Pacific Cycle BRIGHT LIGHT ENERGY HF3305 User Manual

HELMETS

SAVE

CORRECT FITTING - MAKE

SURE YOUR HELMET COVERS

YOUR FOREHEAD.

LIVES !!!

ALWAYS WEAR A PROPERLY

FITTED HELMET WHEN

YOU RIDE YOUR BICYCLE.

DO NOT RIDE AT NIGHT.

AVOID RIDING IN WET

CONDITIONS.

INCORRECT FITTING. FOREHEAD

IS EXPOSED AND VULNERABLE

TO SERIOUS INJURY.

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

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

Serial Number Location

Bike Shown Upside Down

####

PACIFICCYCLE

4902 Hammersley Road

Madison, WI 53711

Customer Service 1.800.626.2811

www.pacific-cycle.com

Serial Number

PART 1

PART 2

PART 3

PART 4

PART 5

PART 6

PART 7

Parts Identification...................................................... 02-05

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

Assembly ..................................................................... 22-62

Servicing ...................................................................... 63-65

Detailed Maintenance.................................................. 66-97

How Things Work.......................................................98-110

Purchase Record and Warranty.............................. 111-112

Warning / Important

Take notice of this symbol throughout this manual and pay particular

attention to the instructions blocked off and preceded by this symbol.

PACIFICCYCLE

P.O. Box 344 · 4730 E. Radio Tower Ln. · Olney, IL 62450

Customer Service 1.800.626.2811 www.pacific-cycle.com

1. PARTS IDENTIFICATION

Mountain Bicycles

BMX Bicycles

2-5

Derailleur Geared Bicycle

Handlebars, Stems and Shifters

-Aheadset

-Sunken Stem

-Shifters

22-45

22-25

Rotors

56-57

59-61

Drivetrain

-Pedals

-Inspection

-Lubrication & Adjustment

-Attachment

81-89

81-82

Axle Peg Assembly

-Non-Threaded Axle Peg

-Threaded Axle Peg

Training Wheels

-Wheels to Brace

-Brace to Bicycle

-C-Shape Brace

-Flat Brace

Tools Required

2. BEFORE YOU RIDE

Correct Frame Size

Riding Position

-Saddle Height

-Reach

-Handlebar Height

6-21

Forks

29-30

-Crank Set

-Inspection

-Lubrication & Adjustment

(one piece cranks)

-Lubrication & Adjustment

(cotterless cranks)

83-86

Seat and Seat Post

Pedals & Crank Set

Front Wheel

-Stabilizer Bracket

Final Check

Quick Release Axle

85-86

Front Brake

30-37

30-31

32-34

4. SERVICING

63-65

Safety Checklist

-Brakes

-Wheels & Tires

-Steering

-Chain

-Bearings

-Cranks & Pedals

-Derailleurs

-Frame & Fork

-Accessories

9-10

-Cantilever with Link Wire

-Cantilever with Straddle Cable

-V-Style

-Check your Brakes

-Disc Brakes

-Chain

-Inspection

-Lubrication

-Adjustment & Replacement

-Freewheel

87-88

88-89

Schedule 1 - Lubrication

Schedule 2 - Service Checklist

Tools Required

36-37

5. DETAILED MAINTENANCE

Wheel Inspection

Tire Inspection

Tire Pressures

Hub Bearing Adjustment

Flat Tire Repair

66-97

68-69

70-71

-Inspection

-Lubrication

Derailleur

-Rear Derailleur

-Front Derailleur

38-39

-Coaster Hub

Dual Suspension

Rear Pivots

Accessories

Reflectors

43-44

Derailleur Systems

-Inspection

-Lubrication

90-92

Handlebar Stem

Handlebars

Helmets

Reflectors

12-13

-Adjustment (Rear)

-Adjustment (Front)

Grip Shift Installation

Riding Safely

-General Rules

14-16

Fenders

-Front Fender

-Rear Fender

Final Check

Cables & Cable Housing

-Wet Weather Riding

-Night Riding

-Pedaling Technique

-Hill Technique

-Cornering Technique

-Rules for Children

Quick Release Levers

Reflectors

Miscellaneous Accessories

-Basket Assembly

Troubleshooting

95-97

Headset

-Inspection

-Adjustment

Single Speed & BMX

Handlebars

46-62

Seat

Saddle & Seat Post

-Inspection

-Lubrication

75-76

Pedals & Crank Set

Front wheel

6. HOW THINGS WORK

-A. Wheel Quick Release

-B. Seatpost Quick Release

-C. Brakes

98-110

98-102

102

103-104

104-107

107

108

108-110

110

Gears - How to Operate

-Derailleur Gears

-Operating Principles

-Hand Grip Shifters

-Thumb Shifters

17-19

-Adjustment

Front Brake

49-50

52-53

Side Pull Brake

Cantilever with Link Wire

Cantilever with Straddle Cable

V-Brake

-D. Shifting

Brakes

-Inspection

-Lubrication

-Adjustment Sidepull Calipers

-Adjustment Cantilever Calipers

77-80

77-78

78-79

79-80

-E. Toeclips & Straps

-F. Clipless (“step-in”) pedals

-G. Tires and Tubes

-H. Bicycle Suspension

-Below the Bar Shifters

Bicycle Care

-Basic Maintenance

-Storage

20-21

U-Brake

-Front U-Brake

-Rear U-Brake

Blake Lever

7. PURCHASE RECORD

& WARRANTY

111-112

-Security

Check your Brakes

3. ASSEMBLY

22-62

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 generally much sturdier than those on

racing style bicycles.

