Kalkhoff Derby, Instruction Manual

Page 1: ...ds Derby Cycle Werke GmbH Siemensstr 1 3 D 49661 Cloppenburg Phone 49 4471966101 Romania S c SportBikeCenter S r l St Penes Carcanul 3 5 RO 300124 Timisoara Phone 40 256220023 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 Kalkhoff bikes Derby Cycle Werke GmbH Siemenss...

Page 2: ...hifter 11 Shift lever operation 11 Racing shift lever 12 Standard shift lever 14 Twistgrips 15 Derailleur 15 Fine adjustment of the derailleur troubleshooting 15 Chain guide 16 Fine adjustment of the chain guide 16 Using the multispeed hub gear shifter with and without a coaster brake 16 Shimano hub gear shifter 17 Shimano 3 speed shift lever 17 Shimano 7 8 speed shift lever 18 Dismounting and mou...

Page 3: ...e clips Always wear suitable protective clothing when riding such as solid shoes and a bicycle helmet Bicycle safety Observe the maximum load of the relevant bicycle type otherwise important operational parts could break or fail Have damaged or bent parts replaced before riding the bicycle again otherwise important operational parts could fail Observe the maximum load of the carrier It is marked o...

Page 4: ... off road use overload or improper repair of faults Mountain bike MTB Cross bike These bicycles may be used off road Do not use these bicycles to take part in competitions These bicycles may not be used on public roads If you wish to use your bike on a public road you must comply with national regulations The manufacturer and dealer shall not be liable for any use of the bicycle which goes beyond ...

Page 5: ...t pedal crank on the chain side Tighten both pedals using a size 15 spanner Pedal types Use MTB racing and system pedals only with the matching shoes You might slip off the pedals with other shoes The use of MTB or racing pedals may lead to serious falls if the user is not experienced If you use system pedals at first practise fastening and unfastening the shoes to and from the pedals whilst stand...

Page 6: ...ction Tilt the tensioning lever away from the OPEN position so that the word CLOSE is readable Adjusting the saddle The seat position is crucial to your comfort and cycling efficiency Do not remove the seat post or the saddle clamp The manufacturer accepts no liability for damage or accidents Tighten all screws to the specified torque otherwise the screws could break off and parts may become loose...

Page 7: ...the quick release Check once again that the saddle height is correct see chapter Determining the correct saddle height left Adjusting the saddle tilt Adjust your saddle so that it is as level as possible or slightly tilted to the rear Determine the most comfortable seating position by making a longer cycling trip If necessary adjust the saddle tilt by proceeding as follows To loosen the locking sc...

Page 8: ...ndlebar stem can slip down To loosen the stem shaft in the steering tube proceed as follows Release the stem spindle in order to loosen the handlebar stem Turn it two to three turns in an anticlockwise direction using an allen key Clamp the front wheel between your knees to prevent the bicycle fork from moving when the stem shaft is loosened Turn the stem shaft backwards and forwards If this is no...

Page 9: ... the headset If the headset is improperly adjusted or tightened too hard breakage may occur therefore always consult a dealer If you ride with a loose headset damage may occur to the bearing casing or the forks The headset forms the bearing of the bicycle forks in the frame A properly adjusted headset can be easily tur ned However there should be no play Shocks from the road place a great strain o...

Page 10: ...between the sprockets and the spokes Change to the lowest gear largest rear sprocket very carefully using the gear shift otherwise the changer mechanism could come into contact with the spokes and damage them Shift lever operation There are various types of gear shit levers The commonest types are described below Racing shift lever The Shimano brake shift lever may exist in two versions All levers...

Page 11: ...Lever a Initial position Lever a Completechain shiftleverstroke Stroke actually performed Levera shiftingtoalargerchainsprocket Ifthelevermovementdoesnotproducea completechangeofchainsprocket thelever mustbemovedagainbyamount X in ordertoexecutethemissinglevermovement distance X andthusthegearshift Lever b Initial position Lever b Complete chain shiftlever stroke Leverb shiftingfromthelargesttothe...

Page 12: ...in touches inner chain guide plate large chain sprocket middle chain sprocket kleines Kettenblatt larger rear sprockets larger rear sprockets larger rear sprockets derailleur movement Chain position Indication Trimming Lever actuation Derailleur movement before trimming after trimming Trimming english français nederlands español te 13 ...

