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InstructIon Manual

Torque Requirements

When performing routine adjustments on nuts and bolts it is

recommended that a torque wrench be used to prevent over

tightening and damage to the threads. the following are key

components that should be tightened using a torque wrench.

component

Torque

Front axle nuts

22-27 newton Metres

Rear axle nuts

24-29 newton Metres

Handlebar clamp nut

17-19 newton Metres

8-10 newton Metres if road/

racing bikes

Head stem expander bolt

17 - 19 newton Metres

seat clamp nuts

18-25 newton Metres

seat post binder nut

15-19 newton Metres

8-10 newton Metres if road/

racing bikes

Brake cable fixing nut

7-11 newton Metres

Brake caliper centre bolt nut

5-10 newton Metres

cotterless crank nut

27 newton Metres

Tools Required

open ended or ring spanners:
8mm, 9mm, 10mm, 12mm, 13mm,

14mm, 15mm

open end or pedal spanner 15mm

allen key wrenches: 4mm, 5mm, 6mm

adjustable wrench

Standard flat head screwdriver

Standard Phillips head screwdriver

standard slip joint pliers

Crank remover

Torque wrench with

newton Meter gradations

10 tyre pump
11 tube repair kit

12 Tyre levers

SERVICING

Содержание Adult Bicycles

Страница 1: ...1 INSTRUCTION MANUAL Instruction Manual BIKE SERVICE INFORMATION 0800 445 313...

Страница 2: ......

Страница 3: ...WAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE DO NOT RIDE AT NIGHT AVOID RIDING IN WET CONDITIONS CORRECT FITTING YOUR HELEMET MUST COVER YOUR FOREHEAD INCORRECT FITTING FOREHEAD IS EX...

Страница 4: ...hased Place of Purchase Brand Model Name Wheel Size Colour Serial Number Your serial number may be located in one of the following locations Toll free service information number 0800 445 313 Rear Left...

Страница 5: ...ntenance of your new bicycle If you have any doubt or difficulty with any of the tasks described please call our toll free service information number on 0800 445 313 Please read the Manual thoroughly...

Страница 6: ...ssbikes 8 Suspension Bicycles 9 BMX Loop Frame U Frame Bicycles 10 ASSEMBLY 11 Derailleur Geared Bicycles 12 Single Geared Bicycles 17 BEFOREYOU RIDE 23 Correct Frame Size 23 Riding Position 24 Saddle...

Страница 7: ...quired 43 DETAILED MAINTENANCE 44 Wheels and Tyres 44 Wheel inspection 44 Tyre inspection 45 Recommended tyre pressures 45 Front wheel removal and replacement 46 Rear wheel removal and replacement 47...

Страница 8: ...rm Chainwheel Fenders Spokes Chainguard Down Tube Front Brake Brake Pad Wheel Reflector Fork Tire Rim Rear Reflector Bicycles are available in a variety of different styles and sizes designed for diff...

Страница 9: ...ed for fast travel over long distances on paved surfaces Seat Post Seat Quick Release Seat stays Rear Derailleur Gear Control Cable Chain Chainstay Pedal Crank Arm Chainwheel Front Derailleur Bottom B...

Страница 10: ...crossbike or hybrid This style of bicycle is lighter than a mountain bicycle but not as fast as a racing bicycle It combines some of the features of comfort and control with lighter weight and higher...

Страница 11: ...fitted with a special shock absorbing seat pillar or even a handlebar stem to cushion and relieve road shocks and add to rider comfort Like standard mountain bikes wide handlebars and conveniently po...

Страница 12: ...styles of frames such as the loop frame and the U shape frame PARTS IDENTIFICATION Seat Seat Post Seat Post Binder Bolt Seat Stay Rear Reflector Wheel Reflector Chain Wheel Crank Arm Pedal Rim Tire T...

Страница 13: ...ction lubrication maintenance additional tools needed and adjustment of any area please refer to the relevant section elsewhere in this manual You will need the following tools Spanners ring or open e...