Shift Lever

Handlebar

Top Tube

Brake Lever

Brake Control Cables

Seat

Seat Post

Handlebar Stem

Front Reflector

Quick Release

Head Set

Front Brake

Seat Stay

Head Tube

Front Fork

Rear Reflector

Wheel Reflector

Rear Brake

Seat Tube

Down Tube

Front Hub

Wheel Reflector

Spokes

Freewheel

Gear Control Cable

Front Derailleur

Bottom

Bracket Axle

Rim

Tire

Chain Wheel

Crank Arm

Pedal

Chain Stay

Tire Valve

Gear Control

Cable

Chain

Rear Derailleur

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.

Front Brake Lever

Handlebar

Seat

Handlebar Grip

Handlebar Stem

Head Set

Brake Control Cable

Seat Post

Seat Post Binder Bolt or

Quick-Release Skewer

Front Reflector

Front Brake

Brake Pad

Head Tube

Seat Stay

Top Tube

Rear Reflector

Wheel Reflector

Front Fork

Wheel Reflector

Front Hub

Spokes

Seat Tube

Down Tube

Chain Wheel

Crank Arm

Pedal

Chain

Rim

Chain Stay

Tire

Rear Sprocket

Training Wheel

Tire Valve

Your new bicycle was assembled and tuned in the factory and then partially disassembled for shipping. You

may have purchased the bicycle already fully assembled and ready to ride OR in the shipping carton in the par-

tially disassembled form. The following instructions will enable you to prepare your bicycle for years of enjoy-

able 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

• A pair of 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

It is important for you to understand your new bicycle. By reading this manual before you go out on your first ride, you’ll know how to get

better performance, comfort, and enjoyment 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 main-

tain or inspect your bicycle. Many of the warnings and cautions say “you may lose control and fall.” Because any fall can result in seri-

ous 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 appli-

cable 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 clearance of no less than 1 - 2 inches 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.

Frame Sizing Guide

Approximate Rider Leg

Length

Suggested Frame Size for

Mountain or Hybrid Bicycle

Suggested Frame Size for

Racing/Touring Bicycle

37cm / 14.5 inches

43cm / 17 inches

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

1-2in.

45cm / 18 inches

50cm / 19.5 inches

55cm / 21.5 inches

57cm / 22.5 inches

60cm / 23.5 Inches

63cm / 25 inches

50cm / 19.5 inches

52cm / 20.5 inches

53-56cm / 21-22 Inches

58-60cm / 23-23.5 inches

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.

Maximum Height /

Minimum Insertion Mark

(Should not be visible)

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

Arms not over-

extended

control and fall. Prior to your first ride, be sure to tighten the

saddle adjusting mechanism properly. A loose 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.

Handlebar stem

height about the

same as

seat height

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. 27 on how to adjust the seat

clamp.)

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.

Stem Wedge Bolt

Handlebar Binder Bolt

Maximum Height/

Minimum Insertion

Mark

Exceeds 2 1/2”

(64mm)

Threadless headsets and clamp-on stems are not adjustable. Please refer to page 23

for instructions on installation.

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 using a reasonable amount of force. 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.

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 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 headset 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

- cover forehead

Always wear a properly fitted helmet which covers the forehead 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 mount-

ing 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 four pedal (orange)

reflectors. (Please Note: Sidewalk bikes, 12” and under, may not have reflectors.) These are an important safety and legal

requirement, and should remain securely fitted and in good, clean condition 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 spacer, washer and the reflector bracket on to the caliper bolt. Insert the

caliper bolt back into the fork and secure firmly with a concave spacer, washer and

the hex nut. Finally, adjust the reflector such that it is in an upright position. See dia-

gram 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 and ensure that it is upright and facing away from the bike.

Seatstay Mount Reflector Bracket Assembly

First insert one washer onto the hex bolt and insert hex bolt through the reflector

bracket and then through the seatstay bridge. Next, insert a second washer onto the

bolt and thread a hex nut onto the bolt behind the seatstay bridge. Tighten bolts until

snug, making sure the reflector is in an upright position. See diagram at the right.

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. Wear proper riding attire and avoid open toe shoes.

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.

Do not lock up the brakes. 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

IT IS RECOMMENDED TO 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

IT IS RECOMMENDED TO NOT RIDE AT NIGHT

- Ensure bicycle is equipped with a full set of correctly positioned and clean reflectors.

- Refer to p. 12-13 and p. 93 of this manual.

- Use a properly functioning lighting set comprising of 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. 17-19)

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.

Please refer to pages 103-4 for braking techniques and pages 104-7 for gear shifting techniques.

Rules for Children

To avoid accidents, teach children good riding skills with an emphasis on safety from an early age. Children should be super-

vised by an adult.

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

Drivetrain

Derailleur Control

Cable

Freewheel

Cogs

Front Derailleur

Derailleur Gears

Most multi-speed bicycles today are equipped with what are known

as derailleur gears. They operate using a system of levers and mecha-

nisms 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 9 cogs on the rear hub.

