Pacific Bicycle, Owner'S Manual

Page 1: ...BICYCLE OWNER S MANUAL 11 99 bikemanual 11 24 99 3 49 PM Page 1...

Page 2: ...ET COVERS YOUR FOREHEAD INCORRECT FITTING FOREHEAD IS EXPOSED AND VULNERABLE TO SERIOUS INJURY ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE DO NOT RIDE AT NIGHT HEL METS SAVE 11 99...

Page 3: ..._____Phone Number ________________________ Pacific Model purchased ____________________________________________________________ Store at which you purchased your Pacific Bicycle ______________________...

Page 4: ...PACIFIC CYCLE BICYCLE FEEDBACK PO BOX 230 MC FARLAND WI 53558 0230 PLACE STAMP HERE Cut along dotted line before mailing 11 99 bikemanual 11 24 99 3 49 PM Page 4...

Page 5: ...repair or maintain your bicycle You will save time and the inconvenience of having to go back to the store if you choose to write or call us concerning missing parts service questions operating advic...

Page 6: ...Take notice of this symbol throughout this manual and pay particular attention to the instructions blocked off and preceded by this symbol 11 99 bikemanual 11 24 99 3 50 PM Page 6...

Page 7: ...eel 41 Front Brake 41 Side Pull Brake 42 Cantilever with LInk Wire 42 43 V Brake 44 45 Cantilever with Straddle Cable 46 Check your Brakes 47 Training Wheels 47 Rotors 48 49 Final Check 50 4 SERVICING...

Page 8: ...fork on mountain style bicycles are much sturdier than those on racing style bicycles Top Tube Seat Seat Post Quick Release Seat Stay Rear Reflector Rear Brake Wheel Reflector Freewheel Shift Lever Ha...

Page 9: ...Post Seat Post Binder Bolt Seat Stay Rear Reflector Wheel reflector Chain wheel Crank Arm Pedal Rim Tire Tire Valve Chain Rear Sprocket Training Wheel Brake Lever Handlebar Brake Control Cable Reflect...

Page 10: ...levant sections in this manual If you need replacement parts or have questions pertaining to assembly of your bicycle call Pacific direct at Monday Friday 8 00 a m 4 30 p m Central Time Tools Required...

Page 11: ...e This makes straddling the frame when off the saddle easier and safer in situations such as sudden traffic stops Women can use a men s style bicycle to determine the correct size women s model The fo...

Page 12: ...lightly bent in this position If the rider then places the heel of that foot on the pedal the leg should be almost straight Ensure that the seat pillar does not extend beyond the minimum insertion mar...

Page 13: ...d the minimum insertion mark Failure to do this may cause serious bodily injury or damage to the bicycle Ensure both the Stem Wedge Bolt and the Handlebar Binder Bolt are tightened securely Failure to...

Page 14: ...have no bulges or excessive wear Ensure rims run true and have no obvious wobbles or kinks Ensure all wheel spokes are tight and not broken Check that axle nuts are tight If your bicycle is fitted wit...

Page 15: ...the axle and are not bent Check that front and rear mechanisms are adjusted and function properly Ensure control levers are securely attached Ensure derailleurs shift levers and control cables are pr...

Page 16: ...riding your bicycle In addition if you are carrying a passenger in a child safety seat they must also be wearing a helmet The correct helmet should be comfortable be lightweight have good ventilation...

Page 17: ...t of concealed driveways Be extra careful at intersections and when preparing to pass other vehicles Familiarize yourself with all the bicycle s features Practice gear shifts braking and the use of to...

Page 18: ...manual Use a properly functioning lighting set comprising a white front lamp and a red rear lamp If using battery powered lights make sure batteries are well charged Some rear lights available have a...

Page 19: ...ys wear a properly fitted helmet 2 Do not play in driveways or the road 3 Do not ride on busy streets 4 Do not ride at night 5 Obey all the traffic laws especially stop signs and red lights 6 Be aware...

Page 20: ...e The front derailleur is operated by the left shift lever and the rear derailleur by the right To operate you must be pedaling forward You can not shift derailleur gears when you are stopped or when...

Page 21: ...t a time by moving the Grip Shift one click or through multiple gears by continued twisting By twisting the left shifter forward or away from you a smaller chainwheel can be selected To select a highe...

Page 22: ...inger 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...

Page 23: ...wipe or spray all unpainted parts with an anti rust treatment Make sure wheel rims are dry so braking performance is not affected After rain dry your bicycle and apply anti rust treatment If the hub a...

