Falcon CYCLES Instructions And Guarantee

NMD 11-04

INSTRUCTION

LEAFLET

AND

GUARANTEE

RIGID FRAME AND FORKS – LIFETIME

All rigid frames and forks (with the exception of suspension forks, suspension

frames and rear shocks) - lifetime warranty.

COMPONENT PA RTS – 1 YEAR

All other components (including suspension forks, suspension frames and rear

shocks) - 1 year warranty.

All the above warranties apply, provided the bicycle has been properly cared

for, maintained and used, and are warranted against manufacturing or material
defects for the warranty period stated. This warranty is applicable from the date of
purchase for the original owner only, who must produce proof of purchase in order

to validate any claim. Claims must be submitted through your retailer. This warranty

does not include labour and transportation charge. The company can accept no
responsibility for consequential or special damage. This warranty applies only in

the case of defective components and does not cover the effects of normal wear

and tear or damage caused by accident, abuse, excessive loads, neglect, improper

assembly, alteration of original specification, improper maintenance or the addition

of any item inconsistent with the original intended use of the cycle.

No bicycle is indestructible and no claims will be accepted for damage caused

by improper use, competition use, stunt riding, ramp jumping, leaping or

similar activities. Our bicycles conform to BS 6102: Part 1: 1992 as set by the

British Institute Testing Services. We reserve the right to change or amend any

specifications within this brochure without notice. All information and specifications

within this brochure are correct at the time of going to press.

NOTIC E

In offering this warranty, Falcon Cycles Ltd in no way seeks to diminish the

statutory rights of the consumer.

Pleas e ref e r to o u r webs i te fo r the l a t est i n forma t i on.

http: / /www.falc o ncycl e s .co.u k

FALCON CYCLES LTD, P.O. BOX 3, BRIDGE STREET, BRIGG,

NORTH LINCOLNSHIRE, DN20 8PB

TEL: [phone] FAX: [phone]

CYCLES LTD

1

Complete this Section and keep it in a safe place. In the event of your machine being

lost or stolen this information should be passed on to the police.

Name ...........................................................................................................................................

Address .......................................................................................................................................

.....................................................................................................................................................

Model Name & Type ...................................................................................................................

Serial No....................................Frame Size & Colour................................................................

Extras and Identifying Marks .....................................................................................................

...................................................................................................................................................

..................................................................................................................................................

FALCON CYCLES LTD

This bike has been designed, developed and sourced fully built by Falcon Cycles Ltd. North
Lincolnshire.

Falcon has carefully selected and developed the product with some of the best suppliers throughout
the world. These suppliers have satisfied the exacting quality standards that have been developed by
Falcon, a company with over a century long reputation for quality and craftsmanship.

All Falcon Cycles Ltd are built to conform to British Standards.
Suspension frames and forks and rear shock absorbers are covered by a separate guarantee.

Included in this manual are details on how to prepare your bicycle for riding, how to maintain your
bicycle to keep it roadworthy, information on accessories and recommendations and tips for a safe and
correct riding position.

Please ensure that the Bicycle Log Sheet below is completed at the time of purchase. The details will

be of value to the police in the unfortunate event of your bicycle ever being lost or stolen. They also act

as a record of your guarantee.

FRAME NUMBER

The frame number is located on the BS6102 label
at the bottom of the seat tube or stamped on the
bottom bracket shell or seat tube. We strongly
recommend that you have either the frame number
or your post code stamped on to your bicycle.

xxxxxx

Dealerʼs Address or Stamp

Date of purchase

2

Service

Dealer Stamp:

Date:

Dealer Stamp:

Date:

Dealer Stamp:

Date:

Dealer Stamp:

Date:

Highly Recommended for safety & support of warranty claims. At 6-monthly
intervals or more frequently if high mileage or subject to heavy use.

YOUR BICYCLE — OWNERʼS RESPONSIBILITY

In this leaflet we describe and illustrate how to ride safely and keep your bicycle in a safe
trouble free operating condition.