Front Chainwheels

Crank Arm

Pedal

Guide Pulley

Rear Derailleur

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 opti-

mal performance and extended chain life, it is recommended that you

avoid using the extreme combinations of gear positions (diagram p.

18) for extended periods.

These combinations are

NOT RECOMMENDED

for optimal performance.

These combinations are

NOT RECOMMENDED

for optimal performance.

Middle

Low

High

Low

Recommended Chainwheel/Rear Sprocket Gear Combinations

Hand Grip Shifters

Some bicycles are now being equipped with a shifting

Front Low Gear

Rear Low Gear

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 shift-

er 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 High Gear

Rear High Gear

Thumb Shifters (Top Mounted)

Left hand lever

Right hand lever

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.

Top Gear

(Harder)

Bottom Gear

(Easier)

Small rear sprocket

Large chainwheel

Large rear sprocket

Small chainwheel

Left hand lever forward

Right hand lever back

Left hand lever back

Right hand lever forward

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. Please refer to page 98 for additional

instructions in “How Things Work”.

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.

We recommend that you consult a bicycle specialist

if you have doubts or concerns as to your experi-

ence or ability to properly assembly, repair, or main-

tain your bicycle.

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

Binder Bolt

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

Top Nut

Minimum Insertion

Mark

Warning: Over tightening the stem bolt or headset

assembly may cause damage to the bicycle and/or

injury to the rider.

Wedge

Head Tube

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.

Tightening/Preloading Aheadset

Compression Bolt

Top Cap

Handlebar

Stem Installation (Should be assembled on the

bike already)

Stem Cap

Bolts

1. Insert the compression bolt through the top

cap and the stem. Begin threading into the

star nut.

2.Tighten compression bolt so it removes all

play from the fork, but allows the fork to rotate

smoothly.

3. Align the stem with the front wheel. Tighten

the stem clamp bolts to secure the stem to the

steerer tube.

Stem Clamp Bolts

Spacer

Stem Cap

Headset Wedge

Bearing Race

Bearing Dust Cover

Bearing Retainer

Star Nut

(Inside Steerer Tube)

Installed

factory

Handlebar Installation

Upper Headset Cup

1. Remove the stem cap bolts and stem cap.

2. Insert handlebar into the stem cap.

3. Tighten the stem cap bolts equally. Note

the distance between the stem and stem cap:

It should be equal on the top and bottom of the

stem cap. A must be equal distance.

Headtube

Lower Headset Cup

Bearing Retainer

fork

Bearing Dust Cover

Headset Crown Race

Sunken Stem Bolt System

1. Remove the protective shipping cap from the stem wedge.

2. Remove the Stem Plug from the stem. Loosen the Stem Bolt

with a 6mm allen wrench.

3. Insert the stem into the headtube of the bicycle. Ensure that the

Minimum Insertion Line is below the top nut of the headset.

4. Align the stem and handlebar so it is in line with the front wheel.

5. Tighten the Stem Bolt with the 6mm allen wrench. Reinsert the

Stem Plug into the stem.

WARNING: MINIMUM INSERTION LINE MUST BE HIDDEN WITHIN

THE HEADTUBE OF THE BICYCLE.

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 instruc-

tions 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 han-

dlebar. 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.

Shifter binder bolt

(2.5 Allen key)

Brake lever binder bolt

(5mm Allen key)

Bar end (5mm Allen key)

Shifters

Tighten all bolts that clamp the shifters, brake levers and bar ends to

the handlebar using a 5mm Allen key or Phillips head screwdriver.

(Figure 1) Handlebar with Grip 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

There are two different types of forks that vary in styles and

dimensions. One type is a rigid fork (Figure 1) consisting of

stationary tubing with curved blades. The other type is a

suspension fork (Figure 2) consisting of stanchion tubes

riding on elastomers or springs inside of a straight fork leg.

This mechanism acts as a shock absorber with a specified

amount of travel that varies between models. Some suspen-

sion forks are not adjustable and are very difficult to disas-

semble. If service is needed on a suspension fork, consult a

professional bicycle repair technician.

Brake Boss

Drop-out

Crown

Blade

Do not attempt to disassemble a suspension

fork yourself. Consult a professional bicycle

repair technician.

Check the tightness of the headset and the fork. Rotate the

fork checking for smoothness. If it feels like the fork is

binding, then an adjustment will need to be made to the

headset. Move the fork in a push/pull manner checking for

tightness. If any play is detected, loosen the top nut, adjust

the bearing cup, and retighten the top nut. Recheck the

rotation and tightness. If necessary, readjust until a smooth

rotation is achieved without backward or forward move-

ment. If your bike is equipped with a suspension fork, check

that the fork compresses and rebounds smoothly. To do

this, place the fork dropouts against the ground, push and

release the handlebar. The fork will generally compress 1-2”

and rebound quickly. Most elastomer type forks will gradually

soften with use.

Brake Bridge

Brake Boss

Crown

Drop-out

Steering Tube

Fork Blade

Seat and Seat Post

Attach the seat to the seat post by loosening the nuts on the seat clamp. Insert the

tapered end of the seat post into the seat clamp until it is at the top of the clamp.

