Huffy freewheel User manual

Owner’s Manual
12” to 20” Freewheel 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.
HFW 12-20 EN 020813 m0078
Copyright Huffy Corporation 2012

2
Owner’s Manual Index
Your Bike
• Owner’s Bicycle Identification Record...................................................3
• Fitting the Rider to the Bicycle...............................................................3
• Warning and Safety Information............................................................4
• Freewheel Brakes..................................................................................4
• Reflectors ..............................................................................................4
• Rules of the Road.................................................................................4/5
• The Owner’s Responsibility...................................................................5
Components
• Parts 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 ..........................................................10
• Testing Stem and Handlebar Tightness................................................11
• Seat Installation....................................................................................12
• Testing Seat Clamp and Post Clamp Tightness ...................................14
• Front and Rear Reflector Installation....................................................14
• Pedal Installation..................................................................................15
• Training Wheel Installation (various models)........................................16
• Brake System Setup (various models)...............................................18/21
Accessories - various models
• Streamers, Handlebar Pad and Bag.....................................................22
• Plaques.................................................................................................23
• Bell Installation .....................................................................................24
Maintenance and Service
• Repair and Service...............................................................................26
• Chain Adjustment .................................................................................26
• Tires .....................................................................................................27
• Lubrication and Lubrication Table.........................................................28
• Inspection of the Bearings....................................................................29
Warranty
• Huffy Corporation Limited Warranty ...................................................30/31

3
Owner’s Bicycle Identification Record
NOTE: This information is only available on the bicycle itself. It is not available from
Huffy.
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 find 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 flat 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 inflated.
• The minimum leg-length for the rider is the highest
part of the top tube plus one inch (3).
Each Huffy 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

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 traffic 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.
Reflectors
WARNING: For your own safety, do not ride the bicycle if the reflectors are
incorrectly installed, damaged, or missing. Make sure the front and rear reflectors are
vertical. Do not allow the visibility of the reflectors to be blocked by clothing or other
articles. Dirty reflectors do not work well. Clean the reflectors, as necessary, with
soap and a damp cloth.
Freewheel Brakes
WARNING:
• This product does 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 file, 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 reflectors of your bicycle are correctly positioned. Do not remove
the reflector or replace the reflectors with lighted devices that look similar to
reflectors.
• Do not let anything cover the reflectors.
• 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 first 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 pages 11 and 14: Testing Stem,
Handlebar and Seat Clamp tightness.
Rules of the Road - continued
Introduction

6
Components
4
5 32
3 7
6 10
1
14
13
29
2
12 12
18
30
17
15
16
9
9
11
8
22 20 21
27
28
19 20 21
26
31
23
24
25
Part Assembly View

7
Components
No. Description No. Description
1 Frame 23 Front Brake 2 Fork 24 Front Brake Lever 3 Handlebars 25 Rear Brake Lever 4 Grips (x2) 26 Rear Brake 5 Handlebar Pad (some models) 27 Chain 6 Handlebar Stem 28 Chain Guard 7 Front Reflector 29 Crank and Spindle Set 8 Seat 30 Rear Wheel Nut (x2) 9 Seat Post Hardware 31 Training Wheel Set
10 Seat Post
11 Rear Reflector Accessories (various models)
12 Quick Release and Lever Nut 32 Bell 13 Head Set Bearings 33 Handlebar Bag 14 Right Pedal 34 Streamers 15 Left Pedal 35 Plaque 16 Kick Stand 17 Wheel Retainer (x2) 18 Front Wheel Nut (x2) 19 Front Wheel Assembly 20 Tire (x2) 21 Tube (x2) 22 Rear Wheel Assembly
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, reflectors,
cup holders, racks, etc.
• All features, components and accessories are not included on all models.
• Use the Index page to locate specific sections of this manual.
• Please read through this entire manual before beginning assembly or mainte-
nance.
• If you are not confident 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
Bicycle Assembly

