CRUZBIKE Silvio User manual

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CRUZBIKE Silvio Assembly
CRUZBIKESilvioAssembly ...................................................................................................1
Generalnotesonassembly.............................................................................................1
FrameAssembly .............................................................................................................. 1
Un‐boxandevaluatetheframeandmajorparts............................................................1
Preparation .................................................................................................................1
Group[1and8]:Fitthecushionsandprotectivestrip ...................................................2
Group[2and3]:PreparetheSeatStayassembly...........................................................3
Group[2‐3and1]:FittheRearTriangle .........................................................................4
Group[4]:PreparethePivotClampassembly ................................................................5
Group[1,6and4]FittheFork........................................................................................6
Group[5]:PreparetheBoomAssembly .........................................................................7
Group[7and5]FittheFrontTriangle ............................................................................8
FittingandAdjustment ...................................................................................................8
ProperInstallationofyourFrontDerailleuronyourSilvio .............................................8
SuspensionAdjustment ..................................................................................................9
Ridinginstructions...........................................................................................................9
CongratulationsonpurchasingaCruzbikeSilvio!Oursupportspecialistsarealways
availabletoassistyoushouldyouhavequestionsaboutassembling,adjustingor
ridingtheSilvio.Use[e-mail].
General notes on assembly
ThegeneralorderofassemblyforSilvioisindicatedinthecontentstable.
ThisinstructionsetdescribesassemblyoftheSilvio451andSilvio559Cruzbikes.
Althoughthebikeshaveminordifferencesinspecification,assemblyisthesame.
WARNING
Ifyouareunsureaboutadjustingbrakesorgearingonabicycle,youshouldtake
yourSilviotoaprofessionalbicyclemechanicforadjustment.Improperlyadjusted
brakesordrivetraincomponentscouldcausesevereinjuryordeath.
Frame Assembly
AssemblingtheSilviocanbeeasierifyouhaveabikeworkstand,butthese
instructionsassumeyoudon’thaveone.Thebestplacetoclamptheframeisacross
thebottlecagebraze‐onsundertheseatpan.Besuretotightentheclamp
sufficientlythattheframewon’trotateoutoftheclamp.Toproperlyadjusttherear
brakes,youmayneedtoremovethebikefromtheworkstandtofreeuptherear
brakecable.
Un-box and evaluate the frame and major parts
TheSilvioFramesetcomesmostlyunassembled.Pleasetakethefollowingapproach
tocompletingtheassembly.TheseinstructionsmakereferencetotheSilvioParts
Diagram.
Preparation
Unpacktheitemsandunwrapthem,exceptfortubeprotectionwhichmaybe
retaineduntilthebikeisreadytoberidden.
Identifytheheadsetbearings,donotunpackthem.Ifthedetailsofaheadsetsare
newtoyou,twoofmanyusefullinksexplainingthemareSheldonBrown's
authoritativeglossaryandthisgeneraldescriptionwithdiagramsthatdescribethe
IntegratedHeadsetasfoundonSilvio.

SilvioAssemblyManual
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Identifythereare8Chainstayboltsetsusedforattachingthechainstays.Each
chainstayhastwoboltsetsateachend.
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Layalltheitemsoutonalargeworkarea,inthesamearrangementasshownonthe
explodedviewsoftheSilvioPartsDiagramthatisincludedwithyourframesetand
verifythatyouhavethepartsastheyappear.
Onceyouhaveallthepartslaidout,begintheassembly.
Inthepartsnumbering,thefollowingabbreviationsareused:
SilvioSV;
ChainstayDropoutCSDO;FrontF;RearR;LeftL;RightR.Hence,
CSDORLisChainstayDropoutRearLeft;
FrontDeraileurFD;RearDerailleurRD.
Group [1 and 8]: Fit the cushions and protective strip
FitthevelcrostripstotheSeatBackandSeatPanandapplytheSeatCushions.
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Fittheprotectiverubberstripstotheflangeoftheseat.Onecontinuouspiece
aroundtheseatbackandtwopieces,leftandrightfortheseatpan.Dothisfirstto
protecttheflangepaintworkwhiletheframeisbeingassembled.

SilvioAssemblyManual
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Group [2 and 3]: Prepare the Seat Stay assembly
BoltthetitaniumleafspringSV29EbetweenthetopoftheSeatStaySV30andthe
mountingplaceSV29Gwithfourbolts.SV29Gissquare,butwithroundedcorners.
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BolttheRearCarboyokeChainstaytotheseatstaywith2Chainstaybolts,withthe
raisedareasoftheChainstayfacingup.
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SilvioAssemblyManual
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Group [2-3 and 1]: Fit the Rear Triangle
ChecktherubberbootSV29PisinplaceontheMainFrame.
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SlidetheheadoftheRearChainstayintothemountingslotSV28LontheMain
Frame,checkingthatthetitaniumspringalignswithpartSV28NontheMainFrame,
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thenfit2Chainstaybolts;
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thenfitthetitaniumspringtotheMainFrameusingSV29Fandfourbolts.