Partially tighten the nuts on the seat clamp until the seat is snug, but can still be

turned. Insert the seat assembly into the frame of the bicycle and adjust the seat to

the proper height. The seat post must be inserted to at least the “Minimum Inser-

tion” line marked on the seat post. If equipped with a quick release skewer; tighten

the adjusting nut by hand and move the quick release lever to the closed position.

You should feel considerable resistance while moving the lever. If not, re-open and

re-tighten the lever, then move it to the closed position so it is in line with the frame

as pictured. If equipped with a binder clamp; Insure the lip on the binder clamp is

fitted completely against the top of the seat tube of the frame. With the seat post

inserted, tighten the binder bolt securely. Position the top of the seat parallel with

the ground. Push the front of the seat up and down to firmly mesh the serrations

together. The serrations must mesh completely together to insure a stabilized rid-

ing position. Securely tighten the nut on the seat clamp. If there is a nut on both

sides of the clamp, tighten each one by alternating from one to the other. Check for

tightness by twisting the seat from side to side, and from front to back. If the seat

moves at the seat clamp or quick release, reposition and re-tighten the appropriate

clamping mechanism.

Seat

Clamp

Seat

Post

Quick

Release

Adjusting

Nut

Attach

Seat Here

Boot

NOTE: Comfort Series (CS) bicycles may be equipped with a suspension

seat post (See Diagram-bottom left). Some suspension posts can be adjusted for stiff-

ness using the preload adjusting screw. Turning the 6mm Allen screw Clockwise will

decrease travel and make the suspension stiffer, while turning the 6mm Allen screw

Counter-clockwise will increase travel and make the suspension less rigid.

Note: In addition to normal assembly, please be aware that the preload adjusting

screw must be flush with the bottom of the post. Some bicycles may come equipped

with a shim that should be positioned over the lower half of the seat post and inserted

into the seat tube of the frame. Failure to do this may cause irreparable damage.

Minimum

Insertion

Mark

Insert this

end into

frame

The seat post must be inserted so that the minimum insertion

mark cannot be seen. The quick release mechanism must be

tightened securely to prevent a sudden shift of the seat when

riding. Failure to do this may cause loss of bicycle control.

Preload adjusting

screw on underside

Pedals & Crank Set

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. It is very important that you check

the crank set for correct adjustment and tightness before riding your

bicycle. New cranks may become loose with initial use, refer to p. 83-86

for proper crank set adjustment and maintenance. Once the pedals have

been installed, remove the dust caps from the center of each crank arm.

Using a 14mm socket wrench, tighten the spindle nuts securely (approx.

350 in. lbs.) and replace the dust caps.

Dust

Cap

Attachment of an incorrect pedal into a crank arm can

strip pedal threads and cause irreparable damage. Before

your first ride, please check to insure your pedals are

attached correctly.

Front Wheel

Quick Release

Axle

Adjusting

Nut

Quick

Release

Lever

Check the wheel hub before attaching it 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 checking for

trueness. Some bicycles have wheel axles that incorporate a Quick

Release (QR) mechanism. This allows easy wheel removal without

the need for tools. The mechanism uses a long bolt with an adjusting

nut on one end, and a lever operating a cam-action tensioner on the

other. If the wheel is fitted with a Quick Release type axle, turn the

adjusting nut so that the locking lever is moved to the closed position

with a firm action. At the halfway closed position of the quick release

lever, you should start to feel some resistance to this motion. Do not

tighten the quick release by using the quick release lever like a wing

nut. If the quick release lever is moved to the closed position with no

resistance, clamping strength is insufficient. Move the quick release

lever to the open position, tighten the quick release adjusting nut,

and return the quick release lever to the closed position.

Spring

Hub

Axle

Hub

Closed Position

Correct Quick Release Axle Setting

1. To set, turn the lever to the open position so that the curved

part faces away from the bicycle.

2. While holding the lever in one hand, tighten the adjusting nut

until it stops.

Open Position

3. Pivot the lever towards the closed position. When the lever is

halfway closed, there must be firm resistance to turn it

beyond that point. If resistance is not firm, open the lever and

tighten the adjusting nut in a clockwise direction.

4. Continue to pivot the lever all the way to the closed position

so that the 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.

7. Turn the bicycle upright using the kickstand to support it.

If you can fully close the quick release without wrapping your

fingers around the fork blade for leverage, and the lever does

not leave a clear imprint in the palm of you hand, the tension is

insufficient. Open the lever, turn the adjusting, and try again.

Continue until the QR lever closes properly. Secondary retention

devices are not a substitute for a correct quick release adjust-

ment. Failure to properly adjust the quick release mechanism

can cause the wheel to wobble or disengage, which could cause

you to lose control and fall, resulting in serous injury or death.

Cantilever

Brakes

1. Install the cable into

Front Brake

Determine which type of brake your bike is equipped with and refer to

the appropriate assembly instructions. For more information on brake

adjustment and maintenance, refer to p. 77-80.

Cable

End

Cantilever Brakes - Utilizing a Link Wire

If fitted with cantilever type brakes, insert the brake cable into the link

wire lead, and notch the cable end into the slot of the left brake arm.

