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.
Correct CORRECT FITTING Make sure your helmet covers your forehead Correct Incorrect INCORRECT FITTING Forehead is exposed and vulnerable to serious injury ©2011
Personal Care from Congratulations on your new purchase! Our Service Department is dedicated to your satisfaction with Pacific Cycle and its products. For questions regarding performance, assembly, operation, parts or returns, contact the experts at Pacific Cycle directly by calling toll free 1-800-626-2811 8:00am - 5:00pm Central Time Monday thru Friday or by email customerservice@pacific-cycle.
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.
ABOUT THIS MANUAL It is important for you to understand your new bicycle. By reading this manual before you go out on your first ride, you’ll know how to get better performance, comfort, and enjoyment 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. GENERAL WARNING Bicycling can be a hazardous activity even under the best of circumstances.
1 PARTS IDENTIFICATION .................................................................................................6-7 Single Speed Bicycle • Multi Speed Bicycle 2 BEFORE YOU RIDE .......................................................................................................8-24 Warning, Note to parents • Fit • Helmets, Protective Gear & Clothing • Safety Checklist • Riding Safety • Operation • Security • Maintenance • Storage 3 ASSEMBLY .......................................................
SINGLE SPEED BICYCLE PARTS IDENTIFICATION Get to know the parts of your bicycle. This will help with assembly, maintenance, and troubleshooting. Single speed bicycles vary greatly. Your model may have additional accessories such as fenders, bags, carriers, etc. Note that smaller children’s bicycles also contain training wheels.
MULTI SPEED BICYCLE Get to know the parts of your bicycle. This will help with assembly, maintenance, and troubleshooting. Multi speed bicycles vary greatly. Your model may have additional accessories such as fenders, bags, carriers, etc.
SIZING GUIDE & CHART When choosing the correct size bicycle, there are some guidelines that will help you determine the correct fit. It is important that you are able to safely mount and dismount the bicycle, and that while riding you are comfortable and can operate the brakes, steering and pedal without any added difficulty.
Saddle Height Handlebar stem height about the same as seat 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 cause 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.
Handlebar Height Maximum comfort is usually obtained when the handlebar height is equal to the height Stem wedge bolt Handlebar of the seat. You may wish to try different heights to find the most comfortable position. binder bolt Threadless headsets and clamp-on stems are not adjustable. Please refer to assembly-adjustments (p. 27) for instructions on installation.
HELMETS, PROTECTIVE GEAR & CLOTHING Helmets A WORD TO PARENTS REGARDING CHILDREN AND HELMETS: Many states have passed helmet laws regarding children. Make sure you know your states 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.
BEFORE YOU RIDE Choosing Riding Clothing and Protective Gear When choosing to ride a bicycle, the riders should always consider the clothing they will wear. Any loose clothing parts or strings can get caught in a bicycles moving parts and cause an accident. Be sure there are no loose cords, strings, over sized cuffs or pant legs. Loose pants should be tied or tucked into a sock. A leg band is often used to keep pants from getting caught in the chain of the bicycle.
SAFETY CHECKLIST Before every ride, it is important to carry out the following safety checks: Brakes • Ensure front and rear brakes work properly. • Ensure brake shoe pads are not overly worn and are correctly positioned in relation to the rims. • Ensure brake control cables are lubricated, correctly adjusted and display no obvious wear. • Ensure brake control levers are lubricated and tightly secured to the handlebar.
BEFORE YOU RIDE 14 Bearings • Ensure all bearings are lubricated, run freely and display no excess movement, grinding or rattling. • Check headset, wheel bearings, pedal bearings and bottom bracket bearings. Cranks and Pedals • Ensure pedals are securely tightened to the cranks. • Ensure cranks are securely tightened to the axle and are not bent. Derailleurs • Check that front and rear derailleurs are adjusted and function properly.
Reflectors +/– 5 degrees of ver cal 16” and under bicycles are considered “sidewalk bicycles”, and may not be fitted with reflectors. These bicycles should not be ridden on streets, at night or unattended by an adult. All other bicycles are supplied with one front (white), one rear (red), two wheel (white), and four pedal (orange) reflectors.
