200386 Bike Assembly Manual
Instruction Manual

200386 Bike Assembly Manual

Bike Assembly Manual

Important – Please read these instructions fully before starting assembly.
These instructions contain important information that will help you get the best from your bike, ensuring safe and correct assembly, use and maintenance.
If you need help or have damaged or missing parts please return to store or contact our customer service team.
Smyths Toys HQ UC / Smyths Toys EU HQ UC
ROI: Lyrr Building 1, Mervue Business Park, Galway, Ireland, H91K4HV
UK: Lymedale Business Park, Newcastle under Lyme, UK, ST5 9QH

WARNINGS AND RECOMMENDATIONS FOR SAFE RIDING

Please observe national legal requirements for cycling on public roads.
Please visit the below websites for further information:

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https://www.citizensinformation.ie/en/traveland
recreation/cycling/cycling_offences.html| https://www.gov.uk/guidance/the-highway-code/annex-1-you-and-your-bicycle

• Ensure your bike is equipped with any peripherals needed due to national legal requirements for cycling on public roads. (e.g. lighting and reflectors).
• This bike has been designed and tested in accordance with the relevant standard to ensure your safety. The relevant standard it was tested to will be labelled on the individual bikes.
• Before use, the user must learn how to properly use the bikes braking system.
• It is important that parents/carers ensure that children are properly instructed in the use of a child’s bike, in particular, braking systems.
• Please be aware of the risk of entrapment. Avoid touching any moving parts (i.e chain, the chainwheel, the freewheel or any other component that moves).
• Look out for any possible dangers when cycling, be alert and bear your own safety and third parties’ safety in mind
• Under no circumstances should this bike be used for competitive cycling, stunting, jumping or acrobatic manoeuvres. These types of cycling may result in serious personal injury and damage to the bike. Please note, this warning is not applicable to BMX bikes tested under EN 16054:2021.
• Always wear a cycle helmet when riding the bike. The bike should be the correct size for the user’s head and must conform to the European Standard EN1078.
• If you ride in the dark, always use your front and rear lights and make sure the bike is equipped with suitable reflectors.
• Always take extra care when riding in wet, foggy, windy, or icy conditions. The brakes may not be as effective and the braking distances may be increased.
• Only cycle wearing tight-fitting leg wear. Baggy clothing can get caught in the bike and lead to serious accidents. When cycling make sure that you wear suitable clothing that does not restrict the operation of the bike or impair your vision. Do not wear anything that may impair your hearing.
• When assembling the handlebar and stem to the bike frame, make sure the fork is facing in the correct direction. If the fork is assembled correctly, the brakes should be facing forward. Failure to observe the warning may impede their correct operation and may lead to personal injury and damage to the bike. Please also ensure that the handlebar is correctly aligned.
• When assembling the seat post, make sure it is inserted beyond the minimum insert mark. Failure to observe this warning may lead to a potentially unstable seat post and may result in serious personal injury.
• Before attempting to ride the bike, the front and rear tyres must be properly inflated. The tyres should not be inflated beyond their maximum pressure. Too low a tyre pressure leads to increased likelihood of punctures but mostly dangerous handling. The tyre can come off the rim on bends and cause the tyre to become detached from the rim. This can lead to dangerous riding conditions, falling, accidents and material damage.
• Worn rims and/or substantial warping or run-outs may lead to dangerous riding conditions, falling, accidents and material damage. Worn rims must be replaced.
• Do not use any other type of pump to inflate the tyres other than a bike pump.
• WARNING: As with all mechanical components, the bike is subjected to wear and high stresses. Different materials and components may react to wear or stress fatigue in different ways. If the design life of a component has been exceeded, it may suddenly fail possibly causing injuries to the rider.
• WARNING: For composite components, damage caused by impact may be invisible to the user. In the event of an impact accident, composite components should be inspected by a professional or destroyed.
• Please only use genuine replacement parts for safety critical components. Appropriate spares include tyres, tubes and brake friction components.
• Assemble the bike only using suitable tools, such as the one included. Using unsuitable tools may lead to injury and damage to the bike.
• Ensure to remove all packaging from the bike before use.
• Regular maintenance is the only way to ensure a bike’s safety and smooth operation. Always ensure the bike is maintained in accordance with the information in this manual.
• Before attaching the handlebar, ensure all cables are free to move and are not tangled. Failure to do this may lead to an injury or damage to the bike.
• Before assembling the bike, check all the parts indicated in the manual are in the box. Inspect the parts for signs of damage. Do not assemble the bike if you observe any damaged components.
• The threads on the left and right pedals are different. To prevent damage to the threads, only tighten the pedals in the direction indicated.
• After long descents, the bike rims and brake disks can get very hot. Do not touch.
• This bike is not suitable for the fitting of a luggage carrier and/or child seat.
• EN 16054:2012 WARNING: BMX pedals are designed to provide greater grip capability of the pedal tread surface than that provided by an ordinary bike pedal. This can result in the pedal tread surface being very rough and containing sharp edges. Riders  should therefore wear  adequate safety protection.
• Always ride with the flow of traffic. The side of the road you should ride on depends on your location, so please be aware of the correct side.
• Control your speed and avoid moving from side to side.
• Never hold on to a moving vehicle.
• Never cycle two abreast, only ride in a single file.
• Keep an eye out for obstructions, including, but not limited to, cars or open car doors.
• Give pedestrians the right-of-way. Do not ride too close to pedestrians.
• Do not park your bike where it can get in the way or constitute a hazard.
• Avoid road hazards, which may hinder your ability to control your bike. Potholes, ruts, uneven pavement, railroad crossing, manhole covers, storm grating, soft road edges, gravel, curbs, speed bumps, leaves, puddles, and debris can all influence your riding and result in loss of control.
• Do not carry passengers on your bike.
• Never ride with packages in your hands or anything attached to your bike that could obstruct your vision or control.
• Intersections and roundabouts should be approached with caution.
• Always keep both hands on the handlebar when riding.
• Always wear safety equipment. A helmet, long-sleeves shirt, long pants, shoes and elbow and knee pads are suggested. Gloves and eye protection also make good sense. Cover your stem, handlebar, and top tube with safety pads for additional protection
• If your bike comes supplied with a chain cover, do not cycle without it attached.

