CONGRATULATIONS ON YOUR NEW BIKE! Cycle Force Group is dedicated to making sure you are satisfied with your new bicycle and wants to help with any questions or comments you may have. VISIT US AT: WWW.CYCLEFG.COM FOR CUSTOMER SERVICE VISIT: WWW.BIKEAIDONLINE.COM OR CALL US AT: 1-877-BIKEAID DO NOT RETURN THIS PRODUCT TO THE STORE. PLEASE CONTACT CYCLE FORCE GROUP FOR ASSISTANCE.
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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 that you have purchased is a complex object. Cycle Force Group recommends 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 SECTIONS PART 1 PARTS IDENTIFICATION. . . . . . . . . . . . . . 6 PART 2 BEFORE YOU RIDE . . . . . . . . . . . . . . . . 10 PART 3 ASSEMBLY. . . . . . . . . . . . . . . . . . . . 24 PART 4 SERVICING. . . . . . . . . . . . . . . . . . . . 58 PART 5 DETAILED MAINTENANCE . . . . . . . . . . . .
24 24 26 27 28 29 29 30 30 32 32 35 36 38 38 39 40 41 42 42 43 44 44 44 45 45 46 46 48 48 52 53 53 54 56 SERVICING 58 ROUTINE MAINTENANCE Schedule 1 - Lubrication Schedule 2 - Service Checklist Tools Required Travel Tools 58 58 59 60 60 24 DETAILED MAINTENANCE 62 24 WHEELS AND TIRES 62 4 CRUISER/ROAD BICYCLES MOUNTAIN/BMX BICYCLES TOOLS REQUIRED 4-5 6-7 8 BEFORE YOU RIDE 10 CORRECT FRAME SIZE RIDING POSITION Saddle Height Reach Handlebar Height SAFETY CHECKLIST 1. Brakes 2.
CRUISER BICYCLE Cruiser bicycles also known as beach cruisers are designed for comfort and style.
ROAD BICYCLE Road bicycles are designed for racing and exercise. It can be valued as a commuter if long distance or speed is required. Road bicycles use narrow, high-pressured tires to decrease rolling resistance and equipped with drop handlebars.
MOUNTAIN BICYCLE PARTS IDENTIFICATION 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 style bicycles are much sturdier than those on racing style bicycles.
BMX BICYCLE BMX style 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.
TOOLS REQUIRED Your new bicycle was assembled and tuned in the factory and then partially disassembled for shipping. You may have purchased the bicycle already fully reassembled. 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.
9 BEFORE YOU RIDE
CORRECT FRAME SIZE BEFORE YOU RIDE When selecting a new bicycle, the correct choice of frame size is a very important safety consideration. Most full sized bicycles come in a range of frame sizes. These sizes usually refer to the distance between the center of the bottom bracket and the top of the frame seat tube.
RIDING POSITION Saddle Height Maximum Height / Minimum Insertion Mark (Should not be visible) Ensure that the seat pillar does not extend beyond the minimum insertion mark. (Refer to p.72 on how to adjust seat height.) Arms not over- extended Handlebar stem height about the same as seat height BEFORE YOU RIDE 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.
Handlebar Height BEFORE YOU RIDE 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 Ensure that the handlebar stem does not extend beyond the minimum insertion mark. Failure to do this may cause serious bodily injury or damage to the bicycle.
SAFETY CHECKLIST Before every ride, it is important to carry out the following safety checks: 1. Brakes Ensure front and rear brakes work properly. Ensure brake shoe pads are not over 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. 2.
5. Bearings BEFORE YOU RIDE – 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. 6. Cranks and Pedals – Ensure pedals are securely tightened to the cranks. – Ensure cranks are securely tightened to the axle and are not bent. 7. Derailleurs – Check that front and rear mechanisms are adjusted and function properly. – Ensure control levers are securely attached.
Helmets The correct helmet should: - be comfortable - be lightweight - have good ventilation - fit correctly Always wear a properly fitted helmet when riding a bicycle. BEFORE YOU RIDE It is strongly advised that a properly fitting, ANSI or SNELL 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.
RIDING SAFELY 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. Concentrate on the path ahead.
