PACIFIC CYCLE Part Instruction Manual Download Page 3

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Summary of Contents for Part

Page 1: ...ELMET COVERS YOUR FOREHEAD INCORRECT FITTING FOREHEAD IS EXPOSED AND VULNERABLE TO SERIOUS INJURY ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE DO NOT RIDE AT NIGHT AVOID RIDING IN W...

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Page 3: ..._____________ _______________________________________________________________________ _______________________________________________________________________ __________________________________________...

Page 4: ...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 se...

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Page 7: ...tenance 66 97 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...

Page 8: ...rake 52 53 U Brake 54 Front U Brake 54 Rear U Brake 54 Blake Lever 55 Check your Brakes 55 Rotors 56 57 Axle Peg Assembly 58 Non Threaded Axle Peg 58 Threaded Axle Peg 58 Training Wheels 59 61 Wheels...

Page 9: ...raction on rough surfaces The frame and fork on mountain style bicycles are generally much sturdier than those on racing style bicycles Top Tube Seat Seat Post Quick Release Seat Stay Rear Reflector R...

Page 10: ...Post Seat Post Binder Bolt or Quick Release Skewer Seat Stay Rear Reflector Wheel Reflector Chain Wheel Crank Arm Pedal Rim Tire Tire Valve Chain Chain Stay Rear Sprocket Training Wheel Front Brake Le...

Page 11: ...ity 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 dire...

Page 12: ...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...

Page 13: ...addling 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 an...

Page 14: ...he 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 control a...

Page 15: ...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 c...

Page 16: ...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 ar...

Page 17: ...ecurely 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 shif...

Page 18: ...ourself 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...

Page 19: ...e 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...

Page 20: ...p 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 B...

Page 21: ...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...

Page 22: ...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 ar...

Page 23: ...ildren 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...

Page 24: ...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...

Page 25: ...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 sel...

Page 26: ...mb 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...

Page 27: ...rosive 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 an...

Page 28: ...ber 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...

Page 29: ...sen 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 ar...

Page 30: ...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 Handlebar Installation 1 Remove...

Page 31: ...he stem is too loose Re align the handlebar with the front wheel and re tighten the stem bolt Sunken Stem Bolt System 1 Remove the protective shipping cap from the stem wedge 2 Remove the Stem Plug fr...

Page 32: ...1 Handlebar with Grip Shifter Figure 2 Top mounted thumb shifter Failure to properly tighten clamping bolts may cause sudden movement of the component resulting in loss of steering control 1 2 Bar en...

Page 33: ...ian 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...

Page 34: ...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...

Page 35: ...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 importan...

Page 36: ...on 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 Mov...

Page 37: ...ral adjustments may be necessary to achieve the correct brake position 3 1 Install the cable into 2 Set the cable into 1 2 5 The wheel is tightly secured when the serrated surfaces of the quick releas...

Page 38: ...78 in lbs 6 If balance adjustment is necessary adjust with the spring tension adjustment screw 1 mm 10 mm wrench 5 mm Allen key Cable Anchor Bolt Touching End cap Cut off any unneces sary cable attac...

Page 39: ...ll 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...

Page 40: ...k fixing bolt 1 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 mor...

Page 41: ...verything is operating correctly and that the shoe clearance is correct before using the brakes 6 Pass the inner cable through the inner cable lead Set the cable with a clearance of 1mm between each b...

Page 42: ...rim than the front portion of the brake pad 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 sto...

Page 43: ...Ensure the cable hous ing seats appropriately into the end of the barrel adjuster and check for any kinks or damage Slide the exposed brake cable through the rotating rod located on the caliper body...

Page 44: ...Centering Bolt inside 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...

Page 45: ...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 tension and direct the c...

Page 46: ...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 g...

Page 47: ...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...

Page 48: ...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 t...

Page 49: ...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 shape...

Page 50: ...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 th...

Page 51: ...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 th...

Page 52: ...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 t...

Page 53: ...em 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...

Page 54: ...seat and handlebars The seat pillar must be inserted so that the minimum insertion mark cannot be seen Attachment of an incorrect pedal into a crank arm will cause irreparable damage Pedals Crank Set...

Page 55: ...te 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...

Page 56: ...dle holder 1 2 Cantilever Brakes Side Pull Brakes 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 i...

Page 57: ...78 in lbs 6 If balance adjustment is necessary adjust with the spring tension adjustment screw 1 mm 10 mm wrench 5 mm Allen key Cable Anchor Bolt Touching End cap Cut off any unneces sary cable attac...

Page 58: ...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 s...

Page 59: ...nk fixing bolt 1 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 or 3 mm so that dimension A is kept at 39 mm or mor...

Page 60: ...that everything is operating correctly and that the shoe clearance is correct before using the brakes 6 Pass the inner cable through the inner cable lead Set the cable with a clearance of 1mm between...

Page 61: ...e cable approximately 20mm from the brake arms when they are closed against the rim Attach the Straddle cable to the carrier Hook cable end into the brake slot pull excess straddle cable through the c...

