Owner’s Manual BMX Bicycles This manual contains important safety, assembly, operation and maintenance information. Please read and fully understand this manual before operation. Save this manual for future reference.
Owner’s Manual Index Introduction • Owner’s Bicycle Identification Record ................................................... 3 • Fitting the Rider to the Bicycle ............................................................... 3 • Warning and Safety Information ............................................................ 4 • Freewheel Brakes .................................................................................. 4 • Reflectors ......................................................................
Owner’s Bicycle Identification Record Introduction NOTE: This information is only available on the bicycle itself. It is not available from Huffy. Each Huffy bicycle has a Serial Number stamped into the frame. The Serial Number can be found on the bottom of the crank housing as shown (1). xxx 1 xx xx xxx Write this number below to keep it for future reference. If the bicycle is stolen, give this number and a description of the bicycle to the police. This will help them find the bicycle.
Warning and Safety Information Introduction Meanings of Warnings: a This symbol is important. See the word “CAUTION” or “WARNING” which follows it. The word “CAUTION” is before mechanical instructions. If you do not obey these instructions, mechanical damage or failure of a part of the bicycle can occur. The word “WARNING” is before personal safety instructions. If you do not obey these instructions, injury to the rider or to others can occur. • • • • • • • Adult assembly is required.
• • • • • Always wear shoes. Ride on the correct side of the road, in a single file, and in a straight line. Bikes under 20” not intended for use on roads. Avoid riding at night, dusk, dawn and any other time of poor visibility. Make sure the reflectors of your bicycle are correctly positioned. Do not remove the reflector or replace the reflectors with lighted devices that look similar to reflectors. • Do not let anything cover the reflectors.
2 3 4 24 25 26 27 28 29 30 Components 17 6 8 11 31 15 16 32 1 13 12 14 18 19 20 21 23 22 16 5 3 4 17 9 10 7 22 21 Part Assembly View
Handlebar Stem Right Pedal Left Pedal Kick Stand Wheel Retainer (x2) Axle Nut (x4) Pegs Seat Post Clamp 11 12 13 14 15 16 17 18 27 Chain Chain Guard Lower Brake Cable Coupler (various models) 8 9 Crank and Spindle Set 7 10 26 Fork 6 32 31 30 29 28 25 24 23 22 21 Tube (x2) Tire (x2) 3 20 Rear Wheel Assembly Front Wheel Assembly 2 19 5 Frame 1 No. 4 Description No.
Introduction Assembly This Owner’s Manual is made for several different bicycles: • Some illustrations may vary slightly from the actual product. • Follow instructions completely. • If the bicycle has any parts that are not described in this manual, look for separate “Special Instructions” that are supplied with the bicycle. • Models may have different accessory items such as bags, baskets, reflectors, cup holders, racks, etc. • All features, components and accessories are not included on all models.
1. If the Axle Nuts (18) are already attached to the front wheel axle, begin by removing them with an open end wrench or adjustable wrench. 2. Set the wheel into the front fork (2) (fig 04). 3. Install wheel retainers (17) making sure the tabs are in the fork (D) tab holes. 4. Attach the front wheel with the Axle Nuts. 5. Tighten Axle Nuts to 21 ft-lbs. Assembly Assemble the Front Wheel to the Fork D 17 18 2 18 fig 04 17 NOTE: Ensure wheel spins freely without contacting fork or fender.
Assembly Handlebar and Stem Installation - No Gyro Brake WARNING: To prevent steering system damage and possible loss of control, the “MIN-IN” (minimum insertion) mark (A) on the stem must be below the top of the Locknut (B). NOTE: Remove plastic Cap (E) from the end of the Stem (11). D 1. Insert the Stem (11) into the fork (fig 07). 2. Point the Stem towards the front of the bike. 3. Tighten the Stem Bolt (C) just enough to hold it in position. 4.
Handlebar and Stem Installation - continued • Bicycle Assembly Assembly Four Bolt Clamp Top Mount: • If necessary, re-adjust Handlebar. • Tighten Clamp Screws (D) evenly according to pattern. D NOTE: Do not over tighten. Torque to 17 ft-lbs. 3 1 2 4 28 Four Bolt Clamp, Front Mount: • If necessary, re-adjust Handlebar. • Tighten Clamp Screws (D). fig 08 28 NOTE: Do not over tighten. Torque to 17 ft-lbs. D 3 1 2 4 fig 08b Two Bolt Stem: • • • Loosen Clamp Screws (A).
Stem and Handlebar Setup - Gyro Brake Assembly Note: The Handlebar Stem Clamp may be pre-installed from the factory. • Carefully unpack Handlebar and Brake Cables. • If needed, loosen the Stem Bolt (A) and point the Stem (B) towards the front of the bike as shown. • Tighten the Stem Bolt securely. • Install the Handlebar (C) and rotate to a comfortable riding position. • Tighten Clamp Screws (D) securely.
