Infinity Cycle Innovations - Owners Manual by Infinity Cycleworks

BICYCLE

Owner’s Manual

General Information

Assembly

How Things Work

Repair and Maintenance

Warranty

Any Questions or Concerns? Call Toll Free phone: 1-855-521-1127 www.infinitycycleworks.com

Bicycle Ownerʼs Manual Congratulations on the purchase of your new bicycle!

repair facility.

At Infinité Cycle Works Ltd. wish you years of cycling pleasure. To get the most out of your cycling experience, we recommend that you completely read and understand this manual in order to better acquaint yourself with your new bike. It is extremely important that you pay close attention to all safety information presented within this manual, as your safety is our chief concern.

We sincerely hope your new bicycle will give you a great deal of cycling pleasure and satisfaction. If you should have any problems, comments or questions that cannot be handled by your authorized retailer, we would welcome your letter or phone call.

While we have not illustrated all models and components specifically, the illustrations and descriptions of parts and operation are similar for all bicycles. In addition to the information in the Safety sections, warnings for your safety are spread throughout this manual.

Infinité Cycle Works Ltd. 722 Chester Road Delta, BC V3M 6J1 Canada Call Toll Free: 1-855-521-11277 Fax: 1-604-521-1163 Email: info@infinitycycleworks.com

Introduction

Please read and review the contents of this manual on a regular basis. We recommend that you become familiar with all operating systems and components and that you be thoroughly familiar with all applicable regulations, prior to operation or riding.

We do not keep a record of your Serial #. Complete page 37 for your personel records, insurance and warranty claims.

This manual will assist you in setting up and maintaining your bicycle. We recommend inspecting your bicycle frequently. Remember, proper maintenance and adjustment will greatly enhance performance and riding enjoyment. Part replacementand major repairs for the bicycle should always be done by your authorized Infinité Cycle Works Ltd. 3

Bicycle Ownerʼs Manual

Bicycle Owner’s Manual

Section 1: General Information 1.1 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.2 Bicycle Components . . . . . . . . . . . . . . . . . . . . . . . 7 1.3 Bicycle Size and Fit . . . . . . . . . . . . . . . . . . . . . . . 8 1.4 Safety Components . . . . . . . . . . . . . . . . . . . . . . . . 9 1.5 About your Dealer . . . . . . . . . . . . . . . . . . . . . . . . 10 Section 2: Assembly 2.1 Before Assembling . . . . . . . . . . . . . . . . . . . . . . . 11 2.2 Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.3 Tires and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.4 Handlebar and Stem . . . . . . . . . . . . . . . . . . . . . . 14 2.5 Seat and Seatpost . . . . . . . . . . . . . . . . . . . . . . . . 15 2.6 Reﬂectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.7 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.8 Warning before riding your bike . . . . . . . . . . . . . 17 Section 3: How Things Work 3.1 Types of Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Headsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Crank Sets Lubrication and Adjustment . . . . . . . 3.4 Front and Rear Derailleur . . . . . . . . . . . . . . . . . .

28 29 31 34

Section 5: Warranty 5.1 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . 36 5.2 Bicycle Identiﬁcation Record . . . . . . . . . . . . . . . 37

Figures Section 1 - General Information Fig

Figure Name

Pag

1.2a

Bicycle Components

1.3a

Standover Height Clearance

Figures Section 2 - Assembly

Figures Section 3 - How Things Work Fig

Figures Section 4 - Repair and Maintenance

Figure Name

Pag

3.1a

Using The Coaster Brake

3.1b

Caliper Brake with Rotor

3.1c

Side Pull Caliper Brake

3.1d

V-Brake Step 1

Fig

Figure Name

Pag

4.2a

Fork Suspension

4.2b

Frame Suspension

4.3a

Thumb Shifters

4.3b

Trigger Shifters

3.1e

V-Brake Step 2

4.3c

Twist Shifters

Fig

Figure Name

Pag

3.1f

V-Brake Step 3

4.3d

Twist Shifter Lubrication

2.1a

Tools Required

3.1g

V-Brake Step 4

4.3e

Twist Shifter Assembly

2.2a

Front Wheel Assembly

3.1h

V-Brake Step 5

4.3f

Rear Twist Shifter (1)

2.2b

Quick Release Axle Settings

3.2

Threaded Headset Parts

4.3g

Rear Twist Shifter (2)

2.4

Handlebar and Stem

3.3a

Cotterless Crank (3 pc)

4.3h

Rear Twist Shifter (3)

2.5a

Seat Clamp

Rear Twist Shifter (4)

Seat & Seat Post

Cotterless Crank Disassembly and Reassembly

4.3i

2.5b

3.3b

Front Twist Shifter (1)

Pedal Assembly

Cotterless Crank Removal

4.3j

2.7

3.3c 3.3d

One Piece Crank Assembly

4.3k

Front Twist Shifter (2)

4.3l

Front Twist Shifter (3)

Figures

Table of Contents

i. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ii. Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 4 iii. Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Section 4: Repair and Maintenance 4.1 Service and Maintenance . . . . . . . . . . . . . . . . . . 4.2 Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Shifters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Service Check List . . . . . . . . . . . . . . . . . . . . . . .

iii

18 24 25 27

General Information

General Information for example, itʼs important for you to make sure that it fits before you ride it.

1.3

Size and Fit

Make sure the bike fits. A bike thatʼs too big or too small for the rider is more difficult to control and can be uncomfortable. ! WARNING: IF THE BICYCLE DOES NOT FIT PROPERLY, YOU MAY LOSE CONTROL AND FALL. IF YOUR NEW BIKE DOESNʼT FIT, ASK YOUR DEALER TO EXCHANGE IT BEFORE YOU RIDE IT.

Size: Your dealer will have recommended the best bicycle size for you, based on the information provided. If you picked your bike at the dealerʼs, someone took the time to fit you to the correct size of bicycle. If someone else selected the bike for you, as a gift, 8

Fig. 1.3a Standover Height Clearance

2”

You should have a minimum standover height clearance of one to two inches - see Fig. 1.3a.

1.4 Safety

Components

Helmet

! WARNING: ALWAYS WEAR AN APPROVED BICYCLE HELMET WHEN RIDING YOUR BIKE. ALWAYS KEEP THE CHINSTRAP SECURELY BUCKLED. FAILURE TO WEAR A BICYCLE HELMET MAY RESULT IN SERIOUS INJURY OR DEATH.

Your helmet must fit correctly, be worn correctly and be properly secured to do its job. Ask your dealer to help you with the fit and adjustment of your helmet, and refer to the ownerʼs manual provided with your helmet. Lights Do not ride after dusk or before full daylight. If you must ride your bike after dusk or before full daylight, your bicycle must be equipped with lights

so that you can see the road and avoid road hazards, and so that others can see you. Vehicle laws treat bicycles like any other vehicle. That means you must have a white front and a red rear light operating if you are riding after dusk or before full daylight. Your bike dealer can recommend a lighting system appropriate to your needs. Brake Lever Position If your bicycle is equiped with hand operated brakes, the brake levers are positioned on the handlebar where they work best for most people. The angle and position of the levers can be changed. Ask your dealer to show you how, or to make the adjustments for you. Brake Reach Many bikes with hand-operated brakes have brake levers which can be adjusted for reach. If you have small hands and find it difficult to squeeze the brake levers, your dealer can either adjust the reach or fit shorter reach brake levers.

