AND VULNERABLE TO SERIOUS INJURY.
Dynacraft Customer Service 1.800.551.0032 7AM TO 4PM PACIFIC TIME Please have the following information available when you call: Model Number: (Sample: 8595-95) Production Date: (Sample: 2003.10.10) Serial Number: (Sample: 03TD5899988) Having this information is required and helps us handle your call more effectively. For help on where to find this information please see page IV. STOP I. DO NOT Return this Product to the Store. Please Call Dynacraft for Assistance.
PLEASE RETAIN YOUR SALES RECEIPT AS PROOF OF PURCHASE. FILL OUT THE INFORMATION BELOW AND KEEP THIS MANUAL IN A SAFE PLACE.
ABOUT THIS MANUAL This manual was written to help you get the most performance, comfort, enjoyment and safety when riding your new bicycle. It is important for you to understand your new bike. By reading this manual before you go out on your first ride, you’ll know how to get the most 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.
The following manual is only a guide to assist you and is not a complete or comprehensive manual of all aspects of maintaining and repairing your bicycle. The bicycle you have purchased is a complex object. 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.
DIRECTORY Index ..............................................................................................1 Parts Identification ..........................................................................................2-4 Before You Ride ........................................................................................5-20 Assembly ......................................................................................21-53 How Things Work .................................................
2.
PA R T S I D E N T I F I C AT I O N Mountain Bicycles . Mountain bicycles are designed to give maximum comfort over a wide variety of road surfaces. The wider handlebars and convenient shift lever position make them very easy to control. Wider rims and tires give them a softer ride with more traction on rough surfaces. The frame and fork on mountain bicycles are much sturdier than those on racing style bicycles.
Brake Lever Handlebar Seat Handlebar Grip Seat Post Handlebar Stem Seat Post Binder Bolt Brake Control Cable Head Set Seat Stay Rear Reflector Reflector Head Tube Front Brake Top Tube Brake Pad Wheel Reflector Front Fork Wheel Reflector Front Hub PA R T S I D E N T I F I C AT I O N BMX Bicycles . BMX bicycles are a popular general purpose type most suited for young riders. They are valued because of their sturdy and simple construction, and low maintenance.
PA R T S I D E N T I F I C AT I O N Road Bicycles .Road bikes are designed for fast travel, hard training and competition on paved surfaces exclusively. It is the lightest, most aerodynamic and “fastest” type of bicycle.
When selecting a new bicycle, the correct choice of frame size is a very important safety consideration. For safe and comfortable riding there should be a clearance of not less than 1 inch between the groin area of the intended rider and the top tube of the bicycle frame, while the rider straddles the bicycle with both feet flat on the ground. The ideal clearance will vary between types of bicycles and rider preference.
BEFORE YOU RIDE 06 RULES OF THE ROAD AND SAFETY TIPS NOTE: Like any sport, bicycling involves risk of injury and damage. By choosing to ride a bicycle, you assume the responsibility for that risk. Not the people who sold you the bike. Not the people who made it. Not the people who distribute it. Not the people who manage or maintain the roads and trails you ride on. YOU. So you need to know - and to practice - the rules of safe and responsible riding. 1.
BEFORE YOU RIDE 13. HAVE PROPER LIGHTS AND REFLECTORS. IF YOU RIDE AT NIGHT, be sure to have a strong headlight, a tail light, and a full set of reflectors. CHECK THAT REFLECTORS ARE CLEAN, STRAIGHT, UNBROKEN, AND SECURELY MOUNTED. 14. NEVER CARRY PACKAGES OR OBJECTS WHICH OBSTRUCT VISION. 15. NEVER HITCH RIDES, Never hold onto a moving vehicle while riding. 16. THE KICKSTAND IS DESIGNED TO SUPPORT THE BICYCLE ONLY, not the bicycle and the rider. 17.
BEFORE YOU RIDE Pedaling Technique - Position the ball of your foot on the center of the pedal. - When pedaling, ensure your knees are parallel to the bicycle frame. - To absorb shock, keep your elbows slightly bent. - Learn to operate the gears properly. (Refer to p. 16-18) Hill Technique - Gear down before a climb and continue gearing down as required to maintain pedaling speed. If you reach the lowest gear and are struggling, stand up on your pedals.
Saddle Height In order to obtain the most comfortable riding position and offer the best possible pedaling efficiency, the seat height should be set correctly in relation to the rider’s leg length. The correct saddle height should not allow leg strain from over-extension, and the hips should not rock from side to side when pedaling. While sitting on the bicycle with one pedal at its lowest point, place the ball of your foot on that pedal.
BEFORE YOU RIDE Handlebar Height Stem Wedge Bolt Handlebar Binder Bolt Exceeds 2 1/2” (64mm) Maximum comfort is usually obtained when the handlebar height is equal to the height of the seat. You may wish to try different heights to find the most comfortable position. Maximum Height/ Minimum Insertion Mark Warning: Over tightening the stem bolt or headset assembly may cause damage to the bicycle and/or injury to the rider.
