Milazo Adult Bicycles Instruction Manual

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BIKE SERVICE INFORMATION 0800 445 313

INSTRUCTION MANUAL

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Page 1 Instruction Manual BIKE SERVICE INFORMATION 0800 445 313 INSTRUCTION MANUAL...
Page 3 CORRECT FITTING. Your HElEMEt Must coVEr Your ForEHEaD. ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE. DO NOT RIDE AT NIGHT. AVOID RIDING IN WET CONDITIONS. INCORRECT FITTING. ForEHEaD Is EXPosED to sErIous InJurY. InstructIon Manual...
Page 4: Purchase Record Card
PURCHASE RECORD CARD Fill in immediately and retain as a record of your purchase. Owners Name: Address: Postcode: e of Purc Date Purchased: Plac hase: Brand: Model Name: Wheel Size: Colour: Serial Number: Your serial number may be located in one of the following locations. Serial Number Location Bike Shown Upside Down Rear Left...
Page 5 CONGRATULATIONS! You have chosen one of the finest bicycles available. consult a specialist bicycle dealer, particularly if: Your bicycle has been carefully manufactured with the benefit of years of • You have any doubts or concerns as to your experience or ability to properly experience and fully tested to ensure the highest standards of safety and repair or maintain your bicycle; comfort for the rider. In order to fully enjoy your bicycle, a certain amount of • The following manual does not cover a particular matter, or ...
Page 6: Table Of Contents
DIRECTORY INDEX Parts IDEntIFIcatIon PurcHasE rEcorD cruiser Bicycles racing Bicycles Parts IDEntIFIcatIon 6-10 Mountain Bicycles and crossbikes suspension Bicycles assEMBlY 11-22 BMX/loop Frame/u-Frame Bicycles assEMBlY BEForE You rIDE 23-39 Derailleur Geared Bicycles single Geared Bicycles sErVIcInG 40-43 BEForE You rIDE correct Frame size DEtaIlED MaIntEnancE 44-96...
Page 7 INDEX rotors suspension sErVIcInG accessories schedule 1 lubrication saddle & seat Post Helmets Schedule 2 Service Checklist Brakes Reflectors Torque Requirements Inspection riding safety Tools Required calipers sidepull General rules Cantilever calipers DEtaIlED MaIntEnancE Wet weather riding V brake - linear Wheels and tyres night riding u brake Wheel inspection...
Page 8: Parts Identification
PARTS IDENTIFICATION Bicycles are available in a variety of different styles and sizes designed for different uses. Despite the different styles, all are made up of a frame, wheels, drivetrain, saddle, handlebar assembly and brakes. Study and familiarise yourself with the names of various parts on the diagram similar to your bicycle. This will help when you come to the assembly and basic maintenance instructions described later in this manual. cruiser Bicycle Handlebar Grip cruiser Bicycles also known as beach cruisers are designed Shifter for comfort and style. Handlebars Brake Lever Brake Control Cables Top Tube Seat Seat Post Handlebar Stem Quick Release Head Set...
Page 9: Parts Identification
PARTS IDENTIFICATION Seat Seat Post Handlebar Stem Shifter Quick Release Seat stays Head Set Brake Lever Tire Head Tube Spoke Brake Seat Tube racing Bicycles Down Tube Front Derailleur racing style, or road bicycles, are light in weight and are Fork designed for fast travel over long distances on paved ...
Page 10: Mountain Bicycles And Crossbikes
PARTS IDENTIFICATION Mountain Bicycles and crossbikes Mountain bicycles are designed to give maximum comfort over a wider variety of road surfaces. The wider Shift Lever handlebars and convenient shift lever position make them Handlebar Top Tube very easy to control. Wider wheel rims and tyres give Brake Lever Seat them a softer ride with more traction on rough surfaces. Brake Control Cables Seat Post Handlebar Stem Front Reflector the frame and fork on mountain bicycles is much sturdier Quick Release Head Set Front Brake...
Page 11: Suspension Bicycles
20067_OWNERS-MANUAL.qxp 08/03/2006 10:34 AM Page 6 PARTS IDENTIFICATION Suspension Bicycles . With similar components to standard frame mountain bicycles, suspension fitted bicycles give even more comfort over uneven road surfaces. Some are fitted with shock absorbing front forks only, while others are designed with special frames which also have a rear suspension mechanism.
Page 12 PARTS IDENTIFICATION BMX Bicycles Brake Lever BMX style bicycles are a popular general purposes Handlebar type most suited to younger riders. they are Seat Handlebar Grip Brake Control Cable valued because of their sturdy and simple Seat Post Handlebar Stem construction an low maintenance. Seat Post Binder Bolt Head Set Reflector other kinds of children’s bicycles use different...
Page 13: Assembly
Your new bicycle was assembled and tuned in the factory and then partially disassembled for shipping. You may have purchased the bicycle already fully re-assembled and ready to ride OR in the shipping carton in the partially disassembled form. If it was purchased in the carton the following instructions will enable you to prepare your ASSEMBLY bicycle for years of enjoyable cycling.
Page 14: Derailleur Geared Bicycles
ASSEMBLY DERAILLEUR GEARED BICYCLES Foreword: Assembling a bicycle is an important responsibility. Proper Includes 20", 24” and 26" Wheel Mountain Bikes DERAILLEUR GEARED BICYCLES assembly not only gives the rider more enjoyment of the bicycle; it Assembly is the same for men’s and women’s bikes. Foreword: Assembling a bicycle is an important responsibility.
