Schwinn HELMETS SAVE LIVES User Manual

HELMETS SAVE LIVES !!!

ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE. DO NOT RIDE AT NIGHT. AVOID RIDING IN WET CONDITIONS.

CORRECT FITTING - MAKE SURE YOUR HELMET COVERS YOUR FOREHEAD.

INCORRECT FITTING. FOREHEAD IS EXPOSED AND VULNERABLE TO SERIOUS INJURY.

ersonal

are

from Pacific Cycle

1.800.626.2811

Congratulations on your new bike!

Our Service Department is dedicated

to your satisfaction with Pacific Cycle.

We want to help with any questions

or comments you may have.

You can also reach us by email at:

service@pacific-cycle.com.

DO NOT Return this Product to the Store.

Please Call Pacific Cycle for Assistance.

STOP

RIDING SAFELY

General Rules

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. Avoid pot holes, gravel, wet road markings, oil, curbs, speed

bumps, drain grates and other obstacles. Cross train tracks at a 90 degree angle or walk your bicycle across. Expect the unexpected such as opening car doors or cars backing out of concealed driveways. Be extra careful at intersections and when preparing to pass other vehicles. Familiarize yourself with all the bicycle's features. Practice gear shifts, braking, and the use of

toe clips and straps, if fitted. If you are wearing loose pants, use leg clips or elastic bands to prevent them from being caught

in the chain. Don't carry packages or passengers that will interfere with your visibility or control of the bicycle.

Don't use items that may restrict your hearing. When braking, always apply the rear brake first, then the front. The front brake is more powerful

and if it is not correctly applied, you may lose control and fall. Maintain a comfortable stopping distance from all other riders, vehicles and objects.

Safe braking distances and forces are subject to the prevailing weather conditions.

Wet Weather

DO NOT RIDE IN 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.

- Refer to p. 82 of this manual.

- Use a properly functioning lighting set comprising a white front lamp and a red rear lamp.

- If using battery powered lights, make sure batteries are well charged.

- Some rear lights available have a flashing mechanism which enhances visibility.

- Wear reflective and light colored clothing.

- Ride at night only if necessary. Slow down and use familiar roads with street lighting, if possible.

Pedaling Technique

- Position the ball of your foot on the center of the pedal.

- When pedaling, ensure your knees are parallel to the bicycle frame.

- To absorb shock, keep your elbows slightly bent.

- Learn to operate the gears properly. (Refer to p. 13-15)

Do not ride at night

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. Maintain the inside pedal at the 12 o'clock position and slightly point the inside knee in the direction you are turning. Keep the other leg straight, don't pedal through fast or tight corners.

Rules for Children

To avoid accidents, teach children good riding skills with an emphasis on safety from an early age.

1. 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. Be aware of other road vehicles behind and nearby.

7. Before entering a street: Stop, look right, left, and right again for traffic.

If there's no traffic, proceed into the roadway.

8. If riding downhill, be extra careful. Slow down using the brakes and maintain control of the steering.

9. Never take your hands off the handlebars, or your feet off the pedals when riding downhill.

The Consumer Protection Safety Commission advises that the riding of small wheel diameter bicycles at excessive speeds can lead to instability and is not recommended.

Children should be made aware of all possible riding hazards and correct riding behavior before they take to the streets

- Do not leave it up to trial and error.

GEARS - HOW TO OPERATE

Derailleur Gears

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. This means your riding will be less tiring without unnecessary straining up hills or fast pedaling down hill. Bicycles come with a variety of gear configurations from 5 to 27 speeds. A 5-6 speed bicycle will have a single front chainwheel, a rear derailleur, and 5 or 6 cogs on the rear hub. Bicycles with more gears will also have a front derailleur, a front chainwheel with 2-3 cogs, and up to 8 cogs on the rear hub.

Operating Principles

No matter how many gears, the operating principles are the same. The front derailleur is operated by the left shift lever and the rear derailleur by the right. To operate you must be pedaling forward. You can not shift derailleur gears when you are stopped or when pedaling backwards. Before shifting ease up on your pedaling pressure. For a smooth gear change when approaching a hill, shift to a lower gear BEFORE your pedaling speed slows down too much. When coming to a stop, shift to a lower gear first so it will be easier when you start riding again. If, after selecting a new gear position, you hear a slight rubbing noise from the front or rear gears, gently adjust the appropriate shifter using the barrel adjusters until the noise goes away. For optimal performance and extended chain life, it is recommended that you avoid using the extreme combinations of gear positions (diagram p.