Страница 14: ...e fork blade 4 Install axle nut and securely tighten Make sure the wheel is centered between the fork blades 5 Spin the wheel to make sure that it is centered and clears the brake shoes Tighten the br...

Страница 15: ...fork steerer tube If these instructions are not followed it could cause an unsafe condition and risk injury to the rider Check steering tightness prior to riding by straddling the front wheel Try tur...

Страница 16: ...lly engaging the thread initially by hand Note that the right hand pedal attaches to the chain wheel side crank with a right hand clockwise thread The left pedal attaches to the other crank arm and ha...

Страница 17: ...o set the brake shoes to within 2mm of and parallel to the rim with the brake arms in a vertical position Position the drum shaped end button of the control cable into the hand brake lever Loosen the...

Страница 18: ...lamp the front and rear derailleur control cables are firmly fastened Only then test the gears ensuring the drive chain moves freely into each position when the control levers are activated If further...

Страница 19: ...offers an important measure of safety Front Wheel 1 Make sure the brakes are loose enough to allow the wheel to pass through the brake pads easily 2 Place wheel into fork drop outs 3 Install retainin...

Страница 20: ...l Axle Nut Metal locating bracket Frame ASSEMBLY ASSEMBLY Note Some models may come packed with the stem pointing up Loosen the stem handlebar binder bolt s and rotate the stem so that the neck is poi...

Страница 21: ...icycle observing the minimum insertion mark on the pillar 3 Tighten with a spanner or torque wrench 4 The bicycle may be equipped with seat binder bolt or quick release QR please refer to seat section...

Страница 22: ...y contact squarely with and are aligned parallel to the rim surface Firmly squeeze the control lever and check the brake pads are 1 5mm to 2mm away from the rim each side after lever is released If cl...

Страница 23: ...he spokes of both wheels directly opposite the valve stem and within 76mm of the rim Attach the white reflector to the front reflector bracket and the red reflector to the rear reflector bracket using...

Страница 24: ...ned securely and that the reflectors are properly angled Pads If your bike is supplied with pads wrap the foam inner cushion around the appropriate bar Place the outer cover over the inner cushion and...

Страница 25: ...ody and leg lengths vary a lot even in same age groups Kid s bikes come in different wheel sizes and there are different frame styles such as Y Frames to suit the rider s size Most full sized gent s b...

Страница 26: ...to be slightly bent in this position If the rider then places the heel of that foot on the pedal the leg should be almost straight Reach To obtain maximum comfort the rider should not overextend his o...

Страница 27: ...way from the wheel rim when you change stem height take your bicycle to your dealer for correct brake adjustment before riding it WARNING Failure to properly tighten the stem binder bolt the handlebar...

Страница 28: ...n and are correctly positioned in relation to the rims Ensure brake control cables are lubricated correctly adjusted and display no obvious wear Ensure brake control levers are lubricated and tightly...

Страница 29: ...he frame and fork are not bent or broken If either are bent or broken they should be replaced Suspension Check that all components of fork and rear suspension if fitted are correctly tightened Check t...

Страница 30: ...ty seat they must also be wearing a helmet A bicycle helmet must be labeled with the New Zealand Standards approved mark The right helmet should Fit correctly Be comfortable Be lightweight Have good v...

Страница 31: ...brake from the fork Insert a spacer washer and the reflector bracket on to the caliper bolt Insert the caliper bolt back into the fork and secure firmly with a concave spacer washer and the hex nut F...

Страница 32: ...Mount Reflector Bracket Assembly First insert one washer onto the hex bolt and insert bolt through the re ector bracket and then through the Seat Stay bridge Next insert a second washer onto the bolt...

Страница 33: ...cle across Expect the unexpected such as opening car doors or cars backing out of concealed driveways Be extra careful at intersections and when preparing to pass other vehicles Familiarize yourself w...

Страница 34: ...ctioning lighting set comprising a white front lamp and a red rear lamp If using battery powered lights make sure batteries are well charged If using dynamo powered lights ensure wiring is properly co...

Страница 35: ...t pedal through fast or tight corners Rules For Children To avoid accidents teach children good riding skills with an emphasis on safety from an early age Always wear a properly fitting helmet Do not...

