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Zize Bikes. Bikes with Attitude!
A. Cables
Check the cables for kinks, rust, broken strands, or frayed ends. Also
check the housing for loose wire strands, bent ends, cuts, and wear. If
you suspect a problem with a cable, do not ride the bicycle; follow the
instructions to replace a cable, or have your dealer service the bicycle.
To Install a Cable
1. Note the path of the old cable, loosen the cable anchor bolt, and re-
move the worn cable.
2. Grease the new cable and reinstall, feeding it along the same path as
the old cable, including through the cable anchor bolt.
3. Make sure the leaded cable-end is seated properly in the lever, and
the housing is properly seated in the lever.
4.
If needed when installing a cable in a brake, re-adjust the brake.
5. Turn the adjusting barrel clockwise so the threads on the adjusting
barrel are not exposed.
6.
For a shift cable, put the shifter in the position with the least cable
tension. For a brake, hold the brake closed while you do the next
step.
7. Tighten the cable clamp bolt to52-
69 lb•in. (6
-
8 N•m).
8.
Cut the cable so that no more than 2” (51 mm) extends beyond the
anchor bolt.
9. Crimp a metal cap or place a bit of solder on the end of the cable to
prevent fraying.
Installing a cable in a cantilever brake requires special tools and training,
so should only be done by your dealer or local bike shop.
To align a Cable-Actuated Disc Brake
There are several parts to this procedure:
1st. 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 next
instructions
2nd. To adjust left brake pad clearance to the disc
,
or to re-set the right
pad
:
1. Turn the cable 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).
2. If the pads cannot be adjusted properly in this manner, loosen the
cable clamp bolt and re-attach the cable
.
Tighten the cable clamp
bolt to 50-
70 lb•in (5.7
-
7.9 N•m).
3. After adjustment, turn the locking nut clockwise to help prevent
rotation of the barrel adjuster.
Zize Bikes. Bikes with Attitude!
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If it requires more than 45 pounds force to completely close the quick-
release lever, open the lever and slightly loosen the quick-release adjust-
ing nut. If it requires less 12 pounds force to
begin to open the lever from the fully closed position, open the lever and
slightly tighten the quick-release adjusting nut.
Remember that a quick release system is based on a cam and is not sup-
posed to be turned all the way as one would do a wing nut
Always be sure that you have a snug feel to the quick release lever when
closing it. As you are installing the front wheel be sure that the rotor for
the brake is passing through the brake mechanism without touching either
side .
WARNING!
Be aware that though the rotor for the front brake is not sharp , injury
could result from touching or grabbing the rotor while the wheel is spin-
ning . It is possible to get a finger caught and injured in the rotor even if
the wheel is spinning at a slow rate of speed
–
be careful even if just wip-
ing the rotor with a rag to clean it.
B. Install the Handlebars and Stem
Using a 5mm allen wrench, remove the face plate of the handlebar stem .
Place the handlebar in the stem and put the face plate back on. Be sure
not to over tighten the bolts for the top cap and be sure to tighten them
evenly.
To adjust the angle of the handlebar
1. Loosen the handlebar clamp bolt(s) on the
stem just enough that the handlebar can be
rotated in the stem.
2. Position the handlebar to the desired angle,
making sure it is centered in the stem.
3. Tighten the handlebar clamp bolt(s) 100-
120 lb/inch.
A Word About Torque Specifications
Torque is a measurement of the tightness of a threaded fastener such as
a screw or bolt, determined by using a torque wrench. The torque specifi-
cations should be used to make sure you do not over-tighten the fasten-
ers. 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.