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PACIFIC CYCLE Part Instruction Manual

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SAVE
LIVES !!!
ALWAYS WEAR A PROPERLY
FITTED HELMET WHEN
YOU RIDE YOUR BICYCLE.
DO NOT RIDE AT NIGHT.
AVOID RIDING IN WET
CONDITIONS.
CORRECT FITTING - MAKE
SURE YOUR HELMET COVERS
YOUR FOREHEAD.
INCORRECT FITTING. FOREHEAD
IS EXPOSED AND VULNERABLE
TO SERIOUS INJURY.

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Summary of Contents for PACIFIC CYCLE Part

  • Page 1 HELMETS SAVE CORRECT FITTING - MAKE SURE YOUR HELMET COVERS YOUR FOREHEAD. LIVES !!! ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE. DO NOT RIDE AT NIGHT. AVOID RIDING IN WET INCORRECT FITTING. FOREHEAD CONDITIONS. IS EXPOSED AND VULNERABLE TO SERIOUS INJURY.
  • Page 3 Please Retain your Sales Receipt as Proof of Purchase. Notes: _______________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ ________ _______________________________________________________________________...

  • Page 4: Part

    The following manual is only a guide to assist you and is not a complete or comprehensive manual of all aspects of maintaining and repairing your bicycle. The bicycle you have purchased is a complex object. We recommend 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 7 PART 1 Parts Identification ............02-05 PART 2 Before You Ride ............06-21 PART 3 Assembly ..............22-62 PART 4 Servicing ..............63-65 PART 5 Detailed Maintenance ..........66-97 PART 6 How Things Work ............98-110 PART 7 Purchase Record and Warranty ......111-112 Warning / Important Take notice of this symbol throughout this manual and pay particular attention to the instructions blocked off and preceded by this symbol.

  • Page 8: Table Of Contents

    1. PARTS IDENTIFICATION Derailleur Geared Bicycle 22-45 Rotors 56-57 Drivetrain 81-89 Mountain Bicycles Handlebars, Stems and Shifters 22-25 Axle Peg Assembly -Pedals 81-82 BMX Bicycles -Aheadset -Non-Threaded Axle Peg -Inspection -Sunken Stem -Threaded Axle Peg -Lubrication & Adjustment Tools Required -Shifters Training Wheels 59-61...
  • Page 9 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 10 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. Front Brake Lever Handlebar Seat Handlebar Grip Brake Control Cable Seat Post Handlebar Stem Seat Post Binder Bolt or...

  • Page 11: Tools Required

    Your new bicycle was assembled and tuned in the factory and then partially disassembled for shipping. You may have purchased the bicycle already fully assembled and ready to ride OR in the shipping carton in the par- tially disassembled form. The following instructions will enable you to prepare your bicycle for years of enjoy- able cycling.

  • Page 12: About This Manual

    ABOUT THIS MANUAL It is important for you to understand your new bicycle. By reading this manual before you go out on your first ride, you’ll know how to get better performance, comfort, and enjoyment from your new bicycle. It is also important that your first ride on your new bicycle is taken in a controlled environment, away from cars, obstacles, and other cyclists.
  • Page 13 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 14 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 when pedaling.

  • Page 15: Handlebar Height

    Handlebar Height Maximum comfort is usually obtained when the handlebar height is Stem Wedge Bolt equal to the height of the seat. You may wish to try different heights to find the most comfortable position. Handlebar Binder Bolt Maximum Height/ Minimum Insertion Mark Exceeds 2 1/2”...

  • Page 16: 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 17 4. Chain - 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 18 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 19 Reflectors Your bicycle is supplied with one front (white), one rear (red), two wheel (white), and four pedal (orange) reflectors. (Please Note: Sidewalk bikes, 12” and under, may not have reflectors.) These are an important safety and legal requirement, and should remain securely fitted and in good, clean condition at all times. Periodically, inspect all reflectors, brackets and mounting hardware for signs of wear or damage.
  • Page 20 Seat and Handlebar Mounting Reflectors First attach the reflector to the reflector bracket with the reflector screw, see the top diagram. Next, remove the clamp screw and open the clamping reflector bracket. Place clamping reflector bracket around the handlebar or seatpost. If the clamp is too loose, insert the shim inside of the clamp.
  • Page 21 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 22 Wet Weather IT IS RECOMMENDED TO NOT RIDE IN 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.
  • Page 23 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 24 GEARS - HOW TO OPERATE Drivetrain Derailleur Control Cable Derailleur Gears Freewheel Front Derailleur Cogs Most multi-speed bicycles today are equipped with what are known as derailleur gears. They operate using a system of levers and mecha- nisms to move the drive chain between different sized driving gears or cogs.
  • Page 25 These combinations are These combinations are NOT RECOMMENDED NOT RECOMMENDED Middle High High for optimal performance. for optimal performance. Recommended Chainwheel/Rear Sprocket Gear Combinations Hand Grip Shifters Front Low Gear Rear Low Gear 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.
  • Page 26 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 27 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 28 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. Deflate the tires to half pressure and hang the bicycle off the ground.

