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MONTAGUE DIRECT CONNECT, Owner'S Manual

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MONTAGUE DIRECT CONNECT Owner'S Manual Download Page 48

48

Suspension Forks 

Each month, lubricate your suspension 

fork. Refer to the instructions on the CD, 

or consult your dealer. 

Each year, replace the oil in your 

suspension fork. To replace the oil, 

special tools and training are necessary, 

so only your dealer should do this.

Cables 

Apply lubricant to a cable when you 

install it. 

To install a cable in a cantilever brake, 

special tools and training are necessary, 

so only your dealer should do this. 

To install a cable 

1.  Before you remove the used cable, 

note its path on the frame. Loosen 

the cable-clamp bolt, and remove 

the worn cable.

2.  Apply grease to the new cable 

where it passes through housing or 

guides. Install the new cable on the 

same path as the used cable. 

3.  Make sure the leaded end of the 

cable is installed correctly in the 

lever. Make sure the housing is 

correctly installed in the housing 

stop of the lever. • If necessary 

when you install a cable in a brake, 

adjust the brake again. 

4.  Turn the barrel-adjuster clockwise 

so that the threads on the barrel-

PROPER MAINTENANCE AND ADJUSTMENT 

CONTINUED

adjuster do not show. • For a 

derailleur cable, put the shift-lever 

in the position with the least cable 

tension. • For a brake cable, hold 

the brake closed while you do the 

subsequent step. 

5.  Tighten the cable-clamp bolt to 52-

69 lb•in (6-8 Nm). 

6.  Cut the cable so that no more than 

2” (51 mm) extends through the 

clamp-bolt. 

7.  Put a metal cap or put a bit of 

solder on the end of the cable to 

prevent a frayed cable. 

8.  Use the instructions for adjustment.

Summary of Contents for DIRECT CONNECT

Page 1: ...1 Even if you have ridden a bike for years it is important for you and every rider to read this manual before riding this bicycle IMPORTANT KEEP FOR FUTURE REFERENCE Bicycle Owner s Manual ...

Page 2: ... serious injury WARNING In this manual the CAUTION sign shows a hazardous situation which if not avoided could cause minor or moderate injury CAUTION As with all mechanical components the bicycle is subjected to wear and high stresses Different materials and components may react to wear or fatigue in different ways If the design life of a component has been exceeded it may suddenly fail possibly c...

Page 3: ...ht 16 Think Safety 17 Riding Instructions 18 Using your Brakes 18 Changing Gears Correctly 18 Descending 19 Obstacles and Impacts 20 Assembling your Bicycle 21 Packing List 21 Assembly 21 Installing the Seatpost 21 Installing the Pedals 22 Installing the handlebars 23 Installing the Front Fender 24 Operating RackStand 25 Unfolding your Bicycle 26 To Unfold your Bike 26 Adjusting the Frame Quick Re...

Page 4: ...ide of the bottom bracket shell Fig 1 Record the serial number in this manual below in the event that your bicycle is lost or stolen You may also want to register your serial number with your local police department Register Your Bicycle Bicycle registration is the only record we have of who owns this bicycle Registration and proof of purchase are necessary to make a warranty claim There are two e...

Page 5: ...vity even under the best of circumstances Proper maintenance of your bicycle is your responsibility as it helps reduce the risk of injury All quick releases must be securely fastened before riding any Montague bicycle The quick releases are pictured on page 7 in Fig 2 They are the Clix front wheel quick release 25 the seat post quick release 8 the frame quick release 9 the rear wheel quick release...

Page 6: ...tion 2 bicycles are made to cover all the riding conditions expressed by condition 1 with the addition of gravel roads and groomed off pavement trails Condition 2 bicycles typically feature flat handlebars and 700c or 26 wheels These bicycles have semi slick tires with light knobs on them and direct pull brakes Condition 3 Condition 3 bicycles are made to cover all the riding conditions expressed ...

Page 7: ...ke select models 17 front V brake or caliper brake select models 18 rear disc brake select models 19 front disc brake select models 20 down tube 21 crank arm 22 seat stay 23 cassette 24 front derailleur 25 CLIX front wheel quick release 26 frame Direct Connect 27 chainstay 28 chain wheel 29 rear derailleur 30 pedal 31 rim front rear 32 rear wheel quick release or nut 33 wheel spokes 9 1 2 3 4 5 6 ...