14) for extended periods.

Drivetrain

Freewheel Cogs

Front Derailleur

Derailleur Control Cable

Guide Pulley

Rear Derailleur

Front Chainwheels

Crank Arm

Pedal

Recommended Chainwheel/Rear Sprocket Gear Combinations

Hand Grip Shifters

Some bicycles are now being equipped with a shifting mechanism called Grip Shift, which is built into the handlebar grips and does not make use of separate levers. The actuating mechanism is built into the inside part of the grip that the web of the thumb and index finger closes around. To select a lower gear, twist the right shifter toward you to engage a larger rear cog. You can shift one gear at a time by moving the Grip Shift one click, or through multiple gears by continued twisting. By twisting the left shifter forward or away from you, a smaller chainwheel can be selected. To select a higher gear, twist the right shifter forward or away from you to engage a smaller rear cog. To engage a larger front chainwheel, twist the left shifter towards you. Single shifts can be achieved by twisting one click at a time and multiple shifts by larger twists.

Front Low Gear Rear Low Gear

Front High Gear Rear High Gear

High

Middle Low

High

Low

For optimal performance,

NOT RECOMMENDED

For optimal performance,

NOT RECOMMENDED

Please Retain your Sales Receipt

as Proof of Purchase.

Notes:

_______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________

The following manual is only a guide to assist you and is not a complete or comprehensive manual of all aspects of

Serial Number Location

Bottom View

Serial Number

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. You will save time and the inconvenience of having to go back to the store if you choose to write or call us concerning missing parts, service questions, operating advice, and/or assembly questions.

SERVICE

CALL TOLL FREE 1.800.626.2811

Monday - Friday 8:00 a.m. to 5:00 p.m. Central Time

PACIFICCYCLE

4902 Hammersley Road Madison, WI 53711 Customer Service 1.800.626.2811 www.pacific-cycle.com

Thank You for purchasing your bicycle. Please take a moment to fill out this reply card, and mail it back to us. We value your business and appreciate your feedback.

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__________________________________________________________________________ E-mail Address: ____________________________Phone Number: ________________________ Bicycle Model purchased: __________________________________________________________ Store at which you purchased your bicycle: ____________________________________________ Serial Number ____________________________________________________________________

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BICYCLE REGISTRATION

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4902 HAMMERSLEY ROAD MADISON, WI 53711

PLACE STAMP

HERE

DIRECTORY

PART 1

PART 2

PART 3

PART 4

PART 5

PART 7

Parts Identification ................................................01-05

Before You Ride ....................................................06-21

Assembly ..............................................................22-54

Servicing ................................................................55-57

Detailed Maintenance ............................................58-90

Purchase Record and Warranty ........................104-105

Warning / Important

Take notice of this symbol throughout this manual and pay particular attention to the instructions blocked off and preceded by this symbol.

PART 6

How Things Work ................................................91-103

PACIFICCYCLE

4902 Hammersley Road Madison, WI 53711 Customer Service 1.800.626.2811 www.pacific-cycle.com

1. PARTS IDENTIFICATION 2-5

Mountain Bicycles 2 BMX Bicycles 3

Tools Required4

2. BEFORE YOU RIDE 6-21

Correct Frame Size 6 Riding Position7

-Saddle Height 7

-Reach 7

-Handlebar Height 8

Safety Checklist 9-10

-Brakes 9

-Wheels & Tires 9

-Steering9

-Chain10

-Bearings 10

-Cranks & Pedals10

-Derailleurs 10

-Frame & Fork 10

-Accessories 10 Helmets 11

Reflectors 12-13

Riding Safely 14-16

-General Rules 14

-Wet Weather Riding 15

-Night Riding 15

-Pedaling Technique 15

-Hill Technique 16

-Cornering Technique 16

-Rules for Children 16

Gears - How to Operate 17-19

-Derailleur Gears 17

-Operating Principles17

-Hand Grip Shifters 18

-Thumb Shifters 19

-Below the Bar Shifters 19

Bicycle Care 20-21

-Basic Maintenance 20

-Storage 21

-Security 21

3. ASSEMBLY 22-54

Derailleur Geared Bicycle 22-42

Handlebars 22-24 Forks 25 Seat and Seat Post 26 Pedals & Crank Set 27 Front Wheel 28 Quick Release Axle 28-29

