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

PAGE
PAGE SAFETY CHECK LIST . ... 14
RULES OF THE ROAD - SAFETY TIPS , .. . ... 2 '2 CHANGE ANO 3SPEED ADJUSTMENT. , . . . . . I.
Thrcughout this manual you will adjustments for proper operation, The uses the bicycle has been fully 10'
OWNER'S INFORMATION & RESPONSIBILITY. . .3 CALIPER BRAKE ADJUSTMENT. , ..... 15 find WARNINGS, CAUTIONS and owner or prindple ridet is then respon~ structed in Its operation.
SAFETY WARNINGS. . . . .3
HOW DERAILLEURS OPERATE. . . . . . . . . '6
NOTES or NOTICES. sible for normi maintenance of the 5. Your bicycle conforms to all
BICYCLE PARTS IDENTIFICATION. , . . .4 SHIFT LEVER TENSION ADJUSTMENT. . .16 WARNINGS: Pay .pecial attention bicycle to keep it in good operating Federal CPSC regulations, There may be
SELECTING THE CORRECT FRAME SIZE . . . .4 to these since failure to do so could condition. other federat state or local regulations,
UNPACKING. . . . . ,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
TOOLS REQUIRED FOR ASSEMBLY .s CAUTIONS: If not followed. the,e instrl.letions and necessary adjustments fqre, you should make sure your bicycle
STEP I FRONT FENDER ASSEMBLY. . .5 could result in mechanical failure or have been followed. compties with all applicable regulations
,IB
STEP 2 FRONT WHEE L ASSEMBLY. .6 damage . 2. Perform the safety check list and before it is ridden.
STEP 3 KICKSTAND ASSEMBLY .. .6 POSITRON III REAR DERAILLEUR ADJUSTMENT ,19 NOTES or NOTICES: These specify mark each item listed. 6~ rf your bicycle was obtained
STEP 4 STEM ASSEMBLY .6 something that is of speCial interest, 3. Know how to oper,te all standard assembled, "we recommend that you
OERAILLEUR ADJUSTMENT
STEP 5 HANDLEBAR ASSEMeLY 7 It is the r~$ponsibility of the person and accessory equipment on the bicyCle. review the complete assemblY instruc
, . . . . 20
STEP 6 PEDAL ASSEMBLY... ..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
STEP 7 SEAT ASSEMBLY . . . . . , .s .21
STEP B FOAM "SLIP ON" GRIP ASSEMBLY ..S .21
.1'
STEP 9 HAND BRAKE LEVER ASSEMBLY .. .9 , ..... 2
. 21
STEP 10 HANDLEBAR TAPING. . . ... 10 21 SAFETY WARNINGS
STEP 11 EXTENSION LEVER ASSEMBLY . . . . . . 11 22
. . . . . . . . . 22 Before you ride, please read all the
STEP 12 CABLE TIE ASSEMBLY .... 12 .22 following items making sure you under the bottom of a hill could force 'IOU be allowed to ride a bicycle at night and
STEP 13 REFLECTOR ASSEMBLY . . . . . 12 22
Front and Rear Reflector . . . . . . . . . , , . 12 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.
Wheel Reflector . . . . . . . . . . . , .. , . , , .13 to yourself or others, 5. Use the front brake slowly and H . It is a good idea day or night
Clip-on Reflector. . . . . . , . . . . . . , .. 13 BEAR ING LOCAnONS AND COMPONENTS. 23
ScrewOn Refleetor. . . . . . . . . . , , . . . . . . . 13 LOCK YOUR BICYCLE ,23 Yovr bicycle meets or exceeds carefully, especially while turning or to wear a helmet and have a rear view
Bolt-Qn Reflector. , . .. , .. , .. ,' , . . . . . 13 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 UU) 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
1. IN THE INTEREST OF SAFER 6. REPLACE bent or BROKEN a safe manner.
will reQUire more distance to stOp. the fOf'k stem body. This could cause
CYCLING, MAKE SURE YOU READ spoke, and bent or dam~ged wheel 12. BE CAREFUL AT ALL INTER an unsafe condition and risk of injury
Start braking sooner than normal in
AND UNDERSTAND YOUR rims. SECTIONS. Slow down and look both Do not ride the bicycle until you
wet conditions. to the rider.
OWNER'S MANUAL. 7. OBEY ALL TRAFFIC REGULA ways before crossing. have checked for proper brake adjust