  • Page 29: Getting Started

    DERAILLEUR GEARED BICYCLES Includes 20", 24” and 26" Wheel Mountain Bikes Assembly is the same for men’s and women’s bikes. We recommend that you consult a bicycle specialist if you have doubts or concerns as to your experi- ence or ability to properly assembly, repair, or main- tain your bicycle.
  • Page 30 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 31 Sunken Stem Bolt System 1. Remove the protective shipping cap from the stem wedge. 2. Remove the Stem Plug from the stem. Loosen the Stem Bolt with a 6mm allen wrench. 3. Insert the stem into the headtube of the bicycle. Ensure that the Minimum Insertion Line is below the top nut of the headset.
  • Page 32 Shifter binder bolt (2.5 Allen key) Brake lever binder bolt (5mm Allen key) Bar end (5mm Allen key) Shifters 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.
  • Page 33 Forks Steering Tube There are two different types of forks that vary in styles and dimensions. One type is a rigid fork (Figure 1) consisting of Brake Boss stationary tubing with curved blades. The other type is a suspension fork (Figure 2) consisting of stanchion tubes Drop-out riding on elastomers or springs inside of a straight fork leg.
  • Page 34 Seat and Seat Post Attach the seat to the seat post by loosening the nuts on the seat clamp. Insert the tapered end of the seat post into the seat clamp until it is at the top of the clamp. Partially tighten the nuts on the seat clamp until the seat is snug, but can still be turned.
  • Page 35 Pedals & Crank Set Look for the letters “R” for right, and “L” for 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 (clockwise) thread.
  • Page 36 Front Wheel Quick Release Adjusting Check the wheel hub before attaching it to the fork by rotating the Axle Quick 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 37 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 38 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 the illustration. not necessary at this time. Shoe fixing nut tightening torque: 7.84 - 8.82 Nm (70 - 78 in.
  • Page 39 Cantilever Brakes - Utilizing a Straddle Cable Straddle The length of the straddle cable, the height of the straddle hanger, Cable and the brake pad-to-caliper arm position all have an effect on brak- Brake Brake Cable ing power. Generally, the straddle cable bridge is set low and close Straddle Hanger to the tire for maximum braking force.
  • Page 40 V - Brake While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging the position of the B washers (i.e. 6 mm and 3 mm) so that If fitted with V-Brakes, insert the brake body dimension A is kept at 39 mm or more.
  • Page 41 While holding the shoe against the Adjust the balance with the spring rim, tighten the shoe fixing nut. tension adjustment screws. shoe fixing nut 5 mm Allen key 1 mm 1 mm Spring tension Spring tension adjustment screw adjustment screw Pass the inner cable through the inner Depress the brake lever about 10 times as cable lead.
  • Page 42 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 43 Disc Brakes If fitted with a front disc brake, the components should already Brake Cable Housing be attached. However, please check all connections before attempting to ride the bicycle. Secure tightly the 6 bolts that Barrel Adjuster hold the disc to the front wheel hub and the 2 bolts that hold Lock Nut the brake mechanism to the fork.
  • Page 44 Centering Bolt Fork Leg Disc Mounting Bolts Brake Cable Housing Rotating Caliper Body Disc Cable Boot with Spring inside Centering Bolt (inside) Actuating Cable Anchor Bolt Fork Drop Out Quick Release Caliper Mounting Bolts with spacers lever 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 45 Derailleur Although the front and rear derailleurs are initially adjusted at Freewheel Outer side of Top Gear the factory, you will need to inspect and readjust both before 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 46 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 derailleur;...
  • Page 47 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 48 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 49 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. Some bikes come equipped with a saddle bag or frame bag. Frame Bag The saddle bag installs under the seat with the zipper facing Reflector the rear wheel.
  • Page 50 Fenders figure 1 Front Fender The front fender is mounted at the fork crown. There are two ways in which to mount your front fender. The first is the caliper brake mounting system (see figure 1), and the second is the 10mm nut and bolt system (see figure 2).
  • Page 51 Rear Fender The rear fender is mounted at the seatstay brace. There are two ways in which to mount your rear fender. The first is the screw mounting system (see figure 3), and the second is the 10mm bolt and screw system (see figure 4). Identify the mounting system used on your bicycle and follow the given instructions for that particular type of mounting system.

