l' '~

LIMITED WARRANTY
Bicycles are warranted to the original purchaser to be free from defects in materials and workmanship for II period
Irom date of purchase of

S'X Months on Bicycle Frame and all welded jOints

Three Months on all other component parts.

will replace without charge the bicycle frame 0' those componenl parts that are deter/Til ned by to be defec
6\ctC\'f.
tive In manufacture under normal use and service during the applicable warranty period

Our warranties do nol apply 10 any unit that has been abused, misused, altered by component parts substitutions, or
used for relltat or other commercial uses.

Replacement of bicycle component parts determined 10 be defective shall be the remedy of any purchaser and replace
ment of parts must be handled through the retailer from whom the bicycte was purchased If upon examination II IS
determined that a replacement is Justitied, replacement will be made Without charge. T.ansportation costs and labor
charges incurred in 'he replacement of parts are not covered by this Warranty,

All units and their components are covered as noted above.

CAUTION: THE FOLLOWING EXCLUSION APPLIES TO ALL. MODELS This warranty does not apply to any
I OO~\.\1'1
~
un.t that has been used for stunt riding, bicycle moto.cross, dirt biking, or similar aclivlties and al! units are not
deSigned or intended for such purposes or usage

SHALL NOT BE LIABLE FOA INCIDENTAL OR CONSEQUENTIAL DAMAGES.

NOTICE: The user assumes Ihe risk of any personal injuries, damage to or failure of the bicycle and any other losses
if AandBicycies are used in any competillve event, inctuding bicycle racing, or in bicycle motocross, dirt biking, or similar
activities or training therefor. 00 NOT use BIcycles for wheeling, stunt riding, ramp jumping, acrobatics or similar
ac\ivilles or With motors as power driven vehicles. This Warranty does not cover any personal injuries, damages to or

OWNERS MANUAL
failure of the bIcycle or any other losses due to accident, improper use, neglect, misuse, abuse, normal wear, imprope~
assembly or improper maintenance It is the responsibility of the person who completes the assembly of the bicycle
to properly install all parts oncluded with it in the iactory sealed shiPPing carton and to make minor adjustments at tunc
'ional parts such as caliper brakes, gear shift cables, derailleur assembly. etc required for proper operation.

ThiS warranty gives you spec.fic legal fights and you may also have other fights which vary from state to state

To Implement this warranty, the bicycle purchaser shall go to the relar! store from whom the bicycle was purchased
for replacements under the Warranty
FOR

TOURINe AND RACINe BICYCLE

MOUNTAIN BIKE

PRINTED IN TAIWAN
 J 'J
r: CONTENTS I OWNER'S INFORMATION AND RE$f>ONSIBILITY

RULES OF THE ROAD - SAFETY TIPS , ..
OWNER'S INFORMATION & RESPONSIBILITY. .
SAFETY WARNINGS. . . .
BICYCLE PARTS IDENTIFICATION. , . .
SELECTING THE CORRECT FRAME SIZE
UNPACKING. . . .
TOOLS REQUIRED FOR ASSEMBLY
STEP I FRONT FENDER ASSEMBLY.
STEP 2 FRONT WHEE L ASSEMBLY.
STEP 3 KICKSTAND ASSEMBLY ..
STEP 4 STEM ASSEMBLY
STEP 5 HANDLEBAR ASSEMeLY
STEP 6 PEDAL ASSEMBLY...
STEP 7 SEAT ASSEMBLY . . . . . , .s
STEP B FOAM "SLIP ON" GRIP ASSEMBLY ..S
STEP 9 HAND BRAKE LEVER ASSEMBLY
STEP 10 HANDLEBAR TAPING. . .
STEP 11 EXTENSION LEVER ASSEMBLY . . . . . . 11
STEP 12 CABLE TIE ASSEMBLY .... 12
STEP 13 REFLECTOR ASSEMBLY . . . . . 12
Front and Rear Reflector . . . . . . . . . , , . 12
Wheel Reflector . . . . . . . . . . . , .. , . , , .13
Clip-on Reflector. . . . . . , . . .
ScrewOn Refleetor. . . . . . . . . . , , . . . .
Bolt-Qn Reflector. , . .. , .. , .. ,' , . . . . . 13
PAGE
PAGE SAFETY CHECK LIST . ... 14
. ... 2 '2 CHANGE ANO 3SPEED ADJUSTMENT. , . . . . . I.
Thrcughout this manual you will adjustments for proper operation, The uses the bicycle has been fully 10'
.3 CALIPER BRAKE ADJUSTMENT. , ..... 15 find WARNINGS, CAUTIONS and owner or prindple ridet is then respon~ structed in Its operation.
.3
HOW DERAILLEURS OPERATE. . . . . . . . . '6
NOTES or NOTICES. sible for normi maintenance of the 5. Your bicycle conforms to all
.4 SHIFT LEVER TENSION ADJUSTMENT. . .16 WARNINGS: Pay .pecial attention bicycle to keep it in good operating Federal CPSC regulations, There may be
. . . .4 to these since failure to do so could condition. other federat state or local regulations,
. ,4 FRONT OERAILLEUR ADJUSTMENT!
result in injury to the rider or others. 1. Make certain that all assembly restrictions or equipment laws; there
10 & 11 SPEED MODELS ONLY, 17
.s CAUTIONS: If not followed. the,e instrl.letions and necessary adjustments fqre, you should make sure your bicycle
. .5 could result in mechanical failure or have been followed. compties with all applicable regulations
,IB
.6 damage . 2. Perform the safety check list and before it is ridden.
.6 POSITRON III REAR DERAILLEUR ADJUSTMENT ,19 NOTES or NOTICES: These specify mark each item listed. 6~ rf your bicycle was obtained
.6 something that is of speCial interest, 3. Know how to oper,te all standard assembled, "we recommend that you
OERAILLEUR ADJUSTMENT
7 It is the r~$ponsibility of the person and accessory equipment on the bicyCle. review the complete assemblY instruc
, . . . . 20
..7 who initially assembles the bicycle to do 4. Make certain that anyone who tions and perlorm checks specified in
.21 this manual before riding the biCYCle.
so correctly and make any necessary
.21
.21
.1'
.. .9 , ..... 2
. 21
... 10 21 SAFETY WARNINGS
22
. . . . . . . . . 22 Before you ride, please read all the
.22 following items making sure you under the bottom of a hill could force 'IOU be allowed to ride a bicycle at night and
22
stand them, FaJlure to do so could into oncoming traffic or off the road if adults should avoid night riding, if
cause: damage to the bicycle or possible you are going at an exCess speed, possible.
to yourself or others, 5. Use the front brake slowly and H . It is a good idea day or night
. . . , .. 13 BEAR ING LOCAnONS AND COMPONENTS. 23
. . . 13 LOCK YOUR BICYCLE ,23 Yovr bicycle meets or exceeds carefully, especially while turning or to wear a helmet and have a rear view
industry standards. It is NOT designed when the road is wet or covered with mirtof'.
for off-road use, jumping, stunts and gravel, sand Or leaves. Start braking 7. If the stem is not inserted into the

