Buddy Bike BB102-AL User manual

Owner’s Manual
Bike Models: BB102-AL and BB103-AL
V.5 10/06/08
Please read every word of this manual
BEFORE you ride your Buddy Bike!
Because your safety is most important to us.
we strongly recommend that a trained professional
assemble and adjust your Buddy Bike.
BIKE ASSEMBLY SUPPORT CONTACT INFORMATION
Robert A. Gardner ●707.456.0468 ●[e-mail]

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For your protection it is important to keep a record of the serial number of your bicycle and the date and
place of purchase. The serial number can be found under the Rear Bottom Bracket Shell where the rear
rider crank joins the bike where the Chain Stay is welded. Please fill out the information below and keep
it for your records.
Your name:
Bike serial number:
Bike model: Bike color:
Bike Date of purchase:
Dealer Name:
Dealer Address:
Dealer Phone Number:
To activate your warranty, please fill out and return the enclosed Warranty Registration Form along with
a copy of your purchase receipt to:
Buddy Bike, LLC
2775 Sunny Isles Boulevard, Suite 118
North Miami Beach, FL 33160
ATTN: Warranty Registration

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Table of Contents
Helmets and Safety ...................................................................................4
How To Ride Your Buddy Bike ..................................................................4
Pedaling Techniques .................................................................................5
Fold-out Foot Pegs....................................................................................5
Steering Techniques..................................................................................5
Maximum Weight.......................................................................................6
Kickstands .................................................................................................6
Braking for Safety......................................................................................6
How and When to Shift Gears ...................................................................7
Safe Cycling Procedures ...........................................................................8
Torque Wrench..........................................................................................9
Seat Adjustments.......................................................................................9
Handlebar Adjustments............................................................................10
Brake Lever Adjustments.........................................................................11
Two Ways to Remove Brake Cable Stretch.............................................12
How to Use the Quick Release................................................................13
Front Wheel Removal..............................................................................13
Front Wheel Installing..............................................................................14
Brake Maintenance..................................................................................15
Brake Shoe Adjustments .........................................................................16
Brake Shoe Balance................................................................................16
7 Speed Hub, Cable Adjustment..............................................................17
Inspect the Chain for Wear......................................................................18
Wheels and Care of Tires........................................................................18
Adjusting Roller Brake Cable...................................................................19
Maintenance Schedule ............................................................................20
Specifications for Components (Family BB102-AL).................................22
Specifications for Components (Sport BB103-AL)...................................24
Warranty..................................................................................................26

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Congratulations!
You have purchased the ultimate bicycle built for two! Now you and your loved one can enjoy the
scenery as you pedal your Buddy Bike, talk with each other and be close and companionable on the
road or trail. Now you can ride with any youngster old enough to sit on a bicycle seat and hold onto
the handlebars. You will not need a costly bicycle trailer to carry your child. Put your loved ones first,
up front on a Buddy Bike as you have put them first in your life!
Please read every word of this manual
BEFORE you ride your Buddy Bike!
This manual gives you safety tips on where and how to ride your Buddy Bike, how to adjust its seats,
brakes and handlebars for comfort and safety, how to shift for easy PEDALING, how to brake for safe
speed control, plus instructions on how to keep your Buddy Bike in the same safe operating condition
as it was when you bought it.
Helmets and Safety
Always wear a helmet! Don’t even think about riding
your Buddy Bike unless both riders wear a helmet. Your
head is much too precious to risk, especially since you
used it to buy this tandem! Adjust your helmet as shown
in Figure 1, so it offers maximum protection at all times.
Use a helmet that bears an inside label reading “Meets
ANSI Z90.4 Standards” or “Certified by Snell Memorial
Foundation.”
How to Ride Your Buddy Bike
Before you start the practice rides that get you familiar
with your Buddy Bike’s steering, braking and shifting
performance, please adjust the seats, handlebars and
brake levers to fit your body, as shown later in this man-
ual “How To Fit Your Buddy Bike to You and Yours.” Practice riding your Buddy Bike in a traffic-free
area such as an empty school playground, until both captain and stoker (the stoker sits up front) are
thoroughly familiar with its braking, steering and shifting.
For the Captain
Start with the captain riding alone. Straddle the top tube (the tube from the rear seat to the fork col-
umn, Figure 2) with one foot on the ground, the other foot on a pedal at the 2 o’clock position. Hold
the captain’s handlebar (see Figure 14)firmly. Push off with the foot on the ground and, at the same
time, press down hard on that pedal, hoist your body up onto the seat and KEEP PEDALING. The mo-
mentum will help keep the bicycle balanced.
For Both Riders
Captain and stoker should practice the start-off procedure above until it is automatic and second na-
ture. When you brake to a stop, reverse the mounting and start-off instructions given above so you are
ready to take off again, say from a stoplight. At this point both riders should have one or both feet on
the ground and be straddling the bicycle.
Figure 1
HEAD MEASURING
TAPE POSITION CORRECT POSITION (1 in. above the eye-
brows, sitting down on
top of the head)
CORRECT ANGLE
TOO SMALL
(Sitting too high) TOO LARGE (Covering the eyes) INCORRECT ANGLE
YOU SHOULD NOT WEAR A HELMET THAT FITS INCORRECTLY.

