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Chapter 2 – Maintenance

2.1 MAINTENANCE SCHEDULE

This maintenance schedule is based on normal usage. If you ride your bike more than average, or in rain, snow, or off-road conditions, serv-

ice your bicycle more often than the schedule suggests. If any part appears to be malfunctioning, inspect and service it immediately, or con-

sult your dealer. If a part is damaged, replace it before riding the bicycle again.

After initial break-in, new bikes should be checked for stretched cables and other normal conditions.

Approximately two months after purchasing your new bike, have your dealer thoroughly inspect the bicycle.

All bikes should be thoroughly serviced once a year, even if they have not been ridden.

See Chapters 3 and 4 for adjustment and maintenance details

WARNING

Only the maintenance, adjustment and lubrication items listed in this manual should be attempted by the bicycle owner.

If you are unsure consult your dealer. All other repairs and maintenance should be carried out by your dealer.

Cooper

Bicycle Owners Manual 25

MANUAL 20.11.12 2/7/13 00:00 Page 30

Summary of Contents for BICYCLE

Page 1: ...COOPER BIKES BICYCLE OWNER S MANUAL IMPORTANT KEEP FOR FUTURE REFERENCE 2nd edition 2013 This manual meets EN Standards 14764 and 14766 MANUAL 20 11 12 2 7 13 00 00 Page 2 ...

Page 2: ...hers We hope you share our philosophy and enjoy your new bike IMPORTANT Read CHAPTER 1 before riding your new bicycle Even if you are an experienced cyclist please take a moment to read through CHAPTER 1 of this manual before you ride This manual contains important safety performance and service information Some maintenance should only be performed by your dealer and the manual indicates these tas...

Page 3: ...a potentially hazardous situation which if not avoided may result in minor or moderate injury or is an alert against unsafe practices The word CAUTION used without the safety alert symbol indicates a situation which if not avoided could result in serious damage to the bicycle or the voiding of your warranty Many of the Warnings and Cautions say you may lose control and fall Because any fall can re...

Page 4: ...many models with a variety of equipment so this manual may contain some information that does not apply to your bike Some illustrations may vary from the actual bicycles If you have any questions after reading the information in this manual consult your dealer If you have a question or problem that your dealer can t handle contact us service cooperbikes com MANUAL 20 11 12 2 7 13 00 00 Page 5 ...

Page 5: ...roviding updated safety information your registration is crucial Go to www cooperbikes com and follow the links The website also provides a link to updated safety information If you choose not to register make sure you check the website often KEEP FOR FUTURE RECORDS BICYCLE MODEL SERIAL NUMBER LOCK KEY NUMBER THE SHOP OF PURCHASE MY SHOP PHONE NUMBER MANUAL 20 11 12 2 7 13 00 00 Page 6 ...

Page 6: ...2 Cooper Bicycle Owners Manual MANUAL 20 11 12 2 7 13 00 00 Page 7 ...

Page 7: ...estrians and other obstacles 1 4 3 Wear a helmet and proper cycling clothes 1 4 4 Change your riding to be safe in variable conditions 1 4 5 Use your brakes carefully 1 4 6 Use good shifting techniques 1 5 Take care of your bike 1 5 1 Protect your bike from theft 1 5 2 Protect your bike when parking storing or shipping 1 5 3 Carry repair items 1 5 4 Only install and use approved accessories 1 5 5 ...

Page 8: ...icycle Owners Manual Chapter 3 Adjustment 3 1 Torque specifications 3 2 Handlebar 3 3 Stem 3 4 Headset 3 5 Saddle 3 6 Pedals 3 7 Chainset bottom bracket 3 8 Chain 3 9 Cables 3 10 3 5 speed Sturmey Archer Internal Hub Gear systems 3 11 8 11 speed Shimano Afline Internal Hub Gear systems 3 12 Multi speed derailleur systems 3 13 Brake levers 3 14 Brakes 3 15 Wheels 3 16 Accessories MANUAL 20 11 12 2 ...

Page 9: ...ation in Chapter 1 for further details WARNING Bicycles or their parts can be broken or damaged by riding in a manner more stressful than the intended use of the bike If the bike is damaged you could lose control and fall Do not ride beyond the design limits of the bike If you are unsure of the limits of the bike consult your dealer Ride within the design guidelines for the Classification for your...

Page 10: ...lb 250 kg 1 1 2 CONDITION 2 General Purpose Riding These bikes are designed for riding Condition 1 plus smooth gravel roads and improved trails with moderate grades where the tyres do not lose ground contact INTENDED For paved roads gravel or dirt roads that are in good condition and bike paths NOT INTENDED For off road or mountain bike use or for any kind of jumping Wider tyres suit gravel or dir...

