43144822 74cm Zenith Dual Suspension Bike

KMART
INSTRUCTION MANUAL
BICYCLE ASSEMBLY & MAINTENANCE
ADULT BICYCLE
IMPORTANT NOTICE! Do not Return This Product To The Store, Please Keep Your Instructions! Your Model number is necessary should you need to contact us. Please read through this instruction manual book to familiarize yourself with all parts and assembly steps. Kindly refer to the parts identifier below and be sure that all parts have been included. Although we are dedicated to giving our customers the best product possible, a question may arise or parts may be missing. If you are missing parts, or, if you have any questions, please contact our fast and friendly service centre on: TEL: 1800-124-125

TABLE OF CONTENTS
RULES OF THE ROAD OWNER’S INFORMATION OWNER’S IDENTIFICATION RECORD SAFETY WARNINGS SAFE SIZING OF A BICYCLE TOOLS REQUIRED FOR ASSEMBLY PUTTING YOUR BIKE TOGETHER ASSEMBLE THE FRONT WHEEL TO FORK KICKSTAND REFLECTORS HANDLEBAR STEM HANDLEBAR PEDALS SEAT POST AND SEAT SIDEPULL BRAKE DISC-BRAKE V-BRAKE ABOUT YOUR DERAILLEUR FRONT DERAILLEUR REAR DERAILLEUR GRIP SHIFTER THUMB SHIFTER QUICK RELEASE WHEEL REAR SHOCK PRELOAD ADJUSTMENT REAR SHOCK MAINTENANCE SAFETY CHECK LIST WHAT IS TORQUE? MAINTENANCE RULES OF SAFE CYCLING
WARRANTY STATEMENT
NOTE: YOU COULD HAVE ADDITIONAL INSTRUCTIONS INCLUDED IN YOUR PARTS BAG THAT EXPLAIN THE OPERATION AND ASSEMBLY OF THE SHIFTERS, SHOCK FORK AND REAR DERAILLEUR, REAR AND KEEP THIS INFORMATION FOR FUTURE REFERENCE.
IT IS IMPORTANT TO READ THIS MANUAL THOROUGHLY BEFORE ASSEMBLING, RIDING, OR PERFORMING MAINTENANCE ON THIS BICYCLE. KEEP THIS MANUAL FOR FUTURE REFERENCE.

