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SixThreeZero PAVE N’TRAIL Assembly Manual

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ASS EMB LY G UI DE
PAV E N ' T R A I L
S I X T H R E E Z E R O

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Summary of Contents for SixThreeZero PAVE N’TRAIL

  • Page 1 ASS EMB LY G UI DE PAV E N ’ T R A I L S I X T H R E E Z E R O...
  • Page 3 O UR C OM M ITME NT We want you to love your bike as much as we do. If you run into any issues, no matter how small, let us know and we’ll take care of it. S I X T H R E E Z E R O T H E T E A M @ S I X T H R E E Z E R O .
  • Page 4 MEET JACO B, O UR MEC HANIC Need assembly, repair, or installation assistance? He’s your guy! Want live help? Call or email to schedule an appointment. M E C H A N I C S @ S I X T H R E E Z E R O . C O M 3 1 0 .
  • Page 5 A N OT E F R O M O U R M E C H A N I C Welcome to the sixthreezero experience. Now for the fun rush, and enjoy the process. Part of the fun in building your part...
  • Page 6 TOOL S YOU ’LL N E E D Creating something wonderful with your own hands is basically the best feeling ever. We want you to have fun building your new bike, so there’s only a few things you need to get started.
  • Page 7 M A L L E T O R S C I S S O R S 1 5 M M C R E S C E N T W R E N C H 4 , 5 , A N D 6 M M H A M M E R A L L E N K E Y ( u s e t o c u t z i p t i e s )
  • Page 8 W HAT ’S IN TH E BOX? Lay out all the parts in front of you. Make sure you have all the parts before getting started. P E D A L S + R E A R A X E L 1 4 M M 1 5 M M 1 2 M M...
  • Page 9 F R O N T A N D R E A R H A N D L E B A R / F R A M E / R E A R Q U I C K R E L E A S E W H E E L A N D R E A R R AC K S E T- U P F R O N T W H E E L R E F L E C T O R S...
  • Page 10 A S S E M B LY E X P E R I E N C E G U I D E B O O K L E T M U LT I -T O O L 4 , 5 , A N D 6 M M A L L E N K E YS B O X 2...
  • Page 11 S E AT P E DA L S a t t a c h e d t o s e a t t u b e Q U I C K R E L E A S E H A R D WA R E S K E W E R p r e - i n s t a l l e d B O X 3...
  • Page 12 BIKE PARTS REFERENC E G UIDE All the names of all the parts for your bike, all in one place. Keep this handy during assembly, and everything will go just fine.
  • Page 13 B R A K E L E V E R H A N D L E B A R G R I P S H A N D L E B A R S R E F L E C TO R S U S P E N S I O N S E AT I N D E X S H I F T E R S E AT P O S T C L A M P...
  • Page 14 FRON T W HEEL + RE AR RACK Parts required: Tools you’ll need: Q U I C K R E L E A S E ( 4 ) 4 M M A L L E N F R O N T W H E E L K E Y S C R E W S ( p r e - i n s t a l l e d ) F R A M E , R E A R R A C K...
  • Page 15 Spin the front fork so that the brakes are pointing forward. Pinch front brake arms, pulling the metal tubing up and Turn the handlebars to match the Correct Image so that out until it is disengaged and the brake arms are open. the cables don’t loop around the headtube.
  • Page 16 5 M M A L L E N K E Y Locate the arrow on the wall of the tire and position the Use a 5mm multi-tool to loosen the front brake pads and tire like the image below. With the arrow pointing rotate them horizontally if needed.
  • Page 17 QR2 QR3 - QR1 All of the components for the quick release skewer are Insert the quick release skewer through the hub opening attached out of the box. on either side of the wheel, as shown below. and remove QR4. Do not remove Unscrew Slide quick release skewer completely through the hub.
  • Page 18 - QR1 Place on the open side of the quick skewer, with the Making sure the wheel is straight by pulling the wheel smaller end pointing inward. completely up against the fork. Attach compressing the spring completely. Hold the quick release lever in place and tighten lightly.
  • Page 19 Lift the lever up towards the fork. If the lever does not Once the front wheel is secured, lower the kickstand and lock in place smoothly, loosen slightly and try again. locate the front fender. It will take a small amount of strength, but that is normal. N O T E The lever at a 90º...
  • Page 20 4 M M ( 2 ) 4 M M A L L E N R E A R 4 M M ( 2 ) 4 M M A L L E N R E A R A L L E N K E Y K E Y S C R E W S R A C K A L L E N K E Y...
