Diamondback SHEPPARD CYCLES Owner'S Manual Download

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DRIVETRAIN

The drivetrain of a bicycle refers to all parts that transmit power to the rear

wheel, including the pedals, chain, chainwheel and crank set, and

freewheel.

Pedals

Pedals are available in a variety of shapes, sizes and materials and each are

designed with particular purposes in mind. Some pedals can be fitted with

toe clips and straps. These help to keep the feet correctly positioned and

allow the rider to exert pulling force, as well as downward pressure,

on the pedals. Use of toe clips with straps requires practice to acquire the

necessary skill to operate them with safety.

Never ride in traffic with fully tightened toe straps.

While toeclips and straps give some benefit with any kind of shoe, they work most effectively with cycling shoes designed for

use with toeclips. Your dealer can explain how toeclips and straps work.

WARNING: Getting into and out of pedals with toeclips and straps requires skill which can only be acquired with practice.

Until it becomes a reflex action, the technique requires concentration which can distract the rider’s attention, causing you to

lose control and fall. Practice the use of toeclips and straps where there are no obstacles, hazards or traffic. Keep the straps

loose, and don’t tighten them until your technique and confidence in getting in and out of the pedals

warrants it. Never ride in traffic with your toe straps tight.

Inspection

Pedals should be inspected every month, taking note of the following areas.

- Check correct tightness into the cranks. If pedals are allowed to become loose they will not only be dangerous but

will also cause irreparable damage to the cranks.

Never ride with loose pedals.

- Check that pedal bearings are properly adjusted. Move the

pedals up and down, and right to left, and also rotate them by hand. If you detect any looseness or roughness in the

pedal bearings then adjustment, lubrication or replacement will be required.

- Ensure front and rear pedal reflectors are clean and securely fitted.

- Ensure toe clips, if fitted, are securely tightened to the pedals.

20067_OWNERS-MANUAL.qxp 08/03/2006 10:41 AM Page 61

SHEPPARD CYCLES ABN 60 082 376 289

SC/2012

Summary of Contents for SHEPPARD CYCLES

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Page 3: ... is your responsibility as it helps reduce the risk of injury This Manual contains many Warnings and Cautions concerning the consequences of failure to maintain or inspect your bicycle Many of the Warnings and Cautions say you may lose control and fall Because any fall can result in serious injury or even death we do not repeat the warning of possible injury or death whenever the risk of falling i...

Page 4: ...ssembly Pages 8 16 PART 6 Warranty Inside Back Cover Warning Important Take notice of this symbol throughout this manual PART 3 Before You Ride Pages 17 31 PART 4 Servicing Pages 34 36 PART 5 Detailed Maintenance Pages 37 80 PART 7 Contact Addresses Back Cover SHEPPARD CYCLES ABN 60 082 376 289 SC 2012 ...

Page 5: ...et 48 A headset type assemblies 48 rotors 50 Saddle Seat Post 51 Brakes 53 sidepull calipers 54 cantilever calipers 55 linear pull 57 u brake 59 brake shoe replacement 60 disc brakes 60 Drivetrain 61 pedals 61 crank set 64 one piece cranks 65 cotterless cranks 66 chain 68 freewheel 69 coaster hub 70 Derailleur Systems 71 rear derailleur 72 front derailleur 74 Reflectors 75 Accessories 76 Troublesh...

Page 6: ...iarise yourself with the names of various parts on the diagram similar to your bicycle This will help when you come to the assembly and basic maintenance instructions described later in this manual Care For Your Carbon Frame Assembly Maintenance when assembling or carrying out maintenance on your carbon framed bicycle it is recommended to hold the bicycle in a workstand by the seatpost or use an i...

Page 7: ... are designed to give maximum comfort over a wider variety of road surfaces The wider handlebars and convenient shift lever position make them very easy to control Wider wheel rims and tyres give them a softer ride with more traction on rough surfaces The frame and fork on mountain style bicycles is much sturdier and heavier than a racing style bicycle A variation of the mountain bicycle is the cr...

