Huffy Mountain Bikes User manual

Owner’s Manual
for Mountain Bikes
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.
HMTB EN 110513 m0012
Copyright Huffy Corporation 2013

Owner’s Manual Index
Your Bike
• Owner’s Bicycle Identification Record...................................................3
• Fitting the Rider to the Bicycle...............................................................3
• Warning and Safety Information............................................................4
• Rules of the Road..................................................................................4
• The Owner’s Responsibility...................................................................5
Bicycle Assembly
• Parts Assembly View.............................................................................6
• Parts Assembly List...............................................................................7
• Introduction............................................................................................8
• Tools Needed.........................................................................................9
• Handlebar and Stem Installation ..........................................................10
• Assemble the Front Wheel to the Fork.................................................12
• Setting Up the Handlebars ...................................................................14
• Testing Stem and Handlebar Tightness................................................15
• Seat Installation....................................................................................16
• Testing Seat Clamp and Post Clamp Tightness ...................................17
• Pedal Installation..................................................................................18
• Reflector Brackets Installation..............................................................19
• Installing Derailleur Guard....................................................................19
Maintenance and Service
• Brake System.......................................................................................20
• Final Brake Adjustment Before Riding..................................................21
• Shift System .........................................................................................25
• Front Derailleur Adjustments................................................................28
• Rear Derailleur Adjustments.................................................................30
• Three-Piece Cranks (on some models)................................................32
• Suspension Frame (on some models)..................................................33
• Tires .....................................................................................................34
• Repair and Service...............................................................................35
• Lubrication............................................................................................35
• Lubrication Table...................................................................................36
• Inspection of the Bearings....................................................................37
• Reflectors .............................................................................................37
Huffy Warranty
• Huffy Corporation Limited Warranty .....................................................38

3
Owner’s Bicycle Identification Record
NOTE: This information is only available on the bicycle itself. It is not available from
Huffy.
Each Huffy bicycle has a Serial
Number stamped into the frame.
The Serial Number (1) can be found
on the bottom of the crank housing
as shown.
Write this number below to keep it
for future reference.
x
x
x
x
x
x
x
x
1
x
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
3
1
2
To determine the correct size of bicycle for the rider:
• Straddle the assembled bicycle with feet shoulder width apart and flat on the
ground.
• 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).
Your Bike

4
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.
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 safety standards, as well as local safety
standards.
• Ride on the correct side of the road, in a single file, and in a straight line.
• If possible, avoid riding at night, dusk, dawn and any other time of poor visibility.
• If you must ride at night or at time of poor visibility:
• Purchase, install, and use a headlight and taillight.
• Headlights are required by all states for nighttime riding and taillights are
required in some states.
• Battery-powered lights or flashing safety lights are also recommended.
• 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.
• Make yourself more visible to motorists.
• Wear light-colored or reflective clothing, such as a reflective vest and reflec-
tive bands for your arms and legs.
• Use reflective tape on your helmet.
• 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.
Your Bike

5
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 15 and 17: Testing Stem,
Handlebar and Seat Clamp tightness.
• 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.
• 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.
Rules of the Road -continued
Your Bike

6
Parts Assembly View
8
14 2730
24
20
22
21
23
13
15
15
5 6
10
18
19
35
34
26
1
9
7
2
25
3
17 16
16 17 11
12 31
29
4
28
33
32
36
Parts View

7
Parts Assembly List
No. Description No. Description
1 Handlebar Stem 19 Grips (x2) 2 Handlebar 20 Crank & Spindle Set 3 Front Wheel Assembly 21 Crank Bearings 4 Fork 22 Kickstand 5 Wheel Retainer (x2) 23 Chain 6 Axle Nut (x4) 24 Chain guard 7 Front Reflector 25 Head Set Bearing 8 Seat 26 Seat Post Hardware 9 Seat Post 27 Spring Shock
10 Rear Reflector 28 Front Brake
11 Guard Screws (x2) 29 Rear Brake
12 Derailleur Guard 30 Front Derailleur 13 Frame 31 Rear Derailleur 14 Quick Release Lever & Nut 32 Brake Lever - Left (Front Wheel) 15 Pedal (Left & Right Set) 33 Brake Lever - Right (Rear Wheel) 16 Tire (x2) 34 Shift Mechanism, Front 17 Tube (x2) 35 Shift Mechanism, Rear 18 Rear Wheel Assembly 36 Bell (if equipped)
Parts 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.
Assembly

9
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

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) (fig 01).
NOTE: Bike will have one of two styles of
Stems: Quill and Threadless.
NOTE: Remove plastic Cap (E) from the
end of the Stem (1).
Quill Style Stem:
1. Insert the Stem (1) into the fork.
2. Point the Stem (1) towards the front of
the bike.
3. Tighten the Stem Bolt (C) just enough to
hold it in position.
4. Align the stem (1) with the fork and
tighten the stem bolt (C) securely.
WARNING: Do not over tighten the
stem bolt. Over tightening the stem bolt can
damage the steering system and cause loss
of control.
1
C
A
B2
E
B
g 01
WARNING: The Front Brake (28)
must be positioned in FRONT of the Fork
(4).
g 01a
4
28
Threadless Style Stem >>
Assembly

11
WARNING: To prevent steering system damage and possible loss of control,
completely seat Stem (1) onto Fork Tube (E).
Threadless Style Stem:
Note: This procedure applies to both
the two-bolt Stem and four-bolt Stem
(figs 01b and 01c):
1. Insert the Stem (1) onto the Fork
Tube (E).
2. Point the Stem (1) towards the
front of the bike and in line with
the fork.
3. Tighten the stem bolts (C) se-
curely.
4. Place Cap into stem and tighten
screw securely (D).
D
1
E
C
g 01b
WARNING: Do not over tighten
the stem bolts (C). Over tightening the
stem bolts can damage the steering
system and cause loss of control.
WARNING: The Front Brake
(28) must be positioned in FRONT of
the Fork (4) (fig 01a) D
1
C
E
g 01c
Handlebar and Stem Installation
Assembly