Front Brake 29-36

-Cantilever with Link Wire 29-30

-Cantilever with Straddle Cable 31

-V-Style 31-33

-Check your Brakes 34

-Disk Brakes 35-36 Derailleur 37-38

-Rear Derailleur 37

-Front Derailleur 38 Dual Suspension 39

Rear Pivots 40 Accessories 41 Reflectors 41 Final Check 42

Single Speed & BMX 43-54

Handlebars 43 Seat 44 Pedals & Crank Set 44 Frontwheel 45

Front Brake 45 Side Pull Brake 46 Cantilever with Link Wire 46-47 V-Brake 48-49 Cantilever with Straddle Cable50 Check your Brakes 51 Training Wheels51 Rotors 52-53 Final Check 54

4. SERVICING 55-57

Schedule 1 - Lubrication55 Schedule 2 - Service Checklist 56 Tools Required57

5. DETAILED MAINTENANCE 58-90

Wheel Inspection 58 Tire Inspection59

Tire Pressures59 Hub Bearing Adjustment 60 Flat Tire Repair 60-61 Handlebar Stem 62-63 Handlebars 63

Grip Shift Installation64 Cables & Cable Housing 65

Headset 66

-Inspection66

-Adjustment 66

Suspension Fork67

-RST Maintenance 67

-RST Reassembly67

-Check before each ride 67

Saddle & Seat Post 68-69

-Inspection68

-Lubrication68

-Adjustment 69

Brakes 70-73

-Inspection 70-71

-Lubrication71

-Adjustment Sidepull Calipers 71-72

-Adjustment Cantilever Calipers 72-73

Drivetrain 74-82

-Pedals 74-75

-Inspection74

-Lubrication & Adjustment 75

-Attachment 75

-Crank Set 76-79

-Inspection76

-Lubrication & Adjustment (one piece cranks) 77

-Lubrication & Adjustment (cotterless cranks) 78-79

-Chain 80-81

-Inspection80

-Lubrication80

-Adjustment & Replacement 80-81

-Freewheel 81-82

-Inspection81

-Lubrication82

-Coaster Hub 82

Derailleur Systems 83-85

-Inspection83

-Lubrication84

-Adjustment (Rear)84

-Adjustment (Front)85 Quick Release Levers86

Reflectors 86 Miscellaneous Accessories 87 Troubleshooting 88-90

6. HOW THINGS WORK 91-103

-A. Wheel Quick Release 91-94

-B. Seatpost Quick Release 95

-C. Brakes 96-97

-D. Shifting 97-99

-E. Toeclips & Straps 100

-F. Clipless (“step-in”) pedals 101

-G. Tires and Tubes 101-102

-H. Bicycle Suspension 103

7. PURCHASE RECORD 104-105 & WARRANTY

Gear Control Cable

Rear Derailleur

PART 1 - PARTS IDENTIFICATION

Mountain Bicycles . 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.

Top Tube Seat Seat Post Quick Release Seat Stay Rear Reflector Rear Brake Wheel Reflector Freewheel

Shift Lever

Handlebar

Brake Lever

Brake Control Cables

Front Reflector

Front Brake

Front Fork

Wheel Reflector

Front Hub

Spokes

Handlebar Stem

Head Set

Head Tube

Seat Tube

Down Tube

Gear Control Cable

Front Derailleur

Bottom

Bracket Axle

Rim Tire

Chain Wheel

Crank Arm

Pedal

Chainstay

Chain

Tire Valve

BMX Bicycles . 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.

Seat Seat Post Seat Post Binder Bolt Seat Stay Rear Reflector Wheel Reflector

Chain Wheel

Crank Arm

Pedal

Rim

Tire

Tire Valve

Chain Rear Sprocket Training Wheel

Brake Lever

Handlebar

Brake Control Cable

Reflector

Front Brake

Brake Pad Front Fork

Wheel Reflector

Front Hub

Spokes

Handlebar Grip

Handlebar Stem

Head Set

Head Tube

Top Tube

Seat Tube

Down Tube

Your new bicycle was assembled and tuned in the factory and then partially disassembled for shipping. You may have purchased the bicycle already fully re-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. If you have questions about your ability to properly assemble this unit, please consult a qualified specialist before riding. If you need replacement parts or have questions pertaining to assembly of your bicycle, call the service line direct at:

SERVICE AND TECHNICAL SUPPORT:

1.800.626.2811

Monday - Friday 8:00 a.m. - 5:00 p.m. Central Time.