Loosen the anchor bolt on the right brake arm and slide the brake cable

under the tabbed washer. Squeeze both brake arms together so the

brake shoes hit the rim, pull all slack out of the brake cable, and tighten

the anchor bolt. With the cable fitted, the straddle holder should sit

10-20mm above the reflector bracket. Adjust the brake shoes using a

10mm wrench so that they are parallel with the rim and are positioned

1-2mm away from the rim. Several adjustments may be necessary to

achieve the correct brake position.

2. Set the cable into

3. Temporarily tighten the cable so

that the link wire is at the position in

the illustration.

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.)

Link Wire

10 mm wrench

5 mm Allen key

Touching

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

Cut off any unneces-

sary cable, attach an end

cap, and hook it onto the

notched part of the nut

which secures the shoe.

4. Turn the spring tension

adjustment screw so that the link

wire comes to a position directly

below the cable casing holder.

End cap

Cantilever Brakes - Utilizing a Straddle Cable

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 brak-

ing power. Generally, the straddle cable bridge is set low and close

to the tire for maximum braking force. The straddle cable should be

high enough, however, to adequately clear the tire (and any debris

that may stick to the tire) or to fit over the front reflector hanger. In the

event of brake cable failure, the front reflector hanger would prevent

the straddle cable from catching in the tire and locking up the front

wheel. The straddle cable length (when adjustable) is set to transfer

as much force to the brake pads as possible. For the most efficient

transfer of force, the straddle cable and the line between the cantilever

pivot and the cable anchor should form a right angle (90 degrees). If

the force is not at a right angle, part of the force gets wasted in pulling

on the brake post, which has no effect on braking.

Straddle

Cable

Brake

Brake Cable

Straddle Hanger

Straddle Cable

Pinch Bolt

Cable

Anchor

Caliper Arm

Pivot

V-Style Brakes

If not already assembled, take the brake noodle from the parts box

and slide the cable through the larger opening. The cable housing

will then seat into the end of the noodle. Slide the cable through the

cable lead on the end of the left brake arm, this will cause the noodle

to fit into the lead. Slip the brake cable boot over the cable and posi-

tion it between both brake arms. Next, loosen the 5mm anchor bolt

at the end of the right brake arm and slide the cable under the retain-

ing washer. Pull the slack out of the cable making sure a distance of

39mm or more remains between the end of the lead and the start of

the anchor bolt. Once the cable is secured to the brake arms, engage

the brake lever several times, checking the position of the brake

shoes at the rim. The brake shoes should be 1mm away from the

rim when in a relaxed position. When the brake lever is engaged, the

brake shoe should hit the rim flush (never the tire) with the front brake

pad touching the rim slightly before the rear. This is called “toeing-in”

your brake shoe. If this position is not achieved, adjustments to the

brake shoe are required. Loosen the brake shoe hardware and reposi-

tion the brake shoe. It may take several shoe and cable adjustments

before the required position is accomplished.

Brake

Cable

Boot

Outer

Cable

Lead

Brake

Noodle

Anchor

Bolt

Brake

Arm

Pivot

Bolt

Tension

Screw

Brake

Shoe

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.

V - Brake

If fitted with V-Brakes, insert the brake body

into the center spring hole in the frame mount-

ing boss, and then secure the brake body to the

frame with the link fixing bolt.

39 mm or more

5 mm Allen key

3 mm washer B

6 mm washer B

Shoe fixing nut

Washer

Link

Spring

fixing

hole

bolt

Washer

Washer A

Shoe fixing link

Washer A

Stopper pin

3. While holding the shoe against the

5. Adjust the balance with the spring

rim, tighten the shoe fixing nut.

tension adjustment screws.

shoe fixing nut

5 mm Allen key

1mm

1 mm 1 mm

Spring tension

adjustment screw

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.

6. Depress the brake lever about 10 times as

far as the grip to check that everything is

operating correctly and that the shoe

clearance is correct before using the brakes.

Depress about

10 times

5 mm Allen key

1mm 1mm

Check your Brakes

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 1 mm to 2 mm away from the rim when the brakes are

not applied. Brake pads should be centered on the rim and “toed-in” so the rear portion of each brake pad is about 0.5

- 1.0 mm farther from the rim than the front portion of the brake pad.

Brake pad aligned with the rim surface

Pad and rim should be parallel.

Direction of rim

rotation

1- 2 mm

0.5 - 1.0 mm

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.

Never ride a bicycle that is not functioning properly.

Do not lock up brakes. Sudden or excessive application

of the front brake may pitch the rider over the handlebars,

causing serious injury or death. When braking, always

apply the rear brake first, then the front.

Disc Brakes

Brake Cable

Housing

If fitted with a front disc brake, the components should already

be attached. However, please check all connections before

attempting to ride the bicycle. Secure tightly the 6 bolts that

hold the disc to the front wheel hub and the 2 bolts that hold

the brake mechanism to the fork. Insert the front wheel into the

fork dropouts ensuring that the disc fits into the brake mecha-

nism between the enclosed brake pads. Secure the front wheel

to the bicycle by tightening the quick release mechanism and

clamping the lever to the closed position. Please refer to sec-

tion 6 for further instruction on quick release mechanisms.

Barrel Adjuster

Lock Nut

Brake Lever

Cable

Insertion

Slot

Next, attach the cable to the brake lever by inserting the cable

end into the cable end holder after the barrel adjuster and lock

nut slots have been aligned with the cable end holder. After

the cable is secured to the lever, rotate the barrel adjuster and

lock nut so the slots no longer line up. Ensure the cable hous-

ing seats appropriately into the end of the barrel adjuster and

check for any kinks or damage.

