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PACIFIC CYCLE Bicycle Owner's Manual

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BICYCLEOWNER'S MAHUAL

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Summary of Contents for PACIFIC CYCLE Bicycle

  • Page 1 1 - • BICYCLEOWNER'S MAHUAL...
  • Page 2 II I I I II CORRECT FITTING-MAKE SURE YOUR HELMET COVERS YOUR FOREHEAD. INCORRECT FITTING. FOREHEAD IS EXPOSED AND VULNERABLE TO SERIOUS INJURY. I II I I! Copyright 2000 Pacific...
  • Page 3 {800) 283-3303 Congratulations on your bike! Our Service Department is dedicated to your satisfactioTz with Pacific Cycle. We want to help with any questions or comments you may have. You can also reach us by email at: seraice @pacific-cycle. com.
  • Page 4 The bicycle you have purchased is a complex object. Pacific Cycle recommends that you consult a bicycle specialist if you have doubts or concerns as to your experience or ability to properly assemble, repair, or maintain your bicycle.
  • Page 5 Purchase Record ..........86 Warning / Important Take notice of this symbol throughout this manual and pay particular attention to the instructions blocked off and preceded by this symbol. (_) Copyright 2000 Pacific Cy...

  • Page 6: Table Of Contents

    1. PARTS IDENTIFICATION Handlebars -Freewheel 77-76 18-20 Hub Bearing Adjustment Mountain Bicycles Forks Flat Tire Repair 56-57 -Inspection BMX Bicycles Seat and Seat Post Handlebar Stem -Lubrication Pedals & Crank Set Handlebars Tools Required Front Wheel -Coaster Hub Quick Release Axle 24-25 Grip Shift Installation 2.

  • Page 7: Mountain Bicycles

    Mountain Bicycles. Mountain bicycles are designed to give maximum comfort over a wide variety of road surfaces. The wider handlebars and convenient shift lever position make them very easy to control. Wider rims and tires give them a softer ride with more traction on rough surfaces.

  • Page 8: Bmx Bicycles

    BMX Bicycles. BMX style bicycles are a popular general purpose type most suited for young riders. They are valued because of their sturdy and simple construction, and low maintenance. Brake Lever Handlebar Seat Handlebar Grip Brake Control Cable Seat Post Handlebar Stem -- Seat Post Binder Bolt -- Head...
  • Page 9 Your new bicycle was assembled and tuned in the factory and then partially disassembled for shipping. may have purchased the bicycle already fully re-assembled and ready to ride QR in the shipping carton in the partially disassembled form. The following instructions will enable you to prepare your bicycle for years of enjoyable cycling.

  • Page 10: Correct Frame Size

    CORRECT FRAME SIZE When selecting a new bicycle, the correct choice of frame size is a very important safety consideration. Most full sized bicycles come in a range of frame sizes. These sizes usually refer to the distance between the center of the bottom bracket and the top of the frame seat tube.

  • Page 11: Riding Position

    RIDING POSITION Saddle Height In order to obtain the most comfortable riding position and offer the best possible pedaling efficiency, the seat height should be set correctly in relation to the rider's 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 12: Handlebar Height

    Handlebar Height 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. Stem Wedge Bolt Handlebar Binder Bolt l ..: _,_ Mian:imuLmrn inHseei gr t hi o_n...

  • Page 13: Safety Checklist

    SAFETY CHECKLIST Before every ride, it is important to carry out the following safety checks: 1. Brakes - Ensure front and rear brakes work properly. - Ensure brake shoe pads are not over worn and are correctly positioned in relation to the rims. - Ensure brake control cables are lubricated, correctly adjusted, and display no obvious wear.

  • Page 14: Chain

    4. Chain o Ensure chain is oiled, clean and runs smoothly. - Extra care is required in wet or dusty conditions. 5. Bearings - Ensure all bearings are lubricated, run freely and display no excess movement, grinding or rattling. - Check headset, wheel bearings, pedal bearings and bottom bracket bearings. 6.
  • Page 15 Helmets It is strongly advised that a properly fitting, ANSI or SNELL 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. The correct helmet should: - be comfortable - be lightweight...

