Zinc ZC02990 Instruction manual
ZINC 20 inch BMX-Vital
Instruction Manual
241/6812
Important - Please take time to read the instructions carefully
This BMX is supplied with a chainguard tted.
These instructions contain important information that will help you get the best from your BMX,
ensuring safe and correct assembly, use and maintenance.
If you need help or have damaged or missing parts, call the Customer Helpline on 01582 670100
or visit www.zincHQ.com
Dec 2011
Contents
In the Box .........................................................................................................................................................5
Parts .............................................................................................................................................................5
Tools .............................................................................................................................................................5
Assembly ..........................................................................................................................................................6
Step 1 ...........................................................................................................................................................6
Step 2 ...........................................................................................................................................................7
Step 3 ...........................................................................................................................................................8
Step 4 ...........................................................................................................................................................9
Step 5 .........................................................................................................................................................10
Step 6 .........................................................................................................................................................13
Step 7 .........................................................................................................................................................14
Customer Helpline 01582 670100
Step 8 .........................................................................................................................................................16
Riding Advice .................................................................................................................................................17
Before Riding .............................................................................................................................................17
Using the Brake .........................................................................................................................................17
Riding Using Personal Music Players ......................................................................................................17
Riding in Bad Weather ..............................................................................................................................18
Riding in the Dark ......................................................................................................................................18
Maintenance ...................................................................................................................................................19
2
Customer Helpline 01582 670100
Safety Information
Important - Please read instructions fully before starting assembly
WARNING! Warning! This Bike has been designed, assembled and tested in accordance with
the BS EN16054 Cat 2, max rider weight 70kg. 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 EN1078:2012+A1:2012.
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! Warning! This bike is only suitable for use by riders (including any panniers and/or
luggage) with a weight of less than 70 kg (154 lb)
WARNING! BMX pedals are designed to provide greater grip capability of the pedal tread surface
than that provided by an ordinary bicycle pedal. This can result in the pedal tread surface being very
rough and containing sharp edges. Riders should therefore wear adequate safety protection.
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.
For spares and replacement parts please visit www.zincHQ.com
3
Customer Helpline 01582 670100
Safety Information
Important - Please read 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.
NOTE
IMPORTANT! Always take care when removing the packaging to prevent damage to the bike.
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.
Recommended Tightening Information
While assembling the bike, it is recommended that, where possible, a torque spanner 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 01582 670100In the Box
Parts
C
B
D
A
E
F
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)
F
Pegs
Tools
Multitool (supplied in separate box) Hexagonal key (supplied in separate box)
6 Customer Helpline 01582 670100
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.
• 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 01582 670100
Assembly
Step 2
2a Assembling the Handlebars.
Loosen the stem cap bolts from the stem and remove the stem cap.
Place the centre of the handlebar in the open stem and replace the stem cap in position.
Carefully replace the stem cap bolts taking care to tighten them evenly and rmly. Tighten the top Left
corner rst, then bottom right, bottom left and nally top right.
Check that the handlebars are correctly positioned in relation to the front wheel. Adjust the alignment if
necessary and then ensure that the handlebar expander bolt is tightened.
WARNING! Ensure that the cables are not tangled or twisted as this may affect braking performance.
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