Pedals Some higher performance model bicycles come equipped with pedals that have sharp and potentially dangerous surfaces. These surfaces are designed to add safety by increasing adhesion between the riderʼs shoe and the bicycle pedal. If your bicycle has this type of high-performance pedal, you must take extra care to avoid injury from the pedalsʼ sharp surfaces. Chainguard If your bicycle came with a full chainguard (Full Style) or a semi attached (Screwed on to the chain ring), DO NOT REMOVE IT! If it becomes damaged cracked or loose see your bicycle technition and have it replaced.

Safety Components

Bicycle Size and Fit

1.3 Bicycle

The first check for correct size is standover height. Standover height is the basic element of bike fit. It is the distance from the ground to the top of the top tube at that point where your crotch would be if you were straddling the bike by standing halfway between the saddle and the handlebar stem.

To check for safe standover height, straddle the bike while wearing the kind of shoes in which youʼll be riding, and bounce vigorously on your heels. If your crotch touches the frame, the bike is too big for you. Donʼt even ride the bike around the block.

1.4

IMPORTANT!

When riding your bicycle on city streets you are governed by the same laws, rules, and regulations as any motorist. Contact your local motor vehicle branch for road bicycle safety information and laws in your area. 9

General Information

Assembly There is a wide range of accessories available for your bicycle.

1.5

Your Dealer

Your dealer is here to help you get the bike and accessories which are most appropriate for the kind of riding that you intend to do, and to help you maintain your equipment so that you can get the maximum enjoyment from it. Your bike shopʼs staff has the knowledge, tools and experience to give you reliable advice and competent service. Your dealer carries the products of a variety of manufacturers so that you can have the choices that best meet your needs and your budget. But your dealerʼs staff canʼt make decisions for you, nor can they assume responsibility for your lack of knowledge, experience, skill or common sense. They can explain to you how something works, or what part or accessory will meet your special needs, but they canʼt know your questions or your needs unless you tell them.

Even if you are an experienced rider, donʼt assume that you can properly install and operate the accessories without first reading any instructions that are enclosed with the product. Be sure to read, and understand, the instructions that accompany the accessories you purchase for your bicycle. If you have the slightest doubt as to your ability to install them correctly, ask your dealer to do it. ! WARNING: FAILURE TO INSTALL AND OPERATE ANY ACCESSORY PROPERLY CAN RESULT IN SERIOUS DAMAGE TO THE BICYCLE, AND SERIOUS INJURY TO THE RIDER. ! WARNING: IF YOUR BIKE WAS OBTAINED COMPLETELY ASSEMBLED, WE RECOMMEND THAT YOU REVIEW THE ASSEMBLY PROCEDURES AND PERFORM THE SAFETY CHECKS SPECIFIED IN THIS MANUAL BEFORE RIDING. THIS WILL ALSO HELP YOU TO BECOME MORE FAMILIAR WITH THE COMPONENT PARTS AND OPERATION OF YOUR NEW BICYCLE.

Assembly

Unpacking

• Remove the bike and all parts from the carton, then lay out all unassembled parts.

• Remove all cardboard and corrugated sections from around the frame tubes and at each end of the carton. There may be several items packed in corrugated sections at the ends of the carton.

2.1 Before Assembling

Tools Required

• Open-ended wrench or ring wrenches: 8 mm, 9 mm, 10 mm, 12 mm, 13 mm, 14 mm, 15 mm • Open-end or pedal wrench 15 mm

• Allen key wrenches: 4 mm, 5 mm, 6 mm, 8 mm • Adjustable wrench

• Standard flat head screwdriver

• Standard Phillips head screwdriver

• Standard slip joint pliers • Tire pump

• Remove the plastic axle protectors from the axles, and the plastic fork support. Discard all of these items.

• Carefully read the assembly instructions when assembling your bike. • Record all information on the date code label located on the bottom of the crank housing.

• When ordering replacement parts, specify both the model number and the date code of your unit to avoid any unnecessary delays in obtaining parts.

Before Assembling

About Your Dealer

1.5 About

Section 2:

2.1

Fig. 2.1a Tools Required

If you have a problem with your bike or your riding, talk to your dealer. Make sure that the dealer understands your problem or question, and make sure that you really understand the answers. 10

Assembly

Assembly outer faces of the front fork dropouts.

2.2 Front

Wheel

Front Wheel 2.2

• Remove the plastic protectors (not shown) from the wheel axles and dispose of them. They are for shipping purposes only.

• On bikes with caliper brakes, remove a brake pad, if needed, to install the wheel. Re-install the brake cable /or brake pad immediately. See brake adjustment section.

Attention: The front fork of your bicycle utilizes a secondary wheel retention device to keep the wheel from disengaging if the wheel nuts are insufficiently tightened. Secondary retention devices fall into two basic categories:

• The clip-on type is an accessory part which the manufacturer adds to the front wheel hub or front fork. • The integral type is moulded, cast or machined into the

! WARNING: REMOVING OR DISABLING THE SECONDARY RETENTION DEVICE IS EXTREMELY DANGEROUS AND MAY LEAD TO SERIOUS INJURY OR DEATH. IT ALSO MAY VOID THE WARRANTY. PLEASE ENSURE THAT THESE DEVICES ARE CORRECTLY INSTALLED AND MAINTAINED.

• Put a wheel retainer onto each end of the axle. Hook the retainers into the holes in the fork.

• Loosely thread a flange nut onto each end of the axle. While keeping the wheel centred in the fork, securely tighten each flange nut, alternating from one nut to the other. • Spin the wheel to make sure it doesnʼt wobble. Re-align the wheel if necessary, then securely re-tighten the flange nuts. Fig. 2.2a Front Wheel Assembly

Axle Nut

Retaining Washer

IMPORTANT: If your bike is equipped with Quick Release

(Q.R.) Seat Pin or Quick Release Axles on either the front or the rear, please read the following carefully.

• To set, turn the lever to open position so that the curved part faces away from the bicycle. • While holding the lever with one hand, tighten the adjusting nut until it stops.

• Pivot the lever towards the closed position. When the lever is halfway closed, there must be firm resistance to turning it beyond that point. If the resistance is not firm, open the lever and tighten the adjusting nut in a clockwise direction. • Continue to pivot the lever all the way to the closed position so that the curved part of the lever faces the bicycle.

• 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. • Note that the same procedure applies when operating a quick release seat post binder mechanism.

• Turn the bicycle upright using the kickstand to support it.

! WARNING: Correct adjustment of the quick release is vitally important to avoid an accident caused by loose wheels.

Fig. 2.2b Quick Release Axle Settings

Adjusting Nut Closed Position

Hub

Open Position

Quick Release Lever

2.3 Tires

and Tubes

! CAUTION: WHEELS MUST BE TRUE FOR HAND BRAKES TO WORK EFFECTIVELY. WHEEL TRUING IS A SKILL WHICH REQUIRES SPECIAL TOOLS AND EXPERIENCE. DO NOT ATTEMPT TO TRUE A WHEEL UNLESS YOU HAVE THE KNOWLEDGE, EXPERIENCE AND TOOLS NEEDED TO DO THE JOB CORRECTLY.

During assembly and before every ride check your tire pressure using a bicycle tire pressure gauge. ! WARNING: NEVER INFLATE A TIRE BEYOND THE MAXIMUM PRESSURE ( lbs P.S.I ) MARKED ON THE TIREʼS SIDEWALL. EXCEEDING THE MAXIMUM RECOMMENDED. PRESSURE MAY BLOW THE TIRE OFF THE RIM, WHICH COULD CAUSE DAMAGE TO THE BIKE AND INJURY TO THE RIDER AND BYSTANDERS.

