BIKESTAR City Assembly Instructions Manual Download | Manualshive

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Assembly Instructions for

City Bicycles

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Summary of Contents for City

Page 1: ...Assembly Instructions for City Bicycles ...

Page 2: ...tep from the unpacking to your very first ride We wish you a lot of fun with your new bike Watch out for the following symbols ATTENTION NOTE The steps described over the following pages may somewhat differ from the steps required for your specific bicycle model The image material used shows the typical work steps that are usually required All of our bike models come with an EU standard brake setu...

Page 3: ...wheel 2 5 Installing the brakes 2 6 Functional check 3 Adjusting Installing the handlebars stem 3 1 Adjusting Ahead stem headset bearings 3 2 Adjusting quill stem on threaded headset 3 3 Adjusting the handlebars 3 4 Re mounting dismounted handlebars 4 Mounting the saddle seatpost 5 Fitting the pedals 6 Final check test drive 7 Maintaining the bicycle Contents ...

Page 4: ...afely packaged bicycle 1 x separate front wheel 1 x combination saddle seatpost 1 x accessory box containing an instruction manual tools accessories and pedals if included with your bike model fig 2 fig 1 fig 3 fig 4 fig 5 Remove the seat post with the saddle and the frame with the rear wheel fig 3 4 Remove the accessory box In this you will find the manufacturer s manual the included mounting too...

Page 5: ...ease find and follow the appropriate section for your model 2 Front wheel assembly fig 3 fig 2 fig 4 fig 1 A B Remove the quick release from the accessory package loosen the spring clip A and remove the one spiral spring B fig 2 a Quick release front wheel quick release Remove the protective plastic cover on the right and left of the hub at the centre of the front wheel fig 1 Insert the quick rele...

Page 6: ...ever can typically be found on the left side fig 7 For bicycles with a hub dynamo the hub connector must always be on the right side in the direction of travel On wheels without a brake disc the running direction of the tyre will be printed on the tyre sidewall This will help you determine the left and right sides of the wheel fig 8 To prepare the fork remove the transport safety device from the f...

Page 7: ... on each side Loosen the two axle nuts on the hub axle using a 15 mm open end spanner until there is a 5 10 mm gap between the hub and the nut fig 2 3 Please ensure that a washer is installed on each side fig 4 In order to prepare the fork the transport safety device should then be removed from the fork end In the conventional screw axle system the transport safety device only protects the fork wh...

Page 8: ...le fig 1 This is where the mounting axis is mounted in the next step fig 2 fig 3 The fork should then be prepared for the installation of the front wheel For fork and front wheel for pin axle mounting 12 15 or 20 mm diameter the axle is mounted in the fork end for transport fig 2 It must now be completely unscrewed and put aside ready for use for the subse quent assembly fig 3 Front Wheel Assembly...

Page 9: ... metal rail D of the right brake arm in the direction of travel fig 2 The brake is now suspended and will allow the front wheel to be fitted with an air filled tyre fig 3 fig 4 If the transport safety device has been removed the front bake should not be operated before the front wheel is fitted with the disc brake b Disc brake Removing the transport safety device In the case of bikes with hydrauli...

Page 10: ...ke must be unhooked to mount the front wheel This is the only way to fit the assem bled and air filled tyre through the brake system This does not require the loosening of any screws On the left brake body there is a tool free quick release fastener Open the quick release fastener labelled Close by tilting the lever downwards fig 3 4 fig 4 fig 3 fig 5 Pull the entire left brake body from the brake...

Page 11: ...ig 3 fig 2 Check that the ends of the fork are fully supported on the front axle on both sides fig 2 In the case of disc brakes the brake disc must be guided in the centre between the brake pads without force fig 3 For rim brakes the front wheel brake must be reinserted see section 2 5 The brake is not functional when suspended fig 1 Front Wheel Assembly Installing the front wheel 2 3 Installing t...

Page 12: ...must be adjusted using the clamping nut on the opposite side a Quick release Hand screw the clamping nut on the quick release clamp against the lever until the open quick release tensioner has approx 1 2 mm play Move the quick release lever round 180 From position Open to position Close fig 1 2 fig 3 If the quick clamp has been closed correctly the word Close can now be read on the outside fig 3 F...

Page 13: ...th sides by hand Use the 15mm wrench to screw the axle nuts alternating between right and left until they are evenly and firmly fixed This prevents slipping of the front wheel fig 2 3 fig 4 If your bicycle has a hub dynamo then plug the lighting connector on the right side of the fork to the hub dynamo slot of the front wheel fig 4 Front Wheel Assembly Fitting the front wheel Quick release ...

Page 14: ...rew the thru axle firmly until the front wheel and axle are free of any play and the lever can be completely closed with slight pressure fig 3 4 fig 3 fig 4 Thru axles are designed to prevent slipping of the front wheel and require slightly lower closing forces than conventional quick releases or screw axles If the axle does not have a hinged lever it should be tightened with medium hand force Fro...