RULES OF THE ROAD
INTHE INTERESTOFSAFER CYCLING, MAKE SUREYOU READAND UNDERSTANDYOUROWNER’SMANUAL.
NOTICE:Somestateandlocaltrafficlawsmayrequirethatyourbicyclebeequipped withawarningdevice,suchasahornorbellandalight,if the bicycle is to be ridden afterdark.
Always ensure that appropriate footwear is worn whilst riding this bike. Lace up shoes with rubber soles, never ride barefoot or in sandals, and ensure that shoelaces are tied and kept out of the way of the wheels and drive system.
CAUTION:WETWEATHERWARNING:Checkyourbrakesfrequently.Theabilityto stopyourbicycleiscritical.Roadsareslippery inwetweathersoavoidsharpturnsand allowmoredistanceforstopping.Caliperbrakesmaybecomelessefficient whenwet. Leaves,loosegravelandotherdebrisontheroadcanalso effect stopping distance.
Thekickstandisdesignedtosupportthebicycleonly.Nottherider. Replacebentorbrokenspokes,andbentordamagedwheelrims. Obeyalltrafficregulations.Mosttrafficregulationsapplytobikeridersaswellas
automobileoperators. Followthetrafficflowinastraight lineclose to the curb.Watchforcarsmovinginand
outof traffic. Alwaysridealone.Nevercarry otherriders.This is dangerousanditmakesthebicycle
hardertocontrol. Whenridinginpairsorinlargergroups,fromasinglelinealongtherightsideofroad.
Setupasensibledistancebetween riders. Don’t tailgate. Alwaysbealert.Animalsorpeoplemaydartinfrontofyou.Beonthealert.Peoplehave
therightofway.Bealerttopeopleopeningcardoorswhenpassingparkedcars.Your bicyclewasnotdesignedforstuntingandexperimentation.Enjoyridingitinasafe manner. Be carefulat allintersections. Slowdownandlookbothwaysbeforecrossing. Usehandsignals.Alwaysletotherdriversand pedestrians know what you are going to do.Signal100ft(30.48cm).beforeturningunlessyourhandisneededtocontrolthe bike. CAUTION: NIGHTTIME OPERATION:WedoNOTrecommendridingyourbikeat night. Ifyouhaveanemergencythatmakesitnecessarytorideatright,haveproper lightsandreflectors. DoNOTrideatnight withoutaheadlight,taillight,awhitefront reflector,a redrearreflectorand yellow wheel reflectors. Donotcarrypackagesorobjectswhichobstruct vision. Neverhitchrides.Neverholdontomovingvehicleswhileriding.NeverStunt. ONANDOFFROADOPERATION:Avoidthefollowinghazards:draingrates,potholes, ruts,softroadedges,gravel,andleavesespeciallywhentheyarewet.
OWNER’S INFORMATION Throughout this manual you will find WARNINGS, CAUTIONS and NOTES or NOTICES.
WARNINGS: Pay special attention to these since failure to do so could result in injury to the rider or others.
CAUTIONS: If not followed these could result in mechanical failure or damage.
NOTES OR NOTICES: These specify something that is of special interest. Owner’s information continued next page.
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OWNER’S INFORMATION continued
It is the responsibility of the person who initially assembles the bicycle to do so correctly and make any necessary adjustments for proper operations. The owner or principal rider is then responsible for normal maintenance of the bicycle to keep it in good condition. 1. Make certain that all assembly instructions and necessary adjustments have been
followed. 2. Perform the safety check list and mark each item listed. 3. Know how to operate all standard and accessory equipment on the bicycle. 4. Make certain that anyone who uses the bicycle has been fully instructed in its operation. 5. If your bicycle was obtained assembled, we recommend that you review the complete
assembly instructions and perform checks specified in this manual before riding the bicycle.
OWNER’S RECORD Keep this information as a permanent record In the event of theft or loss, your law enforcement agency will require this information for identification purposes. The same information will be required when ordering parts and service.
Serial number: Wheel Size (On tire sidewall): Model Number: Color of bike: Name of bike (On top tube or chain guard ): Date purchased: Where Purchased:
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SAFETY WARNINGS
Before you ride, please read all the following items making sure you understand them. Failure to do so could cause damage to the bicycle or possible injury to yourself or others. Your bicycle meets or exceeds industry standards. It is NOT designed for off-road use, Jumping, stunts and other types of abusive riding.
BRAKE PRECAUTIONS
Donotridethebicycleuntilyouhavechecked forproperbrakeadjustmentsSee”Hand brakeleverAssembly”and”CaliperBrakeAdjustment”Sections.
WhenridingyourbicyclefRUthefirst timeWestthebrakesataslowspeedonalarge levelsurfacewithoutobstructions.Also,neverattempttostopsuddenlyusingthefront brakeonly,as thiscouldthrowtherideroffthefrontofthebicycle.
Checkandadjustthebrakes,if necessary,atthe first signof failure.Thiswillenablethe ridertomakeaquick andsmoothstop.Oncaliperbrakes, if a brake lever touches the gripwhenitissqueezed,adjustthebrakes.
Goingdownhill fastisdangeroussinceyoucan’t stop nearly as fastasyoucanonlevel Jround.Acurveat thebottomofahillcouldforceyouintooncomingtrafficoroffthe roadifyouaregoingatanexcessivespeed.
Usethefrontbrakeslowlyandcarefully,especiallywhileturningor whentheroadis wet orcoveredwithgravel,sandorleaves.Startbrakingsoonerundertheseconditionsand withless forcetoreducethechancesofskidding.Wetbrakeshoes meanthatitwill requiremoredistancetostop.Startbraking sooner than normalinwetconditions.
Nighttimeriding: D Youcan’tseethecontrolsonyourbicycleatnightsoyoumustknowwherethey arebytouch. E Slowdown.Debris andholesaremuchhardertoseeatnight. F Ifpossible,rideonstreetsthatarefamiliartoyou.Terrainthatyouhaveneverseen duringthedayisdangerousat night. G UsewelOOLWstreetswheneverpossible.AvoidGDUNbikepaths. H Complywithalllegalrequirementsinyourstate.Youshouldatleasthavea”white light”.(notjustawhitereflector)Onthefrontandarearredreflector.Allstates requirethat lampbeusedthatemitsawhitelight. I Children generally should not be allowed toride a bicycleat nightorduringperiods oflow visibility such asdawn,duskor badweather.Adults should avoidnightriding if possible. J$OZDVwearahelmetandhavearearviewmirror.
Ifthestemisnotinsertedinto thehead tube to at least theminimuminsertion line,itis possibleto over-tighten thehandlebar stemboltanddamagetheforkstembody.This couldcauseanunsafeconditionandriskinjuryto therider.
Forsafeoperations, youmustsecure thepedalspindletightly againstthe crank arm withawrenchthatfitstheshoulderof thepedalspindle.Thisisimportant:itavoids stripping threads.Alwaysreplacedamagepedals.
Whenadjustingtheseatheight, youmusthavetheminimuminsertionmarkontheseat postinsertedinsidetheframe.
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The correct frame size is the largest frame that the rider can automatically straddle keeping both feet on the ground and allowing 25 mm (1 inch) clearance between the rider’s crotch and the top of the frame tube (see illustration) Noted Ladies can use men’s bicycle to determine their correct frame size. Rider must be able to straddle bicycle with at least 1 inch (2.54cm) clearance above the horizontal bar when standing. UNPACKING Important: Remove the bicycle and all pars from the carton. Lay out all unassembled parts and READ THE ASSEMBLY INSTRUCTIONS In this manual before assembling our bicycle. The instructions are a step by step procedure. Follow the steps that pertain to your model.
NOTE: Your bicycle may be equipped with a different component than the one illustrated. However, the procedure for assembly or adjustment is basically the same.