Tools Required:

Phillips head screw driver; 4mm, 5mm 6mm & 8mm Allen keys; adjustable wrench or a 9mm, 10mm, 14mm & 15mm open and box end wrenches; and a pliers with cable cutting ability.

To avoid injury, this product must be properly assembled before use. If your bicycle was obtained assembled, we strongly recommend that you review the complete assembly instructions, and perform checks specified in this manual before riding.

ABOUT THIS MANUAL

This manual was written to help you get the most performance, comfort, enjoyment and safety when riding your new bicycle. It is important for you to understand your new bike. By reading this manual before you go out on your first ride, you’ll know how to get

the most 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. Proper maintenance of your bicycle is your responsibility as it helps reduce the risk of injury. This manual contains many “Warnings” and “Cautions” concerning the consequences of failure to maintain or inspect your bicycle. Many of the warnings and cautions say, “you may lose control and fall.” Because any fall can result in serious injury or even death, we do not repeat the warning of possible injury or death whenever the risk of falling is mentioned.

A SPECIAL NOTE FOR PARENTS

It is a tragic fact that most bicycle accidents involve children. As a parent or guardian, you bear the responsibility for the activities and safety of your minor child. Among these responsibilities are to make sure that the bicycle which your child is riding is properly fitted to the child: that it is in good repair and safe operating condition; that you and your child have learned, understand and obey not only the applicable local motor vehicle, bicycle, and traffic laws, but also the common sense rules of safe and responsible bicycling. As a parent, you should read this manual before letting your child ride the bicycle. Please make sure that your child always wears an approved bicycle helmet when riding.

CORRECT FRAME SIZE

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.

For safe and comfortable riding there should be a clearance of between 25mm and 50mm between the groin area of the intended rider and the top tube of the bicycle frame, while the rider straddles the bicycle with both feet flat on the ground.

The ideal clearance will vary between types of bicycles and rider preference. This makes straddling the frame when off the saddle easier and safer in situations such as sudden traffic stops. Women can use a men’s style bicycle to determine the correct size women’s model.

The following chart and diagram will help you make the correct choice. Rider leg length refers to approximate pant inseam.

PART 2 - BEFORE YOU RIDE

Approximate Rider Leg

Length

61-69cm / 24-27 inches 66-76cm / 26-30 inches 71-79cm / 28-31 inches 76-84cm / 30-33 inches 79-86cm / 31-34 inches 81-89cm / 32-35 Inches 86-94cm / 34-37 inches

Suggested Frame Size for

Racing/Touring Bicycle

50cm / 19.5 inches 55cm / 21.5 inches 57cm / 22.5 inches

60cm / 23.5 Inches

63cm / 25 inches

Suggested Frame Size for

Mountain or Hybrid Bicycle

37cm / 14.5 inches

43cm / 17 inches

45cm / 18 inches 50cm / 19.5 inches 52cm / 20.5 inches

53-56cm / 21-22 Inches

58-60cm / 23-23.5 inches

Frame Sizing Guide

25-50mm

RIDING POSITION Saddle 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 allow 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. The correct saddle height will allow the knee to be slightly bent in this position. If the rider then places the heel of that foot on the pedal, the leg should be almost straight.

Under no circumstances should the seat post project from the frame beyond its “Minimum Insertion” or “Maximum Extension” mark. If your seat post projects

from the frame beyond these markings, the seat post or frame may break, which could cause you to lose control and fall. After any saddle adjustment, be sure to tighten the saddle adjusting mechanism properly before riding. Aloose saddle clamp or seat post binder can cause damage to the bicycle or can cause you to lose control and fall. Periodically check to make sure that the saddle adjusting mechanism is properly tightened.

Reach

To obtain maximum comfort, the rider should not overextend his or her reach when riding.

To adjust this distance, the position of the seat can be altered in relation to the seat pillar. (Refer to p. 65 on how to adjust the seat clamp.)

Maximum Height / Mini-

mum Insertion Mark

(Should not be visible)

Arms not over-

extended

Handlebar stem

height about the

same as

seat height

Pedal at

bottom position

Handlebar Height

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.

Threadless headsets and clamp-on stems are not adjustable and are outside the scope of this manual. Please consult a qualified bicycle technician for details and instructions on how to adjust and maintain these types of systems.

The stem’s “Minimum Insertion” mark must not be visible above the top of the headset. If the stem is extended beyond this mark, the stem may break or damage the fork’s steerer tube, which could cause you to lose control and fall.