RULES OF THE ROAD _ SAFETY TIPS
1. IN THE INTEREST OF SAFER
CYCLING, MAKE SURE YOU READ
AND UNDERSTAND YOUR
OWNER'S MANUAL.
2. NOTICE: Some state and local
laws may require that your bicycle be
equjpped with a warning device such
as a horn or beU and a light, it the
bicyde is to be ridden atter dark.
3. ALWAYS WEAR SHOES when
riding a bicycle and AVOID loose fitting
clothing.
4. CHECK YOUR BRAKES FRE
QUANTLY. The ability to stoP your
biC'(de is CRITICAL. Roads are SLIP
PERY in wet -mer so AVOID
sharp turns and allow more distance
for stopping.
Caliper brakes may become I...
efficient when _t. leaves, Ioo$e
growl and o",",r debris on the road can
also affect SlOPPing distance.
5. The kickstand is designed to
support the bicyde only, not bicycle
and rider.
6. REPLACE bent or BROKEN
spoke, and bent or dam~ged wheel
rims.
7. OBEY ALL TRAFFIC REGULA
TIONS. Mo.t traffic regulation, apply
to bike riders as well as automobile
operators.
8. KEEP TO THE RIGHT. Follow
the traffic flow in 8 straight line close
to the curb. Watch for cars m()'ling in
and out of traffic.
9.
a is
acceptable if used s.tely.
10. "HEN RIDING IN PAIRS or in
large groups, form a .ingl" line along
the right side of the road. Set up a .en
sible di.tance betwllen riders. DON'T
TAILGATE.
11. ALWAYS BE ALERT. Animal. or
peol)!e may dert in front of you. Be on
the ALERT-people haw the right
of-way. Be ALERT to people opening
doors when passing perked cars. Your
bicyde was not designed for stunting
and experimentation. Enjoy riding it in
:2
UU)
a safe manner.
12. BE CAREFUL AT ALL INTER
SECTIONS. Slow down and look both
ways before crossing.
13. USE HAND SIGNALS. Alway' let
other drivers and pedestrians know
what you are gOillg to do. Signal 100 It.
before turning unless your hand is
neOOOO to control the bike.
14, HAVE PROPER LIGHTS AND
REFLECTORS. Nevor ride at night
without a white front reflector and
headlight, a red rear reflector and
whee! rd!ectorS, Other devices, I ike
+Iags and reflective tape, also holp you
become more yisibfe.
15. DO NOT CARRY PACKAGES Or
OBJECTS whieh obstruct vision, reo
strict (:OntrOI or eould get entangled
in the spokes.
16. NEVER HITCH RIDES. N.....r hold
onto a moving whicfe while riding.
Never ustunt".
17. AVOID the following HAZARDS;
drai~, pot holes, ruts, soft road
edgn. grow" sand and 1 _ especiol
1'1' when they are wet.
other types of abusive riding, sooner under these conditions and with
less force to reduce the chances of
head tube to at teast the minimum in
sertion line, it is possib~e to overtighten
skIdding. Wet brake shoes mean that i1 the handlebar' stem bolt and damage
will reQUire more distance to stOp. the fOf'k stem body. This could cause
an unsafe condition and risk of injury
Start braking sooner than normal in
Do not ride the bicycle until you
wet conditions. to the rider.
have checked for proper brake adjust
6. NIGHTIME RIDING: 8 For safe oM;ration, the handlebar
ments. See "Hand Brake Lever As
A You can't see the controls on stem bolt and clamp nut mutt be
sembly" and "Caliper Brake Adjust
your bieycle at night sO you must know securely tightened.
ment" sections,.
whete they are by touch. 9 For safe operation, you must
4, When riding 'your bicycle for the
first time. test the brakes at a slow
e Slow down. Debris and holes seCure the pedal spindle tightly against
are much harder to see at night the crank arm with a wrench that fits
speed on a large fevel surface without
C If possible, ride on streets the shoulder of the pedal spindle. This
obstructtons, Also, never attempt to
that are familiar to Y9u. Terrain that is: rrr.portant; it avoids stripping thread$.
stop suddenly vsing the front brake
you have nevet seen during the day fS Always replace damaged pedais,
only, zs this could throw the rider off
dangetous at night. 10, When adjusting the seat height. you
the tront of the bicycle,
E Use well lighted streets when must have .the minimum insertion mark
3 Check and adjust the brake" if
ever possible. Avoid unlighted bike on the seat post remaining inside the
nCCf'ssary, at the first s~gn of failure.
path, frame.
This will enable the rider to make a
qvick and smooth stop. Cn caliper
r: Comply with aU legal reQuire,
ments ill your state. You should at least
brakes, if a brake lever touches the
have a "white L;ght", (nOt just a white
grip when it is squeezed, ad;ust the
reflector), on the front and a rear red
brakes,
reflector. All states require that a
4, Going downhiU fast is dangerous
lamp be used that emits a INhite light
since YOll can't stop nearly as fast as
G Children generally should not
you can on level ground. '" curve at
3

.")
[ BICYCLE PARTS IDENTIFICATION
SEAT
REAR CALIPER BRAKE - - -.....
REAR FREE WHEel
ASSEMBLY
REAR
DERAILLEUR
CHAIN
FRONT DERAilLEUR
The correct frame si]e ts: the largest
frame that the rider can comfor'.ably
straddle keeping both feet flat on the
ground and aUowfng 2SAmm (1 inch)
clearance between the rider's crotch
and the top of the frame tube. tSee
illustration).
NOTE: Ladies can use man's bike to
determine their correct frame
IMPORTANT: Remove the bicycle .nd
aU parts from the carton. lay out aU
Ihe un.....mbled parts .nd READ THE
ASSEMBLY INSTRUCTIONS in this
booklet before assembting your bicycle,
The instructions .re STEPBYSTEP
ptocedure. Follow the steps that pertain
to your modet.
NOTE: Your bicYcle may be equiPP<'d
w~th a different style component than
the one itlustrated. However, the
procedure for aswmbly or adjustment
is basically the same,.
WARNING: If you' bicycle wao 0b
tained anembled. we recommend that
")
c=
TOOLS REOUIRED FOR ASSEMBLY
MEOItJMSlZE
These tools should be available to per '0' AOJUSTABlE PHilliPS STANDARD
WRENCH SCREWDRIVER 5CREWDRIYER PLIERS
form the basic steps of assembling the
b[cyc{e. They can also be used to make
maintenance adjustments outlined in < .. :'~i':.~~8lE ,~' ~ ~
this manual. Special tooJs are required
to disauemble chain, remove the rear , " ~~~" ~
hub parts and true wheets. Special
tools are not required for assembly a"d
.~:v ~
CALIPER BRAKE normal maintenance.
NOTE: A pair 01 pliers is not a substitute lor tile propers;ze wrench.
NOTE; I f an alter wrench is required.
it will be supplied with your bicycle.
STEP 1 FRONT F,ENDER ASSEMBLY STEP 1
TOOLS REQUIRED
.6" ADJUSTABLE WRENCH
'''laUREAI
MEDIUM SIZE STANDARD
SCREWDRIVER
NOTE: Your bicYcle may be packed in
a shortpack carton, If so, you wHf need
SELECTING THE CORRECT FRAME SIZE nn_-. fa i:lssemble the front fender and wheel
to the front fork, Follow instructions
.If;
'v
Ir....'
'?\ ..
~ (1 ~)
01~
p~
Hot Less Than 1 Inch
dccordingly.
[FIGURE AI
FRONT FENDER
(WITHOUT CALIPER BRAKEI
IIE:~
I. With the fork turned lorw.rd. lean
Il \, -"i: \ the bicycle against a surface wall,
L/lJ! It
2. Remove nUl. lockwamer and
size,
_ mounting boft from fork top plate.
3. Ush8P<'d mounting bracket: Place
Rider must be able to .traddle
bicycle with allea.tI Inch the shortest end of U..haped mounting
clearance above the horizon"'l bracket forward, Lshaped mounting (FiGURE C!
bar when standing_
bracket: Place the L..h.ped bracket to MOUNTING BOLT
UNPACKING nmn______] ..ar of folk top plilte. Align the mount
ing bracket hoi .. or hole with the hole
in fork top plate.
RECORD All INFORMATION ON RECORD SERIAL NUMBER lOCAT 4. Fasten fender using mounting bort~
MOUNTING
LABEL LOCATED AT BOTTOM OF ED ON THE SIDE OF HEAD TUBE; tockwas:her and nut just removed,
BRACKET
SEAT MAST. OR ON REAR PLATE; OR ON THE
BOTTOM OF CRANK HOUSING. (F fG1JREJi]
(FENDER BRACKET MOUNTED
WITH CALIPER BRAKE I
1. With the fork turned forward, lean
the bieycle against. w.U.
CRANK _REAR 2. Re(Jl()W two self-tapping screws
HOUSING PLATE .nd lockw.she" from the fender IIFIGURE CI
mounting bracket, the bolt on caliper brake.
(FENDER BRACKET NOT MOUNTEDI
3. With the ohmt p.rt of fender facing 3. With the short part 01 tender f.clng
DATE PURCHASED _ _ _ _ _ __
forward, attach fender to mounting 1. With the fork tur""d forward, I.an fotward, attach fender to mounting bo
you review the complete assemblv in WHERE ___ .~~~~_ _ _ _ _ __
MODELNO. ____________ bracket with t!;le two lockw.sh....nd the bicycle against' waU. with lockwather and nut. Cenler brake
structions. and perform checks spHi
SERIAL NO. _ _ _ _ _ _ __
.elftapping scr...., 2. Remove IoekwIsl1er and nut f,om a.,..,. Ind tighten nut JecurelV.
fied in this manuel before 'Kling.
5
 )
''J

STEM ASSEMBL Y, con't,

r POStTMifiIil
I STEP 2 FRONT WHEEL ASSEM8L Y STEP 2
A. If your mr)del hlH POS~lror' STEM
BOLT
TOOL REQ\.!IRED shift lever'5. p\ISh the levers dewil .:J'io
6" ADJUSTABLE WRENCH :Uu:Hrated ~n the next page n'ls
IS t()
WASHER _ _ _ _ .,,_
WHEEL
jJrO\lIde eilSy access to the Hem uolt 10
AXLE NUT RETAINER
tighten down In Im31 assembly
Recommef"lrled tOH,JUe 15 250 In Ibs B A.ssemble the lever bracket to the
AXLE
stt'm by :>iidirl9 the slot In th~ lever
PROTECTOR
\)r3cl<et under the head 0 t the stt:m !::loll
\ ~ and washer.