Page 8: ...spension Bicycles With similar components to standard frame mountain bicycles suspension fitted bicycles give even more comfort over uneven road surfaces Some are fitted with shock absorbing front forks only while others are designed with special frames which also have a rear suspension mechanism In addition some bikes may be fitted with a special shock absorbing seat pillar or even a handlebar st...

Page 9: ...e frame Top Tube Seat Seat Post Seat Post Binder Bolt Seat Stay Rear Reflector Wheel Reflector Rear Sprocket Training Wheel Crash Pad Handlebar Stem Head Set Head Tube Crash Pad Seat Tube Down Tube Crank Arm Pedal Chain Chainstay Chainwheel Rim Tyre Tyre Valve Handlebar Grip Brake Lever Handlebar Brake Control Cable Reflector Front Brake Brake Pad Front Fork Wheel Reflector Front Hub Spokes 20067_...

Page 10: ... needed are at your disposal For more detail on inspection lubrication maintenance additional tools needed and adjustment of any area please refer to the relevant section elsewhere in this manual You will need the following tools Spanners ring or open ended 8mm 10mm 12mm 13mm 14mm and 15mm or adjustable wrenches Spanners open ended narrow 15mm Torque Wrench with newton meter graduations Phillips h...

Page 11: ...ay use a 13mm hexagonal bolt instead of an Allen key bolt Place the handlebar stem into the top of the head tube ensuring all cables are free of tangles Tighten the handlebar stem in the frame while observing the minimum insertion mark and checking that the forks and handlebars are both facing forward Ensure that the handlebar binder clamp on the stem is tightened For MTB bicycles supplied with ha...

Page 12: ...and handlebars The seat pillar must be inserted so that the minimum insertion mark cannot be seen 4 Pedals Attach the pedals carefully engaging the thread initially by hand Note that the right hand pedal attaches to the chainwheel side crank with a right hand clockwise thread The left pedal attaches to the other crank arm and has a left hand counter clockwise thread The ends of each pedal spindle ...

Page 13: ...tments must be made Be sure that the right hand control lever operates the front brake and the left lever operates the rear brake To connect the front brake position yourself so you can comfortably squeeze the brake calipers together with one hand while adjusting and fastening the brake cable with the other hand If your bike is fitted with sidepull type brakes grasp and firmly squeeze the caliper ...

Page 14: ...cle 8 Gears Gears are preset at the factory and normally will not require further adjustment before riding However before testing them check that the 10mm anchor bolts which clamp the front and rear derailleur control cables are firmly fastened Only then test the gears ensuring the drive chain moves freely into each position when the control levers are activated If further adjustment is needed ref...

Page 15: ...nstead Insert the handlebar stem with handlebars attached into the head tube of the bicycle re tighten it while observing the minimum insertion mark and ensuring both the forks and handlebar assembly are facing forward Ensure that the handlebar clamping mechanism on the stem is tightened Note for some 12 30cm BMX bicycles the handlebar and stem is a one piece assembly and is tightened via a clamp ...

Page 16: ...dals very firmly using a narrow 15mm open ended spanner Note damage will occur if pedals are not correctly and firmly attached Attachment of an incorrect pedal into a crank arm will cause irreparable damage 5 Front Wheel and Mudguard For bicycles where a front mudguard is supplied this should be attached before fitting the front wheel Position it with the short end facing forward and attach the me...

Page 17: ...e brake cable with a 10mm spanner firmly pull the cable through the hole and then re tighten To connect and adjust V style or Linear Pull type brakes use a 10mm spanner or Allen key to set the brake shoes to within 2mm of and parallel to the rim with the brake arms in a vertical position Position the drum shaped end button of the control cable into the hand brake lever Loosen the cable eyebolt on ...

Page 18: ... pegs Please consult our service department if you have any questions Some BMX bicycles come with two or four pegs If your bicycle is a dirt Jumping style bicycle you will receive only two pegs These are designed for the front wheel Freestyle bicycles come with four pegs two for each wheel 9 Finally For BMX bicycles attach the safety crash pads as shown Check tyre pressure is inflated to the range...

Page 19: ...comfortable riding there should be a clearance of between 25mm and 50mm between the crotch of the intended rider and the top frame tube of the bicycle while rider straddles the bicycle with both feet flat on the ground Female riders should take into account the slope of the top tube to determine frame size suitability If in doubt ask your dealer The ideal clearance will vary between types of bicyc...

