THIS INSTRUCTION BOOKLET CONTAINS IMPORTANT SAFETY INFORMATION. PLEASE READ AND KEEP FOR FUTURE REFERENCE.
FOR SERVICE ASSISTANCE CALL TOLL FREE 1.800.451.5368 Monday - Friday 8:00 a.m. to 4:00 p.m. Eastern Standard Time Congratulations on the purchase of your new bike! With proper assembly and maintenance it will offer you years of enjoyable riding! IMPORTANT: Carefully read and follow this manual (and any other materials included with this bike) before riding. Please retain this manual for future use.
RESPONSIBILITY OF THE OWNER! IMPORTANT: Reading and following the information and instructions in this manual are essential to your ability to ride safely. 1. It is the responsibility of the owner or in the case of a younger rider the parents of the rider to be certain all assembly instructions have been followed, even if the bike has been assembled by the seller or a professional assembly company. 2. Brakes are essential to safety. Be sure they are checked and working properly before each use.
OWNER’S RESPONSIBILITY continued NOTE. Carefully read this manual and follow instructions. Your bicycle may come with additional instruction sheets that cover features unique to your bike. Please ensure that you read and become familiar with their contents. Always wear a CPSC approved helmet when riding your laws. Keep all materials which come with the bike for future reference. Any major service or adjustments on your bike should be carried out by a competent adult or professional bike mechanic.
Table of Content Parts Identification Graphics........................5-6 Before Riding................................................7-12 Assembly Instructions..................................13-35 Maintenance ................................................36-53 Warranty ......................................................54 Warning / Caution ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE. DO NOT RIDE AT NIGHT. AVOID RIDING IN WET CONDITIONS.
NOTE: This is a typical bicycle. Your bike may have other or different parts, and in some cases, may not have all parts shown here. Seat Clamp IMPORTANT: Use this Diagram when reading this manual to help you understand directions and instructions.
NOTE: This is a typical bicycle. Your bike may have other or different parts, and in some cases, may not have all parts shown here. Seat Clamp Rear Reflector Seat Post Clamp Rear Suspension Rear Brake Rear Derailleur IMPORTANT: Use this Diagram when reading this manual to help you understand directions and instructions.
RULES OF THE ROAD In the interest of safe cycling, make sure you read and understand the owner’s manual. DANGER, WARNING , CAUTION, IMPORTANT, and NOTE or NOTICE. These are important signal words telling you to pay special attention to that text as rider safety is involved. DANGER and WARNING: Pay special attention to these since failure to do so could result in serious injury or death to the rider or others.
RULES OF THE ROAD continued 4. CAUTION: WET WEATHER WARNING: Check your brakes frequently. The ability to stop is critical. Roads are slippery in wet other debris on the road can also affect stopping distance. If at all possible, do not ride in wet weather. Vision and control are impaired, creating a greater risk of accidents and injury. 5. CAUTION that restricts your vision or your hearing. 6. When riding, ALWAYS WEAR A CPSC APPROVED BIKE HELMET your bike. 9. Never carry passengers.
RULES OF THE ROAD continued 14. WARNING: NIGHT TIME OPERATION: We do NOT recommend riding your bike at night. If you have an emergency that requires you to ride at night you must have proper lights and reflectors. NEVER ride at night without a helmet, taillight, a white front reflector, a red rear reflector, pedal reflectors and white wheel reflectors. You ust be able to clearly see the surface where you are riding and be seen by others. 15.
BEFORE RIDING: Your new bicycle was assembled and tuned in the factory and then partially disassembled for shipping. 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. If you have questions about your ability to properly assemble this bicycle, please consult a professional bicycle mechanic before riding.
BEFORE EVERY RIDE: each time before you ride make a habit of performing the following safety checks. • Stand in front of the bicycle facing rearward and hold the front wheel securely between your legs. Try to twist the handlebar and verify that they do not move. Then pull the handlebars up, trying to lift the bike. There should be no movement. handlebars and strike wheel downward with the heel of your hand and conrirm that it is securely attached to the wheel.
CORRECT FRAME SIZE When selecting a new bicycle, the correct choice of frame size is a very important safety consideration. The ideal clearance will vary between types of bicycles and rider preference.