O
~
Remove plastic axle protectors NOTE The washer should be seated the mi:OImum insert'on line indicated
off wheel axle and dispose of them behihd the two loc3tirlg pins on the
They are fOt shipping purposes only L NUT bracket.
on the stem.
5, Face the handlebar stem torward
2 Remove nut$., washers and wheel WARNING The handiebar stem directly in line with the front wheel GEARSHIFT
retainers from whee! axle, if necessary must be inserted into the head tube to and tighten the stem bolt securely, LEYER
If nOt, they will be included in the of axle, Hook the retainer'S into holes
hardware package.
3. Slide whee~ axte into open ends of
in fork end,
5, Install fender brace (If equipped) anti 16, Center wheel If) fork, and tighten
STEP 5 HANDLEBAR ASSEMBLY STEP 5 I
the fork, washer then and an axle nut loosety onto axle nutS securely alternating from un!' TOOL REQUIRED
4, Slfp a wt)eel retainer onto each end each end of axle. to the other. 6" ADJUSTABLE WRENCH
HANDLEBAR CLAMP NUT
STEP 3 KICKSTANO ASSEMBLY STEPg--]
ReCOI'!"Hnended torque is 276 In !bS
TOOL REQUIRED WARNING; For safe operation, the
6" ADJUSTABLE WRENCH 5 Replace the washer and nut onto nem bolt and clamp nut muU be
mounting bolt. Hold kickstand arm in Sf;:clJrety Ughtened
1, Place the bicyde in upright position up po:>ition atigned ,with frame tube 1 Sli~p. the handleoor through the
against a wall or have someone hold It then s,curely tighten the mounting bolt. stem unul knurled seCtlor. of handlebar
up,ight. 6, leave!eg of kickstand down so it is cent(>~ed if' stem
2. Remove tOP plate from the kick
will support the bicycle during the rest Take c;;re not to scratch handlebar
stand, keeping mounting bolt in POSI'
of the assembly, v,;,en Sliding it into the stem.
tion on kickstand.
2 Adiust handlebar to desired angle
3, From left stde of bicyde. place the
3:, Securety tighten clamp nut
kickstand in position beneath the two
WARNING, The kickstand is designed 4. Check handlebar for tightness, I 5. Check steering by straddling the
rear fork legs
to support the btcYcle only. not bicycle you caf' move it torward or backward, front wheel and trying to turn the the stem is too loose. line up handlebar
4. Replace the top plate, Hange down,
and rider, the damp nut is not tight ef'ough. handlebar. If you can turn the handle with" tront wheel. Retighten the Sf~m
onto mounting bolt.
REPEAT PART 3, bar without turning thE: tront wheel, bolt: clockwise.

STEP 4 STEM ASSEMBLY STEP 4 -- I [ STEP 6 PEDAL ASSEMBLY STEP 6 I

TOOL REQUIRED TOOL REQUIRED
STEM FRONT OF BI KE
6" ADJUSTABLE WRENCH iJIoo 6" ADJUSTABLE WRENCH RIGHT SIDE
SHIfT

~
STEM BOLT PEDAL SPINDLE

LEVER --...
Recommended torque is 216 In. Ibs Recomme(;ded torque IS 276 in Its.

CLAMP NUT STEM '\

Recommended torque is 276 in. Ibs, BOLT WARN1NG: For $afe opt!'ration, you
NOTE: Some models may Ie, must :secure pedal spindle tightly
quire an allen wrench. against crank arm. Always replace LEFT SIDE
NOTE: If your model is equipped with HEM
damaged ped __ h:.
a
~
a cable hanger, place il on the frame
before the reffector bracket. (See so the wedge plug nut is in line with the NOT ICE Star. each pedal spindle by
stem body, 1'I3 n O a'Joid stripping the threads.
to
dotted line,'

~
LINE
1. Put the (eflector bracket in place 4. Insert the stem Into the head tube Look for the retters "R" or "L"
on frame. tSee iUustnnion below J to the minimum insertion line indicated starnped on the pedal spindle.
WEDGE :2 Thread pedal marked "R" into
2, Thr~act the fork adiusting nut onto on the stem. 3, Thread pedal marked "l" into
PLUG crank on tight (sproeket) s.lde of bi CAUTION: Ma~. certain .. ell ped.1
the stem. Securely tightctn the nut 5. Face stem forward directly in line crank on 'eft side of b~cyde. Turn
NUT cycle Turn spindle 10 a clockwise spindle i, tightened securely. Always
with the front wheel and tighten stem spindle in a counterclockwise direction
3, Loosen the stem bolt, if neausary, directiOI'l-, Tighten securely wear shoe, when riding the bicycle.
bolt securely, and tighten securely

6 CONTINUED NEXT PAGE lI

 )
r)

STEP 7 SEAt ASSEMBLY STEP 7

,--S-TEP-9- HAND BRAKE LEVER ASSEMBLY STEP 9

TOOLS REOUIR ED
It is important to become familiar with
6" ADJUSTABLE WRENCH
the use of hand brakes. When properly
MAINTAIN CLEARANCE HERE Normally ~ the (front lever) is mounted
on left side of hand lebar and (rear lever)
WARNING: Keep brakes in proper
adjustment. Always ,apply brakes with

SEAT POSTCLAMP BOLT
adjusted, hand brakes are an efficient.
Recommended, torque ~s. 260 in. Ibs.
braking system. For top efficiency.
SEAT CLAMP BOLT
the Wheel "rim contacting the brake
Recomf'l'l(llnded torque 1$ 260 in. Itts.
1. loo$8n nut on stat clamp. Add
3 or 4 drops of oU onto the threads of
the bolt. Place seat post up into the seat
clamp. If seat post doesn't have a bulge
or dimple on' it, make sure clearance
is maintained between the top of the
post and the underside of seat as shown.
Otherwise. the seat clamp should fest on
()
the bulg., or dimple. If the post hits the
underside of seat, raise seat until clear
SEAT
ance exists.
2.. Partially tighten nut on seat clamp.
3. Put seat post clamp onto the
seat mast. About 3.1 mm (1/8'" of
seat mast must show above the clamp
and stot in $eat mast must be centerE:r!
between clamp legs. U equipped with
reftector bracket illustrated, put the
bracket ooto mounting bolt from the
side shown, Secure ctamp loosely Jsing
the washer and nut provided.
equal pressure' on both hand levers so
that both wheels come to a smooth.
SERRAtiONS
DIMPLE
.:\ ~
J~- . nnm1I.\--,BOLT
,~
o ~LECTOR
BRACKET
MAST
PROPER SEAT HEIGHT
serrations. Partially tighten bott on seal
clamp. Push front of seat up and down
to firmly mesh the serrations Jogether
5. Securely tighten nut on seat clamp.
6. To assure holt on seat post clamp
will tighten securely, loosen nut and add
3 or 4 drops of oil onto bolt. Adjust
seat to desired height.
CAUTION: When adjusting seat height.
~""~,
on the right side.
hand
TOURING LEVER.
TOOL REOUIRED
MEDIUM SIZE STANDARD
SCREWDRIVER
When sitting on the seat in a riding
position. the knee shol,lld be slightly
bent whlle the baH of the foot is resting
on the pedal in its lowest position.
7. While holding rear portion of
reflector bracket so it remains vertical
(see side view), securely tighten the nut
on seat post clamp. Check for tightness
by attemPting to twist the seat. If
This tilh be reversed to accommodate
right or 1m handed people.
NOTE. The right hand side is the side
that the chi2in is on.
A greater for(.'e is required to activate
the re<tr brake due to fonger cable
length. It I'S advisable to mount the rear
brake lever on the side of the stronger
be with the hand brakes.
This includes water. soap, oil, silicone,
powders, etc. Do not use compressed
air. ICompressed air often contains
moisture and oIl.)
L Loosen mounting serew or screws
depending on make of hand brake lever.
',( Loosely slip a hand brake lever
daITlp onto the left and right side of
handlebar.
3. Refer to illl,lstration and position
levers onto handlebar.
4 The handlebar grips can now be
thumb shifter/s, nlace the clamp around
assembled as fonows. Start grip on
dean, dry bar, in de$ired position.
ellen stOp. It can be dangerous for an
shoes must be kept clean and free from
inexperienced rider to apply the front
wax, lubricants or dirt of any kind.
brake only, espeeiall)" if it is applied
Keep brakes properly adjusted and in
good worklng order at all times. Re
too hard. This is particularly tmportant
if the streets are wet or covered with
member that, with most "multispeed
bikes. the rear hub is f(ee wheeling and
the only way to stop your bicycle will
sand or gr~vel. The same is true if you
are making a turn or happen to be ufi
balance.
5. After installation, test to see
grips are tight. Replace grips that
become worn or loose.
6. Securely tighten mounting screw or
sCrews so the levers cannot rotate or
slip.
7. If your model has a 3 or 5 speed
WARNfNG: Fai1ure to securely tighten
mounting screw or screws will cause an
the h~JOdlcbar and securely fasten the unsafe ridrng condition.
#