  • Page 16: Riding Safely

    RIDING SAFELY General Rules When riding obey the same road laws as all other road vehicles, including giving way to pedestrians, and stopping at red lights and stop signs. For further information, contact the Road Traffic Authority in your State. Ride predictably and in a straight line.

  • Page 17: Wet Weather Riding

    Wet Weather - In wet weather you need to take extra care. - Brake earlier, you will take a longer distance to stop. - Decrease your riding speed, avoid sudden braking, and take corners with additional caution. - Be more visible on the road. - Wear reflective clothing and use safety lights.

  • Page 18: Hill Technique

    Hill Technique - Gear down before a climb and continue gearing down as required to maintain pedaling speed. - If you reach the lowest gear and are struggling, stand up on your pedals. You will then obtain more power from each pedal revolution.

  • Page 19: Gears - How To Operate

    GEARS - HOW TO OPERATE Drivetrain Derailleur Control Cable Freewheel Front Derailleur Derailleur Gears Most multi-speed bicycles today are equipped with what are known as derailleur gears. They operate using a system of levers and mechanisms to move the drive chain between different sized driving gears or cogs. The purpose of gears is to let you maintain a constant, steady pedaling pace under varying conditions.

  • Page 20: Hand Grip Shifters

    3ii Ill Ill ,1111 ,!ll "llll ,,il! II !!n[ ,_i ,_i ] _'.: _i ; S . j !i_" .,,.,. ,,,,,, ,,,,,. -:.." For optimal performance, For optimal performance, Middle High NOT RECOMMENDED High NOT RECOMMENDED Recommended Chainwheel/Rear Sprocket Gear Combinations Hand Grip Shifters Front Low Gear Rear Low Gear...

  • Page 21: Thumb Shifiers

    Thumb Shifters (Top Mounted) Left hand lever Right hand lever Most mountain style bicycles are equipped with shifters mounted on the top of the handlebars and operated by the thumbs. To select a lower, easier gear, shift to a bigger rear cog and a small chainwheel.

  • Page 22: Bicycle Care

    BICYCLE CARE Basic Maintenance The following procedures will help you maintain your bicycle for years of enjoyable riding. For painted frames, dust the surface and remove any loose dirt with a dry cloth. To clean, wipe with a damp cloth soaked in a mild detergent mixture.

  • Page 23: Storage

    Storage Keep your bicycle in a dry location away from the weather and the sun. Ultraviolet rays may cause paint to fade or rubber and plastic parts to crack. Before storing your bicycle for a long period of time, clean and lubricate all components and wax the frame.

  • Page 24: Assembly

    DERAILLEUR GEARED BICYCLES Includes 20", 24" and 26" Wheel Mountain Bikes Assembly is the same for men's and women's bikes. Getting Started Open the carton from the top and remove the bicycle. Remove the straps and protective wrapping from the bicycle. Inspect the bicycle and all accessories and parts for possible shortages.
  • Page 25 NOTE: Comfort Series (CS) bicycles may be equipped with a stem that has an adjustable angle. In addition to the normal assembly, these stems will require angling the stem to the desired position, and securely tightening the 6mm angle bolt located in front of the stem bolt. Failure to do this may cause loss of steering control.
  • Page 26 Tighten all bolts that clamp the shifters, brake levers, and bar ends to the handlebar using a 5mm Allen key or Phillips head screwdriver. (Figure 1) Handlebar with Grip Shifter. (Figure 2) Top mounted thumb shifter. Shift binder bolt (Phillips head or 5mm Allen key) Failure to properly tighten clamping bolts may...

  • Page 27: Forks

    Forks Steering Tube There are two different types of forks that range in styles and Brake Boss dimensions. One type is a rigid fork (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.

  • Page 28: Seat And Seat Post

    Seat and Seat Post Attach the seat to the seat post by inserting the smaller end of the seat post into the seat clamp and tighten. Insert the larger end of the seat post into the seat tube of the bicycle frame observing the minimum insertion Seat mark on the seat post.