*rider + luggage

TYPES OF BIKES

JUNIOR  CHILDREN BIKES| These bikes have been designed for use on roads and bike paths. These bikes are not built for trails, off-road paths or general off-road use.  Saddle height should be between 435mm and 635mm.
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JUNIOR ADULT BIKES| These bikes have been designed for road use by young adults weighing less than 40kg. They have saddle height between 635mm and 750mm.
These bikes are not built for trails and paths off the road.
MOUNTAIN BIKES| These bikes have been designed for off-road use on trails and bike paths, and are also suitable for use on roads. They are equipped with a strengthened frame and other components, like wider tyres, with a unique trail pattern and a wide gear range. Maximum saddle height should be higher than 635mm.
ROAD BIKES| These bikes have been designed for amateur use on high-speed roads. They are fitted with a handlebar that adapts to various positions (for an
aerodynamic posture), with a wide gear range, maximum tyre length of 28mm and maximum weight of 12kg (when fully mounted). Maximum saddle height should be higher than 635mm. These bikes are not built for trails and paths off the road.
CITY/TREKKING BIKES| These bikes have mainly been designed for leisure and commuting on the road. Maximum saddle height should be higher than 635mm. These bikes are not built for trails and paths off-road.
BMX BIKES (EN 16054:2012)| These bikes have been designed for road use and bike paths. They are also suitable for acrobatics and stunts (on the ground and in the air).
They are divided into two categories:
Category 1- For cyclists weighing less than 45 kg.
Category 2 – For cyclists weighing more than 45 kg. Maximum saddle height should be higher than 435mm.

BIKE BREAKDOWN

Bikes (With training wheels)
Please note, not all parts listed below may be included with your particular bike.

Fitting the Rider to the Bike
To determine the correct size of bike for the rider, straddle the assembled bike with feet shoulder width apart and flat on the ground. There must be at least one inch of clearance between the highest part of the top tube and the crotch of the rider. The minimum leg-length for the rider is the highest part of the top tube plus 25mm.
The rider must be able to easily reach and operate the brake levers (if so equipped).
To determine the correct seat height, check the seat to pedal distance by having your child sit on the seat.
The child’s leg should be slightly bent and on the pedal. If the foot does not reach, adjust the seat height accordingly. Be sure the seat is tight and secure before your child rides.
Tools Required for Assembly Assemble the bike only using suitable tools, such as the ones included.
Using unsuitable tools may lead to injury and damage to the bike.