4, Position top of seat parallel wJth
the ground. Serrations on seat clamp
must mesh completely with seat frame
you r.1ust have the minimum insertion
line on seet post remaining inside the
frame.
loose. retighten the nut. mOl,lnting screw/s.
Bump on with the palm of your hand or
8. Tap a plastic cap onto end of bolt any suitable device such as a mallet NOTE. FERRULE MUST BE SEATED
on the seat post clam!? until the grip is all the way on the bar. INTO LEVER HOUSING FOR
Do not use any lubricants whatsoever. PROPER BRAKE ADJUSTMENTS _ _

I STEP 8 FOAM "SLIP' ON" GRIP ASSEMBLY STEP S-::J HOODED len"_
I
BRAKE
CABLE
, jj

1. In a container. mix 3 parts water

with 1 part Ivory Liquid detergent.

o
TOOLS REOUIRED
MEDIUM SIZE STANDARD
SCREWDRIVER
II MOUNTING
BOLT
Lestoif or lY$01 detergent,
B
ENDE L L E D l; ? . 0 1

~
6" ADJUSTABLE WRENCH
"
NOTE: Grips with large holes in

PLIERS RETAINER
both ends must be assembled first. The

1. Remove brake cable from the

belled end of grips mu<t go 00 first.

Plug one end of grip with your finger.

hooded lever, if attached, by loosening -==" ~CABlE

t he cable anchor nut -then squeeze the
LiberaUy apply mtxture to inside of
'\STEM 1 \ ANCHOR
grip and onto the handlebar.

brake lever so the slotted retainer is ~I NUT

/ visib1e. Remove the brake cable from
2. With someone holding .c,nd"'bar

in position and using a cloth to keep

grip from slipping in your hands. push

o
INSTALL BRAKE LEVERS BEFORE
MOUNTING END GRIPS
the slotted retainer, This permits access
to the mounting bolt.
2. lnstall the hand brake levers on the
HOODED
BRAKE
LEVER

~ ~fY
and twist grip onto bar against the stem.

knurled section of hand~ebar as $hown

Repeat procedure on the other side of

the illustration. If your handlebar

handlebar.
TO\JRI"IG BAA
does not have a knurled section on it,
3. Refer to #"Brake Lever Assembly"

make certain that the 3 112" dimension

MCtion for proper anembly of the hand

shown is maintained. Securely tighten WARNING; Failure to securely tighten KNURLED

brake levers. After levers have been

..,blf!!l. perform part 4 -below.

4. Mount the _ grips in same

manner making certain they are on
handlebar as f.r possible. After 2 to
3 hours the liquid will evaporate, lea'ling
a soaplike residue; this bonal the bar
and grip together.

mounting bOlt.
3. Check brake lever tightness by

trying to twist or move levers on the

handlebar. If a lever moves, retighten

the brake levers will cause an unsafe

rid ing condition.

4. Place" cable endnipple into the

mounting bott.
slotted retainer.

8 CONTINUED NEXT PAGE. 9

 1\ l )

ASSEMBLY OF CENTILEVER BRAKE STEP 11 EXTENSION LEVER ASSEMI3L Y STEP 11

. -::~~'. ~y
AI'H::hOf Solt Lad: Nut TOOL REQUIRED
Medium Sile Screwdrivet

~OTE Extension levers are a "second

A - LEveR WlTH fLANGEO WASHER
LEFT LEVER SHOWN

Str.\1ld_~ C_ea_: =" '._H:" - ~_-'..-~'\w

:
ary" braking device. They should be
used for speed control ON LY. Use the
"p.rimary" brake levers for maximum
braking fo(:e.
; Some bicycles are equipped with "ex
j~~~;;tm. tension levers" in addition to the harld
brake !ever. This deVice makes It pos
sible to activate the brakes from tWO
different positiOns. You can apply the BRACKET
~,~ brakes by squeezing the "prtmary"

Q'l
hand brake: lever with your hands in the
Straddle Ca~e lower or racing position. Or, you can
pull up on the "secondary" extenSion
~ 19 1
lellers with your hands on top of the
handlebars.
" " 1'
~"'~,
Refer to illustration pertaining to your I~ ..J
~o(J.!.1 1.4 ~ model for installing extension levers

1 PLACE ENOS OF STRADDLE CABLE IN GROOVE ON 8AAKE ARM ON 80TH SIDES Of WilE H p\J r ~~ 'I:-FiG'URE B LeVER WlTH SHlM WASHER
L LEFT LEVER SHOWN
STRADDLE CABLE INTO STRADDLE CABLE HANGER (RE'BR FlOURE 1 Remove mounting screw, lock

LOOSEN ACORN NUT AT 8A~ OF STRADDLE CABLE HANGER, PUi 8RAKE CABLE FROM washer and flanged w3shN.

BAA THROUGH HOLE IN BOLTON FRONT SIDE OF CABLE HANGER & TiGHTEN 2. Insert flanged washer Into ex
FLANGE
3 WSING 5mm ALLEN KEY, PLACE INTO BRAKE eOL T IN POSITION ON f!GURE :2' & LOOSEN HUT tension fever. Place washer onto mount
Smn\ FORM RIM OF WHEEL & TIGHiEN (AEHA FIGURE ::1.) ing bracket. Plllce extension lever into

position on the mounting bracket. Place

MOUNTING

STEP 10 HANDLEBAR TAPING 'STEP 10 I flange behind the mounting bracket.

3. Place !ockwasher ontO mounting
BRACKET

screw.
1. Before laPing, cut tape in half 4. install and tighten the mounting
( unl... supplied with two rolls I. screw securely. 1\
2. Sun tape approximately 63.5mrn S. Use same procedure to instal! the ,\
(2 1/2 inches' from the stem. KEYED WA~HER
right hand extension lever,
I "
NOTE: You may find it easier to ,Start
the handlebar tape by applying a piece ~
BRAKE
LEVER
,! 1'
,
!:IGURE B EXTENSION LEVER
of adhesive tape onto the end of the CLAMP I I
handlebar tapa. Remove mounting screw. lock
3. With textured surface on the out washer and alignment washe(.
$idfJ~ wrap one end of tape tight upon 2. Place extension lever into positton EXTENSION
itseU in a spiral patteff'l. Each spiral on the mo.,;nting bracket, Keyed washer

~~-PLUG
LEVER
wind should overlap approximately and shim washers should remain
3.2mm (lIB inchl. Th. tapa should be place while positioning flange behInd
pulled tight as you wrap. It will be the mounting bracket,
necessary to wind tape over and around 3. Place pin on the aJignment washer
the brake lever damp. into the: center hole of the keyed
4. Continue to wind tape in this washer.
FLANGE
pattern to the end of the bar. Be sure 4, Place lockwasher onto mounting

not to love any gaps of metal between Of handlebar and fold in any other securely, Assembly may be easier if screw.

each spiral.
S. When you reach the end of handle
bar. push remaining tape msKJe the end
overlap_
BRAKE
6. Insert handlebat plug into end of
handlebar. Thi, will lasten the tape
you soak the plugs in wa(m water. 5, lI'st311 and tighten the mounting
I
7. Repeat part 2 thru 6 on the other
side of handlebar.
screw securely.

6. Use same procedure to Install the

other extension lever

LEVER

10
 STEP 12 BRAKE CABLE MOUNTING BRACKET ASSEMBLY STEP 12
1
",
jWHEEL REFLECTOR I
NOTE: The center of reflector must
be 3 inches or less from inside surface 1. Loosen mounting screws. so groove
TOOL REQUIRED of wheel rim. in mounting clips can slide onto spokes.