Tire Pressure: Always use a bicycle tire pump to inflate your tires. Your dealer can help you select an appropriate pump. ! CAUTION: GAS STATION AIR HOSES MOVE A LARGE VOLUME OF AIR VERY RAPIDLY AND WILL RAISE THE PRESSURE IN YOUR TIRE VERY RAPIDLY. TO AVOID OVERINFLATION WHEN USING A GAS STATION AIR HOSE, PUT AIR INTO YOUR TIRE IN SHORT, SPACED BURSTS.

Tires and Tubes

NOTE: THE DIRECTIONS “LEFT”, “RIGHT”,” FRONT”, “REAR”, ETC., ARE USED IN THIS MANUAL AS SEEN BY A RIDER WHILE SEATED ON THE BIKE. AFTER THE FRONT WHEEL IS ASSEMBLED, PUT THE KICKSTAND IN THE DOWN POSITION.

Ask your dealer to explain the particular secondary retention device on your bike.

Quick Release Axle Setting & Quick Release Seat Pin

2.3

! WARNING: RIDING YOUR BICYCLE WITH A FLAT OR UNDER- INFLATED TIRE CAN SERIOUSLY DAMAGE THE TIRE, TUBE AND BICYCLE, AND COULD CAUSE YOU TO LOSE CONTROL AND FALL.

Assembly

Assembly Under no circumstances should the seat post project from the frame beyond its “Minimum Insertion” or “Maximum Extension” mark - Fig. 2.5b.

and be sure to tighten the bolts more tightly than before.

2.4

Stem

! WARNING: THE STEMʼS MINIMUM INSERTION MARK MUST NOT BE VISIBLE ABOVE THE TOP OF THE HEADSET - SEE FIG. 2.4. IF THE STEM IS EXTENDED BEYOND THE MINIMUM INSERTION MARK, THE STEM MAY BREAK OR DAMAGE THE FORKʼS STEERER TUBE, WHICH COULD CAUSE YOU TO LOSE CONTROL AND FALL.

• Remove the protective plastic cap from the bottom of the handlebar stem and loosen the stem bolt using a 6 mm Allen wrench. (Some stems will use a 13 mm bolt instead of an Allen key bolt.)

• Insert the handlebar stem into the head tube. Make sure that the stem is inserted far enough in so that the minimum insertion line stamped on the stem disappears inside the head tube. Check to make sure that the cables are not tangled. Check to see that the fork and the handlebar are facing straight forward and aligned with the front wheel. Tighten the stem bolt.

Test the tightness of the handlebar clamp by holding the bicycle stationary and trying to move the handlebars forward and backward. If the handlebar moves, loosen the bolts of the handlebar clamp, put the handlebar in the correct position 14

Fig. 2.4 Handlebar and Stem

Stem Bolt Minimum Insertion Mark must not be visible

Handlebar Clamp

Head Tube

Stem Bolt must be secure to avoid Handle Bar from becomming loose.

2.5 Seat

and Seat Post

• Loosen the nut (or nuts) on the seat clamp. • Put the tapered end of the seat post up into the seat clamp until it is at the top of the clamp. ! CAUTION: IF THERE IS NO “LIP” ON THE TOP OF THE SEAT POST, MAKE SURE THAT THE SEAT POST IS ALL THE WAY THROUGH THE CLAMP BUT DOESNʼT HIT THE UNDERSIDE OF THE SEAT. IF IT DOES HIT, RAISE THE SEAT UP UNTIL CLEARANCE EXISTS.

• Partially tighten the nut (or nuts) on the seat clamp until the seat is snug, but can still be turned.

• Adjust the seat to the proper riding position, then securely tighten the bolts on the seat post clamp.

Lip

! WARNING: IF YOUR SEAT POST PROJECTS FROM THE FRAME BEYOND THE MINIMUM INSERTION OR MAXIMUM EXTENSION MARK - SEE FIG. 2.5b, THE SEAT-TUBE MAY BREAK, WHICH COULD CAUSE YOU TO LOSE CONTROL AND FALL. FAILURE TO PROPERLY ADJUST SEATPOST HEIGHT WILL VOID THIS WARRANTY. ! ATTENTION: Failure to properly install and adjust a seatpost

with a quick release device could allow the saddle seatpost to loosen while riding and lead to serious personal injury. Check your quick release adjustments before each ride! Fig. 2.5b Seat & Seat Post

Fig. 2.5a Seat Clamp

• Insert the seatpost into the seat mast. Make sure that the “minimum insertion mark is not visible.

• Tighten the binder bolt until you can not twist the seat from side to side. If your bicycle is equipped with a quick release seat pin see “Quick release axle setting” for quick release instructions.

Seat and Seat Post

Handlebar and Stem

2.4 Handlebar and

Tighten the handlebar clamp bolts equally. Do this over again until the handlebar does not move in the handlebar clamp.

2.5 Seat Clamp Seat Post Clamp and Bolt

Nut Seat Post Minimum Insertion Mark

Seat Mast

Assembly 2.6 Reflectors

Reflectors 2.6

THE REFLECTORS MUST ALWAYS BE VERTICAL (PERPENDICULAR TO THE GROUND) AND POINTED TOWARD THE FRONT AND REAR OF THE BIKE.

• Rear frame, handlebar and seatpost reflectors are already installed on to your bicycle, check to make sure that they are secured tightly and positioned correctly. • Front fork reflector. Attach the white fork reflector to the fork reflector bracket Using the bolt attached to the center of the fork crown secure the bracket and reflector to the fork. • Make sure there are at least 3 inches of clearance between the top of the seat and the top of the red rear reflector.

! WARNING: DO NOT REMOVE THE REFLECTORS OR BRACKETS FROM YOUR BICYCLE. THEY ARE AN INTEGRAL PART OF THE BICYCLEʼS SAFETY SYSTEM. ASIDE FROM REDUCING YOUR VISIBILITY TO OTHERS, SOME 16

REFLECTOR BRACKETS PREVENT THE BRAKE STRADDLE CABLE FROM CATCHING ON THE TIRE IN THE EVENT OF BRAKE CABLE FAILURE. IF A BRAKE STRADDLE CABLE CATCHES ON THE TIRE, IT CAN CAUSE THE WHEEL TO STOP SUDDENLY, CAUSING YOU TO LOSE CONTROL AND FALL.

Wheel Reflectors

NOTICE: IF YOUR BIKE HAS ONE AMBER AND ONE RED WHEEL REFLECTOR, THE AMBER REFLECTOR GOES ON THE FRONT WHEEL AND THE RED ONE GOES ON THE REAR WHEEL.

• Loosely assemble the bolt and nut onto the reflector. The nut goes on the side with the hexagon-shaped indentation.

• Position the reflector between the spokes on the side of the wheel opposite the valve stem. One spoke should fit into the slot under the bolt while two spokes are on the other side. • Slide the reflector toward the rim. The reflector should be about 76.2 mm (3”) from the rim. • Tighten the bolt after making certain that it overlaps the spoke, then repeat the same procedure for the other wheel.

2.7 Pedals

2.8 Before You

! WARNING: FOR SAFE OPERATION, PEDALS MUST BE SECURELY TIGHTENED AGAINST THE CRANK ARMS. ALWAYS REPLACE DAMAGED PEDALS, AND ALWAYS WEAR SHOES WHEN RIDING.