RECORD SERIAL NUMBER Note: This information is only available on the bicycle itself. Be sure to keep your own record of this number. Each bicycle has a serial number stamped into the bottom of the frame or on the head tube. (See illustration) Record this number on page 2 of your owner’s manual to keep it for future reference.

TOOLSREQUIREDFORASSEMBLY

7mmPhillipsscrewdriver

7mmflatedgescrewdriver

Standardslip jointpliers

hammer Torque Wrench Set

2in 1 of5mm & 6mmAllen wrenchesandopen endset ofmetric flat wrenches6″(15 cm) and10″(25.4

cm)Adjustablewrench(Or OpenEndSetOfMetricFlatWrenches).Thesetoolsshould beavailableto

performthe basicsteps ofassembling the bicycles.Theycan alsobe used tomake maintenance

adjustments outlinedin thismanual.Special toolsarerequiredtodisassemblechain,removethe rear

hubpartsandtrue wheels.Specialtoolsarenotrequired for assembly andnormalmaintenance.

NOTE:UseahandorfootpumptoInflatetres.Neverinflatetrewithanaircompressorata

gasstation.WARNING: IMPROPERINFLATIONISTHEBIGGESTCAUSEOFT<RE

FAILURE.DUETOTHESLIGHTLYPOROUSNATUEOFBICYCLEINNERTUBES,ITISNORMAL

FORYOURT<RESTO/O2SEPRESSUREOVERTIME.FORTHISREASON,ITISCRITICALLY

IMPORTANTTOMAINTAINTHEPROPERT<REINFLATIONONYOURBIKE.

Manybicyclesaresoldunassembledincartons.For thesebikesitistheresponsibilityofthe

ownertomakesuretheassemblyinstructionsinthis book are followed exactly.Forbicycles

thatarepurchasedinanassembled condition,itistheresponsibilityoftheownertocarefully

checkandtestthebike.Thebicycleproductdoes notprovideabovetools.