  • Page 52: 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 53 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 54 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 55 Front Wheel Retaining 1. Make sure the brakes are loose enough to allow the wheel to Washer Axle Nut pass through the brake pads easily. Axle 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 56 Side Pull Brake Side Pull Cable Loosen the cable anchor nut and thread the brake cable through it. Brakes Adjusting 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 57 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 the illustration. not necessary at this time. Shoe fixing nut tightening torque: 7.84 - 8.82 Nm (70 - 78 in.
  • Page 58 Cantilever Brakes - Utilizing a Straddle Cable Straddle The length of the straddle cable, the height of the straddle hanger, Cable Brake Brake Cable and the brake pad-to-caliper arm position all have an effect on brak- ing power. Generally, the straddle cable bridge is set low and close Straddle Hanger to the tire for maximum braking force.
  • Page 59 V - Brake While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging the position of the B washers (i.e. 6 mm or 3 mm) so that If fitted with V-Brakes, insert the brake body dimension A is kept at 39 mm or more.
  • Page 60 While holding the shoe against Adjust the balance with the spring the rim, tighten the shoe fixing nut. tension adjustment screws. 5 mm Allen key 1 mm 1 mm 1 mm Spring tension Spring tension adjustment screw adjustment screw Pass the inner cable through the inner Depress the brake lever about 10 times as cable lead.
  • Page 61 U-Brakes Front U-Brake Begin by adjusting the pads of the U-brakes using a 10mm wrench. Make sure the pad is hitting the rim and not the tire. Ideally the front of the pad should hit the rim approximately 1mm before the rear pad. Front U-Brake Slide the brake cable and housing through the Housing Barrel and through the cable anchor bolt.
  • Page 62 Blake Lever™ Cable Installation 1. Slide the covering plate back towards the brake lever. (Figure 1). Squeeze the brake lever so the cable roller is exposed. 2. Rotate out the cable roller. Push the lower cable roller assem- bly down towards the hinge assembly. The top plate should not move.
  • Page 63 to set the bearing for maximum travel. The bearing should Rotors be as far down as it can go without resting on the lower Some freestyle BMX bicycles come equipped with a detangler system that will allow the handlebar to spin 360-degrees without plate or the adjusting barrels screwed into the lower plate.
  • Page 64 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) Adjusting Barrel Locknut Upper Plate Set for Max. Travel Keyed Washer 37mm + or - 1mm Bearing...
  • Page 65 Repeat for all the remaining pegs. PLEASE NOTE: Not all axles are able to accept axle pegs. Please consult the Pacific Cycle Service Department if you have any questions. Some BMX bicycles come with two or four pegs. If your bicycle is a Dirt Jumping style bicycle, you will receive only two pegs.

  • Page 66: Training Wheels

    Repeat for both training wheels. It is very important to check the training wheel connection to the bicycle. Failure to properly tighten may cause the train- ing wheel to dislodge. Please contact Option 2 Pacific Cycle Service with any questions.

  • Page 67: Flat Brace

    Attaching Training Wheel Brace to Bicycle There are two different braces used to attach the training wheels to the bicycle: the C-Shape Brace and the Flat Brace. Determine which brace was included with your bicycle and fol- low the given instructions for that particular brace. C-Shape Brace Remove the axle nut and washer from the rear wheel axle.

  • Page 68: Stabilizer Bracket

    Cycle to help determine if after-market training wheels can be attached. It is very important to check the training wheel connection to the bicycle. Failure to properly tighten may cause the training wheel to dislodge. Please contact Pacific Cycle Service with any questions.

  • Page 69: Final Check

    Final Check Install any additional parts that are supplied with your bike. Pads 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 Phil- lips head screwdriver.
  • Page 70 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 71: Schedule 2 - Service Checklist

    Schedule 2 - Service Checklist Frequency Task Page Reference Before every ride Check tire pressure Check brake operation 77-80 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 derailleur adjustment...