  • Page 21 H AN D L EBAR, S EAT + PEDAL S P E D A L S 5 M M 1 5 M M B I C Y C L E A L L E N K E Y M U LT I -TO O L P U M P H A N D L E B A R S E AT AT TA C H E D...
  • Page 22 5 M M A L L E N K E Y Your bike is equipped with a “threadless stem”. It clamps Loosen the top cap of the fork steerer with a 5mm Allen to the outside of the steerer tube. key and remove the top cap and bolt.
  • Page 23 5 M M A L L E N K E Y Loosen the stem clamp bolts with a 5mm Allen key before twisting the stem to face forward. Align the stem to be in line with the front wheel. WATC H A S S E M B LY V I D E O S O N O U R Y O U T U B E C H A N N E L , H T T P S : / / S I X T H R E E Z E R O . C O M / PA G E S / A S S E M B LY...
  • Page 24 5 M M A L L E N K E Y Now tighten the stem clamp bolts evenly with the After making sure that the stem bolts are properly handlebar assembly facing directly forward. tightened, use a 5mm allen key to re-install the top cap. N O T E These bolts are designed to be tighten to correct torque.
  • Page 25 6 M M 6 M M A L L E N K E Y A L L E N K E Y Loosen the bolts on the handlebar faceplate using a 6mm Place handlebar between the stem and faceplate ensuring Allen key.
  • Page 26 P H I L L I P S F R O N T B I C Y C L E O R S C R E W D R I V E R R E F L E C TO R A U TO G R E A S E Adjust the position of the front reflector by loosening the Our suspension seat post doesn’t need any adjustment...
  • Page 27 B I C Y C L E O R 1 5 M M P E D A L S A U TO G R E A S E M U LT I -TO O L Apply grease to the threading on both Align threading with the right crank arm, We recommend hand tightening initially and pedals.
  • Page 28 B I C Y C L E P U M P Pump air into the tires to PSI 40-65MAX, as recommended Sit on the bike and check the angle formed by your knee. on the sidewall of the tire. If your knee forms the incorrect angle, use the seat post clamp lever to raise the seat until you have a subtle bend or achieve a comfortable height.
  • Page 29 B R AK E AS SE MBLY D I AG R A M TO O L S R E Q U I R E D M E TA L T U B E B A R R E L A D J U S T E R C A B L E H O U S I N G B R A K E...
  • Page 30 N O T E Only follow steps 1-9 if your brake cable is not attached to the bicycle. If your brake cable is attached, skip to step 10. There are two ends to the brake cable. One end has a barrel attached, while the other end has an open piece of cable.
  • Page 31 Attach the brake cable to the brake lever Pull on the cable and slide it through the by squeezing the lever and inserting the narrow crevice that runs along the brake barrel into the barrel hanger. lever. B A R R E L B A R R E L B R A K E A D J U S T E R...
  • Page 32 Insert the open end of the brake cable into the larger end Slide the metal tube up the brake cable until the housing of the metal tube. fits snugly into the cable housing. C A B L E G U I D E M E TA L T U B E M E TA L T U B E H AV I N G T R O U B L E ? WA N T L I V E H E L P ? C A L L 3 1 0 .
  • Page 33 5 M M A L L E N K E Y Slide the exposed end of the metal into the metal tube Using a 5mm Allen key, loosen the brake cable adjustment hanger, located on the left brake arm. Make sure the screw.
  • Page 34 5 M M A L L E N K E Y Pull the cable outward, reducing the distance between Make sure the pads are evenly lined up with the rim. If the brake pads and the rim by about 1/4 inch on both the pads rub against the tire, they are too high;...
  • Page 35 If one pad seems to run against the rim while the other still has plenty of space, you will need to center the brakes. To do this, adjust the spring tensioner screws located at the base of each brake arm. Tightening the screw on the right brake arm pushes the right brake pad away from the rim, and the left brake pad towards the rim.
  • Page 36 7 S P EED D ER AILLE U R TU NI NG D I AG R A M TO O L S R E Q U I R E D B A R R E L C A B L E A D J U S T E R H L I M I T S C R E W L L I M I T S C R E W...
  • Page 37 To adjust the rear derailleur, first twist the shifter until the Rotate pedals until the chain falls into the smallest cog. number 7 is highlighted on the shift knob. S M A L L E S T C O G WATC H A S S E M B LY V I D E O S O N O U R Y O U T U B E C H A N N E L , H T T P S : / / S I X T H R E E Z E R O .
