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Part 3 - Assembly

138692 Rev 0 (04/22)

Table of Contents

GT Bicycle Owner’s Manual

Part 3 - Assembly

STEP 1.

Introduction . . . . . . . . . 161

STEP 2.

Consulting Resources. . . . . . 161

STEP 3.

Tools And Working Area . . . . . 162

STEP 4

Getting Your Bike Ready

For Assembly . . . . . . . . . 163

STEP 5.

Installing Seatpost

And Saddle . . . . . . . . 164-166

STEP 6.

Installing Handlebar

And Stem . . . . . . . . . 167-173

STEP 7.

Bikes With Disc Brakes-

Install Rotor To Hub . . . . 174-175

STEP 8.

Install Front Wheel . . . . 176-196

STEP 9.

Front Brake Assembly

And Adjustment . . . . . . 196-204

STEP 10.

Install Pedals . . . . . . . 205-207

STEP 11.

Security Checks . . . . . . 208-209

STEP 12.

Mountain Bike

Components And Set Up . . 210-211

STEP 13.

Electric Bikes . . . . . . . . . 212

STEP 14.

Other Types Of Bikes,

Special Components . . . . . . 213

STEP 15.

Final Inspection . . . . . . . . 213

STEP 16.

Test Ride And

50 Mile Tune Up . . . . . . 214-215

WARNING: This product contains chemicals known

to the State of California to cause cancer and birth

defects or other reproductive harm. (California

requires this warning to be given to customers in the

State of California under Proposition 65.)

Содержание Grade

Страница 1: ...Bicycle Owner s Manual THIS MANUAL CONTAINS IMPORTANT SAFETY PERFORMANCE AND SERVICE INFORMATION Read it before you take the first ride on your new bicycle and keep it for reference 138692 Rev 0 04 22...

Страница 2: ...lands service cyclingsportsgroup com GT UK Cycling Sports Group Vantage Way The Fulcrum Poole Dorset BH12 4NU 44 0 1202732288 sales cyclingsportsgroup co uk Register Your New GT Bike It only takes a m...

Страница 3: ...n death or serious injury CAUTION Indicates special precautions that must be taken to avoid damage This manual meets 16 CFR 1512 and EN Standards 14764 14766 and 14781 V lo certifi conforme aux exigen...

Страница 4: ...combination of bicycle rider and conditions Thus as a reasonable person would expect the GT manuals and supplements focus on the bicycle not teaching you to ride GT Owner s Supplements GT Owner s Man...

Страница 5: ...Riding in Traffic Commuting 71 Riding at Night Dusk Dawn 72 73 Understanding E Bikes 74 E Bike Drive System ID 75 Operating an E Bike 76 79 E Bike Batteries and Chargers 80 82 Table of Contents Part 1...

Страница 6: ...Tire Rim Compatibility 97 Checking Wheel Rim Wear 98 Understanding Disc Brakes on Road Bikes 98 Brake Power Modulators 99 Aftermarket Brake Systems 100 Aftermarket Power Systems 100 Riding Off Road 10...

Страница 7: ...on Fiber 137 140 Understanding Components 141 144 Bicycle Lifespan 144 Useful Life of Light weight Frames 144 Section E Maintenance 145 Importance of a Maintenance Routine 145 Basics of a Good Mainten...

Страница 8: ...8 Install Front Wheel 176 196 STEP 9 Front Brake Assembly And Adjustment 196 204 STEP 10 Install Pedals 205 207 STEP 11 Security Checks 208 209 STEP 12 Mountain Bike Components And Set Up 210 211 STEP...

Страница 9: ...jury or death CAUTION The combination of the safety alert symbol and the word CAUTION shown above indicates a potentially hazardous situation which if not avoided may result in minor or moderate injur...

Страница 10: ...warnings and the bicycle s functions and operating procedures with your child before letting your child ride the bicycle WARNING Make sure that your child always wears an approved bicycle helmet when...

Страница 11: ...ully understand how to operate your new bicycle If not before your first ride have your dealer explain any functions or features which you do not understand 1 B Safety First 1 Always wear an approved...

Страница 12: ...e Nuts Bolts Screws Other Fasteners Because manufacturers use a wide variety of fastener sizes and shapes made in a variety of materials often differing by model and component the correct tightening f...

Страница 13: ...ing sound feel or look loose Do a visual and tactile inspection of the whole bike Any loose parts or accessories If so secure them If you re not sure ask someone with experience to check Tires Wheels...

Страница 14: ...es seated and securely engaged Do the brake pads contact the wheel rim squarely and make full contact with the rim Do the brake pads touch the wheel rim within an inch of brake lever movement Can you...

Страница 15: ...ars have bar end extensions make sure they are clamped tight enough so you can t twist them WARNING Loose or damaged handlebar grips or extensions can cause you to lose control and fall Unplugged hand...

Страница 16: ...oo hard can lock up a wheel which could cause you to lose control and fall Skidding is an example of what can happen when a wheel locks up If your bicycle has toeclips or clipless pedals practice gett...

Страница 17: ...cle traffic laws It s your responsibility to know and obey the laws 2 A The Basics 1 Always wear a cycling helmet which meets the latest certification standards and is appropriate for the type of ridi...

Страница 18: ...bike can be fun but it can put huge and unpredictable stress on the bicycle and its components Riders who insist on jumping their bikes risk serious damage to their bicycles as well as to themselves B...