Brake Cable

Cable End

Holder

Brake Type

Selector

“C” Clip

Rotating Rod

Caliper

Slide the exposed brake cable through the rotating rod located

on the caliper body and seat the housing into the same stop.

Insert the cable into the spring and spring boot.

Mounting

Bolt with

spacers

Actuating Arm

Next, slide the cable through the cable anchor and pull all the

slack out. Secure the cable in place by tightening the bolts that

comprise the anchor assembly. Some disc brakes will have a

centering devise while others are a free-floating mechanism.

If your caliper body is equipped with centering bolts, apply the

brake lever after the cable has been connected. While engaging

the lever, tighten the centering bolts securely. This will center

the caliper body on the disc.

Brake Pads

Caliper

Mounting

Bolt with

spacers

DISC GETS HOT! Severe injury could result from

contact with the hot disc! Mind your legs, as well

as your hands.

Cable Anchor

Bolt

Centering Bolt

Hub

Fork Leg

Disc Mounting

Bolts

Brake Cable

Housing

Rotating

Rod

Caliper

Body

Disc

Cable Boot

with Spring

inside

Centering Bolt (inside)

Actuating

Arm

Cable Anchor

Bolt

Fork Drop Out

Caliper Mounting

Bolts with spacers

Quick Release

lever

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. Please be aware that your brake system will

change in performance throughout the wear-in process. The disc brake

should be cleaned before the first ride using rubbing alcohol. NEVER use oil

or similar products to clean your disc brake system.

Derailleur

Freewheel

Outer side of Top Gear

Although the front and rear derailleurs are initially adjusted at

the factory, you will need to inspect and readjust both before

riding the bicycle.

Pulley Adjustment

Screw

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.

Guide Pulley

Adjust the High limit screw so the guide pulley and the

smallest sprocket are lined up vertically. Reconnect the cable,

pull out any slack, and retighten the anchor bolt securely. Shift

through the gears, making sure each gear achieved is done

quietly and without hesitation. If necessary, use the barrel

adjuster to fine tune each gear by turning it the direction you

want the chain to go. For example, turning clockwise will loos-

en the cable tension and move the chain away from the wheel,

while turning counter-clockwise will tighten cable

Adjustment

Screws

Tension Pulley

SIS Cable Adjuster

tension and direct the chain towards the wheel. Shift the rear

shifter to the gear one and place the chain on the largest cog.

Adjust the Low limit screw in quarter turn increments until the

guide pulley and the largest cog are aligned vertically. Again,

shift through each gear several times, checking that each gear

is achieved smoothly. It may take several attempts before the

rear derailleur and cable is adjusted properly.

High Gear

Adjustment Screw

Low Gear

Adjustment

Screw

Ensure all bolts are secured tightly and the chain

does not fall off in either direction.

Barrel

Adjuster

Rear Derailleur Side View

Front Derailleur

Low Adjusting Screw

Shift both shifters to the smallest number indicated and place

the chain on the corresponding cog and chainwheel. Discon-

nect 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

1-3mm when fully engaged.

High Adjusting

Screw

Cable Anchor Bolt

Chainguide

clearance of

1-3mm

With the chain on the smallest chainwheel in front and the

largest cog in back, adjust the Low limit screw so the chain is

centered in the front derailleur cage. Reconnect the cable, pull

any slack out, and tighten the anchor bolt securely. Shift the

front shifter to the largest chainwheel. If the chain does not go

onto the largest chainwheel, turn the high limit screw in 1/4 turn

increments counter-clockwise until the chain engages the largest

chainwheel. If the chain falls off the largest chainwheel, and

into the pedals, you will need to turn the High limit screw in 1/4

turn increments clockwise until the chain no longer falls off.

Shift through every gear, using the barrel adjusters to fine tune

each transition. The barrel adjuster for the front derailleur is

located on the front shifter where the cable comes out of the

shifter. Clockwise will loosen the cable tension and direct the

chain closer to the frame while counter-clockwise will tighten

the cable tension and direct the chain away from the frame.

Outer Chainguide

Inner Chainguard

Do not ride a bicycle that is not shifting proper-

ly. Overlooking proper adjustments may cause

irreparable damage to the bicycle and/or bodily

injury. Never move the shifter while pedaling

backward, nor pedal backwards after having

moved the shifter. This could jam the chain

and cause serious damage to the bicycle

and/or rider.

Dual Suspension

Dual Suspension bikes (DS) 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 adjusting plate. Clockwise will increase spring

tension and decrease travel, while turning counter-clockwise

will decrease spring tension and increase travel. There are

many different types of suspension systems-too many to deal

with individually in this manual.

