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Summary of Contents for Kettler ALU RAD
- Page 1 Montage- und Bedienungsanleitung Assembly and User Manual Garantieunterlagen Guarantee Documents Fahrradpass Bike Pass...
- Page 2 KETTLER gibt Ihnen die volle Garantie auf den KETTLER Alu-Rahmen, wenn Sie diesen ursprünglich zum privaten Gebrauch (und KETTLER gives you a full guarantee on the KETTLER aluminium frame if originally purchased for private use (and not for resale) nicht zum Weiterverkauf) von KETTLER oder einem von KETTLER ermächtigten Händler erworben haben (ursprünglicher Kauf).
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Page 3: Table Of Contents
Headlamp/Rear Lamp Contents Assembly/Disassembly of the front Wheel in Hubgears KETTLER Aluminium-Bike - an exellent choice Assembly/Disassembly of the rear Wheel in the Roller Brakes Aluminium - the high-tech Material in the Construction of bikes Assembly/Disassembly of the Rear Wheel in the Roller Brakes... -
Page 4: Kettler Aluminium-Bike - An Exellent Choice
In order to ensure long-term enjoyment of your KETTLER aluminium bike, we recommend that you carry out regular maintenan- ce and repair work with the KETTLER aluminium bike dealer of your choice at the applicable cost in compliance with the assembly and maintenance manual. -
Page 5: Aluminium - The High-Tech Material In The Construction Of Bikes
Aluminium – The high-tech Material in the Construction of Bikes You have chosen a KETTLER aluminium bike – thank you for your confidence. Aluminium bike frames has proved itself with practice. This is particularly due to the material’s outstanding “lightweight fea- tures”. -
Page 6: Safety And Manufactury Of Kettler Aluminium-Bikes
Safety and Manufacturing of KETTLER Aluminium Bikes “Safety on the inside and outside” is the argument given in car manufacturing. KETTLER aluminium bikes can also be conside- red as having “inner safety” in relation to the materials used and purposeful manufacturing. ”Outer safety” is achieved by the protective design of parts and accessories against injury hazards. -
Page 7: Your Contribution To Enviromental Protection
Your Contribution to environmental Protection You have chosen a KETTLER aluminium bike which is progressive in all senses of the word, including the environment. Your new vehicle is developed in such a way that the environment suffers as little as possible. -
Page 8: Road And Operational Safety
Carrying children is only allowed with the appropriate child’s seat in compliance with DIN 79120. We would recommend the KETTLER child’s seats from our extensive range of accessories. • Child’s seats must be equipped with adjustable foot supports or foot rests accordingly •... - Page 9 Road and operational Safety • When using a child’s seat, the seat’s open coil springs should be covered to avoid squashing (KETTLER clamp protection, Art. No. 08947-690) • Children should only wear the appropriate bike helmet. Carrying Loads If carrying an increased load on the bike you should: •...
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Page 10: General Cycling Advice
General Cycling Advice General Cycling Indications • For your own safety each time, and at frequent intervals, before you use the bike check all the screw joints, brakes and lights. • Before starting to cycle the bike stand has to be retracted, no objects (luggage parts, garments etc.) should come into contact with the turning parts. •... -
Page 11: Bike-Overview
Bike – Overview The illustration below shows the most important bike components and their correct names. Please remember that this is a general overview thus different components perhaps look different or are differently equipped in your bike or are not available for your model. -
Page 12: Pedals
Pedals Assembly • Turn the pedal which is labelled with an “R” located at the threaded bush in the right-hand pedal arm (the chain wheel side) to the right and turn the pedal which is labelled with an “L” in the left pedal arm to the left. •... -
Page 13: Adjusting The Stem
Adjusting the Stem Adjusting the Handlebar Height and the Stem Angle 1.In order to modify the handlebar height, loosen the clamping screw (fig. 1). You can now pull the stem out to the maximum mark and by doing so adjust the height. Attention! Do not pull out further than the maximum mark (breaking hazard;... -
Page 14: Stem Ahead Set System
Stem Ahead Set System With Ahead steering bearing systems the stem is used for adjusting the initial bearing tension. Should the stem be modified the bearing has to be readjusted. A height adjustment is only possible by changing the spacers. In order to do so it is necessary to remove the spacer ring and to place it over the stem again. -
Page 15: Ahead Stem/Downward Inclination Adjustment Handlebar Arm