Страница 19: ...signed for it If the bicycle is suitable for a child carrier or trailer make sure that the carrier or trailer is correctly mounted and the child secured and wearing an approved and properly fitted hel...

Страница 20: ...ow who you are in case of an accident and take along a couple of dollars in cash for a candy bar a cool drink or an emergency phone call 5 Yield right of way to pedestrians and animals Ride in a way t...

Страница 21: ...y A bicyclist is very difficult for motorists and pedestrians to see Therefore children should never ride at dawn at dusk or at night Adults who chose to accept the greatly increased risk of riding at...

Страница 22: ...take the following strongly recommended additional precautions Purchase and install battery or generator powered head and tail lights which meet all regulatory requirements and provide adequate visib...

Страница 23: ...r Competition Riding Whether you call it Aggro Hucking Freeride North Shore Downhill Jumping Stunt Riding Racing or something else if you engage in this sort of extreme aggressive riding you will get...

Страница 24: ...at speed do stunt riding or ride in competition know the limits of your skill and experience Ultimately avoiding injury is your responsibility 2 G Changing Components Or Adding Accessories There are m...

Страница 25: ...rt Making the adjustments to your bicycle which result in correct fit for your body and riding conditions requires experience skill and special tools Always have your dealer make the adjustments on yo...

Страница 26: ...p through frame bicycles Standover height does not apply to bicycles with step through frames Instead the limiting dimension is determined by saddle height range You must be able to adjust your saddle...

Страница 27: ...ost does not project from the frame beyond its Minimum Insertion or Maximum Extension mark fig 4 NOTE Some bicycles have a sight hole in the seat tube the purpose of which is to make it easy to see wh...

Страница 28: ...touching the curved part of the rails and that you are using the recommended torque on the clamping fastener s See manufacturer s instructions 3 Saddle Angle Adjustment Most people prefer a horizonta...

Страница 29: ...ent be sure that the saddle adjusting mechanism is properly tightened before riding A loose saddle clamp or seat post binder can cause damage to the seat post or can cause you to lose control and fall...

Страница 30: ...he stem to above the stem or vice versa Otherwise you ll have to get a stem of different length or rise Consult your dealer Do not attempt to do this yourself as it requires special knowledge If your...

Страница 31: ...rols WARNING Always tighten fasteners to the correct torque Bolts that are too tight can stretch and deform Bolts that are too loose can move and fatigue Either mistake can lead to a sudden failure of...

Страница 32: ...s WARNING The shorter the brake lever reach the more critical it is to have correctly adjusted brakes so that full braking power can be applied within available brake lever travel Brake lever travel i...

Страница 33: ...e wheels are designed to be removable for easier transportation and for repair of a tire puncture In most cases the wheel axles are inserted into slots called dropouts in the fork and frame but some s...

Страница 34: ...release lever and a disc brake If the bicycle is ridden with the lever incorrectly adjusted or open and the lever contacts the disc or wheel next figure the front wheel could stop suddenly causing the...

Страница 35: ...wheel securing method for your bicycle with your dealer It is very important that you understand the type of wheel securing method on your bicycle that you know how to secure the wheels correctly and...

Страница 36: ...NG Do not remove or disable the secondary retention device As its name implies it serves as a back up for a critical adjustment If the wheel is not secured correctly the secondary retention device can...

Страница 37: ...with the other hand until everything is as tight as you can get it will not clamp a cam action wheel safely in the dropouts See also WARNING on page 33 b Adjusting the cam and cup mechanism fig 8B The...

Страница 38: ...evice and a traditional cam action system fig 8a loosen the tension adjusting nut enough to allow removing the wheel from the dropouts If your front wheel uses a cam and cup system fig 8b squeeze the...

Страница 39: ...of the slots in the fork dropouts and at the same time centering the wheel rim in the fork a With a cam action system move the cam lever upwards and swing it into the CLOSED position fig 8a b The leve...

Страница 40: ...the brake lever and make sure that the brakes are operating correctly c Removing a disk brake or rim brake rear wheel 1 If you have a multi speed bike with a derailleur gear system shift the rear dera...

Страница 41: ...the chain Put the chain on the rear wheel sprocket 4 Then insert the wheel into the frame dropouts and pull it all the way in to the dropouts 5 On a single speed or an internal gear hub replace the ch...

Страница 42: ...pin the wheel to make sure that it is centered in the frame and clears the brake pads then squeeze the brake lever and make sure that the brakes are operating correctly 4 B Seat Post Cam Action Clamp...

Страница 43: ...with one hand and turning the lever like a wing nut with the other hand until everything is as tight as you can get it will not clamp the seat post safely WARNING If you can fully close the cam lever...

Страница 44: ...e when using them 4 Some bicycle brakes are equipped with a brake force modulator a small cylindrical device through which the brake control cable runs and which is designed to provide a more progress...

Страница 45: ...your dealer to make sure that you understand the way the brake quick release works on your bike see figs 12 13 14 15 and check each time to make sure both brakes work correctly before you get on the b...

Страница 46: ...shift your body toward the rear of the bike to transfer weight back on to the rear wheel and at the same time you need to both decrease rear braking and increase front braking force This is even more...

Страница 47: ...47 PART 1 1 Brake Controls And Features Section 4 Tech GT Bicycle Owner s Manual Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 OPEN OPEN OPEN PUSH...