---7-9'
CABLE MOUNTING BRACKET ~
PHILLIPS SCREWDR IVER 2. Place: the white' reflector onto,two
TOOL REQUIRED spokes of the front wheel opposite
Some models are equipped with

meta1 brake cable mounting brackets

- - r9 MEDIUM SIZE SCREWDRIVER valve stem.
3. Slide reflector as close tarim as
which are to be assembled onto the top

MOUNTING SCREWO NOTE: The wheel reflector', mounting possible.

bar of the bicycle.
base is slanted. This permits the re 4. Tighten both screws securely.
1. Remove the mounting screw from
MAN'S FRAME LADY'S FRAME flectors to be installed perpendicular 5. Repeat same procedure to mount
each mounting bracket. if necessary.
to the wheel rim. rear wheel reflector.

~ ::;J\~
2. Place a mounting bracket in each

position on tl;1e top bar In positions

CLIP ON REFLECTOR - - - - - - - - - - - - - - -.......

shown.

3. Reprace each mounting screw onto TOOL REQUIRED

the brackets and tighten securely. MEDIUM SIZE STANDARD
SCREWDRIVER
r STEP 13 REFLECTOR ASSEMBLY STEP 13
1. Position white reflector on front
Regardless of shape or size. all re
flectors are mounted in it similar man
ney. Follow mounting instructions ae
rordingly.
w

} wheel spokes opposite valve stem.

2. Open clamps slightly with screw
oriver and attach damp$ to spokes.
3. Slide reflector as close to rim as
po.. ible.
CAUTION: When assembling front and 4. Repeat same procedure to mount
WHITE
rear reflectors, make certain the word rear wheel reflector.
~'top" imprinted on the back of the
reflector is pointed up~ or one of
the
arrows '1 A " point up when mounted TOOL REQUIRED
to the bicycle. SPOKE
MEDIUM SIZE STANDARD
SCREWDRIVER
NOTICE: . Failur. to mount .nd dis
play the reflectors supplied could 1. Place a reflector between the
constitute a violation of the law with,n 3. Insert
the spoke fastener through
spokes opposite valve stem on front
your city or state. For your safety. the mounting hole in the reflector from'

wheet.
the side opposite the spoke.

-==H",-""J~
please mount all reflecton as indicated.
For additional night riding safety and NOTE: The reflector should fit firmly 4. Using
a screwdTlver that fits the
to comply with the taws of many cities WHITE between a single spoke on one side and slot of the fastener. pre~' inward with

and states~ your bicycle should be

WHITE
two spokes on the other side with the firm
pressure and make a 1/4 turn ~KE"rDE
equipped with head and taillights. reflector as close to the rim as possible. clockwise until the fastener snaps onto

TOOLS REQUIRED
6" ADJUSTABLE WRENCH
FRONT AND REAR REFLECTORS].......

I FRONTI I REAR I
2. Fit the groove" in the reflector to
a spoke which matche, the .ngle of the
groove, but opposite valve stem.
the spoke.

S. Use
same procedure to mount
white reffector to rear wheel.

BOLTON REFLECTOR
rf
'MEDIUM SIZE STANDARD TOOL REQUIRED
SCREWDRIVER MEDIUM SIZE STANDARD

{
SCREWDRIVER

NOTE: Mount white reflector onto

front bracket and red reflector onto
rear bracket.
1. Position locating pin and mounting
pin (or bolt) into slot in front of moun
ting bracket.
2. Fasten using a wing nut or lock
washer and nut onto mounting pin
lor bolt).
-~
3. Tighten wing nut untit reflector is
secure. If lockwasher and nut are used.
tighten nut securely.
1. Loose~y assembie the reflector.
retainer. nut and. bolt together.
;.
NUT1iffi :
2. Place a reflector between the two spokes on the other side with the ~.~
spokes opposite valve stem on front reflector as close to th~ rim as possible. -===- J'~
wheel.
NOTE: Curvature of reflector shOUld
S. Place single spoke under retainer
and two spokes on the other side.
RETAINER L BOLT
match that of wheel rim. 4. Securely tighten bolt.
NOTE: The reflector should fit firmly 5. Repeat same procedure to mount
between a single spoke on one side and rear wheel reflector.

12 13

I SAFETY CHECK LIST
Perform each check below after all the
assembly instnlctions and any necessary
adjustments have been cornpleted,
WARNII'IG: Failure to perform these
checks could result ,I" serious injury to
YOlJnelf or others.
01, STEERING: Make certain that
the stem is inserted into the head tube
to at least the minimum InserHoll line,
Check the clamp nut and stem bo!t to
make sure they are tightened securely.
(See handiebar and stem assembly
sections for recommended torque.)
02. Check and adjust.
brake adjustment
Before riding. activate
front and rear brakes 20 to 25 times
then make finar brake adjustments. This
procedure take:'l care of initial cable
stretch.
03. SEAT: Check for tightness of
seat clamp and seal post Clamp and that
the minimum insertion line is inside
the frame
See that the seat is at the proper
height for the intended rider. 1See
seat (lssem'oiv seCtion 10r recommended
torque.)
04. PEDALS: Check pedal spondles,
making sure they fit tightly against
the crank arms. (See pedal assembly
section for recommended torqu.e,)
.~
1
OS. TIRES: Check and IOflate. if
necessary, using a hand pump. The
correct pressut'e is marked on the side
of the tire. DO NOT OVERINFLATE
06, GENERAL INSPECTION: See
that all ,reflectors have been properly
installed. Replace any mjss~n9 or
damaged reflectors. Check all fasten ....
and ti9hten. if necessary.
07, TO THE RIDER OF.!J!!
Make certain that you know
to operate the bicycle. We recom
mend that you read aU safety and
warning information in this manual
before riding,
WARNING: Before riding, activate
front and ",ar brak.. 20 to 25 ti"",,,
Then make final bnoka adjunmeMl.
This procedure takes cere of initial
cable stretch.
WARI'I!NG: Adjustments must be
mad. poriodically due to cabl. stretch
and w..r on the rubber brake moe.
Do nol rid. your bicycle until you ha
thoroughly chocked your brake.. s...
thaI me hendbrak. I..... have very
little free mo.em.nt. The brake, should
!PROCEDURE FOR MAKING
~INE ADJUSTMENT
TOOLS REQUIRED
.6" ADJUSTABLE WRENCH
MEDIUM SIZE STANDARD
CALIPER BRAKE ADJUSTMENT
start to close at lOOn 81 lelWer action is
applied. If you can push the bicycle
wilh Ih. brake applied, tho brake need.
adju.ting. B. sur. to check both front
and rear brakes, (if equipped I.
Adjust the front or rear brakes using the
same procedure',
caliper brake for location of adjusting
Twv adjustments can be made on
catiper brakes: 8 fine adjustment or
a major adjustment. A fine adjustment
ISIOEPULL BRAKE}
I
is for moving brake shoes: slightly in
or out. A major adjustment may be
necessary after extensive use of the
brakes whjch has caused the cable to
stretf;h. In this case, the shoes win not
contact the rim when the brake lever
is squeezed.
Use the illustration for your type of
barrel, locknut and ollble anchor nut
used in making the necessary adjust
ment.
I CENTERPULL BRAKE]

I 12 CHANGE AND 3SPEED ADJUSTMENT I SCREWDRIVER

PLIERS
1. loosen adjusdng barre! locknut.
TOOL REQUIRED 2. Turn adjusting barrel clockwise if
E,GURE C brake shoes are: rubbing against rim.
PHILLlP~ SCREWDRIVER flfi.YI!s.l!
STuRMEY ARCHER Turn adjusting barrel counterclockwise
The shifting mechanism will require
,f brake shoes are too far away from

~
little maintenance if operated and
rim. Brake shoes should be approxi

maintained properly.
matelv 0.8mm 11/32 inch) below top
For your convenience, your 3.speed
of rim and approximately 1.6mm
hub unit has been pre-adjusted at the
(1/16 inch) from rim.
factory. but due to jarring in shipment, EJURE e 3. Tighten locknut ,,",uroly. WIRE
the unit may need minor adjustments. SHiMANO E.!m:LRS 0

