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BICYCLE
ASSEMBLY
BICYCLE
ASSEMBLY
HANDLEBAR AND STEM
1.
Assemble the stem to the fork: If necessary, assemble the stem
to bolt (4),washer (5), and wedge nut (2) to the stem (1).
Turn the stem bolt only four revolutions into the wedge nut (2).
Point the stem toward the front of the bicycle and put it into the
locknut. Put the stem at a comfortable height for the rider.
WARNING:
To prevent steering system damage and possible
loss of control, the “MIN-IN” (minimum insertion) mark on the
stem must be inside the locknut. Make sure you can not see the
“MIN-IN” (minimum insertion) mark (3) on the stem above the
locknut. Tighten the stem bolt just enough that the stem will not
fall into the locknut.
2.
Assemble the handlebar to the stem: Put the handlebar into the
stem, but do not tighten the handlebar clamp at this time. Align
the stem with the front wheel and tighten the stem bolt
3.
Assemble the brake lever to the handlebar. Loosen the clamp
screw of each brake lever. If necessary, move the handlebar to
each side to install the brake levers put the brake levers on the
handlebar with the brake lever for the rear brake on the right side
of handlebar.
Do not tighten the clamp screw of the brake levers at this
time.
4. Tighten stem bolt and the handlebar clamp:
WARNING:
do not overtighten the stem bolt. Over tightening the
stem bolt can damage the steering and cause loss of control. Make
sure the stem is aligned with the front wheel and tighten stem bolt.
MINIMUM
INSERTION
LINE
Stem Diagram
Adjuster Bolt
Headset
Top Cap
Stem
Binder
Bolts
Headset
Frame
Handlebar
ADJUSTING THE HANDLEBAR STEM
AND HEADSET
NOTE:
the handlebar stem and headset are an integrated system. Both
must be adjusted at the same time.
1.
To adjust the headset or stem, irst loosen the two stem binder bolts,
then the adjuster bolt in the top cap.
2.
Align the handlebar stem with the front wheel.
3.
To remove play from the headset, begin by tightening the adjuster bolt
in the top cap. This will tighten the headset and remove side to side
movement of the fork. If the fork fails to rotate freely, the adjuster bolt
is too tight and needs to be loosened.
WARNING:
Do not over tighten the adjuster bolt. Its function is to
adjust the headset. The stem binder bolts’ function is to hold the fork
and stem in place.
4.
Once the headset is adjusted, tighten the two stem binder bolts to
the recommended torque of 140 pounds per inch. Do not over tighten
these bolts.
WARNING: Do not over tighten the stem binder bolts and
handlebar binder bolts. Failure to properly tighten these bolts
may damage the handlebar and/or stem to fork assembly. This may
compromise the steering action, causing you to possibly lose control,
and possibly injure yourself.