Страница 36: ...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 the left shift lever and the rear derai...

Страница 37: ...LTD ABN 53 098 742 708 29 Thumb Shifters Top Mounted Most MTB style bicycles are equipped with shifters mounted on the top of the handlebars and operated by the thumbs To select a lower easier gear s...

Страница 38: ...ilt into the handlebar grips and does not make use of separate levers The actuating mechanism is built into the inside part of the grip that the web of the thumb and index finger closes around To sele...

Страница 39: ...WARNING Never shift a mal adjusted derailleur onto the largest or the smallest sprocket The chain could jam causing you to lose control and fall 20067_OWNERS MANUAL qxp 08 03 2006 10 38 AM Page 31 Dua...

Страница 40: ...le and apply anti rust treatment If the hub and bottom bracket bearings of your bicycle have been submerged in water they should be taken out and re greased This will prevent accelerated bearing deter...

Страница 41: ...ocated on the frame underneath the bottom bracket 2 Register the bicycle with the manufacturer distributor and local police 3 Invest on a high quality bicycle lock that will resist hack saws and bolt...

Страница 42: ...r bicycle it s condition changes The more you ride the more frequently maintenance will be required We recommend you spend a little time on regular maintenance tasks The following schedules are a usef...

Страница 43: ...can Brake callipers Oil 3 drops from oil can Brake levers Oil 2 drops from oil can Monthly Shift levers Lithium based grease Disassemble Brake cable ends Oil 1 drop from oil can 6 Monthly Hubs Lithiu...

Страница 44: ...looseness Check derailleur adjustment Check pedals are tight Check brake adjustment Check handlebars are tight Check brake and gear cable adjustment Check seat and seat post are tight and comfortably...

Страница 45: ...17 19 Newton Metres Seat clamp nuts 18 25 Newton Metres Seat post binder nut 15 19 Newton Metres 8 10 Newton Metres if Road Racing bikes Brake cable fixing nut 7 11 Newton Metres Brake caliper centre...

Страница 46: ...spokes Check that all spokes are tight and that none are missing or damaged Caution Such damage can result in severe instability and possible a crash if not corrected Again spoke repairs are best han...

Страница 47: ...r hose pressure settings are genera and should not be depended on for consistent accurate pressure Instead use a good quality dial gaug 20067_OWNERS MANUAL qxp 08 03 2006 10 38 AM Page 38 PBLF 09 PACI...

Страница 48: ...placement 1 Replacement follows almost the reverse sequence to removal 2 Place the wheel into the frame ensuring that the axle fits well up against the fork end slots You may need to slightly prise ap...

Страница 49: ...ding the unit fully back Feed the top part of the smallest hub cog into the top part of the chain and fit the wheel into the frame 3 For single geared bicycles lift the chain over the axle and onto th...

Страница 50: ...loose wheels Warning Riding with an improperly adjusted wheel quick release can allow the wheel to wobble or disengage from the bicycle causing damage to the bicycle and serious injury or death to th...

Страница 51: ...istance to turning it beyond that point If resistance is not firm then further tighten the adjusting nut in a clockwise direction 4 Continue to pivot the lever all the way to the closed position so th...

Страница 52: ...urself 1 Remove the wheel from the frame 2 Remove the axle nut cone lock nut and the bearing cone from one side of the hub axle 3 Remove the axle complete with cone and locknut from the other side of...

Страница 53: ...ate the leaks and patch using a tube repair kit carefully following the instructions or replace the tube Note Ensure the replacement tube size matches the size stated on the tyre sidewall and the valv...

Страница 54: ...ely in position 14 Fit the rest of the tyre rolling the last most difficult part on using your thumbs Note Avoid using tyre levers as these can easily puncture the tube or damage the tyre 15 Check tha...

Страница 55: ...ape and check the tyre bead is evenly seated all the way around the rim When properly seated fully inflate the tyre to the pressure marked on the sidewall Use a tyre air pressure gauge to check 17 Rep...

