Insportline KAWASAKI Juniso 12 User manual

USER MANUAL –EN
IN 16920 Kids Bike KAWASAKI Juniso 12"
IN 16921 Kids Bike KAWASAKI Juroku 16"
IN 16922 Junior Bike KAWASAKI Nijumo 20"
May not be exactly as illustrated

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CONTENTS
SAFETY EQUIPMENT ............................................................................................................................ 4
MECHANICAL SAFETY CHECK......................................................................................................... 5
RIDING SAFETY AND RESPONSIBILITY.............................................................................................. 6
THE OWNER’S RESPONSIBILITY..................................................................................................... 6
AN IMPORTANT NOTE TO PARENTS............................................................................................... 6
THE BASICS........................................................................................................................................ 8
RULES OF THE ROAD ....................................................................................................................... 8
RULES OF THE TRAIL........................................................................................................................ 9
WET WEATHER RIDING .................................................................................................................. 10
NIGHT RIDING .................................................................................................................................. 10
BICYCLING IN TRAFFIC................................................................................................................... 11
ASSEMBLY, MAINTENANCE AND ADJUSTMENT............................................................................. 12
TOOLS / TECHNICAL SUPPORT..................................................................................................... 12
REFLECTORS................................................................................................................................... 13
PEDALS INSTALLATION.................................................................................................................. 14
SADDLE INSTALLATION.................................................................................................................. 14
BRAKE AND BRAKE CABLE INSTALLATION ................................................................................. 15
ADJUSTING THE HANDLEBAR STEM AND HEADSET ................................................................. 16
HANDLEBAR AND STEM ................................................................................................................. 16
FRONT WHEEL ASSEMBLY ............................................................................................................ 17
BRAKES............................................................................................................................................. 18
REAR DERAILLEUR ADJUSTMENT................................................................................................ 20
TIRES................................................................................................................................................. 20
REPAIR AND SERVICE.................................................................................................................... 21
LUBRICATION / MAINTENANCE ..................................................................................................... 23
SERIAL NUMBER ................................................................................................................................. 24
TERMS AND CONDITIONS OF WARRANTY, WARRANTY CLAIMS................................................. 24

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This manual contains important safety, performance and maintenance information. Please read
this manual before taking your first ride on your new bicycle, and keep this manual handy for
future reference.
CHOOSING THE CORRECT SIZE: The bicycle must be chosen to fit the rider. Straddle the
assembled bicycle with feet shoulder width apart and flat on the ground. There must be at least one
inch of clearance between the highest part of the top tube and the crotch of the rider.
SADDLE ADJUSTMENT: Once you're in the saddle, make sure you can reach the bottom of the
pedal stroke with a slightly bent knee and flat foot.
ASSEMBLY: Read and follow assembly instructions in this manual and make sure all nuts and bolts
are tightened properly.
WEIGHT LIMIT:
•14ʺ/16ʺ Kids Bikes: 50kg
•20ʺ/24ʺ Junior Bikes: 100kg
Like any sport, bicycling involves risk of injury and damage. By choosing to ride a bicycle, you assume
the responsibility for that risk. Not the people who sold you the bike. Not the people who made it. Not
the people who distribute it. Not the people who manage or maintain the roads or trails you ride on.
You. So you need to know –and to practice –the rules of safe and responsible riding.

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SAFETY EQUIPMENT
WARNING: Many states require specific safety devices. It is your responsibility to familiarize yourself
with the laws of the state where you ride and to comply with all applicable laws, including properly
equipping yourself and your bike as the law requires.
1. HELMET
While not all states require bicyclists to wear approved protective headgear, common sense dictates
that you should wear an ANSI or Snelll approved helmet whether the requires it or not. Most serious
bicycle injuries involve head injuries which might have been avoided if the rider had worn a helmet.
Your dealer has a variety of attractive helmets, and can recommend one to suit your needs. Your
helmet must fit correctly, be worn correctly and be properly secured to do its real job. Ask your dealer
to help you with the fit and adjustment of your helmet.
WARNING: Always wear a helmet when riding your bike. Always keep the chin strap securely
buckled. Failure to wear an approved helmet may result in serious injury or death.
2. REFLECTORS
Reflectors are important safety devices which are designed as an integral part of your bicycle.
Federal regulations require every bicycle to be equipped with front, rear, wheel and pedal reflectors.
The size, performance and location of each reflector is specified by the U.S. Consumer Products
Safety Commission. The reflectors are designed to pick up and reflect car lights in a way that helps
you to be seen and recognized as a moving bicyclist.
CAUTION: Check reflectors and their mounting brackets regularly to make sure that they are clean,
straight, unbroken and securely mounted. Have your dealer replace damaged reflectors and straighten
or tighten any that are bent or loose.
WARNING: Do not remove the reflectors or reflector mounting brackets from your bicycle. They are an
integral part of the bicycles safety system.
Being struck by other vehicles often results in serious injury or death. Remember: reflectors are not a
substitute for lights. Always equip your bicycle with all state and locally mandated lights.
3. LIGHTS
We strongly recommend that children not ride after dusk or before daylight. If you must ride your bike
after dusk or before full daylight, your bicycle must be equipped with lights so that you can see the
road and avoid road hazards; and so that others can see you. Vehicle laws treat bicycles like any
other vehicle. That means you must have a white front and a red rear light operating if you are riding
after dusk or before full daylight. Your bike dealer can recommend a battery or generator powered
lighting system appropriate to your needs.
WARNING: Reflectors are not a substitute for proper lights. It is your responsibility to equip your
bicycle with all state and locally mandated lights. Riding at dawn, at dusk, at night or at other times of
poor visibility without a bicycle lightning system which meets local and state laws and without
reflectors is dangerous and may result in serious injury or death.
4. PEDALS