Although your bicycle looks completely assembled, you must continue to read through this manual to ensure that every thing is functioning correctly. Every component must be inspected.

Ride Your Bicycle

NOTICE: TRY TO START EACH PEDAL BY HAND TO AVOID STRIPPING THE THREADS. WE RECOMMEND APPLYING A SMALL AMOUNT OF GREASE TO THE THREADS OF BOTH PEDALS BEFORE ASSEMBLY. USE A WRENCH IF NEEDED, BUT DO NOT FORCE THE THREADS.

Here is a simple, sixty-second mechanical safety check, which you should get in the habit of making every time youʼre about to get on a bike.

• Look for the letter “L” or “R” stamped on the sides or ends of the pedal spindles. If no markings exist, identify the right pedal by matching the threads to the illustration shown here. Fig. 2.7 - Pedal Assembly

• Do a visual and hands-on inspection of the whole bike. Are there any loose parts or accessories? If so, secure them. If youʼre not sure, ask someone with experience to check.

• Thread the pedal marked “R” by hand into the crank arm on the right (sprocket side) of the bike. Turn the spindle in a clockwise direction. If the threads do not turn easily, back the spindle out and re-start it. Securely tighten the spindle against the crank arm. • Thread the pedal marked “L” into the crank arm on the left side of the bike by hand. Turn the spindle in a counter-clockwise direction. Securely tighten the spindle against the crank arm.

• Lift the front wheel off the ground by two or three inches, then let it bounce on the ground. Does anything sound, feel or look loose?

• Are the tires in good shape? Spin each wheel slowly and look for cuts in the tread and sidewall. Replace damaged tires before riding the bike. • Are the wheels true? Spin each wheel and check for brake clearance and side-to-side wobble. If a wheel wobbles from side to side or hits the brake pads, take the bike to a qualified bike shop to have the wheel trued. Are the front and rear wheels straight and secure in the dropouts? Are the wheel nuts properly tightened?

Before You Ride Your Bicycle

NOTICE: IT IS IMPORTANT TO CHECK REFLECTORS AND THEIR MOUNTING BRACKETS DURING ASSEMBLY AND BEFORE EVERY RIDE TO MAKE SURE THAT THEY ARE CLEAN, STRAIGHT, UNBROKEN AND SECURELY MOUNTED. HAVE YOUR DEALER REPLACE DAMAGED RFLECTORS AND BRACKETS.

Assembly

2.8

• Are the saddle, handlebar and stem tight enough so that you canʼt twist them out of alignment?

How Things Work Section 3:

3.1

of Brakes

If your bicycle has hand-operated brakes, squeeze the brake levers. Are the brake shoes contacting the wheel rim within an inch of brake lever movement? Can you apply full braking force at the levers without having them touch the handlebar? If not, your brakes need adjustment. Do not ride the bike until the brakes are properly adjusted. If your bicycle has a coaster brake, check to make sure that the coaster brake arm is securely clamped to the bicycle frame. If the arm or its mounting bracket is loose, do not ride the bike until the brake arm is properly secured.

! WARNING: RIDING WITH IMPROPERLY ADJUSTED AND SECURED BRAKES OR WORN BRAKE SHOES IS DANGEROUS AND CAN RESULT IN SERIOUS INJURY OR DEATH.

It is your responsibility to read - and to understand - this section of the manual. If you have even the slightest doubt as to whether you understand something, talk to your dealer.

BE SURE THAT YOU UNDERSTAND HOW YOUR BICYCLEʼS BRAKES WORK BEFORE YOU TAKE YOUR FIRST RIDE BY. 18

Hand Brakes A bicycle with hand brakes may have one hand lever which operates a rear brake, or two hand levers, one of which operates the front wheel and the other, the rear wheel. Itʼs important to your safety that you instinctively know which brake lever controls which brake on your bike.

In Canada, bikes are required to be set up with the right brake lever controlling the rear brake, and the left lever controlling the front brake.

! WARNING: SUDDEN OR EXCESSIVE APPLICATION OF THE FRONT BRAKE MAY PITCH THE RIDER OVER THE HANDLEBARS, WHICH MAY RESULT IN SERIOUS INJURY OR DEATH.

Make sure that your hands can reach and squeeze the brake levers comfortably. If your hands are too small to operate the levers comfortably, consult your dealer before riding the bike. The lever reach may be adjustable, or you may need a different brake lever design.

Some hand brakes have a quick release mechanism to allow the brake shoes to clear the tire when a wheel is removed or reinstalled. When the brake quick release is in the open position, the brakes are inoperative. Ask your dealer whether you have a quick release on your brakes; if you do, make sure that you understand the way the brake quick release works, and check each time to make sure both brakes work correctly before you get on the bike.

Coaster Brake The coaster brake is a sealed mechanism which is a part of the bicycleʼs rear wheel hub. The brake is activated by reversing the rotation of the pedal cranks - see Fig. 3.1a. Start with the pedal cranks in a nearly horizontal position, with the front pedal in about the 4-oʼclock position, and apply downward foot pressure on the pedal that is to the rear. The more downward pressure you apply, the more braking force, up to the point where the rear wheel stops rotating and begins to skid.

Apply reverse pressure to the pedal to slow down or stop

Removing a Bolt-On Rear Wheel with Coaster Brake

• Disengage the coaster brake arm from its frame bracket.

• With a correctly sized box wrench or a six-inch adjustable wrench, loosen the two axle nuts. • Push the wheel forward to slacken the chain and remove the chain from the chain ring and wheel sprocket. • Pull the wheel out of the frame.

Installing a Bolt-On Rear Wheel with Coaster Brake

Fig. 3.1a Using the Coaster Brake

! CAUTION: BEFORE RIDING, MAKE SURE THAT THE BRAKE IS WORKING PROPERLY. IF IT IS NOT WORKING PROPERLY, HAVE THE BICYCLE CHECKED BY YOUR DEALER BEFORE YOU RIDE IT.

Adjusting Your Coaster Brake. Coaster brake service and adjustment requires special tools and special knowledge. Do not attempt to disassemble or service your coaster brake. ASK YOUR DEALER TO HELP YOU!

• Put the chain onto the wheel sprocket. Then insert the wheel into the frame dropouts and push it all the way in to the dropouts. The axle nut washers should be on the outside, between the frame and the axle nut. • Put the chain onto the chain ring.

• Pull the wheel back in the dropouts so that it is straight in the frame and the chain has about 1/4 inches of up-anddown play. • Secure the coaster brake arm to its frame bracket, but do not fully tighten the securing nut and bolt.

Types of Brakes

3.1 Types

How Things Work

3.1

• Tighten the axle nuts as tightly as you can, using a six- inch adjustable wrench or a correctly sized box wrench. Spin the wheel to make sure it is straight in the frame. • Fully tighten the coaster brake arm securing nut and bolt.

How Things Work Installing a Bolt-On Rear Wheel with Hand Brake

• Pull the wheel back in the dropouts so that it is straight in the frame and the chain has about 1/4 inches of up-anddown play.

3.1

• Close the brake, then spin the wheel to make sure that it is centred in the frame and clears the brake shoes.

Removing a Bolt-On Rear Wheel with Hand Brake • Open the rear brake shoes.

• With a correctly sized box wrench or a six-inch adjustable wrench, loosen the two axle nuts. • Push the wheel forward to slacken the chain, and remove the chain from the chain ring and wheel sprocket. • Pull the wheel out of the frame.