Page 24: ...missions may effect the rubber and paint Don t cover with plastic as sweating will result which may cause rusting It is advisable that the following steps be taken to prepare for and help prevent poss...

Page 25: ...compo nents than the ones illustrated Remove the protective cap from the handlebar stem wedge and loosen the Allen key bolt using the 6mm Allen key Some models may use a 13mm hexagonal bolt instead of...

Page 26: ...embly these stems will require angling the stem to the desired position and securely tightening the 6mm angle bolt located in front of the stem bolt Failure to do this may cause loss of steering contr...

Page 27: ...ip Shifter Figure 2 Top mounted thumb shifter Failure to properly tighten clamping bolts may cause sudden movement of the component resulting in loss of steering control 1 2 Bar end 5mm Allen key Shif...

Page 28: ...ess of the headset and the fork Rotate the fork checking for smoothness If it feels like the fork is binding then an adjustment will need to be made to the headset Move the fork in a push pull manner...

Page 29: ...g screw Turning the 6mm Allen screw Clockwise will decrease travel and make the suspension stiffer while turning the 6mm Allen screw Counter clockwise will increase travel and make the suspension less...

Page 30: ...read The left pedal attaches to the other crank arm and has a left hand counter clockwise thread It is very important that you check the crank set for correct adjustment and tightness before riding yo...

Page 31: ...hten the quick release by using the quick release lever like a wing nut If the quick release lever is moved to the closed position with no resistance clamping strength is insufficient Move the quick r...

Page 32: ...mm above the reflector bracket Adjust the brake shoes using a 10mm wrench so that they are parallel with the rim and are positioned 1 2mm away from the rim Several adjustments may be necessary to achi...

Page 33: ...djustment is necessary adjust with the spring tension adjustment screw 1 mm 10 mm wrench 5 mm Allen key Cable Anchor Bolt Touching End cap Cut off any unnecessary cable attach an end cap and hook it o...

Page 34: ...dle Slide the cable through the cable lead on the end of the left brake arm this will cause the noodle to fit into the lead Slip the brake cable boot over the cable and position it between both brake...

Page 35: ...g 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 2 5 mm Allen key Washer Li...

Page 36: ...orrectly and that the shoe clearance is correct before using the brakes 6 Pass the inner cable through the inner cable lead Set the cable with a clearance of 1mm between each brake pad and the rim tig...

Page 37: ...ed on the rim and the rear portion of each brake pad should be about 0 5 1 0 mm farther from the rim than the front portion of the brake pad Do not ride the bicycle until the brakes are functioning pr...

Page 38: ...appropriately into the end of the barrel adjuster and check for any kinks or damage Slide the exposed brake cable through the rotating rod located on the caliper body and seat the housing into the sam...

Page 39: ...hese brakes require breaking in Ride and use the brakes gently for 13 miles before using the brakes in downhill conditions for sudden stops or any other serious braking Please be aware that your brake...

Page 40: ...example turning clockwise will loosen the cable tension and move the chain away from the wheel while turning counter clockwise will tighten cable tension and direct the chain towards the wheel Shift...

Page 41: ...counter clockwise until the chain engages the largest chainwheel If the chain falls off the largest chainwheel and into the pedals you will need to turn the High limit screw in 1 4 turn increments cl...

Page 42: ...ment of the rear triangle The amount of Rear Suspension travel can be adjusted by turning the adjusting plate Clockwise will increase spring tension and decrease travel while turning counter clockwise...

Page 43: ...fore attempting to work on the pivot Some models have two small 2 5mm Allen bolts on the underside of the bottom bracket shell These must be removed before attempting to disassemble the pivot After di...

Page 44: ...leur guard to protect the rear derailleur from damage To install remove the the rear wheel axle nut on the drive side install the rear derailleur guard over the axle with the U shaped guard pointing d...

Page 45: ...the sidewall of the tire Check that the kickstand operates smoothly and the kickstand bolt is secured tightly Finally examine the bicycle Make sure all accessories are attached and all quick releases...

Page 46: ...and loosen the stem bolt using the 6mm Allen key Some models may use a 13mm hexagonal bolt instead of an Allen key bolt Place the handlebar stem into the head tube observing the minimum insertion mark...

Page 47: ...release mechanism please refer to page 24 25 The seat pillar must be inserted so that the minimum insertion mark cannot be seen Attachment of an incorrect pedal into a crank arm will cause irreparable...

Page 48: ...equired to activate the rear brake due to longer cable length It is advisable to mount the rear brake on the side of the stronger hand It is important to become familiar with the use of hand brakes Wh...