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PUTTING YOUR BIKE TOGETHER
REMOVE BIKE FROM CARTON Be sure all parts are removed from carton. Check before you discard the carton. Remove all protective packing material. STEP# 1 ­ ASSEMBLE THE FRONT WHEELTO FORK
1. Turn the fork until the fork Plate points to the front of the Bicycle. (See illustration A)
2. Insert the wheel into the fork.
3. Install an axle nut to each side of the axle. (see illustration B)
4. Tighten the axle nuts by hand. Make sure there is an equal distance between each fork tube and the wheel. Then use a wrench and securely tighten the axle nuts. (See illustration C & D)
TORQUE REQUIREMTNTS (SEE PAGE 19)
STEP # 2 KICKSTAND
TYPE 2A – NOTE:FOR YOUR CONVENIENCE,YOUR KICKSTAND MAY BE PREASSEMLED AT THE FACTORY.
1. Place the right side (sprocket side) of the bike against a wall or have someone hold the bike for you.
2. Remove the rear axle nut and washer from the left side rear wheel.
3. Slide the kickstand plate onto the axle, so that it is seated against the rear dropout.
4. Slide the washer and nut back onto the axle and tighten securely.
5. Leave the kickstand leg down so it will support the bike during the rest of the assembly process.
CAUTION: THE KICKSTAND IS DESIGNED TO SUPPORT THE BICYCLE ONLY, NOT THE BICYCLE AND RIDER.
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TYPE 2B – NOTE: YOUR KICKSTAND MAY BE PREASSEMLED AT THE FACTORY. IF SO, PLEASE PROCEED TO STEP 4.
1. Place the bicycle in an upright position. 2. Remove the top plate from the kickstand. 3. From the left side of the bicycle side of
the bicycle (opposite side from chainguard), place the kickstand in position beneath the two rear fork legs. 4. Place the top plate, flange down, onto the mounting bolt. 5. Replace the washer and nut onto the mounting bolt. Hold the kickstand arm in an up position aligned with the frame stay, then securely tighten the mounting bolt. 6. Leave leg of kickstand down so it will support the bicycle during the rest of the assembly.
WARNING: THE KICKSTAND IS DESIGNED TO SUPPORT THE BICYCLE ONLY; NOT THE BICYCLE AND THE RIDER.
STEP# 3 FRONT (WHITE) REFLECTOR
TYPE 3A – NOTE: For your convenience, your front reflector may have been pre- assembled to the handlebar at our factory.
1. Remove the clamp screw from the reflector bracket. 2. Push open the bracket “loop” and slide it onto the
handlebar (If there is a sizing insert included with the bracket, please be sure it is inside the clamp loop before mounting.) 3. Position the reflector bracket on the handlebar between the grip and crossbar, about 5″ (127cm) from the end of the handlebar. 4. Tighten clamp screw securely. CAUTION: Be sure the reflector is in the same longitudinal plane as the bicycle (horizontal to the ground). If the reflector is aimed up or down, oncoming headlights may not reflect properly in the reflector. If the reflector is not horizontal to the ground, loosen the clamp screw and readjust the angle. Tighten clamp screw securely.
TYPE 3B
1. Remove the clamp screw from the reflector bracket. 2. Push open the bracket “loop” and slide it around the
stem neck. (If there is a sizing insert included with the bracket, please be sure it is inside the clamp loop before mounting.) 3. Position the reflector so that it faces the front of the bike and does not interfere with the operation of the bike in any way. 4. Tighten clamp screw securely. CAUTION: Be su re the refl ecto r is in the same longi tudinal plane as the bic ycle (hori zon tal to the grou nd). If the reflec tor is armed up or down, on coming headligh ts may no t reflect prop erly in the reflector.
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If the reflector is not horizontal to the ground, loosen the adjusting screw and readjust the angle. Tighten adjusting screw securely.
STEP# 4 REAR (RED) REFLECTOR For your convenience, your rear reflector may have been preassembled at the factory. NOTE : It is important to check and adjust the position of the reflectors as you assemble your bike. The reflectors must always be vertical (perpendicular to the ground) and pointed toward the front and rear of the bike. Please make sure that the adjustment is correct as a final step in the assembly of your bike. 1. Put the seat post mounted rear reflector in the correct
position by loosening the screws of the rear reflector bracket. 2. Make sure the rear reflector is vertical to the ground
and points straight back. 3. Make sure there are at least 3 inches (7.62 cm) of clearance between the top of the seat and the
top of the red rear reflector.
STEP# 5 WHEEL REFLECTORS NOTE : FAILURE TO MOUNTAND DISPLAY THE REFLECTORS SUPPLIED COULD CONSTITUTE A VOILATION OF THE LAW WITH YOUR CITY OR STATE FOR YOUR SAFETY. PLEASE MOUNT ALL REFLECTORS AS INDICATED. FOR ADDITIONAL NIGHT RIDING SAFETY AND TO COMPLY WITH THE LAWS OF MANY CITIES AND STATES, YOUR BIKE SHOULD BE EQUIPPED WITH HEAD AND TAILLIGHTS. FOLLOW INSTRUCTIOS ACCORDINGLY. YOU WILL RECEIVE EITHER TYPE A OR TYPE B WHEEL REFLECTORS.
T Y PE 5A (may already be assembled)
1. Position the reflector between the left and right layers of spokes opposite the valve stem.
2. Then slide notch in circle of reflector onto spoke slide the reflector as close to the wheel rim as possible without bending spokes.
3. Push slot in white cap over spoke so the flanges fit into large slots in circles. Twist white cap towards the right with a flathea crew driver as far as possible. Reflector should be secure.
NOTE: When assembled, the distance from the center of the reflector to the inside of the wheel rim must be less than 3″ (7.62cm).
T Y PE 5B (may already be assembled)
1 Position the reflector between the left and right layers of spokes opposite stem valve.
2 Slide notch in circle of reflector onto spoke and slide reflector as close to wheel rim as possible without bending spokes.
3 Attach with screw and hex nut supplied with reflector. NOTE : When assembled, the distance from the center of the reflector to the inside of the wheel rim must be less than 3″ (7.6 cm).
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STEP# 6 STEM ASSEMBLY
1. Insert the stem pillar into the fork tube to the minimum insertion line, indicated on the stem pillar.
2. Tighten the 6 mm stem pillar bolt to a torque requirement of 12-15 ft. lb. or 17-19 NM.
WARNING: The handlebar stem pillar must be inserted into the head tube until the minimum insertion line indicated on the stem is covered.
3. Face the handlebar stem forward directly in line with the front wheel.
4. Tighten the two 5 mm Allen screws on the handlebar stem to 7 ft lb. or 10 NM.
WARING: THE ASSEMBLER IS CAUTIONED AGAINST THE DANGER OF DAMAGING THE HANDLEBA STEM PILLAR ASSEMBLY AND POSSIBLE INJURY TO RIDER IN OVERTIGHTENING THE STEM PILLAR BOLT.