Страница 56: ...be adjusted to suit your comfort preference Refer to BEFORE YOU RIDE section If the stem is removed from the steering column you will notice a mark about 65mm up from the bottom with the words max he...

Страница 57: ...e handlebars and forks are facing the front Tighten down the steering assembly via the Allen head centre bolt so there is no freeplay Do not overtighten Tighten up the binder bolts which clamp the han...

Страница 58: ...ssembly Racing Handlebar Assembly Note curved rake of fork faces forward Direction of travel Make sure handlebars and fork are facing forward 0067_OWNERS MANUAL qxp 08 03 2006 10 39 AM Page 46 When re...

Страница 59: ...k is binding then an adjustment will need to be made to the headset Move the fork in a push pull manner checking for tightness If any play is detected loosen the top nut adjust the bearing cup and ret...

Страница 60: ...justment and maintenance instructions Suspension systems may include suspension seat posts and suspension handlebar stems that are designed to provide a more comfortable ride WARNING Failure to check...

Страница 61: ...mance of your bicycle by taking a careful test ride in a hazard free area If your bike has suspension equip ment the increased speed you may develop also increases your risk When braking the front of...

Страница 62: ...a season Please note that on some models the drive side crank arm must be removed from the spindle before attempting to work on the pivot After removing the fixing bolt the bushings may need to be tap...

Страница 63: ...et it will need adjustment Check that the headset is not overtight by slowly rotating the fork to the right and left If the fork tends to stick or bind at any point the bearing are too tight Adjustmen...

Страница 64: ...e forks with one hand and remove the adjusting cup followed by the upper ball retainer 5 Pull the forks out of the frame and remove the lower ball retainer 6 Thoroughly clean and inspect for damage ea...

Страница 65: ...ighten the locknuts at this time LOWER CABLE 1 Slide the cable casing through the cable guide on the frame 2 Connect the lower cable to the lower plate by passing the football ends of the lower cable...

Страница 66: ...position then quickly rotate the handlebars back and forth NOTE The bearing should never be allowed to rest on the lower plate or lower cable adjusting barrels a Screw the lower cable adjusting barre...

Страница 67: ...ally be found WARNING After any saddle adjustment be sure tighten the saddle adjustment mechanism properly before riding A loose saddle clamp or seat post binder can cause damage to the seat post or c...

Страница 68: ...bolt may be either a hexagonal bolt an Allen head bolt or a quick release mechanism The operation of a seat post is the same as for Quick Release Hubs Test the security by grasping the seat and tryin...

Страница 69: ...bicycle with the seat post raised beyond the minimum insertion max height mark Inspection Brake levers should be checked for tightness at least every three months They should be set in a comfortable p...

Страница 70: ...you may have to adjust the cable length Screw the barrel adjuster 3 4 of the way in squeeze the pads against the rim undo the cable anchor bolt and pull the cable through with pliers Re tighten the c...

Страница 71: ...r bolt 20067_OWNERS MANUAL qxp 08 03 2006 10 41 AM Page 55 PBLF 09 PACIFIC BRANDS SPORT LEISURE PTY LTD ABN 53 098 742 708 55 Brake pads should finally be adjusted so that the leading edge of the pad...

Страница 72: ...ices to prevent a possible accident in the event of the brake control cable or the straddle bridge becoming loose or breaking whilst riding These are usually the reflector brackets and must be fitted...

Страница 73: ...tment Linear Pull Brakes 1 If assembling linear pull brakes insert the brake body into the centre spring hole in the frame mounting boss and then secure the brake body to the frame with the link fixin...

Страница 74: ...the balance with the spring tension adjustment screws 6 Depress the brake lever about 10 times as far as the grip and check that everything is operating correctly and that the shoe clearance is corre...

Страница 75: ...and adjust the shoe rim leaving clearance of 1 5mm on both sides c Tighten the straddle cable with the cable fixing nut Tightening torque should be 50 to 70 kgf cm d Cut off the excess straddle cable...