RIDING SAFETY General Rules BEFORE YOU RIDE • When riding obey the same road laws as all other road vehicles, including giving way to pedestrians, and stopping at red lights and stop signs. For further information, contact the Road Traffic Authority in your State. • Ride predictably and in a straight line. Never ride against traffic. • Use correct hand signals to indicate turning or stopping. • Ride defensively. To other road users, you may be hard to see.
Wet Weather • In wet weather you need to take extra care. • Brake earlier, you will take a longer distance to stop. • Decrease your riding speed, avoid sudden braking and take corners with additional caution. • Be more visible on the road. • Wear reflective clothing and use safety lights. • Pot holes and slippery surfaces such as line markings and train tracks all become more hazardous when wet.
Rules for Children BEFORE YOU RIDE To avoid accidents, teach children good riding skills with an emphasis on safety from an early age. Children should be supervised by an adult. 1. Many states require that children wear a helmet while cycling. Always wear a properly fitted helmet. 2. Do not play in driveways or the road. 3. Do not ride on busy streets. 4. Do not ride at night. 5. Obey all the traffic laws, especially stop signs and red lights. 6.
BRAKE OPERATION There are 2 types of braking systems for bicycles; Foot operated and hand operated. Foot Operated Brakes Foot operated brakes allow the rider to pedal forward to accelerate the bicycle, and pedal backwards to brake. The harder you push back on the pedals, the more braking force is applied to the rear wheel. In most cases a foot operated brake is strong enough to “lock up” (stop the wheel from turning) the rear wheel and cause the tire to skid.
BEFORE YOU RIDE 20 Hand Operated Brakes 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. Hand operated brakes may be used alone or on some models in conjunction with foot operated brakes.
GEAR OPERATION Multi speed bicycles can have internal or derailleur gear systems. 1 WARNING: Improper shifting can result in the chain jamming, or becoming derailed resulting in loss of control or a crash. Always be sure the chain is fully engaged in the desired gear before pedaling hard. 2 Avoid shifting while standing up on the pedals or under load. AVOID THESE GEARS! 2.
BEFORE YOU RIDE Freewheel cogs Rear derailleur External Gears (derailleur equipped bicycles) Front derailleur Derailleur control cable Avoid back pedaling on any bicycle with derailleurs. Backpedaling can derail the chain and cause it to jam or fall off the gears. When shifting gears, make sure you pedal forward until the gear has completely changed. (At least one full rotation of the pedals.
Front Shifter Note that not all models have a front shifter. The front (left) shifter will have an indicator that reads either “low to “high” or a series of numbers from 1 up. Low or “1” is the lowest gear. The front shifter acts much like the rear shifter, but the change between gears is greater. This means that one shift at the rear derailleur will be a subtle change in pedaling speed, but one shift at the front derailleur will be a large change in pedaling speed.
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. BEFORE YOU RIDE • Store your bicycle under shelter.
TOOLS FOR ASSEMBLY Your new bicycle was assembled and tuned in the factory and then partially disassembled for shipping. You may have purchased the bicycle already fully assembled and ready to ride OR in the shipping carton in the partially disassembled form. The following instructions will enable you to prepare your bicycle for years of enjoyable cycling. For more details on inspection, lubrication, maintenance and adjustment of any area please refer to the relevant sections in this manual.
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. It is recommended that the threads and all moving parts in the parts package be lubricated prior to installation. Do not discard packing materials until assembly is complete to ensure that no required parts are accidentally discarded.
There are 2 basic types of handlebar mounting; Quill and Threadless. Quill Stems This is a handlebar assembly that has a wedge shaped part at the bottom of the stem that is inserted into the fork steer tube. Loosen the center bolt enough so that the wedge and stem can slide into the fork steer tube. Lower the stem until the mark that says “minimum insertion” is not visible. Tighten the stem center bolt so that the handlebar assembly is in line with the fork.
ASSEMBLY 28 There are two types of front wheel hubs; Nutted and quick release. Axle Axle nut Fork drop out ©2011 FRONT WHEEL Retaining washer Hub Cone nuts Nutted Front Wheels Step retaining washer 3.9 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. If the washer has a hook or a step, be sure that it engages the fork before tightening the axle nuts.