ASSEMBLING YOUR BIKE PREPARATION It is important that you read this owner’s manual before you start to assemble your bicycle. WE RECOMMEND THAT YOU CONSULT A PROFESSIONAL BICYCLE MECHANIC IF YOU HAVE DOUBTS OR CONCERNS AS TO YOUR ABILITY TO PROPERLY ASSEMBLE, REPAIR, OR MAINTAIN YOUR BICYCLE. Remove all parts from the shipping carton. Check to make sure no parts are loose on the bottom of the carton. Carefully remove the front wheel which is attached to the side of the bicycle for shipping.
ASSEMBLING YOUR BIKE FRONT WHEEL 1. Remove the nuts, washers and wheel retainers from the front wheel. 2. Slide the wheel onto the open ends of the fork. Slip an axle retainer onto each end of the axle, and hook the retainers into the holes in the fork end. Loosely install the washer onto each end of the axle (serrated end toward the retainer), then install the hex nut. (Note: there may be a washer head nut in place of the washer and hex nut). 3.
QUICK RELEASE FRONT WHEEL Some bicycles have wheel axles that incorporate a Quick Release (QR) mechanism. This allows easy wheel removal without the need for tools. The mechanism uses a long bolt (called a skewer) with an Adjusting Nut on one end, and a lever operating a cam-action tensioner on the other. With the quick release lever in the open position, insert the front wheel into the open ends of the fork.
KICKSTAND If your bike is equipped with a kickstand, please follow the instructions below. 1. Place the bicycle in an upright position. 2. Remove the top plate from the kickstand. 3. From the left side of the bicycle (opposite side from chainring), place the kickstand in position beneath the two rear fork legs. 5. Replace the washer and nut onto the mounting bolt. Hold the kickstand arm in an up position aligned with the frame stay, then securely tighten the mounting bolt. 6.
PEDAL INSTALLATION 1. Apply a small amount of grease to the threads of each pedal. Look for the letter “L” or “R” on the side or end of each pedal spindle (picture). Turning the spindle clockwise by hand (Picture), thread the pedal marked “R” into the crank arm on the right (drive) side of the bicycle. Make sure that you are not “cross-threading”, which can strip the threads in the crank arm. If the threads do not turn easily, don’t force them. Back the spindle out and start over.
HANDLEBAR AND STEM INSTALLATION QUILL STEM ASSEMBLY 1. Remove plastic packaging material covering the expander wedge. 2. Loosen the stem expander bolt, if necessary, so the wedge nut is in line with the stem body. See illustration. 3. Insert the stem into the head tube past the minimum insertion line indicated on the stem. WARNING: THE HANDLEBAR STEM MUST BE INSERTED INTO THE HEAD TUBE UNTIL THE MINIMUM INSERTION LINE INDICATED ON THE STEM IS COMPLETELY COVERED. 4.
HANDLEBAR AND STEM INSTALLATION STANDARD ONE PIECE STEM ASSEMBLY 1. Remove plastic material covering the expander wedge. Loosen the stem expander bolt, if necessary, so the wedge nut is in line with the stem body. See illustration. 2. Insert the stem into the head tube past the minimum insertion line indicated on the stem. WARNING: THE HANDLEBAR STEM MUST BE INSERTED INTO THE HEAD TUBE UNTIL THE MINIMUM INSERTION LINE INDICATED ON THE STEM IS COMPLETELY COVERED. 3.
HANDLEBAR AND STEM INSTALLATION ADJUSTABLE STEM 1. Remove plastic packaging covering the expander wedge. Loosen the stem expander bolt, if necessary, so the wedge nut is in line with the stem body. See illustration. 2. Insert the stem into the head tube past the minimum insertion line indicated on the stem. WARNING: THE HANDLEBAR STEM MUST BE INSERTED INTO THE HEAD TUBE UNTIL THE MINIMUM INSERTION LINE INDICATED ON THE STEM IS COMPLETELY COVERED. 3.
SEAT & SEAT POST ASSEMBLY 1. Loosen the seat clamp nuts. 2. Insert the top portion of the seat post into the seat clamp. Be sure the seat post is completely inserted into the seat clamp and butted tightly against the underside of the seat. 3. Tighten seat clamp nuts securely. 4. Insert the seat post (with seat attached) into the bike frame. Be sure that the seat post is inserted past the minimum insertion line. 5. Tighten the seat post binder bolt securely at the desired height. 6.
1. Locate the seat, seat post and clamp hardware. SEAT & SEATPOST ASSEMBLY If your bicycle is equipped with a clamp type seat post, please follow instructions. 3. Place the rails of the seat into the channels of the lower seat clamp plate, with the nose of the seat on the opposite side of the clamp set back. SEAT UPPER SEAT CLAMP PLATE LOWER SEAT CLAMP PLATE 2. Place the lower seat clamp plate onto the head of he clamp so the grooves on the plate match the grooves on the head.