Page 8: ...t parts are necessary for the safe operation of your bicycle speak to your dealer or call Montague Corporation 1 617 491 7200 Check your Brakes Steering and Quick Releases Press each hand lever to ensure the brakes are moving freely and stop the bike Braking performance changes with riding conditions Practice braking at low speeds before taking your bike out into high traffic areas or trails If yo...

Page 9: ...noise take the bicycle to your dealer for service Life Span of a Bicycle Bikes and the components that comprise them are not indestructible Depending on the riding forces conditions and mileage endured you should replace your bike or its parts at an appropriate frequency The safe life of a part is determined by its construction materials and wide range of operating conditions so it is not possible...

Page 10: ...rength limit of the carbon fiber the carbon fiber part breaks it does not deform Fig 5 In an accident or impact that does not break the carbon fiber the carbon fiber could have internal or hidden damage but appear normal If that occurs please carefully read these instructions and examine the carbon fiber These tests are not conclusive If you are not sure a part is safe replace it BEFORE EVERY RIDE...

Page 11: ...store a bike with carbon components in places where the temperature will exceed 66 5 C 150 F For example do not leave your bike lying flat in a black pickup truck bed in the desert sun or under the glass of a hatchback auto Excessive heat such as that used in powder coating or any open flame may damage the adhesive which joins carbon composite parts Do not exceed 180 F 82 C exposure to your frame ...

Page 12: ...e wheel Examine Tire Inflation Inflate the tires to the air pressure recommended on the sidewall of the tire Improper tire pressure will cause excessive wear causing premature replacement Pressurized unregulated pumps should not be used for this task The tire should be properly seated in the rim and the fitting of the tire bead and rim bead should be checked If the tube is pinched between the tire...

Page 13: ...s too loose When brakes are not applied brake pads should be 1 to 2mm from rim If brake pads are too near the rim brake is too tight The brake pads should be in line with the rim surface Fig 6 page 13 Disc brake a cable or hydraulic hose connects a hand lever to the brake The lever causes the brake to apply pressure to a disc attached to the hub Pull the brake lever to make sure the brake moves fr...

Page 14: ...nent can bottom out or be fully compressed while riding Quick Releases Check that all quick releases front wheel frame seatpost and on some models rear wheel caliper brake Octagon stem and RackStand latch are fastened Nothing should rattle or be loose Lights Reflectors Make sure lights operate correctly and that batteries are charged Make sure all reflectors are clean and in their correct position...

Page 15: ...Ride single file in a straight line Have a satisfactory signaling device bell horn etc to warn of approach Ride Defensively expect the unexpected Give pedestrians the right of way Do not ride too close to pedestrians and alert them if you intend to pass from behind Slow down at all street intersections and look to the left and right before crossing Always use proper hand signals for turning and st...

Page 16: ...om stress fatigue can fail suddenly causing loss of control or serious injury For more information and a guide for safe on road and off road riding see www montaguebikes com support Caution Wet Weather Riding Brakes do not work as well under wet conditions as they do when dry In wet weather special precautions must be taken to ensure safety in stopping Proper adjustment and cable lubrication will ...

Page 17: ...ebar or other parts of the bicycle for example with a pet or its leash Never carry other riders or packages as they may obstruct vision or proper control of the bicycle Do not ride while intoxicated or while taking medications which can make RIDING SAFELY CONTINUED you drowsy Ride carefully when off road staying on trails and not riding over rocks branches or depressions When approachng a descent ...

Page 18: ...nt brake Changing Gears Correctly The multi gear system provides a means of maintaining a constant pedaling rate regardless of road level conditions The gears are activated by cables connecting the shift levers located on the handlebar to the derailleurs If your bicycle is equipped with twist shifters rotating the twist shifters towards you moves the chain from one chainring or sprocket to the nex...