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Pedaling Techniques
As Figure 2 shows, captain’s and stoker’s pedals
are connected by a bicycle chain. Both sets of ped-
als move simultaneously. As one rider pedals, the
other rider must also pedal. To coast, both riders
must agree to do so. Verbal communication on a
tandem is important! If one rider decides to coast
and the other tries to keep pedaling, balance and
control can be affected. For stoker’s with disabilities,
it is also helpful for the captain to maintain a slow,
steady pace for stoker to work at keeping their feet
on the pedals.
Fold-Out Foot Pegs (sold separately)
To install the fold-out foot pegs (Figure 3A): 1) remove the adhesive
from the padded tape sections and press to the inside curve of each
foot peg; 2) with the pegs folded up, position the pegs on the small
down tube in front of the front rider seat and 3) use the included
screws to secure the pegs to the tube. The foot pegs should be posi-
tioned above the path of the pedals so the stoker’s feet will be safely
out of the pedal motion path.
While the stoker is pedaling, fold the pegs up (Figure 3B).For
smaller riders, fold each peg down so they can rest their feet out of
the way of the pedal motion path (Figure 3C).
Steering Techniques
The Buddy Bike has a much shorter wheelbase than conventional
tandems. Buddy Bike Family BB102-AL has a wheelbase of only
57.125 inches while Buddy Bike Sport BB103-AL measures 58.125
inches. Conventional tandems have wheelbases from 69.7 to 72.2
inches (depending on frame size).
The Buddy Bike is unique in that both sets of handlebars, Figure 5,
turn as the bicycle is steered. The captain leans into the direction of
the turn, moves the handlebars to turn and, as he/she does so, the
stoker’s handlebars will move in the same direction. The stoker
should balance in the same direction. The captain should tell the
stoker when a turn is about to be made, except of course in an emer-
gency situation when a turn must be made immediately. Again, com-
munication between captain and stoker is essential to the safety of
both.
NOTE: A bike shop professional should adjust the stoker handlebars
to accommodate the reach of the stoker. For safety, do not rotate the
handlebars closer than a 90 degree angle.
Figure 2
Figure 3A
Figure 3B
Figure 3C