Page 49: ...2 Cantilever Brakes Side Pull Brakes If fitted with cantilever type brakes insert the brake cable into the link wire lead and notch the cable end into the slot of the left brake arm Loosen the anchor...

Page 50: ...djustment is necessary adjust with the spring tension adjustment screw 1 mm 10 mm wrench 5 mm Allen key Cable Anchor Bolt Touching End cap Cut off any unnecessary cable attach an end cap and hook it o...

Page 51: ...g the shoe against the rim adjust the amount of shoe protrusion by interchanging the position of the B washers i e 6 mm or 3 mm so that dimension A is kept at 39 mm or more 2 5 mm Allen key Washer Lin...

Page 52: ...ting correctly and that the shoe clearance is correct before using the brakes 6 Pass the inner cable through the inner cable lead Set the cable with a clearance of 1mm between each brake pad and the r...

Page 53: ...the event of brake cable failure the front reflector hanger would prevent the straddle cable from catching in the tire and locking up the front wheel The straddle cable length when adjustable is set t...

Page 54: ...ering the training wheel to the proper height Press each brake lever to make sure that there is no binding and that the brake pads press hard enough on the rims to stop the bike The brake pads should...

Page 55: ...ting barrels in the upper plate in or out to set the bearing for maximum travel The bearing should be as far down as it can go without resting on the lower plate or the adjusting barrels screwed into...

Page 56: ...ble Casing Cable Adjuster Cable Splitter Upper Cable short casing Upper Cable long casing Upper Plate Bearing Football Ends Lower Plate Lower Cable Adjusting Barrel Locknut Keyed Washer Locknut Adjust...

Page 57: ...d securely and that the reflectors are properly angled Pads If your bike is supplied with pads wrap the foam inner cushion around the appropriate bar Place the outer cover over the inner cushion and p...

Page 58: ...es bottom bracket pedals derailleur cables wheel bearings headset seat pillar Lubricant chain lube or light oil chain lube or light oil oil oil oil lithium based grease oil lithium based grease lithiu...

Page 59: ...oseness Check pedals are tight Check handlebars are tight Check seat and seat post are tight and comfortably adjusted Check frame and fork for trueness Check all nuts and bolts are tight Lubrication a...

Page 60: ...wrenches 4mm 5mm 6mm 8mm 4 Adjustable wrench 5 Standard flat head screwdriver 6 Standard Phillips head screwdriver 7 Standard slip joint pliers 8 Tire pump 9 Tube repair kit 10 Tire levers 1 Spare Tu...

Page 61: ...hey will need to be adjusted This is quite difficult and is best left to a bicycle specialist Broken or loose spokes Check that all spokes are tight and that none are missing or damaged Caution Such d...

Page 62: ...seated in the rim Tread Check that the tread shows no signs of excessive wear or flat spots and that there are no cuts or other damage Caution Excessively worn or damaged tires should be replaced Val...

Page 63: ...w these steps 1 Remove the wheel from the bicycle 2 Deflate the tire completely via the valve Loosen the tire bead by pushing it inward all the way around 3 Press one side of the tire bead up over the...

Page 64: ...by pushing the edge toward the center of the rim Start on either side of the valve and work around the rim 12 Before the tire is completely mounted push the valve up into the rim to make sure the tir...

Page 65: ...se to the part including the wedge that will be inserted into the frame The height of the handlebar can be adjusted to suit your comfort preference If the stem is removed from the steering column you...

Page 66: ...right position but can be angled back or forward slightly for comfort On MTB and racing style bicycles the handlebar is usually tightened in the stem by a single allen key bolt or hexagonal bolt On BM...

Page 67: ...t rotation 5 Slide handlebar grip over handlebar Thread the cable inner wire through cable housings and frame and attach to derailleur Make sure that the cable is in the V groove at the derailleur att...

Page 68: ...kes or shifters Before every ride check that there are no kinks or frays in the cables and housing Also check that the housing is seated properly into each cable stop of the bicycle It is recommended...

Page 69: ...he right and left If the fork tends to stick or bind at any point the bearings are too tight Loosen the headset top locknut or remove it completely along with the reflector bracket if fitted Turn the...

Page 70: ...d lower tube and turn clockwise until it will not turn anymore 3 Align the brake arch mounts on both lower tubes and install brake arch 4 Tighten brake arch bolts to 70 80 in lbs 8 9 2 Nm 1 Make sure...

Page 71: ...r the seat post the frame or possibly the rider a minimum of 65mm of the seat post must always remain in the frame Remove the seat post from the frame and wipe off any grease rust or dirt Then apply a...