SEAT & QUICK RELEASE SEAT POST ASSEMBLY 1. Loosen the seat clamp nuts. 2. Insert the top portion of the seat post into the seat clamp. Be sure the seat post is completely inserted into the seat clamp and butted tightly against the underside of the seat. 3. Tighten seat clamp nuts securely. 4. Insert the seat post (with seat attached) into the bike frame. Be sure that the seat post is inserted past the Minimum Insertion Line. 5.
HAND BRAKES Determine which type of brake your bike is equipped with and refer to the appropriate assembly instructions. If your bike comes equipped with a foot brake ONLY, no brake adjustment is required. For more information on brake adjustment and maintenance, refer to the maintenance section of this manual. NOTE: A greater force is required to activate the rear brake due to longer cable length. It is important to become familiar with the use of hand brakes.
V-BRAKE ASSEMBLY & ADJUSTMENT 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 Slip the brake cable boot over the cable and position it between both brake arms. Next, loosen the 5mm anchor bolt at the end of the right brake arm and slide the cable under the retaining washer.
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.
3. While holding the shoe against the 5. Adjust the balance with the spring tension adjustment screws. shoe fixing nut 1mm 5 mm Allen key 1 mm Spring tension adjustment screw Allow 1mm clearance below tire edge and brake pad. 4. Pass the inner cable through the inner cable lead. Set the cable with a clearance of 1mm between each brake pad and the 1 mm Spring tension adjustment screw 6.
Tires and Tubes porous nature of bicycle inner tubes, it is normal for your bike tires to lose pressure over time. For this reason it is critically 1. 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 intended. The tire size and pressure rating are marked on the sidewall of the tire.
REFLECTORS , inspect onto your bicycle. Please refer to the following section for instructions on all types of WARNING! REFLECTORS ARE IMPORTANT SAFETY DEVICES WHICH ARE DESIGNED AS AN INTEGRAL PART OF YOUR BICYCLE. FEDERAL REGULATIONS REQUIRE EVERY BICYCLE TO BE EQUIPPED WITH FRONT, REAR, WHEEL, AND PEDAL REFLECTORS. THESE REFLECTORS ARE DESIGNED TO PICK UP AND REFLECT STREET LIGHTS AND CAR LIGHTS IN A WAY THAT HELPS YOU TO BE SEEN AND RECOGNIZED AS A MOVING BICYCLIST.
FRONT REFLECTOR MOUNT WITH CALIPER BRAKE ASSEMBLY First remove the hex nut from the back of the fork and pull the brake from the fork. Insert FRONT REFLECTOR MOUNT ON HANDLEBAR 2. Push open the bracket loop and slide in over the handlebar tube. If there is a sizing insert included with the bracket, please be sure it is inside the clamp loop before mounting. , about 5” from the end of the handlebar. 4. Tighten the clamp screw securely.
REAR REFLECTOR MOUNT ON SEAT POST , see the top diagram. facing away from the bike. REAR REFLECTOR MOUNT ON SEAT STAY BRACKET bracket and then through the seat stay bridge bracket. Next, insert a second washer onto the bolt and thread a hex nut onto the bolt behind the seat stay bridge bracket. it is upright and facing away from the bike.
REAR RACK ASSEMBLY If your bike comes with a rear rack, please follow the instructions below to attach the rack to your bike. 1. Remove any packing material and locate the phillips head screws and washers supplied with your rack. 2. Align holes inb the short stabilizer arms with the holes in the top of the seat stays on your bike. 3. Insert screw and washer on both right and left sides of the bike. Tighten securely. 4. Align holes in the long stabilizer arms with the holes in the rear frame dropout. 5.
SHIFTING GEARS If your bike is a multi speed bike, please read the information below to familiarize yourself with the basics of shifting gears. Your multi-speed bicycle will have a derailleur drivetrain (see 1. below), an internal gear hub drivetrain (see 2. below) or, in some special cases, a combination of the two. 1.
b. 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 sprocket to another. 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. The larger sprockets produce lower gear ratios.
2. How An Internal Gear Hub Drivetrain Works If your bicycle has an internal gear hub drivetrain, the gear changing mechanism will consist of: – one, or sometimes two shifters – one or two control cables~ one front sprocket called a chainring – 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.