Page 13: ...t click any more so that only the click positions for shifting the rear sprok kets remain If the chain is on the largest chain sprocket and the largest rear sprocket the chain rubs against the derailleur which is noticeable from the characteristic noises The derailleur can be move slightly to the inside by lightly pressing lever B to the click position so that there are no more noises Hebel B 1 2 ...

Page 14: ...shifting from the middle to the largest chain sprocket Tighten the adjustment screw for the largest gear to the right approx 1 4 turn Loosen off the adjustment screw for the largest gear to the left approx 1 4 turn Loosen off the adjustment screw for the smallest gear to the left approx 1 4 turn Tighten the adjustment screw for the largest gear to the right approx 1 8 turn Loosen off the adjustmen...

Page 15: ...r the chain The use of alkaline or acidic cleaning agents such as rust remover can damage the chain and lead to operational faults The chain sprockets and rear sprockets should be washed at periodic intervals using a neutral cleaning agent and subsequently lubricated again The chain shifter should be cleaned at periodic intervals and the moving parts mechanism and rollers must be lubricated Using ...

Page 16: ... cable may be caused normal when ub lubricated nsioned If the placed The coaster brake can be controlled very precisely The full braking power is achieved after a certain running in period In order to get used to the brakes operate the brake lever carefully at first to acquire a feel for the coaster brake s deceleration If the bicycle is left standing for a longer period a rust film may form in th...

Page 17: ...h holder Loosen and remove the screws from the brake arm Remove the wheel nuts and place them aside Remove the safety washers from the wheel axle Pull the rear wheel out of the slots in the dropouts Refitting the rear wheel Place the chain on a rear sprocket and position the hub axle in the dropouts Attach the safety washers on both sides of the hub axle CJ 8S20 JAPAN LOCK N ll out of e cable eath...

Page 18: ...lenschraube Schellenmutter Bremsarm Bremsarmschelle Schellenschraube 16 mm M6 2 3 mm When mounting the brake arm clip hold the clip nut tight using a 10 mm spanner whilst tightening the clip screw After mounting the brake arm clip check that the clip screw protrudes 2 to 3 mm beyond the clip nut 19 n the dropouts e chainstay pout the dropout Brake arm Clip nut Clip screw Brake arm clip Chainstay C...

Page 19: ...ble the yellow part of the intermediate piece must be adjusted between the two yellow lines of the window rew or brake is can cause to a fall with Flange nut edge of the window t be aligned to end of the hub axle End of the hub axle SET SET The two yellow lines must be viewed directly from above Note End of the hub axle Red line on the rod Yellow line Yellow line Yellow part of the intermediate pi...

Page 20: ...d rotate the shifter wheel in order to fit the cable anchor screw correctly in the open side of the shifter wheel CJ 8S20 JAPAN LOC K Turn through 60 Hook CJ 8 S20 JAPA N 2 1 Slot Cable sheath holder Pull through the slot Holder Push into the cable sheath holder CJ 8S20 JAPAN LOCK Shifter wheel Holder Shifter cable CJ 8S20 JAPAN LOCK 1 2 3 Shifter wheel hole Push into the cable sheath holder Inser...

Page 21: ...he axle nut on the other end of the axle and remove the fixing washer s 7 Remove the wheel Refitting Insert the wheel in the frame Fit a 2 5 mm thick fixing washer 7 fig 1 on the outside on both sides The serration must lie on the dropout the holding tab must latch in the dropout Alternative 1 x 3 5 mm thick fixing washer on the left end of the axle only Mount and tighten the axle nut with the cyl...

Page 22: ...shifter pin 1 fig 3 in the shifter tube 2 oil the parts lightly and insert them into the axle bore as far as they will go Rotate the slot 6 into an easily visible position Push the clamping bush 3 with the guide pin 4 in front onto the hub axle at the same time feed the interior lug 5 into the slot 6 in the shifter tube until it latches Turn the clamping bush guide pin to the top Check the twistgr...

Page 23: ... the part of the chain which is lying on the front chain sprocket between thumb and forefinger Pull the chain away from the chain sprocket If the bicycle chain can be clearly lifted it is worn and should be replaced with a new one In the case of hub gear shifters the chain tension must be adjusted so that the chain hanging between the front chain sprocket and the rear sprocket has a vertical play ...