Before every ride, it is important to carry out the following safety checks: (For information and instructions on performing specific equipment checks locate the relevent section in the manual using the index on page 1) 1. Brakes - Ensure Ensure Ensure Ensure front and rear brakes work properly. brake shoe pads are not over worn and are correctly positioned in relation to the rims. brake control cables are lubricated, correctly adjusted, and display no obvious wear.
BEFORE YOU RIDE 5. Chain - Ensure chain is oiled, clean and runs smoothly. - Extra care is required in wet or dusty conditions. - On bicycles equipped with coaster brakes, check for proper chain tension. 6. Derailleurs - Check that front and rear mechanisms are adjusted and function properly. - Ensure control levers are securely attached. - Ensure derailleurs, shift levers and control cables are properly lubricated. 7.
It is strongly advised that a properly fitting, CSPC 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: - be comfortable - be lightweight - have good ventilation - fit correctly BEFORE YOU RIDE Helmets Always wear a properly fitted helmet when riding a bicycle. Many states require specific safety devices.
BEFORE YOU RIDE Reflectors Your bicycle is supplied with one front (white), one rear (red), two wheel (white), and two pedal (orange) reflectors. These are an important safety and legal requirement, and should remain securely fitted and in good, clean conditions at all times. Periodically, inspect all reflectors, brackets and mounting hardware for signs of wear or damage. Replace immediately if damage is found. Some bicycles will require you to install your reflectors onto your bicycle.
Slide reflector over bracket as shown in diagram (p.14) and ensure that the tab clicks in to the top hole of the bracket. Next, remove the clamp screw and open the clamping reflector bracket. Place clamping reflector bracket around the handlebar or seatpost. If the clamp is too loose, insert the shim inside of the clamp. Tighten the clamp screw to hold reflector assembly in place, see the second diagram. Finally, adjust the reflector assembly in place.
BEFORE YOU RIDE Drivetrain Freewheel Cogs Derailleur Control Cable Front Derailleur Front Chainwheels Guide Pulley Crank Arm Rear Derailleur Pedal GEARS - HOW TO OPERATE Derailleur Gears Most multi-speed bicycles today are equipped with what are known as derailleur gears. They operate using a system of levers and mechanisms to move the drive chain between different sized driving gears or cogs. The purpose of gears is to let you maintain a constant, steady pedaling pace under varying conditions.
1 3 2 3 High 4 6 5 2 1 Middle Low For optimal performance, NOT RECOMMENDED BEFORE YOU RIDE 4 6 5 1 3 2 2 High 1 Low For optimal performance, NOT RECOMMENDED Recommended Chainwheel/Rear Sprocket Gear Combinations Hand Grip Shifters Front Low Gear Rear Low Gear Front High Gear Rear High Gear Many bicycles are now being equipped with a shifting mechanism that is built into the handlebar grips and does not make use of separate levers.
BEFORE YOU RIDE Thumb Shifters (Top Mounted) Left hand lever Right hand lever Many mountain style bicycles are equipped with shifters mounted on the top of the handlebars and operated by the thumbs. To select a lower, easier gear, shift to a bigger rear cog and a small chainwheel. Pull the left shifter back to operate the front derailleur, and push the right shifter forward to operate the rear derailleur. To select a higher, harder gear, shift to a smaller rear cog and a larger chainwheel.
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.
BEFORE YOU RIDE Storage Keep your bicycle in a dry location away from the weather and the sun. Ultraviolet rays may cause paint to fade or rubber and plastic parts to crack.Before storing your bicycle for a long period of time, clean and lubricate all components and wax the frame. Deflate the tires to half pressure and hang the bicycle off the ground. Don't store near electric motors as ozone emissions may effect the rubber and paint.
Includes 20", 24” and 26" Wheel Mountain Bikes Assembly is the same for men’s and women’s bikes. . Foreword: Assembling a bicycle is an important responsibility. Proper assembly not only gives the rider more enjoyment of the bicycle; it also offers an important measure of safety. Getting Started Open the carton from the top and remove the bicycle. Remove the straps and protective wrapping from the bicycle. Inspect the bicycle and all accessories and parts for possible shortages.
ASSEMBLY Handlebars Handlebar Binder Bolt Stem Wedge Bolt Top Nut Minimum Insertion Mark Wedge Remove the protective cap from the handlebar stem wedge and loosen the Allen key bolt using the 6mm Allen key. Some models may use a 13mm hexagonal bolt instead of an Allen key bolt. Place the handlebar stem into the top of the head tube, ensuring that all cables are free of tangles.
ASSEMBLY Shifter binder bolt (2.5 Allen key) NOTE: When assembling the bicycle or setting it up for a rider, the shifters, brake levers and bar ends may need to be rotated on the handlebars to a position that allows safe and easy operation on the controls. Brake lever binder bolt (5mm Allen key) Bar end (5mm Allen key) 1. Tighten all bolts that clamp the shifters, brake levers, and bar ends to the handlebar using a 5mm Allen key or Phillips head screwdriver. (Figure 1) Handlebar with Grip Shifter.