  • Page 29: Pedals & Crank Set

    Pedals & Crank Look for the letters "R" for right, and "1_' f or left, stamped on each pedal spindle, Start each pedal spindle by hand to avoid stripping the threads. Tighten with a 15mm narrow open ended wrench. Note that the right hand pedal attaches to the chainwheel side crank arm with a right-hand (clock- wise) thread.

  • Page 30: Front Wheel

    Front Wheel Quick Adjusting Release Quick Check the wheel hub before attaching it to the fork by rotating the Axle Release threaded axle. It should be smooth with no lateral movement. Insert Lever the front wheel into the fork dropouts. Tighten the wheel nuts using the appropriate 14mm or 15mm wrench.

  • Page 31: Front Brake

    5. The wheel is tightly secured when the serrated surfaces of the quick release clamping parts actually begin to cut into the bicycle frame/fork surfaces. 6. Note that the same procedure applies when operating a quick release seat post binder mechanism. 7.
  • Page 32 iiii 5. Secure one of the shoes at e time. The 3 Temporarily tighten the cable so that the link wire is at the position in adjustment of the shoe clearance is not the illustration. necessary at this time. Shoe fixing nut tightening torque: 7.84 - 8.82 Nm (70 - 78 in.
  • Page 33 Cantilever Brakes - Utilizing a Straddle Cable The length of the straddle cable, the height of the straddle hanger, and the brake pad-to-caliper arm position all have an effect on braking power. Generally, the straddle cable bridge is set low and close to the tire for maximum braking force.
  • Page 34 V - Brake 2. While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging position of the B washers (i.e. 6 mm and 3 mm) so that 1. If fitted with V-Brakes, insert the brake body into dimension A is kept at 39 mm or more.
  • Page 35 3. While holding the shoe against the 5. Adjust the balance with the spring rim, tighten the shoe fixing nut. tension adjustment screws. shoe fixing nut 1 mm 1 mm Spring tension Spring tension 5 mm Alien key adjustment screw adjustment screw 4.

  • Page 36: Check Your Brakes

    Check your Brakes Press each brake lever to make sure that there is no binding and that the brake pads press hard enough on the rims to stop the bike. The brake pads should be adjusted so they are 1 mm to 2 mm away from the rim when the brakes are not applied.

  • Page 37: Disk Brakes

    Disk Brakes It fitted with a front disc brake, the components should already be attached. However, please check all connections before attempting to ride the bicycle. Secure tightly the 6 bolts that hold the disc to the front wheel hub and the 2 bolts that hold the brake mechanism to the fork.
  • Page 38 Centering Bolt Brake Cable Housing Rotating Caliper Body Cable Boot with Spring inside Centering Bolt (inside) Cable Anchor Bolt Quick Release Caliper Mounting lever Bolts with spacers These brakes require breaking in! Ride and use the brakes gently for 13 miles before using the brakes in downhill conditions, for sudden stops, or any other serious braking.

  • Page 39: Derailleur

    Derailleur Freewheel Although the front and rear derailleurs are initially adjusted at Outer side of Top Gear the factory, you will need to inspect and readjust both prior to Pulley Adjustment riding the bicycle. Screw Rear Derailleur Begin by shifting the rear shifter to largest number indicated, disconnect the cable from the rear derailleur cable anchor bolt, and place the chain on the smallest sprocket.

  • Page 40: Front Derailleur

    Front Derailleur Low Adjusting Screw Shift both shifters to the smallest number indicated and place the chain on the corresponding cog and chainwheel. Discon- High Adjusting Cable Anchor Bolt_ nect the front derailleur cable from the cable anchor bolt. Screw Check the position of the front deraiileur;...

  • Page 41: Dual Suspension

    Dual Suspension Dual Suspension bikes (DS) are equipped with a front fork as well as a rear suspension generally located below the seat. The piston works in conjunction with a spring to allow the bike to rotate on a pivot point. Ensure all attaching hardware is secured and there is no lateral movement of the rear triangle.