Page 11: ...sive over intermediate terrain Cross country and marathon components are light weight favoring nimble speed over brute force NOT INTENDED For very aggressive or extreme riding No spending time in the air landing hard and hammering through obstacles Cross Country and Marathon bikes are light and fast for pedaling efficiency and uphill speed Weight limit 300 lbs 136 kg For more information refer to ...

Page 12: ...echanisms of your bike by riding at slower speeds in a flat empty parking lot If you want your bicycle to perform differently or if you have special needs that require different parts for the safe operation of your bike consult your dealer Learn the power of your brakes The stopping power on bikes varies according to the intended use of the bike If you would like your bike to have more or less sto...

Page 13: ...at slow speed Stop riding if you experience problems Occasionally riders experience problems with their frame or fork or other component If a frame fork or any component has any problem do not ride the bicycle If you experience an unusual vibration noise or behaviour slow down and stop immediately Take your bicycle directly to a dealer for inspection and repair WARNING A vibration or steering wobb...

Page 14: ...e program Wheels Tyre inflation Brakes Handlebar and stem Seat and seat post Lights and reflectors Frame fork and components Check the wheels CAUTION A bicycle that does not work properly can cause you to lose control and fall Inspect the entire bicycle thoroughly before every ride and do not ride it until any problem has been corrected Check that the wheels are straight Spin each wheel and watch ...

Page 15: ...uct you in correct wheel removal and installation and ask him to give you any available manufacturer s instructions Bicycle wheels are designed to be removable for easier transportation and for repair of a tire puncture In most cases the wheel axles are inserted into slots called dropouts in the fork and frame Wheels are secured in one of two ways Cooper use Quick release or Wheel Axle nuts Quick ...

Page 16: ...r the brake is too loose If the brake pads are too close to the rim the brake is too tight Brake pads should be aligned with the rim surface WARNING Never ride a bike if you are not certain the brakes are working properly or you if suspect a problem with the brake cables or hydraulic hose Malfunctioning brakes can cause you to lose control and fall Inspect the brakes thoroughly before every ride I...

Page 17: ...ed into both ends of the handlebar if fitted Check the seat and seat post Make sure the seat is secure by attempting to turn the seat and seat post in the frame and attempt to move the front of the seat up and down It should not move or be loose Check the lights and reflectors Make sure the lights are functioning correctly and that any batteries are charged If the lights use a dynamo make sure it ...

Page 18: ... a hole in the road or a sharp bump can put large forces on your bike WARNING As with all mechanical components the bicycle is subjected to wear and high stresses Different materials and components may react to wear or stress 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 chang...

Page 19: ...ct side of the road never go against traffic Ride defensively expect the unexpected A cyclist is hard to see and many drivers simply are not trained to recognize the rights and special considerations of a bicycle rider 1 4 2 Watch for cars pedestrians and other obstacles Watch for and avoid potholes drain grates soft or low kerbs and other deviations which could impact your wheels or cause them to...

Page 20: ...dry Even properly aligned lubricated and maintained brakes require greater lever pressure and longer stopping distances in wet weather Anticipate the extra distance it will take to stop Wet weather causes reduced traction Use slower cornering when traction is reduced such as when riding over wet leaves painted pelican crossings or manhole covers When wet weather cools to below freezing traction is...

Page 21: ...be visible to others Use front and rear bicycle lights and reflectors when riding in poor visibility conditions Failure to do so will increase your chances of being involved in an accident in low light conditions WARNING Do not use unsafe riding practices Many cycling accidents could be avoided by using common sense Here are a few examples Do not ride no hands Do not ride with loose objects attach...

Page 22: ...e and more frequent inspections Avoid riding too fast Higher speeds create higher risks and greater forces in the event of a crash At higher speeds it is more likely that wheels will slip or that a small bump can create a significant impact to your frame or fork Keep your bicycle under control at all times For children the limit of speed for safe riding is much lower so parents should enforce this...

Page 23: ...o lose control Bicycles are normally manufactured with the right brake lever controlling the front wheel brake and the left brake levercontrolling the rear This set up is normal for the UK If you want your brakes setup European style contact your bike shop Many models of modern brakes are very powerful they are designed to stop a bike in wet or muddy conditions If you feel your brakes are too powe...