Ownerʼs Responsibility and Important Points

Point 1

Carefully and thoroughly read this leaflet and follow the instructions.

Point 2

Any major service or adjustments on your bicycle should be carried out by a

professional repairer; however if this service is not available and you wish to make
adjustments yourself, this manual contains important tips on how to do it

.

CAUTION: Any adjustments you make are entirely at your own risk.

Point 3 To use your bicycle for freestyle and stunt riding, competitive events, off-road use or

any similar activities can be dangerous and you are warned that you assume the risk
for personal injury, damages or losses incurred from such use. The Retailer shall not
be liable to the purchaser of the bicycle or to third parties for consequential or special
damages.

Point 4 Bicycles are built with a variety of equipment and accessories, and you should

familiarise yourself with their function and purpose, to make sure you can operate
them correctly.

LOCATION OF PARTS WITH

ROUTINE MAINTENANCE CHECKS AND LUBRICATION

R

Q

P

Half Yearly — Remove and clean, lubricate chain, derailleur gears and all cables. Check and replace as required.

Refer to table of Recommended torque values - page 7.

O

N

N

M

L

K

S

J

I

H

H

G

G

F

E

E

D

C

B

A

NB — Wash cycle weekly with warm soapy water and polish dry with a soft cloth

T

3

A - Headset

Remove, clean and regrease
bearings yearly, checking if
replacements required.

B -

Stem Nuts

Ensure stem nuts and bolts are
tight. See page 7.

C -

Handlebars

Check handlebar bolt is tight.
Check brake levers securely
mounted to bars and brakes stop
smoothly and efficiently. See
page 7.

D -

Brakes

Lightly oil exposed cables
monthly. Maintain adjustment and
replace brake blocks when worn,
brake cables when frayed.

E -

Reflectors (front & rear)

Ensure reflectors are secure
and undamaged. Replace if
necessary.

F -

Front Suspension unit

(Dealer adjustment only)

G -

Tyres

Check for cuts and wear.
Maintain pressure indicated on
tyre wall for maximum efficiency.

H - Wheel

Reflectors

Check monthly. Securely fixed.

I -

Disc Brakes - Front

(Routine maintenance by your
dealer recommended.)

J -

Wheel Hubs

Grease bearings monthly. Adjust
cones to avoid free play from
side to side.

K - Pedals with Reflectors

Check all fittings are secure.

L - Cranks

Grease bearings monthly. Check
that axle bolts or cotterpin bolts
are tight. Check for free play in
bottom bracket.
Yearly, remove, clean and
regrease hub axles, bottom
bracket set and headset.

M - Chain

Keep lightly oiled weekly, clean
and lubricate half yearly.

N - Wheels

Check that axles are sealed
and secured properly. Rims
should be kept free from wax, oil,
grease and glue. Check for loose
or missing spokes.

O - Bottom Bracket

Clean, regrease yearly checking
for wear.

P -

Gears

Front and Rear — Lightly
oil moving parts. Maintain
adjustments of front and rear
derailleurs.

Q -

Disc Brake - Rear

(Routine maintenance by your
dealer recommended).

R - Seat and Stem Nuts

Be sure seat and
stem nuts are tight. See page 7.

S - Pedals

Lightly oil bearings monthly.

T - Frame Number

SAFE CYCLING AND SAFETY TIPS

Before you ride your bicycle at any time make sure it is in a safe operating condition. Particularly
check that your:-

• Bicycleʼs nuts, bolts and parts are tight and not worn or damaged.

• Riding position is comfortable.

• Brakes are operating effectively.

• Steering is free with no excessive play.

• Wheels run true and hub bearings are correctly adjusted.

• Wheels are properly secured and locked to frame/fork.

• Tyres are in good condition and inflated to correct pressure.

• Pedals are securely tightened to pedal cranks.

• Gears are correctly adjusted.

• All reflectors are in position.