The following pages deal with specific types of brakes and any special instructions regarding maintenance and proper care and setup of these types. Please read carefully and understand these steps to ensure safe operation of your bicycle. If you have any questions, call your authorized bike dealer or repair shop for more specific information and instructions. There are many different types of brakes, almost as many as there are different types of bicycles, each of which requires different setup and maintenance. Some examples of brake styles are: • Caliper Brakes with Rotor • Side Pull Caliper Brakes

It is our intention however, to give you a little more understanding of your new bicycle and a better insight into the complexity of the components on your new bicycle. Caliper Brake With Rotor

• Turn each lower adjusting barrel (1) into the lower cable stop (2) so that the threads are just even with the top of the lower cable stop.

• Make sure that both lower adjusting barrels are turned into the lower cable stop the same amount. • Put each cable wire through the slot of the bearing unit (3) to attach the ball end of each cable wire to the bearing unit as shown.

• V-Brakes

• Disc Brakes - see manufacturers inset IMPORTANT INFORMATION!

Before going any further we would like you to understand that the following instructions and diagrams are intended for experienced bicycle mechanics and is not intended as a trainning tool for inexperienced bicycle technicians. The components may not be exactly as shown, nor will the instructions apply to every model, design or manufacturer of each individual part.

• Tighten the lock nuts of each upper adjusting barrel to hold it in this position. Attach the front brake cable to the front brake:

• Connect the barrel end of the brake cable to the front lever.

• Push the cable and housing down through the hole in the handlebar stem. • Push the cable and housing down through the cable.

3.1

3 2

Types of Brakes

• Tighten the axle nuts as tightly as you can, using a sixinch adjustable wrench or a correctly sized box wrench.

How Things Work

Fig. 3.1b Caliper Brake with Rotor

How Things Work

ATTENTION! THE FOLLOWING TASKS SHOULD NOT BE ATTEMPTED WITHOUT A QUALIFIED BICYCLE MECHANIC DOING THE WORK OR SUPERVISING YOUR ADJUSTMENTS.

3.1

1. Brake Arm 2. Fixing Nut in Back 3. Cable Adjusting Barrel 4. Centre Bolt 5. Cable Anchor Nut 6. Brake Shoe

 Step 1 - If fitted with V-brakes, insert the brake body into

the centre spring hole in the frame mounting boss, then secure the brake body to the frame with the link fixing bolt. Fig. 3.1d V-Brake Step 1

Fig. 3.1e V-Brake Step 2

B + C = 2 mm 4 5 2

1. 5 mm Allen Key 2. Spring Pin Hole 3. Stopper Pin 4. Washer 5. Link Fixing Bolt

The brake shoes should not come into contact with the rim at any point and should be an equal distance from the rim on both sides. Make sure that all nuts and bolts are securely tightened. Test the brake levers 20 – 25 times to take care of any initial cable stretch.

Fig. 3.1g V-Brake Step 4

Fig. 3.1f V-Brake Step 3

Step 6 - Depress the brake lever about 10 times as far as the grip and check that everything is operating correctly and that the shoe clearance is correct before using the brakes.



Fig. 3.1c Side Pull Caliper Brake

Step 3 - While holding the shoe against the rim, tighten the shoe fixing nut - Fig 3.1f - using a 5 mm Allen key.



2 4

5 7

 Step 4 - Pass the inner cable through the inner cable lead. 8

1. Distance of 39 mm or more 2. 3 mm Washer B 3. Washer A 4. Shoe Fixing Link 5. Washer A 6. 6 mm Washer B 7. Washer 8. Shoe Fixing Nut

Step 2 - 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 dimension A is kept at 39 mm or more.

Set the cable with a clearance of 1 mm between each brake pad and the rim. Tighten the cable fixing bolt using a 5 mm Allen key. Step 5 - Adjust the balance with the spring tension adjustment screws.



Fig. 3.1h V-Brake Step5

Types of Brakes

Side Pull Caliper Brake Loosen the cable anchor nut and thread the brake cable through it. Squeeze the brake arms together against the rim of the wheel. Tighten the nut by hand until it holds the cable in place. Loosen the nuts on the brake shoes and turn until they match the angle of the rim. Retighten the nuts securely. Pull down on the end of the brake cable with pliers, hold taut and securely tighten the cable anchor nut. Spin the wheel.

V – Brake

3.1



1 mm 1 mm

3.2 Headsets

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. If you detect any looseness in the headset, it will need adjustment. Check that the headset is not overly tight by slowly rotating the fork to the right and left. If the fork tends to stick or bind at any point, the bearings are too tight.

Headsets

Threadless Headset Steering Assembly Adjustment

• This assembly comes preset from the factory and should not require adjustment, except for the scheduled maintenance for bearings stated in this manual. • Adjustments should be performed by a certified bicycle mechanic in order to ensure the safety of the rider.

• Tightening is achieved by loosening the two stem bolts attaching the stem to the steer tube (fork steering column).

• The stem cap bolt is then turned clockwise to tighten this bolt, and it should only be tightened slightly (25 lbs) to remove any play from the bearing surfaces.

• Centre the stem to the front wheel and retighten the bolts securing the stem to the steer tube. • The handlebars should turn smoothly without any bind.

! WARNING: ALWAYS CONSULT AN EXPERIENCED BICYCLE MECHNIC BEFORE ATTEMPTING TO REPAIR OR REPLACE PARTS ON YOUR BICYCLE. Fig. 3.3a ThreadedHeadset Headset Parts Fig 3.2 Threaded Lock Nut

3.3 Crank

Sets Lubrication and Adjustment

Cotterless Crank (3 pc)

• To adjust the free play in a three-piece-type bottom bracket, loosen the lock ring on the left side by turning it counter-clockwise, then turn the adjusting cup as required. Retighten the lock ring, taking care not to alter the cup adjustment. Fig. 3.3a Cotterless Crank (3 pc) Bottom Bracket

Lock Washer Adjusting Cup/Cone

Fixed Cup

Bolt Retainer Top Head Cup

Cotterless Crank Removing Tool

Disassembly and Reassembly

• Remove the cranks from the axle.

Bottom Head Cup Ball Retainer Crown Race

• Remove the left side lock ring by turning it counter-clockwise. • Remove the adjusting cup by turning it counter-clockwise.

• Remove the right side fixed cup by turning it counterclockwise. Remove the right ball retainer. Clean and inspect all bearing surfaces and ball retainers. Replace all damaged parts. Pack the ball bearing retainers with grease. Reassemble by reversing the order of the above procedure. Fig. 3.3b Cotterless Crank Disassembly and Reassembly 1. Bottom Bracket 2. Axle 3. Ball Retainers 4. Adjusting Cup 5. Lock Ring

Removal To remove cotterless cranks, use the following procedure. Note that a special tool will be required. • Remove the dust cap with a coin or screwdriver.

Fig. 3.3c Cotterless Crank Removal

Crank Sets Lubrication and Adjustment

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.

3.2

How Things Work

3.3

• Loosen the flange nut or bolt and washer, and remove.

• Remove the left ball retainer and slide the axle out of the frame to the left. 25

How Things Work

3.3

One-Piece Cranks Lubrication and Adjustment

To adjust the free play in a one-piece-type bottom bracket, loosen the lock nut on the left side by turning it clockwise and tighten the adjusting cone counter-clockwise using a screwdriver in the slot. When it has been correctly adjusted, retighten the lock nut counter-clockwise. Fig. 3.3d One-Piece Crank Assembly

3 4 5

1. Crank 2. Chainwheel 3. Fixed Cone 4. Ball Retainer 5. Bearing Cup 6. Bottom Bracket 26

8 9 10 11

7. Bearing Cup 8. Ball Retainer 9. Adjusting Cone 10. Lock Washer 11. Lock Nut

Disassembly and Reassembly

• Remove the chain from the chainwheel.