STEP# 7 ASSEMBLE HANDLEBAR
NOTE: Your handlebar has been pre -assembled to the stem at ou r factor y. Please use the foll owing informatio n if you need to adjust the angl e.
WARNING: For safe operation, the clamp bol ts mus t be securely tightened.
1. Loose clamp bolts with an Allen wrench. 2. Adjust handlebar to desired angle. 3. Securely tighten clamp bolts. (Recommended torque is 15 ft. lbs or 17-19 Newton
Metres) 4. Check handlebar for tightness. If you can move it forward or backward, the clamp bolts are not
tight enough. 5. Check steering by straddling the front heel and trying to turn the handlebar. If you can
turn the handlebar without turning the front wheel, the stem is too loose. Line up handlebar with front wheel. Retighten the stem pillar bolt as instructed in step 4.

WARNING: HANDLEBAR GRIPS R TUBE END PLUGS S

BE REPLACED IF DAMAGED,

AS BARE TUBE ENDS HAVE BEEN KNOWN TO CUASE INJURY. IT IS PARTICULARLY

IMPORTANT THAT BICYCLES USED BY CHILDREN BE CHECKED REGULARLY TO ENSURE

THAT ADEQUATE PROTECTION FOR THE ENDS OF THE HANDLEBARS ARE IN PLACE.