Page 19: ...braking covered earlier Weight distribution Keep your weight correctly in balance between the wheels on a steep downhill by moving your weight rearward on the bicycle and as low as possible just like when braking Keep your feet on the pedals and keep the crankarms horizontal and parallel to the ground unless you are cornering as you descend see the next section Keep your knees and elbows bent to a...

Page 20: ...hether it s a sewer grate speed bump gravel or any other hazard If you are going fast even a small obstacle can create a significant impact to your bicycle If you are unsure of your ability to safely ride over an object it is best to either ride around it or dismount and walk around it Your body and bicycle will have a natural tendency to go where you are looking If you focus on an obstacle you ma...

Page 21: ...ls 1 RackStand some models Carefully remove the bicycle and all accessories from the box to avoid scratching the frame Check the carton for loose parts before discarding ASSEMBLING YOUR MONTAGUE BICYCLE Assembly Note If you own a Montague bicycle purchased prior to 2016 your bicycle may be assembled differently For more information please visit montaguebikes com online owners manual Installing the...

Page 22: ... Fig 9 page 21 4 The lever is securely tightened when it leaves an imprint on the palm of your hand from pushing it closed 5 Once the lever is securely closed you should not be able to move it unless you open it again If you can move the seat up and down or side to side with the quick release lever in the closed position repeat the seatpost installation process from step 3 Repeat until the seat ca...

Page 23: ...ue Bicycle tighten the pedals to 350 380 lb in 40 2 42 9 N m Each pedal should be tight against the crank arm Installing the handlebars For some models the handlebars are shipped off the bike If so 1 Using the provided hex wrench remove the two screws or four depending on model holding the stem clamp in place Fig 12 2 Place and center handlebars within the stem some have centerline marks and repla...

Page 24: ...r mount Tighten Fig 16 Mountain Bikes 1 Remove the screw from the rear of the front fork Some forks allow the screw to thread directly into the fork crown Fig 17 while some pass through to a nut on the front of the fork Fig 18 Fig 16 Pavement bike fender installation 2 Position the Fender on the back side of the fork and reinstall the bolt so that it passes through the slotted fender mount Tighten...

Page 25: ... a b Convert from Rack to Stand 1 Prior to removing the front wheel or folding the bike lift up the latch under the seat to release the RackStand Fig 20 2 The RackStand will rotate down until it hits the ground Fig 21 3 Lift the rear of the bike to allow the RackStand to finish rotating under the rear wheel Fig 22 4 The bike can now be more easily folded in this position or the RackStand can be us...

Page 26: ...models The caliper brake release lever Fig 33 page 31 Not on all models Octagon quick release Fig 47 page 37 Not on all models RackStand quick release Fig 20 page 25 Not on all models To Unfold your Bike 1 Undo the Velcro strap holding the handlebar to the rear wheel It should be rolled back onto itself around the handlebar while the bike is unfolded 2 Ensure the frame quick release is in the open...

Page 27: ...3 26 Note When closing if the quick release lever does not leave an imprint on the palm of your hand refer to Adjusting the Frame Quick Release below Fig 26 Adjusting the Frame Quick Release If the frame quick release becomes loose or does not leave an imprint on your palm when closing the lever the quick release may need to be adjusted To adjust the quick release 1 Make sure your bicycle is in th...

Page 28: ...ast the cup and adjusting nut and click onto the hub axle UNFOLDING YOUR MONTAGUE BICYCLE CONTINUED Improper installation or improper use of the quick release system can allow the wheel to WOBBLE or DETACH from the bicycle causing you to crash Read and follow these instructions to properly install and use this product to reduce your chance of SERIOUS INJURY or DEATH WARNING Fork stanchion Fork Dro...

Page 29: ...otion the tire a few sharp downward strikes Fig 30 The wheel should not wobble or come off This does not guarantee that the CLIX quick release lever has been adequately tightened If you are uncertain as to whether the CLIX quick release is tightened correctly see the following information on Adjusting Your CLIX Front Wheel Quick Release or bring your bike to your local bike dealer Adjusting your C...