Page 15 ASSEMBLY Handlebar Binder Bolt Handlebars Remove the protective cap from the handlebar stem and loosen the Allen key bolt using the 6mm Stem Wedge Bolt Allen key. Some models may use a 13mm hexagonal bolt instead of an Allen key bolt. Place the handlebar stem into the top of the head tube, ensuring all cables are free of tangles. tighten the Top Nut handlebar stem in the frame to 17 - 19 Newton metres if using a torque wrench, while observing Minimum Insertion Mark the minimum insertion mark and checking that the forks and handlebars are both facing forward. Ensure that the handlebar is tightened to 17 -19 Newton metres if using a torque wrench. For ...
Page 16 ASSEMBLY seat Insert the smaller end of the seat pillar into the seat clamp and tighten. Insert the seat/pillar assembly into the frame tube of the bicycle observing the minimum insertion mark on the seat pillar. Ensure the seat is level and facing the front. Tighten with a 13mm ring spanner. Tighten to 22-26 Newton metres if using a torque wrench. If your bicycle is fitted with a Quick Release type seat bolt, turn the adjusting nut to ensure the locking lever is moved to the closed position with a firm action. refer to Page 48 for more detail about Quick release Mechanisms. The seat pillar must be inserted so that the minimum insertion mark cannot be seen.
Page 17: Front Brake
ASSEMBLY While holding the shoe against Adjust the balance with the spring the rim, tighten the shoe fixing nut. tension adjustment screws. Brake Outer Cable Cable Front Brake Boot Lead Brakes must be adjusted and firmly tightened so that the brake shoes are correctly aligned with the rim, and have minimal clearance with the rim before the control lever is squeezed. Your ...
Page 18 by turning the cable adjusters at the lever. Ensure end cap is fitted to cable to prevent fraying. Connecting and adjusting rear brakes follows similar procedures as for the front. For more details refer to Brakes section under Detailed Maintenance further on in the manual. Do not ride the bicycle until the brakes are functioning properly.
Page 19: Getting Started
DERAILLEUR GEARED BICYCLES ASSEMBLY SINGLE SPEED & BMX Foreword: Assembling a bicycle is an important responsibility. Proper Includes 20", 24” and 26" Wheel Mountain Bikes assembly not only gives the rider more enjoyment of the bicycle; it Assembly is the same for men’s and women’s bikes. Includes 16"...
Page 20: Handlebars And Stem
ASSEMBLY It is very important to check the front wheel connection to the bicycle. Failure to properly tighten may cause the front wheel to dislodge. Frame Training Wheels Metal locating bracket Axle Nut For 12” (30cm) and 16” (40cm) bicycles supplied with trainer wheels, each wheel must first be assembled onto the metal “L”...
Page 21 ASSEMBLY seat Seat Seat Insert the smaller end of the seat pillar into the seat clamp and tighten. Loosen nut on the seat clamp and add 3 or 4 drops of oil onto the Loosen nut on the seat clamp and add 3 or 4 drops of oil onto the threads of the bolt.
Page 22 ASSEMBLY Front Brake Cable Side Pull Adjusting Brakes Barrel Brakes must be adjusted and firmly tightened so that the brake shoes are correctly aligned with the rim, Center Bolt and have minimal clearance with the rim before the control lever is squeezed. Your bike may be fitted Brake with sidepull, ’V’ style, or other types of brakes but the same adjustments must be made. Cable Be sure that the right hand control lever operates the front brake, and for freewheel models with two ...
Page 23 7_OWNERS-MANUAL.qxp ASSEMBLY 08/03/2006 10:36 AM Page 16 67_OWNERS-MANUAL.qxp 08/03/2006 10:36 AM Page 16 8 . Axle Peg Assembly Instructions Axle Peg Assembly Instructions (If Supplied) 8 . Axle Peg Assembly Instructions Non-Threaded Non-Threaded non-tHrEaDED First remove the axle nut from the wheel. There will be either a retaining washer or a step retaining washer included. Place this washer between the peg and the frame at the bicycle. slide the NON-THREADED NON-THREADED peg onto the axle followed by a flat washer and lastly the axle nut.Tighten the axle nut clockwise ...
Page 24: Assembly
ASSEMBLY Final Check Pads Install any additional parts that are supplied with your bike. Note: Your bicycle may be equipped with different style components than the ones illustrated. Reflectors: Attach the white reflector to the front bracket and the red reflector to the rear bracket using a 8mm wrench or a Phillips head screwdriver. Attach the brackets to the bicycle using the hardware provided. For some models, the front reflector bracket will be mounted on the front brake assembly bolt that fits through the fork. It is important to make sure all connections are tightened securely and that the reflectors are properly angled.
Page 25: Before You Ride
BEFORE YOU RIDE Correct Frame Size The ideal clearance will vary between types of bicycles and rider preference. This makes straddling 20067_OWNERS-MANUAL.qxp 08/03/2006 10:36 AM Page 17 the frame when off the saddle easier and safer in situations such as sudden traffic stops. When selecting a new bicycle the correct wheel and frame the correct sized female style bicycle can be checked using a male model as a guide. size is a very important safety consideration. A bicycle ...
Page 26: Riding Position
BEFORE YOU RIDE Riding Position saddle Height In order to obtain the most comfortable riding position, offering the best possible pedaling efficiency, the seat height should be set correctly in relation to the riders leg length. the correct saddle height should not allow leg length. the correct saddle height should not allow leg strain from over-extension, and the hips should not rock from side to side while pedaling.
Page 27: Handlebar Height
BEFORE YOU RIDE Handle Height Stem Wedge Bolt Maximum comfort is usually obtained when the handlebar height is equal to the height of the seat. You may wish to try different heights to find the most comfortable position. Maximum Height/ Minimum Insertion Handlebar Binder Bolt Mark Ensure handlebar stem does not extend beyond the minimum insertion mark. (Refer to “Handlebars and Folk” Section in DETAILED MAINTANENCE for more details, Exceeds 2 1/2 on how to adjust Handlebars).