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STEP # 8 INSTALL PEDALS
WARNING: For safe operation, the pedal spindle must be securely tightened against the crank arm. Always replace damaged pedals, and always wear shoes or sneakers when riding a bicycle.
NOTE : Start each pedal spindle by hand to avoid stripping the threads.
1. Look for the letters “R” or “L” stamped on the pedal spindle.
2. Thread the pedal marked “R” into the crank arm on the “chain side” of the bike. Turn the pedal spindle in a clockwise direction. Securely tighten the pedal spindle.
3. Thread the pedal marked “L” into the crank on the left side of the bike. Turn the pedal spindle in a COUNTERCLOCKWISE direction. Securely tighten the pedal spindle. NOTE: Both pedals should be tightened towards the front of the bicycle.
TORQUE REQUIREMENTS 18-20 ft-1 bs or 20-26 Newton Netres.
STEP # 9 INSTALL SEAT POST AND SEAT
NOTE: your saddle may have been pre-assembled to the seat post at our factory. Please use this information for adjustment and future reference.
1. Loosen seat clamp nuts. 2. Insert the top portion of seat post
into the seat clamp. Be sure seat post is completely inserted into the seat clamp and butted tightly against the end stop. 3. Retighten seat clamp nuts on both sides (Hand tight). These nuts will be tightened later with an adjustable wrench. 4. Insert seat post into bicycle frame. Be sure that seat post is inserted into frame at least 2 1/2″ (65mm).
CAUTION: MINIMUM INSERTION LINE SHOULD BE COMPLETELY INSERTED INTO FRAME AND NOT VISIBLE.
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STEP # 9 SEAT POST AND SEAT continued
5. Tighten seat post binder bolt securely at desired height. 6. Adjust angle of seat so that top of seat is parallel to the ground or comfortable to the
rider. 7. Retighten seat clamp nuts securely with an adjustable wrench. NOTE : Test the seat to pedal distance by having the rider sit on the seat. When the rider’s leg is lightly bent, the ball of the foot should rest on the pedal when it is in its lowest position. If it does not, adjust the seat height as necessary. Check for tightness by attempting to twist the seat. If the seat is loose, be sure tighten the clamp nut and binder bolt nut securely. TORQUE REQUIREMENTS (SEE PAGE 19). I F YOUR BI CYCLE HA S A QU I CK RELEASE SE AT POST:
5. Tighten the quick release seat post binder bolt securely at desired height. Turning the tension adjusting nut clockwise while keeping the cam lever from rotating increases clamping force, turn it counterclockwise while keeping the cam lever from rotating reduces clamping force. Less than half a turn of the tension adjusting nut can make the difference between safe clamping force and unsafe clamping force. 6. Adjust angle of seat so that top of seat is parallel the ground or comfortable to the rider. 7. Retighten seat clamp nuts securely with an adjustable wrench. NOTE : Test the seat to pedal distance by having the rider sit on the seat. When the rider’s leg is slightly bent, the ball of the foot should rest on the pedal when it is in its lowest position. If it does not, adjust the seat height as necessary. Check for tightness by attempting to twist the seat. If the seat is loose, be sure to tighten the clamp nut and binder blot nut securely. TORQUE REQUIREMENTS (SEE PAGE 19).
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STEP# 10 –
WARNING: The handbrakes on this bicycle were NOT adjusted at the factory. Before you ride this bicycle you must assemble and adjust the hand brakes. The brake levers are pre-assembled. The right side of the handle bar is for the front brake and the left side of the handlebar is for the rear brake. 1. Insert the barrel and of the brake cable into the hole in the brake lever. (See illustration A)
Squeeze the rear brake arms with your hand until the brake rubbers are up against the wheel rim. This will enable the inner brake cable wire to be loose, and have enough space for you to easily slip the barrel end of the brake cable wire into the hold in the brake lever. 2. Next, pull the brake cable wire through the key hold slot the front of the brake lever (See illustration B) and then remove your hand. The brake cable cap will automatically spring back into the slotted key hole on the front of the brake lever assembly. (see illustration C) 3. Next, proceed to adjust the hand brake. (a) Loosen the cable fixing bolt. (b) Again squeeze the rear brake rubbers against the wheel rim. (c) Pull the brake cable wire through the fixing bolt hole until there is no slack in the
brake wire. (d) Tighten the cable fixing bolt. (e) Squeeze the brake lever hard and then release several times. Rotate the rear
wheel, be sure the rear wheel is straight and does not wobble. The brake rubbers should not touch the wheel rim, and there should be about 1/16 inch (1.6mm) clearance between the wheel rim and each brake rubber.
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I F T HE BR AK E RU BBE RS TOU CH T H E WH EEL RIM Loosen the anchor bolt nut and let the brake rubbers spring open a little, to clear the wheel rim. Retighten the anchor bolt nut and squeeze and release the brake lever. Check the clearance again. Repeat the adjustment if necessary. NOTE: If additional brake adjusting is required ­ you can bring the brake rubber closer to the wheel rim by turning the adjusting screw counterclockwise. To move the brake rubbers further from the rim, turn the adjusting screw clockwise. Be sure the cable is locked securely through the anchor bolt. (See illustration D). Reset cable adjuster lock nut when adjustment is final. WARNING: If after brake adjustments are made, and the hand brake still does not function, then have brake repaired or adjusted at a bicycle service shop. Do not ride if brakes do not function properly.
IF YOUR BIKE HAS DISC-BRAKE OR V-BRAKE WARNING: These brakes are highly sensitive and extremely powerful. Before using your new brakes, be sure that you are completely familiar with their operation. Practice your riding and braking techniques on a flat level surface at slow speeds prior to attempting any high speed or off road maneuvers.
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Hexagon socket keys for adjustment

(1) (2) Horse screws (3) Interlocking screw pair (4) Handlebar screw (5) Handlebar

