Fusion Bikes 2009 XRT Rally I User manual

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<<General Bike Assembly Instructions>>
Dear Customer,
Thank you for purchasing the Fusion Range of Mountain Bikes.
THIS IS A PARTIALLY ASSEMBLED BICYCLE
REQUIRING THE ATTACHMENT OF THE
FOLLOWING PARTS IN ACCORDANCE WITH THE
MANUFACTURER’S INSTRUCTIONS
The bike you have bought comes 85 assembled so there are only a few remaining components requiring
attention.
Please note that if you are not familiar with mountain bike components and have limited in experience in
this field, we strongly recommend you take it to a professional for proper assembly.
This assembly manual is suitable for the following models:
 Hard tail mountain bikes
o XRT Rally I (2009 Model),
o BENCHMARK 2200 (2009 Model)
o XRT Rally (2010 Model)
o ATILLA 3500 (2008-2012 Model)
 Dual suspension mountain bikes
o Extreme I (2007 Model),
o Extreme II (2008 Model)
o KinetiK 5700 (2008-2014 Model)
o Symmetry (2012-2014 Model)
1) What is included within the box
 Main bike frame with back wheel and front fork attached.
 Handlebar (unfitted)
 Front wheel (unfitted)
 Small Brown Box containing
i. Seat Post and bar
ii. Left/Right Peddles
iii. Disc Brake Assembly Set (See separate user manual for detailed instructions)
iv. Front White Reflector
v. Rear Red Reflector
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Atilla
KinetiK
Com act
Symmetry
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11) Final checks
Please ensure all nuts and bolts are tightened.
Congratulations. The assembly is complete. Well done!!
Please ensure you read the maintenance manual along with this instructions template for proper use of the
mountain bike. Once again thank you for your purchase and we hope you have countless hours of easy
riding with this Mountain Bike.
PS: Please don’t forget to inflate the tire.
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(The disc brake assembly set should contain the cable wire, the round metal disc brake, the caliper mechanism, and a
pack of nuts/screws)
2) Tools required for assembly.
Before you begin, please ensure you have the following tools. These tools will be required in the
assembly process.
 Full set of allen keys
 Phillip head screwdriver
 Pair of Pliers
 Wrench
 Pair of wire clippers
 Torque wrench
As a general guide, the assembly should take 45 minutes to an hour depending on individual knowledge
and previous assembly experience. Again, we strongly recommend you take it to a professional for proper
assembly if you are not comfortable with the process.
WARNING: IN THE INTERESTS OF SAFET IT IS
RECOMMENDED THAT OU HAVE THIS BIC CLE
ASSEMBLED B A SKILLED BIC CLE MECHANIC
3
Stem
Front Wheel
Peddles
Crank
Handlebar

Let’s get started …….
3) Attaching the Handlebar to the Stem of frame.
Now that we have the right tools, let begin by removing the bike out of the box. Set the main bike frame on
a flat surface such that it is balanced. This will allow us to connect the handlebar to the stem of the main
bike frame with ease.
The handlebar should be loosely dangling. This needs to be connected to the main bike frame. Before you
begin to tighten the handle bar to the stem, please determine if you prefer to have the stem facing down or
facing up. By default, the stem has been set up facing down.
 If the stem is facing down, this allows the handlebar to be closer to the ground and therefore a
lower ride. (option 1)
 If you prefer the handlebar to be closer to your upper body and a more comfortable ride, we
recommend you have the handle bar facing up (option 2)
If you decide to set up the stem facing down, please ignore the following steps (a-g).
If you decide set up the stem facing up, please follow the following steps
a. Remove the rubber seal to expose the top nut.
b. Loosen the top nut using the allen key.
c. Loosen the side nuts using the allen key 4
Stem
Handlebar
Top
Nut
Side
Nut

Fig 1 Fig 2
Fig 3
10) Fit the front and rear reflectors to the bike
The red reflector is to be attached to the rear end on the seat post.
The white reflector is to be attached to the front end on the handlebar. You will need a Philips head
screwdriver for this part of the assembly.
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Pull down, then lock the wire
into position by adjusting the
nut in the disc brake Clip
access wire and cap the end

Incorrect quick-release use is dangerous because these mechanisms hold the wheels in place. The most
common mistake is simply turning the lever like a nut until the wheel seems tight. Used this way the lever
and wheel can loosen as you ride.
9) Adjusting the brake lever and tightening the brakes
Step 1: Pull the brake handle so that the slot in section is exposed
Step 2: Take the brake cable. Using the hammer shaped side, fit the cable into the slot. You might need to
adjust the screw caps such that the opening is aligned (see fig 2)
Step 3: Once the cable is in, screw the caps such that the open is no longer aligned (to prevent cable from
coming out)
Step 4: Now slip the other side of the cable wire through the disc brake lever. (see Zoom instruction set for
further details)- Fig 3
Step 5: Hold the end of the cable, and pull the plastic/rubber cover as much as you can into the handlebar
brake lever.
Step 6: Using a pair of pliers, take firm hold of the cable on the disc brake end and pull downwards.
Step 7: Keeping the tension, secure the cable onto the disc brake by using an Allen Key to lock the cable
(see Zoom instruction set for details)
Step 8: Using a pair of clippers, clip off any wire.
Step 9: Cap the end of the wire using the silver caps provided in the disc brake set package. Apply firm
pressure on the caps using a set of pliers to mould the silver caps into place.
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d. Slide the stem up to remove it from the main frame
e. Flip the stem upside down.
f. Re-attach the stem be tightening the top and side nuts using your allen key.
g. Place the rubber seal back over the top nut.
Align the handlebar such that the centre point is in the middle of the stem. Once you are happy with the
positioning, using the centre plates, tighten the handlebar to the stem using the Allen key and screwing the
nuts into position.
4) Attaching the metal disc brake to the front wheel
- please refer to the Disc brake assembly instructions
5) Attach the brake set to the front fork
- please refer to the Disc brake assembly instructions
5
Centre
plates