6. NIGHTIME RIDING: 8 For safe oM;ration, the handlebar
2. NOTICE: Some state and local TIONS. Mo.t traffic regulation, apply 13. USE HAND SIGNALS. Alway' let ments. See "Hand Brake Lever As
A You can't see the controls on stem bolt and clamp nut mutt be
laws may require that your bicycle be to bike riders as well as automobile other drivers and pedestrians know sembly" and "Caliper Brake Adjust
your bieycle at night sO you must know securely tightened.
equjpped with a warning device such operators. what you are gOillg to do. Signal 100 It. ment" sections,.
whete they are by touch. 9 For safe operation, you must
as a horn or beU and a light, it the 8. KEEP TO THE RIGHT. Follow before turning unless your hand is 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
bicyde is to be ridden atter dark. the traffic flow in 8 straight line close neOOOO to control the bike.
are much harder to see at night the crank arm with a wrench that fits
3. ALWAYS WEAR SHOES when to the curb. Watch for cars m()'ling in 14, HAVE PROPER LIGHTS AND speed on a large fevel surface without
C If possible, ride on streets the shoulder of the pedal spindle. This
riding a bicycle and AVOID loose fitting and out of traffic. REFLECTORS. Nevor ride at night obstructtons, Also, never attempt to
that are familiar to Y9u. Terrain that is: rrr.portant; it avoids stripping thread$.
clothing. 9. without a white front reflector and stop suddenly vsing the front brake
you have nevet seen during the day fS Always replace damaged pedais,
4. CHECK YOUR BRAKES FRE a is headlight, a red rear reflector and only, zs this could throw the rider off
dangetous at night. 10, When adjusting the seat height. you
QUANTLY. The ability to stoP your acceptable if used s.tely. whee! rd!ectorS, Other devices, I ike the tront of the bicycle,
E Use well lighted streets when must have .the minimum insertion mark
biC'(de is CRITICAL. Roads are SLIP 10. "HEN RIDING IN PAIRS or in +Iags and reflective tape, also holp you 3 Check and adjust the brake" if
ever possible. Avoid unlighted bike on the seat post remaining inside the
PERY in wet -mer so AVOID large groups, form a .ingl" line along become more yisibfe. nCCf'ssary, at the first s~gn of failure.
path, frame.
sharp turns and allow more distance the right side of the road. Set up a .en 15. DO NOT CARRY PACKAGES Or This will enable the rider to make a
OBJECTS whieh obstruct vision, reo qvick and smooth stop. Cn caliper
r: Comply with aU legal reQuire,
for stopping. sible di.tance betwllen riders. DON'T ments ill your state. You should at least
Caliper brakes may become I... TAILGATE. strict (:OntrOI or eould get entangled brakes, if a brake lever touches the
have a "white L;ght", (nOt just a white
efficient when _t. leaves, Ioo$e 11. ALWAYS BE ALERT. Animal. or in the spokes. grip when it is squeezed, ad;ust the
reflector), on the front and a rear red
growl and o",",r debris on the road can peol)!e may dert in front of you. Be on 16. NEVER HITCH RIDES. N.....r hold brakes,
reflector. All states require that a
also affect SlOPPing distance. the ALERT-people haw the right onto a moving whicfe while riding. 4, Going downhiU fast is dangerous
lamp be used that emits a INhite light
5. The kickstand is designed to of-way. Be ALERT to people opening Never ustunt". since YOll can't stop nearly as fast as
G Children generally should not
support the bicyde only, not bicycle doors when passing perked cars. Your 17. AVOID the following HAZARDS; you can on level ground. '" curve at
and rider. bicyde was not designed for stunting drai~, pot holes, ruts, soft road
and experimentation. Enjoy riding it in edgn. grow" sand and 1 _ especiol 3
1'1' when they are wet.
:2
 ")
.")