Page 62: ...is locked into place with the top plate 5 Install the adjuster barrels into the proper slots 6 Reattach the covering plate The rest of the assembly will follow the Rotor assembly procedures page 56 be...

Page 63: ...the way in 2 Screw the adjusting barrels in the upper plate in or out to set the bearing for maximum travel The bearing should be as far down as it can go without resting on the lower plate or the adj...

Page 64: ...ury Barrel End Single Cable Casing Cable Adjuster Cable Splitter Upper Cable short casing Upper Cable long casing Upper Plate Bearing Football Ends Lower Plate Lower Cable Adjusting Barrel Locknut Key...

Page 65: ...ded This style of peg is threaded to fit the axle Make sure the axle nut is tight with a 15mm wrench Place a screw driver through the mounting holes of the peg and attach the peg to the axle by turnin...

Page 66: ...on the shoulder bolt Lock the training wheel into place by screwing another hex nut onto the shoulder bolt Repeat for both training wheels Option 2 First attach the training wheels to the wheel brace...

Page 67: ...o the axle and replace the washer and axle nut Tighten the axle nut securely making sure that the wheel brace stays in the proper vertical position The elongated hole on the wheel brace allows the tra...

Page 68: ...secure tightly The elongated hole on the brace allows for raising and lowering the training wheel to the proper height It is very important to check the training wheel connection to the bicycle Failu...

Page 69: ...Pads If your bike is supplied with pads wrap the foam inner cushion around the appropriate bar Place the outer cover over the inner cushion and press the velcro together securely Turn the pad so the v...

Page 70: ...levers shift levers freewheel brake cables bottom bracket pedals derailleur cables wheel bearings headset seat pillar Lubricant chain lube or light oil chain lube or light oil oil oil oil lithium bas...

Page 71: ...s for looseness Check pedals are tight Check handlebars are tight Check seat and seat post are tight and comfortably adjusted Check frame and fork for trueness Check all nuts and bolts are tight Lubri...

Page 72: ...l wrench 15mm 3 Allen key wrenches 4mm 5mm 6mm 8mm 4 Adjustable wrench 5 Standard flat head screwdriver 6 Standard Phillips head screwdriver 7 Standard slip joint pliers 8 Tire pump 9 Tube repair kit...

Page 73: ...are not straight they will need to be adjusted This is quite difficult and is best left to a bicycle specialist Broken or loose spokes Check that all spokes are tight and that none are missing or dama...

Page 74: ...he bead is properly seated in the rim Tread Check that the tread shows no signs of excessive wear or flat spots and that there are no cuts or other damage Caution Excessively worn or damaged tires sho...

Page 75: ...a Flat Tire If you need to repair a tire follow these steps 1 Remove the wheel from the bicycle 2 Deflate the tire completely via the valve Loosen the tire bead by pushing it inward all the way aroun...

Page 76: ...e other side of the tire by pushing the edge toward the center of the rim Start on either side of the valve and work around the rim 12 Before the tire is completely mounted push the valve up into the...

Page 77: ...cluding the wedge that will be inserted into the frame The height of the handlebar can be adjusted to suit your comfort preference If the stem is removed from the steering column you will notice a mar...

Page 78: ...mately horizontal with the ends pointing back and slightly up On BMX bicycles the handlebar should remain in an approximately upright position but can be angled back or forward slightly for comfort On...

Page 79: ...nt the grip from interfering with Grip Shift rotation 5 Slide handlebar grip over handlebar Thread the cable inner wire through cable housings and frame and attach to derailleur Make sure that the cab...

Page 80: ...e needed to operate the brakes or shifters Before every ride check that there are no kinks or frays in the cables and housing Also check that the housing is seated properly into each cable stop of the...

Page 81: ...If your bike is equipped with a threadless headset please see a qualified specialist for repairs and adjustments Adjustment Loosen the headset top locknut or remove it completely along with the reflec...

Page 82: ...minimum insertion To avoid damage to either the seat post the frame or possibly the rider the minimum insertion mark must be inside the frame Lubrication Remove the seat post from the frame and wipe o...

Page 83: ...hten the clamping mechanism There are two types of seat clamps 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 adjus...

Page 84: ...ble 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 reach adjustment screw which can be altered to the distance between th...

Page 85: ...he 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...

Page 86: ...he lock nut If the pads cannot be set close enough to the rim in this manner you may have to adjust either the length of the straddle cable or the length of the brake cable If the brakes use a separat...

Page 87: ...e angle of the pad On some models there is a spring force adjustment screw on the brake arm which allows further fine tuning of the brake shoe position Bicycles with cantilever brakes must be fitted w...

Page 88: ...them safely Inspection Pedals should be inspected every month taking note of the following areas Check correct tightness into the crank arms If pedals are allowed to become loose they will not only be...

Page 89: ...dal which attaches to the other crank arm is marked L on the axle and screws in with a coun ter clockwise thread Insert the correct pedal into the crank arm and begin to turn the thread with your fing...

Page 90: ...rank arms beyond repair Inspection The crank set should be checked for correct adjustment and tightness every month Cotterless crank axle nuts must be kept tight and the bottom bracket bearings must b...