Failure to properly tighten the stem binder bolt, the handlebar binder bolt, or the bar end extension clamping bolts may compromise steering action, which could cause you to lose control and fall. Place the front wheel of the bicycle between your legs and attempt to twist the handlebar/stem assembly. If you can twist the stem in relation to the front wheel, turn the handlebars in relation to the stem, or turn the bar end extensions in relation to the handlebar, you must tighten the appropriate bolts accordingly.

Handlebar Binder Bolt

Exceeds 2 1/2” (64mm)

Stem Wedge Bolt

Maximum Height/ Minimum Insertion Mark

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. Wheels and Tires

- Ensure tires are inflated to within the maximum recommended limit as displayed on the tire sidewall.

- Ensure tires have tread and have no bulges or excessive wear.

- Ensure rims run true and have no obvious wobbles or kinks.

- Ensure all wheel spokes are tight and not broken.

- Check that axle nuts are tight. If your bicycle is fitted with quick release axles, make sure locking levers are correctly tensioned and in the closed position.

3. Steering

- Ensure handlebar and stem are correctly adjusted and tightened, and allow proper steering.

- Ensure that the handlebars are set correctly in relation to the forks and the direction of travel.

- Check that the head set locking mechanism is properly adjusted and tightened.

- If the bicycle is fitted with handlebar end extensions, ensure they are properly positioned and tightened.

4. Chain

- Ensure chain is oiled, clean and runs smoothly.

- Extra care is required in wet or dusty conditions.

5. 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.

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.

- Ensure derailleurs, shift levers and control cables are properly lubricated.

8. Frame and Fork

- Check that the frame and fork are not bent or broken.

- If either are bent or broken, they should be replaced.

9. Accessories

- Ensure that all reflectors are properly fitted and not obscured.

- Ensure all other fittings on the bike are properly and securely fastened, and functioning.

- Ensure the rider is wearing a helmet.

Helmets

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.

The correct helmet should:

- be comfortable

- be lightweight

- have good ventilation

- fit correctly

Always wear a properly fitted helmet when riding a bicycle. Many states require specific safety devices. It is your responsibility to familiarize yourself with the laws of the state where you ride and to comply with all applicable laws, including properly equipping yourself and your bike as the law requires. 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. Check reflectors and their mounting brackets regularly to make sure they are clean, straight, unbroken, and securely mounted. Have your dealer replace damaged reflectors and straighten or tighten any that are bent or loose.

Reflectors

Your bicycle is supplied with one front (white), one rear (red), two wheel (white), and two pedal (orange) reflectors. These are an important safety and legal requirement, and should remain securely fitted and in good, clean conditions at all times. Periodically, inspect all reflectors, brackets and mounting hardware for signs of wear or damage. Replace immediately if damage is found. Some bicycles will require you to install your reflectors onto your bicycle. Please refer to the following section for instructions on all the types of bicycle reflectors.

Fork Mount Reflector Bracket Assembly

First insert one washer onto the hex bolt and insert hex bolt through the reflector bracket and then through the fork. Next, insert a second washer onto the bolt and thread a hex nut onto the bolt behind the fork. Tighten bolts until snug, making sure the reflector is in an upright position. See diagram at the right.

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 a washer and the reflector bracket on to the caliper bolt. Insert the caliper bolt back into the fork and secure firmly with a washer and the hex nut. Finally, adjust the reflector such that it is in an upright position. See diagram at the right.

Seat and Handlebar Mounting Reflectors

First attach the reflector to the reflector bracket with the reflector screw, see the top diagram. Next, remove the clamp screw and open the clamping reflector bracket. Place clamping reflector bracket around the handlebar or seatpost. If the clamp is too loose, insert the shim inside of the clamp. Tighten the clamp screw to hold reflector assembly in place, see the second diagram. Finally, adjust the reflector assembly in place. Finally, adjust the reflector such that it is upright and facing away from the bike.

Chainstay Mount Reflector Bracket Assembly

first insert one washer onto the hex bolt and insert hex bolt through the reflector bracket and then through the chainstay bridge. Next, insert a second washer onto the bolt and thread a hex nut onto the bolt behind the chainstay bridge. Tighten bolts until snug, making sure the reflector is in an upright position. See diagram at the right.

Thumb Shifters (Top Mounted)

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. Pull the left shifter back to operate the front derailleur, and push the right shifter forward to operate the rear derailleur. To select a higher, harder gear, shift to a smaller rear cog and a larger chainwheel. Push the left shifter forward for the front, and pull the right lever back for the rear.