Ahead Stem / downward Inclination Adjustment Handlebar Arm In order to modify the stem angle loosen the Allen screw c. Set the desired handlebar downward incline and afterwards firmly tighten the screw again (observe the torques). You can change the position of the handlebar by loosening the Allen screw d. When changing the position of the handlebar arm observe that the position of the braking and gear handles changes. -
Page 16: Seating Position
General Advice An incorrect seat and / or handlebar position can lead to problems in the knees and back. In order to cycle comfortably, safely and without fatigue your KETTLER aluminium bike seat must be at the correct height. Seat Position The seat is set to the correct height if when seated you can reach the lowest part of the pedal with your heel and whilst doing so your knee is approximately out (Fig. -
Page 17: City Model Seat
City Model Seat Height Adjustment Loosen Allen screw a (a gentle knock against the side of the seat loosens the clamping part), set the seat to the desired height, align and tighten the screws again. Before starting to cycle verify that the seat cannot be turned. Attention: do not pull the seat post tube out over the minimum plug depth c. -
Page 18: Mountain Bike/Trekking Model Seat
Downward Inclination Adjustment Loosen Allen screw c, position the seat horizontally and tighten the screw again. Observe the correct gearing of the seat post clamp. Only the tried and tested seat post used by KETTLER should be used! Torques Attention! Observe the maximum mark. -
Page 19: Brake Power Modulator
Brake Power Modulator Controlled Braking Power In order to attenuate the braking power, which is initially very high, a so-called power modulator is used in all models (except MTB). Should the cyclist use too much hand force a spring mechanism comes into effect thus ensuring that the brakes are not used as aggressively. -
Page 20: Brake Safety Line
This, however, does not cause any defect and can be considered as usual wear and tear. In order to observe the rim’s wear a so-called safety line has been developed. This comprises different systems. In the KETTLER standard rim the safety line is visible as a line all the way round. Should this “line” no longer be visible you must contact a spe- cialist dealer immediately so that the rim can be replaced. -
Page 21: Brake - V Brake Rim Brake
Brake – V Brake Rim Brake V brakes are extremely powerful rim arm brakes. Always use the appropriate amount of braking power. Get used to using the V brake. Practise emergency braking until you are able to control the bike when braking more forcefully. Adjusting the Brakes After a certain amount of time the brakes have to be adjusted... -
Page 22: Brake – V Brake Rim Brake
For safety reasons, we recommend that adjusting work to the braking system should only be carried out by qua- lified personnel. KETTLER cannot accept any liability for any damage resulting from incorrect brake assembly work. When being replaced only use brake pads which are labelled as suitable for the rim, otherwise there could be increased wear and tear as well as a reduction in braking power. -
Page 23: Lighting Equipment / Lateral Running Generator
Lighting Equipment / lateral running Generator The lighting equipment used by us meets the highest standards. With our halogen headlamp, as well as our Toplight rear lamp, you have bike lighting which considerably exceeds the DIN requirements. The complete lighting is connected to the so-called double cabling (+/- lighting cable). This increases road safety since there is no possibility of losses through lacking ground connection. -
Page 24: Lighting Equipment / Hub Generator
Lighting Equipment / Hub Generator Hub Generator A hub generator has the advantage of achieving uniformly high light output regardless of the weather. In connection with a headlamp controlled by sensor you have very comfortable lighting equipment at your fingertips. Headlamp with Sensor Control With a headlamp with sensor technology (a light sensor) the light automatically switches on in the dark or when cycling through tunnels. -
Page 25: Headlamp/Rear Lamp
All KETTLER aluminium bikes are equipped with lighting equipment in accordance with the requirements stipulated in the StVZO (Road Licensing Regulations of the Federal Republic of Germany). An exception to this is our Off Road model in the “X treme”... -
Page 26: Assembly/Disassembly Of The Front Wheel In Hubgears
Assembly / Disassembly of the front Wheel in Hubgears Open the front wheel brake by pulling the brake cable’s small guiding tube a from the guide skids b. Loosen both axle scr- ews c until the cap nuts can slide over the front fork end. In order to assemble the front wheel you do the same but in reverse order. - Page 27 Assembly / Disassembly of the front Wheel in the Roller Brakes First of all loosen both axle nuts a. The locknuts b have to be loosened to ensure that the brake cable hangs out easily and the cable adjusting screw c has to be turned clockwise approx. 5mm. When you press the cam plate d upwards, you can pull the connecting plate e diagonally downwards from the guide.
