PACIFIC CYCLE Bicycle Owner'S Manual Download

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Summary of Contents for Bicycle

Page 1: ...1 ill il I i I i I i Ill I i i BICYCLEOWNER SMAHUAL...

Page 2: ...II I II I I I I I CORRECT FITTING MAKE SURE YOUR HELMET COVERS YOUR FOREHEAD I I mn Nil I II II I I I I II fl INCORRECT FITTING FOREHEAD IS EXPOSED AND VULNERABLE TO SERIOUS INJURY II II I III I III C...

Page 3: ...s dedicated to your satisfactioTz with Pacific Cycle We want to help with any questions or comments you may have You can also reach us by email at seraice pacific cycle com DO NOT Return this Product...

Page 4: ...aintain 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 service questions operating advice and or ass...

Page 5: ...rchase Record 86 Warning Important Take notice of this symbol throughout this manual and pay particular attention to the instructions blocked off and preceded by this symbol _ Copyright 2000 Pacific C...

Page 6: ...with Straddle Cable Check your Brakes Training Wheels Rotors Final Check 4 SERVICING Schedule 1 Lubrication Schedule 2 Service Checklist Tools Required 6 DETAILED MAINTENANCE Wheel inspection Tire Ins...

Page 7: ...ountain style bicycles are much sturdier than those on racing style bicycles Top Tube Seat Seat Post Quick Release Seat Stay Rear Reflector Rear Brake Wheel Reflector Freewheel Handlebar Stem Head Set...

Page 8: ...ntenance Seat Handlebar Grip Seat Post Handlebar Stem Seat Post Binder Bolt Head Seat Stay Head Tube Rear Reflector __ Top Tube Wheel Reflector _ _ _ Seat Tube Down Tube Brake Lever Handlebar Brake Co...

Page 9: ...e details on inspection lubrication maintenance and adjustment of any area please refer to the relevant sections in this manual If you need replacement parts or have questions pertaining to assembly o...

Page 10: ...d rider preference This makes straddling 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 wom...

Page 11: ...side while pedaling While sitting on the bicycle with one pedal at its lowest point place the ball of your foot on that pedal The correct saddle height will allow the knee to be slightly bent in this...

Page 12: ...mfortable position Ensure that the handlebar stem does not extend beyond the minimum insertion mark Failure to do this may cause serious bodily injury or damage to the bicycle Ensure both the Stem Wed...

Page 13: ...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 are tight If your...

Page 14: ...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 15: ...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 The correct helmet should be comfortable be lightweight have good v...

Page 16: ...opening car doors or cars backing out of concealed driveways Be extra careful at intersections and when preparing to pass other vehicles Familiarize yourself with all the bicycle s features Practice g...

Page 17: ...lean reflectors Refer to p 84 of this manual 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 char...

Page 18: ...h an emphasis on safety from an early age 1 Always wear a properly fitted helmet 2 Do not play in driveways or the road 3 Do not ride on busy streets 4 Do not ride at night 5 Obey all the traffic laws...

Page 19: ...nt derailleur a front chainwheel with 2 3 cogs and up to 8 cogs on the rear hub Operating Principles No matter how many gears the operating principles are the same The front derailleur is operated by...

Page 20: ...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...

Page 21: ...nd lever back Bottom Gear Easier Large rear sprocket Small chainwheel Left hand lever back Right hand leverforward Below the Bar Shifters Many mountain style bicycles now use a shift lever arrangement...

Page 22: ...ive 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 and a...

Page 23: ...one emissions may effect the rubber and paint Don t cover with plastic as sweating will result which may cause rusting Security It is advisable that the following steps be taken to prepare for and hel...

Page 24: ...ur bicycle may be equipped with different style compo nents than the ones illustrated Handlebars Remove the protective cap from the handlebar stem wedge and loosen the Allen key bolt using the 6ram Al...

Page 25: ...assembly these stems will require angling the stem to the desired position and securely tightening the 6mm angle bolt located in front of the stem bolt Failure to do this may cause loss of steering co...

Page 26: ...5mm Allen key or Phillips head screwdriver Figure 1 Handlebar with Grip Shifter Figure 2 Top mounted thumb shifter Failure to properly tighten clamping bolts may cause sudden movement of the componen...

Page 27: ...o disassemble a suspension fork yourself Consult a professional bicycle repair technician Check the tightness of the headset and the fork Rotate the fork checking for smoothness If it feels like the f...

Page 28: ...nd handlebars NOTE Comfort Series CS bicycles may be equipped with a suspension seat post See Diagram bottom left Some suspension posts can be adjust ed for stiffness using the preload adjusting screw...

Page 29: ...has a left hand counter clockwise thread It is very important that you check the crank set for correct adjustment and tightness before riding your bicycle New cranks may become loose with initial use...

Page 30: ...fway closed position of the quick release lever you should start to feel some resistance to this motion Do not tighten the quick release by using the quick release lever like a wing nut If the quick r...

Page 31: ...e assembly instructions For more information on brake adjustment and maintenance refer to p 66 69 Cantilever Brakes Utilizing a Link Wire If fitted with cantilever type brakes insert the brake cable i...