12
Assemble the Front Wheel to the Fork
Loosen the Front Brakes:
1. Squeeze the two Brake arms together
(A).
2. Lift out the Brake Cable Guide (B) from
the Guide Bracket (C).
Install the Front Wheel:
3. Set the Front Wheel (3) into the front
fork (4) (fig 03).
4. Install wheel retainers (5) making sure
the tabs are in the Fork Retainer Holes
(C).
5. Attach the front wheel with the Axle
Nuts (6).
6. Tighten Axle Nuts to 21 ft-lbs. g 02
B
C
AA
g 03
4
3
5
C
6
NOTE: Ensure wheel spins freely without contacting fork or fender.
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.
WARNING: Do not use
Nuts (6) without serrations to
attach the front wheel.
Assembly

13
Re-attach Front Brake Cable:
7. Squeeze the two Brake arms together
(A).
8. Insert the Brake Cable Guide (B) into
the cutout in the Guide Bracket (C).
9. Make sure the Brake Cable Guide (B)
is seated securely in the Guide Bracket
(C) cutout.
g 04
B
B
C
C
AA
WARNING:
Check Front Brake Adjustment Before Riding!
See Brakes Section Page 20
Re-attache Front Brake Cable:
Assembly

14
Setting Up the Handlebars
Note: This procedure is for one, two and
four bolt Handlebar Stems.
1. If necessary, loosen the Handlebar
Clamp Screw(s) (A) and rotate Handle-
bar (2) into a comfortable riding posi-
tion.
2. Tighten Handlebar Clamp Screw(s) (A)
securely.
NOTE: Do not over tighten. Torque to 14-17
ft-lbs. g 05
A
2
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. A
2
g 05a
3 1
2 4
2A
g 05b
Assembly

15
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.
To test the tightness of the handlebar clamp:
• Hold the bicycle stationary and try to move the ends of the handlebar up and
down.
CAUTION: Do not exceed 100 lbs downward 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 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.
Assembly

16
Seat Installation
Attach Seat to Seat Post:
(pre-assembled on some models)
• Loosen nuts on seat clamp (A) and
rotate Seat (8) into riding position.
• Put the seat post (9) fully through the
seat clamp (A).
• 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 06
A
9
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 (9) into the Seat Tube (B)
(figs 07, 08).
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.
8CB
9
C
g 07
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 08
E
B
F
9
D
Assembly

17
CAUTION: Operate the Quick Release Lever by hand only. Do not use a ham-
mer 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:
• Open and close the Quick Release Lever with one hand while you turn the Ad-
justing Nut (F) with the other hand (fig 08).
• Tighten or loosen the Adjusting Nut (F) 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 08).
• When in the “close” position, make sure the Quick Release Lever lays against
the Seat Post Clamp.
• The tightening torque of the Quick Release Lever should be tight enough so that
the seat does not move during normal operation.
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 (see page 16).
• 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 06):
• Loosen the Seat Clamp.
• 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.
• If the Seat Post (9) moves in the Seat Tube (B):
• Move the Quick Release Lever 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, tightenAdjusting Nut and re-tighten
Quick Release Lever.
• Do this test again, until the seat post does not move in the seat tube.
Seat Installation - continued
Assembly

18
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 09):
• Make sure the threads of each pedal are fully into the crank arm.
• Make sure pedals are fully tightened with wrench.
NOTE: The recommended torque (tightness) for each pedal is 30 ft.-lbs.
g 09
R
L
Note: A Pedal Wrench is preferred for attaching Pedals. An open-end
wrench can also be used as shown.
WARNING: Ensure pedals are secure in crank arms so they will not loosen.
Periodically check tightness.
Assembly

19
Reflector Brackets Installation
1. Position FRONT Reflector (7) so it
points straight forward (fig 10).
2. Tighten Clamp Screw.
NOTE: Do not over-tighten. This will
damage the Clamp.
g 11
10
g 10
7
1. Position REAR Reflector (10) so it
points straight backward (fig 11).
2. Tighten Clamp Screw.
NOTE: Do not over-tighten. This will
damage the Clamp.
Installing Derailleur Guard (on some models)
1. Remove Screws (11) from Frame Tabs (A).
2. Install Guard (12) using two Screws (11).
3. Make sure the Guard does not contact the Derailleur (B).
4. Tighten Screws (11) securely.
A
B
11
12
g 12
Assembly

20
Brake System
Adjustments
WARNING: You must adjust the front and rear brakes before you ride the
bicycle.
Step 1: Put the brake shoes (B) in the correct position (fig 13):
1. Loosen the Screw (A) of each Brake Shoe (B).
2. Adjust each Brake Shoe so it is flat against the rim and aligned with the curve of
the rim.
3. Make sure each Brake Shoe does not rub the tire.
4. If the surface of the Brake Shoe has arrows, make sure the arrows point toward
the rear of the bicycle.
5. Hold each Brake Shoe in position and tighten the Screw.
A
C
D
B
g 13
Step 2: Test the tightness of each Brake Shoe:
1. Try to move each Brake Shoe out of position.
2. If a Brake Shoe moves, do Step 1 again, but tighten the nut tighter than before.
3. Do this test again, until each Brake Shoe does not move.
Maintenance