(6) Adjusting pole (7) Gland nut (8) Support (9) Outer adjusting screw

(10) Brake boby (11) Set screw (12) Lining member

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V-BRAKE INSTALLATION NOTE: your V-brakes have been pre-Installed at the factory, use this information for adjustment and future reference. Install the v-brakes onto the cantilever bosses: 1. Slide each V-Brake assembly onto the
appropriate cantilever boss and secure by tightening the cantilever blot with a 5 mm hex key. You may hand tighten at this point as you will need to readjust the tension later. (See illustration A) 2. Install the inner brake cable by pushing it through the cable routing tube (or “noodle”) note that we offer two noodle angles (90 degrees and 135 degrees) depending on your bike setup. Now tighten the cable fixing bolt to a torque that does not exceed 9-12 ft. ­lbs. (See illustration B) 3. To ensure maximum leverage the two brake arms must be nearly parallel to each other. To make this adjustment, hold the brake shoes so that they are touching the rim and measure the distance between points a and b. (See illustration C) 4. Adjust the spring tension in each brake arm so that both sides are equally tensioned. Do this by holding the cantilever bolt with a 5mm hex key and turning the spring tension nut with a 23mm spanner. (See illustration D) 5. After ensuring that the total clearance between both brake pads and the rim is 2-3mm stretches the cable by squeezing the brake lever 5-10 times. (See illustration E) Then readjust the brakes as necessary.
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STEP # 11 ABOUT YOUR DERAILLEUR OPERATON OF DERAILLURS: Changing gears gives you more efficient pedaling effort. Too much pressure means change to lower gear. If pedaling is too easy, change to a higher gear. CAUTION: don’t force the shifter. Shifters should move easily and the chain should move easily from one sprocket to another. Please observe the following when shifting. Reduce pedaling pressure while shifting. Shift only when pedals & wheels are in motion. Never pedal backwards while shifting gears. Never force shifters.
HOW IT WORKS When the right shift lever is shifted, the pulley guide or derail the chain allowing it to move to a different sprocket in the rear sprocket cluster. The derailleur cage is spring loaded. It keeps the chain tight, but gives as the chain moves from one sprocket to another.
MAKING ADJUSTMENTS
FRONT DERAILLEUR ADJUSTMENT (PROCEDURE TO ALIGN CHAIN GUIDE)
1. Loosen mounting bolt(s) and position chain guide to within 3.2 mm (1/8inch) to 6.4 mm(1/4inch) above largest sprocket.
2. Re-tighten mounting bolt(s).
Refer to derailleur illustrations for locations of the LOW and HIGH ADJUSTING SCREWS on your type. These adjusting screws are used to center the chain guide over each sprocket. If the chain guides are not centered, the chain will over- shift of fail to seat properly on front sprockets. PROBLEM: Cannot shift into higher gear, or lower gear (depending on make of derailleur).
1. While rotating wheel with Pedals, place shift lever for Front Derailleur at the way to the rear.
2. Continue rotating wheel with pedals; adjust low gear adjusting screw until chain is centered on small front sprocket.
3. Loosen Cable anchor nut. 4. Pull end of cable wire and hold taut wire
tightening cable anchor nut. 5. While rotating wheel with pedals, move shift
lever forward Chain should shift to large front sprocket. 6. A fine adjustment can be made if necessary by turning the proper adjusting screw on the front derailleur so the chain derails onto the required sprocket. 7. The chain guide should derail the chain to the larger or smaller sprocket depending on type of derailleur.
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THUMB SHIFTERS

THE RIGHT SHIFTER
Operates the REAR derailleur and LOWER gears
THE LEFT SHIFTER
Operates the FRONT derailleur and LOWER gears

STEP# 12 IF YOUR BIKE HAS QUICK RELEASE WHEELS

QUICK RELEASE WHEEL INSTALLATION

NOTE: Some bicycles have wheel axles that incorporate a Quick Release(QR) mechanism.

This allows easy wheel removal without the need for tools. The mechanism uses a long bolt

with an ajusting nut on one end, and a lever operating a cam-action tensioner on the other.

1. To set, turn the lever to the open position

so that the curved part faces away from

the bicycle.

2. While holding the lever in on hand, tighten

the adjusting nut by hand until it stops.

3. Pivot the lever towards the closed position. When the lever is halfway closed, there

Front QR Lever (Closed Position)

must be firm resistance 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 that the curved part of the lever faces the bicycle. 5. The wheel is tightly secured when the

Rear QR Lever (Closed Position)

serrated surfaces of the QR clamping parts

actually begin to cut into the bicycle frame/fork surfaces.

6. Note that the same procedure applies when operating a QR seat post binder

mechanism. Adjusting Nut

Quick Release Lever

Spring

Hub Skewer Spring

WARNING: Correct adjustment of the QR is vitally important to avoid and accident caused by 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 the rider. Therefore:
a. Ask your dealer to help you make sure you know how to install and removed your wheels safely.
b. Understand and apply the correct technique for clamping your wheel in place with a quick release.
c. Each time, before your ride, check that the wheel is securely clamped.

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WHAT IS TORQUE?

