Instructions / Assembly

27
Disc Brake System - continued
PAD REPLACEMENT:
1. Remove the Caliper Mounting Bolts
F
.
2. Remove the Caliper assembly
E
.
3. Remove the Brake Pads from the Caliper.
4. Install the new Pads using same type and size.
5. Install the Caliper assembly
E
to the mounts on the fork (front), or frame (rear) (front
shown).
6. Tighten the caliper Mounting Bolts
F
securely. See Torque Table for recommended
torque.
7. Route the Cable
D
through the lower Adjusting Barrel
C
and Cable Clamp
A
.
• Ensure Cable Housing
G
is fully inside Adjusting Barrel
C
.
8. Pull the Cable through the Cable Clamp, and tighten the Clamp
A
Bolt.
NOTE: Brake adjustment involves loosening the Cable Clamp Bolt. During installation, it only
needs to be tightened enough to make sure the Cable End doesn’t pull back through the
Camp.
9. Adjust the Brake (as described above).
BRAKE SYSTEM MAINTENANCE:
• Check brake operation and adjustment before each ride.
• Keep the brake system free of dirt, mud, oil, and other foreign substances that will inhibit
proper operation.
• Frequently check:
• All components for damage.
• The pads - for wear.
• The lever - for smooth operation.
• The cable - ensure there are no frayed ends, cuts, or kinks that inhibit operation. Add
cable lube if the cable is dry.
• All bolts and fasteners - ensure the bolts are tightened, replace any that are damaged.
Adjusting Barrel
C
on the Caliper. Turn the Adjusting Barrel OUT to tighten the brakes
or IN to loosen the brakes.
NOTE: Make sure the Adjusting Barrel threads are fully engaged. Check adjustment again.
8. If you cannot reduce the gap by turning the Adjusting Barrel, the brake pads might be
worn out and need to be replaced.
Shift System
Shift System
PARTS OF THE SHIFT SYSTEM:
• Left-hand Shifter
A
operates the Front
Derailleur
B
• Right-hand Shift Lever
C
operates
the Rear Derailleur
D
• Front Sprocket Set
E
• Rear Sprocket Set
F
OPERATE THE SHIFT SYSTEM AS FOLLOWS:
1. The rider turns the Rear Shift Control
C
around the handlebar (for twist shift models) or
moves the shift lever (thumb shift models) to an index position
2. When the rear shift control moves into each position with a “click” sound, the shift is
complete
3. The rider turns the Front Shift Control
A
around the handlebar (for twist shift models) or
moves the shift lever to an index position (thumb shift models)
4. Each shift control pulls a cable wire that is attached to the derailleur.
5. The derailleur moves and guides the chain from one sprocket to another.
6. If there is some chain noise after the shift, turn the rear shift control a small amount to
“trim” the rear derailleur.
F
E
A
C
B
D
WARNING:
• Never shift a derailleur onto the largest or the smallest sprocket if the derailleur is not
shifting smoothly. The derailleur may be out of adjustment and the chain could jam,
causing loss of control and injury.
• Never move the shifter while pedaling backward, nor pedal backwards immediately
after having moved the shifter. This could jam the chain and cause damage to the
bicycle and/or loss of control and injury.