Quick Release Wheels 1. Locate the quick release skewer from the small parts carton of your bicycle. 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. (Fig. 3.10) 2. Unscrew the lock nut from the quick release skewer, remove outer spring and slide the skewer through the front wheel axle so that the handle is on the left side of the bike (the side opposite the chain). (Fig. 3.11) 3.
SADDLE ASSEMBLY ASSEMBLY The saddle assembly should be adjusted with the saddle centered on the rails and level. Locate the saddle assembly and insert into the frame. It is recommended to add some grease to all threads and binders on a bicycle, especially on the outside of the seat post. Otherwise it may corrode over time, and not be able to be adjusted again.
PEDALS AND CRANKS Attachment of an incorrect pedal into a crank arm can strip pedal threads and cause irreparable damage. Before your first ride, please check to ensure your pedals are attached correctly. Look for the letters “R” for right, and “L” for left, stamped on each pedal spindle. Start each pedal spindle by hand to avoid stripping the threads. (Note that the right hand pedal attaches to the chainwheel side crank arm with a right-hand (clockwise) thread.
Cable adjus ng barrel Handlebar Grip Brake lever ASSEMBLY Cable head Ferrule 3.16 Center bolt (fixing nut in back) Cable anchor nut Cable adjus ng barrel Brake arm Brake shoe 3.17 3.18 32 ©2011 FRONT BRAKE CAUTION: Improper use of the front brake may cause front wheel to lock up resulting in loss of directional control or front pitch over.
Brake pad aligned the rim surface Brakewith pad aligned with the rim Pad and rim should surface be parallel Check the brake pads to be sure they are square to the rim, and do not contact the tire when the brake is applied. Adjust brake pads if needed. Then squeeze and release the brake several times squeezing as hard as you can. After this the cable may “stretch” and need to be tightened further. If so, repeat cable tightening steps. (Fig. 3.
FRONT U-Brake Brake cable If the brake cable is not connected at the brake lever, slide the head of the brake cable into the brake lever per the diagram, and thread the cable through the slot in the brake lever so the cable end rests squarely in the adjustment barrel or cable end rests in the recess of the brake lever. (Fig. 3.16) Housing barrel Cable anchor bolt Cable end cap 5mm Allen bolt To tension spring To tension spring Brake pads Spring tension nut 3.
Check the brake pads to be sure they are square to the rim, and do not contact the tire when the brake is applied. Adjust brake pads if needed. Then squeeze and release the brake several times squeezing as hard as you can. After this the cable may “stretch” and need to be tightened further. If so, repeat cable tightening steps. (Fig. 3.27) Brake pad aligned with the rim surface Pad and rim should be parallel Correct Incorrect 3.26 3.
Cable Detangler Some freestyle bicycles are equipped with a cable detangler for the rear brake. See diagram of the cable routing. If the upper cable is not already assembled, insert the cable barrel end into the right (rear) brake lever. Adjust the brake lever adjustment barrel so that the slots line up with the brake lever and insert the upper cable through the brake barrel slots. Rotate the barrel so that the slots are no longer in line.
Single cable casing Cable adjuster Upper cable (long casing) Cable spli er Barrel end ASSEMBLY Upper cable (short casing) Adjus ng barrel Locknut Upper plate Bearing Set for maximum travel Keyed washer Minimum 1mm (1/32”) Football ends Lower plate Lower cable Minimum 1mm (1/32”) Locknut Lower cable 3.
Linear Pull Brakes Cable adjus ng barrel Handlebar If the brake cable is not connected at the brake lever, slide the head of the brake cable into the brake lever per the diagram, and thread the cable through the slot in the brake lever so the cable end rests squarely in the adjustment barrel or cable end rests in the recess of the brake lever. (Fig. 3.31) ASSEMBLY Grip Brake lever Cable head Ferrule 3.31 Noodle 3.
Check the brake pads to be sure they are aligned with the rim, and that they do not contact the tire when the brake is applied. Adjust brake pads if needed. Then squeeze and release the brake several times squeezing as hard as you can. After this the cable may “stretch” and need to be tightened further. If so, repeat cable tightening steps. (Fig. 3.34) Brake pad aligned with the rim surface Pad and rim should be parallel 1-2 mm Correct Incorrect 3.33 3.