  • Page 72: Tools Required

    Tools Required 1. Open ended wrench or ring wrenches: 8mm, 9mm, 10mm, 12mm, 13mm, 14mm, 15mm 2. Open end or pedal wrench 15mm 3. Allen key wrenches: 4mm, 5mm, 6mm, 8mm 4. Adjustable wrench 5. Standard flat head screwdriver 6. Standard Phillips head screwdriver 7.

  • Page 73: Wheel Inspection

    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 74: Tire Inspection

    Tire Inspection Tires must be maintained properly to ensure road holding and stability. Check the following areas: Inflation: Ensure tires are inflated to the pressure indicated on the tire sidewalls. It is better to use a tire gauge 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 out.
  • Page 75 Hub Bearing Adjustment Ball Bearings When checked, the hub bearings of either wheel will require Bearing Lock adjustment if there is any more than slight side play. Cone Washer Hub Body 1. Check to make sure neither locknut is loose. 2.
  • Page 76 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 77: 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, then give it a tap to loosen the wedge inside.
  • Page 78 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 within the fork steerer tube, by clamping the front wheel between your Stem Bolt Handlebar knees and trying to move the handlebar up and down, and from side...
  • Page 79 Grip 7/8” Plastic Washers Barrel Adjuster Cable 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. 2.
  • Page 80 Cables and Cable Housing Cables and housing are one of the most over- looked 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.
  • Page 81 HEADSET Standard Headset Inspection The headset bearing adjustment should be checked every month. Lock Nut 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, Lock Washer apply the front brake firmly and rock the bicycle back and forth;...

  • Page 82: 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 83 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 84 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 85 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 Cable Adjusting Barrel The brake lever and brake caliper pivot points should be oiled with...
  • Page 86 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 87 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 88 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 89: 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 90: Inspection

    CRANK SET 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 type cotterpins.
  • Page 91 Lubrication and Adjustment - One Piece Cranks To adjust the free play 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 counter-clockwise.
  • Page 92 Lubrication and Adjustment - Cotterless Cranks Bottom Bracket To adjust the free play 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 taking care not to alter the cup adjustment.
  • Page 93 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 94: Adjustment & Replacement