Страница 48: ...edal in about the 4 o clock position and apply downward foot pressure on the pedal that is to the rear About 1 8 turn rotation will activate the brake The more downward pressure you apply the more bra...

Страница 49: ...rs There are several different types and styles of shifting controls levers twist grips triggers combination shift brake controls push buttons and so on Ask your dealer to explain the type of shifting...

Страница 50: ...tion of the rear derailleur is to move the drive chain from one gear sprocket to another The smaller sprockets on the gear cluster produce higher gear ratios Pedaling in the higher gears requires grea...

Страница 51: ...affic until you ve built up your confidence Learn not to use either the smallest to smallest or largest to largest gear combinations because they can cause unacceptable stress on the drive change Lear...

Страница 52: ...s for the greatest speed Shifting from an easier slower gear like 1 to a harder faster gear like 2 or 3 is called an upshift Shifting from a harder faster gear to an easier slower gear is called a dow...

Страница 53: ...rp and potentially dangerous surfaces These surfaces are designed to add safety by increasing grip between the rider s shoe and the pedal If your bicycle has this type of high performance pedal you mu...

Страница 54: ...hey have a plate called a cleat on the sole of the shoe which clicks into a mating spring loaded fixture on the pedal They only engage or disengage with a very specific motion which must be practiced...

Страница 55: ...n the technique requires concentration which can distract your attention and cause you to lose control and fall Practice engaging and disengaging clipless pedals in a place where there are no obstacle...

Страница 56: ...front of a suspended bike dips You could lose control and fall if you do not have experience with this system Learn to handle your suspension system safely See also SECTION 4 C WARNING Changing suspe...

Страница 57: ...many designs and specifications ranging from general purpose designs to tires designed to perform best under very specific weather or terrain conditions If once you ve gained experience with your new...

Страница 58: ...um pressure or as a pressure range How a tire performs under different terrain or weather conditions depends largely on tire pressure Inflating the tire to near its maximum recommended pressure gives...

Страница 59: ...rotate in the correct direction 2 Tire Valves There are primarily two kinds of bicycle tube valves The Schrader Valve and the Presta Valve The bicycle pump you use must have the fitting appropriate to...

Страница 60: ...advances have made bicycles and bicycle components more complex and the pace of innovation is increasing It is impossible for this manual to provide all the information required to properly repair and...

Страница 61: ...nstallation and service instructions for the components on your bike or contact the component manufacturer 2 Ask your dealer to recommend a book on bicycle repair 3 Ask your dealer about the availabil...

Страница 62: ...bike back to the dealer for a checkup Dealers typically suggest you bring the bike in for a 30 day checkup Another way to judge when it s time for the first checkup is to bring the bike in after thre...

Страница 63: ...If any feel loose have your dealer check the wheel for tension and trueness Check the tires for excess wear cuts or bruises Have your dealer replace them if necessary Check the wheel rims for excess...

Страница 64: ...nd have different life cycles If a component s life cycle is exceeded the component can suddenly and catastrophically fail causing serious injury or death to the rider WARNING Scratches cracks fraying...

Страница 65: ...omposite components including fames wheels handlebars stems cranksets brakes etc which have sustained an impact must not be ridden until they have been disassembled and thoroughly inspected by a quali...

Страница 66: ...rvised 1 Rules No playing in the road or in the street No riding on busy streets No riding at dawn dusk or at night Stop for all STOP signs Ride on the right of traffic 2 Lessons The lessons that foll...

Страница 67: ...running stop signs will eventually result in an accident What can you do Take your child to a stop sign near home Explain what it means by emphasizing the following points 1 Stop at all stop signs re...

Страница 68: ...lls and equipment Few children have either Secondly make sure your child understands that if he she gets caught out at dusk or after dark on a bike the thing to do is to call you for a ride home One s...

Страница 69: ...we call attention to a hazard Some low speed falls may result in serious injuries and some wild high speed falls may result in none The reality is that the exact nature of the consequences of a fall o...

Страница 70: ...or eliminated You can minimize risk by doing the following Bicycle training practice Progressive step by step learning of new cycling skills The good judgement to ride in control Bicycle experience r...

Страница 71: ...nual you must learn and obey local traffic laws Riding in traffic is hazardous We cannot teach you about all of these hazards We suggest Effective Cycling ISBN 0 262 06159 7 by John Forester And www b...

Страница 72: ...lectors The location and type of each reflector on your bike is required by a national authority in the US the US Consumer Product Safety Commission CPSC Your GT bike must be delivered with 1 A front...

Страница 73: ...her times of poor visibility without a bicycle lighting system which meets local and state laws and without reflectors is dangerous and may result in serious injury or death If you ride your bike befo...

Страница 74: ...ed Drive For a drive system equipped with a throttle it is important to know that when the drive assist system is turned ON the drive unit engages to provide power when the throttle is pressed Pedal A...

Страница 75: ...al 5 1 3 4 2 6 Drive System Parts E Bike The example shown below is a E Bike in the Mountain category There are many different bkes that have these same basic drive system comnnents 1 Drive unit 2 Dri...

Страница 76: ...ding time to react appropriately is critical to using the drive assist system Always check your surroundings and conditions before accelerating and set the assistance level to lowest assist or off whe...

Страница 77: ...ny part of the E bike The E bike is heavier than ordinary bikes and may result in tip over serious injury or death if not parked properly Always park the E bike in a safe area away from children anima...