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Maximum Weight
The combined weight of captain and stoker should not exceed 300
pounds. As you mount or pedal, do not bear down hard on the handle-
bars, as if you were doing pushups. However, should the handlebars
move up or down as you mount or ride the Buddy Bike tighten all the
handlebar clamp bolts with a 6-mm Allen wrench to 150—225 inch/
pounds as soon as possible, as shown in the paragraph “How to Fit
Your Buddy Bike to You and Yours” later in this manual. Better yet,
stop at the nearest bike shop and have a pro do it.
Kickstands
Buddy Bike Family BB102-AL includes one bi-pod spring kickstand
(Figure 4A). Buddy Bike Sport includes one Pletscher bi-pod kick-
stand (Figure 4B). Once assembled, to lower either kickstand, slightly
raise the bicycle by the rear seat and use your foot to push the kick-
stand down then gently lower the bike. To raise the kickstand, slightly
raise the bicycle by the rear seat and use your foot to sweep the kick-
stand backwards. These kickstands are intended to hold and balance
the bike while it is not being ridden. Raise the kickstand to mount the
bicycle. DO NOT mount the bicycle while it is balanced on the
kickstand.
Keep Speed Under Safe Control at All Times,
Practice Braking
First, be aware that the right side of a bicycle is the side to your right
as you sit on the seat. That’s the side the chainwheel is on. (Figure 5)
was taken from the front of the Buddy Bike). The brake lever on the
left side of the captain’s handlebar is for the front brake, “D” in Figure
5. The brake lever on the right side of the
captain’s handlebar is for the rear brake, “C”
in Figure 5. The brake lever on the stoker’s
handlebar is for the drum brake on the rear
wheel, “E” in Figure 5.
Caution: Your Buddy Bike can go faster
than single bikes, for two reasons:
1. The Buddy Bike with aluminum frame
weighs 53-55 pounds (depending upon
bike model and accessories). That’s just
27.5 pounds or less for each of you. The
rider on a typical bike (excluding road
bikes) has to push its 33 pounds alone.
2. The rear rider, the “captain,” is shielded from wind by the front rider, the “stoker,” so you
both have only half the wind resistance faced by a single biker. For these reasons your
Buddy Bike is a lot easier to pedal, so please keep it at a speed that lets you slow down or
Figure 5
A
B
D C
E
Figure 4A
Figure 4B

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Again, as you practice riding the Buddy Bike in a safe place, like an empty school playground,
try stopping at various speeds, say at 5, 10 and 15 miles per hour. Note how many feet it
takes to stop at each of these speeds. Use the captain’s brakes, then use those plus the
stoker’s brake. Then use this information to keep your speed under control. Go slower in traf-
fic, for example, where you may have to make a sudden, unexpected stop. Look as far ahead
as possible, be alert as you approach parking lot driveways, children and others on foot, bicy-
cles, skate boards or roller blades. Watch out for school and other buses approaching a stop.
When you come to a stop, both captain and stoker should extend one foot to the ground, and
then both feet if you have to wait for a stoplight. Remember, on downhill runs, gravity
alone may propel the Buddy Bike to an unsafe speed.
Use both captain’s and stoker’s brakes to slow or to stop on a downhill ride. On the flats, the
captain can usually control speed by applying both brake levers. Apply the rear brake lever
first, then the front brake lever. On downhill runs, or to make an emergency stop, the stoker
should also apply the drum brake lever, as the captain applies both his/her brakes. Again,
both riders should practice braking on the flats and on downhill runs until you both are thor-
oughly familiar with the excellent braking power and speed control of the Buddy Bike’s
brakes.
Remember, when it’s raining, your brakes, good as they are, will lose some stopping
power. It will take longer to stop when wheel rims are wet. In wet conditions, apply
brakes sooner than you would in dry conditions. Both captain and stoker should use
both sets of brakes, even at low speeds. Reduce speed in wet weather, watch out for
an accumulation of wet leaves in the fall, they can be very slippery.
How and When to Shift Gears
7-Speed Buddy Bike Family (BB102-AL)
Buddy Bike Family is equipped with the Shimano’s NEXUS
INTER 7. It can shift to any gear anytime, even at a stop. To
shift, simply rotate the gripshift on the right of the captain’s
handlebar, “A” in Figure 5. The 7 speed gear combinations
gives you a wide range of choices for easy pedaling. By turn-
ing the gripshift toward you, select gear 6 or 7 for pedaling
downhill. While on level roads or paths use gears 3, 4 or 5.
Upon pedaling uphill, turn the gripshift away from you to gear
1 or 2. By selecting the proper gear, you can make pedaling
comfortable and easier for both riders.
24-Speed Buddy Bike Sport (BB103-AL)
Buddy Bike Sport is equipped with the Shimano’s NEXAVE
C530 INTEGO 24 speed (8 external, 3 internal hub). The 3
internal gears can shift to any gear at anytime, even at a stop.
However, this bike includes a derailleur and it would be best
to shift all gears while pedaling. To shift the internal gears,
push the lever marked “LOW” or “HIGH” on the left side of the
captain’s handlebar (Figure 6A). To shift the external gears,
push the lever marked “LOW” or “HIGH” on the right side of
the captain’s handlebar (Figure 6B).
Figure 6B
Figure 6A