Gyro Stem and Brake Setup - continued • Install the two Cable Adjusters (A) into the Gyro Plate (B) making sure the Shorter Cable (C) is on the same side as the Brake Lever (D). • Turn the Cable Adjusters and Nuts (E) all the way into the Gyro Plate - hand tight. C A Assembly D A E B • Squeeze the two sides of the Gyro Plates (A) together and insert the Cable End (B) into the Gyro Plate Slot (C). • Repeat for other side.
Assembly Gyro Brake Setup - Front Brake Cable Install • Pull the Front Brake Cable (A) up through the Stem Nut (B) so that it is routed as shown. • Ensure the Brake Cable does not touch the Tire (C). 1 A • Insert Cable Barrel (2-1) into Brake Lever. 2 B 2-1 2-1 • Insert Brake Cable (3-1) into Groove as shown. C 3 A 3-1 • Ensure Housing Nut and Housing (4-3, 4-1) are adjusted all the way in towards the Hand Lever.
Gyro Brake Setup - Front Brake Cable Install - continued Assembly • Rotate Brake Levers (A) into a comfortable riding position and tighten securely. A WARNING: Ensure Gyro Handlebar/Stem/Wheel system can rotate 360 degrees without binding any Cables and that the Gyro mechanism works smoothly. Seat Installation (various models) Attach Seat to Seat Post: (pre-assembled on some models) • If needed, loosen nuts on seat clamp (A) and rotate Seat (22) into riding position.
Seat Installation (various models) - continued Assembly • Point the Seat (22) forward and put the Seat Post (19) into the Seat Tube (B) (figs 10, 11). WARNING: To prevent the seat coming loose and possible loss of control, the “MIN-IN” (minimum insertion) mark (C) on the seat post must be below the top of the Seat Tube (B). Tighten the quick release lever: • Move the Quick Release Lever (D) to the “open” position so the word “open” is pointing away from the Seat Post Clamp (E).
Seat Installation - continued You must use strong force to move the quick release lever to the “close” position. If you can easily move the lever to the “close” position, the clamping force is too light. WARNING: If the clamping force of the Quick Release Lever is too light, the seat post can loosen while riding. This can cause injury to the rider or to others. Assembly CAUTION: Operate the Quick Release Lever (D) by hand only. Do not use a hammer or any other tool to tighten the quick release lever.
Front and Rear Reflector Installation Assembly 1. Position FRONT Reflector (27) so it points straight forward. 2. Tighten Clamp Screw. NOTE: Do not over-tighten. This will damage the Clamp. 27 fig 12 20 1. Position REAR Reflector (20) so it points straight backwards. 2. Tighten Clamp Screw. NOTE: Do not over-tighten. This will damage the Clamp. WARNING: Ensure the Front Reflector is White and the Rear Reflector is Red.
Pedal Installation • The pedal marked “R” has right-hand threads. Tighten it in a clockwise direction. • The pedal marked “L” has left-hand threads. Tighten it in a counterclockwise direction (anti-clockwise). • Turn the right pedal marked “R” into the right side of the crank arm, and the left pedal marked “L” into the left side of the crank arm. Assembly CAUTION: There is a right pedal marked “R” and a left pedal marked “L”.
Testing Seat Clamp and Post Clamp Tightness Assembly To test the tightness of the seat clamp and the post clamp: WARNING: Every time the quick release mechanism is loosened, make sure the red reflector is correctly positioned. • • Try to turn the seat side-to-side and to move the front of the seat up and down. If the seat moves in the Seat Clamp (A): • Loosen the Seat Clamp (A). • Put the seat in the correct position and tighten the Seat Clamp tighter than before.
Testing Stem and Handlebar Tightness • Straddle the front wheel between your legs. • Try to turn the front wheel by turning the handlebar. • If the handlebar and stem turn without turning the front wheel, realign the stem with the wheel and tighten the stem bolt(s) tighter than before (about 1/2 revolution only at a time). • Do this test again, until the handlebar and stem do not turn without turning the front wheel.
Brake System Setup and Adjustment Assembly WARNING: You must adjust the front brakes before you ride the bicycle. NOTE: FRONT AND REAR BRAKE SETUP IS THE SAME. Brake Shoe Adjustment: B A Step One: Put the brake shoes (B) in the correct position: • Loosen the Screw (A) of each Brake Shoe (B). • Adjust each Brake Shoe so it is flat against the rim and aligned with the curve of the rim. • Make sure each Brake Shoe does not rub the tire.
Brake System Setup and Adjustment - continued Brake System Adjustment: 1 Assembly 1. Loosen Cable Nut (1-1) so that the cable is loose. 1-1 2. Insert Cable Barrel (2-1) into Brake Lever. 2 2-1 2-1 3. Insert Brake Cable (3-1) into Groove as shown.