• Remove the left pedal by turning the spindle clockwise.

• Remove the left side lock nut by turning it clockwise and remove the keyed lock washer. • Remove the adjusting cone by turning it clockwise with a screwdriver.

• Remove the left ball retainer and slide the crank assembly out of the frame to the right. Remove the right ball retainer. Clean and inspect all bearing surfaces and ball retainers. Replace all damaged parts. Pack the ball bearing retainers with grease. Reassemble by reversing the order of the above procedure.

3.4 Front

and Rear Derailleur

All new bicycles, after having been ridden for a short time, will experience cable stretching, this will effect the shifting of the gears, particularly on the front sprocket! This will necessitate tightening the cables to alleviate this problem. This is considered general maintenance and is not covered under warranty. Front Derailleur To adjust the front derailleur, shift the chain into the small sprocket on the front chain wheel and to the middle sprocket on the rear freewheel. At this position if the cable is slack, loosen the anchor bolt on the front derailleur then pull the cable taught, then tighten the bolt. The chain should now shift to all 3 chainrings. You can now do minor adjustments using the barrel adjuster at the point where the cable enters the Left side shifter. Rear Derailleur Stamped on the rear derailler body there are 2 letters “H & L” These are the high and low limit adjustment screws. The H adjuster will stop the derailleur from going past the smallest sprocket and preventing the chain from coming off! The L adjuster prevents the derailleur from going past the largest

sprocket and preventing the chain from making contact with the spokes.

Before you adjust your cable tention, loosen the anchor bolt holding the derailleur cable. While your bicycle is on a bicycle stand (or upside down) pedal in a forward direction, the chain should drop to the smallest sprocket and should not fall past it! If the chain falls off the smallest sprocket, you need to adjust the H adjustment screw. Put the chain onto the smallest sprocket and screw the H clockwise until you feel resistance from the derailleur hitting the chain. Pull the cable through the anchor bolt and tighten. Shift to the L (Large) sprocket and back to the H sprocket. If the chain goes past the large sprocket, adjust the L adjuster.

If the derailleur is hesitating or refusing to drop onto the H (Small) sprocket you will need to readjust the H adjuster. If the derailleur does not go to the smallest sprocket, while pedaling turn the H adjuster in a counter clockwise direction until the chain drops. If the chain still wonʼt drop, you may have over tightened the cable. Adjust the cable barrel adjuster where the rear derailleur enters the Right shifter.

Front and Rear Derailleur

Crank Set Lubrication and Adjustment

IMPORTANT: DO NOT ATTEMPT TO LOOSEN OR ADJUST THE LOCK NUT OR CRANK WITHOUT A PROFESSIONAL BICYCLE MECHANIC PERFORMING THE WORK FOR YOU OR SUPERVISING YOUR WORK WHILE TEACHING YOU ABOUT THE TASK AT HAND.

3.4

Repair and Maintenance Section 4:

Repair and Maintenance

ATTENTION! ALL SERVICING, REPAIRS, AND ADJUSTMENTS SHOULD BE PERFORMED BY A LICENCED MECHANIC.

4.1

Service and Maintenance

NOTE: TECHNOLOGICAL ADVANCES HAVE MADE BICYCLES AND BICYCLE COMPONENTS MORE COMPLEX THAN EVER BEFORE, AND THE PACE OF INNOVATION IS INCREASING. THIS ONGOING EVOLUTION MAKES IT IMPOSSIBLE FOR THIS MANUAL TO PROVIDE ALL THE INFORMATION REQUIRED TO PROPERLY REPAIR AND/OR MAINTAIN YOUR BICYCLE. IN ORDER TO HELP MINIMIZE THE CHANCES OF AN ACCIDENT AND POSSIBLE INJURY, IT IS CRITICAL THAT YOU HAVE ANY REPAIR OR MAINTENANCE WHICH IS NOT SPECIFICALLY DESCRIBED IN THIS MANUAL PERFORMED BY YOUR DEALER.

Equally important is that your individual maintenance requirements will be determined by everything from your riding style to your geographic location. Consult your dealer for help in determining your maintenance requirements.

How much of your bikeʼs service and maintenance you can do yourself depends on your level of skill and experience, and on whether you have the special tools required. ! WARNING: MANY BICYCLE SERVICE AND REPAIR TASKS REQUIRE SPECIAL TRAINING, SKILL, KNOWLEDGE AND TOOLS. DO NOT BEGIN ANY ADJUSTMENTS OR SERVICE ON YOUR BICYCLE UNLESS YOU KNOW THAT YOU CAN PROPERLY COMPLETE THEM. IMPROPER ADJUSTMENT OR SERVICE MAY RESULT IN DAMAGE TO THE BICYCLE OR IN AN ACCIDENT, WHICH CAN CAUSE SERIOUS INJURY OR DEATH.

If you want to learn to do major service and repair work on your bike, you have three options:

• Ask your dealer whether copies of the manufacturerʼs installation and service instructions for the components on your bike are available. • Ask your dealer to recommend a book on bicycle repair. • Ask your dealer about the availability of bicycle repair courses in your area.

Regardless of which option you select, it is your responsibility to make sure the work is performed correctly. We recommend that you ask your dealer to check the quality of your work the first time you work on something and before you ride the bike, just to make sure that you did everything correctly. Since that will require the time of a mechanic, there may be a charge for this service.

4.2 Suspensions

Some bicycles come equipped with suspension systems, which are designed to smooth out some of the shocks encountered when riding. There are many different types of suspension systems - too many to deal with individually in this manual. If your bicycle has a suspension system of any kind, ask your dealer to provide you with the appropriate adjustment and maintenance instructions. ! WARNING: FAILURE TO MAINTAIN, CHECK, AND PROPERLY ADJUST THE SUSPENSION SYSTEM MAY RESULT IN SUSPENSION MALFUNCTION, WHICH MAY CAUSE YOU TO LOSE CONTROL AND FALL. ! CAUTION: CHANGING SUSPENSION ADJUSTMENT CAN CHANGE THE HANDLING AND BRAKING CHARACTERISTICS OF YOUR BICYCLE. NEVER CHANGE SUSPENSION ADJUSTMENT UNLESS YOU ARE THOROUGHLY FAMILIAR WITH THE SUSPENSION MANUFACTURERʼS INSTRUCTIONS AND RECOMMENDATIONS AND ALWAYS CHECK FOR CHANGES IN THE HANDLING AND BRAKING CHARACTERISTICS OF THE BICYCLE AFTER A SUSPENSION ADJUSTMENT BY TAKING A CAREFUL TEST RIDE IN A HAZARD-FREE AREA.

! CAUTION: NOT ALL BICYCLES CAN BE SAFELY RETROFITTED WITH SOME TYPES OF SUSPENSION SYSTEMS. BEFORE RETROFITTING A BICYCLE WITH ANY SUSPENSION, CHECK WITH THE BICYCLEʼS MANUFACTURER TO MAKE SURE THAT THE CHANGE YOU WANT TO MAKE IS COMPATIBLE WITH THE BICYCLEʼS DESIGN.