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. Night Riding – – – – – – Ensure bicycle is equipped with a full set of correctly positioned and clean reflectors.
BEFORE YOU RIDE 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. You will then obtain more power from each pedal revolution. – On the descent, use the high gears to avoid rapid pedaling. – Do not exceed a comfortable speed, maintain control and take additional care. Cornering Technique Brake slightly before cornering and prepare to lean your body into the corner.
Freewheel Cogs Rear Derailleur GEARS - HOW TO OPERATE Derailleur Gears Front Chainwheels Crank Arm Pedal 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.
BEFORE YOU RIDE 4 6 5 20 1 3 2 3 High 4 6 5 2 1 Middle Low For optimal performance, NOT RECOMMENDED 1 3 2 2 High 1 Low For optimal performance, NOT RECOMMENDED Recommended Chainwheel/Rear Sprocket Gear Combinations Front Low Gear Rear Low Gear Front High Gear Rear High Gear Hand Twist Shifters Some bicycles are now being equipped with a shifting mechanism called Twist Shift, which is built into the handlebar grips and does not make use of separate levers.
Left hand lever Right hand lever Thumb shifters (Top Mounted) Top Gear (Harder) Small rear sprocket Large chainwheel Bottom Gear (Easier) Large rear sprocket Small chainwheel Left hand lever forward Right hand lever back Left hand lever back Right hand lever forward BEFORE YOU RIDE Most 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.
BICYCLE CARE Basic Maintenance BEFORE YOU RIDE The following procedures will help you maintain your bicycle for years of enjoyable riding. For painted frame, 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.
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. Security It is advisable that the following steps be taken to prepare for and help prevent possible theft. 1. Maintain a record of the bicycle’s serial number, generally located on the frame underneath the bottom bracket. 2. Register the bicycle with the local police. 3.
DERAILLEUR GEARED BICYCLES ASSEMBLY Includes 20”, 24”, 26” Wheel Mountain Bikes Assembly is the same for men and women’s bikes. 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 be lubricated prior to installation.
Shifter binder bolt (2.5 Allen key) ASSEMBLY 1. Brake lever binder bolt (5mm Allen key) Bar end (5mm Allen key) Tighten all bolts that clamp the shifters, brakes levers, and bar end to the handlebar using a 5mm Allen key or Phillips head screwdriver. (Figure 1) Handlebar with Twist Shifter. (Figure 2) Top mounted thumb shifter. Shift binder bolt (Phillips head or 5mm Allen key) Failure to properly tighten clamping bolts may cause sudden movement of the component resulting in loss of steering control.
Forks Steering Tube Brake Boss ASSEMBLY Drop-out Crown Do not attempt to disassemble a suspension fork yourself. Consult a professional bicycle repair technician. Blade 1 Brake Bridge Crown Brake Boss Drop-out Steering Tube Fork Blade 2 26 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 Note: In addition to normal assembly, please be aware that the preload adjusting screw must be flush with the bottom of the post. Failure to do this may cause irreparable damage. Boot Minimum Insertion Mark NOTE: Comfort bicycles may be equipped with a suspension seat post (See Diagram-bottom left). Some suspension posts can be adjusted for stiffness using the preload adjusting screw.
ASSEMBLY Pedals & Crank Set Dust Cap 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. Tighten with a 15mm narrow open-ended wrench. Note that the right hand pedal attaches to the chainwheel side crank arm with a right-hand (clockwise) thread. The left pedal attaches to the other crank arm and has a left-hand (counter-clockwise) thread.
Quick Release Adjusting Axle Nut Hub Spring Check the wheel hub before attaching in to the fork by rotating the threaded axle. It should be smooth with no lateral movement. Insert the front wheel into the fork dropouts. Tighten the wheel nuts using the appropriate 14mm or 15mm wrench. Spin the wheel nuts using the appropriate 14mm or 15mm wrench. Spin the wheel checking for trueness.
ASSEMBLY curved part of the lever faces the bicycle. 5. The wheel is tightly secured when the serrated surfaces of the quick release clamping parts actually begin to cut into the bicycle frame/fork surfaces. 6. Note that the same procedure applies when operating a quick release seat post binder mechanism. Warning – Correct adjustment of the quick release is vitally important to avoid an accident caused by loose wheel. Cantilever Brakes 1. Install the cable into the link wire. Cable End 2.