Below the Bar Shifters

Many mountain style bicycles now use a shift lever arrangement mounted on the underside of the handlebars, which use two levers operated by the thumb and index finger. To select a lower gear push the larger (lower) right shifter with your thumb to engage a larger rear cog. One firm push shifts the chain one cog, continuing to push will move the chain over multiple cogs. Pulling the smaller (upper) left shifter with your index finger moves the chain from a larger to a smaller chainwheel. To select a higher gear pull the smaller (upper) right lever with your index finger to engage a smaller rear cog. Pushing the larger (lower) left lever with your thumb will move the chain from a smaller to a larger chainwheel.

Top Gear

(Harder)

Small rear sprocket

Large chainwheel

Left hand lever forward

Right hand lever back

Bottom Gear

(Easier)

Large rear sprocket

Small chainwheel

Left hand lever back

Right hand lever forward

Left hand lever Right hand lever

BICYCLE CARE

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.

Store your bicycle under shelter. Avoid leaving it in the rain or exposed to corrosive materials. Riding on the beach or in coastal areas exposes your bicycle to salt which is very corrosive. Wash your bicycle frequently and wipe or spray all unpainted parts with an anti-rust treatment. Make sure wheel rims are dry so braking performance is not affected. After rain, dry your bicycle and apply anti-rust treatment.

If the hub and bottom bracket bearings of your bicycle have been submerged in water, they should be taken out and re-greased. This will prevent accelerated bearing deterioration.

If paint has become scratched or chipped to the metal, use touch up paint to prevent rust. Clear nail polish can also be used as a preventative measure.

Regularly clean and lubricate all moving parts, tighten components and make adjustments as required. (Refer to Parts 4 and 5 of this manual for further details). The use of alloy components and BED, SATIN, and TITANIUM surface treatments minimizes the number of places where rust can surface.

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.Before storing your bicycle for a long period of time, clean and lubricate all components and wax the frame. Deflate the tires to half pressure and hang the bicycle off the ground. Don't store near electric motors as ozone emissions may effect the rubber and paint. Don't cover with plastic as "sweating” will result which may cause rusting. Please notice that your bicycle warranty does not cover paint damage, rust, corrosion, dry rot, or theft.

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. Invest in a high quality bicycle lock that will resist hack saws and bolt cutters. Always lock your bicycle to an immovable object if it is left unattended.

DERAILLEUR GEARED BICYCLES

Includes 20", 24” and 26" Wheel Mountain Bikes Assembly is the same for men’s and women’s bikes. .

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 insure that no required parts are accidentally discarded. Assemble your bicycle following the steps that pertain to your model.

Note: Your bicycle may be equipped with different style components than the ones illustrated.

Handlebars

Remove the protective cap from the handlebar stem wedge and loosen the Allen key bolt using the 6mm Allen key. Some models may use a 13mm hexagonal bolt instead of an Allen key bolt. Place the handlebar stem into the top of the head tube, ensuring that all cables are free of tangles. Tighten the stem bolt observing the minimum insertion mark and checking that the forks and the handlebars are facing forward. Check the headset for smooth rotation and that the top nut is secured tightly. Loosen the 6mm Binder Bolt and rotate the handlebar forward so the levers are at a 45 degree angle below the handlebar. Retighten the Binder Bolt to ensure the handlebar does not rotate in the stem.

Stem Bolt

Head Tube

Binder Bolt

Top Nut

Wedge

Minimum Insertion Mark

Warning: Over tightening the stem bolt or headset assembly may cause damage to the bicycle and/or injury to the rider.

PART 3 - ASSEMBLY

NOTE: Comfort Series (CS) bicycles may be equipped with a stem that has an adjustable angle. In addition to the normal assembly, these stems will require angling the stem to the desired position, and securely tightening the 6mm angle bolt located in front of the stem bolt.

Failure to do this may cause loss of steering control.

If the stem is not inserted into the top nut to at least the “Minimum Insertion” mark, it is possible to over-tighten the stem bolt and damage the fork steerer tube. If these instructions are not followed, it could cause an unsafe condition and risk injury to the rider. Check steering tightness prior to riding by straddling the front wheel. Try turning the handlebar. If you can turn it without turning the front wheel, the stem is too loose. Re-align the handlebar with the front wheel and re-tighten the stem bolt.

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