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Follow These Safe Cycling Procedures
1. Signal when you slow down, or
turn right or left! Let vehicle drivers,
other cyclists and pedestrians know
when you are about to make a turn,
slow down or stop. Both captain and
stoker should use the hand signals in
Figure 7 to alert all traffic as to any of
these moves.
2. Obey all traffic laws. Vehicle traffic
regulations apply to any moving vehi-
cle, including bicycles. Never try to
beat a traffic light, make an illegal
turn, ride on a sidewalk unless permit-
ted by law. While stopped at a stop-
light or stop sign, stoker and captain
should have one foot on the ground,
the other on a pedal which is at the 2
o’clock position, so you can safely
take off when the light turns green.
Read your state’s bicycle safety regu-
lations.
3. Ride only in the direction of traffic,
never into it.
4. Cross railroad and street car tracks at a right angle, to avoid slipping on them. Watch
out for potholes and sewer grates that could trap your tire.
5. Ride Defensively! Never assume that eye contact with a vehicle driver means the driver
sees you, or will give you the right of way, even if it’s yours. Do not challenge a motorist,
the car has more steel around it than you do.
6. Always ride as close to the curb as possible. Watch out for suddenly opening doors of
parked cars as you approach them. Have an escape route in mind at all times.
7. Keep your eyes and ears open for traffic coming from behind as well as to the side.
Be ready to take evasive action at all times. Clip a rear view mirror on your eyeglasses or
attach one to the left side of the captain’s handlebar to monitor upcoming traffic.
8. On a hill climb, you may be hidden from a car coming toward you, as that car, on the
other side of the hill, is hidden from you. Stay as far as possible to the right of the road un-
til you crest the hill.
9. Ride on designated bicycle lanes when possible. The curb lane sign, center in Figure
8, gives bicycles as well as cars preference for right turns. If you are on a bike path, the
sign at the right of Figure 8 will alert motorists that bicycles may cross the street. But as
noted earlier, helpful as this sign may be, let cars go by if they are coming fast. Never dis-
pute the right of way with a vehicle.
Figure 7
Figure 8
TURNING
LEFT TURNING RIGHT SLOW or STOP
A guide sign used for
marking officially
designated Bikeways.
The “diamond lane”
gives preference to
certain vehicles such
as bicycles. Used to warn motorists of a
midblock bike path crossing.

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How to Fit Your Buddy Bike to You and Yours
Before you go off for your first practice rides, have your bicycle dealer inspect the Buddy Bike
and make the following handlebar and seat adjustments to your Buddy Bike for your riding
comfort and safety. You could make them yourself If you wish. But if you do, use a torque
wrench, Figure 9, to tighten nuts and bolts to the torque tightness specified, so you are sure
they are safely tight.
Figure 9—Torque Wrench
Seat Adjustments
You can move each seat in five directions, up or down, closer to or far-
ther from the handlebars, and tilted for comfort.
Seat Height: Adjust seat height for both riders so the knee is slightly
bent when one pedal is at the 6 o’clock position, as shown in Figure
10. To adjust seat height, turn the seat post quick release lever, (QR in
Figure 13) to the OPEN position, (arrows below the seats point to the
quick release levers), move the seat up or down until the rider’s knee
is bent as shown in Figure 10. Tighten the seat post quick release
lever to the closed position, with the end of this lever facing toward the
rear. (Be sure to read instructions on use of the quick release lever, in
the data about front wheel removal and installation later in this man-
ual). CAUTION: For safety, keep at least 4 inches of the seat post
inside the seat tube, as shown in Figure 11.Repeat this procedure
for the rear seat.
Seats to handlebar distance:
The seat should be close
enough to the handlebars so
the riders can reach them with-
out strain. To move the seat
toward or away from the han-
dlebars, simply loosen the seat
clamp bolts that hold the seat
on the seat post, Figure 12,
and move the seat toward to
or away from the handlebars,
until the rider has a slight bend
at the elbows.
Figure 9
Figure 11
Figure 10
100 mm (4”)
minimum
insertion

