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65

Cables and Cable Housing

Cables and housing are one of the most overlooked
parts on the bicycle. The first indication that your
cables and housing need to be replaced is an
increased amount of pressure needed to 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. It is recommended
that the cables and housing are replaced at least
every riding season to prolong the life of your bike.

Do not ride a bicycle that is not
operating properly.

kink

fray

good cable

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Страница 1: ...ELMET COVERS YOUR FOREHEAD INCORRECT FITTING FOREHEAD IS EXPOSED AND VULNERABLE TO SERIOUS INJURY ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE DO NOT RIDE AT NIGHT AVOID RIDING IN W...

Страница 2: ...ations on your new bike Our Service Department is dedicated to your satisfaction with Pacific Cycle We want to help with any questions or comments you may have You can also reach us by email at servic...

Страница 3: ...s 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...

Страница 4: ...d clean reflectors Refer to p 82 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 c...

Страница 5: ...with 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 l...

Страница 6: ...the operating principles are the same The front derailleur is operated by the left shift lever and the rear derailleur by the right To operate you must be pedaling forward You can not shift derailleur...

Страница 7: ...rear cog You can shift one gear at a time by moving the Grip Shift one click or through multiple gears by continued twisting By twisting the left shifter forward or away from you a smaller chainwheel...

Страница 8: ..._____________________ _______________________________________________________________________ _______________________________________________________________________ __________________________________...

Страница 9: ...ence or ability to properly assemble repair or maintain 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 par...

Страница 10: ..._______Phone Number ________________________ Bicycle Model purchased __________________________________________________________ Store at which you purchased your bicycle ______________________________...

Страница 11: ...BICYCLE REGISTRATION 4902 HAMMERSLEY ROAD MADISON WI 53711 PLACE STAMP HERE Cut along dotted line before mailing Cut along dotted line before mailing...

Страница 12: ...Maintenance 58 90 Purchase Record and Warranty 104 105 Warning Important Take notice of this symbol throughout this manual and pay particular attention to the instructions blocked off and preceded by...

Страница 13: ...Cantilever with Straddle Cable 50 Check your Brakes 51 Training Wheels 5 1 Rotors 52 53 Final Check 54 4 SERVICING 55 57 Schedule 1 Lubrication 55 Schedule 2 Service Checklist 56 Tools Required 5 7 5...

Страница 14: ...more traction on rough surfaces The frame and fork on mountain style bicycles are much sturdier than those on racing style bicycles Top Tube Seat Seat Post Quick Release Seat Stay Rear Reflector Rear...

Страница 15: ...maintenance Seat Seat Post Seat Post Binder Bolt Seat Stay Rear Reflector Wheel Reflector Chain Wheel Crank Arm Pedal Rim Tire Tire Valve Chain Rear Sprocket Training Wheel Brake Lever Handlebar Brak...

Страница 16: ...ility to properly assemble this unit please consult a qualified specialist before riding If you need replacement parts or have questions pertain ing to assembly of your bicycle call the service line d...

Страница 17: ...Many of the warnings and cautions say you may lose control and fall Because any fall can result in seri ous injury or even death we do not repeat the warning of possible injury or death whenever the r...

Страница 18: ...ddling 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 women s model The following chart and...

Страница 19: ...beyond its Minimum Insertion or Maximum Extension mark If your seat post projects from the frame beyond these markings the seat post or frame may break which could cause you to lose control and fall A...

Страница 20: ...ed beyond this mark the stem may break or damage the fork s steerer tube which could cause you to lose control and fall Failure to properly tighten the stem binder bolt the handlebar binder bolt or th...

Страница 21: ...re sidewall Ensure 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...

Страница 22: ...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...

Страница 23: ...of the state where you ride and to comply with all applicable laws including properly equipping yourself and your bike as the law requires Reflec tors are important safety devices which are designed a...

Страница 24: ...eflectors Fork Mount Reflector Bracket Assembly First insert one washer onto the hex bolt and insert hex bolt through the reflector bracket and then through the fork Next insert a second washer onto t...

Страница 25: ...ld reflector assembly in place see the second diagram Finally adjust the reflector assembly in place Finally adjust the reflector such that it is upright and facing away from the bike Chainstay Mount...

Страница 26: ...use two levers operated by the thumb and index finger To select a lower gear push the larger lower right shifter with your thumb to engage a larger rear cog One firm push shifts the chain one cog con...

Страница 27: ...rosive 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 an...

Страница 28: ...ber and paint Don t cover with plastic as sweating will result which may cause rusting Please notice that your bicycle warranty does not cover paint damage rust corrosion dry rot or theft Security It...