Page 28: Safety Checklist
BEFORE YOU RIDE safety checklist Wheels and tyres • E nsure tyres are inflated to within the maximum Before every ride it is important to carry out the following recommended limit as displayed on the tyre sidewall safety checks. In addition to these, and the recommended maintenance in • Ensure tyres have tread and have no bulges on DETAILED MAINTENANCE of this manual, every fortnight a thorough excessive wear inspection should be carried out with all nuts and bolts tightened, worn and • ...
Page 29: Cranks & Pedals
BEFORE YOU RIDE chain suspension • Ensure chain is oiled, clean and run smoothly • C heck that all components of fork and rear suspension (if fitted) • Extra care is required in wet or dust conditions are correctly tightened • C heck that there is no excessive wear or side play in rear Bearings suspension components • E nsure all bearings are lubricated, run freely and display no • C heck that components function smoothly without binding excess movement, grinding or rattling • ...
Page 30: Helmets
BEFORE YOU RIDE Helmets It is strongly advised that a properly fitting, New Zealand approved bicycle safety helmet be worn at all times when riding your bicycle. In addition, if you are carrying a passenger in a child safety seat, they must also be wearing a helmet. A bicycle helmet must be labeled with the New Zealand Standards approved mark. The right helmet should: • Fit correctly • Be comfortable • ...
Page 31: Reflectors
r (red), two wheel (orange), and four pedal (orange) reflectors. BEFORE YOU RIDE have reflectors). These are an important safety and legal requirement, rear (red), two wheel (orange), and four pedal (orange) reflectors. condition at all times. Periodically, inspect all reflector, brackets and not have reflectors).
Page 32 BEFORE YOU RIDE Page 24 age 24 seat and Handlebar Mounting reflectors First attach the reflector to the reflector bracket with the reflector screw, see diagram. Next, remove the clamp screw and open the clamping reflector bracket. Place clamping reflector bracket around the handlebar or seat post. If the clamp is too loose, insert the shim inside of the acket with the et with the clamp. Tighten the clamp screw to hold reflector assembly in place, see the attached diagram. remove the clamp move the clamp Finally, adjust the reflector assembly in place and ensure that it is upright and facing away from the ...
Page 33: Riding Safety
BEFORE YOU RIDE riding safely • Expect the unexpected such as opening car doors or cars backing out of concealed driveways. General rules • Be extra careful at intersections and when preparing to pass other vehicles. • When riding obey the same road laws as all other road • Familiarize yourself with all the bicycle’s features. vehicles, including giving way to pedestrians and stopping Practice gear shifts, braking. at red lights and stop signs. • If you are wearing loose trousers, use leg clips or elastic bands • For further information contact the Road Traffic Authority. to prevent them being caught in the chain. • Ride predictably and in a straight line on the left side of the • Don’t carry packages or passengers that will interfere road. Never ride against the traffic. with your visibility or control of the bicycle. • ...
Page 34: Wet Weather Riding
BEFORE YOU RIDE Wet Weather riding • If using battery powered lights make sure batteries are well charged. If using dynamo-powered lights ensure In wet weather you need to take extra care. wiring is properly connected and not loosely fitted. • Some rear lights available have a flashing mechanism, Brake earlier, you will take a longer distance to stop. which enhances visibility. • Decrease your riding speed, avoid sudden braking • ...
Page 35: Hill Technique
BEFORE YOU RIDE Hill Technique • Always wear a properly fitting helmet. • Do not play on driveways or the road. • Gear down before a climb and continue gearing down as required to maintain pedaling speed. • Do not ride on busy streets. • I f you reach the lowest gear and are struggling, stand up • Do not ride at night. on you pedals. You will then obtain more power from each • Obey all the traffic laws, especially stop signs and red lights. pedal revolution. • Be aware of other road vehicles behind and nearby. • On the descent, use the high gears to avoid rapid pedaling. • Before entering a street: Stop. Look rights, left, and right again for ...
Page 36: Gears: How To Operate
BEFORE YOU RIDE Gears – How To Operate Derailleur Gears. Most multi-speed bicycles today are equipped with what are known as derailleur Derailler gears. The operate using a system of levers and mechanisms to move the drive control cables chain between different sizes driving gears or cogs. The purpose of gears is to Front derailleur let you maintain a consistent, steady pedaling pace under varying conditions. Freewheel cogs this means your riding will be less tiring without unnecessarily straining up hills to fast pedaling down hill. Bicycles come with a variety of gear configurations form 5 through to 24 speed. A 5-6 speed bicycle will have a single front chain wheel, a rear derailleur only and 5 or 6 cogs on the rear hub. Bicycles with more gears will also have a front derailleur, a front chain wheel with 2-3 cogs and up ...
Page 37: Thumb Shifters (Top Mounted)
20067_OWNERS-MANUAL.qxp 08/03/2006 10:37 AM Page 29 BEFORE YOU RIDE Thumb Shifters (Top Mounted) Top Gear Bottom Gear (Easier) Most MTB style bicycles are equipped with shifters mounted on the top of (Harder) thumb shifters (top Mounted). top Gear (Harder) Small rear sprocket Large rear sprocket the handlebars and operated by the thumbs.
Page 38: Below The Bar Shifters
BEFORE YOU RIDE Below the Bar shifters. Left hand lever Right hand lever Many of today’s more up market Mountain style bicycles now use a shift lever arrangement mounted on the underside of the handlebars, which uses two levers operated by the thumb and the 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, continuing to push will move the chain over multiple cogs. Pushing the smaller (upper) left shifter with you index finger mover the chain from a larger to a smaller chain wheel. Hand Grip shifters Some bicycles are now being equipped with a shifting mechanism, called Grip Shift, which is built into the handlebar grips and does not make use of separate levers. The actuating ...