9
Assemble the Front Wheel to the Fork
1. If the Axle Nuts (18) 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 (2) (fig 04).
3. Install wheel retainers (17) making sure the tabs are in the fork (D) tab holes.
4. Attach the front wheel with the Axle Nuts.
5. Tighten Axle Nuts to 21 ft-lbs.
g 04
17
18
D
17
18
2
NOTE: Ensure wheel spins freely without contacting fork or fender.
WARNING: Do not use Nuts (18) without serrations 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.
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.
Bicycle Assembly

10
Handlebar and Stem Installation
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 (6).
NOTE: Some models do not have Handle-
bar Clamp Nut/Screw (D).
1. Insert the Stem (6) into the fork (fig 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
Clamp Nut/Screw (D) and rotate Han-
dlebar (3) into a comfortable riding posi-
tion (fig 08/08a).
5. Tighten Handlebar Clamp Nut/Screws
(D) just enough to hold it in position (fig
08/08a).
6. Align the stem with the front tire and
tighten the Stem Bolt (C) securely (fig
07).
6
A
A
B
E
B
C
g 07
WARNING: Do not over tighten the stem bolt. Over tightening the stem bolt
can damage the steering system and cause loss of control.
Four Bolt Clamp (fig 08a):
• If necessary, re-adjust Handlebar (3).
• Tighten Clamp Screws (D) evenly ac-
cording to pattern.
NOTE: Do not over tighten. Torque to 17
ft-lbs.
WARNING: 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.
3 1
2 4
D
3
g 08a
Bicycle Assembly

11
Testing Stem and Handlebar Tightness
To test the tightness of the stem:
• Straddle the front wheel between your legs.
• Try to turn the front wheel by turning the handlebar.
• If the handlebar and stem turn without turning the front wheel, realign the stem
with the wheel and tighten the stem bolt(s) tighter than before (about 1/2 revolu-
tion only at a time).
• Do this test again, until the handlebar and stem do not turn without turning the
front wheel.
• Bicycle Assembly
To test the tightness of the handlebar clamp:
• Hold the bicycle stationary and try to move the
ends of the handlebar up and down or forward
and back.
WARNING: Do not exceed 100
lbs force.
• If the handlebar moves, loosen the
bolt(s) of the handlebar clamp.
• Put the handlebar in the correct
position and tighten the bolt(s) of
Handlebar and Stem Installation - continued
One Bolt Clamp (fig 08):
• If necessary, re-adjust Handlebar (3).
• Tighten Clamp Nut (D).
NOTE: Do not over tighten. Torque to 17
ft-lbs.
WARNING: 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.

g
08
D
3
the handlebar clamp tighter than before.
• If the handlebar clamp has more than one bolt, tighten the bolts equally.
• Do this test again, until the handlebar does not move in the handlebar clamp.
Bicycle Assembly

12
Seat Installation (various models)
Attach Seat to Seat Post (fig 09):
(pre-assembled on some models)
• Loosen nuts on seat clamp (A) and
rotate Seat (8) into riding position.
• Put the seat post (10) 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
10
8
CAUTION: If you accidentally drop the seat post into the seat tube, it may be
difficult to remove it.
• Point the Seat (8) forward and put the
Seat Post (10) into the Seat Tube (B)
(figs 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
A
10
C
B
B
C
8
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
10
D
Bicycle Assembly

13
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 (fig 11).
• Tighten or loosen the adjusting nut by hand, so that you first feel resistance to
the quick release lever when it perpendicular to the bicycle frame.
• Push the Quick Release Lever to the “close” position (fig 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.
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.
DB
10 C
A
g 24
Bicycle Assembly

14
Front and Rear Reflector Installation
g 12
11
7
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 reflector 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) (fig 09):
• Loosen the Seat Clamp (A).
• Put the seat in the correct position and tighten the Seat Clamp tighter than be-
fore.
• Do this test again, until the seat does not move in the Seat Clamp.
• If the Seat Post (10) moves in the Seat Tube (B):
• Move the Quick Release Lever (D) to the “open” position.
• Put the seat in the correct position and tighten the Quick Release Lever tighter
than before.
• If necessary, loosen Quick Release Lever, tighten Adjusting Nut (F) and re-tight-
en Quick Release Lever.
• Do this test again, until the seat post does not move in the seat tube.
1. Position REAR Reflector (11) so it
points straight backwards.
2. Tighten Clamp Screw.
NOTE: Do not over-tighten. This will
damage the Clamp.
1. Position FRONT Reflector (7) so it
points straight forward.
2. Tighten Clamp Screw.
NOTE: Do not over-tighten. This will
damage the Clamp.
Bicycle Assembly