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Some higher performance model bicycles come equipped with pedals that have sharp and potentially
dangerous surfaces. These surfaces are designed to add safety by increasing adhesion between the
rider’s shoe and the bicycle pedal. If your bicycle has this type of high-performance pedal, you must
take extra care to avoid serious injury from the pedals sharp surfaces.
Based on your riding style or skill level, you may prefer a less aggressive pedal design. Your dealer
can show you a number of options and make suitable recommendations.
MECHANICAL SAFETY CHECK
Here is a simple, sixty-second mechanical safety check which you should get in the habit of making
every time you’re about to get on the bike.
1. NUTS, BOLTS
Lift the front wheel off the ground by two or three inches, then let it bounce on the ground. Anything
sound, feel or look loose? Do a quick visual and tactile inspection of the whole bike. Any loose parts or
accessories? If so, secure them. If you’re not sure, ask someone with experience to check.
2. TIRES & WHEELS
Tires correctly inflated? Check by putting one hand on the saddle, one on the intersection of the
handlebars and stem, then bouncing your weight on the bike while looking at tire deflection. Compare
what you see with how it looks when you know the tires are correctly inflated; and adjust if necessary.
Tires in good shape? Spin each wheel slowly and look for cuts in the tread and sidewall. Replace
damaged tires before riding the bike.
Wheels true? Spin each wheel and check for brake clearance and side-to-side wobble. If a wheel
wobbles side to side or hits the brake pads, take the bike to a qualified bike shop to have the wheel
trued.
CAUTION: Wheels must be true for hand brakes to work effectively. Wheel truing is a skill which
requires special tools and experience. Do not attempt to true a wheel unless you have the knowledge
and tools needed to do the job correctly.
3. BRAKES
If your bicycle has hand-operated brakes, squeeze the brake levers. Are the brake shoes contacting
the wheel rim within an inch of brake lever movement? Can you apply full braking force at the levers
without having them touch the handlebar? If not, your brakes need adjustment. Do not ride the bike
until the brakes are properly adjusted. If your bicycle has a coaster brake, check to make sure that
the coaster brake arm is securely clamped to the bicycle frame. If the arm or its mounting bracket are
loose, do not ride the bike until the brake arm is properly secured.
WARNING: Riding with improperly adjusted and secured brakes or worn brake shoes is dangerous
and can result in serious injury or death.
4. WHEEL NUTS
Are the front and rear wheels straight and secure in the dropouts? Are the wheel nuts properly
tightened?
WARNING: Riding with an improperly installed or insufficiently tightened wheel can cause the wheel to
wobble or disengage from the bicycle, which can cause damage to the bicycle and serious injury or
death.
5. HANDLEBAR AND SADDLE ALIGNMENT
Are the saddle and handlebar stem correctly parallel to the bikes top tube and tight enough so that you
can twist them out of alignment?
6. HANDLEBAR ENDS
Are the handlebar grips secure and in good condition? If not, replace them. Are the handlebar ends
plugged? If not, plug them before you ride.