[ BICYCLE PARTS IDENTIFICATION

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

SEAT
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 , " ~~~" ~
REAR CALIPER BRAKE - - -..... hub parts and true wheets. Special
tools are not required for assembly a"d
.~:v ~
REAR FREE WHEel CALIPER BRAKE normal maintenance.
ASSEMBLY 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

REAR

DERAILLEUR
TOOLS REQUIRED

.6" ADJUSTABLE WRENCH

'''laUREAI
CHAIN
MEDIUM SIZE STANDARD
SCREWDRIVER
FRONT DERAilLEUR

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

The correct frame si]e ts: the largest

frame that the rider can comfor'.ably
.If;
'v
Ir....'

'?\ ..
~ (1 ~)
01~
p~
Hot Less Than 1 Inch
dccordingly.

[FIGURE AI
FRONT FENDER

straddle keeping both feet flat on the (WITHOUT CALIPER BRAKEI

IIE:~
ground and aUowfng 2SAmm (1 inch)
clearance between the rider's crotch I. With the fork turned lorw.rd. lean
Il \, -"i: \ the bicycle against a surface wall,

L/lJ! It
and the top of the frame tube. tSee
illustration). 2. Remove nUl. lockwamer and
NOTE: Ladies can use man's bike to
determine their correct frame 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.
IMPORTANT: Remove the bicycle .nd RECORD All INFORMATION ON RECORD SERIAL NUMBER lOCAT 4. Fasten fender using mounting bort~
MOUNTING
aU parts from the carton. lay out aU LABEL LOCATED AT BOTTOM OF ED ON THE SIDE OF HEAD TUBE; tockwas:her and nut just removed,
BRACKET
Ihe un.....mbled parts .nd READ THE SEAT MAST. OR ON REAR PLATE; OR ON THE
BOTTOM OF CRANK HOUSING. (F fG1JREJi]
ASSEMBLY INSTRUCTIONS in this
booklet before assembting your bicycle, (FENDER BRACKET MOUNTED

The instructions .re STEPBYSTEP WITH CALIPER BRAKE I

ptocedure. Follow the steps that pertain

1. With the fork turned forward, lean
to your modet.
the bieycle against. w.U.
NOTE: Your bicYcle may be equiPP<'d
CRANK _REAR 2. Re(Jl()W two self-tapping screws
w~th a different style component than
HOUSING PLATE .nd lockw.she" from the fender IIFIGURE CI
the one itlustrated. However, the
mounting bracket, the bolt on caliper brake.
procedure for aswmbly or adjustment (FENDER BRACKET NOT MOUNTEDI
3. With the ohmt p.rt of fender facing 3. With the short part 01 tender f.clng
is basically the same,. 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
WARNING: If you' bicycle wao 0b structions. and perform checks spHi
SERIAL NO. _ _ _ _ _ _ __
.elftapping scr...., 2. Remove IoekwIsl1er and nut f,om a.,..,. Ind tighten nut JecurelV.
tained anembled. we recommend that 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 MAINTAIN CLEARANCE HERE Normally ~ the (front lever) is mounted
It is important to become familiar with
6" ADJUSTABLE WRENCH
on left side of hand lebar and (rear lever)
the use of hand brakes. When properly WARNING: Keep brakes in proper
adjustment. Always ,apply brakes with

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

4, Position top of seat parallel wJth you r.1ust have the minimum insertion loose. retighten the nut. mOl,lnting screw/s.
Bump on with the palm of your hand or
the ground. Serrations on seat clamp line on seet post remaining inside the 8. Tap a plastic cap onto end of bolt any suitable device such as a mallet NOTE. FERRULE MUST BE SEATED
must mesh completely with seat frame frame. 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. overlap_ you soak the plugs in wa(m water. 5, lI'st311 and tighten the mounting
BRAKE
S. When you reach the end of handle
bar. push remaining tape msKJe the end
6. Insert handlebat plug into end of
handlebar. Thi, will lasten the tape 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
-~ 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 ~.~
rear bracket.
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
1. Position locating pin and mounting 2. Fasten using a wing nut or lock 3. Tighten wing nut untit reflector is match that of wheel rim. 4. Securely tighten bolt.
pin (or bolt) into slot in front of moun washer and nut onto mounting pin secure. If lockwasher and nut are used. NOTE: The reflector should fit firmly 5. Repeat same procedure to mount
ting bracket. lor bolt). tighten nut securely. between a single spoke on one side and rear wheel reflector.