Page 20: ...t pillar does not extend beyond the minimum insertion mark Refer P 52 on how to adjust seat height If your bicycle is fitted with a suspension type seat post the same caution should be noted 2 Reach To obtain maximum comfort the rider should not overextend his or her reach when riding While placing your elbow against the seat and stretching out your arm the distance between the outstretched finger...

Page 21: ... the front brake shoes move in towards the wheel rim or out away from the wheel rim when you change stem height take your bicycle to your dealer for correct brake adjustment before riding it WARNING 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 th...

Page 22: ...ensure tyres have tread and have no bulges or excessive wear ensure rims run true and have no obvious buckles 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 Saddle ensure clamp underneath saddle is firmly tightened to the saddle ...

Page 23: ...ks and Pedals ensure pedals are correctly and securely tightened to the cranks ensure cranks are securely tightened to the axle and are not bent 8 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 where gear components are supplied with a separate...

Page 24: ...ng Australian Standards 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 A bicycle helmet must be labelled with the Australian New Zealand Standards approved mark AS NZS 2063 fit correctly The right helmet should be comfortable be lightweight have good ventilation In mo...

Page 25: ...r 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 h...

Page 26: ...n 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 sea...

Page 27: ...t of concealed driveways Use your bell as a warning Be extra careful at intersections and when preparing to pass other vehicles Familiarise 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 trousers use leg clips or elastic bands to prevent them being caught in the chain Don t carry packages or passengers th...

Page 28: ... when riding after dark Use a properly functioning lighting set comprising a white front lamp and a red rear lamp If using battery powered lights make sure batteries are well charged If using dynamo powered lights ensure wiring is properly connected and not loosely fitted Some rear lights available have a flashing mechanism which enhances visibility Wear reflective and light coloured clothing Ride...

Page 29: ...ccidents teach children good riding skills with an emphasis on safety from an early age 1 Always wear a properly fitting helmet 2 Do not play on 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...

Page 30: ...operated by the left shift lever and the rear derailleur by the right To operate you must be pedalling forward You can not shift derailleur gears when you are stopped or when pedalling backwards Before shifting ease up on your pedalling pressure On approaching a hill shift to a lower gear before your pedalling speed slows down too much for a smooth shift When coming to a stop shift to a lower gear...

Page 31: ...e handlebar stem or toward the top of the frame down tube To select a lower gear push the left shifter forward to engage a smaller front chainwheel and pull the right shifter back to engage a larger rear cog To select a higher gear pull the left lever back to engage a larger chain wheel and push the right lever forward to engage a smaller rear sprocket Top Gear Harder Small rear sprocket Large cha...

Page 32: ...ng mechanism called Grip Shift which is built into the handlebar grips and does not make use of separate levers The actuating mechanism is built into the inside part of the grip that the web of the thumb and index finger closes around To select a lower gear twist the right shifter toward you to engage a larger rear cog You can shift one gear at a time by moving the Grip Shift one click or through ...

Page 33: ...liminate noise pushing again will engage a smaller chainwheel To select a higher gear push the small right lever to engage a smaller rear cog By pushing the large left lever inwards a larger front chainwheel will be engaged High Gear Rear Low Gear Rear Rapid Fire Shifters Low Gear Front High Gear Front High Middle Low Recommended Chainwheel Rear Sprocket Gear Combinations High Low CAUTION Never mo...

Page 34: ...erged 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 vanish 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 fu...

Page 35: ...t 2 Register the bicycle with the manufacturer distributor and 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 such as a lamp post if it is left unattended Solid Post Bicycle Frame U Lock Rear wheel High Security using a U Lock 20067_OWNERS MANUAL qxp 08 03 2006 10 38 AM Page 33 SHEPPARD CYCLES ABN 60 ...

Page 36: ... Monthly hubs lithium based grease disassemble bottom bracket lithium based grease disassemble pedals lithium based grease disassemble freewheel oil 2 squirts from oil can brake cables lithium based grease disassemble derailleur cables lithium based grease disassemble Yearly wheel bearings lithium based grease disassemble headset lithium based grease disassemble seat pillar lithium based grease di...

