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Kalkhoff Derby Instruction Manual

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Instruction manual
Kalkhoff bikes
Belgium: Derby Cycle Werke GmbH, Siemensstr. 1-3, D-49661 Cloppenburg, Phone: +49-4471966101
Guide d'utilisation
France: Derby Cycle Werke GmbH, Siemensstr. 1-3, D-49661 Cloppenburg, Phone: +49-4471966101
Derby Cycle Werke GmbH
Great Britain: 50Cycles Ltd., Unit M Littlemoor Lane, GB-Loughborough LE11 1SF, Phone: +44-1509 266656
Siemensstraße 1-3
Italy: Bike Evolution, Rigaste S. Zeno 39/B, I-37123 Verona, Phone: +39-045592410
Handleiding
49661 Cloppenburg
Latvia: Laterns Ltd., Brivibas 353/16, LV-1000 Riga, Phone: +371-9848860
Lithuania: Meibalt, Svitrigailos 5, LT-2000 Vilnius, Phone: +370-52651259
Tel. +49 (4471) 966-0
Instrucciones de uso
Netherlands: Derby Cycle Werke GmbH, Siemensstr. 1-3, D-49661 Cloppenburg, Phone: +49-4471966101
Fax +49 (4471) 966-44845
Romania: S.c. SportBikeCenter. S.r.l, St. Penes Carcanul 3-5, RO-300124 Timisoara, Phone: +40-256220023
E-Mail: info@kalkhoff-bikes.de
Slovakia: AGF Invest s.r.o., Hlinikova 365/39, SK-95201 Vrable, Phone: +421-262859549
Spain: Clean Laguna S.L., Urbanisation Sant Jordi da Alfama, E-43860 Ametlla de Mar, Phone: +34-977486160
www.kalkhoff-bikes.com
1973K0110002

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  • Page 1 Instruction manual Kalkhoff bikes Belgium: Derby Cycle Werke GmbH, Siemensstr. 1-3, D-49661 Cloppenburg, Phone: +49-4471966101 Guide d’utilisation France: Derby Cycle Werke GmbH, Siemensstr. 1-3, D-49661 Cloppenburg, Phone: +49-4471966101 Derby Cycle Werke GmbH Great Britain: 50Cycles Ltd., Unit M Littlemoor Lane, GB-Loughborough LE11 1SF, Phone: +44-1509 266656 Siemensstraße 1-3...

  • Page 2: Table Of Contents

    Foreword Adjusting the saddle Determining the correct saddle height Your bicycle was delivered to you fully assembled. In case any bicycle parts are not Adjusting the saddle height assembled, please contact your bicycle dealer. Adjusting the saddle tilt Suspension seat post These instructions help you in the Adjusting the handlebar appropriate,...

  • Page 3: Safety Advice

    Frame Safety advice Forks Checking the wheels Read all warnings and notices in this operating manual completely before using the Checking the tyres and inner tubes bicycle. Always store the operating manual near to the bicycle so that it is available at Tyres all times.

  • Page 4: Appropriate Use As Intended

    Trekking bikes / ATBs These bicycles may be used on public and made roads. They are also suitable for Road traffic safety light off-road use. Always obey the valid traffic regulations. The manufacturer and dealer shall not be liable for any use of the bicycle which Never ride hands-free.

  • Page 5: Assembling The Pedals

    Racing cycles / fitness bikes Thread sealant prevents screws from working loose on their own. If racing cycles are to be used on public roads, the national regulations must be com- Thread sealant is available from hardware stores. plied with. The manufacturer and dealer shall not be liable for any use of the bicycle which goes Screw the left pedal in an anticlockwise direction into the left pedal crank.

  • Page 6: Before Each Use

    Before each use To open the quick release, proceed as follows: Tilt the tensioning lever, so that the word OPEN is readable. Open the quick release as far as it will go. Despite taking great care during production and final checking, parts To loosen the quick release, turn the locking nut in an anticlockwise direction.

  • Page 7: Determining The Correct Saddle Height

    Determining the correct saddle height To adjust the saddle height, proceed as follows: Sit on the bicycle saddle. Loosen the saddle locking screw by turning Try to reach the pedal at its lowest position it anticlockwise using an allen key or by with your heel.