Page 32: ...a position directly below the cable casing holder 5 Secure one of the shoes at e time The adjustment of the shoe clearance is not necessary at this time Shoe fixing nut tightening torque 7 84 8 82 Nm...

Page 33: ...the brake post which has no effect on braking V Style Brakes Take the brake noodle from the parts box and slide the cable through the larger opening The cable housing will then seat into the end of th...

Page 34: ...e link fixing bolt L _I 5 mm Allen key Spring hole Stopper pin 2 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...

Page 35: ...rim tighten the cable fixing bolt _ _lb 5 mm Alien key 5 Adjust the balance with the spring tension adjustment screws 1 mm 1 mm Spring tension adjustment screw Spring tension adjustment screw 6 Depres...

Page 36: ...ed Brake pads should be centered on the rim and the rear portion of each brake pad should be about 0 5 1 0 mm farther from the rim than the front portion of the brake pad Brake pad aligned with the ri...

Page 37: ...uster and lock nut slots have been aligned with the cable end holder After the cable is secured to the lever rotate the barrel adjuster and lock nut so the slots no longer line up Ensure the cable hou...

Page 38: ...any other serious braking Please be aware that your brake system will change in performance throughout the wear in process The disc brake should be cleaned before the first ride using rubbing alcohol...

Page 39: ...he anchor bolt securely Shift through the gears making sure each gear achieved is done quietly and without hesitation If necessary use the barrel adjuster to fine tune each gear by turning it the dire...

Page 40: ...e front shifter to the largest chainwheel If the chain does not go onto the largest chainwheel turn the high limit screw in 1 4 turn increments counter clockwise until the chain engages the largest ch...

Page 41: ...attaching hardware is secured and there is no lateral movement of the rear triangle The amount of Rear Suspension travel can be adjusted by turning the adjusting plate Clockwise will increase spring...

Page 42: ...Please note the drive side crank arm must be removed from the spindle before attempting to work on the pivot Some models have two small 2 5mm Allen bolts on the underside of the bottom bracket shell...

Page 43: ...ps around the seat post Frame bags install at the apex of the top and seat tubes Secure the straps around each tube NOTE The frame bag straps must not bind the cables The straps must go around the fra...

Page 44: ...ommended psi as stated on the sidewall of the tire Check that the kickstand operates smoothly and the kickstand bolt is secured tightly Finally examine the bicycle Make sure all accessories are attach...

Page 45: ...discarded Assemble your bicycle following the steps that pertain to your model Note Your bicycle may be equipped with different style components than the ones illustrated Handlebars Remove the protec...

Page 46: ...d with a quick release mechanism please refer to page 24 25 The seat pillar must be inserted so that the minimum insertion mark cannot be seen Pedals Crank Set Look for the letters R for right and I f...

Page 47: ...bicycle Failure to properly tighten may cause the front wheel to dislodge Front Brake Determine which type of brake your bike is equipped with and refer to the appropriate assembly instructions For m...

Page 48: ...tightened Test the brake levers 20 25 times to take care of any initial cable stretch Be sure to tightly secure the brake fixing nut behind the fork When assembling or adjusting the brakes make sure...

Page 49: ...on directly below the cable casing holder 5 Secure one of the shoes at a time The adjustment of the shoe clearance is not necessary at this time Shoe fixing nut tightening torque 7 84 8 82 Nm 70 78 in...

Page 50: ...ing bolt Spring hole 5 mm Allen key Stopper pin Washer Link fixing b0 2 While holding the shoe against the rim adjust the amount of shoe protrusion by interchanging the position of the B washers i e 6...

Page 51: ...e cable fixing bolt B C 2mm 5 mm Allen key ii ii iii 5 Adjust the balance with the spring tension adjustment screws q Spring tension adjustment screw 1 mm tmm Spring tension adjustment screw 6 Depress...

Page 52: ...ire or to fit over the front reflector hanger In the event of brake cable failure the front reflector hanger would prevent the strad dle cable from catching in the tire and locking up the front wheel...

Page 53: ...rd to make sure they will stop the bicycle Shoulder Bo t Stabilizer Washer l l Nut Star Washer Training Wheels 1 Position a washer on the shoulder bolt Insert the shoulder bolt through the wheel Follo...

Page 54: ...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 adjust...

Page 55: ...Single Cable Casing Cable Adjuster Cable Splitter Upper Cable long casing Upper Cable short casing Upper Plate 37ram 0r 1ram Bearing Football Ends Lower Plate Lower Cable Barrel Locknut Set for Max Tr...

Page 56: ...rough the fork It is important to make sure all connections are tightened securely and that the reflectors are properly angled Pads If your bike is supplied with pads wrap the foam inner cushion aroun...

Page 57: ...y Every Six Months Yearly 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 lithiu...

Page 58: ...stment Check tire wear and pressure Check wheels are true and spokes tight Check hub head set and crank bearings for looseness Check pedals are tight Check handlebars are tight Check seat and seat pos...

Page 59: ...len key wrenches 4mm 5ram 6mm 8ram 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 10 Tire levers T...