Page 37: ...Check frame and fork for trueness 45 Check all nuts and bolts are tight 36 6 Monthly Lubrication as per schedule 1 34 Check all points as per Monthly service 35 Check and replace brake pads if required 60 Check chain for excess play or wear 68 Yearly Lubrication as per schedule 1 34 WARNING Like any mechanical device a bicycle and its components are subject to wear and stress Different materials a...

Page 38: ... 25 Newton Metres Seat post binder nut 15 19 Newton Metres 8 10 Newton Metres Brake cable fixing nut 7 11 Newton Metres Brake caliper centre bolt nut 5 10 Newton Metres Crank attachment systems 12 14 Newton Metres or as recommended by manufacturer Tools Required 1 Open ended or ring spanners 8mm 9mm 10mm 12mm 13mm 14mm 15mm 2 Open end or pedal spanner 15mm 3 Allen key wrenches 4mm 5mm 6mm 4 Adjust...

Page 39: ... none are missing or damaged Caution Such damage can result in severe instability and possibly a crash if not corrected Again spoke repairs are best handled by a specialist Loose hub bearings Lift each wheel off the ground and try to move the wheel from side to side Caution If there is movement between the axle and the hub do not ride the bicycle Adjustment will be required Axle nuts Check that th...

Page 40: ...the tyre inflation pressure instructions which are written on the tyre sidewalls BMX 30cm 12 40cm 16 50cm 20 models 240 344 KPa 35 50 psi MTB 50cm 20 61cm 24 66cm 26 models 240 380 KPa 35 55 psi Road Touring 69cm 27 700C models 483 620 KPa 70 90 psi Road Racing 700C 755 862 KPa 110 125 psi Hybrid Crossbike 700C 414 690 KPa 60 100 psi Tyre pressure written on the sidewall may be given either as a m...

Page 41: ...is correct and close the lever so that it is parallel to the fork This position will prevent accidental opening when riding 4 If secondary retention devices are fitted make sure they are correctly located in the fork ends 5 Tighten both axle nuts firmly if fitted 6 Re set the brake quick release and check the brake pad clearance Adjust the brake cable pad clearance if necessary Slot Tab Axle Nut S...

Page 42: ...e up the tension in the rear derailleur spring by holding the unit fully back Feed the top part of the smallest hub cog into the top part of the chain and fit the wheel into the frame 3 For single geared bicycles lift the chain over the axle and onto the cog and fit the wheel into the frame 4 Make sure the wheel is properly centred in the frame by checking the distance between the front of the whe...

Page 43: ... 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 QR clamping parts actually begin to cut into the bicycle frame fork surfaces 6 Note that the same procedure applies when operating a QR seat post binder mechanism WARNING Riding with an improperly adjusted wheel qu...

Page 44: ...wheel from the frame 2 Remove the axle nut cone lock nut and the bearing cone from one side of the hub axle 3 Remove the axle complete with cone and locknut from the other side of the hub 4 Carefully remove the dust caps if fitted from both sides of the hub to expose the ball bearings 5 Carefully remove the loose ball bearings or ball retainers if fitted from both sides of the hub 6 On rear hubs w...

Page 45: ...Remove the tyre completely and inspect for a nail glass etc and remove if located Also inspect the inside of the rim to ensure there are no projecting spokes rust or other potential causes Replace the rim tape which covers the spoke ends if damaged 9 Remount one side of the tyre onto the rim 10 Using a hand pump inflate the tube just enough to give it some shape 11 Place the valve stem through the...

Page 46: ...g a hand pump or service station pump by removing the valve dust cap and then screwing on or pushing on the pump connector to the end of the valve stem Deflation is a simple matter of depressing the pin in the end of the valve stem Note Always replace the valve dust cap to prevent entry of dirt and damage to the valve The other commonly used valve type is the Presta valve also known as the French ...

Page 47: ...g column you will notice a mark about 65mm up from the bottom with the words max height or minimum insertion Never ride a bicycle if the stem has been raised so that the minimum insertion max height line can be seen On some MTB bicycles the front brake cable is routed through a hole in the front of the stem If the height is adjusted on this type of stem you will need to re adjust the front brake B...