  • Page 8: Suspension Seat Post

    In the case of a saddle with a collar clamp, the Determine the optimum handlebar height for your body height as follows: locking screw is located at the side. If necessary, Sit on the bicycle saddle. adjust the saddle tilt by proceeding as follows: If necessary, ask someone to hold the bicycle.

  • Page 9: Adjustment Of The A-Head System Handlebar Height

    Adjustment of the A-Head system handlebar height The retaining catch screws are located on the underside of the stem on many stem models. Stems such as the one illustrated here are called A-Head stems. If this system is fitted, it is compulsory to have the handlebar height adjusted by a dealer. Adjust the handlebar stem to the desired height Tip the handlebar stem to the desired tilt.

  • Page 10: Using The Gear Shifter

    The crank arms must be seated tightly, otherwise the crank assembly may become damaged. The bicycle chain may not sit simultaneously on the smallest chain Since the crank arms can become loose, check the tightness of the sprocket at the front and the small outer sprocket at the rear, nor may it sit bottom bracket regularly.

  • Page 11: Racing Shift Lever

    Actuating the chain guide lever Actuating the derailleur lever (standard) Lever a: shifting to a larger chain sprocket. Lever A: shifting to a larger Lever B: shifting to a smaller rear rear sprocket. Lever A latches sprocket. By pressing lever B once, in positions 1, 2 and 3.
  • Page 12 Trimming (noise minimisation) Depending on the chain position after completion of shifting, the chain may rub against the outer or inner chain guide plate and cause noises. In this case, press lever ‘a’ or lever ‘b’ lightly in order to move the derailleur slightly so that it no longer contacts the chain.

  • Page 13: Standard Shift Lever

    Standard shift lever Both levers (A) and (B) return to their initial positions after actuation. Shifting from a large to a smaller rear The crank must always be turned when actuating a lever. sprocket Pressing once shifts to a smaller rear Actuating the derailleur shift lever sprocket.

  • Page 14: Twistgrips

    Twistgrips Tighten the adjustment screw for If the chain falls on the crank arm To shift by one gear only, turn the twistgrip forwards or backwards by one position. the largest gear to the right side: (approx. 1/4 turn). If shifting from the middle to the large Loosen off the adjustment screw chain sprocket is difficult: for the largest gear to the left...

  • Page 15: Chain Guide

    Chain guide Optimum adjustment When the slack is taken up by the gear shift lever, the chain should rub against the third rear sprocket and make a noise if the adjust- Have the chain gear shifter maintained, adjusted or replaced ment is optimal.

  • Page 16: Shimano Hub Gear Shifter

    When mounting the hub in the frame, the correct safety washers must be The coaster brake can be controlled very precisely. The full braking inserted on both sides and the hub nuts must be tightened to the prescribed torque. power is achieved after a certain running-in period. If the safety washers are inserted on one side only, or if the hub nuts are not correctly tightened, a safety washer can fall out.

  • Page 17: Shimano 7/8-Speed Shift Lever

    Cable anchor screw Shimano 7/8-speed shift lever Shifter wheel Turn the twistgrip to shift to all 8 (7) gears. Remove the cable anchor screw Increasing pedal force Indicator against 8 (7) Increasing pedal force Indicator against 8 (7) from the shifter wheel. Indicator Indicator CJ-8S20...
  • Page 18 Tension the chain and fix the wheel to the frame with the cap nuts, Turn the shifter arm so that the safety washers latch in the slots in the dropouts. tightening torque 30 – 45 Nm. In this case, the shifter arm can be mounted almost parallel to the chainstay. Illustration of 7/8-speed shifter: Illustration of 7/8-speed shifter: Illustration of 3-speed shifter:...
  • Page 19 Adjusting the angle lever – fine adjustment If the clip nut loosens itself from the brake arm or the clip screw or brake arm clip are damaged, the brake arm can rotate on the chainstay. This can cause Set the Revo twistgrip to (2). the handlebar to move suddenly or the wheel to lock, which can lead to a fall with Turn the cable adjustment screw so that the red line on the rod is aligned serious injuries.
  • Page 20 Hook Turn the cable 60° to the right and Turn the crank arms and switch the Revo twistgrip two to three times from (3) fix it to the hook. to (1) and back from (1) to (3) to check the shifting operation. Set the Revo twistgrip to (2) and check that the red line on the rod is aligned CJ-8S20 Turn...