  • Page 38 P H I L L I P S S C R E W D R I V E R Turn the barrel adjuster located on the rear derailleur If the chain still hasn’t reached the smallest cog, then you clockwise until it stops. will need to adjust the “High Gear”...
  • Page 39 9 M M M U LT I -TO O L Now adjust the cable tension, which controls how your bike will shift. Using a 9mm crescent wrench or the multi-tool, loosen the cable adjustment screw and pull on the cable. While keeping tension on the cable, tighten the cable adjustment screw. Rotate the pedals and try to shift between gears.
  • Page 40 2 1 SP EED D ER AILLE U R TU NI NG D I AG R A M F R O N T D E R A I L L E U R O U T E R C A G E H I G H &...
  • Page 41 N O T E C A U T I O N I N D E X S H I F T E R Please be careful with the derailleur cage as it We tune every bike before packaging, but The front and the rear shifters are called has tension that causes the cage to pull back I would still recommend checking the tun- “Index”...
  • Page 42 D E R A I L L E U R P O S I T I O N 2 P E N N I E S Check your bike’s tuning by taking it for a test ride. Shift Begin by shifting the front derailleur to 2nd gear. Lift the the front derailleur up and down to check each gear while chain and pull the cage away from the bike to place a penny riding.
  • Page 43 5 M M A L L E N K E Y Untighten the clamp with a 5mm Allen key a quarter turn at a time until you are able to tap the derailleur slightly up and down without it falling completely down the seat tube.
  • Page 44 Once the height is set, we must check the angle of the cage. Lift the chain and pull the cage forward and view the cage from above. The inside of the outer cage plate must be parallel to the largest chainwheel. If your outer cage plate is parallel to the largest chainwheel, you can move to step 6.
  • Page 45 5 M M M A L L E T A L L E N K E Y O R H A M M E R If your outer cage plate is NOT parallel to the largest chainwheel, untighten the clamp a quarter turn at a time until you are able to slightly move the derailleur.
  • Page 46 L I M I T E R S C R E W S N O T E Derailleurs work off of tension, and this is the reason that they are designed with High and Low Limiter screws. The High and Low Limiters essentially act as boundaries so that no matter how much tension you put into Now, let’s check the H limit screw.
  • Page 47 P H I L L I P S S C R E W D R I V E R Reference the bottom left image below to check if the derailleur is properly adjusted. If it matches the images, please move forward to Step 8. Looking through the front of the derailleur cage, decide whether the chain is too close to the inner or outer cage plates.
  • Page 48 P H I L L I P S S C R E W D R I V E R Now, let’s check the L limit screw. Begin by shifting the Reference the image below on the left, if the chain is cen- derailleur to 1st gear.
  • Page 49 C A B L E T E N S I O N A N D S H I F T I N G P H I L L I P S S C R E W D R I V E R Based on the screws original position, take note of the Now that you have adjusted the limiter screws, let’s check amount of quarter turn rotations given in either direction...
  • Page 50 F O R K S U S P E N S I O N Locate the barrel adjuster located on the front shifter Your bike is equipped with front fork spring suspension. where the cable comes out of the shifter. Note/ Explanation: The barrel adjuster will change the amount The position of blue lever indicates whether the front fork of tension on the shifting cable.
  • Page 51 (310) 982-2877 theteam@sixthreezero.com WATC H A S S E M B LY V I D E O S O N O U R Y O U T U B E C H A N N E L , H T T P S : / / S I X T H R E E Z E R O . C O M / PA G E S / A S S E M B LY...
  • Page 52 S U R V E Y Tell us about your assembly experience. If you have/had any trouble at all or didn’t, and would like to leave feed- back and help us improve our assembly instructions you can. Type this URL into your browser: goo.gl/kdJeJx H AV I N G T R O U B L E ? WA N T L I V E H E L P ? C A L L 3 1 0 .
  • Page 53 WATC H A S S E M B LY V I D E O S O N O U R Y O U T U B E C H A N N E L , H T T P S : / / S I X T H R E E Z E R O . C O M / PA G E S / A S S E M B LY...
  • Page 54 C O NG RAT U L ATI ONS You did it! Time to take your brand new bike for a spin. Still have questions? We’re happy to help. Want to share your journey with us? We’re happy about that, too. S I X T H R E E Z E R O T H E T E A M @ S I X T H R E E Z E R O .
  • Page 56 T H E T E A M @ S I X T H R E E Z E R O . C O M S I X T H R E E Z E R O LO S A N G E L E S , C A 3 1 0 .