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Page 28: Assembly/Disassembly Of The Rear Wheel In The Roller Brakes
Assembly / Disassembly of the rear Wheel in the Roller Brakes First of all loosen the axle nuts a. In order to loosen the connecting rivet b from the cam plate c the cam plate has to be pressed towards the front and the connecting rivet pushed in the direction of the rear wheel. The connecting rivet is now free and can be loosened from the cam plate. -
Page 29: Assembly/Disassembly Of The Rear Wheel In The Hubgears
Assembly / Disassembly of the Rear Wheel in the Hubgears SRAM 5 / 7-Gear Hubgears If, in the event of a defect, (e.g. damage to the tyre) the rear wheel has to be disassembled from the frame, please observe the following assembly steps: 1.) Set the gear lever to the 3rd gear (in the 7th gear hubgears position the gear lever to 4th gear). -
Page 30: Assembly/Disassembly Of The Rear Wheel In The Hubgears
Assembly / Disassembly of the Rear Wheel in the Hubgears Shimano 7-Gear Hubgears If, in the event of a defect, (e.g. damage to the tyre) the rear wheel has to be disassembled from the frame, please observe the following assembly steps: 1.) Position the gear lever to 1st gear. -
Page 31: Assembly/Disassembly Of The Front Wheel In Quick Release Hubs
Assembly / Disassembly of the front Wheel in Quick Release Hubs Open the front wheel brake as already described on page 27. Loosen the quick release cocking lever a. Then open the quick release nut b until the front wheel slides over the fork front end. The front wheel can be assembled in the reverse order. -
Page 32: Assembly/Disassembly Of The Rear Wheel In Quick Release Hubs
Assembly / Disassembly of the rear Wheel in Quick Release Hubs Open the brake as described on page 27. Switch the rear gear shifter to the smallest external gear sprocket. Open the quick release cocking lever a and loosen the quick release nut b. Lift the rear wheel a few centimetres from the floor. As you pull the rear derailleur towards the rear press the rear wheel towards the front until it is freed from the front end. -
Page 33: Setting Instructions For The Sprung Seat Post
Setting Instructions for the sprung Seat Post The seat post is continuously adjustable to the desired spring range. The maximum load is 120 Kg. The suspension force can be adjusted to individual bodyweight by using a 6mm Allen key. 1)The original adjustment by the factory = light = largest spring range (for approx. -
Page 34: Setting Instructions For The Spring Damper Components
Setting Instructions for the Spring Damper Components City Models In order to prevent damage, before using the bike for the first time the spring components should be approximately set to the corresponding bodyweight. The desired fine adjusting of the spring damper mechanism can subsequently be undertaken. Approximate Adjusting The approximate setting when leaving the factory is based on the middle setting corresponding to approx. - Page 35 Setting Instructions for the Spring Damper Components Safety Indications 1.) Before starting to cycle you should check that the dampers work correctly. Ensure that the mounting screws are tight. 2.) In the event that oil ever leaks from the shock absorbers or they make a noise indicating overshooting, have the shock absorbers checked by your specialist dealer.
- Page 36 Setting Instructions for the Spring Damper Components Changing the Suspension Rate In order to take full advantage of the spring range, the spiral spring should occasionally be completely mounted, i.e. the spiral spring’s spring range has been completely used and, due to this, the suspension becomes very hard. Observe the spiral spring’s mount when cycling quickly over ground waves or uneven surfaces.