Suspension can increase the handling capabilities and comfort of your bicycle. This enhanced capability may allow you to ride faster, but you must not confuse the enhanced capabilities of the bicycle with your own capabilities as a rider. Increasing your skill will take time and practice. Proceed carefully until you are sure you are competent to handle the full capabilities of your bike. ! WARNING: IF YOUR BIKE HAS SUSPENSION, THE INCREASED SPEED YOU MAY DEVELOP ALSO INCREASES YOUR RISK. WHEN BRAKING, THE FRONT OF A SUSPENSION BIKE DIPS AND THE REAR SHOCK ON A FULL SUSPENSION BIKE EXTENDS. YOU COULD LOSE CONTROL AND FALL IF YOUR SKILL IS NOT UP TO HANDLING THIS SYSTEM. GET TO KNOW HOW TO HANDLE YOUR SUSPENSION SYSTEM SAFELY BEFORE TRYING ANY DOWNHILL OR VERY FAST RIDING. DO NOT ATTEMPT TO PERFORM THESE PROCEDURES ON YOUR OWN UNTIL YOU HAVE COMPLETED A BICYCLE MECHANICS AND SAFETY COURSE. VISIT YOUR AUTHORIZED REPAIR FACILITY FOR SERVICE.

Suspensions

Service and Maintenance

4.1

Repair and Maintenance

4.2

Repair and Maintenance

Forks Suspension Maintenance The following maintenance should be performed every month (if riding off-road), or whenever you feel performance is deteriorating. • With the fork apart, thoroughly clean all parts. • Apply a thin coat of grease to the upper tubes, coil springs, and all internal bushings.

4.2

Fig. 4.2b Frame Suspension

Fig. 4.2a Fork Suspension

1. Sleeves 2. Seal 3. Slider 4. Elastomer 5. Top-Out 6. Through-Shaft 7. Bottom-Out 8. Drop-Out

1 2 3 4 5 6 7

Frame Suspension

2 4

2 3

1. Body Pivot 2. Pivot Spacer 3. Spring Collar 4. Shaft Pivot 5. Spring 6. Spring Retainer

4.3 Shifters

Thumb Shifters (Top-Mounted) 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. Pull the left shifter back to operate the front derailleur, and push the right shifter forward to operate the rear derailleur.

To select a higher, harder gear, shift to a smaller rear cog and a larger chainwheel. Push the left shifter forward for the front, and pull the right lever back for the rear. Fig. 4.3a Thumb Shifters (Left and Right Hand Levers)

Top Gear (Harder)

Bottom Gear (Easier)

Large chainwheel

Small chainwheel

Small rear sprocket

Left hand lever forward Right hand lever back

Large rear sprocket

Trigger Shifters (Below the Bar) Many mountain-style bicycles now use a shift lever arrangement mounted on the underside of the handlebars which uses two levers operated by the thumb and index finger. To select a lower gear, push the larger (lower) right shifter with your thumb to engage a larger rear cog. One firm push shifts the chain one cog; continuing to push will move the chain over multiple cogs. Pushing the smaller (upper) left shifter with your index finger moves the chain from a larger to a smaller chainwheel.

To select a higher gear, push the smaller (upper) right lever with your index finger to engage a smaller rear cog. Pushing the larger (lower) left lever with your thumb will move the chain from a smaller to a larger chainwheel. Fig. 4.3b Trigger Shifters (Left and Right Hand Levers)

Shifters

Suspension

Reassembly • Slide the upper tubes into the lower tubes. • Firmly hold the lower tube and turn it clockwise until it will not turn any more. • Align the brake arch mounts on both lower tubes and install the brake arch. • Tighten the brake arch bolts to 70-80 in.-lbs (8-9.2 Nm).

Check Before Each Ride • Make sure that the headset is properly secured. • Make sure that the exposed portions of the upper tubes are clean. • Make sure that the quick releases are properly secured. • Make sure that the front brake cable housing is properly seated into the brake cable stop. • Check the tire clearance between the top of the brake straddle cable carrier and the bottom of the cable stop. Make sure that the front brake cable is routed to the brake cable stop located on the brake arch. Do not rout the cable through the stem or any other mounts or cable stops.

4.3

Left hand lever back

Right hand lever forward 31

Repair and Maintenance

Installation • Slide the front twist shift assembly over the left side of the handlebar, leaving proper clearance for the handlebar grip. If necessary, move the brake lever to accommodate the twist shift and handlebar grip. • Rotate the assembly until the cable exits below the brake lever with adequate clearance for brake lever movement. • Firmly tighten the recessed clamp screw. Installation torque should be 20 in./lb. • Slide the two 7/8” plastic washers over the handlebar. The washers prevent the grip from interfering with twist shift rotation. • Slide the handlebar grip over the handlebar. Do not use solvents, lubricants or hairspray. Thread the cable inner wire through the cable housings and frame, and attach it to the derailleur. Make sure that the cable is in the V groove of the derailleur attachment bolt. If it is necessary to trim the cable housing, be sure to replace the housing end cap. • Adjust the indexing. Fig. 4.3c Twist Shifters

4.3

1 32

1. Grip 2. Barrel Adjuster 3. 7/8” Plastic Washers 4. Cable

• Slide the rear twist shift over the right side of the handlebar and repeat steps. • Actuate the front and rear brake levers to be certain of proper operation. If the twist shift interferes with brake lever movement, rotate the brake lever or the twist shift. Check for proper brake lever operation again.

Lubrication • Disassemble. “Replacing the Control Cable”, below and wash parts in keroFig. 4.3d Twist Shifter Lubrication sene or degreaser. Blow parts clean 2 4 with compressed air. 1 • Apply either SRT 3 Series grease (“jon5 nisnot”) or Vaseline 1. Cable Groove Notches 2. Spring Cavity to areas shown in 4. Around Tube 3. All Detente 5. Cable Groove Fig. 4.3d.

Replacing the Control Cable • Release the shifter cable from the front and rear derailleurs. • Twist the shifter back until the cable is fully pulled, as if you were shifting to the large chain ring or the largest rear sprocket. • Remove the cable retention cover. Some models require a Phillips head screwdriver, others a flat head screwdriver. • Separate the twist shift assembly by pulling outward.

The spring may unseat from the spring cavity. • Remove and discard the old cable. • If necessary, clean and lubricate before reassembly. See “Lubrication”. • Replace with twist shift-approved cable. Thread the new cable through the housing cable inlet hole. • Loop the cable around the housing and through the cable exit. Make sure that the spring is in the spring cavity.

Fig. 4.3e Twist Shifter Assembly 2

5 6 4

1. Cable Inlet Hole 2. Spring Cavity 3. Cover Screw 4. Cable Retention Cover 5. Housing 6. 3 mm Hex Clamp Bolt 7. Barrel Adjuster

• For rear shifters: Slide the grip over the handlebar. Position the grip so that the largest number is aligned with the gear indicator on the handlebar. Fig. 4.3f Rear Twist Shifter (1)

Fig. 4.3g Rear Twist Shifter (2)

Fig. 4.3h Rear Twist Shifter (3)

Fig. 4.3i Rear Twist Shifter (4)

• For front shifters: Slide the grip over the housing. Position the grip so that the 1 is aligned with the gear indicator on the housing. Move the portion of the cable that is next to the gear number surface. Push the grip inward while pulling the cable until the grip snaps into the housing.