Correct routine maintenance of your new bike will ensure a longer life for your bike and a safer ride for you. Every time you ride your bike, 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 will assist you in knowing what tasks need to be performed and how often.
NOTE: Many instructions for adjustments can be found in the assembly portion of this manual.
1. Open ended wrench or ring wrenches: 8mm, 9mm, 10mm, 12mm, 13mm, 14mm, 15mm 2. Open end or pedal wrench 15mm 3. Allen key wrenches: 4mm, 5mm, 6mm, 8mm 4. Adjustable wrench 6. Standard Phillips head screwdriver 7. Standard slip joint pliers 8. Tire pump 9. Tube repair kit 10. Tire levers TRAVEL TOOLS We suggest you take the following items with you when going on a long bike ride: 1. Spare tube 2. Patch kit 3. Pump 4. Tire levers 5. Multi-tool 6.
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: cause of tire failure. Due to the slightly porous nature of bicycle inner tubes, it is normal for your tires to lose Bead Seating: Tread: Caution: Excessively worn or damaged tires should be replaced. Valves: A slow leak caused by the entry of the dirt can RECOMMENDED TIRE PRESSURES: The recommended pressure molded on the sidewall of your bicycle tires should match the following chart.
If you need to repair a tire, follow these steps: 1. Remove the wheel from the bicycle. 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. 4. Remove the tube, leaving the tire on the rim. 5. Locate the leaks and patch using a tube repair kit or replace the tube. Note: Ensure that the replacement tube size matches the size stated on the tire sidewall and that the valve is the correct type for your bicycle. 6.
Ball Bearings When checked, the hub bearings of either wheel will require adjustment if there is any more than slight side play. Bearing Cone Hub Body 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 open end wrench. 3.Rotate the adjusting cone as needed to eliminate free play. 4.Re-tighten the locknut while holding the adjusting cone in position. 5.Re-check that the wheel can turn freely without excessive side play.
MAINTENANCE & REPAIR 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. Slide the 7/8” plastic washer over handlebar.
Cables and housing are one of the most overlooked parts on the bicycle. 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. Check that the brake cables are correctly routed and not wrapped around the stem or frame in a manner that prevents smooth operation or hampers control of the bicycle. Also check that the housing is seated properly into each cable stop of the bicycle.
MAINTENANCE & REPAIR LUBRICATION 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 Cable Adjusting Barrel Lock nut Brake Lever ADJUSTMENT - SIDEPULL CALIPERS Minor brake adjustment can be made via the cable adjusting barrel, usually located at the upper cable arm.
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 ‘friction’ type system where you will need to feel each gear shift into position. Pre-stretch the derailleur cables to remove slack position to a positive click mechanism in the shifter, and makes shifting very simple and precise.
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 chainguide is parallel with the outer chainwheel on the crankset. There must be a 3-5mm gap between the bottom of the derailleur cage and the top of the outer chainwheel teeth to ensure the derailleur will clear the chainwheel when shifting.
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.
Pedals are available in a variety of shapes, sizes and materials, and each are designed with a particular purpose in mind. Some pedals as downward pressure, on the pedals. Use of toe clips with straps requires practice to acquire the necessary skill to operate them safely. Inspection: Pedals should be inspected every month, taking note of the following areas: – Check that the pedals are tightened securely against the crank arm.
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, f links, they must all move freely. Lubrication The chain should be lubricated with light oil at least every month, or after use in wet, muddy, or dusty conditions. Take care to wipe off excess oil, and not to get oil on the tires or rim braking surfaces.
Remedy Possible Cause 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 derailleurs - 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 - Lubricate or r
Possible Cause Remedy Freewheel does not rotate - Freewheel internal pawl pins are jammed - Lubricate.
Possible Cause Remedy Steering not accurate - Wheels not aligned in frame - Headset loose or binding - Front forks or frame bent - Stem wedge bolt not tight - Align wheels correctly - Adjust/tighten headset - Take bike to a bike shop for possible frame realignment Frequent punctures - 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 tire - Replace with
LIMITED WARRANTY This Limited Warranty extends only to the original retail purchaser, who must produce proof of purchase in order to validate any claim. This warranty is not transferable to anyone else. What does this Limited Warranty cover? This warranty covers all parts of the bicycle to be free of defects in workmanship and materials. What must you do to keep the Limited Warranty in effect? This warranty is effective only if: - The bicycle is completely and correctly assembled.