After you have made any adjustments to your bicycle, check that all nuts and bolts are securely
tightened and cables are free from kinks and fixed securely to the bicycle frame.
Every six months (more frequently if high mileage or subject to heavy use) your bicycle should
be professionally checked to ensure that it is in correct and safe working order. A ʻService
Recordʼ is provided for your use.

Do Notʼs when riding

• Do not ride on same side of road as oncoming traffic.

• Do not ride two abreast.

• Do not carry a passenger unless cycle is equipped to do so.

• Do not swerve in and out of traffic.

• Do not hang items over the handlebars to impede steering or catch in the front wheel.

• Do not hold on to another vehicle.

• Do not ride too close behind another vehicle.

CAUTION: Wet Weather Riding No brakes work as well under wet or icy conditions as they do
under dry conditions. In wet weather special precautions must be taken to assure safe stopping.
Ride slower than normal and apply your brakes well in advance of anticipated stops.

CAUTION: Night Riding We recommend you minimise the time you ride after dark. If you
should have to be out on your bicycle at night you must to comply with the law, use a headlight
(white) and a taillight (red) on your bicycle in addition to the all-around reflectors that are
fitted. For added safety wear light coloured clothing with reflective stripes. Check that the
reflectors are firmly secured in their correct position and clean and not obscured. Damaged
reflectors must be replaced immediately.

CAUTION: Suspension Units Your cycle may be fitted with suspension units built into parts
of the frame and forks. We recommend these are serviced by your dealer as required. More
details may be found in the suspension manufacturerʼs handbook.

Front Suspension Unit

Frame Suspension Unit

Pre Load Adjustment

We recommend that Pre-Load load for optimum safe riding should be set as follows.
1 Pre-Load alters the amount of bottom bracket drop when seated on the saddle. We

strongly recommend you set Pre-Load so as to experience no more than 1" (25mm) of
sag. Measured as a decrease in bottom bracket height.
To adjust Pre-Load, grasp knurled adjuster (A) and spring, and either:

2 Increase Pre-Load by turning to compress the spring

3 Decrease Pre-Load by turning to allow spring extension.

Riding Position

It is important that you and your bicycle are fitted to each other, not only for comfort and riding
ease but for control and safety. Normally your Dealer will custom fit your bicycle to you but the
following few pages should help you to find your most comfortable, safe and efficient position.

4

Bottom Bracket Height

Pre Load Adjust

SEAT

Seat Adjustment

Loosen the nut on the seat-post clamp enough to allow the saddle to move forward and back.
The seat can then be aligned forward and back and the angle can also be adjusted (it is
recommended that the seat be parallel to the ground).

To adjust the seat up and down, loosen the binder-bolt on the seat tube, position the seat and
re-tighten the binder-bolt.

CAUTION: Insert the seat-post to a point above the insertion mark. The MINIMUM INSERTION
MARK should not be visible. Securely tighten the seat-post binder bolt/nut by using a 6 mm Allen
key or a 13 mm spanner. Test by grasping the seat and attempting to turn. Keep tightening until
the seat will no longer turn.Please refer to table of torque values Page 7

WARNING: Bicycle should not be ridden if seat adjustments are not properly tightened.

5

Allen head
Binder-bolt

Normal 13mm
Binder-bolt

Saddle

Seat Post

Minimum
Insertion mark

Seat posts differ according to saddle types
and accordingly the procedure for fitting
varies. If in doubt consult your dealer.

Close

Op

en

Seat Forwards

or Backwards

Seat Angle

End of
Seat Pillar

Seat Pillar adjustment—
Suspension frames.Take care
when inserting seat pillar that the
protruding end cannot interfere
with the frame suspension unit
during use. If in doubt consult
you dealer about adjustment.

CYCLING POSITION — Seat

Saddle Angle

The seat should be horizontal or parallel with the ground. Slight variation around the horizontal
may suit individual comfort but if excessive angles are felt necessary check other aspects of your
position.