Page 91: ...lockwise 3 Remove the left side locknut by turning 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 s...

Page 92: ...ut of the frame to the left 5 Remove the right side fixed cup by turning it counter clockwise and remove the right ball retainer Clean and inspect all bearing surfaces and ball retainers and replace a...

Page 93: ...lace the dust cover Adjustment After Use 1 Remove dust cap 2 Tap the crank arm lightly with a mallet 3 Re tighten the flange nuts and refit the dust caps New cotterless cranks may become loose with in...

Page 94: ...ed and move the wheel forward to loosen or backward to tighten in the frame 2 When correctly adjusted the chain should have approximately 10mm of vertical movement when checked in the center between t...

Page 95: ...with rivet facing away from the bicycle Bring the two ends together within the special tool and punch the rivet into place Be sure not to push rivet too far through side plate FREEWHEEL Inspection Lik...

Page 96: ...ers the advantages of reliability and easy operation The brake is operated by applying back pedal pressure and allows the rider to coast without pedaling if desired There are several models of coaster...

Page 97: ...he 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 i...

Page 98: ...tation If noise occurs use the barrel adjuster to fine tune the cable tension Turning the barrel adjuster clockwise will decrease cable tension and allow the derailleur cage to move farther away from...

Page 99: ...chainwheel If the chain does not shift onto the largest chainwheel you will need to turn the High limit screw counter clockwise until the chain moves to the largest chainwheel If the chain falls into...

Page 100: ...for the appropriate assembly instructions REFLECTORS Your bicycle is supplied with one front white one rear red two wheel white and two pedal orange reflectors These are an important safety and legal...

Page 101: ...and through the basket bracket assembly on bike Next insert a second washer onto the bolt and thread a 10mm nylox nut onto the bolt behind the basket bracket assem bly Tighten bolts until snug Repeat...

Page 102: ...t of adjustment Stiff chain link Loose pedal axle bearings Loose bottom bracket axle bearings Bent bottom bracket or pedal axle Loose crankset Pedal bearings too tight Bottom bracket bearings too tigh...

Page 103: ...se Bulge in the rim or rim out of true Brake mounting bolts loose Brakes out of adjustment Fork loose in head tube Axle broken Wheel out of true Hub comes loose Headset binding Hub bearings collapsed...

Page 104: ...ove sharp object embedded in tire Correct tire pressure File down spoke Problem Steering not accurate Frequent punctures Possible Cause Wheels not aligned in frame Headset loose or binding Front forks...

Page 105: ...lever on one end and a nut on the other the wheel quick release uses a cam action to clamp the bike s wheel in place Because of its adjustable nature it is critical that you understand how it works an...

Page 106: ...type secondary retention device disengage it and go to step 5 If your front fork has an integral secondary retention device loosen the tension adjusting enough to allow removing the wheel then go to...

Page 107: ...EN position 5 Lift the rear wheel off the ground a few inches and with the derailleur still pulled back push the wheel forward and down until it comes out of the rear dropouts d Installing a Quick Rel...

Page 108: ...so that the axle seats firmly at the top of the slots which are at the tips of the fork blades The axle nut washers should be on the outside between the fork blade and the axle nut If your bike has a...

Page 109: ...herefore 1 Make sure you know how to correctly clamp your seat post 2 Understand and apply the correct technique for clamping your seat post quick release 3 Before you ride the bike first check that t...

Page 110: ...s to clear the tire when a wheel is removed or reinstalled When the brake quick release is in the open position the brakes are inoperative Make sure that you under stand the way the brake quick releas...

Page 111: ...ng and weight transfer techniques where there is no traffic or other hazards and distractions Everything changes when you ride on loose surfaces or in wet weather Tire adhesion is reduced so the wheel...

Page 112: ...es of application because of its ergonomic performance and price characteristics The designers of your bike have selected the shifter design which they believe will give the best results on your bike...

Page 113: ...ust be pedaling forward 2 Shifting the Front Derailleur The front derailleur which is controlled by the left shifter shifts the chain between the larger and smaller chainrings Shifting the chain onto...

Page 114: ...es hazards or other traffic until you ve built up your confidence Once you ve learned the basics experience will teach you which gear is appropriate for which condition and practice will help you shif...

Page 115: ...your pedals G Tires and Tubes 1 Tires Bicycle tires are available in many designs and specifications ranging from general purpose designs to tires designed to perform best under very specific weather...

Page 116: ...scribed in you ll know how correctly inflated tires should look and feel Some tires may need to be brought up to pressure every week or two Some special high performance tires have unidirectional trea...

Page 117: ...bicycle Never change suspension adjustment unless you are thoroughly familiar with the suspension system manufacturer s instructions and recommendations and always check for changes in the handling an...

Page 118: ...______________ Date Purchased _______________ Place of Purchase _____________ Model Brand Information _____________________________________ Wheel Size ____________________ Color ______________________...

Page 119: ...ns of this Limited Warranty If failure of any part should occur due to faulty materials or workmanship during the warranty period the part will be replaced All warranty claims must be submitted to the...

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