Страница 29: ...illustrated Handlebars Remove the protective cap from the handlebar stem wedge and loosen the Allen key bolt using the 6mm Allen key Some models may use a 13mm hexagonal bolt instead of an Allen key b...

Страница 30: ...ontrol If the stem is not inserted into the top nut to at least the Minimum Insertion mark it is possible to over tighten the stem bolt and damage the fork steerer tube If these instruc tions are not...

Страница 31: ...gure 1 Handlebar with Grip Shifter Figure 2 Top mounted thumb shifter Failure to properly tighten clamping bolts may cause sudden movement of the component resulting in loss of steering control 1 2 Ba...

Страница 32: ...cian Check the tightness of the headset and the fork Rotate the fork checking for smoothness If it feels like the fork is binding then an adjustment will need to be made to the headset Move the fork i...

Страница 33: ...the seat clamp If there is a nut on both sides of the clamp tighten each one by alternating from one to the other Check for tight ness by twisting the seat from side to side and from front to back If...

Страница 34: ...attaches to the chainwheel side crank arm with a right hand clockwise thread The left pedal attaches to the other crank arm and has a left hand counter clockwise thread It is very important that you...

Страница 35: ...on Do not tighten the quick release by using the quick release lever like a wing nut If the quick release lever is moved to the closed position with no resistance clamping strength is insufficient Mov...

Страница 36: ...may be necessary to achieve the correct brake position 1 Install the cable into the link wire 2 Set the cable into the straddle holder 1 2 5 The wheel is tightly secured when the serrated surfaces of...

Страница 37: ...78 in lbs 6 If balance adjustment is necessary adjust with the spring tension adjustment screw 1 mm 10 mm wrench 5 mm Allen key Cable Anchor Bolt Touching End cap Cut off any unnecessary cable attach...

Страница 38: ...r opening The cable housing will then seat into the end of the noodle Slide the cable through the cable lead on the end of the left brake arm this will cause the noodle to fit into the lead Slip the b...

Страница 39: ...k fixing bolt 1 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 3 mm so that dimension A is kept at 39 mm or mor...

Страница 40: ...verything is operating correctly and that the shoe clearance is correct before using the brakes 6 Pass the inner cable through the inner cable lead Set the cable with a clearance of 1mm between each b...

Страница 41: ...uld be about 0 5 1 0 mm farther from the rim than the front portion of the brake pad Do not ride the bicycle until the brakes are functioning properly To test apply the brakes while trying to push the...

Страница 42: ...nsure the cable housing seats appropriately into the end of the barrel adjuster and check for any kinks or damage Slide the exposed brake cable through the rotating rod located on the caliper body and...

Страница 43: ...Centering Bolt inside These brakes require breaking in Ride and use the brakes gently for 13 miles before using the brakes in downhill conditions for sudden stops or any other serious braking Please...

Страница 44: ...you want the chain to go For example turning clockwise will loosen the cable tension and move the chain away from the wheel while turning counter clockwise will tighten cable tension and direct the c...

Страница 45: ...If the chain falls off the largest chainwheel and into the pedals you will need to turn the High limit screw in 1 4 turn increments clockwise until the chain no longer falls off Shift through every g...

Страница 46: ...do this may cause the mechanism to fail Failure to maintain check and properly adjust the suspension system may result in suspension malfunction which can cause you to lose control and fall Changing s...

Страница 47: ...be removed from the spin dle before attempting to work on the pivot Some models have two small 2 5mm Allen bolts on the underside of the bottom bracket shell These must be removed before attempting t...

Страница 48: ...s come with a rear derailleur guard to protect the rear derailleur from damage To install remove the the rear wheel axle nut on the drive side install the rear derailleur guard over the axle with the...

Страница 49: ...and the kickstand bolt is secured tightly Finally examine the bicycle Make sure all accessories are attached and all quick releases nuts and bolts have been tightened securely Correct maintenance of y...

Страница 50: ...13mm hexagonal bolt instead of an Allen key bolt Place the handlebar stem into the head tube observing the minimum insertion mark on the handlebar stem and ensuring that all cables are free of tangle...

Страница 51: ...seat and handlebars The seat pillar must be inserted so that the minimum insertion mark cannot be seen Attachment of an incorrect pedal into a crank arm will cause irreparable damage Pedals Crank Set...

Страница 52: ...efer to p 68 71 A greater force is required to activate the rear brake due to longer cable length It is advisable to mount the rear brake on the side of the stronger hand It is important to become fam...

Страница 53: ...le holder 1 2 Cantilever Brakes Side Pull Brakes Cantilever Brakes Utilizing a Link Wire If fitted with cantilever type brakes insert the brake cable into the link wire lead and notch the cable end in...

