dk BMX Bicycles User manual

Owner’s Manual
‘BMX’ Bicycles
Please read and fully understand this manual
before operation.
Save this manual for future reference.
This manual contains important safety, assembly, operation
and maintenance information.
Date Code Label
Here
H-DK BMX EN 072314 m0104
Copyright DK Bicycles 2014

Owner’s Manual Index
Introduction
• Owner’s Bicycle Identication Record ................................................... 3
• Fitting the Rider to the Bicycle............................................................... 3
• Warning and Safety Information ............................................................ 4
• Freewheel Brakes.................................................................................. 4
• Reectors .............................................................................................. 4
• Rules of the Road.................................................................................. 4
• The Owner’s Responsibility................................................................... 5
Components
• Part Assembly View............................................................................... 6
• Parts Assembly List ............................................................................... 7
Assembly
• Introduction............................................................................................ 8
• Tools Needed......................................................................................... 8
• Assemble the Front Wheel to the Fork .................................................. 9
• Handlebar and Stem Installation - No Gyro Brakes.............................. 10
• Gyro Brake and Stem Setup - Rear Brake ........................................... 12
• Gyro Brake Setup - Front Brake Cable Install ...................................... 14
• Seat Installation (various models) ......................................................15/16
• Front and Rear Reector Installation.................................................... 18
• Pedal Installation .................................................................................. 19
• Testing Seat Clamp and Post Clamp Tightness ................................... 20
• Testing Stem and Handlebar Tightness................................................ 21
• Brake System Setup and Adjustment ................................................... 22
• Coaster Brakes (various models) ......................................................... 26
• Pegs Installation ................................................................................... 27
Maintenance and Service
• Repair and Service ............................................................................... 28
• Chain Adjustment ................................................................................. 29
• Lubrication ............................................................................................ 30
• Lubrication Table................................................................................... 31
• Inspection of the Bearings .................................................................... 32
• Tires ..................................................................................................... 33
Warranty
• Limited Warranty.................................................................................34/35

3
Owner’s Bicycle Identication Record
NOTE: This information is only available on the bicycle itself. It is not available from
the manufacturer.
1
x
x
x
x
x
x
x
x
x
x
Write this number below to keep it for future reference.
If the bicycle is stolen, give this number and a description of the bicycle to the police.
This will help them nd the bicycle.
Model / Serial Number:
Purchase Date:
Model Name:
Fitting the Rider to the Bicycle
To determine the correct size of bicycle for the rider:
• Straddle the assembled bicycle with feet shoulder width apart and at on the
ground.
3
1
2
• There must be at least 1 inch (2.5 cm) of clearance
(1) between the highest part of the top tube (2) and
the crotch of the rider with tires properly inated.
• The minimum leg-length for the rider is the highest
part of the top tube plus one inch (3).
Each bicycle has a Serial Number
stamped into the frame. The Serial
Number can be found on the bottom of
the crank housing as shown (1).
Introduction
Introduction

4
Rules of the Road
WARNING: Failure of the rider to obey the following “Rules of the Road” can
result in injury to the rider or to others.
• Obey all trafc regulations, signs, and signals.
• Always wear a bicycle helmet that meets CPSC safety standards, as well as lo-
cal safety standards.
Warning and Safety Information
Meanings of Warnings:
aThis symbol is important. See the word “CAUTION” or “WARNING” which
follows it.
The word “CAUTION” is before mechanical instructions. If you do not obey these
instructions, mechanical damage or failure of a part of the bicycle can occur.
The word “WARNING” is before personal safety instructions. If you do not obey
these instructions, injury to the rider or to others can occur.
• Adult assembly is required.
• Continuous adult supervision is required.
• Do not add a motor to the product.
• Do not tow or push the product.
• Do not modify the product.
• Replace worn or broken parts immediately.
• If anything does not operate properly, discontinue use.
Reectors
WARNING: For your own safety, do not ride the bicycle if the reectors are
incorrectly installed, damaged, or missing. Make sure the front and rear reectors are
vertical. Do not allow the visibility of the reectors to be blocked by clothing or other
articles. Dirty reectors do not work well. Clean the reectors, as necessary, with
soap and a damp cloth.
Freewheel Brakes
WARNING:
• Some models do NOT have a foot (pedal) brake.
• Ensure your child understands and can operate the hand brakes.
• Always use both hand brakes when stopping the bike.
• When stopping, apply front and rear brakes evenly.
• An unstable condition can occur if the front brake is used too hard resulting in
injury to the rider or others.
Introduction