Страница 78: ...ks When not riding Turn the drive system off to prevent unauthorized use Do not ride the e bike without the battery Make sure the battery is fully charged before every ride to help ensure adequate bat...

Страница 79: ...age for accidents involving the use of this bicycle To determine if coverage is provided you should contact your insurance company or agent Also make sure your speed e bike is insured and registered a...

Страница 80: ...not plug or unplug the battery charger with wet hands Do not place any items on the battery charger or cover ventilation Do not place the battery charger in any wet or damp location Overcharging the b...

Страница 81: ...electrical fires explosion or severe burns Transportation The battery is subject to hazardous materials regulations when in transit Always contact the proper authorities regarding the requirements to...

Страница 82: ...tem active could result in accidental activation of the drive assist system Always remove the battery from the e bike before performing maintenance Cleaning live electrical components may result in sh...

Страница 83: ...d the e bike has moving parts and components e g battery Never allow children to play or come into contact with the e bike or its parts Always follow all rules regulations and laws regarding age limit...

Страница 84: ...anodize or chrome plate your frame Any of these procedures will seriously harm the structural integrity and or longevity of your frame which could lead to serious accident and injury Modifications wil...

Страница 85: ...any required additional equipment registration and applicable rider age restrictions Vehicle category a definition of the european union of the different types of e bikes who and where they may be use...

Страница 86: ...upported and stabilized by the kickstand The kickstand is not designed to support the weight of a person Trailers WARNING Riding with a bike trailer that is incompatible with the bike could create dan...

Страница 87: ...l springs when the rider hits a bump and the springs compress Be sure that the child cannot reach the springs when properly strapped in the carrier We encourage use of trailers or bicycles specially d...

Страница 88: ...ater be located See Inspect for Safety for some information on how frame and fork materials can be broken Avoid Riding Over Sticks Debris The riders were taken by surprise and crashed hard As many rid...

Страница 89: ...d to illuminate the road or hazards in the road While riding stop before changing the operating mode Higher risks riding at night the risk of an accident particularly being struck by a motor vehicle i...

Страница 90: ...ks To Center Of The Fork Axle From Bottom Of Frame Head Tube Maximum Fork Length WARNING You must select a replacement fork not only based on head tube diameter but the critical factor of frame maximu...

Страница 91: ...tire and the component or accessory 4 If there is less than 10 mm of clearance available the component or accessory must be adjusted or changed until l there is at least 10 mm of clearance WARNINGS Ma...

Страница 92: ...ded Go to a professional bicycle re painter often a frame builder Ask about the professional s experience with aluminum and or carbon frames Be sure your frame is never sanded with paper coarser than...

Страница 93: ...tress of bar ends others are not Very lightweight handlebars may be particularly poorly suited for bar ends If you want bar ends consult your authorized dealer about suitable choices read and follow i...

Страница 94: ...o added by customers Understand that when riding on these extensions your steering and braking are adversely affected When on the extensions most riders find it hard to look back over their shoulder w...

Страница 95: ...c and hazards and you have a long line of sight When using the extensions understand that you are compromising steering and braking in favor of speed If you need to take evasive steering or braking ac...

Страница 96: ...ap or toe clip overlap What is It What is It Toe overlap or Toe clip overlap describes the toe of your shoe your shoe attached to a clipless pedal or your toe clip contacting the front tire or front f...

Страница 97: ...n cpsc requires at least 1 16 1 6 Mm tire clearance from any part of the bike Allowing for lateral rim flex and a wheel or rim that is out of true will likely mean choosing a rear tire that provides e...

Страница 98: ...raking or wheel failure Replace your wheel when they become worn out or damaged Do not ride your bike when the wheels are damaged or worn out Ask your Dealer for help with inspecting the rim wear of y...

Страница 99: ...A brake modulator will not prevent wheel lock up or being thrown off the bike due to overly hard or fast or abrupt application of the brakes It is important that you understand modulators are not an...

Страница 100: ...read the literature provided by the brake manufacturer When choosing replacements please ask your authorized dealer have your bike s brakes installed and adjusted by a professional bike mechanic After...

Страница 101: ...ing all this while surrounded by nature makes this a challenging and wonderful sport We recommend that children not ride on rough terrain unless they are accompanied by an adult Here are just some off...

Страница 102: ...b the ecosystem by cutting your own trail or shortcut through vegetation or streams It is your responsibility to minimize your impact on the environment Leave things as you found them and always take...

Страница 103: ...ike is required by a national authority in the US the US Consumer Product Safety Commission CPSC Your bike have 1 A front mounted forward facing reflector 2 A rear mounted rear facing reflector 3 A sp...

Страница 104: ...seat post and tighten the seat binder to the specified torque with an accurate torque wrench Consult the seat post manufacturer s instructions for torque information 5 Check tightening torques of the...

Страница 105: ...uch torque may break the bolts Too little torque will result in movement which leads to fatigue and bolt breakage WARNING To avoid seat post or frame damage 1 FOLLOW THE SEAT POST MANUFACTURER S INSTR...

Страница 106: ...y used in honing and solvents and including chemical cleaners can attack and weaken composite bonds holding the frame together leading to breakage Follow the seat post and frame manufacturer instructi...