Page 24: ...faults are found If the cable is not replaced braking malfunctions may occur Checking hub brakes Hub brakes are virtually maintenance free since the braking body is located inside the hub A hub brake may only be fitted at a later stage to the front wheel if the letter N is stamped on the bicycle fork otherwise the brakes may malfunction Hub brakes become hot when subjected to constant load Braking...

Page 25: ... towards the front Adjusting the gap between the brake pad and the wheel rim Turn the cable adjustment screw adjusting bush To increase the brake pad gap the adjusting screw is turned towards the inside clockwise To decrease the brake pad gap the adjusting screw is turned towards the outside anticlockwise The gap bet ween the brake block and the wheel rim should be 1 mm If necessary adjust the spr...

Page 26: ...s located on the right hand side opposite side to the brake disc If the quick release lever is located on the same side as the brake disc there is a danger that the lever and the brake disc could impair one another A worn cracked or bent brake disc must be replaced Consult a dealer If the thickness of the brake block is less than 0 5 mm it must be replaced Hydraulic disc brakes The hydraulic oil p...

Page 27: ...s remove the lid of the reservoir and try again please remember that oil may overspill from the reservoir After fitting the wheel check whether or not the quick release lever is located on the right hand side opposite side to the brake disc If the quick release lever is located on the same side as the brake disc there is a danger that the lever and the brake disc could impair one another Cleaning ...

Page 28: ...e lever powerfully several times and if necessary turn the adjusting screw further until the brakes drag slightly once again Tighten the hexagonal nut 6 Repeat the adjustment if the braking effect wears off after prolonged use or if the manual brake lever can be pulled back to the handlebar grip If the cable needs to be replaced consult your dealer If the clip nut loosens itself from the brake arm...

Page 29: ...der When attaching the connecting piece to the cam plate it must pushed until it latches Check that the connecting piece is located correctly in the position shown The rivet must be located in the middle of part A of the cam plate Pull the brake lever and check the brake function If the brake does not function properly the brake cable must be adjusted RE LEA SE GREA SE 1 2 Auf die Seite herausschi...

Page 30: ...en Nut Wenn die Nockenplatte nach vorne gedrückt ist 1 2 Verbindungsstück JAPAN MIN 2Nm GREASE RELEASE Verbindungsstück Nut Stark nach hinten ziehen 3 RELEASE Teil A der Nockenplatte Verbindungsstückniete Kabeleinstell schraube Kabeleinstell mutter JAPAN MIN 2N m RE LE AS E Bremsar Führungsschlitz Kabelhüllenhalter Kabeleinstellschraube 31 Cable adjustment screw Connecting piece Groove When the ca...

Page 31: ... riding over high kerbs These can lead to frame damage and thus to serious accidents The frame number of the bicycle is located on the seat tube or on the bottom bracket The bicycle can be identified by the frame number in case of theft In the case of a carbon frame the frame number may be located on the inner side of the dropouts If your bicycle does not travel in a straight line have the trackin...

Page 32: ...ob anti clockwise If the shock absorber is particularly dirty clean it carefully especially the piston rod and the wiper At the same time check whether the stop buffer is damaged If so have it repai red by a specialist workshop Air dampers are generally used where comfort is required Apart from pumping up air suspension needs no maintenance How often you need to pump up will depend on the desired ...

Page 33: ...oove which runs along the com plete circumference of the rim Checking the tyres and inner tubes Tyres There are many different types of tyre The suitability for a particular type of terrain and the roll resistance depend on the tyre tread Pump up the tyre only to the maximum permissible pressure otherwise it may burst If the tyre pressure is too low the tyre can loosen itself from the wheel rim Th...

Page 34: ...ou must remove the defective wheel First remove the brakes The procedure depends on the type of brakes fitted to your bicycle Read the chapter on brakes before removing the brakes otherwise the braking system may be damaged This can lead to accidents Removing a cantilever or V brake Grip the wheel with your hand Press the brake pads or the brake arms together against the wheel rim Unhook the brake...