5
• Always wear shoes.
• Ride on the correct side of the road, in a single le, and in a straight line.
• Bikes under 20” not intended for use on roads.
• Avoid riding at night, dusk, dawn and any other time of poor visibility.
• Make sure the reectors of your bicycle are correctly positioned. Do not remove
the reector or replace the reectors with lighted devices that look similar to
reectors.
• Do not let anything cover the reectors.
• Use extra caution in wet weather:
• Ride slowly on damp surfaces because the tires will slide more easily.
• Avoid these hazards to prevent loss of control or damage to your wheels:
• Be aware of drain grates, soft road edges, gravel or sand, pot holes or ruts, wet
leaves, or uneven paving.
• Cross railroad tracks at a right angle to prevent the loss of control.
• Avoid unsafe actions while riding.
• Do not carry any passengers.
• Do not carry any items or attach anything to your bicycle that could hinder your
vision, hearing, or control.
• Do not ride with both hands off the handlebar.
The Owner’s Responsibility
WARNING: This bicycle is made to be ridden by one rider at a time for general
transportation and recreational use. It is not made to withstand the abuse of stunting
and jumping.
If the bicycle was purchased unassembled, it is the owner’s responsibility to follow
all assembly and adjustment instructions exactly as written in this manual, and any
“Special Instructions” supplied and to make sure all fasteners and components are
securely tightened.
NOTE: Periodically check that all fasteners and components are securely tightened.
If the bicycle was purchased assembled, it is the owner’s responsibility, before riding
the bicycle for the rst time, to make sure the bicycle has been assembled and ad-
justed exactly as written in this manual, and any “Special Instructions” supplied and
to make sure all fasteners and components are securely tightened.
NOTE: If product is assembled, please proceed to the following sections:
• Testing Seat Clamp and Post Clamp Tightness
• Testing Stem and Handlebar Tightness
Rules of the Road - continued
Introduction

6
Components
15
18
3 4
9
7
14 10
12
13
33
34
15
16
17
2
24 25 26 27 28 29 30
32
31
3 4
6 8
23
19
11
20
21
22
22
21
Components
Part Assembly View

7
Components
No. Description No. Description
1 Frame 19 Seat Post 2Front Wheel Assembly 20 Rear Reector 3 Tire (x2) 21 Seat Post Hardware 4 Tube (x2) 22 Seat 5Rear Wheel Assembly 23 Rear Brake 6 Fork 24 Front Brake 7 Crank and Spindle Set 25 Head Set Bearings 8 Lower Brake Cable Coupler (various models) 26 Gyro Head Set 9 Chain 27 Front Reector
10 Chain Guard 28 Handlebars
11 Handlebar Stem 29 Upper Brake Cable Coupler (various models)
12 Right Pedal 30 Right Brake Lever 13 Left Pedal 31 Left Brake Lever 14 Kick Stand 32 Grips (x2) 15 Wheel Retainer (x2) 33 Rear Axle Nut (x2) 16 Front Axle Nut (x2) 34 Rear Pegs 17 Front Pegs 18 Seat Post Clamp
Parts Assembly List