Page 24: ...d shifting systems a movement of the shifter from one position to the next or movement of the shifter to the shift position should promptly move the chain from one gear to the next However bikes equipped STI road shifters and triple chainrings may shift better particularly when shifting from the smallest chainring to the middle if you hold the lever for a moment before letting go of the shifter Sh...

Page 25: ...e carefully When not riding keep your bike where it will be protected from rain snow sun etc Do not store the bike near electric motors as ozone from motors destroys rubber and paint Rain or snow may cause the metal on your bicycle to corrode Ultraviolet radiation from the sun may fade the paint or crack any rubber or plastic on the bicycle Before storing your bike for an extended period of time c...

Page 26: ...t damp cloth and bike cleaner or a solution of dish soap and water Use of industrial solvents or harsh chemicals for cleaning may damage the paint Caring for your Brookes leather saddle Each Brooks Saddle comes with a care leaflet Maintaining your saddle as described therein will ensure that it becomes the most comfortable and durable saddle you could ever wish for Clean and oil your chain Ask you...

Page 27: ... a bike or even crush the tubing When putting a bike in a repair stand clamp the seat post When carrying a bike in a car carrier clamp the wheels and the fork tips WARNING Never modify your frameset or parts in any way including sanding drilling filing removing redundant retention devices installing incompatible forks or by any other method Improper components or improper assembly can place unknow...

Page 28: ...24 Cooper Bicycle Owners Manual MANUAL 20 11 12 2 7 13 00 00 Page 29 ...

Page 29: ... bikes should be checked for stretched cables and other normal conditions Approximately two months after purchasing your new bike have your dealer thoroughly inspect the bicycle All bikes should be thoroughly serviced once a year even if they have not been ridden See Chapters 3 and 4 for adjustment and maintenance details WARNING Only the maintenance adjustment and lubrication items listed in this...

Page 30: ...our bicycle with a damp cloth Check for loose spokes Monthly Check the attachment of the handlebar and stem Check the attachment of the seat and seat post Check the chain tension and lubricate Check the chain guard and other accessories Inspect cables for wear Check the operation of shifters Check the internal shift system 26 Cooper Bicycle Owners Manual MANUAL 20 11 12 2 7 13 00 00 Page 31 ...

Page 31: ...r Every 3 Months Clean and polish finish Check the bottom bracket Lubricate brake levers Every year Lubricate handlebar stem Lubricate seat post Service pedal threads and bearings Service bottom bracket Service wheel bearings Service headset bearings Cooper Bicycle Owners Manual 27 MANUAL 20 11 12 2 7 13 00 00 Page 32 ...

Page 32: ...r N m gradations 2 4 5 6 8 mm allen keys 9 10 15 mm open end spanners 15 mm spanner or socket No 1 Phillips head screwdriver Bicycle tube patch kit tyre pump with gauge and tyre levers Note Not all bikes require all these tools 28 Cooper Bicycle Owners Manual MANUAL 20 11 12 2 7 13 00 00 Page 33 ...

Page 33: ...ed to make sure you do not over tighten the fasteners Applying more than the recommended torque to a fastener does not provide extra holding power and may actually lead to damage or failure of a part Always perform the simple function tests listed in this chapter to make sure a part is properly tightened whether or not the part was tightened with a torque wrench If a part fails inspection at the r...

Page 34: ...20 lb in 11 3 13 6 N m Forged stems 150 180 lb in 17 20 3 N m 3 3 STEM There are two types of stems Direct connect A Head Quill type Adjusting the handlebar height on a direct connect stem affects the headset bearing adjustment This procedure requires special tools and training so this should only be done by your dealer 30 Cooper Bicycle Owners Manual Handlebars A Handlebar clamp bolts B Steerer c...

Page 35: ...t to loosen the stem wedge 3 Adjust the handlebar to the desired height but with the minimum insertion line inside the frame A minimum of 23 4 70 mm of the stem quill must always remain in the frame 4 Tighten to 120 lb in 13 6 N m WARNING Never ride your bicycle with a quill stem raised above the minimum insertion mark A quill stem that is positioned too high can damage the bike and can cause you ...

Page 36: ...ly be performed by your dealer 3 5 SADDLE The correct adjustment of the seat angle is largely a matter of personal preference With proper adjustment the right bike saddle will be reasonably comfortable even for long rides To select the saddle angle first try riding with the top of the seat parallel to the ground The seat may also be moved forward or backward along the seat post to increase comfort...

Page 37: ...the saddle can be tilted fore and aft Some seat posts use two bolts where angle adjustment is done by loosening one bolt and tightening the other bolt 2 Place a straight edge such as a level or ruler across the top of the seat to better see the angle 3 Adjust the seat and re tighten the seat fixing bolt according to the type of seat post Double bolts using a 5 mm Allen wrench 80 125 lb in 9 6 14 1...