    CHAIN Rear Sprocket Front Chainwheel Inspection The chain must be kept clean, rust free and frequently lubricated in Pull up 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 95 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 96 Lubrication Remove any accumulated dirt from the freewheel with a brush Brake Arm Clip and a degreaser. Disassembly of the freewheel 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 Sprocket chain, taking care to wipe off any excess.
  • Page 97 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 98 Lubrication Outer side of Top Gear Freewheel All the pivoting points of the front and rear derailleurs should be Pulley Adjustment lubricated with light oil at least every month. Be sure to wipe off any Screw excess oil to prevent attraction of dirt into the mechanisms. The shift- ing cables should be cleaned and re-coated with a thin layer of grease every six months, or whenever new cables are being installed.
  • Page 99 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 the High Adjusting Cable Fixing Bolt Screw front derailleur cable from the cable anchor bolt and place the chain on the smallest chainwheel.
  • Page 100 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 reinstalling, it is very important to ensure the connections are made properly. Please refer to page 29-30 for the appropriate assembly instructions.
  • Page 101 MISCELLANEOUS ACCESSORIES Your bicycle might be shipped with accessories that can be added onto you new bicycle. The following will detail how and where to attach your micilanious accessories. Basket Assembly Your bicycle may be supplied with an attachable front basket.
  • Page 102 Problem Possible Cause Remedy Gear shifts not working properly - Derailleur cables - Lubricate/tighten/replace cables sticking/stretched/damaged - Front or rear derailleur not adjusted - Adjust derailleurs properly - Indexed shifting not adjusted properly - Adjust indexing Slipping chain - Excessively worn/chipped chainring - Replace chainring, sprockets and or freewheel sprocket teeth chain...
  • Page 103 Problem Possible Cause Remedy Freewheel does not rotate - Freewheel internal pawl pins are - Lubricate. If problem persists, jammed replace freewheel Brakes not working effectively - Brake blocks worn down - Replace brake blocks - Brake blocks/rim greasy, wet or dirty - Clean blocks and rim - Brake cables are binding/stretched/damaged...
  • Page 104 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 Frequent punctures - Inner tube old or faulty...
  • Page 105 6. How Things Work It’s important to your performance, enjoyment and safety to understand how things work on your bicycle. Even if you’re an experienced bicyclist, don’t assume that the way things work on your new bike is the same as how they work on older bikes. Be sure to read and to understand this section of the Manual.
  • Page 106 2. Front Wheel Secondary Retention Devices Many bicycles have front forks which utilizes a secondary wheel retention device to keep the wheel from disengaging if the quick release is incorrectly adjusted. Secondary retention devices are not a substitute for correct quick release adjustment. Secondary retention devices fall into two basic categories: a) The clip-on type is an accessory part which the manufacturer adds to the front wheel hub or front fork.
  • Page 107 CAUTION: If you can fully close the quick release without wrapping your fingers around the fork blade for leverage, and the lever does not leave a clear imprint in the palm of your hand, the tension is insufficient. Open the lever; turn the tension adjusting nut clockwise a quarter turn; then try again. (5) If the lever cannot be pushed all the way to a position parallel to the fork blade, return the lever to the OPEN position.
  • Page 108 (7) Push the rear derailleur back into position. (8) Close the brake shoes; then spin the wheel to make sure that it is centered in the frame and clears the brake shoes. 4. Removing and Installing Bolt-On Wheels a. Removing a Bolt-On Front Wheel (1) Open up the brake shoes.
  • Page 109 d. Installing a Bolt-On Rear Wheel (1) Shift the rear derailleur to its outermost position and pull the derailleur body back with your right hand. (2) Put the chain on to the smallest sprocket. Then, insert the wheel into the frame dropouts and pull it all the way in to the dropouts.
  • Page 110 C. Brakes NOTE: For most effective braking, use both brakes and apply them simultaneously. WARNING: Sudden or excessive application of the front brake may pitch the rider over the handlebars, causing serious injury or death. 1. How brakes work It’s important to your safety that you instinctively know which brake lever controls which brake on your bike. In the U.S., bikes are required to be set up with the right brake lever controlling the rear brake, and the left lever controlling the front brake.
  • Page 111 WARNING: Some bicycle brakes, such as linear-pull and disc brakes, are extremely powerful. You should take extra care in becoming familiar with these brakes and exercise particular care when using them. Applying these brakes too hard or too sud- denly can lock up a wheel, which could cause you to lose control and fall. When you apply one or both brakes, the bike begins to slow, but your body wants to continue at the speed at which it was going.
  • Page 112 The purpose of having multiple gears on a bicycle is to let you chose the gear that allows you to maintain your optimum cadence under the widest range of riding conditions. Depending on your fitness level and experience (the more fit, the higher the cadence), optimum cadence is between 60 and 90 pedal revolutions per minute.
  • Page 113 Whether upshifting or downshifting, the bicycle derailleur system design requires that the drive chain be moving forward and be under at least some tension. A derailleur will shift only if you are pedaling forward. 1) Shifting the Rear Derailleur The rear derailleur is controlled by the right shifter. The function of the rear derailleur is to move the drive chain from one gear to another on the rear gear cluster, thereby changing gear drive ratios.
  • Page 114 • one or two control cables • one front sprockets called chainrings • a drive chain a) Shifting internal gear hub gears Shifting with an internal gear hub drivetrain is simply a matter of moving the shifter to the indicated position for the desired gear.
  • Page 115 F. Clipless (“step-in”) pedals Clipless pedals (sometimes called “step-in pedals”) are the means most racers use to keep their feet securely in the correct position for maximum pedaling efficiency. They work like ski bindings ... a plate on the sole of the shoe clicks into a spring- loaded fixture on the pedal.
  • Page 116 Tire pressure is given either as maximum pressure or as a pressure range. How a tire performs under different terrain or weather conditions depends largely on tire pressure. Inflating the tire to near its maximum recommended pressure gives the lowest rolling resistance; but also produces the harshest ride. High pressures work best on smooth, dry pavement. Very low pressures, at the bottom of the recommended pressure range, give the best performance on smooth, slick terrain such as hard-packed clay, and on deep, loose surfaces such as deep, dry sand.
  • Page 117 The Presta valve has a narrower diameter and is only found on bicycle tires. To inflate a Presta valve tube using a Presta headed bicycle pump, remove the valve cap; unscrew (counterclockwise) the valve stem lock nut; and push down on the valve stem to free it up.
  • Page 118 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 & Brand Information: _____________________________________ Wheel Size: ____________________ Color: _________________________ # # # #...
  • Page 119 This warranty does not apply to damage due to improper installation of parts or failure to properly maintain or adjust the bicycle. NOTICE: Bicycle specifications subject to change without notice. PACIFIC CYCLE INC 4902 Hammersley Road Madison, WI 53711 Call Toll Free 1.800.626.2811...

This manual is also suitable for:

Mountain bicycles; bmx bicycles

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