8
Introduction
This Owner’s Manual is made for several different bicycles:
• Some illustrations may vary slightly from the actual product.
• Follow instructions completely.
• If the bicycle has any parts that are not described in this manual, look for sepa-
rate “Special Instructions” that are supplied with the bicycle.
• Models may have different accessory items such as bags, baskets, reectors,
cup holders, racks, etc.
• All features, components and accessories are not included on all models.
• Use the Index page to locate specic sections of this manual.
• Please read through this entire manual before beginning assembly or mainte-
nance.
• If you are not condent with assembling this unit, refer to a local bike shop.
WARNING: Keep small parts away from children during assembly.
NOTE: All of the directions (right, left, front, rear, etc.) in this manual are as seen by
the rider while seated on the bicycle.
Do not dispose of the carton and packaging until you complete the assembly of the
bicycle. This can prevent accidentally discarding parts of the bicycle.
Tools Needed
Small Adjustable Wrench
(Jaws must open at least 9/16 inch.)
Open-end Wrenches
Flat-blade Screwdriver Phillips Screwdriver
Slip-Joint Pliers Metric Allen Wrenches
Assembly
Assembly

9
Assembly
Assemble the Front Wheel to the Fork
1. If the Axle Nuts (A) are already attached to the front wheel axle, begin by remov-
ing them with an open end wrench or adjustable wrench.
2. Set the wheel into the front fork (B).
3. Install Step Washers (C) making sure the small end goes towards the fork Indent
(D).
4. If installing Axle Pegs (E), follow instructions on pages 27 and 28.
5. Attach the front wheel with the Axle Nuts.
6. Tighten Axle Nuts to 21 ft-lbs (28.4 N•m).
B
C
A
D
A
CE
G
F
NOTE: Some models may have Wheel Retainers (F)
instead of Step Washers (C). Install Wheel Retainers
(F) making sure the Tabs are in the Fork (G) Tab Holes.
NOTE: Ensure wheel spins freely without contacting
fork or fender.
WARNING: Do not use Nuts (A) without serra-
tions to attach the front wheel.
WARNING: Put the wheel in the center of the fork
and tighten both nuts to the recommended torque of 21
ft-lbs (28.4 N•m)
WARNING: Failure to obey these steps can allow the front wheel to loosen
while riding. This can cause injury to the rider or to others.

10
Handlebar and Stem Installation - No Gyro Brake
WARNING: To prevent steering system damage and possible loss of control,
the “MIN-IN” (minimum insertion) mark (A) on the stem must be below the top of the
Locknut (B).
NOTE: Remove plastic Cap (E) from
the end of the Stem (11).
1. Insert the Stem (11) into the fork
(g 07).
2. Point the Stem towards the front of
the bike.
3. Tighten the Stem Bolt (C) just
enough to hold it in position.
4. If necessary, loosen the Handlebar
Screws (D) and rotate Handlebar
(28) into a comfortable riding posi-
tion.
5. Tighten Handlebar Screws (D) just
enough to hold it in position (g
08).
6. Align the stem with the front tire
and tighten the Stem Bolt (C) se-
curely (g 07).
11
A
A
B
E
B
C
D
g 07
WARNINGS:
• Do not over tighten the stem bolt. Over tightening the stem bolt can damage the
steering system and cause loss of control.
• If the handlebar clamp in not tight enough, the handlebar can slip in the stem.
This can cause damage to the handlebar or stem, and can cause loss of control.
Assembly

11
Handlebar and Stem Installation - continued
Four Bolt Clamp Top Mount:
• If necessary, re-adjust Handlebar.
• Tighten Clamp Screws (D) evenly ac-
cording to pattern.
NOTE: Do not over tighten. Torque to 17
ft-lbs.
3 1
2 4
D
28 g 08
Four Bolt Clamp, Front Mount:
• If necessary, re-adjust Handlebar.
• Tighten Clamp Screws (D).
NOTE: Do not over tighten. Torque to 17
ft-lbs.
g 08b
3 1
2 4
28
D
Two Bolt Stem:
• Loosen Clamp Screws (A).
• Re-adjust Handlebar (B) to a comfort-
able riding position.
• Tighten Clamp Screws (A).
NOTE: Do not over tighten. Torque to 17
ft-lbs.
A
B
WARNINGS:
• Do not over tighten the stem bolt. Over tightening the stem bolt can damage the
steering system and cause loss of control.
• If the handlebar clamp in not tight enough, the handlebar can slip in the stem.
This can cause damage to the handlebar or stem, and can cause loss of control.
Assembly