PROPER SEAT HEIGHT

GENERAL MAINTENANCE

General: Ensure all nuts and bolts are tightened every 1-2 weeks. Check regularly for any damaged parts, fork alignment and the positioning of components.
Brakes: Ensure the brakes are adjusted correctly as per assembly instructions. Ensure to clean any dirt accumulation that occurs on the bike rim that may interfere with braking.
Control/Brake Cables: These cables may stretch with use. Inspect regularly and replace if damaged. Do not allow the cables to kink.
Front Fork: Bent or damaged fork should be replaced immediately. Do not attempt to repair the fork by straightening it. Headset (interface between the fork to the bike frame): Ensure locknut is tight while allowing the fork to turn freely.
Front Wheel: The wheel should be cantered in the front fork with axle nuts tight. The hub is sealed against dirt and moisture, however, it should be inspected periodically, especially after riding in water. Remove the front wheel and turn the axle with your hands. It should move freely, with very little friction or play.
Crank Bearing: The crank bearing should also be inspected after a wet or muddy ride. The spindle should turn freely without moving side to side. Keep the lockring tight and the bearing well-greased.
Crank and Pedals : Replace bent cranks and chainrings if required. Do not attempt to straighten. Pedals will require greasing occasionally, especially after riding in water. After the first 50 miles/80 KM, tighten crank bolts, and check chainring bolts and pedal spindles.
Rear Wheel: Wheel should be centered in frame with axle nuts/ quick releases tight. Keep spokes and rims true. This sealed-bearing hub can be inspected by removing the wheel and turning the axle with your hands. It should move freely, with very little friction.
Handlebar and stem: Adjust for comfort of the rider, keeping to the MAXIMUM HEIGHT mark within the frame. Tighten bolts securely. Replace worn grips.
Chain: Check frequently for damage or stretch, replacing when necessary. Lubricate often, taking care to oil/grease each link.
Derailleurs: Keep them well adjusted as per instructions. Shift only while pedalling and avoid impact to rear derailleur.
Seat Adjustment: Adjust height and angle for comfort. Tighten the quick- release seat bolt/seat clamp bolt until the seat cannot be rotated in the frame.
Tyres: Keep tyres inflated to the pressure indicated on tyre wall. A foot or frame pump should be used. (DO NOT use unregulated pressure pumps). Make sure tyres are properly seated on rims and check tyre-beads.
Reflectors: Reflectors should be mounted on the handlebar, rear of seat, pedals, and front/rear wheels. Damaged units should be promptly replaced.
Frame: Check for cracks in paint around tube junctions periodically. They may indicate a bent or cracked frame. Immediately replace a bent or broken frame. Frame damage causes excess strain on other bike parts and is very dangerous.
Paint: Please do not leave your bike exposed outdoors under sunshine for more than 24 hours to avoid colour fading. Please do not leave your bike outside and exposed to rain as this will cause the bike to rust.

LUBRICATION
A bike has many moving parts that are constantly exposed to the elements.
Cleaning and lubricating these parts will keep them running smoother and longer.
Parts should be lubricated regularly- approx. 3-6 months.

• Brake Levers – Put one drop of oil on the pivot point of each brake lever. (Lubricant: oil)
• Caliper Brakes – Put one drop of oil on the pivot point of each caliper brake. (Lubricant: oil)
• Brake Cables – Put four drops of oil into both ends of each cable. Allow the oil to soak back along the cable wire. (Lubricant: Lithium based grease)
• Pedals – Put one drop of oil where the axles go into the pedals. (Lubricant: Lithium based grease)
• Chain – Put one drop of oil on the each roller of the chain. Wipe all excess oil off the chain. (Lubricant: Chain lube or light oil)

CHECKING THE RIMS
Warning: Worn rims and/or substantial warping or run-outs may lead to dangerous riding conditions, falling, accidents and material damage. Worn rims must be replaced.
With rim brakes: Dirty rims may reduce braking efficiency. Dirty rims must be cleaned.
Rim with wear indicators:

Fingernail check: Run your fingernail across the rim shoulder. No scoring should be felt.If the wear indicator is no longer visible or if the rim has discernible scoring, the rim must be replaced.