Adjustment as follOWS: rl1~ BRAK

PROCEDURE fOR MAKING T 11Ft SHOE
1. Place the shift control at "J".
A MAJOR ADJUSTMENT
ISee Fig. A) Place the STUAMEY
BRAKE
ARCHER AW shift control at II. TOOLS REQI.:IRED LEG
(See Fig. B) 6" ADJUSTABLE WRENCH
NOTE: For SH IMANa to be pro MEDIUM SIZE STANDARD

perly adjusted. the small "SET" trio SCREWDRIVER

angle must align with the small tab
on the bell crank assembly. (See Fig C)
NOTE: For STURMEY ARCHER
AW to be properly adjusted, the end of
the indicator rod must be flush with
the end of rear axle, {See Fig. Dl
2. For STURMEY ARCHER AW,
loosen adjusting barrel locknut,
loosen or tighten adjusting barre!
to obtain proper adjustment. (See
above NOTES,)
If the previous steps were followed
and proper adjustment does. not exist.
make a further adjustment by continu
ing with part 3.
3. Turn adjusting barre! clockwise
approximately 12.7mm (1/2 inch)
of threads are showing,
BRAKE
SHOE
PLIERS
1. Turn adjusting barrel clockwise 6. Jf the brakes do not release evenly.
until it bottoms out then back it off loosen mounting bolt and adjust desired A ~."\~:w:-.:.u:{[LL::::::::==--:I
1 1/2 or 2 turns. amount then securely tighten mounting
2. Loosen cabfe anchor nut.
3. Squeeze brake legs to!J"ther and
bolt. .. (""'"\:.~~=.{[::;: ===::1
hold so brake shoes remain against rim. WARNING: Th. mounting bolt and nut en-.~~'~~'~_~,.,::J
LocKNUT
Tie with a cord. mult be secure so as to maintain proper
4. Pull dow~ on end of cabl. wire braking and continued ..f. cycling.
o fJ=."'""=====<:.::n::.:.:.:----'
with pli.rs and hold whil. tighlening
4, Loosen and move cable stop to
ward 1ront of bicycle to elimInate
cable anchor nut. Untie cord. WARNING: Th. rear center pull cable ..
t!O'~~~"Z..~,l r-"~-----,
CAUTION: A >tOW hub should be 5. Spin tho wheel. Tho brake shoes hanger is held in position by the seat
cable :slack should not COntact the rim at any point. pod clamp bolt and nut. This must be TYPES OF ENDNIPPLES
5. Tighten 'the cable 'Stop securely oiled before use through the lubricator
on the rear hub shell. Two drops of oil If they touch at any point. make aligned with the brake for adjustment Use key letters when ordering new
6. Perform step number 2.
should be added every month. Use fine adjustment. and safe operation. cable and casing assemblies,
Tighten adjusting barre! ~ocknut
securely SA E 30 motor cil.
15
14
 1 J
[- HOW DERAILLEURS OPERATE - :::J FRONT llERAILLEUR ADJUSTMENT/10& 12 SPEED MODELS ONLY

TOOLS REQUIRED
Changing gears gives you more 5 SPEEO 10 or 12 SPEEO PHILLIPS SCREWORIVER
efficient pedalling effort. Too much SHIFTER SHIFTER MEDIUM SIU STANOARD
pressure means change to a lower gear. SCREWDRIVER
If pedalling is too easy, cha.,9O to a .6" ADJUSTABLE WRENCH
high.rgea r. I-EXCEL FRONT DERAilLEUR I
PLIERS
/ \\ MIIGH

Derailleur assemblies require Uttle

I I

fr~-
maintenance if operated and maintained
properly. On t.n or twelVe speed models
there or. two 'hift I.vers. The RIG}H \\ -~"':""';=.-~.-~
PROCEDURE TO ALIGN CHAIN
GUIDE:
shift lever (rider's right side when sitting
on the seat), CONTROLS the REAR ').."i/;t1!t
..,~TEN~
'iliUM.
s.c;Flrn
HIGH
derailleur. The LEFT shift lever CON
TROLS the FRONT derailleur.
F.v. speed bicycle. have just ONE LOW ~.' \
1. Loosen mounting boltll) and po,,'
tion chain guide to within 3.2mm
'hift lever that CONTROLS the REAR 11/8 Inchl to 6.4mm 11/4 inch) above
derailleur. There iso'+ a front derailleur largest sprocket.
on five speed bicycles. 2. R.tlght.n mounting boIUs/.
Five and ten speed bicycles haIJc' 5 Refer .to derailleur iUustrations for loca
rear sprockets or "cogsr~ of different tions of the LOW and HIGH AD.
sizes. Twelve speed bicycles have 6 JUSTING SCREWS on your type.
rear sprockets. Ten or twefve speed SHIFT LEVER FOR
These adjusting screws are used to
bicycles have two front sprockets. FRONT DERAILLEUR
<:enter the chain 91,,1 ide over each
SHIFT LEVER FOR sprocket. If the chain guides are not
CAUTION: Oon't force the .hlft lev.... centered, the chain will overshift or
AlwaY1 move iust one shift lever at a fail to seat properly on front sprockets.
time to avoid damaging the derailleurs. PROBLEM: Cannol 'hift into higher I QUICKSHI!!]
Shift levers should move easily and the gear, or lower gear (depending on make
chain should move easily from one of derailleur).
sprocket to another ~ Please observe 1. While rotating wheel with pedal.,
the following when shifting; pia"" shift lever for front d.railleur all
the way forward. For ltQu;ck Shift"
mod.ls: shift I"".r should be po.itioned
Reduce pedaUing pressure while sh.ft ADJUSTING
so the "9" appears in window. BARREL
lng.
2, Continue rotatIng wheel with
Shift only when pedals & wh.... are in CABLE
pedals, adjust low gear adjusting screw
motion.
until chain is eentered on small front
Nev.r pedal beckwardl whil. shifting
sprocket.
gears.
3. Loosen cable anchor nut.
Never force shift leven.
4. Pull end of cable wire and hold
taut while tightening cable anchor
nut.
OERAILLEUR
6. While rotating wheel with pedal.,
I FALCON FRONT DERAilLEUR I I SHIMANO FRONT DERAILLEUR I
SHIFT LEVER TENSION ADJUSTMENT
move shift lever beckw.rd. Chain should

~g~.=~"
....
shift to large front sprocket. For LOW"=seotW

di

It is necessary that proper friction be
maintained on the shift levers. If e~ther
the front or the rear derailleurs have a
tendency to shift while rjding~ you
should tighten the tension s~rews on
the shift I.v .... This will probably take
only a slight turn. If the tension screw
is too tight, the shift Iev.r will b. dif
ficult to operate and will not shift
smoothly.
ABOUT THE REAR DERAILLEUR
When the right lever is shifted, the
pull.y guide guid., or "d.rails" the
chain allOWing it to mow to a different
~ocket in the rear sprocket cluster.
The derailleur cage is UspringAoaded. u
It keepS the chain tight, but "gives"
as the chain moves from one sprocket
to another.
ABOUT THE FRONT OERAILLEUR
Even though it looks totally dif
ferent than the rear derailleUr, it also
moves the chain from one sprocket to
the other. Remember that the chain
must be in forward motion before
either derailleur can work properly.
"Quick Shift" models: shift lev.r
forward to "10". Chain should shift to
large front sprocket.
I! necessary, a fina adjustmant can
be made on the "'Quick Shift" by
turning the adjusting be"el 01\ shifter
or adjusting $Crew on front deraineur.
I!. On models Oilier than !he "Quick
Shift" a fin. adjustment can be made,
if _ r y , by turning the proper ad-
~~:J:~SCMN
*cM~'
MAlSnHC SCNW
0 ,.&;.~.'1lJ I
justlng screw on the front derailleur 7. The "".in guide shOuld derail !he
so the chain derail. onto the required chain to !he I."", or smaller sprocket,
sprocket. depending on tYpe of derailleur.

16 17
 ') }

5-10 or 12 SPEED REAR DERAILLEUR ADJUSTMENT POSITRON III REAR DERAILLEUR ADJUSTMENT

~\~
TOOLS REOUIRED TOOLS REOUIREO
6" ADJUSTABLE WRENCH
.6" ADJUSTABLE WRENCH ~eAR OERAlllEUR I MEDIUM SIZE STANDARD

MEDIUM SIZE STANDARD

~~-l
SCREWDRIVER

SCREWDRIVER

PLIERS
1. Rear wheel must be supported off
~or

B~jL I
your convenience, the 5, 10 or 12

the ground using a bicyde st;llm;, or

speed deraiHeur has been pre-adjusted

place bicycle upside down resting it on

at the factory; but, due to jarring in

the seat and handlebar. Cushion handle

shipment, it may need minor adjust
STEEL .
ments.

e rJ..O-"~"'lE "Ur .--.. I)J '&!IJrn-... bars to prevent damage to stem lIohifters
NOTE Always move JUS! One shift

AOJUSnw;.
and caliper brake levers.
2. Place shift lever for rear derailleur
~
.::~~
lever at a time to avoid damaging the
6MAf'l

deraille-vr. Please observe the following

all the way forward. The chain should

now be on the smalles.t sprocket "'high
I FIG. ci
precavt!ons '

LEV~R
/'~~'~'.
LOW GEM gear"
"'OJUS~C~fW
3. Check: that the steel ball IS per
Reduce pedaUing pressure while
H~HO~ /
fectly recessed il'\ the hole nearest to REAR
shifting.