Page 39: Dual Control Shifters
BEFORE YOU RIDE 20067_OWNERS-MANUAL.qxp 08/03/2006 10:38 AM Page 31 Dual control shifters Dual Control Shifters Some “top of the range” racing bicycles now use dual control levers. Some “top of the range” racing bicycles now use dual control levers. These actuate both the High Gear Low Gear These actuate both the brakes, like a conventional brake lever, and also brakes, like a conventional brake lever, and also the gears, when moved inward toward the ...
Page 40: Bicycle Care
BEFORE YOU RIDE Bicycle care measure. Regularly clan and lubricate all moving parts, tighten components and make adjustments as required. The use of alloy components minimizes the Basic Maintenance number of places where rust can surface. the following procedures will ensure your bicycle is maintained on top storage condition. For painted frames, dust the surface and remove and loose Keep your bicycle in a dry location away from the weather and the sun. dirt with a dry cloth.
Page 41: Security
BEFORE YOU RIDE security It is advisable that the following steps be taken to prepare solid Post for and help prevent possible theft. 1 Maintain a record of the bicycle serial number, generally Bicycle Frame located on the frame underneath the bottom bracket. 2 register the bicycle with the manufacturer/distributor u-lock and local police. 3 ...
Page 42: Servicing
SERVICING correct routine Maintenance of your new bike will ensure: • Smooth running • Longer lasting components • Safer riding • Lower running costs • Every time you ride your bicycle it’s condition changes. The more you ride, the more frequently maintenance will be required. We recommend you spend a little time on regular maintenance tasks. The following schedules are a useful guide and by referring to DETAILED MAINTENANCE of this manual, you should be able to accomplish most tasks. If you require assistance we recommend you see your specialist bicycle dealer. 40 InstructIon Manual...
Page 43: Schedule 1 Lubrication
SERVICING schedule 1 lubrication Note: The frequency of maintenance Frequency component lubrication How to lubricate should increase with lots of usage are use in wet or dusty conditions. Weekly chain chain lube or light Brush on or squirt Do not over lubricate – remove excess Derailleur wheels chain lube or light oil Brush on or squirt lubricant to prevent dirt build up.
Page 44: Schedule 2 Service Checklist
SERVICING Schedule 2 Service Checklist Frequency task Before every Ride check tyre pressure check brake operation check wheels for loose spokes Make sure nothing is loose After every ride Quick wipe down with damp cloth Weekly lubrication as per schedule 1 Monthly lubrication as per schedule 1 check hub, head set and crank bearings for looseness check derailleur adjustment check pedals are tight...
Page 45: Servicing
SERVICING Torque Requirements Tools Required When performing routine adjustments on nuts and bolts it is open ended or ring spanners: recommended that a torque wrench be used to prevent over 8mm, 9mm, 10mm, 12mm, 13mm, tightening and damage to the threads. the following are key 14mm, 15mm components that should be tightened using a torque wrench. open end or pedal spanner 15mm allen key wrenches: 4mm, 5mm, 6mm adjustable wrench 5 ...
Page 46: Detailed Maintenance
Detailed maintenance DETAILED MAINTENANCE DETAILED MAINTENANCE Wheels and tyres loose hub bearings Lift each wheel off the ground and try to move the wheel from side to side. Wheel Inspection Caution: If there is movement between the axle and the hub, do not ride the bicycle. Adjustment will be required. It is most important that wheels are kept in top condition. Properly Axle nuts maintaining your bicycle’s wheels will help braking performance and stability check that all these are tight before each ride.
Page 47: Tyre Inspection
Tyre Inspection Tyre Inspection Tyres must be maintained properly to ensure road holding and stability. Check the following areas: Tyres must be maintained properly to ensure road holding and stability. Check the following areas: . Inflation: Ensure tyres are inflated to the pressure indicated on the tyre sidewalls. It is better to use a tyre gauge and a hand .
Page 48 Detailed maintenance DETAILED MAINTENANCE DETAILED MAINTENANCE Front Wheel Removal retaining Washer Axle Axle 1 Open the brake quick release, if fitted, or slacken the brake cable adjuster. 2 If wheel is fitted with standard axle nuts, use a spanner to loosen them off. If secondary retention devices are fitted you will need to loosen the nuts sufficiently to allow clearance to remove the wheel. 3 If a quick release axle is fitted, move the lever to the open position. If secondary retention devices are fitted, loosen the adjusting nut at the opposite end to the QR lever enough to allow the wheel to be removed. 4 Remove the wheel. Front Wheel replacement cone nut 1 Replacement follows almost the reverse sequence to removal. step retaining Fork Drop out Washer 2 Place the wheel into the frame ensuring that the axle fits well up against the fork end slots. You may need to slightly prise apart the fork legs. 3 ...
Page 49 067_OWNERS-MANUAL.qxp 08/03/2006 10:38 AM Page 40 Detailed maintenance Rear Wheel Removal Rear Wheel Removal 1 . Open the brake quick release, if fitted, or screw in the brake cable 1 Open the brake quick release, if fitted, or slacken the brake cable adjuster. adjuster. If more clearance is needed you may need to undo the brake If bicycle has derailleur gears, engage the chain onto the smallest rear cog.
Page 50: Correct Qr Axle Setting
Detailed maintenance DETAILED MAINTENANCE Correct QR Axle Setting Quick Release Adjusting Axle Quick Release Some bicycles have wheel axles that incorporate a Quick Release (QR) mechanism. This allows Lever easy wheel removal without the need for tools. The mechanism uses a long bolt with an adjusting nut on one end, and a lever operating a clam-action tensioner on the other. Spring Axle Correct adjustment of the QR is vitally important to avoid an 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.