Forks ASSEMBLY Steering Tube Brake Boss Drop-out Crown Do not attempt to disassemble a suspension fork yourself. Consult a professional bicycle repair technician. Fork Leg 1. Brake Bridge Crown Brake Boss Drop-out Steering Tube Fork Leg 2. 24 There are two different types of forks that range in styles and dimensions. One type is a rigid fork (Figure 1) consisting of stationary tubing with curved blades.
Seat and Seat Post Seat Post Adjusting Nut Quick Release Attach Seat Here Boot ASSEMBLY Seat Clamp Attach the seat to the seat post by loosening the nuts on the seat clamp. Insert the tapered end of the seat post into the seat clamp until it is at the top of the clamp. Partially tighten the nuts on the seat clamp until the seat is snug, but can still be turned. Insert the seat assembly into the frame of the bicycle and adjust the seat to the proper height.
ASSEMBLY Pedals & Crank Set Dust Cap Check for the right (R, red) sticker and left (L, green) sticker on each pedal and crank arm. Match the appropriate pedal to each crank (right to right and left to left) for assembly. Start each pedal spindle by hand to avoid stripping the threads. Tighten with a 15mm narrow open ended wrench so that the shoulder of the pedal spindle is securely tightened against the crank arm.
1. Install the cable into the link wire. Cable End 2. Set the cable into the straddle holder. Brakes Determine which type of brake your bike is equipped with and refer to the appropriate assembly instructions. For more information on brake adjustment and maintenance, refer to p. 80-82. Cantilever Brakes - Utilizing a Link Wire If fitted with cantilever type brakes, insert the brake cable into the link wire lead, and notch the cable end into the slot of the left brake arm.
ASSEMBLY 3. Temporarily tighten the cable so that the link wire is at the position in the illustration. 5. Secure one of the shoes at a time. The adjustment of the shoe clearance is not necessary at this time. Shoe fixing nut tightening torque: 7.84 - 8.82 Nm (70 - 78 in. lbs.
V-Style Brakes Brake Cable Boot Brake Noodle Anchor Bolt Brake Arm Pivot Bolt Brake Shoe Tension Screw If not already assembled, take the brake noodle from the parts box and slide the cable through the larger opening. The cable housing will then seat into the end of the noodle. Slide the cable through the cable lead on the end of the left brake arm, this will cause the noodle to fit into the lead. Slip the brake cable boot over the cable and position it between both brake arms.
ASSEMBLY V - Brake 1. If fitted with V-Brakes, insert the brake body into the center spring hole in the frame mounting boss, and then secure the brake body to the frame with the link fixing bolt. 2. While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging the position of the B washers (i.e. 6 mm and 3 mm) so that dimension A is kept at 39 mm or more.
5. Adjust the balance with the spring tension adjustment screws. ASSEMBLY 3. While holding the shoe against the rim, tighten the shoe fixing nut. shoe fixing nut 1 mm 5 mm Allen key 1 mm Spring tension adjustment screw 4. Pass the inner cable through the inner cable lead. Set the cable with a clearance of 1mm between each brake pad and the rim, tighten the cable fixing bolt. 1 mm Spring tension adjustment screw 6.
ASSEMBLY Check your Brakes Press each brake lever to make sure that there is no binding and that the brake pads press hard enough on the rims to stop the bike. The brake pads should be adjusted so they are 1 mm to 2 mm away from the rim when the brakes are not applied. Brake pads should be centered on the rim and the rear portion of each brake pad should be about 0.5 - 1.0 mm farther from the rim than the front portion of the brake pad.
Disk Brakes Disc brakes require breaking in before full breaking power is achieved. While the break in period varies by model and manufacturer, a distance of 13 miles or 40 to 50 applications is the minimum before using the brakes for downhill conditions, for sudden stops, or other serious braking. Please read the specific instructions and warnings for the disc brakes supplied on your bicycle before riding your bicycle. Disc brakes are extremely powerful.
ASSEMBLY Derailleur Freewheel Outer side of Top Gear Pulley Adjustment Screw Guide Pulley Adjustment Screws Tension Pulley Barrel Adjuster High Gear Adjustment Screw Low Gear Adjustment Screw Rear Derailleur Begin by shifting the rear shifter to largest number indicated, disconnect the cable from the rear derailleur cable anchor bolt, and place the chain on the smallest sprocket. Adjust the High limit screw so the guide pulley and the smallest sprocket are lined up vertically.
Chainguide clearance of 3-5mm Front Derailleur Shift both shifters to the smallest number indicated and place the chain on the corresponding cog and chainwheel. Disconnect the front derailleur cable from the cable anchor bolt. Check the position of the front derailleur; it should be parallel with the outer chainwheel and clear the largest chainwheel by 35mm when fully engaged.