Страница 107: ...ols Smoothly finish the new lower edge of the shortened seat post Re mark the CPSC required minimum insertion line on the seat post Install with the proper lubricant or carbon gel WARNING DON T CUT A...

Страница 108: ...me via a frame decal and or in the owner s manual supplement as minimum seat post insert in the Geometry Specifications section How Does It Affect My Bike You must always have at least the required mi...

Страница 109: ...Read Understanding Composites for information on carbon fiber REPLACE THE FORK WITH A NEW ONE IF THE DROPOUT TABS ARE MISSING OR DAMAGED The dropout tabs located at the bottom of the fork dropout act...

Страница 110: ...OF A TYPICAL CARBON ROAD FORK DROPOUT TAB PARTS OF A TYPICAL ROAD STEM STEERER TUBE CROWN Figure 34 NOTE Carbon fiber bicycle forks and stems come in many different shapes The basic parts common to m...

Страница 111: ...r stem can place significant stress on the steerer tube It could break Always tighten fasteners of the headset stem system and brake with a torque wrench Observe the manufacturer s torque limits and l...

Страница 112: ...on t think availability means compatibility Here are some factors affecting compatibility 1 A compatible handlebar stem must be compatible for use with both steerer and handlebar 2 The stem must be de...

Страница 113: ...of the steerer tube to avoid placing a clamping force on the steerer tube which could produces cracks Alternatively you can clamp the steerer in grooved wooden blocks positioned in vice Do not over ti...

Страница 114: ...114 PART 2 Carbon Fiber Forks Stems 138692 Rev 0 04 22 Section A Important Safety Information GT Bicycle Owner s Manual This page has been left blank intentionally...

Страница 115: ...ycles that mix features For example we have road racing bikes with triple cranks These bikes have the low gearing of a touring bike the quick handling of a racing bike but are not well suited for carr...

Страница 116: ...aphic and description text directly from the standard ASTM F2043 Suitable for road riding only ASTM F2043 For off road riding and jumps less than 12 30cm ASTM F2043 For rough off road riding and jumps...

Страница 117: ...ver both light weight and specific performance You must understand that 1 these types of bikes are intended to give an aggressive racer or competitive cyclist a performance advantage over a relatively...

Страница 118: ...118 PART 2 Intended Use 138692 Rev 0 04 22 Section B Intended Use GT Bicycle Owner s Manual This page has been left blank intentionally...

Страница 119: ...mps should be limited to 30cm 12in or less Graphic For off road riding and jumps less than 12 30cm INTENDED For paved roads gravel or dirt roads that are in good condition and bike paths NOT INTENDED...

Страница 120: ...so work well for all weather rough road riding and commuting NOT INTENDED For off road or mountain bike use or jumping Cyclocross riders and racers dismount before reaching an obstacle carry their bik...

Страница 121: ...like roots rocks loose surfaces and hard pack and depressions There are no large sick drop or drop offs jumps or launches wooden structures dirt embankments requiring long suspension travel or heavy d...

Страница 122: ...ve more suspension travel than a cross country bike allowing them to be ridden in more difficult terrain over larger obstacles and moderate jumps 4 intermediate in suspension travel and use components...

Страница 123: ...be hardcore mountain north shore slopestyle This is extreme riding and the terms describing it are constantly evolving Gravity Freeride and Downhill bikes are 1 heavier and have more suspension travel...

Страница 124: ...y BMX bikes A Dirt Jumping bike does not give you skills to jump Read our Freeride Downhill warning See page 64 The same message is true NOT INTENDED For terrain drop offs or landings where large amou...

Страница 125: ...off road is a process It does not automatically occur because you have a mountain bike Learning to ride off road does not come from watching extreme mountain bike videos or TV In fact the riders in t...

Страница 126: ...nt of skill Some of the riders you see are well paid pros who have gradually built up their skills through endless hours of practice and who have also had their share of stitches concussions and buste...

Страница 127: ...e part of the sport we communicated frankly about the risks in this freeride warning Givem very strong consideration to neck braces designed for mountain biking and motocross riding fitted between the...

Страница 128: ...ping related damage is your fork Riders who insist on jumping their bikes risk serious damage to their bicycles as well as themselves Stay In Control WARNING Failure to ride in control could result in...

Страница 129: ...t How often this more detailed inspection is needed depends upon you You the rider owner have control and knowledge of how often you use your bike how hard you use it and where you use it Because a bi...

Страница 130: ...um is not perfectly corrosion resistant and particular care must be used where it contacts other metals and galvanic corrosion can occur Metals are comparatively ductile Ductile means bending buckling...

Страница 131: ...he frame is damaged Above some load the carbon fork will be completely broken Metal Fatigue 101 Common sense tells us that nothing that is used lasts forever The more you use something and the harder...

Страница 132: ...ce we want requires that we inspect the structure In most cases a fatigue crack is not a defect It is a sign that the part has been worn out a sign the part has reached the end of its useful life When...

Страница 133: ...ng sign that a crack exists SIMPLE RULE 3 Inspect and investigate any staining to see if it is associated with a crack SIGNIFICANT SCRATCHES GOUGES DENTS OR SCORING CREATE STARTING POINTS FOR CRACKS T...

Страница 134: ...eed to inspect The more you fit the lengthen product life profile the less frequent your need to inspect Factors that shorten product life Hard harsh riding style Hits crashes jumps other shots to bik...