Page 51 Detailed maintenance 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 one hand, tighten the adjusting nut until it stops. 3 Pivot the lever towards the closed position. When the lever is halfway closed, there 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. the wheel is tightly secured when the serrated surfaces of the Qr clamping parts actually begin to cut into the bicycle frame/fork surfaces.
Page 52: Hub Bearing Adjustment
Detailed maintenance DETAILED MAINTENANCE DETAILED MAINTENANCE Hub Bearing adjustment Ball Bearings When checked, the hub bearings of either wheel will require adjustment if there is any more than Bearing Lock slight side play. Cone Washer Hub Body 1 To adjust, remove wheel from bicycle and loosen the locknut on one side of the hub while holding the adjusting cone on the same side with a flat open-end spanner. rotate the adjusting cone as needed to eliminate free play. retighten the locknut while holding the adjusting cone in position.
Page 53: How To Fix A Flat Tyre
Detailed maintenance How to Fix a Flat Tyre If you need to repair a tyre follow these steps: 1 Remove the wheel from the bicycle 2 Deflate the tyre completely via the valve loosen the tyre bead by pushing it towards all the way round the rim 4 Prise one side of the tyre bead up over the edge of the rim. N ote: Use tyre levers, not a screwdriver, otherwise you may damage the rim. 5 Remove the tube, leaving the tyre on the rim locate the leaks and patch using a tube repair kit, carefully following the instructions, or replace the tube.
Page 54 Detailed maintenance DETAILED MAINTENANCE DETAILED MAINTENANCE remount one side of the tyre onto the rim. 10 Using a hand pump, inflate the tube just enough to give it some shape 11 Place the valve stem through the hole in the rim and work the tube into the tyre. note: Do not let it twist. 12 using your hands only, remount the other side of the tyre by pushing the edge toward the centre of the rim. Start either side of the valve and work around the rim.
Page 55: Tyre Valves
marked on the sidewall. Use a tyre air pressure gauge to check. 17 . Replace the wheel into the frame checking that all gears, brakes and quick release levers are properly adjusted. Detailed maintenance Tyre Valves Tyre Valves Bicycles today commonly use one of two kinds of tyre valves. In order to Bicycles today commonly use one of two kinds of tyre valves. ...
Page 56: Handlebars & Fork
Detailed maintenance DETAILED MAINTENANCE DETAILED MAINTENANCE Handlebars and Fork Handlebar Clamp Bolts Handlebar Binder Bolt Handlebar stem the handlebar stem fits into the steering column and is held firm by the action of a binder bolt and expander wedge, when tightened, binds with the inside of the fork steerer tube. Stem Bolt some bikes now use a different,”ahead”...
Page 57 Detailed maintenance When re-fitting the stem, make sure the handlebars are correctly aligned and tightened using the Grip appropriate hex wrench or Allen key to a minimum 17Nm of torque. Do not over tighten. test the security of the handlebars stem within the fork steerer tube, by clamping the front wheel between your knees and trying to move the handlebars up and down and from side to side. The handlebar should not move when applying turning pressure. Stem Wedge Bolt “a Headset”...
Page 58: Handlebars
Grip and tightened using the appropriate hex wrench or allen key to a When re-fitting the stem, make sure the handlebars are correctly aligned Grip minimum 17Nm of torque. Do not overtighten. and tightened using the appropriate hex wrench or allen key to a Test the security of the handlebars within the stem, and the stem within minimum 17Nm of torque.
Page 59: Forks
Detailed maintenance DETAILED MAINTENANCE Forks Steering Tube there are two different types of forks that range in styles and dimensions. one type is a rigid fork Brake Boss (Figure 1) consisting of stationary tubing with curved blades. The other type is a suspension fork (Figure 2) consisting of stanchion tubes riding on elastomers or springs inside of a straight fork leg. Drop-out This mechanism acts as a shock absorber with a specified amount of travel that varies between ...
Page 60: Bicycle Suspension
Detailed maintenance Bicycle suspension Some Mountain Bikes come equipped with suspension systems that are desinged to provide a smoother more comfortable riding experience by lessening some of the shocks or jarring effects encountered when riding on roads with irregular surfaces such as unsealed gravel, or those with undulating surfaces. There are many different types of suspension systems - too many to deal with individually in this manual. suspension can increase the handling capabilities and comfor tof your bicycle. this enhanced capability may allow your to ride faster; but you must not confuse the enhanced capabilities of the bicycle with your own capabilites as a rider. Bicycling can be a potentially hazardous activity. We recommend that you do not use your bicycle in the following manner; competitive events, bicycle racing, dirt ...
Page 61: Dual Suspension
Detailed maintenance Dual Suspension Dual Suspension bikes are equipped with a front fork as well as a rear suspension generally located below the seat. The rear suspension unit is a combination of a piston that works in Dual Suspension conjunction with a spring to allow the rear swing arm to rotate Dual suspension Dual Suspension bikes are equipped with a front fork as well on a pivot point.
Page 62: Rear Pivots
Detailed maintenance Rear Pivots Rear Pivots The pivot assembly is a simple mechanism that allows Rear Pivots the rear swing arm to move up and down in combination The pivot assembly is a simple mechanism that allows The pivot assembly is simple mechanism that allows the rear swing arm to move up and down in with a rear suspension unit. Size, shape and compo- the rear swing arm to move up and down in combination combination with a rear suspension unit. Size, shape and components will vary between models: ...
Page 63: Headset
Detailed maintenance Headset standard Lock Nut Headset Inspection Lock Washer The headset bearing adjustment should be checked every month. This is important, as it is the headset, which locks the fork into the frame, and if loose can cause damage or result in an accident. While standing over the frame top tube with both feet on the ground, apply the front brake firmly Adjusting Cup/Cone and rock the bicycle back and forward. If you detect any looseness in the headset, it will need adjustment.