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Seat Tilt: Reduce pressure on the hands by tilting each seat
so its nose points slightly upward, as shown at arrow ST in
Figure 13. To make these adjustments, loosen the seat clamp
bolts (arrows, Figure 12) with a 5-mm Allen wrench, slide the
seat forward or back as necessary and tilt it as noted above.
Tighten the clamp bolts to 180—250 inch/pounds with a
torque wrench, Figure 9. Again, use the torque wrench on
all applicable nuts and bolts noted throughout this man-
ual so you are sure they are safely tightened.
Handlebar Adjustments
Adjust both handlebars so they can be reached without strain.
Move the handlebars up or down, tilt (rotate) them and move
them closer to or further away from the rider as needed for
comfort. Here’s how:
Captain’s Handlebar
The captain’s handlebar is the one that
arches back toward the rear seat, the
longest bar on the Buddy Bike. Loosen
clamp bolts arrows A in Figure 14 with a
6-mm Allen wrench. Tilt the captain’s
handlebar up or down until the captain
can ride with a comfortable bend of his
upper body while sitting on the rear seat.
Once the handlebar is at a convenient
angle, tighten these bolts to 150—225
inch/pounds.
Caution: The handlebar stem, arrow B, supports both
captain and stoker handlebars. The stem is held by the
two clamp bolts, arrows A in Figure 15. The stem must
always be in the position shown in Figure 15, all the
way down to the fork bearing locknut, arrow B. Do not
loosen these bolts to raise the handlebars. Handlebar
height can only be adjusted as shown above.
Now make the following adjustments to the stoker’s handle-
bar: A
A
B
Figure 13
ST
STA
SEATPOST
QR
Figure 15
A
B
C C
A
D
D
Figure 14

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Stoker’s Handlebar
The stoker’s handlebar, the short one up front, is adjust-
able to three different positions, tilt, up or down, and dis-
tance from the stoker’s seat.
Tilt: Loosen clamp bolt arrow B in Figure 14 with a 6-mm
Allen wrench, and rotate the handlebar until the stoker can
reach it without strain and with ease. Tighten this bolt to
150—225 inch/pounds.
Distance from seat: Loosen clamp bolts arrows C in Fig-
ure 14 with a 6-mm Allen wrench and move the stoker’s
handlebar closer to or away from the stoker’s seat until it
can be reached in comfort. Tighten these bolts to a torque
of 150—225 inch/pounds. Caution: Keep at least two
inches of the stoker’s handlebar stem INSIDE the stoker’s
handlebar tubes, as shown in Figure 16.
Up or Down: Loosen clamp bolts arrows D in Figure 14 with a 6-mm Allen wrench and rotate
the stoker’s handlebar to move it up or down to suit the stoker’s arm length. Tighten these
bolts to 150—225 inch/pounds.
Caution: Before your first ride and every four to six months thereafter (depending on
ride frequency), stand in front of the Buddy Bike, hold the front wheel between your
knees, grasp the captain’s handlebar and rotate it firmly from side to side. If the han-
dlebar moves but the wheel does not, retighten the clamp bolts arrows A and A in
Figure 15 with a 6-mm Allen wrench to a torque of 180—250 inch/pounds. These two
handlebar stem bolts, arrows A and A shown in Figure 15, hold both stoker and captain
handlebars securely on the fork steerer tube.
Brake Lever Adjustments
There are two adjustments for each
of the three brake levers, one for
hand “reach” and one for finger “fit.”
1. Hand reach: You should be able
to grasp brake levers quickly from a
hand rest position on the handle-
bars. Rotate each brake lever until
you can do so. Loosen the brake
lever clamp bolt, arrow E Figure
17, with the 5-mm Allen wrench
shown, and rotate the lever on the
handlebars to a quickly reachable
position. Tighten the clamp bolt to
44—60 inch/pounds.
E
D
C
Figure 17
B
Figure 16
2” MIN