SilvioAssemblyManual
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Group [4]: Prepare the Pivot Clamp assembly
PlacethebushingsintothePivotClampFC20S,
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thentaketheStemSleeveandconnectittothePivotClampwiththestainlesssteel
pinandbolts.
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SilvioAssemblyManual
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Group [1, 6 and 4] Fit the Fork
Unwraptheheadsetandtakecaretokeepthemanypartsintheiroriginalsequence
andorientation!!!!Dividethesetofpartsbetweenthetwobearingsetstoseparate
themintothelowerandupperbearingsets.Setasidethecapandboltfromthe
upperbearingset.
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Nowbuildthestack:slidethelowerbearingsetovertheforkneck(withthebearing
uppermost),notethelowertaperedcompressionringissilverandtheupperoneis
gold:
1.Upperdustcap
2.Thinwasher
3.Uppergoldcompressionring
4.Uppersealedbearingunit
5.Lowersealedbearingunit
6.Lowersilvercompressionring
7.shoulderoffork
Thelowersilvercompressionringwillbeatightfit
overtheshoulderofthefork.
slidetheforkneckthroughthemainframe:slidethe
upperbearingsetovertheforkneck(withthebearing
lowermost);
slideaspaceron,
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slidethePivotClampon,finishwiththecapand
looselyfittheboltintothestarnutwhichisinsidethe
forkneck.

SilvioAssemblyManual
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GraduallytightenthebearingstackbeforetighteningthetwoPivotClampbolts.
Group [5]: Prepare the Boom Assembly
FittheBBRingClampsaroundtheBottomBracket.PlaceSV33LontheleftandSV33R
ontheright.ThismeanstheRingClampboltswillnotbevisiblefromthetop,butwill
beeasilyaccessiblefrombelow.Pressthemtogethertillthecastellatedsurfaces
mate.
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PositiontheheadoftheFrontChainstayontheRingclampswithholesalignedand
withtheraisedareasoftheChainstayfacingup,thenplacetheplateSV33P
underneathandfitandtightenthetwochainstaybolts.Donotfitthecablerolleryet,
thisisbetterdonewhilethefrontderailleurcableisbeingfitted.
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Identifythechainstaydropoutsasfollows.Bothhaveasmallgrooveonthetopinside
edge.Placethemtogetherwiththesmallgrooveadjacent.Thenplacethemoverthe
Forkdropoutsandnoticehowtheyfit,yetcanrotate.Now,identifythattheright
chainstaydropoutCSDOFRhasasecondaryrecessunderneathwhereitfitsoverthe
Forkdropout.ThisrecesstakestheRearDerailleurhangerSVRD,whichis
sandwichedinplace.TakeSVRDandfititinsideCSDOFR,withthelowersection
disposedtotheinside,thenplaceovertherighthandForkdropouttoidentifyhow
thepartsassemblewhenthefrontwheelislaterfitted.
Nowwiththeraisedareasofthechainstayontopfitthechainstaydropoutstothe
endsofthechainstayarmsusingthetworemainingchainstaybolts,andtighten.