IMPORTANT: Torque is a measurement of how tight a fastener needs to be. A person using a 12 inch (30.5cm) wrench and applying one pound of force at the end of the handle, puts one foot-pound (ft-lb.) of torque on a fastener. Torque can be measured with a torque wrench. Torque wrenches are available at most stores that have hand tools. The ranges of torque in this chart cover many different parts from different manufacturers. To determine the torque value for a part, use the following as a guide. a) Torque nuts to the lowest value specified in the range. b) If the part continues to move, increase the amount of torque by half the difference
from the present torque and the top of the torque range (an increase of 1 or 2 foot pounds between each test is the best procedure). c) If parts start deforming, stop tightening. DO NOT under tighten fasteners. Part may slip or fall to function. DO NOT tighten the fasteners too tight. You may damage the thread, which may cause an accident.

TORQUE REQUIREMENTS PART TO BE TIGHTENED
Front Axle Nut Handlebar Clamping Bolt & Nut Stem Expander Bolt Seat Seat Post Binder Bolt Rear Axle Nut Brake Cable Fixing Nut Brake Caliper centre bolt nut Cotterless Crank nut Pedals

SUGGESTED TORQUE

MAINTENANCE
RECOMMENDED GENERAL MAINTENANCE SCHEDULE To maintain the original brilliant planted and chrome finish, keep the bicycle and dry. Wipe off dirt moisture and oil clean, soft cloth, periodically polish with clear coat of wax. WARNING: Do not use a wax of any kind on the rims of your bicycle. In order for the caliper brakes to operate properly, the rims should be kept clean and free of dirt and lubricants. Due to wear of new parts, we recommend that you inspect the bicycle frequently for adjustment of brakes, bearings, wheels, etc. Adjust or tighten nuts and screws. The frequency of inspection would depend on how much and how hard you ride. Normally, we recommend a service check at least annually. Any component that does not function properly should be checked and corrected immediately. If you do not feel qualified to make the adjustment, we recommend that you take your bike to a qualified bicycle repairman. Your bicycle will require maintenance. Although simple in most cases, there are times when the repairs and adjustment take special knowledge and proper tools. We recommend that when service is required. You should have a qualified bicycle repairman do it for you. FRONT WHEEL REMOVAL TOOLS REQUIRED ­ 6″ (15CM) AD. JUSTABLE WRENCH 1. Place bicycle upside down, resting it on the seat and handlebar. If necessary, remove
one caliper rake shoe to allow clearance for wheel removal. 2. Remove axle nuts and depending on your model. Washer retainers or axle nuts, washers and
wheel retainers. 3. Remove wheel from fork. NOTE: To assemble front wheel to fork, see front wheel assembly section.
19

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RULES FOR SAFE CYCLING
D Observeallstateandlocaltrafficregulations,signs,andsignals.Checkwithyour localpoliceonbicyclelicensingandinspection,andwhereitislegaltorideyour bicycle.
E Stayon the/()7SIDEandalwaysridewiththeflowoftraffic.Neverridetwo abreast- singlefileonly.Watchoutforopeningcardoorsorcars.
F DoNOTrideatnight.Visionisquitelimitedatdawnanddusk. G Givepedestrianstheright-of-way.Don’tridetooclosetopedestrians,anddon’t
parkyourbicyclewhereitcangetintheway. H Avoidroadhazardswhichmayhinderyour abilitytocontrolyourbicycle.Potholes,
ruts,unevenpavement,railroadcrossing,manholecovers,stormgrating,softroad edges,gravel,curbs,speedbumps,leaves,puddles,and debriscanall haveeffect onyourridingandresultinlossofcontrol. I Nevercarrypassengersonyourbicycle.Nevercarrypackagesinyourhandsor attachanythingtoyourbicyclewhichcouldhinder yourvisionorcontrol. J Don’tplayinthestreets.Use caution at intersections. K Don’twearanythingthatrestrictsyourhearing. L Alwaysridewithbothhandsonthehandlebars. M Don’twearextremelylooseclothingwhichcouldhangdownandgetcaughtinthe wheelsofyourbicycle.Wearacuffbandortrousercliptokeepyourpantsfromgetting caughtinthechainwheel. N Always wear propersafetyequipment.Ahelmet,longsleevedshirt,longpants, shoes,andelbowandkneepadsaresuggested.Glovesandeyeprotectionalso makegoodsense. O Coveryourstem,handlebar,andtoptubewithsafetypadsforadditionalprotection. P Donotridebicycleifchaincoverisnotattached.
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REPLACED WITH DETAILS
NOTE:There are many types of bike frame styles.Your bike may look slightly different from this illustration.

No. PART DESCRIPTION

No. PART DESCRIPTION No. PART DESCRIPTION

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12 MONTH WARRANTY
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