Page 64 Detailed maintenance lubrication A complete lubrication should be carried out every year. this is a complicated procedure, which you may wish to refer to a specialized bicycle dealer. However the following procedure should enable you to carry out the work yourself. Find a way to suspend the bicycle so that the front wheel is off the ground. 2 Remove the handlebar assembly form the steering tube. 3 L oosen and remove the headset locknut, followed by the lock washer and reflector bracket, if fitted. 4 S upport the forks with one hand and remove the adjusting cup, followed by the upper ball retainer. 5 ...
Page 65: Rotors
Detailed maintenance Rotors Some BMX Freestyle bikes are equipped with a Rotor - a special headset mechanism which allows the handlebars to be turned 360 degrees without causing the brake cables to become tangled. The front brake cable is routed throuth the centre of a hollow headstem and the fork, then up to the right control lever. The rear brake cable is split at the rotor bearing mechanism which transfers the left control lever pressure to actuate the rear brake. The system must be correctly adusted. Components will already be installed on a new bike but the cables may need connecting. Rotors Installation and Adjustment uPPEr caBlE 1. First connect the barrel end of the upper cable to the left rear brake lever. Make sure the long casing is on top of the short cable casing; otherwise, the upper cable will have a twist in it. 2. Route the upper cable throuth the handlebars(below the crossbar) with the short cable casing on the same side as the rear brake lever. 3. connect the upper cable to the upper plate by passing the football ends of the upper cable through the threaded holes in the upper plate and connecting them to the bearing.
Page 66: Saddle & Seat Post
Detailed maintenance 5. Screw the cable adjuster on the upper cable splitter out until all slack is removed from the upper Single Cable Casin cable. then screw the cable adjuster out one more turn to raise the bearing an additional 1mm away Cable Adjuster from the lower cable adjusting barrels. Cable Splitter catIon: Don’t screw the cable adjusters on the upper cable splitter out more than 8mm. use the cable adjuster on the rear brake lever if more adjustment is needed.
Page 67 Detailed maintenance this may cause damage to either the seat post, the frame or possible the rider. a minimum of 65mm of seat tube must always remain in the frame. lubrication Seat Fixing Bolt Remove the seat post from the frame and wipe off any old grease rust or dirt. Then apply a thin film of new grease to the part that will be inserted into the frame. re-insert, adjust and tighten the seat post in the frame.
Page 68 Detailed maintenance the saddle can also be adjusted by sliding it forward or back along the mounting rails to obtain the most comfortable reach to the handlebars. When fitting, position the seat post into the clamp under the seat and place it in the frame without tightening.
Page 69: Brakes
Detailed maintenance Brakes Side Pull Cable Brakes Adjusting Barrel The correct adjustment and operation of your bicycle’s brakes is extremely important for safe operation. Brakes should be checked for effective operation before every ride. Frequent checking Center Bolt of adjustment is necessary as the control cables will stretch and the brake pads will become worn Brake with use. Never ride a bicycle with the seat post raised beyond the Cable Anchor minimum insertion/ max.
Page 70 20067_OWNERS-MANUAL.qxp 08/03/2006 10:40 AM Page 54 Some brakes have a Quick Release mechanism to allow easier wheel removal. Whenever you adjust the brakes, make sure the QR mechanism is in the closed position. Detailed maintenance Some brakes have a Quick Release mechanism to allow easier wheel removal. Whenever you adjust the brakes, make sure the Never ride unless the Quick Release is firmly locked in the closed position.
Page 71: Cantilever Calipers
Detailed maintenance 20067_OWNERS-MANUAL.qxp 08/03/2006 10:41 AM Page 55 20067_OWNERS-MANUAL.qxp 08/03/2006 10:41 AM Page 55 20067_OWNERS-MANUAL.qxp 08/03/2006 10:41 AM Page 55 If one pad is closer to the rim than the other, loosen the fixing nut at the back of the brake, apply Brake pads should finally be adjusted so that the leading edge of the Brake pads should finally be adjusted so that the leading edge of the Link Cable Link Cable Brake Cable...
Page 72 Detailed maintenance 20067_OWNERS-MANUAL.qxp 08/03/2006 10:41 AM Page 56 0067_OWNERS-MANUAL.qxp 08/03/2006 10:41 AM Page 56 On some newer type cantilever brakes, the main brake cable continues On some newer type cantilever brakes, the main brake cable continues Align brake shoe with On some newer type cantilever brakes, the main brake cable continues through the central cable ...
Page 73 Detailed maintenance 20067_OWNERS-MANUAL.qxp 08/03/2006 10:41 AM Page 57 20067_OWNERS-MANUAL.qxp 08/03/2006 10:41 AM Page 57 Adjustment - Linear Pull Brakes Adjustment - Linear Pull Brakes Adjustment - Linear Pull Brakes 1. If assembling linear pull brakes insert the brake body into 2.
Page 74 20067_OWNERS-MANUAL.qxp 08/03/2006 10:41 AM Page 58 3. While holding the shoe against the rim, 5. Adjust the balance with the spring tension tighten the shoe fixing nut. adjustment screws. Detailed maintenance 067_OWNERS-MANUAL.qxp 08/03/2006 10:41 AM Page 58 3. While holding the shoe against the rim, 5.
Page 75 e 60 to 80 kgf. cm. akeshoe. Be sure to place the brakeshoe so that the direction of the arrow Detailed maintenance and tighten the nut with a 10mm wrench. (the tightening torque should be Adjustment / Installation - U-Brakes Fig.
Page 76: Brakeshoe Replacement
Detailed maintenance Brake Shoe Replacement Brake shoes must be replaced if worn so far that there is insufficient effective pad material remain- ing or they are worn past the “wear line” indication. To replace, first remove the worn brakes shoes after disconnecting the holding mechainsm. Depending on the type of brake, as described on tread tread Worn off previous pages, the holding mechanism may be a hexagonal nut or an Allen screw arrangement, or a combination of both. Take note of the order and position in which the various curved washers Worn out Brake shoe and spacers are attached. Fix the new brake shoes., adjusting the angel and clearance to the rim as ...