SilvioAssemblyManual
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Group [7 and 5] Fit the Front Triangle
PasstheLongStemthroughtheStemSleeveandintotheMainBoom.Lightlytighten
both34.9mmclamps.TheLongStemisalsoreferredtoastheSlider.
InserttheRearDerailleurHanger,fittheChainstayDropoutsaroundtheforkand
passthelongskewerthrough.
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Noteplacementofderailleurhangerasfollows:
1)theskewerpassesthroughthemountingeyeofthederailleurhanger
2)theeyeofthehangerissandwichedbetweentheouterChainStayDropOut
(CSDOR)andtheForkDropOut.
3)thebodyofthehangerisoffsettotheinside,towardsthecassette
Thedropoutsandderailleurhangerwilltightenupwhenawheelisinplace.Once
thisisidone,tightedthesetscrewontherearsurfaceoftheCSDORtopinchthe
derailleurhangerandkeepitinplace.
Fitting and Adjustment
Component Assembly
Allcomponentsshouldbeassembledaccordingtotheirmanufacturer'sinstructions.
ThefrontderailleurcableshouldlooparoundtheFDCableRoller.Ifusingastand,
placetheclamparoundtheLongStem,betweentheStemSleeveandMainBoom,
withthefrontofthebikeupsothatthebackofthebikehangsdownanddoesnot
swing.
Stem Sleeve
FormostriderstheStemSleeveshouldpointupfromitspivot,forverytallriders,it
mayfacedown.
Long Stem (Slider)
Formostriders,theLongStemwillallowsuitablehandlebarreachadjustment.For
shortriders,wheretheBBandhandlebarsareclosetogether,theLongStemmaynot
plungefarenoughintotheMainBoom.Inthiscase,reducethelengthoftheLong
Stembyupto2"/30mm.
Arm and Leg Adjustments
Onceassembled,pleasenotethefollowingcriticalprocedureforadjustingtheleg
lengthorarmreachonyournewSilvio:
1)loosentheBBringclampsSV33RandSV33Laroundthebottombracket.
2)releasethequickreleasefrontaxleskewer.
3)loosentheMainBoom34.9clampforlegadjustmentandortheStemSleeve34.9
clampforlegandarmreachadjustment.
4)adjustasrequired
5)re‐tightenthe34.9clamps.
6)re‐tightentheBBringclamps.
7)securethequickreleasefrontaxleskewer
8)sightalongtheFrontChainstaySV31toverifythatitisstraight,notheldina
curvedposition.
Proper Installation of your Front Derailleur on your Silvio
Thepurposeofthemultiplemountingpointsforthefrontderailleur(FD)istoallow
optimumfunctionofyourFDacrossarangeofriderx‐seams(leglengths).
Understandingchainstayangleisimportant.Thechainstayangleistheangleformed
bythechainstayandthemountingaxisofthefrontderailleur(seephoto).

SilvioAssemblyManual
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Thechainstayangledeterminestherelationshipbetweentheupperchainrunand
thefrontderailleur.Ondiamond‐framebikes,thisisafixedangledeterminedby
framegeometry,andmostderailleursaredesignedforthistobeintherangeof63
to66degrees.
Cruzbikeshaveadjustableboomstoallowfordifferentleglengths.Oneofthe
consequencesofthisisthatonaCruzbike,thechainstayanglevarieswithboom
adjustmentlength.Ifyouhaveshorterlegs,thiscancausethechainstayangletobe
veryopen(larger),andthiscausestherear"bridge"ofthederailleurcagetodragthe
chainwhenthesmallestchainringisbeingused.
Tocompensate,weallowforseveraldifferentFDattachmentpointstorestorethe
chainstayangletoascloseto66degreesaspossible,thusputtingtheFDinthe
configurationforwhichitwasdesigned.
Whenyousetupyourbike,youshouldusethehighestFDattachmentpointthatwill
allowyourFDtoclearthechaininthelowestgear,andthechainstayangleshouldbe
closeto66degrees.Wesuggestyoutrythefollowingsettingsfirst:
X-seam less than 40 inches Æuse 4th (bottom) row
X-seam 40 to 42 inches Æuse 3rd row
X-seam 42 to 44 inches Æuse 2rd row
X-seam greater than 44 inches Æuse 1st (top) row
Wheneveranyadjustmentsaremadetotheleglength,whetherdirectlybytheMain
Boom34.9clamporindirectlybytheStemSleeve34.9clamp,repeatstep8to
ensurethechainstayisinastraight'relaxed'position.Failuretodosomayresultin
damagetotheFrontChainstay.
Suspension Adjustment
TheSilvioisequippedwithanairheadsuspensionforkandcomeswithahigh
pressuresuspensionpumpthatcansupplyhighpressuresinverysmallvolumesin
incrementsofabout5psi.Toadjustthepressure,connectthehosetothevalveusing
thebarrelnutattheend.Oncethepressureisright,firstunscrewtheHOSEoutof
thisbarrelnutabout5mm,itwon'tdetachbutwillreleasethepumpsidepressure
whileallowingthevalvetoclosewithoutadropinpressureintheairheadunit.Then,
disconnectthebarrelnutfromthevalve.Theworkingrangefortheairheadis50to
200psi.Travelis40mm(justover1.5").Adjusttheairpressuresothatthesagis
about20%oftravel,orabout8mm,(about5/16").Startatabout150psi.While
sittingonthebikewiththebrakeson,rockbackandforthalittletosetthesag.At
thissetting,therubbercovershouldbejustslightlydeformed.Monitortheair
regularly,justasyoudoatire.
Checksbeforeriding,especiallyafterlegorarmreachadjustmentshavebeenmade
1)AllChainstayboltsaretight
2)FrontChainstayisstraight,notheldinacurvedposition
2)RingClampboltsaretight
3)Otherchecksasusualforaroadbike
Riding instructions
Itisimperativethatyouconsultthecruzbikeownersmanualforinstructionsonhow
tolearntoride.Contactusimmediatelyifyoudonothavethismanual.
Youarenowreadyforyourfirstride.Enjoy!