Zinc 3322280 Instruction manual
ZINC 16 inch Bike
Instruction Manual
Maintenance Guide
332/2280
332/2228
Important - Please take time to read the instructions carefully
Important – Please read these tips fully.
These instructions contain important information that will help you get the best from your bike,
ensuring safe and correct maintenance.
If you need help or have damaged or missing parts, call the Customer Helpline on 0871 226 2034
Dec 2011
Contents
In the Box .........................................................................................................................................................5
Parts .............................................................................................................................................................5
Tools .............................................................................................................................................................5
Assembly ..........................................................................................................................................................6
Step 1 ...........................................................................................................................................................6
Step 2 ...........................................................................................................................................................7
Step 3 ...........................................................................................................................................................9
Step 4 .........................................................................................................................................................10
Step 5 .........................................................................................................................................................11
Step 6 .........................................................................................................................................................14
Riding Advice .................................................................................................................................................15
Customer Helpline 0871 226 2034
Before Riding..............................................................................................................................................15
Riding in Bad Weather ...............................................................................................................................16
Riding in the Dark ......................................................................................................................................16
Riding Using Personal Music Players.......................................................................................................16
2
Safety Information Customer Helpline 0871 226 2034
Important – Please read these instructions fully before starting assembly
WARNING! This Bike has been designed, assembled and tested in accordance with the BS EN
14765:2005 standard to ensure your safety. To make sure the bike remains safe, it should only
be used for recreational use. Under no circumstances should it be used for competitive cycling,
stunting, jumping or acrobatic manoeuvres. These types of cycling may result in serious personal
injury and damage to the bike.
WARNING! Always wear a cycle helmet when riding the bike. The helmet should be the correct size
for your head and must conform to the European Standard EN1078:1997.
WARNING! When riding in the dark, always make sure that the bike is tted with suitable reectors
and use a white front light and a red rear light.
WARNING! Always take extra care when riding in wet, foggy, windy or icy conditions. The brakes
may not be as effective and the braking distances may be increased.
WARNING! Always wear suitable cycling clothing when riding the bike. Loose clothing which may
get caught in moving parts should be avoided.
WARNING! This bike is only suitable for use by riders (including any panniers and/or luggage) with
total weight including the bike of 60 kg (132 lb) or less.
WARNING! When assembling the handlebars and stem to the bike frame, make sure the forks
are facing in the correct direction. If the forks are assembled correctly, the brakes should be facing
forwards. Failure to observe this warning may prevent their correct operation and may lead to
personal injury and damage to the bike.
WARNING! When assembling the handlebars and stem, make sure it is inserted beyond the
minimum insert mark. Failure to observe this warning may lead to a potentially unstable bike and
may result in serous personal injury.
WARNING! When assembling the seat post, make sure it is inserted beyond the minimum insert
mark. Failure to observe this warning may lead to a potentially unstable seat post and may result in
serous personal injury.
WARNING! The front and rear tyres must be fully inated before attempting to ride the bike. Under
no circumstances should the tyres be inated above the maximum pressure stated on the side of
the tyres.
WARNING! Only inate the front and rear tyres of the bike using a bicycle pump. Do not attempt to
use another type of pump to inate the tyres.
WARNING! As with all mechanical components, the bike is subjected to wear and high stresses.
Different materials and components may react to wear, stress or fatigue in different ways. If the
design life of a component has been exceeded, it may suddenly fail, possibly causing injuries to the
rider. Any form of crack, scratches or change of colouring in highly stressed areas indicate that the
life of the component has been reached and it should be replaced.
WARNING! Ensure only genuine replacement parts are used, especially for safety critical parts.
3
Safety Information Customer Helpline 0871 226 2034
Important – Please read these instructions fully before starting assembly
CAUTION! Only use suitable tools to assemble the bike. The use of unsuitable tools may lead to
personal injury and damage to the bike.
CAUTION! Always ensure all packaging is removed from the bike before assembly and use. Failure to
remove the packaging may prevent the correct operation and may lead to personal injury and damage
to the bike.
CAUTION! The safety and smooth running of the bike can only be preserved with regular
maintenance. Always ensure the bike is maintained in accordance with the supplied maintenance
manual.
CAUTION! Before attaching the handlebar assembly, make sure all the cables are free to move
and are not tangled. Failure to observe this caution may prevent correct operation and may lead to
personal injury and damage to the bike.
IMPORTANT! Before assembling the bike, check all the parts indicated in the manual are in the
box. Inspect the parts for signs of damage. Do not assemble the bike if you observe any damaged
components.