Dual Suspension ASSEMBLY Dual Suspension bikes are equipped with a front fork as well as a rear suspension generally located below the seat. The rear suspension unit is a combination of a piston that works in conjunction with a spring to allow the rear swing arm to rotate on a pivot point. Ensure all attaching hardware is secured and there is no lateral movement of the rear triangle. The amount of Rear Suspension travel can be adjusted by turning the adjusting plate.
Rear Pivots 3 ASSEMBLY 1 The pivot assembly is a simple mechanism that allows the rear swing arm to move up and down in combination with a rear suspension unit. Size, shape and components will vary between models: however operating principles are the same. The pivot point consists of a split bushing set, held in place by a bolt that rotates inside of fixed bushings in the frame. The pivot point should be kept clean and free of grime, and should be disassembled and re-greased at least once a season.
ASSEMBLY Accessories If your bike is supplied with a water bottle and cage, attach the cage to the bicycle using the allen bolts provided. Saddle Bag Frame Bag Reflector Reflector Reflector Water bottle and cage If the kickstand is not mounted to your bicycle; place the bicycle in an upright position against a wall or have someone hold it upright. Place the kickstand in the bracket mounted on the frame and use the fixing bolt to secure the kickstand in place .
Final Check Check that brakes operate smoothly with no binding. To test, apply the brakes while trying to push the bicycle forward to make sure they will stop the bicycle. Do not ride your bicycle unless the brakes are functioning properly. - Test the security of the handlebar within the stem, and the stem within the fork steerer tube, by clamping the front wheel between your knees and trying to move the handlebar up and down, and from side to side.
ASSEMBLY SINGLE SPEED & BMX Includes 16" and 20" BMX Bikes Assembly is the same for boy’s and girl’s bikes. Foreword: Assembling a bicycle is an important responsibility. Proper assembly not only gives the rider more enjoyment of the bicycle; it also offers an important measure of safety. Getting Started Open the carton from the top and remove the bicycle. Remove the straps and protective wrapping from the bicycle. Inspect the bicycle and all accessories and parts for possible shortages.
Stem Cap Binder Bolts Minimum Insertion Mark Remove the protective cap from the stem wedge and loosen the bolt using the 6mm Allen key. Some models may use a 13mm hexagonal bolt instead of an Allen key bolt. Place the handlebar stem into the head tube, checking that the curved rake of the fork and handlebars are facing forward. Align the stem with the front wheel, observing the minimum insetion mark on the stem and ensuring that all cables are free of tangles. Tighten the stem wedge bolt.
ASSEMBLY Seat Loosen nut on the seat clamp and add 3 or 4 drops of oil onto the threads of the bolt. Place the smaller end of the seat post into the seat clamp until it stops with the bolt to the rear of the seat post. Thread the nut on the seat clamp loosely. Insert the larger end of the seat post into the seat tube of the bicycle frame observing the minimum insertion mark on the seat post. Position the top surface of the seat parallel with the ground.
Brake Nipple Ferrule Determine which type of brake your bike is equipped with and refer to the appropriate assembly instructions. For more information on brake adjustment and maintenance, refer to p. 80-82. It is important to become familiar with the use of hand brakes. When properly adjusted, hand brakes are an efficient braking system. Keep the rim and brake shoes clean and free from wax, lubricants and dirt at all times. Keep brakes properly adjusted and in good working condition at all times.
ASSEMBLY Cantilever Brakes 1. Install the cable into the cable carrier. Cable End 2. Set the cable onto the straddle holder. Cantilever Brakes - Utilizing a Link Wire If fitted with cantilever type brakes, insert the brake cable into the link wire lead, and notch the cable end into the slot of the left brake arm. Loosen the anchor bolt on the right brake arm and thread brake cable through it.
5. Secure one of the shoes at a time. The adjustment of the shoe clearance is not necessary at this time. 3 Link Wire ASSEMBLY 3. Temporarily tighten the cable so that the link wire is at the position in the illustration. 10 mm wrench To u c h i n g 5 mm Allen key Cable Anchor Bolt Pad and rim should be parallel. 1 mm Direction of rim rotation 1- 2 mm 0.5 - 1.0 mm Pad and rim should be parallel.
ASSEMBLY V - Brake 1. If fitted with V-Brakes, insert the brake body into the center spring hole in the frame mounting boss, and then secure the brake body to the frame with the link fixing bolt. 2. While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging the position of the B washers (i.e. 6 mm or 3 mm) so that dimension A is kept at 39 mm or more.
5. Adjust the balance with the spring tension adjustment screws. 5 mm Allen key 1 mm 1 mm Spring tension adjustment screw 4. Pass the inner cable through the inner cable lead. Set the cable with a clearance of 1mm between each brake pad and the rim, tighten the cable fixing bolt. ASSEMBLY 3. While holding the shoe against the rim, tighten the shoe fixing nut. 1 mm Spring tension adjustment screw 6.