Страница 54: ...78 in lbs 6 If balance adjustment is necessary adjust with the spring tension adjustment screw 1 mm 10 mm wrench 5 mm Allen key Cable Anchor Bolt Touching End cap Cut off any unnecessary cable attach...

Страница 55: ...k fixing bolt 1 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 or 3 mm so that dimension A is kept at 39 mm or more...

Страница 56: ...that everything is operating correctly and that the shoe clearance is correct before using the brakes 6 Pass the inner cable through the inner cable lead Set the cable with a clearance of 1mm between...

Страница 57: ...e or to fit over the front reflector hanger In the event of brake cable failure the front reflector hanger would prevent the straddle cable from catching in the tire and locking up the front wheel The...

Страница 58: ...lows for raising or lowering the training wheel to the proper height Check your Brakes Press each brake lever to make sure that there is no binding and that the brake pads press hard enough on the rim...

Страница 59: ...the 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 adj...

Страница 60: ...ury Barrel End Single Cable Casing Cable Adjuster Cable Splitter Upper Cable short casing Upper Cable long casing Upper Plate Bearing Football Ends Lower Plate Lower Cable Adjusting Barrel Locknut Key...

Страница 61: ...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 press the velcro together securely Turn the pad so the v...

Страница 62: ...hift levers 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 lithium based grease...

Страница 63: ...gs for looseness Check pedals are tight Check handlebars are tight Check seat and seat post are tight and comfortably adjusted Check frame and fork for trueness Check all nuts and bolts are tight Lubr...

Страница 64: ...l wrench 15mm 3 Allen key wrenches 4mm 5mm 6mm 8mm 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...

Страница 65: ...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 missing or dam...

Страница 66: ...e bead is properly seated in the rim Tread 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 shou...

Страница 67: ...a Flat Tire If you need to repair a tire follow these steps 1 Remove the wheel from the bicycle 2 Deflate the tire completely via the valve Loosen the tire bead by pushing it inward all the way aroun...

Страница 68: ...e other 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 12 Before the tire is completely mounted push the valve up into the...

Страница 69: ...cluding the wedge that will be inserted into the frame The height of the handlebar can be adjusted to suit your comfort preference If the stem is removed from the steering column you will notice a mar...

Страница 70: ...remain in an approximately upright position but can be angled back or forward slightly for comfort On MTB and racing style bicycles the handlebar is usually tightened in the stem by a single allen ke...

Страница 71: ...nt 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 attach to derailleur Make sure that the cab...

Страница 72: ...needed to 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...

Страница 73: ...If your bike is equipped with a threadless headset please see a qualified specialist for repairs and adjustments Adjustment Loosen the headset top locknut or remove it completely along with the reflec...

Страница 74: ...pper tubes into lower tubes 2 Firmly hold lower tube and turn clockwise until it will not turn anymore 3 Align the brake arch mounts on both lower tubes and install brake arch 4 Tighten brake arch bol...

Страница 75: ...insertion To avoid damage to either the seat post the frame or possibly the rider a minimum of 65mm of the seat post must always remain in the frame Lubrication Remove the seat post from the frame and...

Страница 76: ...hten the clamping 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 adjus...

Страница 77: ...ble 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 screw which can be altered to the distance between th...

Страница 78: ...e rim loosen the lock nut and turn the adjuster 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...

Страница 79: ...he lock nut If the pads cannot be set close enough to the rim in this manner you may have to adjust either the length of the straddle cable or the length of the brake cable If the brakes use a separat...

Страница 80: ...a six inch adjustable wrench or a 15mm box wrench to tighten the axle nuts as tight as you can 3 Close the brake shoes then spin the wheel to make sure that it is centered in the frame and clears the...

Страница 81: ...lar around the seat post to hold the seat post securely in place The amount of clamping force is controlled by the tension adjusting nut Turning the tension adjusting nut clockwise while keeping the c...

Страница 82: ...re that you under stand the way the brake quick release works on your bike and check each time to make sure both brakes work correctly before you get on the bike Brakes are designed to control your sp...

Страница 83: ...educes their ability to grip The way to main tain control on loose or wet surfaces is to go more slowly to begin with 2 Adjusting your brakes If either brake lever on your bike fails the Mechanical Sa...

Страница 84: ...shift to a slower gear one which is easier to pedal An upshift is a shift to a faster harder to pedal gear What s confusing is that what s happening at the front de railleur is the opposite of what s...

Страница 85: ...must be pedaling forward 2 Shifting the Front Derailleur The front derailleur which is controlled by the left shifter shifts the chain between the larger and smaller chainrings Shifting the chain ont...

