Retrospec Chatham - City Bike Manual

TOOLS

What we give you: 3 Hex Wrenches (4mm, 5mm, & 6mm), a 10-function multi-tool.
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 and set it aside.
7. Ex-mine your new bike for any visible damage that may have occurred during shipping.
8. Special Note: For tightening all fasteners, please refer to Appendix D in the back of your owner's manual for all fastener torque specifications.

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. Remove the plastic shipping plug from the top of the seat tube (Fig. 2).
   
2. Use the included Hex wrench to loosen the seat clamp at the top of the seat tube.
3. RECOMMENDED; Apply a thin layer of grease to the inside of the frame seat tube.
4. Insert the seat with the seat post into the seat tube of the frame to at least the minimum insertion line on the shaft of the seat post.
   
   The minimum insertion line must NOT show above the seat tube (Fig. 3).
   
5. Using the Hex wrench, tighten the seat clamp once it is at the correct height.
   Note: You can make the final adjustment to the height of the seat as needed after the bike is assembled.

HANDLEBARS

1. Loosen the stem bolt at the top of the stem one turn and remove the plastic packing cap from the bottom of the stem (Fig. 4).
   RECOMMENDED: Apply a thin layer of grease to the end of the stem shaft by the wedge.
   
2. Untwist the handlebars and control cables and insert the quill end of the stem into the fork steer tube. You may have to loosen the bolt and wedge a small amount to allow the quill to fit into the steer tube (Fig. 5).
   
3. Make sure that the fork is facing forward and the handlebars are lined up with the fork dropouts.
4. Adjust the height of the stem to your desired level and tighten the stem bolt using a 6mm wrench. You can make final adjustments to the height of the stem after the bike is assembled (Fig. 6).
   

NOTE: Be sure that the minimum insertion mark on the shaft of the stem is inside the frame, it must not be visible outside of the frame (Fig. 7).

Installing the stem with the minimum insertion mark showing outside of the frame could create a dangerous condition allowing the stem to break causing the rider to lose control resulting in serious injuries to the rider (Fig. 7).

FRONT WHEEL

1. Flip the bike over so it's resting on the saddle and handlebars.
2. Remove the small black plastic protector from the fork dropouts.
3. 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. 8).
   
4. Inspect the wheel to make sure it is centered in the fork (Fig. 9). Tighten each axle nut a little at a time with a 15mm wrench, alternating between sides, until each axle nut is properly tightened.
   
5. Return the bike onto its wheels and align the handlebar stem to the front wheel. Once the stem is aligned to the front wheel, tighten the stem bolt located at the top of the stem (Fig. 6).

PEDALS

Right Pedal

1. Locate the pedal stamped "R" on the end of the spindle (this is the RIGHT pedal) (Fig. 10).
   
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. 11).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. 10).
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. 12).
   

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.

REFLECTORS

1. Attach the plastic brackets to the handlebar and seat post. (Fig. 13 - Front).
   
2. Slide the reflectors onto the brackets (white in the front, red in the back). (Fig. 14 - Rear).
   
3. Attach the wheel reflectors onto the spokes of the wheels (If not already installed at the factory).

BRAKES AND GEARS

NOTE: We highly recommend taking your bike to a local bike shop and having your brakes and gears (if equipped) set-up by a professional mechanic.

BRAKES
1 & 3-Speed Models: Thesemodelsare equipped with a foot operated rear coaster brake. No adjustment is required. Simply push backwards on the pedals to activate the brake.
7 -Speed Models: Your 7-speed bicycle is equipped with front and rear linear-pull brakes.

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. 15).
   
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. 16).
   
4. Squeeze the brake lever hard several times to stretch the cable and make sure that it does not slip 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 clearance between 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. 17).
   

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