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

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

BRAKE
angle must align with the small tab SHOE
PLIERS
on the bell crank assembly. (See Fig C)
NOTE: For STURMEY ARCHER 1. Turn adjusting barrel clockwise 6. Jf the brakes do not release evenly.
AW to be properly adjusted, the end of until it bottoms out then back it off loosen mounting bolt and adjust desired A ~."\~:w:-.:.u:{[LL::::::::==--:I
the indicator rod must be flush with 1 1/2 or 2 turns. amount then securely tighten mounting
the end of rear axle, {See Fig. Dl
2. For STURMEY ARCHER AW,
2. Loosen cabfe anchor nut.
3. Squeeze brake legs to!J"ther and
bolt. .. (""'"\:.~~=.{[::;: ===::1
loosen adjusting barrel locknut, hold so brake shoes remain against rim. WARNING: Th. mounting bolt and nut en-.~~'~~'~_~,.,::J
LocKNUT
loosen or tighten adjusting barre! Tie with a cord. mult be secure so as to maintain proper
to obtain proper adjustment. (See 4. Pull dow~ on end of cabl. wire braking and continued ..f. cycling.
o fJ=."'""=====<:.::n::.:.:.:----'
above NOTES,) with pli.rs and hold whil. tighlening
If the previous steps were followed 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-"~-----,
and proper adjustment does. not exist. CAUTION: A >tOW hub should be 5. Spin tho wheel. Tho brake shoes hanger is held in position by the seat
make a further adjustment by continu 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
ing with part 3. 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
3. Turn adjusting barre! clockwise 6. Perform step number 2.
should be added every month. Use fine adjustment. and safe operation. cable and casing assemblies,
approximately 12.7mm (1/2 inch) Tighten adjusting barre! ~ocknut
securely SA E 30 motor cil.
of threads are showing, 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 ABOUT THE REAR DERAILLEUR "Quick Shift" models: shift lev.r ~~:J:~SCMN
maintained on the shift levers. If e~ther forward to "10". Chain should shift to *cM~'
MAlSnHC SCNW
the front or the rear derailleurs have a When the right lever is shifted, the ABOUT THE FRONT OERAILLEUR large front sprocket.
tendency to shift while rjding~ you pull.y guide guid., or "d.rails" the I! necessary, a fina adjustmant can
should tighten the tension s~rews on chain allOWing it to mow to a different Even though it looks totally dif be made on the "'Quick Shift" by 0 ,.&;.~.'1lJ I
the shift I.v .... This will probably take ~ocket in the rear sprocket cluster. ferent than the rear derailleUr, it also turning the adjusting be"el 01\ shifter
only a slight turn. If the tension screw The derailleur cage is UspringAoaded. u moves the chain from one sprocket to or adjusting $Crew on front deraineur.
is too tight, the shift Iev.r will b. dif It keepS the chain tight, but "gives" the other. Remember that the chain I!. On models Oilier than !he "Quick justlng screw on the front derailleur 7. The "".in guide shOuld derail !he
ficult to operate and will not shift as the chain moves from one sprocket must be in forward motion before Shift" a fin. adjustment can be made, so the chain derail. onto the required chain to !he I."", or smaller sprocket,
smoothly. to another. either derailleur can work properly. if _ r y , by turning the proper ad- 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
 1
REAR DERAILLEUR ADJUSTMENT "QUICK SHIFT" MODELS
I MAINTENANCE I
TO'pLS REQUIRED Your bicycle will require regular main~ 5. Pivot der.tUeur to rear of bicycle. 2. Remove a.!. nuts and. depending
MEDIUM SIZE STANDARD tenance. Although simple in most GUide wheel out of frame and remove on your model, washer retainers or ax'e
SCREWDRIVER cases, there .re t,mn when the repairs chain from sprocket. nuts. washers and whet retainers.
PLIERS and adjustments take speeial knowledge 6. Remove Wheel from frame. R. a. Remove wheel f,om fork.
and proper toots, We recommend that lease derailleur. NOTE: To ....mbl. front wheel to
Rear wheel must be supported off the when service is required you should fork, see front Wheel ....mbly section.
ground using a bicycle stand, or place have a quaHfied bicycle repairman do
REAR WHEel INSTALLATION TIRE REMOVAL
hicycle upside: down resting it on the it for you,
seat and handlebar. Cushion handlebars TOOL REQUIRED
Most tires can be remOWtl and replaced
to prevent damage to the "Quick RECOMMENDED GENERAL
.6" ADJUSTABLE WRENCH
by hand; tires that cannot nlquire
MAINTENANCE SCHEDULE
Shift" lever.

