retrospec Sully Klunker Bike Instruction Manual

retrospec Sully Klunker Bike Instruction Manual

ASSEMBLY INSTRUCTIONS SULLY

WARNING

Using the bike with the minimum insertion line on the lower portion of the seat post showing above the frame could result in a failure of the seat post and/or the frame causing a loss of
control with potential injury to rider. Such failures are not covered by warranty as it is improper use of the product.

TOOLS

What we give you: 3 Hex Wrenches (4mm, 5mm, & 6mm), a 10-function multi- tool.(fig. 2)
What you need: Scissors, Phillips Screwdriver, 15mm wrench or crescent wrench.

UNPACK YOUR BIKE

1. Cut the shipping straps on the outside of the box.

2. Remove the box staples as these are sharp and can cut you as you access the bike. Lift bike out by frame and rear wheel.

3. Rotate the fork so that it is facing forward of the bike (Fig.1). Place the bike on the ground, so it’s standing upright on the fork dropouts and rear tire.
   

4. Cut all of the packing zip ties.

5. Separate the front wheel from the bike by carefully slipping it away from the crank arm, which is resting within the spokes.

6. Remove the accessory box (Fig. 2) and set it aside.
   

7. Examine your new bike for any visible damage that may have occurred during shipping.
   Special Note: For tightening all fasteners, please refer to Appendix Din the back of your owner’s manual for all fastener torque specifications.

WARN I N G

Using the bike with the minimum insertion line on the lower portion of the seat post showing above the frame could result in a failure of the seat post and/or the frame causing a loss of control with potential injury to rider. Such failures are not covered by warranty as it is improper use of the product.

SADDLE

1. The seat post will come attached to the saddle from the factory.
   Remove the plastic shipping plug from the top of the seat tube (Fig. 3).
   

2. Use the included hex wrench to loosen the seat post clamp at the top of the frame seat tube.

3. Slide the red rear reflector onto and up the seat post, lightly tighten (red rear reflector is factory installed on some production runs).

4. RECOMMENDED: Apply a thin layer of grease to the inside of the frame seat tube.

5. Insert the seat post/saddle assembly into the seat tube of the frame to at least the minimum insertion line of the seat post (Fig. 6). Adjust the seat to your desired height, align/center seat with frame top tube (Fig. 4).
   

6. Face red rear reflector rearwards and center align with rear wheel – securely tighten (Fig. 5).
   
   Note: You can make the final adjustment to the height of the seat as needed after the bike is assembled.

HANDLEBARS

1. The stem will be secured onto fork steer tube from the factory.

2. Using a hex wrench, remove the 4 bolts/washers of the handlebar clamp on the front/face of the stem (Fig. 7).
   

3. Untwist the handlebar and brake cable and face the handlebar forward (reflector facing forward).

4. Make sure that the fork is facing forward (Fig. 1).

5.  Place the handlebar in the stem and the stem front clamp over the handlebar. Center the handlebar in the stem.
   Install the 4 stem bolts. Tighten each bolt a little at a time to ensure even pressure on all four corners using a cross pattern (Fig. 7).

6. The front white reflector should already be installed on the handlebar from the factory. You may need to position the reflector forward and then tighten the bracket (Fig. 8).
   

FRONT WHEEL

1. Remove the plastic shipping protector from the fork dropouts and plastic axle protector(s).

2. Loosen the axle nuts on the front wheel and insert the front wheel into the fork dropouts. Insert the tab of the safety washers into the small holes on the outside of the fork dropouts. (Fig. 9).

3. Inspect the wheel to make sure it is centered in the fork (Fig.10). Tighten each axle nut a little at a time with a 15mm wrench, alternating between sides, until each axle nut is properly tightened .
   