Disc Brake Cable adjus ng barrel Handlebar If the brake cable is not connected at the brake lever, line up brake barrel slots with brake lever slot before installing the cable. Then slide the head of the brake cable into the brake lever per the diagram, and thread the cable through the slot in the brake lever so the cable end rests squarely in the adjustment barrel or cable end rests in the recess of the brake lever. (Fig. 3.37) Grip Brake lever ASSEMBLY Cable head Ferrule 3.
Centering brake If you squeeze the brake and one side moves more than the other, or one side does not move at all, then the brake is not centered, or the wheel is not centered. First determine if the wheel is centered. Look at the gap between the tire and the fork or frame on either side. If it is not even, loosen wheel axle nuts and center the wheel, then proceed to centering the brake. (Fig. 3.39, 3.40) Adjust brake caliper so disc is centered between brake pads 3.
DERAILLEUR Freewheel Although the front and rear derailleurs are initially adjusted at the factory, you will need to inspect and readjust both before riding the bicycle. Pulley adjustment screw ASSEMBLY Outer side of top gear Rear Derailleur Guide Pulley Adjustment screws Tension Pulley SIS cable adjuster 3.42 High gear adjustment screw Low gear adjustment screw Barrel adjuster 3.
Low adjus ng screw Cable anchor bolt High adjus ng screw Chainguide clearance of 1-3mm Outer chainguide 3.44 (Fig. 3.44) 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.
ASSEMBLY FRONT FENDER - if equipped The front fender is mounted at the fork crown. There are two ways in which to mount your front fender. The first is the caliper brake mounting system (see Fig. 3.45), and the second is the 10mm nut and bolt system (see Fig. 3.46). Identify the mounting system used on your bicycle and follow the given instructions for that particular type of mounting system. (Fig. 3.
PEGS Some models may come equipped with 2 or 4 pegs. To install pegs, DO NOT loosen or remove axle nuts. Check to make sure axle nuts are properly tightened before installing pegs. Thread the pegs on the axle over the axle nut, and insert a screwdriver or similar tool through the peg holes and tighten by turning the peg with the tool. (Fig. 3.
Flat Brace Inner axle Flat wheel brace Brace stabilizer washer Axle nut Remove the outer axle nut and washer from the rear wheel axle. Place the flat wheel brace onto the axle. Next place the brace stabilizer washer onto the axle and align it so that the notch fits into the rear frame drop out. Replace the washer and axle nut. Tighten the axle nut securely, making sure that the wheel brace stays in the proper vertical position.
FINAL CHECK Never inflate a tire beyond the maximum pressure marked on the tire’s sidewall. Exceeding the recommended pressure may blow the tire off the rim, which could cause damage to the bicycle and injury to the rider and bystanders. Tighten both front/rear wheel axle nuts or the quick release mechanism securely. Failure to do this may cause the front/rear wheel to dislodge from the frame dropouts resulting in serious damage or injury.
Correct routine maintenance of your new bike will ensure: 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.
WHEELS Quick release: Check that these are set to the closed position and are properly tensioned before each ride. CAUTION: Maintain the closed position and the correct adjustment. Failure to do so may result in serious injury. Axle nuts: Check that these are tight before each ride. 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.
DETAILED MAINTENANCE How to fix a flat tire If you need to repair a tire, follow these steps: 1. Remove the wheel from the bicycle. 4.1 2. Deflate the tire completely via the valve. Loosen the tire bead by pushing it inward all the way around. (Fig. 4.1) 3. Press one side of the tire bead up over the edge of the rim. NOTE: Use tire levers, not a screwdriver, otherwise you may damage the rim.
Hub Bearings Hub body Lock washer Ball 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. (Fig. 4.4) Bearing cone 1. Check to make sure neither locknut is loose. 2.
MAINTENANCE 52 Brakes Usable brake shoe Never ride a bicycle unless the brakes are functioning properly. 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. (Please refer to p.