Страница 135: ...inspect the area where the crankset and rear wheel come closest to the right chainstay particularly on the innermost part of the chainstay and the outermost part of the chainstay Next look at the wel...

Страница 136: ...ot bosses or caliper mount Other Suspension Forks If you have a fork made by a third party please read and follow the inspection instructions contained in the manual that covers that fork If you do no...

Страница 137: ...num 2 75 grams cm3 Contrast these numbers with carbon fiber composite at 1 45 grams cm3 The composites with the best strength to weight ratios are made of carbon fiber in a matrix of epoxy plastic The...

Страница 138: ...e momentum carrying you over the front of the bike You cannot and will not stay on the bike and what happens to the frame and fork is irrelevant to what happens to your body What should you expect fro...

Страница 139: ...or deformed shape If delamination occurs the surface shape may change The surface may have a bump a bulge soft spot or not be smooth and fair A difference in sound when tapping the surface If you gent...

Страница 140: ...by a handlebar rotating and striking the top tube is common The resulting impact cracks and breaks the top tube This is not a warranty The frame is not safe to ride Any impact or crash damage can prod...

Страница 141: ...erious injury paralysis or death If you have carbon fiber components you must read part ii section d 2 Understanding composites Do not ride any component with a crack even a small one Replace the comp...

Страница 142: ...handlebar mounted components Clean and inspect carefully for cracks Pay particular attention to the area where the handlebar emerges from the stem This is the area where virtually all handlebars will...

Страница 143: ...ost clean and inspect the rails carefully for cracks Check the saddle rails to the saddle body make sure that the rails are firmly attached Pedals Remove both from the crankset Clean and inspect caref...

Страница 144: ...ted Use in competitive events trick riding ramp riding jumping aggressive riding riding on severe terrain riding in severe climates riding with heavy loads commercial activities and other types of non...

Страница 145: ...lp you develop a complete maintenance program a program which includes a list of the parts on your bike for YOU to check regularly 2 All bicycles and bicycle components are subject to wear and stress...

Страница 146: ...trol cables and wheel spokes may stretch or seat when a new bike is first used and may require readjustment by a professional bike mechanic See also Mechanical Safety Check This section will help you...

Страница 147: ...ne pedal and rock it toward and away from the center line of the bike then do the same with the other pedal Anything feel loose If so have a professional bicycle mechanic check it Take a look at the b...

Страница 148: ...l secure and tighten any which are not Check the frame particularly in the area around all tube joints the handlebars the stem and the seatpost for any deep scratches cracks or discoloration These are...

Страница 149: ...lvents which can damage the finish or attack and destroy both the outside and internal parts When rinsing avoid directing the spray directly at shock fork adjusters or bearings Importance of Lubricati...

Страница 150: ...who has access to current and correct technical information WARNING Always use a correctly calibrated torque wrench to tighten critical fasteners on your bike Carefully follow the torque wrench manuf...

Страница 151: ...place your bike in a bike stand by clamping the frame Place your bike in a stand by extending the seat post and positioning the stand clamp on the extended seat post Don t extend beyond the MINIMUM I...

Страница 152: ...can produce a rocking motion or vibration of the attached cage A loose cage will damage the insert and possibly lead to the inserts to pull out It may be possible to repair a loose insert or install...

Страница 153: ...ke that is submerged or exposed to large amounts of water will require a complete bearing overhaul to prevent extensive and expensive damage Shifting Gears While Pedaling CAUTION Shifting under extrem...

Страница 154: ...d cracked or dented by the clamps and support systems of a bike rack Both carbon and aluminum can suffer serious abrasion damage by the movement of the bike in the rack during transport All damage to...

Страница 155: ...any other part of the frame Suitable for both carbon and aluminum frames Be sure quick release on rack is properly adjusted and tightly closed The Thule Echelon with ETC Equalized Twin Cam is suitabl...

Страница 156: ...thinner dropout may move in the rack causing wear and abrasion The fork blade attached to the thicker dropout takes most of the loads caused by 70 mile per hour wind and bumps The result may be damage...

Страница 157: ...e Substitute a heavy classic all steel quick release and clamp it tight Relative movement will wear parts weaken and damage your bike Note that many modern quick releases will not fit the clamping con...

Страница 158: ...e frame Applying Frame Protection Some areas of your bicycle require protection from abrasion If protection is not in place damage can result Please consult with your Authorized GT Dealer about the re...

Страница 159: ...Right Chainstay Plate On mountain or road bikes the chainstay plate 1 is located on the right chainstay 2 just behind the chainrings 3 This plate protects the carbon composite chainstay from damage i...

Страница 160: ...untain or road bikes the chainstay protector is a clear adhesive film applied to the upper surface of the right chainstay This protector can prevent damage to the chainstay caused by the chain Figure...

Страница 161: ...s available from a variety a different sources described in the next section WARNING Failure to assemble and adjust your bike correctly could lead to an accident with risk of serious injury paralysis...

Страница 162: ...turer of that component You can identify the make and model of a component and can access instructions on that manufacturer s website For example Shimano https si shimano com SRAM https www sram com e...

Страница 163: ...y stand Exactly which of these tools you will need will depend upon the model of bike you are assembling Details regarding particular tools are covered in the particular sections of these assembly ins...

Страница 164: ...ube You may need to slightly loosen the clamp bolt or quick release clamping mechanism Aluminum frames Grease inside the seat tube and on the seat post Grease prevents corrosion which can cause a seat...