PEDALS

Right Pedal

1. Locate the pedal stamped “R” on the end of the spindle (this is the RIGHT pedal) (Fig. 11).
   

2. RECOMMENDED; Apply a thin layer of grease to the pedal threads prior to installation.
   Carefully insert the Right pedal into the Right side crank arm (the side with the chain} and thread it Clockwise (Fig. 12). You should be able to thread the pedal in part of the way by hand with minor
   resistance. If it seems difficult and binds, stop, remove the pedal, realign the threads and try again. Be sure you are turning the right pedal axle in a clockwise direction!
   

3. Tighten the pedal with a 15mm or adjustable wrench until the pedal is securely attached to the crank arm. The pedals need to be tightened with a considerable amount of force so that they do not
   come lose.

Left Pedal

4. Locate the pedal stamped “L” on the end of the spindle (this is the LEFT pedal} (Fig. 11).
5. RECOMMENDED; apply a thin layer of grease to the pedal threads and insert your Left pedal into the Left side crank arm.
6. Thread it Counterclockwise and tighten with a 15mm or adjustable wrench following the instructions in step #3 above (Fig. 13).
   
   NOTE: Be sure to tighten both pedals with an adjustable wrench or 15mm open end wrench to the recommended torque specification otherwise they will unscrew while riding causing an unsafe condition for the rider and damaging the threads in the crank.

BRAKES

Your Sully is equipped with a rear linear-pull brake which is factory installed and should be adjusted from the factory. If adjustment is needed, use the following steps:

1. Be sure that the brake pads are aligned with the curve of the rim and that they contact the rim surface flat and evenly. The brake shoe angle and height can be adjusted by loosening the hex
   bolt attaching the brake shoe to the brake arm. Notice that the brake shoe can articulate a certain amount up and down and side to side (Fig. 14).
   

2. – Loosen the brake cable anchor bolt on the brake arm held by a hex bolt allowing the brake cable to freely glide through its anchor.

3. Squeeze the brake arms together until the brake shoes contact the rim surface. Pull the cable taught through its anchor and tighten the cable anchor bolt. Make sure the brake cable housing is seated properly at the cable stop ferrules before tightening the anchor bolt (Fig. 15).
   

4. Squeeze the brake lever hard several times to stretch the cable and make sure that it does notslip through its anchor. If the cable tension is too tight to allow the brake shoes to retract and clear the rim surface, loosen the anchor bolt and give the cable some slack. If the cable has too much slack and you cannot apply enough stopping force to the rim, repeat procedure “2” and take the slack out of the cable.

5. Be sure that the brake arms are evenly spaced from the wheel and there is some clearancebetween the brake pads and the rim surface. If the arms are not evenly spaced from the wheel, you can balance the spacing by tightening or loosening the spring tension using the small screw located at the lower side of each brake arm (Fig. 16).
   

TIRES

• Locate the tire manufacturer’s recommended inflation pressure found on the tire idewall (listed as “PSI”).
• Using a hand or floor pump with a gauge, begin to inflate the tire to half its recommended inflation pressure and check to see that the tire is properly seated on the rim. Be sure to inspect both sides of the tire for proper fit.
• If the tire is seated unevenly or bulges out along the rim, let some air out of the tire and reposition the tire by hand so that it sits evenly on the rim.
• Continue to inflate the tire to the manufacturer’s recommended pressure.
• Do not exceed the recommended pressure as this will cause an unsafe condition potentially causing the tire to unexpectedly explode.
• Do not use a compressed air device to inflate your tires as the rapid inflation of the tire can cause it to blow off the rim.
• Tires and tubes are not warranted against damage caused by over-inflation or punctures from road hazards.

SERIAL NUMBER

It is important that you locate and record the serial number of your bicycle in case of a recall or if the bicycle is stolen. The serial number can be found under the crank bottom bracket stamped into the frame (Fig. 17).

BEFORE YOUR FIRST RIDE

We strongly recommend you take your bike to a professional bike shop and have them check your work and fine tune the bike to ensure your bike is safe to ride.

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