15
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 (fig 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.
Bicycle Assembly

16
Training Wheel Installation (various models)
C
30
B
B
A
A
30
g 18
To attach the Training Wheels (30) to the
Frame:
1. Remove outside Axle Nuts (A) from
both sides of Axle (C).
2. Put the Alignment Tab (B) and a
Training Wheel Leg (30) and an Axle
nut (A) on each end of the rear wheel
Axle (C).
WARNING: Make sure the notch
of the tab of the Alignment Tab (B) is
to the rear of the axle and in the slot of
the frame (fig 19).
g 19
B
C
continued >>
Bicycle Assembly

17
Training Wheels - continued
3. Make sure both Training Wheels are
the same distance from the ground
(fig 20) and pointing straight down.
4. Tighten Axle Nuts (A) securely.
1/8” 1/8”
g 20
AA
Operation:
WARNING: Before each ride, make sure both axle nuts are tight. Also make
sure both training wheels are the same distance from the ground (fig 20).
As your child’s ability improves, you may raise and eventually remove the training
wheels. Raising the training wheels little by little will help them learn to ride on the
bike’s two wheels.
• To move the training wheels, loosen the axle nuts, slide the leg to the correct
position, and retighten the axle nuts.
• To remove the training wheels, remove the axle nut, leg and alignment tab. Then
reinstall and tighten the axle nut securely.
WARNING: When riding with training wheels:
• Ride only on level areas.
• Do not ride on steep hills, uneven sidewalks, or near steps. The bicycle can tip
over if a training wheel goes off the edge of the riding surface.
• Ride straight up and down sloped surfaces, because the bicycle can tip over
when riding across sloped surfaces.
• Slow down at corners because you can not turn as quickly as bicycles without
training wheels.
Bicycle Assembly

18
continued >>
Brake System Setup
WARNING: You must adjust the front brakes before you ride the bicycle.
NOTE: FRONTAND REAR BRAKE SETUP IS THE SAME.
A
B
Step One: Put the brake shoes (B) in the correct position:
• Loosen the Screw (A) of each Brake Shoe (B).
• Adjust each Brake Shoe so it is flat against the rim and aligned with the curve of
the rim.
• Make sure each Brake Shoe does not rub the tire.
• If the surface of the Brake Shoe has arrows, make sure the arrows point toward
the rear of the bicycle.
• Hold each Brake Shoe in position and tighten the Screw.
Step Two: Test the tightness of each Brake Shoe:
• Try to move each Brake Shoe out of position.
• If a Brake Shoe moves, do Step 1 again, but tighten the nut tighter than before.
• Do this test again, until each Brake Shoe does not move.
Bicycle Assembly

19
Bicycle Assembly
Brake System Setup - continued
1. Loosen Cable Nut (1-1) so that the
cable is loose. 1
1-1
2. Insert Cable Barrel (2-1) into
Brake Lever.
2-1
2
3. Insert Brake Cable (3-1) into
Groove as shown.
3-1
3
continued >>

20
Brake System Setup - continued
4. Rotate Housing (4-1) Groove
away from Cable Groove (4-2)
and tighten Housing Nut (4-3).
4-3
4-2
4-1
4
5. Squeeze Brake Arms (5-1) so that
Brake Pads (5-2) are against the
Rim. 5
5-1
5-25-2
6. Pull Brake Cable (6-1) tight.
• Tighten Cable Nut (6-2).
• Adjust Cable Nut (6-3) for 1/16”
Brake Pad clearance.
6-3
6-2
6
6-1
1/16” 1/16”
Bicycle Assembly