  • Page 42: Rear Pivots

    Rear Pivots ®® The pivot assembly is a simple mechanism that allows the rear triangle to move up and down in combination with a rear suspension. Size, shape, and compounds will vary between models; however, operating principles are the same. A shaft will pivot inside of two bushings Attaching Bolt secured in place with bolts.

  • Page 43: Accessories

    Accessories If your bike is supplied with a water bottle and cage, attach the Saddle Bag cage to the bicycle using the Allen bolts provided. Most bikes come equipped with a saddle bag or frame bag. Flame Bag eo,or The saddle bag installs under the seat with the zipper facing the rear wheel.

  • Page 44: Final Check

    Final Check After all adjustments have been made, shift through every gear several times at varying speeds. This will ensure all your adjustments are correct and will allow you to pinpoint any trouble areas. If you encounter any problems, refer to the appropriate section and make any necessary adjustments.

  • Page 45: Single Speed & Bmx

    SINGLE SPEED & BMX Includes 16" and 20" BMX Bikes Foreword: Assembling a bicycle is an important responsibility. Proper Assembly is the same for boy's and girl's bikes. assembly not only gives the rider more enjoyment of the bicycle; it also offers an important measure of safety.

  • Page 46: Pedals & Crank Set

    Seat Loosen nut on the seat clamp and add 3 or 4 drops of oil onto the threads of the bolt. Place the smaller end of the seat post into the seat clamp until it stops with the bolt to the rear of the seat post. Thread the nut on the seat clamp loosely.

  • Page 47: Frontwheel

    Front Wheel Axle Nut 1. Make sure the brakes are loose enough to allow the wheel to Axle pass through the brake pads easily. 2, Place wheel into fork drop outs. 3. Install retaining washers with raised lip pointed towards the fork, and insert into the small hole of the fork blade.

  • Page 48: Side Pu_L Brake

    Side Pull Brake Side Pull "_"_ d Cable Brakes Loosen the cable anchor nut and thread the brake cable through it. justing Tighten the nut by hand until it holds the cable in place. Squeeze the Barrel brake arms together against the rim of the wheel. Loosen the nuts on Center Bolt the brake shoes and turn until they match the angle of the rim.
  • Page 49 3. Temporarily tighten the cable so 5. Secure one of the shoes at a time. that the link wire is at the position in The adjustment of the shoe clearance is not necessary at this time. Shoe fixing nut tightening torque: 7.84 - 8.82 Nm (70 - 78 in.

  • Page 50: Brake

    Brake 2. While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging position of the B washers (i.e. 6 mm or 3 mm) so that 1. If fitted with V-Brakes, insert the brake body into dimension A is kept at 39 mm or more.
  • Page 51 3. While holding the shoe against 5, Adjust the balance with the spring the rim, tighten the shoe fixing nut. tension adjustment screws. ® 5 mm Allen key 1 mm Spring tension Spring tension adjustment screw adjustment screw 4. Pass the inner cable through the inner 6.
  • Page 52 Cantilever Brakes - Utilizing a Straddle Cable Straddle Cable The length of the straddle cable, the height of the straddle hanger, and Brake Brake Cable the brake pad-to-caliper arm position all have an effect on braking power. Generally, the straddle cable bridge is set low and close to the Straddle Hanger Pinch Bolt tire for maximum braking force.

  • Page 53: Check Your Brakes

    Check your Brakes Press each brake lever to make sure that there is no binding and that the brake pads press hard enough on the rims to stop the bike. The brake pads should be adjusted so they are lmm to 2 mm away from the rim when the brakes are not applied. Brake pads should be centered on the rim and the rear portion of each brake pad should be about 0.5 - 1.0 mm farther from the rim than the front portion of the brake pad.