12
Gyro Stem and Brake Setup
• Make sure Rear Brake Cable Sheath (A)
is fully inserted into the adjustment Hous-
ing at the Caliper and Hand Lever (B).
• Ensure Housing Nut and Housing (B, C)
are adjusted all the way in towards the
Hand Lever.
• Rotate Housing (B) Groove away from
Cable Groove (D) and tighten Housing
Nut (C).
ABD
C
continued >>
Stem and Handlebar Setup - Gyro Brake
Note: The Handlebar Stem Clamp may be pre-installed from the factory.
3 1
2 4
A
B
C
D
• Carefully unpack Handlebar and Brake
Cables.
• If needed, loosen the Stem Bolt (A) and
point the Stem (B) towards the front of
the bike as shown.
• Tighten the Stem Bolt securely.
• Install the Handlebar (C) and rotate to a
comfortable riding position.
• Tighten Clamp Screws (D) securely.
Assembly

13
Gyro Stem and Brake Setup - continued
A
AB
C
E
D
• Squeeze the two sides of the Gyro Plates (A) together and insert the Cable End (B)
into the Gyro Plate Slot (C).
• Repeat for other side.
A
B
C
WARNING: Ensure Gyro Handlebar/Stem/Wheel system can rotate 360 de-
grees without binding any Cables and that the Gyro mechanism works smoothly.
• Install the two Cable Adjusters (A) into
the Gyro Plate (B) making sure the
Shorter Cable (C) is on the same side
as the Brake Lever (D).
• Turn the Cable Adjusters and Nuts (E)
all the way into the Gyro Plate - hand
tight.
continued >>
Assembly

14
Gyro Brake Setup - Front Brake Cable Install
• Pull the Front Brake Cable (A) up
through the Stem Nut (B) so that it is
routed as shown.
• Ensure the Brake Cable does not touch
the Tire (C).
A
A
C
B
1
• Insert Cable Barrel (2-1) into Brake
Lever.
• Insert Brake Cable (3-1) into
Groove as shown.
• Ensure Housing Nut and Housing
(4-3, 4-1) are adjusted all the way
in towards the Hand Lever.
• Rotate Housing (4-1) Groove
away from Cable Groove (4-2) and
tighten Housing Nut (4-3).
2-1
2
2-1
3
3-1 44-2
4-3
4-1
continued >>
Assembly

15
Gyro Brake Setup - Front Brake Cable Install - continued
A
WARNING: Ensure Gyro Handlebar/Stem/Wheel system can rotate 360 de-
grees without binding any Cables and that the Gyro mechanism works smoothly.
• Rotate Brake Levers (A) into
a comfortable riding position
and tighten securely.
continued >>
Seat Installation (various models)
Attach Seat to Seat Post:
(pre-assembled on some models)
• If needed, loosen nuts on seat clamp
(A) and rotate Seat (22) into riding posi-
tion.
• Put the Seat Post (19) fully through the
seat clamp.
• Tighten the Seat Clamp so the seat
stays on the seat post.
• If the Seat Clamp has a nut on each
side, tighten both nuts equally. g 09
A
19
22
CAUTION: If you accidentally drop the seat post into the seat tube, it may be
difcult to remove it.
Assembly

16
• Point the Seat (22) forward and put the
Seat Post (19) into the Seat Tube (B)
(gs 10, 11).
WARNING: To prevent the seat com-
ing loose and possible loss of control, the
“MIN-IN” (minimum insertion) mark (C) on
the seat post must be below the top of the
Seat Tube (B). g 10
22 CB
19
C
B
Tighten the quick release lever:
• Move the Quick Release Lever (D) to
the “open” position so the word “open”
is pointing away from the Seat Post
Clamp (E).
NOTE: The words “open” and “close” are on
opposite sides of the quick release lever.
g 11
E
B
F
19
D
21
22
Seat Installation (various models) - continued
Seat to Seat Post (Single Bolt Style): Some models are
equipped with a seat and seat post assembly that uses a
single bolt and nut to secure the seat to the seat post. The
seat is assembled to the seat post at the factory.
Ensure the seat is secure to the seat post and the seat bolt
is tightened. Recommended torque = 7.3 ft-lbs (10 N•m).
Assembly