Check rims for run-out:

Lift the bike up and spin first the front and then the rear wheel.Note the distance between the rim and the brake shoes, and on disk brakes, note the distance between the rim and the frame strut or fork leg. The maximum permissible deviation per rotation amounts to 2 mm. Check your rims for dirt, especially oil and grease. Dirty rims must be cleaned immediately.

CHECKING TYRES

WARNING: Too low a tyre pressure leads to increased likelihood of punctures but mostly dangerous handling. The tyre can come off the rim on bends and cause the tyre to become detached from the rim. This can lead to dangerous riding conditions, falling, accidents and material damage.
Tyre pressure is indicated on the sidewall of the tyre.

• Check your tyre pressure before each ride by squeezing the tyre between your thumb and fingers. It should feel very firm, but not hard. When you sit on your bike, the tyre sidewalls should not compress very much under your body weight. Check your tyre pressure at least once weekly with a tyre pressure gauge.

• Use hand or foot pump to inflate your tyres. NEVER INFLATE YOUR TYRES WITH AN AIR COMPRESSOR AT A SERVICE STATION.
  A service station air compressor releases a high volume of air under great pressure.
  This much air can explode a bike tyre and tube in a matter of seconds and may cause serious personal injury. DO NOT LET CHILDREN INFLATES TYRES.

• A bike tyre will wear out faster when underinflated. An overinflated tyre can become unseated from the rim and blow out. Be cautious of both these inflation areas.

• If wheels and tyres make abnormal noises, have an authorized dealer check your bike. Strange noises from any part of your bike can mean something is wrong – troubleshoot these problems immediately.

• The biggest cause of wheel damage is loose spokes. When wheel spokes become loose, have your wheels trued by a professional bike mechanic. Wheel spokes should be checked before riding, for damage and looseness.

Cheking tyres for external damage

The tyre rubber must have the same pattern as the original over its entire surface.
The tyre canvas beneath the layer of rubber must not be visible. There must be no bulges or tears.

SPARE PARTS

Appropriate spares include tyres, tubes and brake friction components. Please only use genuine replacement parts for safety critical components. For further information on the availability of spare parts, please return to any of our stores or contact our customer service team via the below:
To make sure your bike is safe and operating correctly, you should perform the following checks before riding it.

• Ensure the seat is secure
  Try moving the seat side to side while standing next to the bike. You should retighten the seat clamp bolts or the seat post bolts if the seat moves.

• Ensure the Front and Rear Tyres are Inflated as Per the Requirements
  Apply pressure to the sides of the front and rear tyres. They may need to be inflated if they are soft. Re-inflate to the pressure indicated on the sides of the tyres using an approved bike pump.

• Ensure that the Pedals are Tight
  Make sure both pedals are securely tightened with the supplied multi-tool. Remember that the left and right pedals have threaded shafts that tighten in different directions.

• Ensure that the Brakes are functional
  Apply the front brake and push the bike forward while standing next to it. If the wheels move, the front brake may not be working properly. If necessary, adjust the front brakes as described in the manual. Repeat this for the rear brake.

• Ensure that the Handlebar do not move
  Try to move the handlebar while holding the front wheel between your legs. The stem bolt may have gotten loose if the handlebar move. Replace the stem bolt and tighten it.

• Ensure that the bike is clean and lubricated
  To ensure proper operation, the bike should be cleaned and re-oiled on a regular basis.

TORQUE REQUIREMENTS

Step / Part to be Tightened| Suggested| Torque

1| Front Wheel Axle Nut| 21-23 ft-lb| (27-31 N-m)

2| Handlebar Clamping Bolt| 18-20 ft-lb| (24-28 N-m)

| & Nut Stem Expander Bolt| 15-18 ft-lb| (20-24 N-m)

3| Pedals| 18-20 ft-lb| (24-28 N-m)

4| Seat| 15-20 ft-lb| (20-28 N-m)

5| Rear Wheel Axle Nut| 21-23 ft-lb| (27-31 N-m)

8| Hand Brake Nuts| 6-7 ft-lb| (14-18 N-m)

CONTENTS

Remove the protective cardboard from the frame.
Remove the accessories box that contains the pedals and tools you’ll need for assembly.