AJ)JUSTlNQ SCAEW
the stopper on the dick plate {see ~.'~~
Shift only when pedals & whecis are tn
, / ' \\
mOfion.

Never back-pedal while shifting gears.

Fig. AJ. If it is not recessed properly

in the hote (Fig. 8). rnove the rear
lever handle back to")ow geal'a:'ld then
STOPPER 'L:. CLICK PLATE
Never force shift Ie vcrs.

return it to top gear again until the steet

ball is properly located,
NOTICE: If your model 1$ cQufppeu

NOTE.: The wire in the cable has a

with a Positron III rear derailleur or
REAR DERAILLEUR LEVER POSITIONS
tendency to stretch after the bicycle
a "Quick Shift", see the rear derailleur

has been ridden for a while. If there is

adjustment sections 10r those mr)dels.
LEVER FORWARD
too much slack:, the chain will not
transfer to all speeds. If the cab!e wire "HJGH GEAR"
Rear wheel must be supported ott
is not taut. conttnue with Step 4.
the ground lJsing a bicycle stand, or
4. Loosen the nut on the cable anchor
place bicycle upside down resting It on
bolt,
the seat and handlebar. Cushion handle
I FIG, 01
(
5, Pull end of cable wire taut with
bars. to prevent damage to s.tem shiftefs
pliers and hold taut while tightening
and c.allper brake levers
cable anchor nut.
P!')ce shift lever for rear derailleur lEVER DOWN
6, While rotating wheel with pedals, PULLEY
all {h~ way forward The chain s.hould NUr "lOW GEAR
move shift lever backward and forward GUIDE
now be on the s.mallest sprocket
slowly. As the shift lever is moved
"hIgh gear"
toward the rear, the derailleur movogs
Refer to rr.a. deralUiwr iHustratlons. "L" STROKE
toward the large fear sprocket "low
for it)car:ng Jdjustment pomts. on your gear': As the shift lever is moved for, ADJUSTING SCREW

(j
type .of derailleur wise direct,on, the pu\!ey 9'siuli' move~ ward, the derailleur moves toward the
3 Check for stack In cable a1 point 6 While rotatlOg wheel v,nth pedals. toward the larger stnorket "Iow( imall rear sprocket "high gear".
'A" and tightness. of the nut on the rnow~ shift lever backward and forward gear"po~!tion, (FIg. D1
7, With the rear deraiUeur rever for
cable anchOl bolt s.lowly, As the shift lever is moved 8. Set the rear deraillf'ur lever
ward in "high gear'; turn the "H" "high
toward the rear, the derailleur moves largest sprocket "!ow gear" P(}S!tIO"'"
gear, adjusting screw" until the' rear
NOTE The w.(e in the cable has a toward the large rear sprocket "low 9. Checl<. that the chai~ does not shp
derailleur puUey guide is in line under
umde:ocy to stre'tch after thf' bicycle gear". As the shift lever is moved tOt off the large sprocket.
the freewheet top gear,
'1{)S bt~n rjdden fot a while, ff there IS ward. the derailleur moves toward the 10, If so. turn the "L" "low gear"
"H" STROKE

too much slack, the chain will not ~mal! rear sprocket "high gear". adjusting screw in a clockwise direction
ADJUSTING SCREW

NOTE: When the "H" "high gear

tU!lI'S'fet to all speeds. It the cable wir, 7 With the rear dera!!leut lever for until the chain does not slip off ~hi!
adjusting screw" is turned in a clock t
not tallC continue with step 4 ward in high gear, turn the "H" "high larger sprocket when ~htftcd
wise direction the pulley guide moves 9. Check that the chain does not tall
<1 Lt'iosen the nut ,:m ihe cable an-;ho( gear adjusting screw" untd the ~ear 11. If the chain is unable to reach the
toward the larger sprocket "'ower off the large sprocket. 11. If the chain is unable to reach
bolt. derailleur pulley guide IS 'n line under largest sprocket "'ow gear", or move
ge.r" position, (Fig, D) 10, If chain does fall off. turn the ~'L" the largest sprocket "low gear", or
Pull end of cabli> ~vm? with pliers the freewheel top ge"r, rnent is difficult turn the "L" "1011'1
~"tow gear'" adjusting strew in a efockwise movement is. difficult, turn the "l"
.:Hld t'lold while tightening c2:ble anchor NC TE> When the "H" "high gear gear" adjusting screw in a COtJnwr
8. Set the rear derailleur lever to direction until the chain does not faU "tow gear" adjusting screw in a counter
"crt adjusting screw" Il turned in a clock clod, wise direction
largest sprocket "low gear" poisition off the larger sprocket \lVhen shifted. clockwise direction.

18 19

REAR DERAILLEUR ADJUSTMENT "QUICK SHIFT" MODELS
TO'pLS REQUIRED
MEDIUM SIZE STANDARD
SCREWDRIVER
PLIERS
Rear wheel must be supported off the
ground using a bicycle stand, or place
hicycle upside: down resting it on the
seat and handlebar. Cushion handlebars
Most tires can be remOWtl and replaced
to prevent damage to the "Quick
by hand; tires that cannot nlquire
Shift" lever.
if you are using t~re tools.
1. While rotating wheel with pedals,
shift: through all positions with $hift
lever. Observe reaf derailleur positioning
in all positions. (See illustration of rear
detent.1
2. Sh itt into sixth gear. (Position 6
of any kind on the rims 01 your bicycl
in window.) Loosen the cable anchor
bolt.
3. Shift into fifth gear. NOTE: 00
nOt shift from sixth to seventh gear.
cants.
4 Check, rear detent position and
verify that the derailleur is in the 56
detent. (See illustration)
frequently for adjustment of brakes
5. Pull end of oable with pliers end
hold whil. tightening cabl. anchor
bolt.
6. Check to see tnat derailleur is
work iog properly and that there is, no
chatter when chain Is engaged with a
sprocket on the freewheel. If there is
noise' when derailleur is in a particular
gear ~ correct this by using the center
adjusting screw. If d....illeur has trouble
moving from smaller sprockets to the
larger ones N'undershift," correct by
turning adjusting screw clockwise. If
derailleur tends to uovershift", move
toward largest. sprocket, oorrect by
turning adjusting screw c:ounterclock~
wise.
7. No maintenance is required on the
''Quick Shift" other than the rep'ace~
ment of damaged or broken control
wire or cable.
1
I MAINTENANCE
Your bicycle will require regular main~
tenance. Although simple in most
cases, there .re t,mn when the repairs
and adjustments take speeial knowledge
and proper toots, We recommend that
when service is required you should
have a quaHfied bicycle repairman do
it for you,
RECOMMENDED GENERAL
MAINTENANCE SCHEDULE
r- -] To matntatn the original brilliant patnt
eo: and chrome finish, keep your
"DETENT POSITION"' bicycle cl.an and dry. Wipe off dirt.
SHOWN IN 5--6 GEAR
moisture and oil with a clean~ soft cloth.
POSITION.
Periodically, polish with a clear coat of
wax.
WARNING: Do not u. . . Wa>( polish
2. Place chain on small sprocket.
In orde# lor the caliper brakes to 3. Position axle in rear fork slots and
ope.ate pt'Operl", the ,ims should be release derailleur.
ieept clean and f,ee of dirt and lubri 4. InstaU serrated washerS on both
sides of axle with serrations against
frame. Thread axle ruts onto ends of
Due to wear of new parts, we
REAR CLUSTER
axle hand tight. hand.
recommend that you inspect the bicycle
GEAR LOCATIONS
l
brackct and tighten right side axle lIut.
-:-!-. bearings, wheels. etc. Adjust or tighten
nuts and screws. The frequency of
am
left side axle nut.
inspection would depend on how much
7. Reinstall brake shoes. if removed.
and how hard you ride. NormaUy, we
NOTE: Check rear brake for prope'
recommend a service check at Jeast
7-. 9-'10
annual'ly. Any component that does not
function properly should be checked
and corrected immediatety. If you do
not feel qualified to make the adjust~
ment, we reeommend that you take
,your bicycle to a ~uafified bicycle
repairman.
REAR WHEEL REMOVAL
TOOLS REQUIRED
6" ADJUSTABLE WRENCH
1, Place bl(;vcle upside down, resting
it on the seat and handlebars. Cushion
handlebars to prevent damage to stem.
shifters and caliper brake levers,
2, if necessary. remove one caliper
brake shoe to aUow dearar.ce for
wheel remoyal.
3. Shift chain "nto small sprocket.
4, Remove axle nuts and washers
from both sides of axle.
20
5. Pivot der.tUeur to rear of bicycle.
GUide wheel out of frame and remove
chain from sprocket.
6. Remove Wheel from frame. R.
lease derailleur.
REAR WHEel INSTALLATION
TOOL REQUIRED
.6" ADJUSTABLE WRENCH
REAR AXLE NUT
Recommended torque is 276 in. Ibs.
1. Pivot derailleur to rear of bicycle.
GUtde wheel into rear fork slots whh
sprockets on the wheel on same side
as chain.
7. Whil. holding tire with one hand.
peel tire off 01 whee! rim with othe,
S. Position rtgbt side of axle against
6. Center wheel in frame and tighten
2. Insert tire valve stem into ho'e in
adjustment,
FRONT WHEEL REMOV IL
TOOL REQUIRED
.6" ADJUSTABLE WRENCH
1. Place bicycl. upside down, resting
it on the seat and hendl.ban. II neces
sary, remove one c~diper brake shoe to
allow clearance for wheel removal.
21
I
2. Remove a.!. nuts and. depending
on your model, washer retainers or ax'e
nuts. washers and whet retainers.
a. Remove wheel f,om fork.
NOTE: To ....mbl. front wheel to
fork, see front Wheel ....mbly section.
TIRE REMOVAL
special tools. Be careful; pinching the
tire tube can easily.. put a hole in it even
1. Remov. valv. stem cap.
2. Rele_ air Irom tire by depressing
val.. stem.
3. Tir. shouk! be loose in th. rim.
4. Place wheel on floor.
5. Grasp ti,e with thumbs and fingers
of both h..icls.
6. Lift tire and slide o..r one ,ide of
rim.
TIRE INSTALLATION
1. Position tube inside of tire casing.
rim.
3. With tube inside ti,e casing, roll
tlr. casing onto the rim. Be .careful not
to pinch tube, and be su,e III. tube i.
not twisted in the tire.
4. Hold val.. stem whil. inflating tire
to pressure spec:ffied on side of tire.
TIRE INFLATION
TOOLS REQUIRED
HAND PUMP
TIRE GAUGE
It is norma' for tires to lose air due to
the porOSitY of the materials. Main
tain proper tire pressure. UnderinfJa
tad ti.... incr.... the chance for blow
outs. Check air pressure with- a gauge, If
you don't have one, pind:l tire between
the thumb and forefinger; the tire
should f, firm. The ti,. shape should
remain constant. If the dre changes
shape lit the point 01 contact with the
ground while ,iding, the tire needs
lir. The correct tire pressure is marked
on the side 01 the tire. DP NOT
OVERINFLATE.
CONnNUEO NEXT PAGE ~