r- -] To matntatn the original brilliant patnt REAR AXLE NUT

special tools. Be careful; pinching the

tire tube can easily.. put a hole in it even
eo: and chrome finish, keep your Recommended torque is 276 in. Ibs.
if you are using t~re tools.
"DETENT POSITION"' bicycle cl.an and dry. Wipe off dirt.
1. While rotating wheel with pedals, SHOWN IN 5--6 GEAR 1. Remov. valv. stem cap.
shift: through all positions with $hift moisture and oil with a clean~ soft cloth. 1. Pivot derailleur to rear of bicycle.
POSITION. 2. Rele_ air Irom tire by depressing
lever. Observe reaf derailleur positioning Periodically, polish with a clear coat of GUtde wheel into rear fork slots whh
val.. stem.
in all positions. (See illustration of rear wax. sprockets on the wheel on same side
3. Tir. shouk! be loose in th. rim.
detent.1 WARNING: Do not u. . . Wa>( polish as chain.
4. Place wheel on floor.
2. Sh itt into sixth gear. (Position 6
of any kind on the rims 01 your bicycl 2. Place chain on small sprocket.
5. Grasp ti,e with thumbs and fingers
in window.) Loosen the cable anchor
In orde# lor the caliper brakes to 3. Position axle in rear fork slots and
of both h..icls.
bolt.
ope.ate pt'Operl", the ,ims should be release derailleur.
6. Lift tire and slide o..r one ,ide of
3. Shift into fifth gear. NOTE: 00
ieept clean and f,ee of dirt and lubri 4. InstaU serrated washerS on both
rim.
nOt shift from sixth to seventh gear.
cants. sides of axle with serrations against 7. Whil. holding tire with one hand.
4 Check, rear detent position and
frame. Thread axle ruts onto ends of peel tire off 01 whee! rim with othe,
Due to wear of new parts, we
verify that the derailleur is in the 56 REAR CLUSTER
axle hand tight. hand.
recommend that you inspect the bicycle
detent. (See illustration) S. Position rtgbt side of axle against
GEAR LOCATIONS
frequently for adjustment of brakes l
TIRE INSTALLATION
5. Pull end of oable with pliers end
brackct and tighten right side axle lIut.
hold whil. tightening cabl. anchor

-:-!-. bearings, wheels. etc. Adjust or tighten

nuts and screws. The frequency of
6. Center wheel in frame and tighten 1. Position tube inside of tire casing.

am
bolt.
left side axle nut. 2. Insert tire valve stem into ho'e in
inspection would depend on how much rim.
6. Check to see tnat derailleur is
7. Reinstall brake shoes. if removed.
and how hard you ride. NormaUy, we 3. With tube inside ti,e casing, roll
work iog properly and that there is, no
NOTE: Check rear brake for prope'
recommend a service check at Jeast
chatter when chain Is engaged with a