Page 35: ...l rim inside the tyre Press one side of the tyre completely into the wheel rim Pump up the inner tube just enough so that it is round Place the inner tube inside the tyre Press the tyre over the wheel rim Pull the tyre down strongly The area already mounted slides into the base of the wheel rim Check again that the inner tube is correctly seated Push the tyre completely over the wheel rim with the...

Page 36: ...o is very high wear on the other hand is very low Some bicycles with a hub dynamo are fitted with a switch or a sensor on the back side of the headlamp The sensor switches on the light at dusk or when riding in a tunnel Other models have a switch on the handlebar If you need to remove the front wheel first remove the connecting clamp Fit the front wheel so that the connecting clamp is located on t...

Page 37: ...tors again afterwards If your bicycle is fitted with mudguards they will usually be made from metal or plastic Plastic has the advantage that electrical cables can be integrated in rear wheel mud guards These plastic mudguards are fitted with special eyes or fixing guides for electrical cables This ensures that the cables can be laid in such a way that they are optimally protected and cannot be to...

Page 38: ...hild in a child seat mounted behind the saddle otherwise the child s fingers could be squashed Always fasten the child seat s safety belts otherwise the child could fall out and be seriously injured Ensure that children wear well fitting bicycle helmets otherwise serious head may occur in case of a fall The bicycle s handling will be unfavourably influenced when using a child seat The extra weight...

Page 39: ...and boot racks Use only roof and boot racks which conform to the national traffic regulations Roof and boot racks which are not approved are not safe for use in traffic and can lead to accidents Loose parts tools bags child seats bicycle pump etc may fall off during transport and endanger other road users Remove loose parts from the bicycle before setting off The bicycle can detach itself from the...

Page 40: ... the A head stem inside and out If you have changed the handlebar position remember that the stem must enclose the carbon part extensively Carbon handlebar stem Screws in the clamping area fork shaft inside and out If you have changed the handlebar stem remember that the stem must enclose the carbon part extensively Carbon seat support Area of transition from saddle support to seat tube area of tr...

Page 41: ...icycle regularly with warm water a small quantity of detergent and a sponge Use the opportunity to check your bicycle for cracks gouges or material deformation Have defective parts replaced before using the bicycle again Repair defective paintwork Particularly in winter or in an aggressive environment e g at the coast treat all parts which are subject to corrosion especially often with suitable pr...

Page 42: ...ry Check regularly that the grips are seated tightly Hydraulic oils and lubricants Hydraulic oils and grease lose their efficiency over a period of time Failure to exchange lubricants regularly will result in greater wear of the affected parts and bearings Clean and lubricate all relevant parts and bearings regularly Gear shift and brake cables Maintain all Bowden cables regularly Have defective p...

Page 43: ...le chain rear sprockets andchain sprockets Lubricate them with chain grease Check that all screws are tight Have the brake hub checked and the brake sleeve replaced if necessary Inspection plan When 100 km after purchase after that at least once a year Maintenance Check Check tyres and wheels Have the tightening torques of the following checked handlebar pedals pedal cranks saddle saddle support a...

Page 44: ...on meter Screwed component Tightening torque Pedal crankset steel 30 Nm Pedal crankset aluminium 30 Nm Pedals 30 Nm Wheel front 25 Nm Wheel rear 40 Nm Handlebar screw 15 Nm Stem clamp spindle 15 Nm A head clamping screw 9 Nm Bar Ends clamping screw on the handlebar 10 Nm Bar Ends horn clamps on clamping collar 6 Nm Saddle support clamp screw M8 20 Nm Saddle support clamp screw M6 14 Nm Saddle supp...

Page 45: ...k assembly FC Crank arm fixing screw 35 Nm Chain sprocket fixing screw 10 Nm Pedals FC Pedal axle 35 Nm Cassettes HG Fixing ring 30 Nm Quick release see page 7 We recommend the use of a plastic mounting paste under the components Tyres and tyre pressures Observe any differing manufacturer s specifications The tyres and inner tubes could otherwise be damaged Conversion table PSI Bar Tyre width in m...

Page 46: ...rovided these are not due to faulty information or production Repairs with used parts or damage resulting from such repairs Special equipment or accessories or non standard equipment especially technical alterations such as replacement of gear shifter bicycle fork alteration of the frame geometry Parts fitted later which at the time of handover did not belong to the standard equipment of the produ...