3. Temporarily tighten the cable so that the link wire is at the position in the illustration. 3 Link Wire 10 mm wrench To u c h i n g 5 mm Allen key Cable Anchor Bolt ASSEMBLY 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.
Cantilever Brakes – Straddle Cable Straddle Cable Brake Brake Cable ASSEMBLY Straddle Hanger Pinch Bolt Straddle Cable 90o Cable Anchor Caliper Arm Pivot Outer Cable Lead Brake Cable Boot Brake Noodle Anchor Bolt Brake Arm Pivot Bolt 32 Brake Shoe Tension Screw The length of the straddle cable, the height of the straddle hanger and the brake pad-to-caliper arm position all have an effect on braking power.
V - Brake ASSEMBLY 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.
ASSEMBLY 3 While holding the shoe against the rim, tighten the shoe fixing nut. 5 Adjust the balance with the spring tension adjustment screws. 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.
Check your Brakes Brake pad aligned with the rim surface Pad and rim should be parallel. Direction of rim rotation 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 2mm 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.
Disk Brakes Brake Cable Housing ASSEMBLY Barrel Adjuster Lock Nut Brake Lever Cable Insertion Slot Brake Cable C Clip Cable End Holder Brake Type Selector Rotating Rod Caliper Mounting Bolt with spacers Actuating Arm Brake Pads Caliper Mounting Bolt with spacers 36 Cable Anchor Bolt If fitted with a front disc brake, the components should already be attached. However, please check all connections before attempting to ride the bicycle.
Hub Fork Leg Centering Bolt Disc Mounting Bolts Rotating Rod Caliper Body Disc Cable Boot with Spring inside ASSEMBLY Brake Cable Housing Centering Bolt (inside) Actuating Arm Cable Anchor Bolt Fork Drop Out Quick Release lever Caliper Mounting Bolts with spacers These brakes require breaking in! Ride and use the brakes gently for 13 miles before using the brakes in downhill conditions, for sudden stops, or any other serious braking.
Freewheel Outer side of Top Gear ASSEMBLY Pulley Adjustment Screw Although the front and rear derailleurs are initially adjusted at the factory, you will need to inspect and readjust both prior to riding the bicycle. 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.
Low Adjusting Screw Cable Anchor Bolt Inner Chainguard Chainguide clearance of 1-3mm 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 3-5mm 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 piston works in conjunction with a spring to allow the bike 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 adjustment plate.
3 1 Rear Pivots 2 2 3 1 1 3 ASSEMBLY 1.Attaching Bolt 2.Bushing 3.Shaft The pivots assembly is a simple mechanism that allows the rear triangle to move up and down in combination with a rear suspension. Size, shape, and compounds will vary between models; however, operating principles are the same. A shaft will pivot inside of two bushings secured in place with bolts. Pivots should be kept clean and free from grime and should be disassembled and regreased at least once a riding season.
Accessories Saddle Bag ASSEMBLY Frame Bag Reflector Reflector Reflector Water bottle and cage If your bike is supplied with a water bottle and cage, attach the cage to the bicycle using the Allen bolts provided. Some bikes come equipped with a saddlebag or frame bag. The saddlebag installs under the seat with the zipper facing the rear wheel. Undo the straps that wrap around the bag, thread them through the rails underneath the seat and secure around the bag.
Final Check Check the tire pressure and inflate each tube to the recommended psi as stated on the sidewall of the tire. Check that the kickstand operates smoothly and the kickstand bolt is secured tightly. Finally, examine the bicycle. Make sure all accessories are attached and all quick releases, nuts and bolts have been tightened securely. ASSEMBLY After all adjustments have been made, shift through every gear several times at varying speeds.
SINGLE SPEED & BMX Includes 16” and 20” BMX Bikes Assembly is the same for boy and girl’s bikes. ASSEMBLY 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 package be lubricated prior to installation.
Seat ASSEMBLY 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.