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WARNING: Loose or damaged handlebar grips can cause you to lose control and fall. Unplugged
handlebars can act like a cookie cutter on your body, and cause serious injury in an otherwise minor
accident.
RIDING SAFETY AND RESPONSIBILITY
NOTE: Like any sport, bicycling involves risk of injury and damage. By choosing to ride a bicycle, you
assume the responsibility for that risk. Not the people who sold you the bike. Not the people who made
it. Not the people who distribute it. Not the people who manage or maintain the roads or trails you ride
on. You. So you need to know –and to practice –the rules of safe and responsible riding.
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 with
the bicycle. The owner must make sure all components are securely attached.
If the bicycle was purchased assembled, it’s the owner’s responsibility, before riding the bicycle for the
first time, to make sure the bicycle is assembled and adjusted exactly as written in this manual and
any “Special Instructions” supplied with the bicycle. The owner must make sure all components are
securely attached.
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.
There must be at least one inch of clearance (1) between the highest part of the top tube (2) and the
crotch of the rider.
The minimum leg-length for the rider is the highest part of the top tube plus one-inch (3).
The rider must be able to easily reach and operate the brake levers (if so equipped).
AN IMPORTANT NOTE TO PARENTS
In addition to The Basics, the Rules of the Road, the Rules of the Trail, Wet Weather Riding,
Night Riding and Bicycling in Traffic, kids need to be taught … and to have frequently reinforced …
the following rules and lessons which adults are already expected to know. We urge you to take the
time to familiarize yourself with these rules and to teach them to your child before you let your child
ride unsupervised.
1. RULES
•No playing in the road or in the street,
•No riding on busy streets.
•No riding at night.
•Stop for all STOP signs.

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•Ride on the right of traffic.
2. LESSONS
The lessons that follow relate to some of the most common real situations that children encounter
when riding their bikes. Go over these situations with your child and make sure the lesson objective is
accomplished.
Driveway Rideout: When a youngster rides out of the driveway and is struck by a car, that is called a
rideout accident.
What can you do?
First, realize the danger of your own driveway. If there are obstructions to the view of passing
motorists (like bushes or trees), trim them back. You might park your car in front of the driveway, if
local ordinance permits. This way, your child can’t use the driveway as a launching pad.
But the most important thing you can do is teach your child about driveway safety. Take your child
outside to the driveway and have him/her practice the following steps.
•Stop before entering the street.
•Look left, right and left again for traffic.
•If there is no traffic, proceed into the roadway.
Running the Stop Sign: Car/bike crashes can happen when a cyclist runs a stop sign. Most cyclists
who get hit riding through stop signs know that they were supposed to stop. They just thought it would
be OK this time; or they may have been distracted.
The thing to impress upon your child is that while he/she may not get hit every time, running stop signs
will eventually result in an accident.
What can you do?
Take your child to a stop sign near home. Explain what it means by emphasizing the following points:
1) Stop at all stop signs, regardless of what is happening.
2) Look in all directions for traffic.
3) Watch for oncoming cars making left turns.
4) Watch for cars behind you making right turns.
5) Wait for any cross traffic to clear.
6) Proceed when safe.
In order to make this lesson stick, you may have to change your own driving habits. If you creep
through intersections controlled by stop signs, you are showing your child that you don’t really believe
what you preach. For your child’s sake, stop at stop signs.
Turning Without Warning: Another major accident type involves cyclists who make unexpected left
turns. They neither look behind for traffic, nor do they signal. The key factor here is neglecting to look
to the rear: If the cyclist had looked, he/she would have seen the danger coming up from behind.
What can you do?
Of course, you ought to teach your child not to ride across busy streets –at least until the child has
had some advanced training and is old enough to understand traffic. But in the meantime, for
residential street riding, you can teach your child to always look and signal before turning left. A big
part of this lesson is teaching the child how to look to the rear without swerving.
Take your child to a playground to practice riding along a straight line while looking behind. Stand
alongside and hold up a different number of fingers on your hand after the child rides by. Call his/her
name. After 15 minutes of practice, a ten-year-old should be able to look behind his/herself and
identify how many fingers you are holding up –without swerving.