sprocket on the freewheel. If there is 7-. 9-'10

annual'ly. Any component that does not
function properly should be checked
adjustment, tlr. casing onto the rim. Be .careful not
to pinch tube, and be su,e III. tube i.
noise' when derailleur is in a particular not twisted in the tire.
and corrected immediatety. If you do FRONT WHEEL REMOV IL 4. Hold val.. stem whil. inflating tire
gear ~ correct this by using the center
not feel qualified to make the adjust~ to pressure spec:ffied on side of tire.
adjusting screw. If d....illeur has trouble
ment, we reeommend that you take
moving from smaller sprockets to the TOOL REQUIRED
,your bicycle to a ~uafified bicycle TIRE INFLATION
larger ones N'undershift," correct by
repairman. .6" ADJUSTABLE WRENCH TOOLS REQUIRED
turning adjusting screw clockwise. If
HAND PUMP
derailleur tends to uovershift", move
TIRE GAUGE
toward largest. sprocket, oorrect by
REAR WHEEL REMOVAL
turning adjusting screw c:ounterclock~
It is norma' for tires to lose air due to
wise.
TOOLS REQUIRED the porOSitY of the materials. Main
7. No maintenance is required on the

6" ADJUSTABLE WRENCH tain proper tire pressure. UnderinfJa

''Quick Shift" other than the rep'ace~

tad ti.... incr.... the chance for blow

ment of damaged or broken control

1, Place bl(;vcle upside down, resting outs. Check air pressure with- a gauge, If
wire or cable.

it on the seat and handlebars. Cushion you don't have one, pind:l tire between
handlebars to prevent damage to stem. the thumb and forefinger; the tire
shifters and caliper brake levers, should f, firm. The ti,. shape should
2, if necessary. remove one caliper remain constant. If the dre changes
brake shoe to aUow dearar.ce for shape lit the point 01 contact with the
wheel remoyal. 1. Place bicycl. upside down, resting ground while ,iding, the tire needs
3. Shift chain "nto small sprocket. it on the seat and hendl.ban. II neces lir. The correct tire pressure is marked
4, Remove axle nuts and washers sary, remove one c~diper brake shoe to on the side 01 the tire. DP NOT
from both sides of axle. allow clearance for wheel removal. OVERINFLATE.
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21 CONnNUEO NEXT PAGE ~
 71 '\
)

SEATING TIRE from. rim and spin wheel. If marker NOTE: Steering tension can be loos bicYcle repairman. Caliper brake cables
After repairing or changing the tires
touehes rim, sPokes on same side as ened or tightened by rotating the adjus should be removed from housing and
tt is important that the tire is seated
marks must be loosenf!d by turning in t ing cone by hand. greased. Clean and lubricate whef:l<1
properly on the rim.
CQunten:;loc:kw;ise directton. Spokes on , . Loosen the lock nut and turn the bearings. head bearings. and crank
1, Run your fingers around the bead
opposite side of mark must be tight adjusting (:One to desired tension_ bearings. <:.Meek spokes and wheels and
of the trre to insure it is inside the outer
ened. Adjust spokes (w,ith spoke 2, Hold adjusting eone with channel have trued if out of fine.
rim ridge.
wreneh) on mark and four spokes on locks to prevent it from moving while NOTE: Due to complexity of the rear
2. Partially inflate the tire with a each side of mark. If distance still tightening the locknut, whee! seetion, we recommend the
hand pump. varies, repeat above procedure. If rear wheel bearings be adjusted or

WARNING: It is not recommended to

problem continues, see bieyele repair WHEEL B A RING CHECK 8< lubricated by a qualified repairman. BEARING LOCATIONS AND COMPONENTS
1T\aI1, ADJUSTMENT
use a gas station~s air pump. The high
air preuure of the pump can cause you
BEARING ADJUSTMENT TOOL REQUIRED
to blow out your tires and tubes if not
There are several areas on your bicyele 6" ADJUSTABLE WRENCH
properly used.
containing bearings that must be adjus
80th the front and rear wheels have
3. Inspect the tire ((') see that ia} ted andlor lubrieated. Proper main
bearings and are clleeked In the same
valve stem is perpendicular to the rim; tenance in these areas will fnsure longer
manner, The wheel should be held off
(bl tire bea,a is property. seated inside bearing life.' easier ~nd safer riding of rACE aA.ll 8EAAtN;;.S
the ground to see if it rotates freely and 1"':0 CuP
the rim; (c) spin tire to see if it is your bieycte. Proper adjustment of
easily. Cheek for :iide-play at the wheel's '-----HEADCUP
aligned straight on the rim. these bearings requires special tools and
rim, There should only be a traee of HaID OF FRAME
knowledge. We suggest these adjust
side-play. If wheel has excessive side ----HEADCUP
BEAI:) NOT SEATED OR OFF,RIM ment, be MADE BY A QUALIFIED
play:
!'lEAR WHEEL
Deflate tire, seat bead with hands and. REPAIRMAN, The following para' BEARINGS
1, Loosen left hand axle nut and
FACE eA.l.l BEA.AII\IGS
partially inflate t~re for insPection. graphs give procedures for checking to II\o:lOLuP
adjust left hand cone.