Page 60: ...d If wheels 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 mis...

Page 61: ...is properly seated in the rim 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 should be replac...

Page 62: ...olding the adjusting cone in position 5 Re check that the wheel can turn freely without excessive side play How To Fix a Flat Tire If you need to repair a tire follow these steps 1 Remove the wheel fr...

Page 63: ...ther 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 Before the tire is completely mounted push the valve up into the rim to...

Page 64: ...grease and grime then applying a thin film of grease to the part including the wedge that will be inserted into the frame The height ef the handlebar can be adjusted to suit your comfort preference I...

Page 65: ...ately 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 66: ...tic washers over handlebar The washers prevent 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...

Page 67: ...o 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 bicycle I...

Page 68: ...nds to stick or bind at any point the bearings are too tight Adjustment Loosen the headset top Iocknut or remove it completely along with the reflector bracket if fitted Turn the adjusting cup clockwi...

Page 69: ...lower tube and turn clockwise until it wilt not turn anymore 3 Align the brake arch mounts on both lower tubes and install brake arch 4 Tighten brake arch bolts to 70 80 in Ibs 8 9 2 Nm Check before e...

Page 70: ...frame you will notice a mark about 65mm up from the bottom with the words max height or minimum insertion To avoid damage to either the seat post the frame or possibly the rider a minimum of 65mm of...

Page 71: ...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 adjustable clamp uses a...

Page 72: ...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 reach adjustment s...

Page 73: ...cable adjusting barrel usually located 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 fr...

Page 74: ...rim as required 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 e...

Page 75: ...nut and adjust Move the brake pad along its mounting post to alter the distance from the rim and move the curved adjustment washer to alter the angle of the pad On some models there is a spring force...

Page 76: ...s with straps requires practice to acquire the necessary skill to operate them safely Inspection Pedals should be inspected every month taking note of the following areas Check correct tightness into...

Page 77: ...on the end of the axle and screws in with a clock wise thread The left pedal which attaches to the other crank arm is marked L on the axle and screws in with a counter clockwise thread Insert the cor...

Page 78: ...ra care Never ride your bike if the cotterless cranks are loose This may be dangerous and will damage the crank arms beyond repair Inspection The crank set should be checked for correct adjustment and...

Page 79: ...ft side Iocknut by turning it clockwise and remove the keyed Iockwasher 4 Remove the adjusting cone by turning it clockwise with a screwdriver 5 Remove the left ball retainer slide the crank assembly...

Page 80: ...ve the left side ockring by turning it counter clockwise 3 Remove the adjusting cup by turning it counter clockwise 4 Remove the left bail retainer and slide the axle out of the frame to the left 5 Re...

Page 81: ...he crank arm onto the axle 2 Tap the crank arm lightly with a mallet 3 Refit the washer and tighten flange nut or bolt securely to a torque of 27Nm 4 Replace the dust cover Adjustment After Use 1 Remo...

Page 82: ...ear axle nuts and coaster brake arm clip if fitted and move the wheel forward to loosen or backward to tighten in the frame 2 When correctly adjusted the chain should have approximately lOmm of vertic...

Page 83: ...th 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 tee far through side plate FREEWHEEL Inspection Like...

Page 84: ...rear wheel This type of brake offers 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 T...

Page 85: ...leur 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 h...

Page 86: ...t sprocket are lined up vertically Remove any slack in the cable by pulling it taut then re connect the cable and tighten the cable anchor bolt securely 3 Shift up through the gears making sure that e...

Page 87: ...curely 4 Shift the front shifter into the largest gear and pedal the bike so the chain jumps to the largest chainwheel If the chain does not shift onto the largest chainwheel you will need to turn the...

Page 88: ...er to page 21 and 22 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 import...

Page 89: ...true Chainring loose Chainring teeth bent or broken Rear or front derailleur side to side travel out of adjustment Re true if possible or replace Tighten mounting bolts Repair or replace chainring set...

Page 90: ...they squeal squeak Brake blocks worn down Brake block toe in incorrect Brake blocks rim dirty or wet Brake arms loose Replace blocks Correct block toe in Clean blocks and rim Tighten mounting bolts Kn...

Page 91: ...a bike shop for possible frame realignment Frequent punctures Inner tube old or faulty Tire tread casing worn Tire unsuited to rim Tire not checked after previous puncture Tire pressure too low Spoke...

Page 92: ...diately and retain as a record of your purchase Please retain your sales receipt for any possible warranty claims Your Name Address Date Purchased Place of Purchase Model Name Wheel Size Color Serial...

Page 93: ...s warranty does not cover paint damage rust or any modifications made to the bicycle Normal Wear Parts are defined as grips tires tubes cables and saddle covering These parts are warranted to be free...

Page 94: ...E LLC 4902 Hammersley Road Madison WI 53711 Phone 608 268 2456 Fax 608 268 2455 Customer Service 1 800 283 3303 E mail service pacific cycle corn Web Address www pacific cyclelcom _ Copyright 2000 Pac...

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PACIFIC CYCLE Bicycle, Owner'S Manual

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