IMPORTANT! Always take care when removing the packaging to prevent damage to the bike.
NOTE
NOTE! Always recycle the packaging in accordance with local recycling schemes.
NOTE! The pedals and crank arms have colour coded stickers to indicate which pedal matches which
Crank Arm.
NOTE! The threads on the left and right pedals are different. To prevent damage to the threads, only
tighten the pedals in the direction indicated on the stickers.
NOTE! The left and right sides of the bike are determined by sitting correctly on the bike.
Recommended Tightening Information
While assembling the bike, it is recommended that, where possible, a torque wrench is used to tighten
nuts and bolts. The table below provides a list of torque settings for the various nuts and bolts.
Front Wheel Nuts
Rear Wheel Nuts
Seat Binding Nut
Seat Pillar Clamp Nut
Brake Anchor Nut
Handle Bar Clamp Nut
Head Stem Expander Bolt
Crank Cotter Pin Nuts
Brake Centre Bolt
Pedals
22 - 27 Newton Metres
24 - 29 Newton Metres
12 - 17 Newton Metres
4 - 19 Newton Metres
7 - 11 Newton Metres
5 - 19 Newton Metres
17 - 19 Newton Metres
5 - 10 Newton Metres
5 - 7 Newton Metres
35 - 40 Newton Metres
4
5 Customer Helpline 0871 226 2034In the Box
Parts
C
B
D
A
E
A
Bike (supplied with rear wheel assembled)
B
Handlebar and stem
C
Seat post and saddle
Front wheel
D
E
Pedals (supplied in separate box)
Tools
Multitool (supplied in separate box) Hexagonal key (supplied in separate box)
6 Customer Helpline 0871 226 2034
Assembly
Step 1
IMPORTANT! Before assembling the bike, check all the parts indicated in the manual are in the
box. Inspect the parts for signs of damage. Do not assemble the bike if you observe any damaged
components.
IMPORTANT! Always take care when removing the packaging to prevent damage to the bike.
1. Remove the bike from the box and carefully remove all packaging. The following types of
packaging are used to protect the bike during transit:
• Cardboard Wrapping - This is used to protect the painted surfaces of the bike frame.
• Bubble Wrapping - This is used to protect the painted surfaces of the bike frame.
• Cable Ties - These are used to secure loose parts to the partially assembled bike.
• Stem Caps - These are placed in unprotected ends of the bike frame.
• Axle Protectors - These are used to protect the outer edges of the front and rear wheel axles.
• Fork Protectors - These are used to prevent the suspension forks from bending or being
damaged.
NOTE
2. The packaging should be retained until the bike is fully assembled. Use the box to store the
packaging during assembly.
NOTE! Always recycle the packaging in accordance with local recycling schemes.
7 Customer Helpline 0871 226 2034
Assembly
Step 2
2a
B
Minimum
Insertion
Mark
A
2a Insert the Stem
WARNING! When assembling the handlebars and stem, make sure it is inserted beyond the
minimum insert mark. Failure to observe this warning may lead to a potentially unstable bike and
may result in serious personal injury.
If necessary, loosen the stem bolt at the top of the handlebars and stem
move freely.
Ensuring the wedge nut is correctly aligned, insert the lower end of the handlebars and stem
the head tube of the bike
A
.
B
to allow the wedge nut to
B
into
8 Customer Helpline 0871 226 2034
Assembly
Step 2 (continued)
2b 2c
B
Loosen
Tighten
90°90°
F
2b Align the Stem
WARNING! When assembling the handlebars and stem to the bike frame, make sure the forks are
facing in the correct direction. If the forks are assembled correctly, the front brake should be facing
forwards. Failure to observe this warning may prevent their correct operation and may lead to personal
injury and damage to the bike.
Adjust the handlebars and stem
B
to the desired height and align with the forks . The forks must
be facing the right direction as shown.
2c Securing the Stem
Using the supplied hexagonal key, tighten the stem bolt rmly.
Step 3
3a 3b
Minimum
Insertion
Mark
C
A
3a Insert the Seat Post and Saddle
F
Loosen
Tighten
H
WARNING! When assembling the seat post, make sure it is inserted beyond the minimum insert
mark. Failure to observe this warning may lead to a potentially unstable seat post and may result in
serous personal injury.
Insert the lower end of the seat post and saddle
C
into the seat tube of the bike A.
3b Securing the Seat Post
Using the supplied hexagonal key, tighten the seat post bolt
H
rmly.
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