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2. Finger Fit: If the brake lever begins to apply braking force as soon as you depress it, ad-
just its “reach” with a 2-mm Allen wrench, arrow B in Figure 17, until your fingers can
safely and comfortably apply force to the brakes. The brake lever can be safely depressed
up to about one inch from the handlebar. If the brake lever comes any closer the brake
cable has stretched. Cable stretch reduces braking power and response, so remove this
stretch.
Two ways to remove cable stretch
1. Minor cable stretch can be removed at each brake lever: Loosen cable slack adjuster
locknut arrow D in Figure 17 a few turns. Turn slack adjuster arrow C counterclockwise
until slack is removed. Tighten locknut arrow D against the brake body. Repeat if the brake
lever still comes more than an inch from the handlebars. Make this adjustment on all brake
levers as necessary.
2. Major cable stretch at the brakes.
Captain’s brakes: If cable slack can’t be
removed at brake levers, reverse the ad-
justments in Step 1 above so the cable is
as slack as possible. At captain’s brake
(front or “V” caliper brakes) loosen the ca-
ble clamp bolt, right arrow in Figure 18,
with a 5-mm Allen wrench, while holding
brake shoes against the wheel rim. Pull out
cable slack with a pair of pliers. Tighten
the cable clamp bolt to a torque of 44—60
inch/pounds. Repeat as necessary.
3. Stoker’s drum brake: Remove cable
slack with the slack adjuster, similar to
the cable slack adjuster on brake levers
in Step 1 above. The adjuster locknut is
arrow A, the adjuster is arrow B in Fig-
ure 19.
Figure 18
CABLE
CLAMP
BOLT
B A
Figure 19

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Important!
Learn how to use the front wheel and seat Quick Releases:
There are three quick release mechanisms on your Buddy Bike, one on the front wheel and
one on each seat post. They make it easier to remove and reinstall the front wheel and to
move seats up and down. For the front wheel particularly, it is very important to understand
how to use the quick release, to insure that the wheel is tightly and safely held in the fork, and
that the wheel will stay in place even if you should hit a bump or pothole.
A quick release is a cam action device, not a nut and bolt unit.
Use only your fingers to adjust and tighten the quick release. The
opening and closing lever of the quick release has an eccentric bump,
a cam on it, (arrow A in Figure 20) which is, in effect, a powerful lever.
This lever amplifies the turning force made by your hand as you force
the quick release lever to the closed position (Figure 26). First, make
the test in Step 1 below:
1.Before every ride make sure the
front wheel is securely clamped in the
fork, so it won’t fall out if you hit a
bump. Lift the Buddy Bike up a few
inches. Punch down hard on the front tire
with the side of your fist. Do this even if you
rode the Buddy Bike the day before. You
never know when someone has tampered
with, or accidentally turned, the quick re-
lease lever to the OPEN position that could
let the wheel fall out. Here’s how to use the
quick release.
To Remove the Front Wheel
You need to know how to remove and install the front wheel to fix
a flat or to carry the Buddy Bike in your car, and how to reinstall it
so it will not pop out and cause loss of control. Here’s how:
1. Hold brake shoes against the wheel rim while you pull the
cable carrier up and out of the slot in the crossbar, “A” in
Figure 21. Now the brake shoes will be far enough apart so
you can remove the front wheel, as shown in Figure 22.
The crossbar should now appear as in Figure 23.
2. Turn the quick release lever to the OPEN position,
Figure 24, which is when the lever is pointed toward
the front of the Buddy Bike.
3. Remove the front wheel. Punch down on the tire if necessary.
A
Figure 21
Figure 23
Figure 22
Figure 20
A
4
Figure 24
Stronger
Adjusting
nut
Weaker open