  • Page 54: Rotors

    Rotors to set the bearing for maximum travel. The bearing should Some freestyle BMX bicycles come equipped with a detangler be as far down as it can go without resting on the lower system that will allow the handlebar to spin 360-degrees plate or the adjusting barrels screwed into the lower plate.
  • Page 55 Failure to adjust correctly may result in loss of braking power and personal injury. Single Cable Casing Cable Adjuster Cable Splitter Upper Cable Barrel End (long casing) Upper Cable (short casing) Barrel Locknut Upper Plate Set for Max. Travel Keyed Washer 37ram + 0r - 1ram Bearing...

  • Page 56: Final Check

    Final Check 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 an 8mm wrench or a Phillips head screwdriver.

  • Page 57: 15 4. 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, its condition changes, The more you ride, the more frequently maintenance will be required.
  • Page 58 Schedule 2 - Service Checklist Frequency Task Page Reference Before every ride Check tire pressure 66-69 Check brake operation Check wheels for loose spokes Make sure nothing is loose 16-17 After every ride Quick wipe down with damp cloth Weekly Lubrication as per schedule 1 Monthly...

  • Page 59: Tools Required

    Tools Required Open ended wrench or ring wrenches: 8mm, 9mm, 10mm, 12ram, 13mm, 14mrn, 15mm Open end or pedal wrench 15mm Allen key wrenches: 4mm, 5ram, 6mm, 8ram Adjustable wrench Standard flat head screwdriver Standard Phillips head screwdriver Standard slip joint pliers Tire pump Tube repair kit 10.

  • Page 60: 17 6. Detailed Maintenance

    WHEELS AND TIRES Wheel Inspection It is most important that wheels are kept in top condition. Properly maintaining your bicycle's wheels will help braking performance and stability when riding. Be aware of the following potential problems: •Dirty or greasy rims: Caution: These can render your brakes ineffective.

  • Page 61: Tire Inspection

    Tire Inspection Tires must be maintained properly to ensure road holding and stability. Check the following areas: Ensure tires are inflated to the pressure indicated on the tire sidewalls. It is better to use a tire gauge Inflation: and a hand pump than a service station pump. Caution: If inflating tires with a service station pump, take care that sudden over inflation does not cause tire to blow up.

  • Page 62: Hub Bearing Adjustment

    Hub Bearing Adjustment Bali Bearings When checked, the hub bearings of either wheel will require Lock Bearin 9 Cone Washer adjustment if there is any more than slight side play. Hub Body 1. Check to make sure neither Iocknut is loose. 2.
  • Page 63 Match the position of the leak in the tube with the tire to locate the possible cause and mark the location on the tire. Remove the tire completely and inspect for a nail, glass, etc. and remove if located. Also inspect the inside of the rim to ensure there are no protruding spokes, rust or other potential causes.

  • Page 64: Handlebar Stem

    HANDLEBARS AND STEM Handlebar Stem The handlebar stem fits into the steering column and is held firm by the action of a binder bolt and expander wedge which, when tightened, binds with the inside of the fork steerer tube. When removing the stem, loosen the stem bolt two or three turns, Max.

  • Page 65: Handlebars

    When re-fitting the stem, make sure the handlebars are correctly aligned and tightened using the appropriate hex wrench or allen key. Grip Do not over tighten. Test the security of the handlebar within the stem, and the stem - Stem Bolt within the fork steerer tube, by clamping the front wheel between your Handlebar knees and trying to move the handlebar...

  • Page 66: Grip Shift Installation

    Grip 7/8" Plastic Washers Cable Barrel Adjuster GRIP SHIFTERS Grip Shift - Installation 1. Slide front Grip Shift assembly over left side of handlebar leaving proper clearance for handlebar grip. If necessary, move the brake lever to accommodate Grip Shift and handlebar grip.

  • Page 67: Cables & Cable Housing

    Cables and Cable Housing Cables and housing are one of the most overlooked parts on the bicycle. The first indication that your cables and housing need to be replaced is an increased amount of pressure needed to operate the brakes or shifters. Before every ride, check that there are no kinks or frays in the cables and housing.

  • Page 68: Headset

    HEADSET Inspection Lock Nut 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. Lock Washer While standing over the frame top tube with both feet on the ground, apply the front brake firmly and rock the bicycle back and forth;...