Axle Nut Front Wheel Retaining Washer ASSEMBLY Axle Hub Cone Nuts Fork Drop Out Step Retaining Washer 1. Make sure the brakes are loose enough to allow the wheel to pass through the brake pads easily. 2. Place wheel into fork drop outs 3. Install retaining washers with raised lip pointed towards the fork, and insert into the small hole of the fork blade. 4. Install axle nut and tighten. Make sure the wheel is centered between the fork blades. 5.
U-Brake Link Fixing Bolt (A) Washer (C) Brake Arm Pivot ASSEMBLY Fixing Nut (B) 1. Install the left brake arm onto pivot on the frame, assemble washer (C) and the inner hex fixing bolt(A) without fastening them tightly. Repeat the same procedure to assemble the right arm. 2. Position the brake pads and make sure they match well with th rim. 3. Turn 90 degrees clockwise to fasten the tension adjuster waster (B) with a 19mm wrench. Then fasten inner hex fixing bolt with a 5mm allen key. 4.
Side Pull Brakes Cable Adjusting Barrel ASSEMBLY Center Bolt Brake Arm Cable Anchor Nut Fixing Nut in Back Brake Shoe Cantilever Brakes 1. Install the cable into the cable carrier. 48 Loosen the cable anchor nut and thread the brake cable through it. Tighten the nut by hand until it holds the cable in place. Squeeze the brake arms together against the rim of the wheel. Loosen the nuts on the brake shoes and turn until they match the angle of the rim. Tighten the nuts securely.
3. Temporarily tighten the cable so that the link wire is at the position in the illustration. 3 Link Wire 10 mm wrench To u c h i n g 5 mm Allen key Cable Anchor Bolt Spring tension adjustment screw 1 mm 6. If balance adjustment is necessary, adjust with the spring tension adjustment screw. Cable Casing Holder 1 2 4. Turn the spring tension adjustment screw so that the link wire comes to a position directly below the cable casing holder. ASSEMBLY 5. Secure one of the shoes at a time.
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.
3 While holding the shoe against the rim, tighten the shoe fixing nut. 5 Adjust the balance with the spring tension adjustment screws. ASSEMBLY 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.
Cantilever Brakes – Straddle Cable Straddle Cable Brake Brake Cable ASSEMBLY Straddle Hanger Pinch Bolt Straddle Cable 90o Cable Anchor Caliper Arm Pivot Brake pad aligned with the rim surface The length of the straddle cable, the height of the straddle hanger and the brake pad-to-caliper arm position all have an effect on braking power. Generally, the straddle cable bridge is set low and close to the tire for maximum braking force.
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 Wheels ASSEMBLY Press each brake lever to make sure that there is no binding and that brake pads press hard enough on the rims to stop the bike. The brake pads should be adjusted so they are 1mm to 2mm away from the rim when the brakes are not applied.
2. Screw the adjusting barrels in the upper plate in (or out) to set the bearing for maximum travel. The bearing should be as Some freestyle BMX bicycles come equipped with a detangler far down as it can go without resting on the lower plate or the system that will allow the handlebar to spin 360-degrees without adjusting barrels screwed into the lower plate. binding the cables. It is very important that this system is adjusted 3. Use the adjusting barrels that are screwed into the upper plate correctly.
Failure to adjust correctly may result in loss of braking power and personal injury. ASSEMBLY 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.
Final Check ASSEMBLY Pads 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: Attach the white reflector to the front bracket and the red reflector to the rear bracket using a 8mm wrench or a Phillips head screwdriver. Attach the brackets to the bicycle using the hardware provided.
SERVICING
ROUTINE MAINTENANCE SERVICING 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.
Schedule 2 - Service Checklist Frequency Before every ride Every Six Months Yearly Page Reference 63 74-77 62 62 22-23 58 58 87-89 74-77 69,74 63 62 64,70,81 78 66 72 71 58 59 77 84 58 SERVICING After every ride Weekly Monthly 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 shecdule 1 Check derailleur adjustment Check brake adjustment Check brake and gear cable adjus
SERVICING Tools Required 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 5. Standard flat head screwdriver 6. Standard Phillips head screwdriver 7. Standard slip joint pliers 8. Tire pump 9. Tube repair kit 10. Tire levers Travel Tools 1. 2. 3. 4. 5.