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Page 37: Suspension Fork
Suspension Fork Some bikes are equipped with a suspension fork. This is meant for absorbing uneven surfaces and for achieving optimal cycling enjoyment. The use of a suspension fork increases cycling comfort and with correct use provides greater cycling safety. There are different types of suspension forks. -
Page 38: Tyres / Valves
Tyres / Valves Technical Characteristics The KETTLER aluminium wheels are made of tyres out of heat-moulded light covers with hermetically sealed butyl tubes. Depending on the model the tubes are equipped with Sclaverand valves or so-called “Blitz” valves. Through its tread, as well as its rubber mixture, it provides optimal adhesion and traction on all surfaces. We use differently- sized tyres in our range. -
Page 39: Tyres / Valves
Remove any stones, nails or glass etc. from the tyre thereby increasing your tyre’s lifespan. Should you not use your KETTLER aluminium bike over a longer period of time it is recommendable to hang the bike up. -
Page 40: Derailleur Gearing- Shifting Tips
Derailleur Gearing– Shifting Tips Before cycling familiarise yourself with the derailleur gearing characteristics. With the derailleur you have the possibility of indi- vidually controlling your pedalling and cycling speed. The light speeds are used when cycling uphill. • Never change gears when pedalling backwards. The chain can only be moved from one freewheel to another when the pedals are being moved forwards. -
Page 41: Derailleur Gearing– Shifting Tips
Derailleur Gearing– Shifting Tips With the front large Wrong! chain ring the rear freewheel’s 4 external sprockets. Important Advice! Adjustment work on the rear derailleur should only be carried out by a specialist dealer! The front and rear derailleur has been set by the factory, initially an adjustment is not necessary. In spite of this you should control the functioning of your shifting mechanism on a regular basis. -
Page 42: Maintenance
Maintenance General Maintenance and Care Indications With your purchase of the KETTLER aluminium bike you have bought a high-quality product. In order to keep it in top conditi on you must carefully maintain and take care of it. KETTLER aluminium bikes do not require much maintenance and are easy to care for, however they are not maintenance- free. - Page 43 Maintenance KETTLER recommends: You should get your specialist dealer to carry out the following maintenance work after having cycled 250 Km or at the latest after 6 weeks: • Re-centre the wheels • Check the steering head and pedal bearings for possible clearance •...
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Page 44: Care
Our bike accessories are valuable helpers in the cleaning or care of your bike. “KETTLER Profi assembly stands” as well as the KETTLER wall and ceiling holders. These articles can be purchased from authorised bike dealers. -
Page 45: Chain
Chain The chain should be regularly cleaned to remove dirt and sand particles and greased with the appropriate lubricants. We recommend cleaning the chain with a cloth and having it checked at least once a year by your specialist dealer. The bike chain is the part which is most subject to wear and tear. -
Page 46: Torque Specifications
Torque Specifications Article Article Description Manufacturer Tool / Torque Key Torque HANDLEBAR Stem (Handlebar arm) No Information 5 mm Allen key Approx. 15 Nm Stem (Shaft) No Information 5 mm Allen key 20-25 Nm Brake lever No Information 5 mm Allen key 6-8 Nm Shift lever Revo gear lever SL-7S... -
Page 47: Tyres Specifications
Torque Specifications / Tyres Article Article Description Manufacturer Tool / Torque Key Torque PEDAL BEARINGS INNER SET Pedal bearings inner set Special key 27-30 Nm Pedal bearings inner set Ofmega Special key 30 Nm Pedal bearings inner set Shimano TL-UN-65/74-5 50- 70 Nm Pedal bearings / pedal arm Ofmega... -
Page 48: Guarantee And Warranty Conditions
KETTLER guarantees that the product, on the day of the original purchase, is in perfect condition both in material and manu facturing quality. Should the product, in spite of considerable efforts in quality, show defects within the guarantee period, it will either be repaired or replaced as decided by KETTLER free of charge. - Page 49 01.01.2002. Technical modifications to your bike can only be carried out after prior consultation with KETTLER since the parts used by KETTLER will be subjected to higher load test than is nor- mal.
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Page 50: Checklist For The Handover Inspection / Maintenance Control
Cross off the inspection points listed below on the check list once they have been carried out by your specialist dealer. • Check handlebar and stem position....„ • Set and tighten seat position ......„ • Set seat post height and fix screw Your KETTLER Contractual Partner: or seat clamp ............„ Stamp • Screw in the greased pedals straight ....„... -
Page 51: Inspection Certificates
Annual Inspection Certificates Annual Inspection Annual Inspection Annual Inspection (at the latest 2 years (at the latest 5 years (at the latest 8 years after the purchase date) after the purchase date) after the purchase date) Date Signature + Dealer’s Stamp Date Signature + Dealer’s Stamp Date... - Page 52 HEINZ KETTLER GmbH & Co. KG · Postfach 1020 · D-59463 Ense-Parsit Telefon 0 29 38 / 8 10 · Telefax 0 2938 / 40 15 www.kettler.net · E-Mail: alu-rad@kettler.net...
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