Page 38: ...parallel to the seat tube 3 Loosen the seat post binder bolt or quick release 4 Extend the seat post until with your heel resting on the bottom pedal your extended leg is straight When wearing your shoes there should be a slight bend in your knee in a proper riding position with the ball of your foot on the pedal 5 Make sure the minimum insertion mark on the seat post is not visible above the bike...

Page 39: ...OM BRACKET To check the bottom bracket bearing adjustment 1 Lift the chain from the chain rings 2 Rotate the crank so that one of the arms is parallel to the seat tube 3 Put one hand on the crank arm and one hand on the seat tube and attempt to move the crank arm laterally toward and away from the seat tube 4 Spin the cranks If the crank feels or sounds loose or if the motion stops abruptly or you...

Page 40: ...e fully retightened 4 Check the chain is free and does not bind by lifting the rear wheel from the ground and rotating the crank If the motion becomes tight during rotation re adjust the chain tension starting with step 1 5 For bikes with internal hub gears the shifter cable will require adjustment WARNING The chain tension when running fixed wheel is critical If the chain tension is set too loose...

Page 41: ...ARCHER INTERNAL HUB GEAR SYSTEMS To adjust the shifter cable and set the shifting 1 Rotate the shifter to the 2nd gear position 2 Remove the indicator protection cover if fitted 2 Align the coloured line on the push rod with the end of the axle as viewed through the rear hub nut window 3 If the indicators do not line up adjust the gear cable tension by rotating the barrel adjuster until this align...

Page 42: ...nd the largest rear cog 2 Loosen the front derailleur cable clamp bolt until the cable is free 3 Turn the low gear adjusting screw marked L until the inner chain guide of the derailleur is approximately 0 5 mm from the chain 4 Pull on the cable end and down shift the left shift lever several times so that it is in the small chainring position 5 On the shifter or down tube turn the shift cable adju...

Page 43: ...re the chain does not fall off when you shift and the derailleur cage does not rub on any part of the crankset To adjust the middle gear position with three chainrings 1 Shift the chain onto the largest front chainring and the smallest rear cog 2 Rotate the cable tension barrel adjuster on the downtube or on the lever counter clockwise increasing cable tension to align the inner derailleur cage un...

Page 44: ... pull the shift cable taut and tighten the cable clamp bolt to 44 60 lb in 5 0 6 8 N m To adjust the large cog position 1 Turn the low gear adjusting screw on the rear derailleur usually marked L far enough counter clockwise that it will not restrict the movement of the derailleur 2 Carefully shift the chain onto the smallest front chainring and the largest rear cog Do not over shift the rear dera...

Page 45: ...pulleys align with the second smallest cog 4 Go through the gear combinations to ensure the chain smoothly lines up with all the rear cogs If the derailleur cannot be adjusted in this manner the derailleur hanger may be out of alignment take the bike to your dealer for service 3 13 BRAKE LEVERS The brake system allows you to slow or stop your bike a function critical to your safety The brake syste...

Page 46: ...e pad clearance to the rim 1 Turn the barrel adjuster To increase the pad clearance turn the barrel adjuster in clockwise To reduce the pad clearance turn the barrel adjuster out counter clockwise For most direct pull or cantilever systems the barrel adjuster is on the lever For most road calliper systems the barrel adjuster is on the brake itself 2 If the brake pads cannot be adjusted properly lo...

Page 47: ... 1 Lift the brake release lever to the open UP position To close simply turn the lever to the Down position To align a cable actuated brake There are several parts to this procedure To adjust right brake pad clearance to the disc 1 Turn the fixed pad adjuster 2 If the pads cannot be adjusted properly in this manner follow the instructions To adjust left brake pad clearance to the disc and re set t...

Page 48: ... disk 1 Loosen the brake mounting bolts 2 Slide a business card or similar thin object between the right brake pad and the disc 3 Apply the lever fully and gradually tighten the bolts to 100 110 lb in 11 3 12 4 N m To remove disc break pads 1 Remove the wheel 2 With your fingers or thin tipped pliers grasp the installation tang of the brake pad and pull out To open the brake for wheel removal For ...

Page 49: ...coaster brake is a sealed mechanism which is a part of the bicycle s rear wheel hub The brake is activated by reversing the rotation of the pedal cranks Start with the pedal cranks in a nearly horizontal position with the front pedal in about the 4 o clock position and apply downward foot pressure on the pedal that is to the rear About 1 8 turn rotation will activate the brake The more downward pr...