Page 77 both.Take note of the order and position in which the various curved washers and spacers are attached. Fix the new brake shoes, adjusting the angle and clearance to the rim as previously described, and Usable Brake Shoe Worn out Brake Shoe (Replace) tighten firmly.
Page 78: Drivetrain
Detailed maintenance Drive Train The drive train of a bicycle refers to all parts that transmit power to the rear wheel, including the pedals, chain, chain wheel and crank set, and freewheel. Pedals Pedals are available in a variety of shapes, sizes and materials and each are designed with particular purposes in mind. some pedals can be fitted with toe clips and straps. these help to keep the feet correctly positioned and allow the rider to exert pulling force, as well as downward pressure, on 20067_OWNERS-MANUAL.qxp 08/03/2006 10:42 AM Page 62 the pedals. Use of toe clips with straps requires practice to acquire the necessary skill to operate ...
Page 79: Lubrication And Adjustment
Detailed maintenance L = Left Turn counter-clockwise Never ride with loose pedals. to tighten. - Check that pedal bearings are properly adjusted. Move the pedals up and down, and right to left, and also rotate them by hand. If you detect any looseness or roughness in the pedal bearings then adjustment, lubrication or replacement will be required. - Ensure front and rear pedal reflectors are clean and securely fitted. - Ensure toe clips, if fitted, are securely tightened to the pedals.
Page 80 Many pedals cannot be disassembled to allow access to the internal bearings and axle. However, it is usually possible to inject a little oil onto the inside bearings, and this should be done every six months. If the pedal is the type that can be fully disassembled, then the bearings should be removed, cleaned and greased every six to twelve months.
Page 81: Crank Set
Detailed maintenance 20067_OWNERS-MANUAL.qxp 20067_OWNERS-MANUAL.qxp 08/03/2006 08/03/2006 10:42 AM 10:42 AM Page 64 Page 64 Crank Set Crank Set Crank Set The crank set refers to the Bottom Bracket axle and bearings, The crank set refers to the Bottom Bracket axle and bearings, Crank Arm Crank Arm The crank set refers to the Bottom Bracket axle and bearings, the Crank Arms and Chainrings.
Page 82: One Piece Cranks
Detailed maintenance Lubrication and Adjustment - One Piece Cranks to adjust the freeplay in a one piece type bottom bracket, loosen the locknut on the left side by turning it clockwise and tighten the adjusting cone counter- clockwise using a screwdriver in the slot. When correctly adjusted re-tighten the locknut counterclockwise. to disassemble: 1 . Remove the chain from the chainwheel.
Page 83: Cotterless Cranks
Detailed maintenance Lubrication and Adjustment - Cotterless Cranks Bottom Bracket to adjust the freeplay in a three piece type bottom bracket, loosen the lockring on the left side by turning it counter-clockwise, then turn the adjusting cup as required. Re-tighten the lockring being sure not to alter the cup adjustment. To disassemble: 1 . Remove the cranks from the axle. Fixed Cup Cotterless Crank removing tool 2 . Remove the left side lockring by turning it counter-clockwise.
Page 84 Detailed maintenance Cotterless Crank Replacement: Screw in the removal tool. 1 . Replace the crank arm onto the axle. Turn the screw bolt clockwise. 2 . tap the crank arm lightly with a mallet. 3 . Refit the washer and tighten flange nut or bolt securely to a torque of 27Nm. 4 . Replace the dust cover. New cotterless cranks may become loose with initial use. Position the crank on the axle. Perform the following task after several hours riding, and repeat it two or three times after further use.
Page 85: And Replacement
Detailed maintenance Chain Rear Sprocket Front Chainwheel Inspection The chain must be kept clean, rust free and frequently lubricated in order to extend it’s life as long Pull up as possible. It will require replacing if it stretches, breaks or causes inefficient gear shifting. Make sure that there are no stiff links, they must all move freely. Lubrication The chain should be lubricated with light oil at least every month, or after use in wet, muddy or 10 mm dusty conditions. Take care to wipe off excess oil, and not get oil on the tyres or rim braking Straightedge surfaces. Adjustment and Replacement on derailleur geared bicycles and rear derailleur automatically tensions the chain. to adjust the chain on single speed freewheel, coaster hub brake or 3-speed hub geared bicycles: 1 Loosen the rear axle nuts (and coaster brake arm clip if fitted) and move the wheel forward, ...
Page 86: Freewheel
Detailed maintenance 20067_OW NERS- M ANUAL. qxp 08/ 03/ 2006 10: 43 AM Page 69 Derailleur geared bicycles use narrower chains and require a special each end of the chain, position the master link side plate, and slip on the u-shaped snap-on tool to fit and remove, or to change the length.
Page 87: Coaster Hub
Detailed maintenance Lubrication 0067_OW NERS- M ANUAL. qxp 08/ 03/ 2006 10: 43 AM Page 70 Remove any accumulated dirt from the freewheel with a brush and some kerosene. Disassembly of the free wheel is a complicated procedure requiring special tools, and should be left to a specialist dealer. Apply oil to the freewheel whenever you lubricate the chain, taking care to wipe off any excess. Coaster Hub Coaster Hub Many BMX style and other children’s bicycles are fitted with a Coaster Hub Many BMX style and other children’s bicycles are fitted with a coaster Hub Brake in the rear wheel. Brake Arm Clip This type of brake offers the advantages of reliability and easy operation. The brake is operated by ...