DETAILED MAINTENANCE
WHEELS AND TIRES DETAILED MAINTENANCE 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 brake 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.
Tire Inspection Tires must be maintained properly to ensure road holding and stability. Check the following areas: 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: When inflating or refitting tire, make sure that the bead is properly seated in the rim.
Ball Bearings DETAILED MAINTENANCE Lock Washer 64 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 come on the same side with a flat open-end wrench. 3.
DETAILED MAINTENANCE Remove tire bead from the rim. 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 in some shape. 10. Place the valve stem through the hole in the rim and work the tube into the tire. Note: Do not let it twist. 11.
HANDLEBARS AND STEM DETAILED MAINTENANCE Handlebar Stem 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. Max. Height/ Minimum Insertion Mark Lubricate by first wiping off any old grease and grime; then applying a thin film of grease to the part, including the wedge, that will be inserted into the frame.
When refitting the stem, make sure the handlebars are correctly aligned and tightened using the appropriate hex wrench or Allen key. Grip Do not over-tighten. Stem Wedge Bolt Handlebar Stem Stem Bolt Wedge Test the security of the handlebar within the stem, and the stem with 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 68 7/8 Plastic Washer Barrel Adjuster Cable TWIST SHIFTERS Twist Shift – Installation 1. Slide front twist shift assembly over left side of handlebar leaving proper clearance for handlebar grip. If necessary, move the brake lever to accommodate twist 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.
Cables and Cable Housing kink Do not ride a bicycle that is not operating properly. DETAILED MAINTENANCE good cable 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. Also check that the housing is seated properly into each cable stop of the bicycle.
DETAILED MAINTENANCE Standard Headset Lock Nut Lock Washer Adjusting Cup/Cone Inspection The headset bearing adjustment should be checked every month. This is important, as it is the headset that 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.
SUSPENSION FORK Some fork models differ from the one illustrated. Those models are not adjustable and require no maintenance other than keeping it free from dirt and grime. The following maintenance should be performed every month (if riding off-road) or whenever you feel performance is deteriorating. 1. With the fork apart, thoroughly clean all parts. 2. Apply a thin coat of grease to the upper tubes, coil springs and all internal bushings. Reassembly 1. 2. 3. 4.
SADDLE AND SEAT POST DETAILED MAINTENANCE 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 Fixing Bolt Micro Adjustable Seat Post To avoid damage to either the seat post, the frame or possibly the rider, a minimum of 65mm of the seat post must always remain in the frame.
Adjustment As mentioned in Part 2, the seat can be adjusted in height, angle and distance from the handlebar 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. There are two types of seat clamps commonly in use. The most common employs a steel clamp with hexagonal nuts on either side to tighten.
Brakes DETAILED MAINTENANCE 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 two types of hand operated bicycle brakes in common use: sidepull calipers and cantilever calipers.
Some brakes have a quick release mechanism to allow easier wheel removal. Whenever you adjust he brakes make sure that quick release mechanism is in the closed position. Lock nut Lubrication Brake Lever 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.
DETAILED MAINTENANCE Some brakes have a special mechanism that enables you to set the clearance on either side of the rim using a screwdriver. Brake pads should finally be adjusted so that the leading edge of the pad makes first contact with the rim. Some brakes have special curved washers to allow this, but on less complex models it will be necessary to apply a little force to the pad and its mounting.
Tread Worn Out Brake Shoe (Replace) On some newer type cantilever brakes, the main brake cable continues through the central cable carrier to an anchor bolt on one of the brake arms. A shorter link cable reaches form the carrier and the hook on the other brake arm. Adjustment of the cable length is made after loosening the anchor bolt on the brake arm. Adjust the brake pad position so that it is parallel to the wheel rim and so that the leading edge makes first contact.
DRIVETRAIN DETAILED MAINTENANCE 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.
Lubrication and Adjustment Never ride in traffic with fully tightened toe straps. Pedal with toe clip and strap attached Attachment 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.
DETAILED MAINTENANCE CRANK SET The crank set refers to the bottom bracket axle and bearing, the crank arms, and chainrings. Your bike may be fitted with either a one piece crank, where the crank arms and bottom bracket are 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.