Screw the barrel adjuster 3/4 of the way in, squeeze the pads against the rim, undo the cable anchor bolt and pull the cable through with pliers. Re-tighten the cable anchor bolt and apply full force to the brake lever to test, then fine tune using the barrel adjuster. If one pad is closer to the rim than the other, loosen the fixing nut at the back of the brake, apply the brake to hold it centered, and re-tighten the fixing nut. (Fig. 4.
Note: The right and left pedals of a bicycle each have a different thread and are not interchangeable. Never force a pedal into the incorrect crank arm. The right pedal, which attaches to the chainwheel side, is marked ‘R’ on the end of the axle, and screws in with a clockwise thread. The left pedal, which attaches to the other crank arm, is marked ‘L’ on the axle, and screws in with a counter-clockwise thread.
Rear sprocket To disassemble: 1. Remove the chain from the chainwheel. 2. Remove the left pedal by turning the spindle clockwise. 3. Remove the left side locknut by turning it clockwise and remove the keyed lockwasher. 4. Remove the adjusting cone by turning it clockwise with a screwdriver. 5. Remove the left ball retainer, slide the crank assembly out of the frame to the right, and remove the right ball retainer.
Adjustment and replacement On derailleur geared bicycles the rear derailleur automatically tensions the chain. To adjust the chain on single speed freewheel, coaster hub braked or 3-speed hub geared bicycles: 1. Loosen the rear axle nuts (and coaster brake arm clip if fitted) and move the wheel forward to loosen, or backward to tighten, in the frame. MAINTENANCE Chain rivet tool 2.
Lubrication 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. Brake arm clip Brake arm Spocket Coaster Brake Hub Many BMX style and other children’s bicycles are fitted with a coaster hub brake in the rear wheel.
Freewheel Guide Pulley Adjustment screws Tension Pulley MAINTENANCE Outer side of top gear Pulley adjustment screw The front derailleur should also shift the chain cleanly and without hesitation between each chainring. If your bicycle is equipped with front indexing (a click between gears), then each click or stop in the shifter should equate exactly to a new gear position.
Low adjus ng screw Cable anchor bolt 5. Shift through the gears ensuring each gear is achieved quietly and without hesitation. NOTE: It may take several adjustments to achieve the desired positioning. Please refer to the troubleshooting section for more assistance. High adjus ng screw Adjustment - Front Derailleur (Fig. 4.18) 1. Shift the rear shifter to the smallest number indicated, then shift the front shifter to the smallest number indicated.
Quick Release Levers It is important to check the quick release levers before every ride to ensure all connections are made properly and securely. Periodically, disassemble the mechanism from the bicycle and inspect for any wear or damage and replace if necessary. When reinstalling, it is very important to ensure the connections are made properly. (Please refer to p. 29-30 for the appropriate assembly instructions.
Problem Gear shifts not working properly Possible Cause Remedy • Derailleur cables sticking/ stretched/damaged • Front or rear derailleur not adjusted properly • Indexed shifting not adjusted properly • Lubricate/tighten/replace cables 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 o
MAINTENANCE Problem Possible Cause Remedy Grinding noise when pedaling • Pedal bearings too tight • Bottom bracket bearings too tight • Chain fouling derailleurs • Derailleur jockey wheels dirty/binding • Adjust bearings • Adjust bearings • Adjust chain line • Clean and lubricate jockey wheels Freewheel does not rotate • Freewheel internal pawl pins are jammed • Lubricate.
Problem Possible Cause Remedy • Axle broken • Wheel out of true • Hub comes loose • Headset binding • Hub bearings collapsed • QR mechanism loose • Replace axle • True wheel • Adjust hub bearings • Adjust headset • Replace bearings • Adjust QR mechanism Steering not accurate • Wheels not aligned in frame • Headset loose or binding • Front forks or frame bent • Align wheels correctly • Adjust/tighten headset • Take bike to a bike shop for possible frame realignment Frequent punct
PURCHASE RECORD Fill in immediately and retain as a record of your purchase. *Please retain your sales receipt for any possible warranty claims.
LIMITED WARRANTY AND POLICY ON REPLACEMENT PROCEDURES & 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.
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