Saddle Height

The correct seat height is determined by sitting on the seat with your leg fully extended. Your
heel (in flat shoes) should just touch the pedal when it is positioned at its lowest point. When
riding normally with the ball of your foot on the pedal your knee should be slightly flexed at the
bottom of the pedal stroke (see diagram following).

Saddle Forwards/Backwards Position

With the ball of one foot on the pedal and the cranks parallel to the ground the saddle should
be adjusted backwards or forwards to a position whereby the pedal centre is directly below the
knee joint.

Very small changes in saddle position can have a substantial effect on performance and
comfort. Consequently, whenever you make a change to your saddle position, make only
one directional change at a time and make the changes in small increments, until you have
found the point at which you are most comfortable.

6

Knees slightly
bent

Handlebar Stem
approximately level
with seat or slightly
lower

Pedal at bottom
position

Loosen saddle from seat
pillar to adjust forwards
or backwards. Tighten
when set correctly

The saddle should be moved forwards or backwards so that the
knee is directly above the pedal when the crank is parallel to
the ground.

HANDLEBARS AND STEMS

As your cycle may be fitted with a standard ʻquillʼ stem or an A-Head stem, you must always check
that all the bolts are tight before cycling.

STANDARD STEM

: Loosen expander bolt so that expander wedge is not tight in bottom of

handlebar stem. Gently tap the top of the expander bolt to further loosen the wedge if necessary.
When the expander wedge is loose, move the handlebars up or down until you find the optimum
height at which you can easily reach the brake levers and comfortably grasp the handlebars. Usually
this height is level with, or slightly lower than, the top of the saddle. Be sure the stem is in line with
the front wheel.

CAUTION: A minimum insertion ring is marked on the handlebar stem and this marking
should remain in the head tube. Under no circumstances should the minimum height
insertion mark be visible on the handlebar stem. It must be down in the head tube.

When desirable height has been achieved, align the handlebar with the front wheel and securely
tighten expander bolt. It is extremely important to tighten the expander bolt sufficiently, so that when
the wheel is held between your legs and the handlebars are twisted, the handlebars do not move.
Do not over tighten, as it may increase risk of injury to the rider. Position grip portion of handlebars
horizontally and securely tighten the binder bolt.

Note: On models equipped with stem mounted gear levers the levers may be moved up or down to
the riderʼs most comfortable position. When moving them, be certain that the levers face upwards
and that the cables are not twisted.

Refer to table of recommended torque values on page 7.

Note: Whenever the handlebar stem is removed from the head tube then the expander bolt should
be lightly greased.

Note: On some ATB’s raising the stem requires brake cable adjustment. Do not attempt this if low
profile brakes are fitted with a stem mounted cable stop.

A-HEAD STEM

: Has 2 steerer clamp bolts on the back of the stem, which clamp around the

steerer tube. Loosen these bolts to align the stem with the front wheel. Re-tighten the steerer
clamp bolts.

CAUTION: Do not adjust the top compression bolt, this should be pre-set to eliminate bearing
play, overtightening will cause premature wear.

Contact your retailer for service.

Handlebar Position

The position of the handlebar should be set to allow a comfortable and easy reach of gear control
and brake levers.

When riding, your weight should be so balanced that your hands rest lightly on the handlebars.
This prevents strain on wrists and forearms when pedalling. If you alter the riding position,
remember to tighten all nuts and bolts securely

.

Refer to table of recommended torque values - page 7.

CAUTION:

NEVER EXTEND THE HANDLEBAR STEM OR SEAT POST ABOVE THE MINIMUM INSERTION

MARK AS THIS IS DANGEROUS

6mm Allen Key

Handlebar

Stem Expander Bolt
(Allen Head)

Recessed Type

Minimum
Insertion
Mark

Stem
Binder
Bolt

Stem Expander
bolt

Standard Stem

Steerer
Clamp Bolts

A-Head Type

Compression Bolt

Compression Cap

Extension

Spacers

Bearing Seat

Top cup with Bearings
inside

5 Star Washer

Stem Binder
Bolts