ASSEMBLY U-BRAKE INSTRUCTIONS 48 Adjust the pads of the U-brake using a 10mm wrench. Make sure the pad is hitting the rim and not the tire. Ideally the front of the pad should hit the rim approximately 1mm before the rear pad. Next tighten the Cable Carrier to the brake cable approximately 20mm from the brake arms when they are closed against the rim. Attach the Straddle cable to the carrier.
Check your Brakes Do not ride the bicycle until the brakes are functioning properly. To test, apply the brakes while trying to push the bike forward to make sure they will stop the bicycle. Training Wheel ASSEMBLY Press each brake lever to make sure that there is no binding and that the brake pads press hard enough on the rims to stop the bike. The brake pads should be adjusted so they are 1mm to 2 mm away from the rim when the brakes are not applied.
ASSEMBLY Rotors 50 Some freestyle BMX bicycles come equipped with a detangler system that will allow the handlebar to spin 360-degrees without binding the cables. CAUTION: Bicycles not equipped with rotors do not have this capability for spinning the handlebars. It is very important that this system is adjusted correctly. Installation should only be done by a qualified bicycle mechanic with the correct tools. Upper Cable 1. First connect the barrel end of the upper cable to the rear brake lever.
ASSEMBLY Failure to adjust correctly may result in loss of braking power and personal injury. Single Cable Casing Cable Adjuster Cable Splitter Upper Cable (long casing) Barrel End Upper Cable (short casing) Adjusting Barrel Upper Plate 37mm + or - 1mm Bearing Football Ends Lower Plate Lower Cable Locknut Set for Max.
ASSEMBLY 52 PLEASE NOTE: Not all axles are able to accept axle pegs. Please consult your local bicycle specialist if you have any questions. Some BMX bicycles come with two or four pegs. Non-Threaded Threaded Make sure the axle nuts are tight with a 15mm wrench or adjustable wrench. Place the domed washer (if supplied) over the axle and axle nut. Slide the peg onto the axle, and then using the supplied tool or a 15mm socket and extended driver, thread the peg-fixing nut onto the axle.
Front Reflector (White) Rear Reflector (Red) Install any additional parts that are supplied with your bike. NOTE: Your bicycle may be equipped with different style components than the ones illustrated. Reflectors: If not already attached, attach the reflctor mounts to the bicycle (see pages 14-15).
HOW THINGS WORK 54 6. How Things Work It’s important to your performance, enjoyment and safety to understand how things work on your bicycle. Even if you’re an experienced bicyclist, don’t assume that the way things work on your new bike is the same as how they work on older bikes. Be sure to read and to understand this section of the Manual. If you have even the slightest doubt as to whether you understand something, talk to your local bicycle specialist. Call 1-800-551-0032 with any further questions.
a. Removing a Bolt-On Front Wheel (1) Open up the brake shoes. (2) With a 15mm box wrench or a six inch adjustable wrench, loosen the two axle nuts. (3) If your front fork has a clip-on type secondary retention device, disengage it and go to step (4). If your front fork has an integral seondary retention device, loosen the axle nuts about six full turns; then go to step (4).
HOW THINGS WORK B. Seatpost Quick Release Many bikes are equipped with quick-release seat post binders. While a quick release looks like a long bolt with a lever on one end and a nut on the other, in fact the quick release uses a cam action to firmly clamp the seat post. WARNING: Riding with an improperly tightened seat post can allow the saddle to turn or move and cause you to lose control and fall. Therefore: 1.
NOTE: For most effective braking, use both brakes and apply them simultaneously. WARNING: Sudden or excessive application of the front brake may pitch the rider over the handlebars, causing serious injury or death. 1. How brakes work It’s important to your safety that you instinctively know which brake lever controls which brake on your bike. In the U.S., bikes are required to be set up with the right brake lever controlling the rear brake, and the left lever controlling the front brake.
HOW THINGS WORK When you apply one or both brakes, the bike begins to slow, but your body wants to continue at the speed at which it was going. This causes a transfer of weight to the front wheel (or, under heavy braking, around the front wheel hub, which could send you flying over the handlebars). A wheel with more weight on it will accept greater brake pressure before lockup; a wheel with less weight will lock up with less brake pressure.
HOW THINGS WORK 2.
HOW THINGS WORK 60 1) Shifting the Rear Derailleur The rear derailleur is controlled by the right shifter. The function of the rear derailleur is to move the drive chain from one gear to another on the rear gear cluster, thereby changing gear drive ratios. The smaller sprockets on the gear cluster produce higher gear ratios. Pedaling in the higher gears requires greater pedaling effort, but takes you a greater distance with each revolution of the pedal cranks.
If your bicycle has an internal gear hub drivetrain, the gear changing mechanism will consist of: • a 3, 5, 7 or possibly 12 speed internal gear hub • one, or sometimes two shifters • one or two control cables • one front sprockets called chainrings • a drive chain a) Shifting internal gear hub gears Shifting with an internal gear hub drivetrain is simply a matter of moving the shifter to the indicated position for the desired gear.