It the bead is properly seated. innate see if bearings need adjusting.

2. Center wheel in f!~;lle and tighten ~OWER
to recommended pressure. srAllOHAIIY
reft hand axle nut,
HEAD BEARING CHECK ---FOIlK
TIRE NOT ALIGNED CRANK 8EARING CHECK
Partially defiate tire. align usi"'~~ hands. TOOLS REQUIRED The crank bearings are checked by
Inflate tire to recommended pressure. 10'" ADJUSTABLE WRENCH holdIng one end of the crank arm and
CHANNEL LOCKS trying to move it from side to side,
TI'RE AND TUBE DAMAGE Just a trace of side movement should
To prevent tire cuts, ruptures, rim be felt. The crank should turn very
bruise and star breaks, avoid rough freely and easity. If crank is tight or
streets and alleys having glass and other
debris. Don't jump curbings, Crooked
has too mUCh play, have an adjustment ICRANK ArnNGS I
made, CRANK
wheels cause chafing of tires as well as AO.l H I J T - - - - - ,
AXLE
uneven treadwear. Skidding stops de LU8RICATION AND CLEANING WASHER-----~
HUB SNEll
crease the life of the tire due to uneven
wear of tread To prevent distorted tire
WARNING: 00 not Uie a ve~~table 4J"-'--- SEARING & RETAINER
Q . CONE AND DUST CoVER
casings, hang your bicycle up or turn it ADJUSTING base oil to lubricate bicycle parts. This
~ WHEEL AETAINER
upside down when storing for long CONE type of ail may dry and leave a harmful ~ WASHER
BALL
gum residue. AXLE NUT
periods.
BEARING wEEKl Y Wipe bicycle clean with
TRUEING WHEEL cloth MONTHLY Wipe bicycle with CR_CUP I _
(ADJUSTING SPOKES) damp cloth. Wt(Je dry., Polish metal
surfaces. On caliper brake models, do
TOOLS REOUIRED not polish nms. Make o;;ure no oil gets BEARING &
SPOKE WRENCH BEARING CUP on caliper brake shoes, With spray RETAINER
FELT MARKER LOCK YOUR BICYCLE
lubricant, lubricate charn and rea(
STANDARD SPOKE WHEEL ONLY sprocket. On caliper brake rnodels, There are many ways to lock your
lubricate hand brake lever cable pivot bicyde. To proyide maximum protec.
To check this area, just lift up on
We suggest spoke adjustments be MADE tion for your bicycle~ you should use
handlebars at handgrip area. In doing points, Wipe seat With damp cloth and
BY A QUALIFIED BICYCLE REPAIR, a good chain and loek, You ,hould
this, there should not be any play of the wipe dry ANNl"ALL Y: The fallowing
MAN, wrap the chain through the frame and
handlebar stem and fork within the components require lubrication, remo",'
1. Place bicycle upside down. frame's head, The handlebars must be ai, disassernbiy, inst;40ation, speeia! the rear whee' and around a station~
able to turn easily. If there is play. tOOls and know!~dge, It IS suggested that ary post or $imilar objeet. Make sure
2. To check, hold a felt marker at
fork leg approximately 1,6mm 11/16'" adjust as follows: this service be penormed by a qualified vour lock is attached to the chain
properly and fullv closed,

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