Page 48: ...ghtly for comfort On MTB and Racing style bicycles the handlebar is usually tightened in the stem by a single allen key bolt or hexagonal bolt BMX style bicycles may have four clamping bolts Tighten to 18Nm Never ride unless the handlebar clamping mechanism has been securely tightened Check handlebar grips and tube end plugs regularly and replace if damaged This is particularly important on bicycl...

Page 49: ...ystems may also include suspension seat posts and suspension handlebar stems that are designed to provide a more comfortable ride WARNING Failure to check and properly adjust the suspension system may result in suspension malfunction which may cause you to lose control and fall Exposed moving portions of suspension system must be kept clean CAUTION Changing suspension adjustment can change the han...

Page 50: ...efore riding AheadSet Type Assemblies This type of head set differs from standard types by utilising an unthreaded full thickness bicycle fork steering tube The mechanism is adjusted via an Allen headed compression bolt then fastened by clamping the handlebar stem directly onto the fork steerer If assembling a new bike with this type of fitting remove dust cap covering the Allen head bolt and unsc...

Page 51: ... 5 Pull the forks out of the frame and remove the lower ball retainer 6 Thoroughly clean and inspect for damage each part of the headset Replace if necessary 7 Pack grease into both head cups Re fit a ball retainer into the lower head cup and work grease into it Then fit the forks into place 8 Re fit a ball retainer into the upper adjusting cup and pack grease into it Then screw the cup down onto ...

Page 52: ...ate and connecting them to the bearing 3 Screw the adjusting barrels into the lower plate Don t tighten the locknuts at this time 4 Connect the lower cable to the rear brake Don t adjust the rear brake at this time NOTE Check to make sure all 11 cable casing ends on the upper and lower cables are seated correctly and that the spring tension of the rear brake is pulling the bearing down ADJUSTMENT ...

Page 53: ... the upper and lower cable to remove it d Repeat steps 6a and 6c until the handlebars can be rotated 360 degrees without any bearing flop 7 Finish adjusting the rear brakes SADDLE AND SEAT POST Inspection The seat fixing bolt and the seat post binder bolt should be checked for tightness and adjustment every month On removing the seat post from the frame you will notice a mark near the bottom of th...

Page 54: ...on and tighten the clamping mechanism There are two types of seat clamp commonly in use The most common employs a steel clamp with hexagonal nuts on either side to tighten The other type known as a micro adjustable clamp uses a single vertically mounted Allen head fixing bolt to tighten After fixing the seat to the desired position on the post adjust the height to the required level and tighten th...

Page 55: ...evers should be checked for tightness at least every three months They should be set in a comfortable position within easy reach of the rider s hands and must not be able to move on the handlebar Some brake levers make use of a screw adjuster which can be altered to change the distance between the handlebar grip and the lever as required The brake pads should be checked for correct positioning and...

Page 56: ...at the upper cable arm To adjust squeeze the brake pads against the rim loosen the lock nut and turn the adjuster Brake pad clearance should be a maximum 2mm from the rim When correct re tighten the lock nut If the pads cannot be set close enough to the rim in this manner you may have to adjust the cable length Screw the barrel adjuster 3 4 of the way in squeeze the pads against the rim undo the c...

Page 57: ... If the brakes use a separate brake cable and straddle cable adjust the straddle length by first screwing the barrel adjuster 3 4 of the way in then loosening the straddle cable fixing bolt then pulling or pushing the cable through the fixing bolt to adjust the length and finally re tightening the fix ing bolt Check that the straddle bridge is in the middle of the cable to ensure even brake pad co...

Page 58: ...the brake arm which allows further fine tuning of the brake shoe position Bicycles with cantilever brakes must be fitted with safety devices to prevent a possible accident in the event of the brake control cable or the straddle bridge becoming loose or breaking whilst riding These are usually the reflector brackets and must be fitted front and rear The bracket will prevent the straddle cable fouli...

Page 59: ...nd then secure the brake body to the frame with the link fixing bolt 2 While holding the shoe against the rim adjust the amount of shoe protrusion by interchanging the position of the B washers i e 6mm and 3mm so that dimension A is kept at 39mm or more 20067_OWNERS MANUAL qxp 08 03 2006 10 41 AM Page 57 SHEPPARD CYCLES ABN 60 082 376 289 SC 2012 ...