  • Page 21: Sram Hub Gear Shifter

    SRAM hub gear shifter Check that the cable is inserted properly into the shifter wheel guide. Shifting Continue to pedal without force when shifting gear. If the desired gear does not engage immediately, stop pedalling briefly. Change down in good time before uphill sections. Brakes CJ-8S20 CJ-8S20...

  • Page 22: Sram 5(7)-Speed Brake Gear Hub

    Shifter adjustment Refitting Place the shifter lever in gear position ‘3’. Move the pedal arm to ensure that Fit a 2.5 mm thick fixing washer (4, fig. 2) on the outside on both sides the gear is engaged. of the dropout. The serration must lie on the dropout, the tab must latch Push the clamping bush (2, fig.

  • Page 23: Bicycle Chain Maintenance

    Bicycle chain maintenance If the clip nut loosens itself from the brake arm or the clip screw or brake Bicycle chains are consumable parts. In the case of hub gear shifters, the chain is worn arm clip are damaged, the brake arm can rotate on the chainstay. This can after about 3000 km, in the case of chain gear shifters after around 2000 km.
  • Page 24 There are several different kinds of brakes, depending on where they are used: hub brakes, disc brakes and Brake cables are consumable parts. Check them regularly for wear wheel rim brakes. and have them replaced if necessary. Check the brake cable for rust and fraying and replace it if any faults are found. The brakes may be actuated mechanically or hydraulically.

  • Page 25: Brake Levers

    Brake levers Adjusting the brakes Your bicycle’s brakes have been correctly adjusted in the factory or by your dealer. The Standard brake levers gap between the brake block and the wheel rim is approx. 1 – 1.5 mm. However, the The bicycle is fitted as standard with a suitable brake lever.

  • Page 26: Disc Brakes

    If the brakes do not work correctly, of if the brake blocks are worn to the extent that The brake saddle and the disc may be hot after braking, therefore do not touch adjustment is no longer possible, have the bicycle checked and the brake blocks them during or immediately after riding, as you could burn yourself.

  • Page 27: Drum Brakes And Roller Brakes

    Carry out a braking test after each adjustment by pushing the bicycle strongly Brake pads and brake blocks are consumable parts. whilst pulling the brake lever. Only use your bicycle when it can be safely braked. Have the brake pads of hydraulic oil pressure disc brakes checked regularly by a dealer and replaced if necessary.

  • Page 28: Sram Drum Brakes

    The brake arm of the drum brake is fixed to the frame by means of a suitable Roller and drum brakes require a specially matched brake lever. pipe clip (1). Check regularly that the screws on the brake lever are tight. Tighten them in a clockwise direction if necessary.

  • Page 29: Shimano Drum Brakes

    Groove Shimano drum brake (Inter-M) Front wheel roller brake Dismantling (before removing the wheel) Connecting piece Verbindungsstück If any of the following signs occur when braking, you must not ride any further: 1) abnormal braking noises, or 2) unusually high braking power or Push the cam plate as far as it will go.
  • Page 30 Connecting piece Groove Verbindungsstück Adjusting the brake cable When the cam plate is Check whether the wheel shows resistance to rotation when the brake cable Wenn die pushed towards the front Nockenplatte nach is taut. Pull the brake lever strongly about ten times towards the grip in order to vorne gedrückt ist stretch the cable.

  • Page 31: Frame

    Frame The rivet must be located in the middle of part A of the cam plate. The shape of the frame depends on the type and function of the bicycle. Frames are manufactured from a variety Pull the brake lever and check the brake function. of materials, such as steel or aluminium If the brake does not function properly, the brake cable must be adjusted.
  • Page 32 To adjust an oil-air fork, proceed as follows: Chainstay dampers Adjust the suspension hardness via the air pressure in the fork. The chainstay dampers provides a more comfortable ride. Check the air pressure regularly with a pump. 1 Spring dampers To adjust an elastomer fork, proceed as follows: 2 Air dampers To increase the spring tension, turn the adjustment knob on the top of the fork...