SEATING TIRE
After repairing or changing the tires
touehes rim, sPokes on same side as
tt is important that the tire is seated
marks must be loosenf!d by turning in
properly on the rim.
CQunten:;loc:kw;ise directton. Spokes on
1, Run your fingers around the bead
opposite side of mark must be tight
of the trre to insure it is inside the outer
ened. Adjust spokes (w,ith spoke
rim ridge.
wreneh) on mark and four spokes on
2. Partially inflate the tire with a
hand pump.
WARNING: It is not recommended to
use a gas station~s air pump. The high
air preuure of the pump can cause you
to blow out your tires and tubes if not
properly used.
3. Inspect the tire ((') see that ia}
valve stem is perpendicular to the rim;
(bl tire bea,a is property. seated inside
the rim; (c) spin tire to see if it is
aligned straight on the rim.
BEAI:) NOT SEATED OR OFF,RIM
Deflate tire, seat bead with hands and.
partially inflate t~re for insPection.
It the bead is properly seated. innate
to recommended pressure.
TIRE NOT ALIGNED
Partially defiate tire. align usi"'~~ hands.
Inflate tire to recommended pressure.
TI'RE AND TUBE DAMAGE
To prevent tire cuts, ruptures, rim
bruise and star breaks, avoid rough
streets and alleys having glass and other
debris. Don't jump curbings, Crooked
wheels cause chafing of tires as well as
uneven treadwear. Skidding stops de
crease the life of the tire due to uneven
wear of tread To prevent distorted tire
casings, hang your bicycle up or turn it
upside down when storing for long
periods.
TRUEING WHEEL
(ADJUSTING SPOKES)
TOOLS REOUIRED
SPOKE WRENCH
FELT MARKER
STANDARD SPOKE WHEEL ONLY
We suggest spoke adjustments be MADE
BY A QUALIFIED BICYCLE REPAIR,
MAN,
1. Place bicycle upside down.
2. To check, hold a felt marker at
fork leg approximately 1,6mm 11/16'"
from. rim and spin wheel. If marker
ened or tightened by rotating the adjus
t ing cone by hand.
, . Loosen the lock nut and turn the
adjusting (:One to desired tension_
2, Hold adjusting eone with channel
locks to prevent it from moving while
each side of mark. If distance still
varies, repeat above procedure. If
problem continues, see bieyele repair
1T\aI1,
BEARING ADJUSTMENT
There are several areas on your bicyele
containing bearings that must be adjus
ted andlor lubrieated. Proper main
tenance in these areas will fnsure longer
bearing life.' easier ~nd safer riding of
your bieycte. Proper adjustment of
these bearings requires special tools and
knowledge. We suggest these adjust
ment, be MADE BY A QUALIFIED
!'lEAR WHEEL
REPAIRMAN, The following para'
graphs give procedures for checking to
see if bearings need adjusting.
HEAD BEARING CHECK
TOOLS REQUIRED
10'" ADJUSTABLE WRENCH
CHANNEL LOCKS
ADJUSTING
CONE
BALL
BEARING
BEARING CUP
To check this area, just lift up on
handlebars at handgrip area. In doing
this, there should not be any play of the
handlebar stem and fork within the
frame's head, The handlebars must be
able to turn easily. If there is play.
adjust as follows:
22
71 '\
)
NOTE: Steering tension can be loos bicYcle repairman. Caliper brake cables
should be removed from housing and
greased. Clean and lubricate whef:l<1
bearings. head bearings. and crank
bearings. <:.Meek spokes and wheels and
have trued if out of fine.
NOTE: Due to complexity of the rear
tightening the locknut, whee! seetion, we recommend the
rear wheel bearings be adjusted or
WHEEL B A RING CHECK 8< lubricated by a qualified repairman. BEARING LOCATIONS AND COMPONENTS
ADJUSTMENT
TOOL REQUIRED
6" ADJUSTABLE WRENCH
80th the front and rear wheels have
bearings and are clleeked In the same
manner, The wheel should be held off
rACE aA.ll 8EAAtN;;.S
the ground to see if it rotates freely and 1"':0 CuP
easily. Cheek for :iide-play at the wheel's '-----HEADCUP
rim, There should only be a traee of HaID OF FRAME
side-play. If wheel has excessive side ----HEADCUP
play:
BEARINGS
1, Loosen left hand axle nut and
FACE eA.l.l BEA.AII\IGS
II\o:lOLuP
adjust left hand cone.
2. Center wheel in f!~;lle and tighten ~OWER
srAllOHAIIY
reft hand axle nut,
---FOIlK
CRANK 8EARING CHECK
The crank bearings are checked by
holdIng one end of the crank arm and
trying to move it from side to side,
Just a trace of side movement should
be felt. The crank should turn very
freely and easity. If crank is tight or
has too mUCh play, have an adjustment ICRANK ArnNGS I
made, CRANK
AO.l H I J T - - - - - ,
AXLE
LU8RICATION AND CLEANING WASHER-----~
HUB SNEll
WARNING: 00 not Uie a ve~~table 4J"-'--- SEARING & RETAINER
Q . CONE AND DUST CoVER
base oil to lubricate bicycle parts. This
~ WHEEL AETAINER
type of ail may dry and leave a harmful ~ WASHER
gum residue. AXLE NUT
wEEKl Y Wipe bicycle clean with
cloth MONTHLY Wipe bicycle with CR_CUP I _
damp cloth. Wt(Je dry., Polish metal
surfaces. On caliper brake models, do
not polish nms. Make o;;ure no oil gets BEARING &
on caliper brake shoes, With spray RETAINER
LOCK YOUR BICYCLE
lubricant, lubricate charn and rea(
sprocket. On caliper brake rnodels, There are many ways to lock your
lubricate hand brake lever cable pivot bicyde. To proyide maximum protec.
tion for your bicycle~ you should use
points, Wipe seat With damp cloth and
a good chain and loek, You ,hould
wipe dry ANNl"ALL Y: The fallowing
wrap the chain through the frame and
components require lubrication, remo",'
ai, disassernbiy, inst;40ation, speeia! the rear whee' and around a station~
tOOls and know!~dge, It IS suggested that ary post or $imilar objeet. Make sure
this service be penormed by a qualified vour lock is attached to the chain
properly and fullv closed,
23