Страница 86: ...d downshifting to get a feel for the different gears At first practice shifting where there are no obstacles hazards or other traffic until you ve built up your confidence Once you ve learned the basi...

Страница 87: ...your pedals G Tires and Tubes 1 Tires Bicycle tires are available in many designs and specifications ranging from general purpose designs to tires designed to perform best under very specific weather...

Страница 88: ...in one direction than in the other The sidewall marking of a unidirectional tire will have an arrow showing the correct rotation direction If your bike has unidirectional tires be sure that they are m...

Страница 89: ...cycles can be safely retrofitted with some types of suspension systems Before retrofitting a bicycle with any suspen sion check with the bicycle s manufacturer to make sure that what you want to do is...

Страница 90: ...____________________________________ Date Purchased ________________ Place of Purchase ____________ Model Brand Information ____________________________________ Wheel Size ____________________ Color _...

Страница 91: ...anty listed below If failure of any part should occur during the warranty period the part will be replaced for you if the failure was due to faulty materials or workmanship All warranty claims must be...

Страница 92: ...e angle of the pad On some models there is a spring force adjustment screw on the brake arm which allows further fine tuning of the brake shoe position Bicycles with cantilever brakes must be fitted w...

Страница 93: ...them safely Inspection Pedals should be inspected every month taking note of the following areas Check correct tightness into the crank arms If pedals are allowed to become loose they will not only be...

Страница 94: ...edal which attaches to the other crank arm is marked L on the axle and screws in with a counter clockwise thread Insert the correct pedal into the crank arm and begin to turn the thread with your fing...

Страница 95: ...rank arms beyond repair Inspection The crank set should be checked for correct adjustment and tightness every month Cotterless crank axle nuts must be kept tight and the bottom bracket bearings must b...

Страница 96: ...lockwise 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 retainer s...

Страница 97: ...ut of the frame to the left 5 Remove the right side fixed cup by turning it counter clockwise and remove the right ball retainer Clean and inspect all bearing surfaces and ball retainers and replace a...

Страница 98: ...lace the dust cover Adjustment After Use 1 Remove dust cap 2 Tap the crank arm lightly with a mallet 3 Re tighten the flange nuts and refit the dust caps New cotterless cranks may become loose with in...

Страница 99: ...ed and move the wheel forward to loosen or backward to tighten in the frame 2 When correctly adjusted the chain should have approximately 10mm of vertical movement when checked in the center between t...

Страница 100: ...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 FREEWHEEL Inspection Lik...

Страница 101: ...fers 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 There are several models of coaste...

Страница 102: ...he operation of the rear derailleur first then the front The rear derailleur should shift the chain cleanly from one cog to the next without hesitation On SIS equipped bicycles each notched position i...

Страница 103: ...tation If noise occurs use the barrel adjuster to fine tune the cable tension Turning the barrel adjuster clockwise will decrease cable tension and allow the derailleur cage to move farther away from...

Страница 104: ...chainwheel If the chain does not shift onto the largest chainwheel you will need to turn the High limit screw counter clockwise until the chain moves to the largest chainwheel If the chain falls into...

Страница 105: ...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 important safety and leg...

Страница 106: ...then through the basket bracket assembly on bike Next insert a second washer onto the bolt and thread a 10mm nylox nut onto the bolt behind the basket bracket assembly Tighten bolts until snug Repeat...

Страница 107: ...t of adjustment Stiff chain link Loose pedal axle bearings Loose bottom bracket axle bearings Bent bottom bracket or pedal axle Loose crankset Pedal bearings too tight Bottom bracket bearings too tigh...

Страница 108: ...se Bulge in the rim or rim out of true Brake mounting bolts loose Brakes out of adjustment Fork loose in head tube Axle broken Wheel out of true Hub comes loose Headset binding Hub bearings collapsed...

Страница 109: ...ove sharp object embedded in tire Correct tire pressure File down spoke Problem Steering not accurate Frequent punctures Possible Cause Wheels not aligned in frame Headset loose or binding Front forks...

Страница 110: ...cause of its adjustable nature it is critical that you understand how it works and how to use it properly CAUTION The full force of the cam action is needed to clamp the wheel securely Holding the nut...

Страница 111: ...the quick release lever so that it curves away from the wheel This is the OPEN position 2 With the steering fork facing forward insert the wheel between the fork blades so that the axle seats firmly...

Страница 112: ...lease lever to the OPEN position The lever should be on the side of the wheel opposite the derailleur and freewheel sprockets 4 Put the chain on top of the smallest free wheel sprocket Then insert the...

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