Page 30: ...ped bike align the wheel rotor with the slot in the disc brake caliper attached to the left hand fork stanchion Once the rotor is aligned with the caliper slot review Attaching the Front Wheel on page 28 in order to properly secure the front wheel quick release If your front or rear disc brake needs to be adjusted or does not apply adequate stopping power to the wheel it may need to be adjusted Be...

Page 31: ...hes together and level the cable hook unit 2 With the other hand squeeze the end cap into the cable hook unit 3 Release the brake arches and the hook unit and end cap should lock into place 4 Squeeze the brake lever a few times to ensure the brakes are secured in place and working properly Brakes and Gear System The brakes and gear system are factory set However new brake and gear cables may stret...

Page 32: ...while removing the wheel Fig 35 3 Lower the seat Fig 10 page 21 4 Open the frame quick release lever Fig 35 5 With your thumb press and hold the knurled lever inward This opens the quick release clamp Fig 36 6 While holding the quick release open with one hand grasp the handlebars with the other and turn them away from you Fig 37 7 Pull the boom tube of the bike toward you and fold the bike in hal...

Page 33: ...and upside down stand position on the floor with tail facing the front of the bike Fig 40 3 Position the rear of the bike so it is resting on the tabs of the new quick release as shown Fig 40 4 Open the QR lever and lower bike into the RackStand slots Fig 41 5 Close quick release lever and rotate RackStand up to the riding rack position Ensure it is locked into mating latch Fig 42 Fig 39 Installin...

Page 34: ... folded bike to rest at the correct angle the position of the fender tail can be extended or shortened To Adjust RackStand 1 Loosen the two bolts holding the tail of the fender in place Fig 43 2 Slide the fender tail to a length that will hold the folded bike with the seat tube perpendicular to the ground Fig 44 The fender will need to be longer for a mountain bike than a pavement bike Fig 43 Loos...

Page 35: ...Octagon stem assembly is another such safety critical component Only replace the frame quick release and the Octagon stem with a genuine part sourced from Montague Do not switch your fork as your CLIX quick release wheel is not compatible with some forks If you replace the crank or tires with different models you should use caution as there is a possible reduction of toe clearance and the possibil...

Page 36: ...3 N m Stems There are three types of stems Threadless Fig 45 page 35 Quill type Fig 46 Octagon Hand Height Adjustable Stem Fig 47 Some stem models allow for height adjustment Please read the following instructions to determine if your stem is height adjustable Threadless stem height adjustment Handlebar height on bicycles with threadless stems cannot be adjusted Please refer to your local dealer f...

Page 37: ...imum of 70mm of the stem should always be in the frame 4 Tighten the expander bolt to 120 lb in 13 6 N m Handlebar height adjustment with the Octagon Adjustable Stem The Octagon height adjustable stem allows you to raise and lower your handlebars without the use of any tools This system is only on select Montague models To change the height of your handlebars with the Octagon stem follow these ste...

Page 38: ...lt should be tightened to 88 lb in 10 N m For more information about the Octagon height adjustable stem visit www octagoncycles com Seat Saddle Adjustments Saddle angles can be adjusted to meet your preferences It is recommended that you first try to ride with the top of the saddle parallel to the ground The saddle can also be moved forward or rearwards along the seatpost to adjust the distance fr...

Page 39: ...a single speed bicycle 1 Slightly decrease the tightness of the rear wheel axle nut on one side of the wheel then on the other side of the wheel 2 Slide the wheel rearwards to tighten the chain Keep wheel centered between seatstays 3 Tighten the rear wheel axle nuts 260 390 lb in 30 45 N m 4 Make sure you have correctly attached the wheel by lifting the bicycle and hitting the top of the tire with...

Page 40: ...e outermost smallest rear sprocket by turning the right twist shifter all the way away from you or moving the right shift lever all the way towards you 3 While turning the crank forward rotate the right twist shifter or push the right shift lever to the next position 4 The chain should move to the second sprocket quickly and easily If it stays on the first sprocket the tension of the shifting cabl...

Page 41: ...e front derailleur will move to the small chainring 6 Change gears to all the gear combinations Make sure the chain does not come off when you move the shift lever Make sure the derailleur cage does not rub on part of the crankarms Front Derailleur Adjustment With bicycles that have more than one chainring the front derailleur makes gear changes To adjust the small chainring position 1 Move the ch...