Page 60: ...spring tension adjustment screws 6 Depress the brake lever about 10 times as far as the grip and check that everything is operating correctly and that the shoe clearance is correct before using the brakes If further adjustment is required loosen and then re tighten cable fixing bolt as per 4 Fine tuning can be achieved via the adjusting screw at the brake lever 20067_OWNERS MANUAL qxp 08 03 2006 1...

Page 61: ...wrench and tighten the nut with a 10mm wrench the tightening torque should be 70 to 90 kgf see fig 3 3 Connecting to Braking Cable See fig 1 a Attach the braking cable to the straddle cable bridge b Set the straddle cable as in fig 1 and adjust the shoe rim leaving clearance of 1 5mm on both sides c Tighten the straddle cable with the cable fixing nut Tightening torque should be 50 to 70 kgf cm d ...

Page 62: ... cable Always replace brakeshoes in pairs never one side only Before riding test brakes to ensure they are effective Worn out Brake Shoe Replace Usable Brake Shoe Brake shoes must have adequate usable tread Disc Brakes If your bike is fitted with disc brakes the rear brake will be already attached Check all components for tightness and function before riding Installing the front disc When installi...

Page 63: ...l it becomes a reflex action the technique requires concentration which can distract the rider s attention causing you to lose control and fall Practice the use of toeclips and straps where there are no obstacles hazards or traffic Keep the straps loose and don t tighten them until your technique and confidence in getting in and out of the pedals warrants it Never ride in traffic with your toe str...

Page 64: ...unter clockwise thread Insert the correct pedal into the crank arm and begin to turn the thread with your fingers only When the axle is screwed all the way in then securely tighten using a 15mm wrench If removing a pedal remember that the right pedal axle must be turned counter clockwise and the left clockwise ie the reverse of when fitting If replacing the original pedals with a new set make sure...

Page 65: ... show you how to make this adjustment WARNING Clipless pedals are intended for use with shoes specifically made to fit them and are designed to keep the foot firmly engaged with the pedal WARNING Practice is required to learn to engage and disengage the foot safely Until engaging and disengaging the foot becomes a reflex action the technique requires concentration which can distract the rider s at...

Page 66: ...ings must be properly adjusted Remove the chain and try and move the cranks from side to side with your hands The cranks should not move on the axle and there should be only very slight movement in the bottom bracket Next spin the cranks If they don t spin freely without grinding noise then adjustment or lubrica tion will be needed Also check that there are no broken teeth on the chainrings and wi...

Page 67: ...ing it clockwise and remove the keyed lockwasher 4 Remove the adjusting cone by turning it clockwise with a screwdriver 5 Remove the left ball retainer slide the crank assembly out of the frame to the right and remove the right ball retainer Clean and inspect all bearing surfaces and ball retainers and replace any damaged parts Pack the ball bearing retainers with grease then re assemble in the re...

Page 68: ...e the right ball retainer Clean and inspect all bearing surfaces and ball retainers and replace any damaged parts Pack the ball bearing retainers with grease then re assemble in the reverse of the above procedure Cotterless Crank Removal To remove cotterless cranks use the following procedure Note that a special tool will be required 1 Remove the dust cap with a coin or screwdriver 2 Loosen the fl...

Page 69: ...ing task after several hours riding and repeat it two or three times after further use Cranks should then remain tight 1 Remove dust cap 2 Tap the crank arm lightly with a mallet 3 Re tighten the flange nuts and refit the dust caps Screw in the removal tool Position the crank on the axle Lightly tap the crank onto the axle Tighten the flange nut Replace the dust cap Turn the screwbolt clockwise 20...

Page 70: ...rd to tighten in the frame 2 When correctly adjusted the chain should have approximately 10mm of vertical movement when checked in the centre between the chainwheel and rear sprocket Centre the wheel in the frame and re tighten the axle nuts after any adjustment Bicycles which have a single speed freewheel coaster hub brake or 3 speed hub generally use a wider type chain than derailleur geared bic...