HOW THINGS WORK G. Tires and Tubes 1. Tires Bicycle tires are available in many designs and specifications, ranging from general-purpose designs to tires designed to perform best under very specific weather or terrain conditions. Your bicycle has been equipped with tires which the bike’s manufacturer felt were the best balance of performance and value for the use for which the bike was in-tended.
CAUTION: Pencil type automotive tire gauges and gas station air hose pressure settings can be inaccurate and should not be relied upon for consistent, accurate pressure readings. Instead, use a high quality dial gauge. NOTE: Some tires may need to be brought up to pressure every week or two. HOW THINGS WORK Tire pressure is given either as maximum pressure or as a pressure range. How a tire performs under different terrain or weather conditions depends largely on tire pressure.
HOW THINGS WORK H. Bicycle Suspension Some Mountain Bikes come equipped with suspension systems which are designed to smooth out some of the shocks encountered in riding. WARNING: Failure to maintain,check and properly adjust the suspension system may result in suspension malfunction, which may cause you to lose control and fall. CAUTION: Changing suspension adjustment can change the handling and braking characteristics of your bicycle.
Smooth running - Longer lasting components - Safer riding - Lower running costs Every time you ride your bicycle, its condition changes. The more you ride, the more frequently maintenance will be required. We recommend you spend a little time on regular maintenance tasks. The following schedules are a useful guide and by referring to Part 5 of this manual, you should be able to accomplish most tasks. If you require assistance, we recommend you see a bicycle specialist.
SERVICING Schedule 2 - Service Checklist Frequency Before every ride After every ride Weekly Monthly Every Six Months Yearly 66 Task Check tire pressure Check brake operation Check wheels for loose spokes Make sure nothing is loose Quick wipe down with damp cloth Lubrication as per schedule 1 Lubrication as per schedule 1 Check derailleur adjustment Check brake adjustment Check brake and gear cable adjustment Check tire wear and pressure Check wheels are true and spokes tight Check hub, head set and
Tools Required SERVICING 1 Open end or pedal wrench 15mm 2 Allen key wrenches: 4mm, 5mm, 6mm, 8mm 3 Adjustable wrench 4 Tire levers 5 Tire pump 6 Standard slip joint pliers 7 Standard Phillips head screwdriver 8 Standard flat head screwdriver 9. Open ended wrench or ring wrenches: 8mm, 9mm, 10mm, 12mm, 13mm, 14mm, 15mm 10. Tube repair kit Travel Tools 1. 2. 3. 4. 5. 6.
DETAILED MAINTENANCE WHEELS AND TIRES Wheel Inspection It is most important that wheels are kept in top condition. Properly maintaining your bicycle's wheels will help braking performance and stability when riding. Be aware of the following potential problems: •Dirty or greasy rims: Caution: These can render your brakes ineffective. Do not clean them with oily or greasy materials. When cleaning, use a clean rag or wash with soapy water, rinse and air dry. Don't ride while they're wet.
Tires must be maintained properly to ensure road holding and stability. Check the following areas: Inflation: Ensure tires are inflated to the pressure indicated on the tire sidewalls. It is better to use a tire gauge and a hand pump than a service station pump. Caution: If inflating tires with a service station pump, take care that sudden over inflation does not cause tire to blow up. Bead Seating: Tread: When inflating or refitting tire, make sure that the bead is properly seated in the rim.
DETAILED MAINTENANCE Ball Bearings Hub Body Bearing Cone Axle Lock Nut Washer Axle Nut Hub Bearing Adjustment When checked, the hub bearings of either wheel will require adjustment if there is any more than slight side play. 1. Check to make sure neither locknut is loose. 2. 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 bicycle cone wrench or flat, thin open end wrench. 3.
Match the position of the leak in the tube with the tire to locate the possible cause and mark the location on the tire. 7. Remove the tire completely and inspect for a nail, glass, etc. and remove if located. Also inspect the inside of the rim to ensure there are no protruding spokes, rust or other potential causes. Replace the rim tape which covers the spoke ends, if damaged. 8. Remount one side of the tire onto the rim. 9. Using a hand pump, inflate the tube just enough to give it some shape. 10.
DETAILED MAINTENANCE HANDLEBARS AND STEM Handlebar Stem Max. Height/ Minimum Insertion Mark Handlebar Binder Bolt Handlebar Clamp Bolts Stem Bolt Max. Height/ Min. Insertion Mark Stem Bolt Wedge 72 The handlebar stem fits into the steering column and is held firm by the action of a binder bolt and expander wedge which, when tightened, binds with the inside of the fork steerer tube. When removing the stem, loosen the stem wedge bolt two or three turns, then give it a tap to loosen the wedge inside.
Do not over tighten. Stem Wedge Bolt Handlebar Handlebar Stem Test the security of the handlebar within the stem, and the stem within the fork steerer tube, by clamping the front wheel between your knees and trying to move the handlebar up and down, and from side to side. The handlebar should not move when applying turning pressure.