15
To Install the Front Wheel:
1. Replace the front wheel in the fork dropouts. Be sure the tire is
centered between the fork blades, Figure 25.
2. Hold the wheel in place while you tighten the quick release lever all
the way to the closed position, Figure 26.
3. Check quick release tightness. As you move the quick release
lever toward the rear of the Buddy Bike, past the 12 o’clock posi-
tion, Figure 27, you should feel increasing pressure to bring the
lever all the way to the closed position, Figure 26. You should
have a red pressure mark on the palm of your hand from the force
needed to close this lever all the way. If you do not feel this pres-
sure, readjust the quick release mechanism as follows:
Adjust the Quick Release:
1. Open the quick release lever past the 12
o’clock position, Figure 27, to around the 4
o’clock more open position.
2. Hold the adjuster nut with one hand and turn
the quick release lever counter clockwise as
far as possible. Do not use any tool on this
adjuster nut. Use only your fingers!
3. Turn the quick release lever all the way to the
closed position, Figure 26. Again, you must
feel considerable turning resistance as the
lever moves past the 12 o’clock position to the
closed position.
Check quick release tightness these
three ways:
1. See that the red mark from tightening pressure
is on the palm of your hand.
2. Punch down hard on the tire with the flat of
your clenched fist. The wheel should not fall out.
3. Remove the wheel (open the quick release) and inspect the fork dropouts. You should see
“bite” marks on the fork dropout made by the sawtooth edges of the quick release,
Figure 28. Repeat these quick release adjustments and tightening steps until you can see
these “indents.”
Figure 25
Figure 26
CLOSE Position
Figure 27
Turn 1/8 revolution at a time

16
Replace the cable in the crossbar, Figure 21, as you hold
the brake shoes against the wheel rim.
Make sure the brake cable is correctly back in the crossbar
slot. Squeeze the brake lever as tightly as possible. If the
lever drops to the handlebars, the cable has popped out of
the slot. Replace it and check again for correct placement.
Caution: The
brake spring
may also have
popped off the
brake arm, arrow A in Figure 30. If so, replace it
behind the tab on the brake arm, as shown in Fig-
ure 30, where arrow A is the brake spring, arrow B
shows the brake arm with brake tab. This caution
also applies to the rear wheel.
To remove the rear wheel: Shift the chain to the
small freewheel cog. Spread brake shoes as ex-
plained above for front wheel removal, Figure 21. Use a 15-mm wrench and loosen both axle
bolts. Lift the chain off the small cog as you remove the wheel.
Reinstall the wheel so the axle is all the way into the drop-
out slots, and that the wheel is evenly spaced in the bike
frame, similar to Figure 25. Tighten the axle bolts to 300—
320 inch/pounds.
Brake Maintenance Steps
Brake shoes wear as they do on your car. Inspect them
every six months, make sure they are not worn, and that the
brake shoes are properly aligned on the wheel rim for maxi-
mum braking power. Brake shoe replacement is a shop job,
so bring your bike to it for shoe replacement. To replace
them yourself, follow these steps:
1. Remove old brake shoes with a 5-mm Allen wrench.
Brake shoe clamp bolt is shown in the center of the
brake arm, arrow A, Figure 25.
2. Purchase replacement shoes at a bike store, Install all
four new shoes for safety.
Figure 28
Figure 29
Figure 30
A
B