Page 15: ...ether with one hand until the brake pads lie flat on the rim fig 1 Using the other hand pull the metal tube of the brake cable in the direction of the support metal rail with the other hand so that the end of the guide tube can be attached fig 2 fig 3 Slip the rubber sleeve over the end of the guide tube fig 3 Front Wheel Assembly Fitting the brakes Side pull caliper road bike brake After installi...

Page 16: ...Close can be read fig 3 fig 1 fig 2 fig 3 Please note the operating instructions of the brake manufacturer Magura Roller brake To mount the preset roller brake the ca ble retaining screw must first be moun ted in the lower position Press the connector towards the upper brake arm to reduce the cable tension Push the cable sheath holder into the guide slot of the brake arm and engage it in the inten...

Page 17: ...venly or significantly grinds the brake the front wheel has not been installed correctly fig 1 Check the function of the front brake You should be able to easily stop the freely rotating front wheel with the front brake without having to pull the brake lever as far back as the handle fig 2 Front Wheel Assembly Function check ...

Page 18: ...head system for fork steering bearing and stem The stem is clamped with two outer screws on the continuous fork steerer and the headset bearing is adjusted with a screw from above fig 3 fig 1 fig 2 Loosen the screw connection between the stem and the fork steerer until the stem can be rotated fig 1 2 Align the stem in a straight line with the front wheel fig 3 Re adjust the be aring clearance of t...

Page 19: ... has a clamping cone which is inserted into the steerer tube and firmly fixed from above with a screw Loosen the screw on the head of the stem by about two turns fig 1 3 The stem should now be rotatable in the fork and flexible in height fig 1 fig 2 fig 3 The stem can now be positioned so that it is exactly straight on to the direction of travel fig 4 Also the height of the unit of stem and handle...

Page 20: ...the pre fastening bolts fig 3 6 fig 3 fig 5 fig 4 fig 6 Ensure uniform tightening torque for all pre clamp bolts The clearance of the stem clamp must be identical otherwise there is a risk of a serious material defect High clamping forces are not suitable here The lever of the small minitool and medium hand forces are sufficient It is best to use a suitable torque wrench and pay close attention to...

Page 21: ...semble the removed part of the stem clamp fig 4 Turn the handlebars to an individually comfortable position Make sure that the handlebar remains positioned centrally in the stem Tighten the handlebars evenly with the appropriate Allen key on your minitool by alternately tightening the pre fastening bolts fig 5 8 fig 5 fig 7 fig 6 fig 8 Ensure uniform tightening torque for all pre clamp bolts The c...

Page 22: ...es are all inde pendently adjustable of each other These bikes are delivered with a neutral basic setting as standard Individual fine ad justments can be made quickly and easily after the first test ride using the Allen keys on the supplied minitool fig 1 3 Adjustement of handlebar stem Adjusting shifter lever brake lever handles ...

Page 23: ...able to lubricate the post with some assembly grease For carbon seatposts or frames carbon assembly paste should be used fig 4 Adjust the seat height to the right height for you As a rough guideline for the correct seat height in the case of remote seatposts in the extended state the upper edge of your hip bone should be in line with the saddle when you are stood next to the bike fig 4 The exact s...

Page 24: ... quick release If the saddle height is correct and the saddle is in line with the upper tube fig 1 fix the saddle position with the clam ping screw fig 1 3 The minimum insertion depth is marked on the seatpost fig 4 The seatpost must meet this minimum insertion depth otherwise the post and frame may be damaged A material failure can lead to loss of control falls and injuries fig 4 ...

Page 25: ...box of your new bike Identify the right and left pedal They will be clearly marked fig 2 fig 3 fig 4 Screw the right pedal on the right crank drive side clockwise by hand into the thread fig 3 4 fig 5 fig 6 Screw the left pedal to the left crank counter clockwise by hand into the thread fig 5 6 Afterwards carefully tighten the pedal with the appropriate tool It should be screwed firmly but without...

Page 26: ...ng tension For the final check sit in the saddle The gears and brakes have already been set up by our bike mechanics but are the handlebars straight Are gearshift levers and brake levers easy to reach fig 1 fig 1 fig 2 And last but not least have you checked the air pressure in thefront and rear tyres and increased it if needed fig 2 A flat tyre on your first ride is not a great start with a new b...

Page 27: ...having passed Mechanical components such as brakes gears and bearings should be checked again after this initial operating time and readjusted if necessary A professional initial inspection ensures the maximum service life of your new bike and unlimited riding pleasure Inspections should be carried out regularly after 100 km or 6 weeks after 500 km or 6 months after 1000 km or 1 year after 2000 km...

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