Page 72: ...here are two types of seat clamps commonly in use The most common employs a steel clamp with hexagonal nuts on either side to tighten The other type known as a micro adjustable clamp uses a single ver...

Page 73: ...the rider s hands and must not be able to move on the handlebar Some brake levers make use of a reach adjustment screw which can be altered to the distance between the handlebar grip and the lever as...

Page 74: ...ter Brake pad clearance should be a maximum 2mm from the rim When correct re tighten the lock nut If the pads cannot be set close enough to the rim in this manner you may have to adjust the cable leng...

Page 75: ...ose enough to the rim in this manner you may have to adjust either the length of the straddle cable or the length of the brake cable If the brakes use a separate brake cable and straddle cable adjust...

Page 76: ...me models there is a spring force adjustment screw on the brake arm which allows further fine tuning of the brake shoe position Bicycles with cantilever brakes must be fitted with safety devices to pr...

Page 77: ...e inspected every month taking note of the following areas Check correct tightness into the crank arms If pedals are allowed to become loose they will not only be dangerous but will also cause irrepar...

Page 78: ...is marked L on the axle and screws in with a counter clockwise thread Insert the correct pedal into the crank arm and begin to turn the thread with your fingers only When the axle is screwed all the w...

Page 79: ...The crank set should be checked for correct adjustment and tightness every month Cotterless crank axle nuts must be kept tight and the bottom bracket bearings must be properly adjusted Remove the chai...

Page 80: ...ning it clockwise and remove the keyed lockwasher 4 Remove the adjusting cone by turning it clockwise with a screwdriver 5 Remove the left ball retainer slide the crank assembly out of the frame to th...

Page 81: ...side fixed cup by turning it counter clockwise and remove the right ball retainer Clean and inspect all bearing surfaces and ball retainers and replace any damaged parts Pack the ball bearing retaine...

Page 82: ...stment After Use 1 Remove dust cap 2 Tap the crank arm lightly with a mallet 3 Re tighten the flange nuts and refit the dust caps New cotterless cranks may become loose with initial use Perform the fo...

Page 83: ...to tighten in the frame 2 When correctly adjusted the chain should have approximately 10mm of vertical movement when checked in the center between the chainwheel and rear sprocket Center the wheel in...

Page 84: ...ing away from the bicycle Bring the two ends together within the special tool and punch the rivet into place Be sure not to push rivet too far through side plate Like the chain the freewheel must be k...

Page 85: ...nd easy operation The brake is operated by applying back pedal pressure and allows the rider to coast without pedaling if desired There are several models of coaster hubs available and the internal me...

Page 86: ...st then the front The rear derailleur should shift the chain cleanly from one cog to the next without hesitation On SIS equipped bicycles each notched position in the shifter must equate to a new gear...

Page 87: ...er to fine tune the cable tension Turning the barrel adjuster clockwise will decrease cable tension and allow the derailleur cage to move farther away from the bicycle in small increments Turning coun...

Page 88: ...onto the largest chainwheel you will need to turn the High limit screw counter clockwise until the chain moves to the largest chainwheel If the chain falls into the pedals the High limit screw has be...

Page 89: ...the appropriate assembly instructions Your bicycle is supplied with one front white one rear red two wheel white and two pedal orange reflectors These are an important safety and legal requirement and...

Page 90: ...Loose pedal axle bearings Loose bottom bracket axle bearings Bent bottom bracket or pedal axle Loose crankset Pedal bearings too tight Bottom bracket bearings too tight Chain fouling derailleurs Dera...

Page 91: ...he rim or rim out of true Brake mounting bolts loose Brakes out of adjustment Fork loose in head tube Axle broken Wheel out of true Hub comes loose Headset binding Hub bearings collapsed Lubricate If...

Page 92: ...t embedded in tire Correct tire pressure File down spoke Steering not accurate Frequent punctures Wheels not aligned in frame Headset loose or binding Front forks or frame bent Inner tube old or fault...

Page 93: ...____________ Date Purchased ________________ Place of Purchase ____________ Model Name __________________________________________________ Wheel Size ____________________ Color ________________________...

Page 94: ...ver paint damage rust or any modifications made to the bicycle Normal Wear Parts are defined as grips tires tubes cables and saddle covering These parts are warranted to be free from defects in materi...

Page 95: ...11 99 bikemanual 11 24 99 3 55 PM Page 95...

Page 96: ...Street PO Box 230 McFarland WI 53558 Phone 608 838 3732 Fax 608 838 7575 Customer Service 1 800 283 3303 E mail service pacific cycle com Web Address www pacific cycle com 11 99 bikemanual 11 24 99 3...