  • Page 69: Suspension Fork

    SUSPENSION FORK Suspension Some fork models differ from the one illustrated. Those models are Fork not adjustable and require no maintenance other than keeping it free from dirt and grime. RST - Regular Maintenance The following maintenance should be performed every month (if riding off-road), or whenever you feel performance...

  • Page 70: Saddle & Seat Post

    SADDLE AND SEAT POST Inspection The seat fixing bolt and the seat post binder bolt should be checked for tightness and adjustment every month. On removing the seat post from the frame, you will notice a mark about 65mm up from the bottom with the words "max.

  • Page 71: 37 -Adjustment

    Adjustment As mentioned in Part 2, the seat can be adjusted in height, angle and distance from the handlebars to suit the individual rider. Saddle angle is a matter of personal preference but the most comfortable position will usually be found when the top of the seat is almost parallel to the ground, or slightly raised at the front.

  • Page 72: Brakes

    BRAKES 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 of adjustment is necessary as the control cables will stretch and the brake pads will become worn with use. Never ride a bicycle unless the brakes are functioning properly.

  • Page 73: 39 -Lubrication

    Some brakes have a quick release mechanism to allow easier wheel removal. Whenever you adjust the brakes, make sure the quick release mechanism is in the closed position. Never ride unless the quick release is firmly locked in the closed position. Lubrication The brake lever and brake caliper pivot points should be oiled with 2-3 drops of light oil at least every three months to ensure smooth...

  • Page 74: 40 -Adjustment Cantilever Calipers

    Some brakes have a special mechanism which enables you to set the clearance on either side of the rim using a screwdriver. Brake pads should finally be adjusted so that the leading edge of the pad makes first contact with the rim. Some brakes have special curved washers to allow this, but on less complex models it will be necessary to apply a little force to the pad and its mounting.
  • Page 75 On some newer type cantilever brakes, the main brake cable Tread Tread Worn Off continues through the central cable carrier to an anchor bolt on one of the brake arms, A shorter link cable reaches from the carrier and the hook on the other brake arm. Adjustment of the cable length is made after loosening the anchor bolt on the brake arm.

  • Page 76: Drivetrain

    DRIVETRAIN The drivetrain of a bicycle refers to all parts that transmit power to the rear wheel including the pedals, chain, chainwheel, crank set, and freewheel. PEDALS Pedals are available in a variety of shapes, sizes and materials, and each are designed with a particular purpose in mind. Some pedals can be fitted with toe clips and straps.

  • Page 77: Lubrication & Adjustment

    Lubrication and Adjustment 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 78: Crank Set

    CRANK SET ¢'1 The crank set refers to the bottom bracket axle and bearings, the crank arms, and chainrings. Your bike may be fitted with either a one piece crank, where the crank arms and bottom bracket are a single component, or cotterless cranks, where the crank arms bolt onto the bottom bracket axle without using old fashioned...

  • Page 79: Lubrication & Adjustment 50 (One Piece Cranks)

    Lubrication and Adjustment - One Piece Cranks To adjust the free play in a one piece type bottom bracket, loosen the Iocknut 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 !ocknut counter-clockwise.
  • Page 80 Lubrication and Adjustment - Cotterless Cranks Bottom Bracket To adjust the free play in a three piece type bottom bracket, loosen the Iockring on the left side by turning it counter-clockwise, then turn the adjusting cup as required. Re-tighten the Iockring taking care not to alter the cup adjustment.
  • Page 81 3. Screw the removing tool into the crank and tighten. Screw in the removal tool. 4. Turn the screw bolt down until the crank comes away from the axle. Turn the screw bolt clockwise. Cotterless Crank Replacement: 1. Replace the crank arm onto the axle. 2.

  • Page 82: Chain

    CHAIN Rear Sprocket Front Chainwheel Inspection The chain must be kept clean, rust free and frequently lubricated in order to extend its life as long as possible. It will require replacement if it stretches, breaks, or causes inefficient gear shifting. Make sure that there are no stiff links, they must all move freely.