Page 50: ... brake is applied If too much material is removed the rim may become weak and fail suddenly causing a loss of control Regularly inspect your rims for wear and replace them when they are worn 3 15 WHEELS Inspect tyres for wear and damage Make sure rims are clean and check for wear if the grooves on the braking surface disappear replace the rim Make sure there are no loose damaged or broken spokes C...

Page 51: ...m side to side If the wheel attachment fails the test repeat these procedures including the tests or take your bicycle to your dealer for service To reverse the rear wheel flip flop operation Some bikes are supplied with a flip flop rear hub This enables the rider to choose between freewheel and fixed wheel riding For more information on the differences between the two go to www cooperbikes com To...

Page 52: ...n Check the operation of the rear brake before riding WARNING Ensure you are competent and trained to ride your bike with a fixed gear Before you ride make sure that it is safe and legal to ride in this condition 3 16 ACCESSORIES Once a month check any accessories to make sure they are properly attached If any part seems loose or misaligned either tighten the part or take the bike to your dealer f...

Page 53: ...uire yearly re greasing WARNING Only the maintenance adjustment and lubrication items listed in this manual should be attempted by the bicycle owner If you are unsure consult your dealer All other repairs and maintenance should be carried out by your dealer 4 1 STEM Once a year lubricate the stem Note Lubricating a direct connect stem requires adjustment of the headset bearings so should only be d...

Page 54: ...ht align it and tighten the seat post binder bolt 4 3 PEDALS Once a year have your dealer re grease the pedal bearings Once a year re grease the pedal axles where they thread into the crank arms Note There are right and left pedals usually marked with a letter stamped on the end of the pedal axle or on the wrench flats 1 Remove the pedals turn the right pedal spindle counter clockwise but turn the...

Page 55: ... the chain and rear sprocket with specialist chain lubricant available from your dealer 4 8 CONTROL CABLES Lubricate cables whenever they are installed To install a cable Installing a cable in a cantilever brake requires special tools and training so should only be done by your dealer 1 Note the path of the old cable loosen the cable anchor bolt and remove the worn cable 2 Grease the new cable and...

Page 56: ...tions for adjustment 4 9 TYRES Bicycle tyres are available in many designs and specifications ranging from general purpose designs to tyres designed to perform best under very specific weather or terrain conditions If once you ve gained experience with your new bike you feel that a different tire might better suit your riding needs your dealer can help you select the most appropriate design The si...

Page 57: ... check your tire pressures before every ride Some special high performance tyres have unidirectional treads their tread pattern is designed to work better in one direction than in the other The sidewall marking of a unidirectional tyre will have an arrow showing the correct rotation direction If your bike has unidirectional tyres be sure that they are mounted to rotate in the correct direction 4 1...

Page 58: ...p unscrew counter clockwise the valve stem lock nut and push down on the valve stem to free it up Then push the pump head on to the valve head and inflate To inflate a Presta valve with a Schraeder pump fitting you ll need a Presta adapter available at your bike shop which screws on to the valve stem once you ve freed up the valve The adapter fits into the Schraeder pump fitting Close the valve af...

Page 59: ...his information and help is just a click away LIMITED WARRANTY All Cooper bikes are sold exclusively through our network of Authorised Dealers who we entrust with professional assembly and service of your bicycle Cooper Bikes warrants each new Cooper frame rigid fork or original component part of the bicycle against defects in workmanship and materials For one year Paint and decals All original pa...

Page 60: ...ot responsible for incidental or consequential damages Claims under this warranty must be made through an authorised Cooper bike dealer Proof of purchase is required The subject item must be registered with Cooper Bikes either through on line registration or by the receipt of a warranty registration card by Cooper Bikes before a warranty claim may be processed Warranty duration and detail may diff...

Page 61: ...ket shell Put your receipt of sale in this manual for reference This record will also help you with any police investigation or insurance claim and should be recorded in the front of this manual NOTE If there is a loss or theft your personal records will be needed Your receipt of sale should be kept for any warranty service Cooper Bicycle Owners Manual 57 MANUAL 20 11 12 2 7 13 00 00 Page 62 ...

Page 62: ...C O O P E R B I K E S 6 Lewisham Street London SW1H 9AH t 44 0 20 7222 3098 f 44 0 1903 871 223 e sales cooperbikes com www cooperbikes com C O O P E R B I K E S MANUAL 20 11 12 2 7 13 00 00 Page 1 ...

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