Page 88: Derailleur Systems
Detailed maintenance Derailleur Systems The derailleur system comprises the front and rear derailleur, the shift levers, and the derailleur control cables, all of which must function correctly for smooth gear shifting to occur. there are several different types of derailleur systems but all operate using similar principles. Your new bicycle may be fitted with a standard “friction” type system where you will need to feel each gear shift into position. It may be fitted with an “index” system (e.g. SIS), which links each different gear ...
Page 89: Rear Derailleur
Detailed maintenance Derailleur shifting performance. check then for any sign of rust, fraying, kinks, broken strands, and any Freewheel Outer side of Top Gear Although the front and rear derailleurs are initially adjusted at the damage to the cable housing. If you find any problems, the cables may need replacing before factory, you will need to inspect and possibly readjust both before Pulley Adjustment your next ride.
Page 90 Rear Derailleur Begin by shifting the rear shifter to largest number indicated, dis- connect the cable from the rear derailleur cable anchor bolt, and place the chain on the smallest sprocket. Adjust the High limit Guide Pulley screw so the guide pulley and the smallest sprocket are lined up vertically.
Page 91: Front Derailleur
Detailed maintenance 20067_OWNERS-MANUAL.qxp 08/03/2006 10:44 AM Page 74 Adjustment – Front Derailleur Adjustment - Front Derailleur Cable Clamp Bolt The front derailleur must be positioned so that it’s chain guides are the front derailleur must be positioned so that it’s chain guides are parallel to the chainrings. the Low adjusting screw 20067_OWNERS-MANUAL.qxp 08/03/2006...
Page 92: Reflectors
Detailed maintenance then turn the downtube mounted cable adjuster so that the inner chainguide just clears the chain. this completes the adjustment. after a period of use, the front derailleur cable will stretch and you may find difficulty shifting the Reflectors Reflectors chain to the small chainring.
Page 93 Detailed maintenance ACCESSORIES There are a wide variety of accessories available that can enhance your bicycle’s function, safety, versatility and style. If you are purchasing accessories, always make sure they are suitable for your bicycle. Be sure that they are correctly fitted and do not interfere with your ability to safely control your bicycle. Following is a list of some of the many kinds of accessories available for bicycles. 1 . rear carrier Available in many styles and sizes, they allow you to safely carry your luggage. Luggage should only be carried on a properly designed and fitted bicycle luggage carrier. 2 . Pannier Bags Versatile carry bags that usually fit either side of a rear mounted carrier. Several weather resistant compartments make them very useful for bicycle touring when you need to carry extra gear and keep it dry. 3 . saddle Bag These are useful for carrying small items such as tools, a spare tube or a puncture kit. Other small bags available are designed to fit on the handlebars, or in the corner of the main frame where they double as a shoulder pad if carrying the bicycle. 4 . child safety carrier The only way to carry children up to approximately 18kg in weight is in a properly designed carry seat.
Page 94 Detailed maintenance 6 . safety Flag Usually available in bright fluoro colours, these attach to the rear axle and make you more visible when riding in traffic. 7 . Pump Essential for maintaining your tyres at their correct pressure. Make sure the end connection is the same as valves on your bicycle’s tubes. 8 . repair Kit You’ll need one of these to help get you mobile again in the event of a tyre puncture. 9 . lock Your new bicycle is an expensive item which you would not like to lose through theft. There are many kinds of bicycle locks available, some more effective than others. Always lock your bicycle to an immovable object if you leave it unattended. 10 . rear View Mirror A very useful item to keep you aware of traffic moving behind you. 11 . Bar Ends These can be attached to the ends of Mountain Bicycle handlebars to give you added flexibility in hand positioning, especially when hill climbing. 12 . computer Better than a simple speedometer, bicycle computers come with a number of functions so you can measure your speed, distance travelled and time. They are a very useful aid for fitness training. 13 . Mudguards Prevent road dirt and water from soiling your clothes and getting in your eyes.
Page 95 Detailed maintenance 14 . Water Bottles When riding in hot weather you’ll need to increase your body’s liquid intake. Bicycle water bottles are available in attractive fashion colours in various sizes and are conveniently carried in frame mounted carry cages. 15 . Gloves Bicycle gloves help prevent soreness and blisters on your hands during long rides and also give protection in the event of a fall. They are available in a variety of great looking fashion colours and designs. Cycling requires a certain amount of skill and concentration to ride safely and in control. While fitting accessories to your bike can add enjoyment to your cycling experience, it is strongly recommended that any adjustments or actions that would change your normal riding position should be avoided, as the slightest of accidents which could occur can still cause injury.
Page 96: Troubleshooting
Detailed maintenance TROUBLESHOOTING Problem Possible Cause Usual Remedy Gear shifts not working properly Derailleur cables sticking/ stretched/ damaged. lubricate/ tighten/ replace cables Front or rear derailleur not adjusted properly. adjust derailleur Indexed shifting not adjusted properly Adjust indexing slipping chain Excessively worn/ chipped chainring replace chainring, sprockets and chain or freewheel sprocket teeth.
Page 97 Detailed maintenance Problem Possible Cause Usual Remedy Grinding noise when pedaling Pedal bearings too tight adjust bearings Bottom bracket bearings too tight adjust bearings chain fouling derailleur adjust chain line Derailleur jockey wheels dirty/ binding clean and lubricate jockey wheels Freewheel does not freewheel Freewheel internal pawl pins are jammed lubricate.
Page 98: Detailed Maintenance
Detailed maintenance Problem Possible Cause Usual Remedy Wobbling wheel Axle broken Replace axle Wheel out of true true wheel Hub cones loose adjust hub bearings Headset binding adjust headset Hub bearings collapsed replace bearings steering not accurate Inner tube old or faulty replace inner tube tyre thread/casing worn replace tyre...

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Cruiser Suspension Bmx Racing Mountain Crossbikes