DETAILED MAINTENANCE Grip 7/8” Plastic Washer Barrel Adjuster Cable GRIP SHIFTERS Grip Shift - Installation 1. Slide front Grip Shift assembly over left side of handlebar leaving proper clearance for handlebar grip. If necessary, move the brake lever to accommodate Grip Shift and handlebar grip. 2. Rotate assembly until cable exits beneath brake lever with adequate clearance for brake lever movement. 3. Firmly tighten recessed clamp screw. Installation torque should be 20 in.-lbs. 4.
DETAILED MAINTENANCE Cables and Cable Housing Cables and housing are one of the most overlooked parts on the bicycle. The first indication that your cables and housing need to be replaced is an increased amount of pressure needed to operate the brakes or shifters. Before every ride, check that there are no kinks or frays in the cables and housing.
DETAILED MAINTENANCE HEADSET Standard Headset Inspection The headset bearing adjustment should be checked every month. This is important as it is the headset which locks the fork into the frame, and if loose, can cause damage or result in an accident. While standing over the frame top tube with both feet on the ground, apply the front brake firmly and rock the bicycle back and forth; if you detect any looseness in the headset, it will need adjustment.
Inspection The seat fixing bolt and the seat post binder bolt should be checked for tightness and adjustment every month. On removing the seat post from the frame, you will notice a mark about 65mm up from the bottom with the words “max. height” or “minimum insertion”. Seat Clamp Nut Standard Seat Post Under no circumstances should the seat post project from the frame beyond its “Minimum Insertion” or “Maximum Extension” mark.
DETAILED MAINTENANCE Adjustment As mentioned in Part 2, the seat can be adjusted in height, angle and distance from the handlebars to suit the individual rider. Saddle angle is a matter of personal preference but the most comfortable position will usually be found when the top of the seat is almost parallel to the ground, or slightly raised at the front. The saddle can also be adjusted by sliding it forward or back along the mounting rails to obtain the most comfortable reach to the handlebars.
The correct adjustment and operation of your bicycle's brakes is extremely important for safe operation. Brakes should be checked for effective operation before every ride. Frequent checking of adjustment is necessary as the control cables will stretch and the brake pads will become worn with use. Never ride a bicycle unless the brakes are functioning properly. There are three types of hand operated bicycle brakes in common use: sidepull brakes, cantilever brakes, and V-brakes (or Direct Pull brakes).
DETAILED MAINTENANCE The brake lever and brake caliper pivot points should be oiled with 2-3 drops of light oil at least every three months to ensure smooth operation and to reduce wear. Cables should be greased along their entire length, after removing them from their casings, at least every six months. Always grease new cables before fitting.
Adjustment - Cantilever Calipers Minor brake adjustment can be made via the barrel cable adjusters which are located on each brake lever. Caution: The brake cable adjustiong barrels are for minor adjustments only. For major adjustments see the appropriate section in the manual for the type of brakes on your bicycle.
DETAILED MAINTENANCE Tread Usable Brake Shoe Tread Worn Off Worn Out Brake Shoe (Replace) Align brake shoe with rim surface Direction of rim rotation Brake Shoe Holding Nut 0.5 - 1.0 mm 82 Adjust the brake pad position so that it is parallel to the wheel rim and so that the leading edge makes first contact. To do this, fit an Allen key into the brake pad holding bolt, loosen the fixing nut and adjust.
The drivetrain of a bicycle refers to all parts that transmit power to the rear wheel including the pedals, chain, chainwheel, crank set, and freewheel. PEDALS Pedals are available in a variety of shapes, sizes and materials, and each are designed with a particular purpose in mind. Some pedals can be fitted with toe clips and straps. These help to keep the feet correctly positioned and allow the rider to exert pulling force, as well as downward pressure, on the pedals.
DETAILED MAINTENANCE Lubrication and Adjustment Many pedals cannot be disassembled to allow access to the internal bearings and axle. However, it is usually possible to inject a little oil onto the inside bearings, and this should be done every six months. If the pedal is the type that can be fully disassembled, then the bearings should be removed, cleaned and greased every six to twelve months.
The crank set refers to the bottom bracket axle and bearings, the crank arms, and chainrings. Your bike may be fitted with either a one piece crank, where the crank arms and bottom bracket are a single component, or cotterless cranks, where the crank arms bolt onto the bottom bracket axle without using old fashioned type cotterpins. The one piece system is simpler and requires less maintenance, while the cotterless system requires a little extra care.
DETAILED MAINTENANCE Lubrication and Adjustment - One Piece Cranks To adjust the free play in a one piece type bottom bracket, loosen the locknut on the left side by turning it clockwise and tighten the adjusting cone counter-clockwise using a screwdriver in the slot. When correctly adjusted, re-tighten the locknut counter-clockwise. To disassemble: 1. Remove the chain from the chainwheel. 2. Remove the left pedal by turning the spindle clockwise. 3.