  • Page 33: Checking The Wheels

    Checking the wheel rims If you use wheel rim brakes, the wheel rim is subject to greater wear. Tighten all screws to the specified torque, otherwise the screws could break off and parts may become loose. (see chapter ‘Tightening torques of screws, nuts and bolts’, page 45).

  • Page 34: Inner Tubes

    Note the size of the fitted tyre. There are standard descriptions for tyre sizes. To pump up an inner tube with a Dunlop or lightning valve and Schrader or Example 1: ”46-622“ means 46 mm tyre width and 622 mm diameter. automatic valve, proceed as follows: Example 2: ”28 x 1.60 Inch“...
  • Page 35 Removing a side-pull brake Air bubbles will rise to the surface from the place where the inner tube is torn Loosen the screws fastening the brake blocks to the brake arms. or punctured. The tyre slips through between the brake pads. Allow the inner tube to dry.

  • Page 36: Operating The Lighting Components

    Operating the lighting components Turn the dynamo on and off only when standing still, otherwise it is dangerous for yourself and other road users. The efficiency of the side dynamo is reduced in wet weather. If necessary, provide extra lighting. Only lighting elements which are stipulated by and approved according to national regulations may be attached to bicycles.

  • Page 37: Failure Of The Lighting System

    Failure of the lighting system Chainstay carrier Mount child seats on chainstay carriers only Failure of the lighting system when riding in the dark can lead to serious if appropriate fixings are present. Do not exceed the accidents. Have the fault rectified by a dealer before riding further. maximum allowable weight class.

  • Page 38: Bicycle Stand

    Selecting accessories and equipment Never ride if the braces are loose. Refasten them. If it is not possible to refasten the braces, have them replaced by a dealer. Use only accessories which conform to the national bicycle regulations. Accessories which are not approved are not safe for use in traffic and can lead to accidents.

  • Page 39: Handling Carbon Components

    A child may only be carried in a child seat up to the age of 7 years. Attach the basket in such a way that it does not cover up the headlamp The rider must be at least 16 years old. or front reflector.

  • Page 40: Care And Maintenance Of The Bicycle

    Handling carbon components Recutting the thread and the bearing shells or rubbing out the seat Carbon is a special material that requires special treatment and care during assembly, tube are not allowed. It is not permitted to mount a child seat on maintenance, riding, transport and storage of the bicycle.

  • Page 41: Care

    Splinters Carbon fibres are very thin and hard. Therefore, handle damaged carbon parts very Do not clean your bicycle with carefully. Individual fibres may become loose and protrude. If they come into contact acids, with your skin, small splinters may penetrate the skin. greases, hot oil, Small repairs in an assembly stand...

  • Page 42: Consumable Parts

    Consumable parts Chain sprockets, rear sprockets, bottom bracket and gear shift rollers In the case of bicycles with chain gear shifter, the chain sprockets, rear sprockets, bottom bracket and gear shift rollers are subject to wear. The level of wear is Have your bicycle checked regularly by a dealer and the consumable parts dependant on the care, maintenance and usage of the bicycle (mileage, riding replaced.

  • Page 43: Regular Inspection

    Bearings Inspection plan All of the bicycle’s bearings such as headset, wheel hubs, pedals and inner bearings are subject to wear. This is dependant on the level and length of usage and on the Maintenance / Check When? level of care. Check 100 km after purchase, after tyres and wheels.

  • Page 44: Technical Data

    Tightening torques of screws, nuts and bolts After 3000 km Have the hubs, headset, Use only suitable tools for tightening screwed components, e.g. torque pedals, gear shift cables and wrench, otherwise the screws may shear off. brake cables by a dealer dismantled, checked, Parts may be damaged if the screws are over-tightened.

  • Page 45: Tyres And Tyre Pressures

    Racing cycle brake (BR) Fixing screw (welded socket) 5 Nm Inner cable fixing screw 6 Nm In the case of carbon parts, observe any differing information or marking Brake pad fixing bolt 8 Nm regarding the recommended torque. Cantilever brake (BR) Fixing screw (welded socket) 5 Nm Inner cable fixing screw...

  • Page 46: Warranty Conditions

    Reprinting, also of extracts, only with the permission Exclusions from the warranty of Derby Cycle Werke GmbH. Printing errors, mistakes A right to claim on the warranty exists only for the initial faults of defective parts. The following are excluded from the warranty:...

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