Page 71: ...assemble the chain Refer to the makers special instructions when fitting this type of chain Freewheel Inspection Like the chain the freewheel must be kept clean and well lubricated If the chain has become worn and needs replacing then it is likely that the freewheel will also have become worn and should also be replaced Take the chain off the freewheel and rotate it with your hand If you hear a gr...

Page 72: ...ter hubs available and the internal mechanisms are very complex They require infrequent attention as far as lubrication adjustment or replacement of internal parts but this should be left to a specialist if needed Keep the coaster hub sprocket clean and oil it along with the chain Make sure the brake arm is correctly attached to the chainstay with the brake arm clip The brake will not operate othe...

Page 73: ...fer to a specialist bicycle mechanic Inspection The operation of the derailleur system should be checked at least every month Check the operation of the rear derailleur first then the front The rear derailleur should shift the chain cleanly from one cog to the next without hesitation On SIS equipped bicycles each notched position in the shifter must equate to a new gear position After shifting the...

Page 74: ...he cable tension If the chain moves past the second gear turn the adjuster clockwise to decrease the tension Next pedal the cranks and with the chain still in second gear turn the adjuster counter clockwise to increase the inner cable tension Stop turning the adjuster just before the chain makes noise against the third gear This completes the adjustment If more detailed adjustment is needed positi...

Page 75: ...ow gear Test the adjustment by shifting the chain rapidly up and down the freewheel On bicycles equipped with indexed gears SIS the chain should move into each position without hesitation If the chain won t move easily onto the large sprocket while on the small chainring screw out the L adjusting screw slightly If the small sprocket is difficult to engage with the chain on the large chainwheel scr...

Page 76: ...inner or outer chainring in any rear sprocket position then turn the appropriate adjusting screw counter clockwise If the chain falls off either the inner or outer chainring turn the appropriate adjusting screw clockwise If the chain will not shift onto either the inner or outer chainring turn the appropriate adjusting screw counter clockwise To fine tune the adjustment on MTB bicycles fitted with...

Page 77: ...n the cable REFLECTORS Your bicycle is supplied with one white front one red rear and two orange wheel reflectors In addition each pedal has two orange reflectors These are an important safety and legal requirement and they should remain securely fitted and in good clean condition at all If bike is purchased in a carton partially assembled you may have to attach the front and rear reflectors and t...

Page 78: ...handlebars or in the corner of the main frame where they double as a shoulder pad if carrying the bicycle 4 Child Safety Carrier The only way to carry children up to approximately 18kg in weight is in a properly designed carry seat These should be firmly attached to the bicycle be fitted with a restraining harness support the child and not allow access to the spokes of the turning rear wheel 5 Lig...

Page 79: ...ore effective than others Always lock your bicycle to an immovable object if you leave it unattended 10 Rear View Mirror A very useful item to keep you aware of traffic moving behind you 11 Bar Ends These can be attached to the ends of Mountain Bicycle handlebars to give you added flexibility in hand positioning especially when hill climbing 12 Computer Better than a simple speedometer bicycle com...

Page 80: ...joyment to your cycling experience it is strongly recommended that any adjustments or actions that would change your normal riding position should be avoided as the slightest of accidents which could occur can still cause injury Some of these actions may be as simple as helmet adjustment changing mode on your cycle computer reaching into a saddle bag or pannier for a ringing mobile phone mirror or...

Page 81: ...just derailleur travel travel out of adjustment Constant clicking noises when Stiff chain link Lubricate chain pedalling Loose pedal axle bearings Adjust bearings axle nut Loose bottom bracket axle bearings Adjust bottom bracket Bent bottom bracket or pedal axle Replace bottom bracket axle or pedals Loosen crankset Tighten crank bolts Grinding noise when pedalling Pedal bearings too tight Adjust b...

Page 82: ... Steering not accurate Wheels not aligned in frame Align wheels correctly Headset loose or binding Adjust tighten headset Front forks or frame bent Take bike to a bike shop for frame realignment Frequent punctures Inner tube old or faulty Replace inner tube Tyre tread casing worn Replace tyre Tyre unsuited to rim Replace with correct tyre Tyre not checked after previous puncture Remove sharp objec...

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