Brake System Setup and Adjustment - continued 4. Rotate Housing (4-1) Groove away from Cable Groove (4-2) and tighten Housing Nut (4-3). 4-2 Assembly 4 4-1 4-3 5. Squeeze Brake Arms (5-1) so that Brake Pads (5-2) are against the Rim. 5 5-1 5-2 6. Pull Brake Cable (6-1) tight. • Tighten Cable Nut (6-2). • Adjust Cable Nut (6-3) for 1/16” Brake Pad clearance.
Brake System Setup and Adjustment - continued 7. Make sure the Brake Lever is not loose (7-1). 0 7 Assembly 7-1 8. Make sure the cable sheaths are fully inserted into the adjustment housing at the Caliper (8-1) and Hand Lever (8-2). 8 8-1 8-2 • Rotate Brake Levers (A) into a comfortable riding position and tighten securely.
Coaster Brakes (various models) Assembly These models are equipped with a rear ‘coaster’ brake that is operated by rotating the crank backwards. Operation: Operate the coaster brake as follows: • Push the pedals backward to move the chain backward • The chain activates the coaster brake mechanism that is inside the rear wheel hub • As you push the pedals backward with increasing force, the braking action of the coaster brake increases.
NOTES • The pegs are optional. You may choose not to install them on the axles. Pegs can be installed on the front, rear or on one side. • The same procedure is used to install pegs on both the front and rear axles. Front wheel axle is shown. Threaded pegs: • No additional tools are necessary to install the pegs. • Put a peg (17) on each end of the axle. • Make sure the peg is fully seated against the frame or fork. Tighten the peg securely. • Pegs will go over the axle nuts (16).
Accessories Pegs Installation - Bolt on NOTES • The pegs are optional. You may choose not to install them on the axles. Pegs can be installed on the front, rear or on one side. • The same procedure is used to install pegs on both the front and rear axles. Front wheel axle is shown. Pegs that are not threaded: • A socket wrench, a metric socket which fits the axle nuts, and a three-inch socket extension are necessary to install the pegs.
WARNING: • Inspect the bicycle frequently. Failure to inspect the bicycle and to make repairs or adjustments, as necessary, can result in injury to the rider or to others. Make sure all parts are correctly assembled and adjusted as written in this manual and any “Special Instructions”. • Immediately replace any damaged, missing, or badly worn parts. • Make sure all fasteners are correctly tightened as written in this manual and any “Special Instructions”.
Maintenance and Service Lubrication 30 WARNING: • Do not over lubricate. If oil gets on the wheel rims or the brake shoes, it will reduce brake performance and a longer distance to stop the bicycle will be necessary. Injury to the rider or to others can occur. • The chain can throw excess oil onto the wheel rim. Wipe excess oil off the chain. • Keep all oil off the surfaces of the pedals where your feet rest.
What When How Brake Levers every six months Put one drop of oil on the pivot point of each brake lever. Caliper Brakes every six months Put one drop of oil on the pivot point of each caliper brake. Brake Cables every six months Put four drops of oil into both ends of each cable. Allow the oil to soak back along the cable wire. Pedals every six months Put four drops of oil where the axles go into the pedals. Chain every six months Put one drop of oil on each roller of the chain.
Maintenance and Service Inspection of the Bearings Maintenance Frequently check the bearings of the bicycle. Lubricate the bearings according to the lubrication chart or any time they do not pass the following tests: Head Tube Bearings The fork should turn freely and smoothly at all times. With the front wheel off the ground, you should not be able to move the fork up, down, or side-to-side in the head tube.
Maintenance: • Frequently check the tire inflation pressure because all tires lose air slowly over time. For extended storage, keep the weight of the bicycle off the tires. • Do not use unregulated air hoses to inflate the inner tubes. An unregulated hose can suddenly over inflate bicycle tires and cause them to burst. • Replace worn tires. WARNING: Do not ride or sit on the bicycle if a tire is under inflated. This can damage the tire and inner tube.
Warranty Information Huffy Corporation Limited Warranty • Part or model specifications are subject to change without notice. • This Limited Warranty is the only warranty for your Huffy Corporation (“Huffy”) product. There are no other expressed or implied warranties. • This Limited Warranty extends only to the original consumer and is not transferable to anyone else. • Warranty registration is not required. • The only uses for this product are described in this manual.
For how long does this Limited Warranty last? • The frame is warranted for life except aluminum frames which are warranted for ten (10) years, from the date of purchase. • The fork is warranted for life except for shock forks which are warranted one (1) year from date of purchase. • All other components are warranted for six (6) months from the date of purchase. What will Huffy do? Huffy will replace, without charge to you, the component found to be defective by Huffy.
WARNING: ALWAYS WEAR YOUR HELMET WHEN RIDING THIS PRODUCT! CORRECT INCORRECT • • • • • Helmet should sit level on your head and low on your forehead Adjust the strap sliders below the ear on both sides. Buckle the chin strap. Adjust strap until it is snug. No more than two fingers should fit between the strap and your chin. A proper fitting helmet should be comfortable and not rock forward/backward or side to side.