Lubrication and Adjustment - Cotterless Cranks To adjust the free play in a three piece type bottom bracket, loosen the lockring on the left side by turning it counter-clockwise, then turn the adjusting cup as required. Re-tighten the lockring taking care not to alter the cup adjustment. Fixed Cup Cotterless Crank removing tool Ball Retainer Adjusting Cup Bottom Bracket Shell Lockring Axle Remove the dust cap. Loosen and remove the flange nut. To disassemble: 1. Remove the cranks from the axle.
DETAILED MAINTENANCE Screw in the removal tool. Turn the screw bolt clockwise. Adjustment After Use: 1. Remove dust cap. 2. Tap the crank arm lightly with a mallet. 3. Re-tighten the flange nuts, and refit the dust caps. Position the crank on the axle. Lightly tap the crank onto the axle. Tighten the flange nut. Replace the dust cap. 88 Cotterless Crank Replacement: 1. Replace the crank arm onto the axle. 2. Tap the crank arm lightly with a mallet. 3.
Front Chainwheel CHAIN Inspection The chain must be kept clean, rust free and frequently lubricated in order to extend its life as long as possible. It will require replacement if it stretches, breaks, or causes inefficient gear shifting. Make sure that there are no stiff links, they must all move freely. Pull up 10 mm Straightedge DETAILED MAINTENANCE Rear Sprocket Lubrication The chain should be lubricated with light oil at least every month, or after use in wet, muddy, or dusty conditions.
DETAILED MAINTENANCE Chains require a special tool to fit and remove chain links, or to change the length. To remove, fit the rivet tool so that the punch pin is centered over any one of the chain rivets. Push the rivet almost all the way out, then back out the punch and remove the tool. Holding the chain on both sides of the punched rivet, bend it slightly to release link from the rivet.
Brake Arm Sprocket Remove any accumulated dirt from the freewheel with a brush and a degreaser. Disassembly of the freewheel is a complicated procedure requiring special tools, and should be left to a specialist. Apply oil to the freewheel whenever you lubricate the chain, taking care to wipe off any excess. COASTER HUB Many BMX style and other children's bicycles are fitted with a coaster hub brake in the rear wheel. This type of brake offers the advantages of reliability and easy operation.
DETAILED MAINTENANCE DERAILLEUR SYSTEMS The derailleur system includes the front and rear derailleurs, the shift levers, and the derailleur control cables, all of which must function correctly for smooth gear shifting to occur. There are several different types of derailleur systems but all operate using similar principles. Your new bicycle may be fitted with a standard 'friction' type system where you will need to feel each gear shift into position. It may be fitted with an ‘index’ system (e.g.
Cable Fixing Bolt High Adjusting Screw Outer Chainguide Chainguide clearance of 1-3 mm Inner Chainguide Adjustment - Front Derailleur 1. Shift the rear shifter to the smallest number indicated, then shift the front shifter to the smallest number indicated. Disconnect the front derailleur cable from the cable anchor bolt and place the chain on the smallest chainwheel. 2. Make sure the front derailleur cage is parallel with the outer chainwheel on the crankset.
DETAILED MAINTENANCE Outer side of Top Gear Freewheel Pulley Adjustment Screw All the pivoting points of the front and rear derailleurs should be lubricated with light oil at least every month. Be sure to wipe off any excess oil to prevent attraction of dirt into the mechanisms. The shifting cables should be cleaned and re-coated with a thin layer of grease every six months, or whenever new cables are being installed.
Your bicycle is supplied with one front (white), one rear (red), two wheel (white), and two pedal (orange) reflectors. These are an important safety and legal requirement, and should remain securely fitted and in good, clean conditions at all times. Periodically, inspect all reflectors, brackets and mounting hardware for signs of wear or damage. Replace immediately if damage is found. Please see pages 14-15 for more information.
TROUBLESHOOTING 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 indexing 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 - Lubri
Possible Cause Remedy Freewheel does not rotate - Freewheel internal pawl pins are jammed - Lubricate.
TROUBLESHOOTING 98 Problem Possible Cause Remedy Steering not accurate - - Align wheels correctly - Adjust/tighten headset - Take bike to a bike shop for possible frame realignment Frequent punctures - Wheels not aligned in frame Headset loose or binding Front forks or frame bent Stem wedge bolt not tight Inner tube old or faulty Tire tread/casing worn Tire unsuited to rim Tire not checked after previous puncture - Tire pressure too low - Spoke protruding into rim - Replace Inner tube Replace ti
LIMITED WARRANTY Subject to the following limitations, all bicycles manufactured for Dynacraft are warranted to the original purchaser to be free of defects in materials and workmanship for a period from the date of purchase of: Lifetime For The Bicycle Frame and Fork Two Years On All Other Component Parts No other express or implied warranty is given.
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BSC, Inc 89 S. Kelly Rd. American Canyon, CA 94503 1.800.551.0032 www.dynacraftbikes.
