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Sun Bicycles SCOUT Series Assembly Manual

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S C O U T
A S S E M B LY G U I D E
www.sun.bike
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Summary of Contents for Sun Bicycles SCOUT Series

  • Page 1 S C O U T A S S E M B LY G U I D E www.sun.bike...
  • Page 2 Before your first ride, please read the Sun Bicycles Owner’s Manual along with this BICYCLE ASSEMBLY MANUAL included with your new bike. This assembly guide is not a replacement for the Sun Bicycles Owner’s Manual or as a comprehensive repair and maintenance book.
  • Page 3 CONTENTS ■ Introduction Page 2 ■ Contents Page 3 ■ Scout 16 overview Page 4 ■ Scout 20 overview Page 5 ■ Preparing for assembly Page 6 ■ Quick reference Page 7 ■ Unpack your new bike Page 8 ■ What’s in the box Page 9 ■...
  • Page 4 SCOUT 16 Bike Details Model Scout 16 Wheel size 16” Frame size 8” Tire Size 16 x 2.30” Bike weight 21 lb Max tire size 16 x 2.30” Max rider weight 80 lb Tire Pressure 40-65 PSI...
  • Page 5 SCOUT 20 Bike Details Model Scout 20 Wheel size 20” Frame size 10” Tire Size 20 x 2.30” Bike weight 23 lb Max tire size 20 x 2.30” Max rider weight 80 lb Tire Pressure 40-65 PSI...
  • Page 6 PREPARING FOR ASSEMBLY ■ Gather all tools required for assembly ■ Below are the recommended tools and supplies needed for assembly Adj. or Metric Wrenches Pliers / Cutters Bicycle Grease Flat Blade Screwdriver Air Pump Phillips Screwdriver ■ Select your work area ■...
  • Page 7 QUICK REFERENCE Torque Specifications Tool Size Torque Front wheel axle nut 15mm wrench 30-45 Nm Rear wheel axle nut 15mm wrench 30-45 Nm Seat rail clamp 13mm wrench 12-15 Nm Seat post clamp 4mm hex wrench 4-6 Nm Stem - Quill bolt 6mm hex wrench 12-15 Nm Stem - Faceplate bolts...
  • Page 8 UNPACK YOUR NEW BIKE Fig. 1 Fig. 2 ■ Opening the carton ■ Remove the staples from the top of the carton with pliers or a flat-blade screwdriver and open box top flaps ■ Warning: The staples have sharp edges and should be disposed of in a safe manner to ensure they do not become a hazard to yourself and others ■...
  • Page 9 Front wheel - Fig. 3 ■ Handlebar with pre-installed rubber grips - Fig. 3 ■ Saddle and seatpost - Fig. 4 ■ Small parts box containing the Sun Bicycles Owner’s Manual & Assembly Guide, stem, pedals, and reflectors - Fig. 4...
  • Page 10 INSTALL FRONT WHEEL Fig. 5...
  • Page 11 INSTALL FRONT WHEEL 15mm Fig. 6 Fig. 7 Fig. 8 Insert the wheel: Position the keyed washer: Install & tighten the axle nuts: ■ Make sure the axle is fully inserted ■ Place the keyed washer onto each ■ Thread the axle nut (clockwise) onto into the dropout on both sides side axle / dropout with the tab facing each side axle...
  • Page 12 INSTALL STEM Fig. 9 Fig. 10 Fig. 11 Prepare the fork: Insert & align the quill stem: Align & tighten the quill bolt: ■ Ensure the fork steerer tube is clean ■ Loosen the expander bolt (quill bolt) ■ Position the stem so it is centered and free of debris so the wedge can move freely and aligned with the front wheel...
  • Page 13 INSTALL HANDLEBAR Fig. 12 Fig. 13 Fig. 14 Prepare the stem: Insert the handlebar on the stem: Align & tighten the handlebar: ■ Ensure the handlebar clamp is clean ■ Position the handlebar and reattach ■ Adjust the angle to a comfortable and free of debris the faceplate, tightening the bolts riding position...
  • Page 14 INSTALL RIGHT SIDE PEDAL 15mm Smooth Spindle 1/16 Fig. 15 Fig. 16 ■ Identify the right side pedal - Fig. 15 ■ Apply bicycle grease to the pedal threads - Fig. 15 ■ The right pedal is marked with an “R” sticker ■...
  • Page 15 INSTALL LEFT SIDE PEDAL 15mm 1/16 Grooved Spindle Fig. 17 Fig. 18 ■ Identify the left side pedal - Fig. 17 ■ Apply bicycle grease to the pedal threads - Fig. 17 ■ The left pedal is marked with an “L” sticker ■...