Page 42: ...he separate manufacturer s manual Brakes The brake system on your bike lets you slow and stop The function of this system is crucial to your safety The brake system is not easy to adjust without proper training It is strongly recommended that only your dealer adjust your brakes Each month examine the brake pads for wear Replace pads if grooves in the pad surface are less than 1mm deep To adjust th...

Page 43: ... inward until it touches the rotor 4 Back off slightly 1 4 turn until the pad does not touch the rotor surface and the wheel spins freely PROPER MAINTENANCE AND ADJUSTMENT CONTINUED If there is contact between the brake pads and rotor after performing the above steps bring your bike to your local dealer for adjustment Wheels Examine tires for worn areas bulges and damage Make sure rims are clean M...

Page 44: ... 57 tighten the adjusting nut Fig 56 until it is slightly tight 3 Move the quick release into the closed position Fig 57 with the palm of your hand 4 A properly closed quick release lever should leave a mark on the palm of your hand from closing 5 If you can lock the lever with little or no resistance the clamp force is not sufficient Go back to step 2 and tighten the adjustment nut 1 4 turn and r...

Page 45: ...ealer Tighten freehub body 354 lb in 40 N m Tighten cassette sprocket lockring 347 lb in 39 N m Fitted Accessories Racks and Fenders In addition to the parts already discussed in this chapter your bicycle might have accessories such as fenders lights racks chain guard or kickstand Each month check the accessories to make sure they are correctly attached If the part is loose or not in alignment adj...

Page 46: ...emove the stem from the frame 2 Clean the used grease from the stem 3 Apply a thin layer of grease to the section of the stem quill that will be put into the frame Also apply grease to the stem wedge 4 Install the stem Seatpost Each year apply lubricant Use the procedure for your frame and seatpost materials For a metal seatpost in a metal frame 1 Loosen the seatpost binder bolt or release the qui...

Page 47: ...es from the crankarms turn the right pedal axle counterclockwise but turn the left pedal axle clockwise 2 Apply a thin layer of grease on the threads 3 Install the pedals on the correct side put the right pedal on the right crankarm and the left pedal on the left crankarm 4 Tighten the pedal axles Derailleurs Each month apply lubricant to all pivot points on the front and rear derailleurs together...

Page 48: ...ides Install the new cable on the same path as the used cable 3 Make sure the leaded end of the cable is installed correctly in the lever Make sure the housing is correctly installed in the housing stop of the lever If necessary when you install a cable in a brake adjust the brake again 4 Turn the barrel adjuster clockwise so that the threads on the barrel PROPER MAINTENANCE AND ADJUSTMENT CONTINU...

Page 49: ...ks Every Month Examine the attachment of the handlebar and stem Examine the attachment of the saddle and seatpost Examine the chain Examine the cables for wear Examine the operation of the shift levers and derailleurs Lubricate derailleurs Examine headset bearing adjustment Examine brake pads Examine attachment of brakepads Examine chain tension Examine wheel bearing adjustment Examine rims and ti...

Page 50: ...arts replacement or changeover or installation of parts or accessories not originally intended or compatible with the bicycle as it was sold Modification of the frame or components shall void this warranty Montague Corporation shall not be responsible for incidental or consequential damages Some states do not allow the exclusion of incidental or consequential damages so the above exclusion may not...

Page 51: ...51 ...

Page 52: ...52 Montague Corporation P O Box 398032 Cambridge MA 02139 Phone 1 617 491 7200 www montaguebikes com 2017 Montague Corporation Cambridge MA USA ...

Page 53: ...53 ...

Page 54: ...r bikes A local bike shop recommended your bikes I found you by browsing online I saw an ad in a magazine I m a repeat customer Other What kind of riding do you do Bike Trails Paths Urban City Commuting Trekking Touring Road Fitness Off Road Mountain Biking All of the above How will you use your bike when folded Comments Home storage Public Transportation Train Private Plane Boating Car Trunk Airl...

Page 55: ...55 ...

Page 56: ...56 From MONTAGUE CORPORATION P O Box 398032 Cambridge MA 02139 ...

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