Lubrication and Adjustment – One Piece Cranks Bearing Cup Locknut Fixed Cone DETAILED MAINTENANCE To adjust the free play in a one piece type bottom bracket, loosen the locknut on the left side by turning in 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 DETAILED MAINTENANCE Bottom Bracket 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. 82 To adjust the free play in a three piece type bottom bracket, loosen the lockring on the left side by turning in counter-clockwise, then turn the adjusting cup as required. Re-tighten the lockring taking care not to alter the cup adjustment.
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. Retighten the flange nuts, and refit the dust caps. Lightly tap the crank onto the axle. New cotterless cranks may become loose with initial use. Perform the following task after several hours of riding, and repeat it two or three times after further use. Cranks should then remain tight. DETAILED MAINTENANCE Position the crank on the axle.
Rear Sprocket Front Chainwheel Chain DETAILED MAINTENANCE Inspection The chain must be kept clean, rust fee and frequently lubricated in order to extend its life as long as possible. It will require replacement if the stretches, breaks, or causes inefficient gear shifting. Make sure that there are no stiff links, the must all move freely. Pull up 10 mm Straightedge Lubrication The chain should be lubricated with light oil at least every month, or after use in wet, muddy, or dusty conditions.
Chain Rivet Tool FREEWHEEL Inspection Like the chain, the freewheel must be kept clean and well lubricated. If the chain has become worn and needs replacing, then it is likely that the freewheel will also have become worn and should also be replaced. Take the chain off the freewheel and rotate it with your hand. If you hear a grinding noise or the freewheel stops suddenly after spinning it, it may need adjustment or replacement.
Brake Arm Clip Brake Arm DETAILED MAINTENANCE Sprocket 86 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 that 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.
DERAILLEUR SYSTEMS Pre-stretch the derailleur cables to remove slack Stretch Inspection The operation of the derailleur system should be checked at least every month. Check the operation of the rear derailleur first, then the front. The rear derailleur should shift the chain cleanly from on cog to the next without hesitation. On SIS equipped bicycles, each notched position in the shifter must equate to a new gear position. After shifting, the rear derailleur should not rub on the chain.
Outer side of Top Gear Freewheel DETAILED MAINTENANCE 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.
Low Adjusting Screw High Adjusting Screw Outer Chainguide Chainguide clearance of 1-3 mm Inner Chainguide 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 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 re-installing, it is very important to ensure the connections are made properly. Please refer to page 29 and 30 for the appropriate assembly instructions.
Peg Setting Install peg on axle and use a screw driver to tighten peg securely.
DETAILED MAINTENANCE Problem Possible Cause Remedy Gear shifts not working properly - Derailleur cables sticking/stretched/ damaged - Lubricate/tighten/replace cables - Front or rear derailleur not adjusted properly - Adjust derailleurs - Indexed shifting not adjusted properly - Adjust indexing - Excessively worn/chipped chainring or freewheel sprocket teeth - Replace chainring, sprockets and chain - Chain worn/stretched - Replace chain - Stiff link in chain - Lubricate or replac
Possible Cause Remedy Freewheel does not rotate - Freewheel internal pawl pins are jammed - Lubricate.
Problem DETAILED MAINTENANCE Steering not accurate 94 Frequent punctures Possible Cause Remedy - Wheels not aligned in frame - Align wheels correctly - Headset loose or binding - Adjust/tighten headset - Front forks or frame bent - Take bike to a bike shop for possible frame realignment - Inner tube old or faulty - Replace inner tube - Tire tread/casing worn - Replace tire - Tire unsuited to rim - Replace with correct tire - Tire not checked after previous puncture - Remove
You can also register your bicycle with Cycle Force Group at www.cyclefg.com Purchase Record Card Fill in Immediately and retain as a record of your purchase. *Please retain your sales receipt for any possible warranty claims.
CYCLE FORCE GROUP LIMITED WARRANTY Cycle Force Group warranties its bicycles to the original purchaser to be free from defects in material and in workmanship for a period from the date of purchase of: Lifetime on frame and fork as long as the bicycle is owned by the original owner except for the specific models noted below: – downhill – jumping –freestyle – suspension related equipment (bushings, bearings, pivot pins, pivot tubes and bolts) including complete forks except as warranted by the original equipm
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