There must be enough tension on the spring to hold

the spring plate in place. Failure to do this may cause

the mechanism to fail. Failure to maintain, check and

properly adjust the suspension system may result in

suspension malfunction, which can cause you to lose

control and fall. Changing suspension adjustment

can change the handling and braking characteristics

of you bicycle. Never change suspension adjustment

unless you are thoroughly familiar with the suspen-

sion system, manufacturer’s instructions and recom-

mendations, and always check for changes in the

performance of your bicycle by taking a careful test

ride in a hazard free area. If your bike has suspen-

sion equipment, the increased speed you may develop

also increases your risk. When braking, the front of a

suspended bike dips. You could lose control and fall

if your skill is not up to handling this system. Get to

know how to handle your suspension system safely

Spring

Spring plate

Anchor bolt

Adjusting plate

Piston

before trying any downhill or very fast biking.

Rear Pivots

The pivot 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 re-

greased at least once every riding season. Please note

the drive side crank arm must be removed from the spin-

dle before attempting to work on the pivot. Some models

have two, small (2.5mm) Allen bolts on the underside of

the bottom bracket shell. These must be removed before

attempting to disassemble the pivot. After disassembling

and cleaning, the shaft of the pivot assembly should be

lightly coated with lithium-based grease, as well as the

bushings and the threads of the attaching hardware.

Please remember: Never use WD-40™ to grease com-

ponents. It is a degreaser that will not provide required

lubrication and has a tendency to attract dust.

Attaching Bolt

Bushing

Shaft

Pivot Assembly

Bottom Bracket Cup & Lockring

Rear Triangle

Accessories

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 saddle bag or frame bag.

The saddle bag 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. The smaller strap wraps around the seat

post. Frame bags install at the apex of the top and seat tubes.

Secure the straps around each tube.

Saddle Bag

Reflector

Frame Bag

Reflector

NOTE: The frame bag straps must not bind the cables. The

straps must go around the frame only.

Other: Some 20” and 24” model bicycles come with a rear

derailleur guard to protect the rear derailleur from damage. To

install, remove the the rear wheel axle nut on the drive side,

install the rear derailleur guard over the axle with the U-shaped

guard pointing down, and retighten the axle nut. The guard will

sit between the frame and the axle nut.

Reflector

Water bottle and cage

Reflectors

Attach the white reflector to the front reflector bracket and

secure to the fork or handlebar using the hardware provided.

Attach the red reflector to the rear reflector bracket and secure

to the frame or seat post, depending on the bracket style, with

the hardware provided.

Tighten both rear wheel axle nuts or the

quick release mechanism securely. Failure

to do this may cause the rear wheel to

dislodge from the frame dropouts resulting

in serious damage or injury.

figure 1

Fenders

Front Fender

The front fender is mounted at the fork crown. There are two

ways in which to mount your front fender. The first is the caliper

brake mounting system (see figure 1), and the second is the

10mm nut and bolt system (see figure 2). Identify the mounting

system used on your bicycle and follow the given instructions for

that particular type of mounting system.

1. Caliper Brake Mounting System

First remove the front wheel from your bicycle. Remove the

hex nut from the caliper brake bolt on the rear of the fork,

and slide the brake assembly from the fork. Place the fend-

er assembly onto the fork making sure the attachment holes

and fender bracket holes line up. Reattach the caliper

brake making sure that the brake arms are on each side of

the fender. Tighten the bolt until secure.

2. 10mm Nut and Bolt Mounting System

figure 2

First remove the front wheel from your bicycle. Place the

fender assembly onto the fork making sure the attachment

holes and fender bracket holes line up. Attach the fender

with the 10mm hex bolt and nut. Tighten the bolt until secure.

Rear Fender

The rear fender is mounted at the seatstay brace. There are two

ways in which to mount your rear fender. The first is the screw

mounting system (see figure 3), and the second is the 10mm bolt

and screw system (see figure 4). Identify the mounting system used

on your bicycle and follow the given instructions for that particular

type of mounting system.

1. Screw Mounting System

First remove the rear wheel. Place the fender assembly

between the stays, making sure the fender bracket holes

line up with those in the frame. Attach the fener by using

two screws to directly mount the fender onto the frame.

The mounts are located below the seat post and near the

rear of the crank. Tighten all screws until snug.

figure 3

2. 10mm Bolt and Screw System

First remove the rear wheel. Place the fender assembly

between the stays, making sure the fender bracket holes

line up with those in the frame. Attach the fender by using

one screw to directly mount the fender onto the frame near

the crank. Next, use the 10mm hex bolt and nut to attach

the fender to the brace between the seat stays, near the

seat post. Tighten all bolts and screws until snug.

figure 4

Final Check

After all adjustments have been made, shift through every

gear several times at varying speeds. This will ensure all

your adjustments are correct and will allow you to pinpoint

any trouble areas. If you encounter any problems, refer to

the appropriate section and make any necessary adjustments.

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.

Correct maintenance of your bicycle will ensure many years

of happy riding. Service your bicycle regularly by referring

to the relevant sections of this manual, OR take it to a

professional bicycle shop.

Never inflate a tire beyond the maximum

pressure marked on the tire’s sidewall.

Exceeding the recommended pressure

may blow the tire off the rim, which

could cause damage to the bicycle and

injury to the rider and bystanders.

Remember: Always wear a helmet and obey all

traffic laws.

Tighten both rear wheel axle nuts or the

quick release mechanism securely. Failure

to do this may cause the rear wheel to

dislodge from the frame dropouts resulting

in serious damage or injury.

SINGLE SPEED & BMX

Includes 16" and 20" BMX Bikes

Assembly is the same for boy’s and girl’s bikes.