Страница 165: ...165 PART 3 STEP 5 Installing the Seatpost And Saddle Assembling Your Bike GT Bicycle Owner s Manual Hidden Clamp Bolt Clamp Bolt Seat Clamp Quick Release Seat Clamp...

Страница 166: ...you see or feel it contact the frame 3 Try closing the lever Your goal is to tighten the adjusting nut enough so that the lever can be closed but requires significant force to close You want it to be...

Страница 167: ...ved all packaging this assembly will be loose Two packaging methods are used A stem is attached to steering tube With this method you will install the handlebars using the face plate on the stem B Ste...

Страница 168: ...in place Then install all faceplate bolts through the faceplate and into the stem Most handlebars have markings that make it easier to center the handlebars Just snug the bolts enough to hold the ass...

Страница 169: ...STEP 6 Installing the Handlebar And Stem Assembling Your Bike GT Bicycle Owner s Manual Yes Housing is seated inside No Housing is not seated inside Yes Housing is seated inside No Housing is not sea...

Страница 170: ...s at a 45 degree angle with the ground On a road bike with drop bars B most riders like the handlebar set where the flat area at the top or the bottom of the handlebar is parallel to the ground Final...

Страница 171: ...171 PART 3 STEP 6 Installing the Handlebar And Stem Assembling Your Bike GT Bicycle Owner s Manual A B...

Страница 172: ...ese bolts using a torque wrench to the torque value marked on the stem If no torque marking is present tighten to 7Nm Method B Stem is attached to the handlebars Remove the plastic fork protector from...

Страница 173: ...top of the stem Thread the bolt into the threaded fitting inside the steering tube Snug this bolt with the 5 mm allen wrench Rock the bike forward and back a bit and snug this bolt to eliminate play...

Страница 174: ...abs up Place bolts through the holes in the disc brake rotor and thread each one into the threaded holes in the hub Each bolt will have some thread retaining compound on the threads often blue color T...

Страница 175: ...ock ring There are two common designs a internally driven lock rings use a 12 spline tool also used for cassette lockrings e g the Park FR 5 2 b externally driven lock rings use a 16 notch tool also u...

Страница 176: ...l Front Wheel GT Bicycle Owner s Manual 8 Install Front Wheel Identify your wheel attachment system and follow the instructions for that system There are six common systems A Quick Release B Tool Driv...

Страница 177: ...PART 3 STEP 7 Installing Brake Disc to Wheel Hub 8 Install Front Wheel GT Bicycle Owner s Manual A Quick Release B Tool Driven Quick Release C Thru Axles D Thru Axles Pinch Bolts F Nutted Bolt On E Le...

Страница 178: ...the quick release assembly and note the sequence and orientation of parts adjusting nut conical spring skewer a second conical spring and finally the quick release lever assembly Remove the adjusting...

Страница 179: ...er the threaded end of the skewer small end first If quick release has a cam follower a semicircular separate part be sure it is properly aligned Yes Semicurcular shape aligned with shaped lever No Se...

Страница 180: ...the brake pads will need to be pushed outwards to allow the wheel to be installed Rim brakes two types Before installing the front wheel if the front brake is V Brake aka Linear pull or Caliper it ma...

Страница 181: ...ront wheel under the fork First align the brake rotor the shiny disc attached to the wheel with the brake caliper the part mounted to the fork As you lower the fork carefully position the wheel so tha...

Страница 182: ...the bike and hold the bike upright When fully and properly engaged you will see that the wheel is centered in the fork that there is the same amount of space between the tire and the inside of the for...

Страница 183: ...ing until you feel it contact the face of the dropout Next try closing the lever Your goal is to tighten the adjusting nut enough so that the lever can be closed but requires significant force to clos...

Страница 184: ...ons on our SUPPORT page at www gtbicycles com Exact URL https support gtbicycles com hc en us sections 1500000666522 Assembly WARNING Securely clamping the wheel with a cam action retention device tak...

Страница 185: ...pecial nut that is turned by a 5mm allen wrench Remove the adjusting nut and the first conical spring Pick up the front wheel Examine the sidewall of the tire to see if the tread design is directional...

Страница 186: ...curved cable guide fits into the bracket After you disconnect the brake arms and pads will spring outward creating more space for the wheel Placing wheel in fork If your bike has Disc brakes Lift the...

Страница 187: ...roperly engaged you will see that the wheel is centered in the fork that there is the same amount of space between the tire and the inside of the fork on both sides Next hold the adjusting nut station...

Страница 188: ...ideo instructions on our SUPPORT page at www gtbicycles com Exact URL https support gtbicycles com hc en us sections 1500000666522 Assembly C Through Axle Type For shipping the through axle will be th...

Страница 189: ...eel so that the brake rotor fits into the slot in the brake caliper Next lower the fork further and align the hub axle ends with the fork dropouts Be sure that the axle at both ends of the hub is full...

Страница 190: ...ections 1500000666522 Assembly D Through Axle Pinch bolt Type This type uses a threaded through axle as described in E that is then also clamped in place by pinch bolts in the fork dropouts This type...

Страница 191: ...with the dropouts on the fork Push down on the front of the bike and hold the bike upright When fully and properly engaged you will see that the wheel is centered in the fork that there is the same a...

Страница 192: ...192 PART 3 D Through Axle Pinch bolt Type 138692 Rev 0 04 22 8 Install Front Wheel GT Bicycle Owner s Manual...