1 Frame
2 Handlebar
3 Front wheel
4 Bike seat
5 Pedals| 6 Stabilizers
7 Front mudguard
8 Bell*
9 Reflector
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• Not included with all bikes.
  Important: Before assembling the bike, check all the parts indicated in the manual are in the box. Inspect the parts for sign of damage. Do not assemble the bike if you observe any damaged components.

BIKE ASSEMBLY

STEP 1
ATTACHING THE HANDLEBAR

1. Make sure the quill nut at the end of the stem is loose. If it is not loose, loosen it with the multi tool.
2. Make sure the brake cables aren’t twisted, and that the front fork is facing the correct way – with the brake mechanism at the front.
3. Before you insert the handlebar, check that the frame, the front wheel fork, and the handlebar, are all correctly aligned as seen.
4. Insert the handlebar, and make sure that the height is between the maximum and minimum markers as shown. Once in position, tighten the quill nut.

WARNING! When assembling the handlebar and stem, make sure it is inserted beyond the minimum insert mark. Failure to observe this warning may lead to a potentially unstable bike and may result in serious personal injury.

STEP 2 INSERTING THE SEAT

1. Make sure the height is between the maximum and minimum markers as shown.
2. Once you make sure the seat is straight, tighten the bolt with the multi tool.

** When assembling the seat post, make sure the saddle is inserted beyond the minimum insert mark. Failure to observe this warning may lead to a potentially unstable seat post which may result in an injury.
STEP 3 ATTACHING THE FRONT WHEEL** Loosen the break cable nut using the multi-tool provided. Loosen the outer wheel nuts all the way to the edge of the thread. Insert the wheel and make sure the retention washer and the nut are on the outside of the wheel fork.Insert the tab on the retention washer into the hole on the fork on both sides. Tighten the wheel nuts using the multi- tool.

STEP 4  ATTACHING THE MUDGUARD (IF APPLICABLE)
To attach the mudguard, you need to remove the nut atthe back of the fork.Once the nut is removed, attach the mudguard and replace and tighten the bolts.

STEP 4
NOTE: ASSEMBLY / ADJUSTING V-BRAKES
Note:
If your bike comes with the V-Brakes, please refer to page 21.

STEP 5
ASSEMBLING / ADJUSTING CALIPER BRAKESSTEP 6
ATTACHING THE STABILISER   Remove the outer nut and washer. Ensure that the rectangle washer is placed in the correct position.Attach the stabiliser, and secure it with the washer and nut. Tighten the wheel nut using the multi-tool.

Repeat this process on the opposite side.

Check that the stabiliser wheels aren’t touching the ground when the bike is level.

STEP 7 ATTACHING THE PEDALS Take careful note of the Right and Left pedals which will be marked R and L.The right pedal attached to the right side of the bike, which is the side with the chain. It will also be marked by an “R”. Screw the right pedal in clockwise and then tighten with the multi- tool spanner.On the left side, screw the pedal on anti- clockwise – and tighten with the multi-tool spanner – making sure to tighten it anti-clockwise.

IMPORTANT: The threads on the left and right pedals are different.
To prevent damage to the threads, only tighten the pedals in the direction indicated.
So remember: the right pedal is always screwed in a clockwise direction, and the left pedal is always screwed in an anti-clockwise direction.

STEP 8 ACCESSORIES (IF APPLICABLE)

FINISHED BIKE ASSEMBLY

ADJUSTING THE CALIPER BRAKES

Losen the bolt that holds the brake cable until it can be pulled through. Close the brake caliper with one hand andpull through any loose cable.Tighten the clamping bolt again while keeping the calipers closed. Your wheel should still spin freely.

ADJUSTING THE BRAKE LEVER

ADJUSTING THE V-BRAKES

ADJUSTING THE CHAIN. WARNING! Do not attempt chain repairs. If there is an issue with the chain, have a bike service shop make any repairs

Adjustment:
The chain must be at the correct tightness. If too tight, the bike will be difficult to pedal. If too loose, the chain may come off the sprockets.
When the chain c  is at the correct tightness, you can rotate the crank freely and you can pull it no more than half an inch (1.27cm) A away from the straightedge B as shown.
Adjust the tightness of the chain as follows:

• Loosen the axle nuts of the rear wheel
• Move the rear wheel forward or backward as necessary

NOTE: Make sure the rear wheel is in the centre of the bike frame
Hold the wheel in this position and tighten securely (see torque table for recommendation of torque value).

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