Страница 76: ...able be sure to refasten the anchor bolt after adjusting the cable Always replace brake shoes in pairs never one side only Before riding test brakes to ensure they are effective Brake shoes must have...

Страница 77: ...e wear line indication To replace first remove the worn brake shoes after disconnecting the holding mechanism Depending on the type of brake as described on previous pages the holding mechanism may be...

Страница 78: ...low access to the internal bearings and axle However it is usually possible to inject a little oil onto the inside bearings and this should be done every six months If the pedal is the type that can b...

Страница 79: ...e fully disassembled then the bearings should be removed cleaned and greased every six to twelve months Because of the wide variety of pedal types and their internal complexity disassembly procedures...

Страница 80: ...le is screwed all the way in then securely tighten using a 15mm wrench If removing a pedal remember that the right pedal axle must be turned counter clockwise and the left clockwise ie the reverse of...

Страница 81: ...side to side with your hands The cranks should not move on the axle and there should be only very slight movement in the bottom bracket Next spin the cranks If they don t spin freely without grinding...

Страница 82: ...spindle clockwise 3 Remove the left side locknut by turning it clockwise and remove the keyed lockwasher 4 Remove the adjusting cone by turning it clockwise with a screwdriver 5 Remove the left ball...

Страница 83: ...turning it counter clockwise and remove the right ball retainer Clean and inspect all bearing surfaces and ball retainers and replace any damaged parts Pack the ball bearing retainers with grease the...

Страница 84: ...rank arm lightly with a mallet 3 Re tighten the flange nuts and refit the dust caps New cotterless cranks may become loose with initial use Perform the following task after several hours riding and re...

Страница 85: ...b brake or 3 speed hub geared bicycles 1 Loosen the rear 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 adjust...

Страница 86: ...ailleur cage with 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 too far through side plate Some new ty...

Страница 87: ...er hub sprocket clean and oil it along with the chain Make sure the brake arm is correctly attached to the chainstay with the brake arm clip The brake will not operate otherwise PBLF 09 PACIFIC BRANDS...

Страница 88: ...supplied with your bike otherwise please refer to a specialist bicycle mechanic Inspection The operation of the derailleur system should be checked at least every month Check the operation of the rea...

Страница 89: ...the cable taut and re tighten the bolt Detailed maintenance 34 ASSEMBLY Derailleur Although the front and rear derailleurs are initially adjusted at the factory you will need to inspect and possibly...

Страница 90: ...inst the third gear This completed the adjustment After a period of use the derailleur cable will stretch and you may find difficulty shifting the chain to the large freewheel cog or the large chain w...

Страница 91: ...sting screw counter clockwise If the chain falls off either the inner or outer chainring turn the appropriate adjusting screw clockwise If the chain will not shift onto either the inner or outer chain...

Страница 92: ...ting brackets from your bicycle They are an integral part of the bicycle s safety system Removing the reflectors may reduce your visibility to others using the roadway Being struck by other vehicles o...

Страница 93: ...all bags available are designed to fit on the handlebars or in the corner of the main frame where they double as a shoulder pad if carrying the bicycle 4 Child Safety Carrier The only way to carry chi...

Страница 94: ...e many kinds of bicycle locks available some more effective than others Always lock your bicycle to an immovable object if you leave it unattended 10 RearView Mirror A very useful item to keep you awa...

Страница 95: ...e fitting accessories to your bike can add enjoyment to your cycling experience it is strongly recommended that any adjustments or actions that would change your normal riding position should be avoid...

Страница 96: ...kets and chain Replace chain Lubricate or replace link Seek advice at a bicycle shop Chain jumping off freewheel sprocket or chainring Chainring out of true Chainring loose Chainring teeth bent or bro...

Страница 97: ...les are binding stretched damaged Brake levers are binding Brakes out of adjustment Replace brake blocks Clean blocks and rim Clean adjust replace cables Adjust brake levers Centre brakes When applyin...

Страница 98: ...ed after previous puncture Tyre pressure too low Spoke protruding into rim Replace inner tube Replace tyre Replace with correct tyre Remove sharp object embedded in tyre Correct tyre pressure File dow...

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