Foreword: Assembling a bicycle is an important responsibility. Proper

assembly not only gives the rider more enjoyment of the bicycle; it

also offers an important measure of safety.

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.

Stem Cap Binder Bolts

Note: Your bicycle may be equipped with different style components than

the ones illustrated.

Stem

Bolt

Handlebars

Remove the protective cap from the stem wedge and loosen the stem

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 head tube, observing the minimum insertion mark on the

handlebar stem and ensuring that all cables are free of tangles. Check

that the fork and the handlebar are facing forward, and that they are

properly aligned with the front wheel. Tighten the stem bolt. Rotate the

handlebar to the desired position. Tighten stem cap bolt 1 (see picture)

two turns, tighten stem cap bolt 2 two turns and so on. Repeat until

handle bar is secure to the stem. See picture for a 4 or 6-bolt system.

Also check that the stem binder bolts are tightened equally and securely.

Minimum

Insertion Mark

Stem Wedge

Head

Tube

Four Bolt

Face

Plate

Six Bolt

Face

Plate

The handlebar must be inserted so that the minimum insertion

mark cannot be seen. WARNING: Over tightening the stem

bolt or headset assembly may cause damage to the bicycle and/

or injury to the rider.

four bolt

Seat

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. The serrations on the seat clamp must mesh completely with

the seat frame serrations, push the front of the seat up and down to align the

serrations. Securely tighten the seat clamp. Securely tighten the bolts on

the seat post clamp. Turn the bicycle upside down and rest it on the seat

and handlebars.

The seat pillar must be inserted so that the minimum

insertion mark cannot be seen.

Pedals & Crank Set

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. It is very important that you check the crank set for

correct adjustment and tightness before riding your bicycle. New cranks may

become loose with initial use, refer to p. 83-86 for proper crank set adjustment

and maintenance. Once the pedals have been attached, check that the crank

arm rotates smoothly and that there is no lateral movement.

Attachment of an incorrect pedal into a crank arm will

cause irreparable damage.

Front Wheel

Retaining

Washer

1. Make sure the brakes are loose enough to allow the wheel to

pass through the brake pads easily.

Axle Nut

Axle

2. Place wheel into fork drop outs.

Hub

3. Install retaining washers with raised lip pointed towards the fork,

and insert into the small hole of the fork blade. NOTE: Some bikes

may have step retaining washers in place of the retaining washer

(shown in dotted box). If so, install the step retaining washer,

raised portion sliding in to the fork dropouts.

4. Install axle nut and tighten. Make sure the wheel is centered

between the fork blades.

5. Spin the wheel to make sure that it is centered and clears the

brake shoes. Tighten the brakes if necessary.

Cone Nuts

Step

Retaining

Washer

Fork Drop Out

6. Turn the bicycle upright using the kickstand to support it.

It is very important to check the front wheel

connection to the bicycle. Failure to properly tighten

may cause the front wheel to dislodge.

Brake Lever

Nipple

Front Brake

Ferrule

Determine which type of brake your bike is equipped with and refer

to the appropriate assembly instructions. For more information on

brake adjustment and maintenance, refer to p. 77-80. A greater force

is required to activate the rear brake due to longer cable length. It is

advisable to mount the rear brake on the side of the stronger hand.

It is important to become familiar with the use of hand brakes. When

properly adjusted, hand brakes are an efficient braking system. Keep

the rim and brake shoes clean and free from wax, lubricants and dirt

at all times. Keep brakes properly adjusted and in good working

condition at all times.

Cable

Adjusting

Barrel

Open the brake lever and place the nipple end of the short brake

cable into the lever, then close the lever. Secure the ferrule against

the lever using the cable adjusting barrel.

Grip

Handlebar

Side Pull Brake

Side Pull

Brakes

Cable

Adjusting

Barrel

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. Tight-

en the nuts securely. Pull down on the end of the brake cable with pli-

ers, hold taut and securely tighten the cable anchor nut.

Center Bolt

Brake

Arm

Cable

Anchor

Nut

Spin the wheel, the brake shoes should not contact the rim at any

point and should be an equal distance from the rim on both sides.

Make sure all nuts and bolts are securely tightened. Test the brake

levers 20-25 times to take care of any initial cable stretch. Be sure to

tightly secure the brake fixing nut behind the fork.

Fixing Nut

in Back

Brake Shoe

When assembling or adjusting the brakes, make

sure the cable anchor is tight. Failure to securely

tighten the nut could result in brake failure and

personal injury.

Cantilever

Brakes

1. Install the cable into

the cable carrier.

Cable

End

Cantilever Brakes - Utilizing a Link Wire

If fitted with cantilever type brakes, insert the brake cable into the link

wire lead, and notch the cable end into the slot of the left brake arm.

Loosen the anchor bolt on the right brake arm and slide the brake

cable under the tabbed washer. Squeeze both brake arms together

so the brake shoes hit the rim, pull all slack out of the brake cable,

and tighten the anchor bolt. With the cable fitted, the straddle holder

should sit 10-20mm above the reflector bracket. Adjust the brake

shoes using a 10mm wrench so that they are parallel with the rim and

are positioned 1-2mm away from the rim. Several adjustments may

be necessary to achieve the correct brake position.

2. Set the cable onto

the straddle holder.