  • Page 83: Freewheel

    Derailleur geared bicycles use narrower chains and require a special tool to fit and remove chain links, or to change the length. To remove, fit the rivet tool so that the punch pin is centered over any one of the chain rivets. Push the rivet almost all the way out, then back out the punch and remove the tool.

  • Page 84: Lubrication

    Lubrication Brake Arm Clip Remove any accumulated dirt from the freewheel with a brush and a degreaser. Disassembly of the free wheel is a complicated Brake Arm procedure requiring special tools, and should be left to a specialist. Apply oil to the freewheel whenever you lubricate the chain, taking care to wipe off any excess.

  • Page 85: Oerailleur Systems

    DERAILLEUR SYSTEMS The derailleur system includes the front and rear derailleurs, 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.

  • Page 86: Lubrication

    Lubrication Freewheel All the pivoting points of the front and rear derailleurs should be Outer side of Top Gear PulJey Adjustment Screw lubricated with light oil at least every month. Be sure to wipe off any excess oil to prevent attraction of dirt into the mechanisms. The shifting cables should be cleaned and re-coated with a thin layer of grease every six months, or whenever new cables are being installed.

  • Page 87: Adjustment (Front)

    Adjustment - Front Derailleur Low Adjusting Screw 1. Shift the rear shifter to the smallest number indicated, then shift the front shifter to the smallest number indicated. Disconnect High AdJs_tring front derailleur cable from the cable anchor bolt and place the chain on the smallest chainwheel.

  • Page 88: Quick Release Levers

    QUICK RELEASE LEVERS It is important to check the quick release levers before every ride to ensure all connections are made properly and securely. Periodically, disassemble the mechanism from the bicycle and inspect for any wear or damage and replace if necessary. When re-installing, it is very important to ensure the connections are made properly.

  • Page 89: Troubleshooting

    Problem Possible Cause Remedy Derailleur cables Lubricate/tighten/replace cables Gear shifts not working properly sticking/stretched/damaged Adjust derailleurs Front or rear derailleur not adjusted properly Adjust indexing Indexed shifting not adjusted properly Replace chainring, sprockets and Slipping chain Excessively worn/chipped chainring chain or freewheel sprocket teeth Chain worn/stretched Replace chain...
  • Page 90 Problem Possible Cause Remedy Freewheel does not rotate Lubricate. If problem persists, Freewheel internal pawl pins are replace freewheel jammed Brake blocks worn down Replace brake blocks Brakes not working effectively Clean blocks and rim Brake blocks/rim greasy, wet or dirty Brake cables are Clean/adjust/replace cables...
  • Page 91 Problem Possible Cause Remedy Steering not accurate Wheels not aligned in frame Align wheels correctly Headset loose or binding Adjust/tighten headset Front forks or frame bent Take bike to a bike shop for possible frame realignment Inner tube old or faulty Replace Inner tube Frequent punctures...

  • Page 92: Purchase Record

    Purchase Record Card Fill in Immediately and retain as a record of your purchase. *Please retain your sales receipt for any possible warranty claims. Your Name: Address: Date Purchased: Place of Purchase: Model Name: Wheel Size: Color: Serial Number: Serial Number Location...

  • Page 93: Warranty

    PACIFIC LIMITED WARRANTY AND POLICY ON REPLACEMENT PROCEDURES AND RESPONSIBILITIES Your purchase includes the following warranty which is in lieu of all other express warranties. This warranty is extended only to the initial consumer purchaser. No warranty registration is required This warranty gives you specific legal rights and you may have other rights which vary from state to state. FRAME The entire frame is guaranteed against faulty materials and workmanship for as long as the initial consumer purchaser...
  • Page 94 PACIFIC CYCLE LLC 4902 Hammersley Road Madison, WI 53711 Phone 608/268-2456 Fax 608/268-2455 Customer Service .1-800-283-3303 E-mail: service @pacific-cycle:corn Web Address: www.pacific-cyclelcom (_ Copyright 2000 Pacific Cycles...

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