Check for proper assembly by rotating the grip and listening for clicks. Fig. 4.3j Front Twist Shifter (1)

Fig. 4.3k Front Twist Shifter (2)

Shifters

Twist Shifters

Fig. 4.3l Front Twist Shifter (3)

4.3

Repair and Maintenance

Repair and Maintenance Frequency

4.4 Service

Checklist

Correct routine maintenance of your bike will ensure: • Smooth running • Longer-lasting components • Safer riding • Lower running costs

Check tire pressure Check brake operation Check wheels for loose spokes Make sure nothing is loose

After Every Ride

Quick wipedown with damp cloth

Weekly

Lubrication as per Schedule A

Monthly

Lubrication as per Schedule A Check derailleur adjustment Check brake adjustment Check shifters and gear cable adjustment Check tire wear and pressure Check that wheels are true and spokes are tight Check hub, headset and crank bearings for looseness Check that pedals are tight Check that handlebars are tight Check that seat and seat post are tight and comfortably adjusted Check that frame and fork are true Check that all nuts and bolts are tight

Service Checklist 34

We recommend that you spend a little time on regular maintenance tasks. Every Six Months

Yearly

Lubrication as per Schedule A Check all points as per monthly service Check and replace brake pads, if required Check chain for excess play or wear Lubrication as per Schedule A

Suspension Service

Lubrication Schedule

The following maintenance should be performed every month (if riding off-road), or whenever you feel performance is deteriorating.

The following schedule is a useful guide and should help you to accomplish most tasks. If you require assistance, we recommend that you see a certified bike specialist.

Maintenance Schedule

New

Set shock SAG

Set rebound adjustment to desired speed

Tighten shock mounting bolts

Every Every Every Every Ride 8 40 200 Hours Hours Hours

Clean aluminium reducer, check for wear, grease

Send to service centre for oil change and inspection

Clean shaft, seal area, check shaft for damage

Clean shock body

Riding conditions: dry, dusty Riding conditions: extreme mud

X X

Frequency Component

Lubricant

How to Lubricate

Weekly

Chain Chain lube or light oil Brush on or squirt Derailleur wheels Chain lube or light oil Brush on or squirt Derailleurs Oil Oil can Brake calipers Oil 3 Drops from oil can Brake levers Oil 2 Drops from oil can

Monthly

Shift levers

Lithium-based grease Disassemble

Every 6 Months

Freewheel Brake cables

Oil 2 Squirts from oil Lithium-based grease can Disassemble

Yearly

Bottom bracket Pedals Derailleur cables Wheel bearings Headset Seat pillar

Lithium-based grease Lithium-based grease Lithium-based grease Lithium-based grease Lithium-based grease Lithium-based grease

Disassemble Disassemble Disassemble Disassemble Disassemble Disassemble

NOTE: THE FREQUENCY OF MAINTENANCE SHOULD INCREASE WITH LOTS OF USAGE, AND USAGE IN WET OR DUSTY CONDITIONS. DO NOT OVER-LUBRICATE. REMOVE EXCESS LUBRICANT TO PREVENT DIRT BUILDUP.

Service Checklist

Before Every Ride

Every time you ride your bicycle, its condition changes. The more you ride, the more frequently maintenance will be required.

4.4

Task

4.4

Warranty Section 5:

Warranty

5.1

Infinitybicycle frames that have been purchased from an authorized Infinity bicycle dealer are warranted by Infinity to be free from de fects in material and workmanship under normal use for as long as the bicycle is owned by the original owner.* (See page 37) All original parts purchased from an authorized Infinity bicycle dealer, except tires, tubes and cables are warranted by Infinity to be free from defects in materials and workmanship under normal use for one (1) year from the date of purchase. This limited warranty applies only to Infinity bicycles which were fully assembled by an authorized Infinity bicycle dealer at the time of purchase and were not altered in any way inconsistent with the bicycle design. Infinity bicycles should be inspected by an autho rized I n f i n i t y dealer every six months. In order to obtain limited warranty service, the bicycle, together with your proof of purchase must be presented to an authorized Infinity bicycle dealer. For assistance in locating an authorized Infinity bicycle dealer please call 1-(855) 521-1127 or go to www.actiontradersltd.com NOTICE: The user assumes the risk of any personal injuries, dam-

age to, or failure of the bicycle and any other losses if Infinity bi cycles are: used in any competitive event (including bicycle racing, or bicycle motocross, dirt biking, freestyling, or similar activities, or

training for such activities), altered in any way inconsistent with the bicycleʼs originally designed purpose, used for stunt riding, ramp jumping, acrobatics or similar activities, operated with multiple riders, used to tow another person or vehicle, used with motors or any power-driven apparatus. Any of the foregoing will invalidate this limited warranty and Infinity shall not be liable for any failure, loss, damage or injury resulting from such use or alterations. Infinity shall not be responsible for incidental or consequential dam ages. This limited warranty does not cover any personal injuries, damage to, or failure of, the bicycle, or any other losses due to accident, misuse, alteration, neglect, abuse, normal wear and tear, improper assembly, improper fit, improper maintenance or use of unauthorized replacement parts or parts not designed for the bicycle. This limited warranty is the only warranty applicable to Infinity bicycles, and is expressly in lieu of any other warranty. Any implied warranty, including any warranty of merchantability or fitness for a particular purpose, is limited in duration to the duration of this express warranty. This limited warranty gives you specific legal rights and you may also have other rights, which may vary from province to province. This limited warranty applies only to North America. Infinité Cycle Works Ltd. is not responsible for any damages to you or others arising from riding, transporting, or other use of your bicycle. In the event that your bike breaks or malfunctions, Infinité Cycle Works. Ltd. shall have no liability or obligation beyond repair or replacement of your bike, pursuant to the terms outlined in the Service and Warranty provisions of this manual.

Some speciﬁc Warranty issues are as follows: • 5 Years Hi-Tensile frame warranty if defective due to materials or workmanship to the original owner. • Dual Suspension Aluminium frame warranty is for one year against manufacturerʼs defects. • Front Suspension Aluminium frame warranty is for 5 years against manufacturerʼs defects. • Suspension Fork warranty is for one year against manufacturerʼs defects. • 90 Day warranty on shifting components, i.e., derailleurs and shift levers. • One-year limited parts warranty if defective in materials or workmanship to original owner. • Warranty does not include normal wear items such as tires, tubes, seat, grips, and brake pads. • Warranty is void if the bicycle has been neglected or abused. • Warranty covers original owner only.

5.2 Bicycle

Identification Record

We would like to welcome you to the growing family of Infinity bicycle owners. We suggest that you locate the serial number, which is stamped into the bottom bracket shell of the frame. Record the serial number, model name and frame colour in your manual and keep it in a safe place. In the unlikely event that your bicycle is lost or stolen, you will be able to give your local police department this information. In addition, the serial number may also be required to register or license your bicycle.

SERIAL NUMBER ____________________________ FRAME ____________________ MODEL __________ COLOUR _____________ NAME __________________ STORE PURCHASED _____________________________ Thank you for choosing an Infinity bicycle. We hope it provides you with many years of enjoyment. BE SAFE...ALWAYS WEAR A HELMET WHEN RIDING!

Bicycle Identification Record

Infinité Cycle Works Ltd. Limited Warranty

5.1 Infinité Cycle Works Ltd. Limited Warranty*

Warranty

COPYRIGHT INFORMATION All rights reserved. No part of this manual may be reproduced or transmitted without the written permission of Infinité Cycle Works Ltd. The material in his manual is for written information only and is 5.2 subject to change without notice. 37