17
Seat Bolt Mount (various models)
Some models have a Bolt (A), Washer (B) and Nut (C) instead of a Quick Release
Lever.
• If needed, loosen the nut enough to insert the Seat Post.
• Point the seat forward and insert Seat Post to the Minimum Insertion marks (D).
• Tighten Nut securely so it supports the rider without moving.
D
B
C
A
g 24
Seat Installation - continued
CAUTION: Operate the Quick Release Lever (D) by hand only. Do not use a
hammer or any other tool to tighten the quick release lever.
You must use strong force to move the quick release lever to the “close” position. If
you can easily move the lever to the “close” position, the clamping force is too light.
WARNING: If the clamping force of the Quick Release Lever is too light, the
seat post can loosen while riding. This can cause injury to the rider or to others.
Tighten the quick release lever (continued):
• Open and close the Quick Release Lever with one hand while you turn the Ad-
justing Nut (F) with the other hand (g 11).
• Tighten or loosen the adjusting nut by hand, so that you rst feel resistance to
the quick release lever when it perpendicular to the bicycle frame.
• Push the Quick Release Lever to the “close” position (g 11).
• When in the “close” position, make sure the Quick Release Lever lays against
the Seat Post Clamp (E).
• The tightening torque of the Quick Release Lever should be tight enough so that
the seat does not move during normal operation.
Assembly

18
Front and Rear Reector Installation
g 12
20
27
WARNING: Ensure the Front Reector is White and the Rear Reector is
Red.
1. Position REAR Reector (20) so it
points straight backwards.
2. Tighten Clamp Screw.
NOTE: Do not over-tighten. This will
damage the Clamp.
1. Position FRONT Reector (27) so it
points straight forward.
2. Tighten Clamp Screw.
NOTE: Do not over-tighten. This will
damage the Clamp.
Assembly

19
Pedal Installation
CAUTION: There is a right pedal marked “R” and a left pedal marked “L”.
• The pedal marked “R” has right-hand threads. Tighten it in a clockwise direc-
tion.
• The pedal marked “L” has left-hand threads. Tighten it in a counterclockwise
direction (anti-clockwise).
• Turn the right pedal marked “R” into the right side of the crank arm, and the left
pedal marked “L” into the left side of the crank arm.
Tighten the pedals (g 14):
• Make sure the threads of each pedal are fully into the crank arm.
NOTE: The recommended torque (tightness) for each pedal is 30 ft-lbs.
g 14
R
L
Note: A Pedal Wrench is preferred for attaching Pedals. An open-end
wrench can also be used as shown.
WARNING: Ensure ped-
als are secure in crank arms so
they will not loosen. Periodically
check tightness.
Assembly

20
Testing Seat Clamp and Post Clamp Tightness
To test the tightness of the seat clamp and the post clamp:
WARNING: Every time the quick release mechanism is loosened, make sure
the red reector is correctly positioned.
• Try to turn the seat side-to-side and to move the front of the seat up and down.
• If the seat moves in the Seat
Clamp (A):
• Loosen the Seat Clamp (A).
• Put the seat in the correct position
and tighten the Seat Clamp tighter
than before.
• Do this test again, until the seat does
not move in the Seat Clamp.
g 09
A
19
22
• If the Seat Post (A) moves in the Seat Tube (B):
• Move the Quick Release Lever to the “open” position OR loosen the Clamp Bolt
and Nut (C).
• Put the seat in the correct position and tighten the Quick Release Lever tighter
than before OR tighten the Clamp Bolt and Nut tighter than before.
• If necessary, loosen Quick Release Lever, tighten Adjusting Nut (D) and re-tight-
en Quick Release Lever.
• Do this test again, until the seat post does not move in the seat tube.
C
AA
B
D
B
C
Assembly