For three speed coaster brake models, see the Shimano or Sturmey Archer instruction booklet provided. Zip-tie
shifter cable to underside of frame tubing leading up toward the handlebars. Cut off extra plastic on zip ties and spin
cut section, which may have sharp edges, toward bottom of frame.
NOTE: If you have a freewheel model, you can upgrade to a 1 or 3 speed coaster brake at any time. Call 718-322-2000 for details.
3) ATTACH REAR WHEELS
The right side drive wheel has one bearing on the outside, and the left side free-spinning
wheel has two bearings.
BE SURE TO INSTALL WASHERS BETWEEN THE OUTER
FRAME BEARING AND EACH REAR WHEEL!
-
“Style A” axle has a plate welded to it on the right side with three prongs that match up to
three holes on the hub. Insert the prongs into the hub holes and install elastic axle nut.
-
“Style B” axle uses a keyway that slides between the groove in the hub and the groove in
the axle. Insert key and slide wheel on, being sure that slots are aligned. Install axle
nut.
Do not over-tighten axle nuts! Free-spinning wheel should spin very freely, but not move back and forth.
4) TO ATTACH FRONT FORK/WHEEL ASSEMBLY TO THE FRAME:
1) Grease cups (48) with Rustolene 200 lubricant or equal. Bearings (49) are pre-greased at the
factory, but it is always a good idea to add lubrication prior to assembly.
2) Place one bearing (#49) onto the fork steering tube with the balls facing up.
3) Slide the threaded fork (154) steering tube into the frame head.
4) Place the other bearing on the top of the fork tube with the balls facing down towards the cup
(#48), which is already pressed onto the frame.
5) Install the top-adjusting cone (#52) onto the treaded fork steering tube. Hand-tighten, making
certain the bearings do not bind. After hand tightening, turn back ¼ turn.
6) Install the fork key washer (#53) and reflector bracket on top of the adjusting cone with tip of
washer in slot on steering tube.
7) Install head lock nut (#54) and securely tighten. Make sure that the fork rotates freely without
being loose. Excess play or resistance must be adjusted. Failure to adjust properly can lead to
improper steering response.
8) Install handlebar stem (55A) into the fork steering tube with the handlebar clamp facing forward. The stem must be
inserted far enough to reach the minimum insertion line. Tighten the stem bolt slightly at this point. Loosen the
handlebar clamp nut and slide the handlebar through the clamp, centering the knurled center section of the
handlebar into the clamp.
9) Position the handlebar to the desired angle and tighten clamp securely. Recommended torque is 300 IN. LBS.
Adjust the handlebar rotation so that it is straight with the front wheel. Tighten stem bolt securely. Recommended
torque 240 IN. LBS. Be sure not to over tighten, as damage to the parts may occur causing steering failure.
10) Attach brake hand lever (and shift lever for 3 speed models) to handlebar and angle slightly downward. (Some
brake levers can be mounted on either side of handlebar.) Make sure cables are not tangled in any way.
11) Make sure handlebars are clean and dry. Slide on handlebar grips until they are completely seated on handlebar.
Do not use any lubricants, including soap, water, silicon, oil, etc. Do not use compressed air.
5) INSTALLING PEDALS:
Pedals are marked on the shaft with either an
“L”
or
“R”
denoting left or
right. The
“R”
pedal fits on the right (sprocket side) of the crank arm.
Tighten clockwise. The
“L”
pedal fits on the left side of the crank arm.
Tighten counter-clockwise (left-hand thread). Securely tighten.
Recommended torque 275 IN. LBS.
CAUTION: Tightening in the wrong
direction will damage the crank and pedal threads.
6)
REAR
FENDERS:
Attach fender braces to axle housing using provided nuts, U-bolts, and washers. Bend braces if tire is rubbing the
brace.
7) INSTALL REAR BASKET:
1) Place basket on top of rear frame section.
2) Place retention strap in basket and align holes in strap with holes in frame.
3) Install bolt and washer through the top into nut and washer on the bottom, clamping
frame between strap and frame. Bolt through snugly, but do not over-tighten.
8) SEAT ADJUSTMENTS:
1) Insert seatpost completely into seat clamp at bottom of seat. Tighten seat clamp bolt slightly.
2) Insert seatpost into frame and tighten seat binder bolt. (Torque 240 inch lbs.)
3) Adjust seat angle with nose of seat raised slightly upward and tighten seat clamp bolt. (Torque 240 inch lbs.)