17
3. Install the new shoes in the brake arms. Before tightening the brake shoe clamp bolt to
50—70 inch/pounds, adjust brake shoes as follows:
Stoker’s Brake
1 Remove cable slack at the brake itself, Figure 19.
2. Squeeze stoker’s brake lever hard. If the brake lever comes closer than one inch to the
handlebar, take the Buddy Bike to the shop for brake lining replacement.
Captain’s “V” Brake Shoe Adjustments
1. Keep each brake shoe no closer than 1/32” to the tire, Figure 31. The brake shoe must
not rub on the tire, only on the rim, Figure 30. Make this adjustment by loosening the
brake shoe clamp bolt, (arrow, Figure 30) with a 5-mm Allen wrench, move the shoe up or
down in the brake arm slot, tighten the clamp bolt to 50—70 inch/pounds of torque.
2. Adjust brake shoes so they are 1/16” away from the wheel rim, Figure 32. Make this ad-
justment by loosening the brake cable binder bolt in the brake arm, Figure 18, with a 5-
mm Allen wrench, and moving the brake cable in or out of the binder bolt. Tighten that bolt
to 44—60 inch/pounds.
Brake Shoe Balance
Keep each brake shoe the same distance from the wheel rim. Use a 2-mm Allen wrench in
each brake arm, arrows, Figure 33, to balance brake shoes for even clearance.
Figure 31 Figure 32 Figure 33
Brake shoe adjustment
Nut tightening torque:
80—100 kgfcm
(70-85 in./lbs.)
Nut
Shoe
About 1 mm (1/32”) 1/16”

18
7-Speed Hub Cable Adjustment
Set the gripshift dial to 4 . Check to be sure that the red setting lines on the cassette joint
bracket and pulley are aligned.
Cable adjusting bolt
Set to 4
Note: This bike is equipped with the
cable adjusting bolt built into the
grip shift. Adjustment is made by
pulling and turning the spring
loaded adjusting bolt until the red
marks are lined up.
When Bicycle is Upside Down When Bicycle is Standing Up
The red set-
ting lines on
the cassette
joint are lo-
cated in two
places. Use
the one that
is easiest to
see.
The red setting lines should be straight The red setting lines should be straight
Pulley
Cassette joint
bracket Cassette joint
bracket
Pulley

19
Inspect the Chain for Wear Every 3—6 Months
Check for chain wear by measuring the distance between chain links, Figure 34. If the dis-
tance between links exceeds 1/2 inch, replace the chain. Use the correct replacement chain;
take the old one to a bike store to be sure. Better yet, have the shop replace the chain! Shift
to the small front and rear cogs before removing or replacing the chain. Install a new one, or
the cleaned old one, by
threading the chain over the
chainwheel, then in front of
the top derailleur wheel and in
back of the bottom derailleur
wheel. Join the chain with the
rivet tool, Figure 36.
Wheel Alignment
Wobbly wheels cut braking power. So keep both wheels running true. Wheels can lose align-
ment over time as spokes stretch. Wheel alignment takes special tools and know-how so
have this done by a bike shop.
About Your Tires
Keep tires inflated to the pressure marked
on the outer wall of the tire (Figure 35).
Lower pressures can cause a flat and will
cause more rolling resistance. Higher pres-
sures can cause a tube to blow out. Correct
pressure assures longest tire life. Repair
tube punctures with a self-adhering patch,
follow instructions that came with them.
Check inside the tire as well as outside to
find and remove what caused the flat.
Chain Maintenance
Clean the chain every three to six months, more often if
you have ridden over sand and dirt, or through water, as
on a rainy day. Use a solvent such as kerosene, and a
brush. Be careful not to splash solvent on the tire or brake
shoes. It’s best to remove the chain and dunk it in the sol-
vent.
Remove the chain with a chain rivet tool, Figure 36, to
push a rivet out. Dunk the chain in a solvent such as kerosene. Use the rivet tool to replace
the chain.
Figure 35
Figure 36
Figure 34
1/2” 1/2”

20
Depress brake lever
about 10 times
Note:
If the brake cable is not run in, it will
need to be adjusted again after only a
short period of use.
Both ends of the
outer casing should be
securely inserted
Cable adjusting bolt
Cable adjusting bolt
2. There are two methods of adjusting the brake cable: one is for use by the manufacturer
during assembly of the bicycle, and the other is for use by the dealer when making readjust-
ments.
3. Check that both ends of the outer casing are securely inserted into the cable adjusting
bolts of both the brake lever and brake arm.
Adjusting the Roller Brake Cable
1. After checking that the wheel does not easily turn while the brake cable is being pulled,