  • Page 16 INSTALL SEATPOST 13mm Look for minimum insertion line Fig. 19 Fig. 20 Fig. 21 Prepare the seat tube: Insert the seatpost: Attach the saddle to the post: ■ Apply a small amount of bicycle ■ Insert the seatpost below the ■...
  • Page 17 POSITION SADDLE 13mm Fig. 23 Fig. 22 Position the saddle: Positioning tips: ■ The saddle can be moved fore and aft as well as angled up and ■ Positioning the saddle too far forward or too far back down on the rails can cause damage to the saddle and the ■...
  • Page 18 CHECK REAR BRAKE (SCOUT 20 ONLY) Phillips Fig. 25 Fig. 24 Check the brake pads: Adjust the brake cable: ■ Check Alignment - The pads should contact the rim evenly and ■ Squeeze the brake lever to check how far it pulls fully without touching the tire or sitting too low on the rim before engaging ■...
  • Page 19 CHECK BRAKE LEVER (SCOUT 20 ONLY) Fig. 27 Fig. 26 Position the lever: Adjust brake lever reach: ■ Loosen (counterclockwise) the clamp bolt on the underside of the ■ Turning the brake lever reach adjustment screw lever with a 5mm hex wrench clockwise moves the lever closer to the grip, allowing ■...
  • Page 20 OPTIONAL TRAINING WHEELS INSTALLATION (SCOUT 16 ONLY) Training wheels are included only for the Scout 16 model Fig. 29 Fig. 28 ■ Confirm you have everything ■ Training wheel (2) ■ Training wheel bracket (2) ■ Tabbed washer (2) (NOTICE: This washer comes already installed on the Scout 16) ■...
  • Page 21 OPTIONAL TRAINING WHEELS INSTALLATION (SCOUT 16 ONLY) 12mm 13mm Fig. 30 Fig. 31 Assemble the wheel to the bracket: Assembled training wheel bracket: ■ Lightly apply bicycle grease to smooth surface of the main bolt ■ Assembled training wheel brackets ready to be before sliding the bolt into the wheel attached to the bike ■...
  • Page 22 OPTIONAL TRAINING WHEELS INSTALLATION (SCOUT 16 ONLY) 15mm Fig. 32 Fig. 33 Fig. 34 Prepare the axle: Tabbed washer: Training wheel bracket: ■ Remove (counterclockwise) the outer ■ Leave the tabbed washers in place ■ Slide the training wheel bracket onto Flanged axle nuts and washers from on both sides the rear axle on each side...
  • Page 23 OPTIONAL TRAINING WHEELS INSTALLATION (FOR SCOUT 16) 15mm Fig. 35 Fig. 36 Fig. 37 Flat washer: Flanged axle nut: Adjustment ■ Slide the flat washers onto the axle ■ Install the flanged axle nuts onto ■ Ensure both brackets are positioned immediately after the training wheel the axle after the washer by turning evenly so both training wheels sit at...
  • Page 24 INFLATE TIRES Fig. 38 Fig. 40 Fig. 39 Locate the valve: Remove the cap: Inflate the tire: ■ Rotate your wheel so the valve is ■ Remove the valve cap by turning it ■ Attach pump head and inflate to the positioned at the 6 O’clock position counterclockwise recommended tire pressure...
  • Page 25 CHECK / INSTALL REFLECTORS Phillips Phillips Rear Front Reflector Reflector Fig. 41 Fig. 42 Install red seatpost mounted reflector: Install white handlebar mounted reflector: ■ Open the clamp and position it around the seat post and ■ Open the clamp and position it around the handlebar, left secure in place with a phillips screwdriver of the stem and secure in place with a phillips screwdriver ■...
  • Page 26 If the brake feels weak or slips, check that the rear wheel is properly aligned and securely fastened in the dropouts, and if unsure about the brake’s performance, seek help from a Sun Bicycles Retailer.
  • Page 27 SAFETY CHECK ATTENTION! Performing this safety check regularly will help ensure a safe and enjoyable ride.
  • Page 28 DEALER STAMP Distributed by J&B Importers, Inc. | 11925 SW 128th Street, Miami, FL 33186 info@sun.bike Rev. 022525...

This manual is also suitable for:

Scout 16Scout 20