Страница 193: ...193 PART 3 D Through Axle Pinch bolt Type 8 Install Front Wheel GT Bicycle Owner s Manual...

Страница 194: ...194 PART 3 F Nutted or Bolt On Type 138692 Rev 0 04 22 8 Install Front Wheel GT Bicycle Owner s Manual F Nutted or Bolt On Type Tabbed washer inserted into dropout hole Tabbed washer Tabbed washer...

Страница 195: ...f the hub is fully engaged with the dropouts on the fork Push down on the front of the bike and hold the bike upright When fully and properly engaged you will see that the wheel is centered in the for...

Страница 196: ...ions 1500000666522 Assembly STEP 9 Front Brake Assembly Adjustment There are two basic types of brakes 1 disc brakes where you see a large shiny disc brake rotor Some disc brakes are mechanically cabl...

Страница 197: ...sing properly is an important safety step to keep it from interfering with the front wheel Now thread the cable into the cable anchor bolt fitting on the front brake caliper You may need to open this...

Страница 198: ...ble 2 They prevent the cable strands from separating fraying Pro Tip We urge you to borrow or buy a proper bicycle cable cutter These tools have a v shaped or circular jaws that keep the cable strands...

Страница 199: ...he bike and spin the front wheel Do you see or hear dragging from the front brake Likely much less or no dragging If no drag no noise torque the two 5mm caliper mounting bolts to 7 Nm If there is some...

Страница 200: ...will reduce the clearance by moving the brake pad in Turning the screw counter clockwise will increase clearance eliminate drag by moving the brake pad out Your goal is to have clearance between the s...

Страница 201: ...ront wheel Apply the front brake very firmly Hold the front brake lever on very firmly with one hand do not let go With your other hand use the 5mm allen wrench to tighten the two caliper mounting bol...

Страница 202: ...essing firmly against the rim Re attach the curved brake cable guide often called a noodle to the bracket that holds it The smaller diameter lower end of this curved cable guide fits into a slot in th...

Страница 203: ...brake pads should fully contact the rim or brake rotor within 1 inch of brake lever movement The brake lever must never bottom out or contact the handlebar or handlebar grip For caliper and linear pul...

Страница 204: ...204 PART 3 V brakes also Linear Pull 138692 Rev 0 04 22 STEP 9 Front Brake GT Bicycle Owner s Manual Correct alignment Incorrect alignment...

Страница 205: ...changeable have different threading Do Not force the wrong pedal into the wrong crank arm Many crank arms have a removable sticker near the pedal threads so you can match the left and right pedal thre...

Страница 206: ...ner s Manual LEFT PEDAL Turn counter clockwise to install RIGHT PEDAL Turn clockwise to install Lightly grease the both pedal threads before installing Use pedal washer if present between pedal and cr...

Страница 207: ...clockwise direction toward the front Tighten securely with a pedal wrench or 15mm open end wrench Make them very tight Stand on the right side of the bike side with the chain take the threaded end of...

Страница 208: ...ntil your feet lift off the floor The handlebar should not move On a flat handlebar slowly apply body weight to handlebars if installed handlebar ends until your feet lift off the floor The handlebar...

Страница 209: ...sistance DO NOT RIDE THE BIKE Figure Handlebar Twist Test Seat Post Security Before riding the bike test to determine whether the seat and seat post are secure Firmly grab the front of the seat and tr...

Страница 210: ...TECH HELP Rockshox forks www sram com go to Rockshox then SERVICE SUPPORT SR Suntour forks www srsuntour us go to PRODUCT SUPPORT Full suspension Some mountain bikes have full suspension meaning fron...

Страница 211: ...nd we urge you have it properly adjusted and set up and maintained by Authorized Dealer Dropper seat posts Some mountain bikes come with cable actuated dropper seat posts that allow the rider to chang...

Страница 212: ...rations and warnings and the use and maintenance of electric drive train battery You have invested in such a bike and we urge you have it properly adjusted and set up and maintained by your local reta...

Страница 213: ...e up This is an ideal time to fine tune your fit if you bike has an adjustable stem STEP 15 Final Inspections Checklist Before riding please review this checklist Sit down put your feet up and read th...

Страница 214: ...brakes too hard Shift though all the gears up and down Anticipate hills and shift before pedaling gets too hard After shifting is complete is the bike quiet in all gears How do you fit on the bike Is...

Страница 215: ...o the safety of the rider Failure to do so correctly could lead to an accident with serious injury paralysis or death If you have any questions or any doubts about any aspect of the assembly of this b...

Страница 216: ...thorized GT Retailer in order to activate the lifetime frame warranty described below Frames excluding those listed below Lifetime of the original owner Frames of Gravity Freeride Downhill Dirt Jump a...

Страница 217: ...al or bike sharing program Damage resulting from normal wear and tear including the results of fatigue is not covered It is the owner s responsibility to regularly inspect and properly maintain his he...

Страница 218: ...IPTION HEREIN ANY WARRANTIES THAT MAY OTHERWISE BE IMPLIED BY LAW INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED PLEASE REFER TO...

Страница 219: ......

Страница 220: ...d Tubes Are your wheels true Lift each end of the bike and spin each wheel Does the space between the rim and the brake pads or the tire and the frame remain nearly the same size as the wheel turns Ar...

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