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Night Time Riding: Most car/bicycle accidents happen at night where an overtaking car hits a bike.
(An overtaking car is one that comes up from behind and passes the cyclist on the left.) These
overtaking accidents can be very serious.
What can you do?
First, you should keep your youngster from riding at night. It requires special skills and equipment.
Few children have either. Secondly, make sure your child understands that if he/she gets caught out
after dark on a bike, the thing to do is to call you for a ride home. One suggestion is to tape phone
money to the bike so that, in an emergency, the child will be able to call home.
Following the Leader: There is increased risk of car/bike collision if children are following each other,
because if the first one does something dangerous, those following may do it too.
What can you do?
Teach your child to always assess the traffic situation for him/herself. When a group is riding around,
each cyclist should stop for stop signs; each cyclist should look to the rear before making left turns;
and so on. One way to get the message across is to play a game with the child similar to Simon Says.
In this game, however, the emphasis should not be on doing what Simon Says, but rather have the
child make a decision based on the situation. The child should learn to ignore what Simon Says.
Children need to learn to think for themselves to ride safely.
SUMMARY: Teach your child early –the earlier the better. Learning skills such as looking and
avoiding hazards takes time. Be prepared to repeat lessons until your child understands what you’re
trying to get across. Be patient. Your efforts will be rewarded, knowing that your child is aware of safe
riding skills.
THE BASICS
1. Always do the Mechanical Safety Check before you get on a bike.
2. Be thoroughly familiar with the controls of your bicycle.
3. Be careful to keep body parts and other objects away from the sharp teeth of chainrings; the
moving chain; the turning pedals and cranks; and the spinning wheels of your bicycle.
4. Always wear a cycling helmet which meets the latest Snell or ANSI standard.
5. Always wear shoes that will stay on your feet and will grip the pedals. Never ride barefoot or
wearing sandals.
6. Wear bright, visible clothing that is not so loose that it can catch on moving parts of the bicycle
or be snagged by objects at the side of the road or trail.
7. Don’t jump with your bike. Jumping a bike, particularly a BMX bike, can be fun; but it puts
incredible stress on everything from your spokes to your pedals. Perhaps most vulnerable to
jumping –on jumping their bikes risk serious damage, to their bicycles as well as to
themselves.
RULES OF THE ROAD
1. Learn the local bicycle laws and regulations. Many communities have special regulations
about licensing of bicycles, riding on sidewalks, law regulating bike path and trail use, and so
on. Many states have helmet laws, child carrier laws and special bicycle traffic laws. In the
U.S. and in most foreign countries, a bicyclist is required to obey the same traffic laws as the
driver of a car or motorcycle. It’s your responsibility to know and obey the laws.
2. You are sharing the road or the path with others –motorists, pedestrians and other cyclists.
Respect their rights, and be tolerant if they infringe on yours.
3. Ride defensively. Assume that the people with whom you are sharing the road are so
absorbed with wat they are doing and where they are going that they are oblivious to you.
4. Look ahead of where you’re going, and be ready to avoid:

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•Vehicles slowing or turning in front of you, entering the road or your lane ahead of you,
or coming up behind.
•Parked car doors opening in front of you.
•Pedestrians stepping out in front of you.
•Children playing near the road.
•Pot holes, sewer grating, railroad tracks, expansions joints, road or sidewalk
construction, debris and other obstructions that could cause you to swerve into traffic,
catch your wheel or otherwise cause you to lose control and have an accident.
5. Ride in designated bike lanes, on designated bike paths or on the right side of the road, in the
same direction as car traffic and as close to the edge of the road as possible.
6. Stop at stop signs and traffic lights; slow down and look both ways at street intersections.
Remember that a bicycle always loses in collision with a motor vehicle, so be prepared to yield
even if you have the right of way.
7. Use hand signals for turning and stopping. Learn the local vehicle code for the correct signals.
8. Never ride with headphones. They mask traffic sounds and emergency vehicle sirens, distract
you from concentrating on what going on around you, and their wires can tangle in the moving
parts of the bicycle, causing you to lose control.
9. Never carry a passenger.
10. Never carry anything which obstructs your vision or your complete control of the bicycle, or
which could become entangled in the moving parts of the bicycle.
11. Never hitch a ride by holding on to another vehicle.
12. Don’t do stunts, wheelies or jumps. They can cause you injury and damage your bike.
13. Don’t weave through traffic or make any moves that may surprise people with whom you are
sharing the road.
14. Observe and yield the right of way.
15. Never ride your bicycle while under the influence of alcohol or drugs.
16. If possible, avoid riding in bad weather, when visibility is obscured, at dusk or in the dark, or
when extremely tired. Each of these conditions increases the risk of accident.
RULES OF THE TRAIL
1. We recommend that children not ride off-road without the accompaniment of an adult. In any
event, never ride alone in remote areas. Even when riding with others, make sure that
someone knows where you’re going and when you expect to be back. Always take along
some kind of identification, so that people know who you are in case of an accident; and take
a couple of dollars in cash for a candy bar, a cool drink or an emergency phone call.
2. Surface hazards make off-road riding much more difficult and therefore more dangerous than
riding on paved roads. Start slowly and build up your skills on easier terrain before tackling the
more difficult.
3. Learn and obey the local laws regulating where and how you can ride off-road, and respect
private
property. Don’t ride where you are not welcome or where you are not allowed.
4. You are sharing the trail with others - hikers, equestrians, other cyclists. Respect their rights,
and be tolerant if they inconvenience you.
5. Yield right of way to pedestrians and animals. Ride in a way that does not frighten or
endanger them, and stay far enough away so that their unexpected moves don’t endanger
you.

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6. You may be riding in sensitive habitat, so stay on the designated trail. Don’t contribute to
erosion by riding in mud or with unnecessary sliding. Don’t disturb wildlife or livestock; and
don’t disturb the ecosystem by cutting your own trail through vegetation or streams.
7. It is your responsibility to minimize your impact on the environment. Ride accordingly. Leave
things as you found them; and always take out everything you brought in.
8. If you crash: First, check yourself for injuries, and take care of them as best you can. Next,
check your bike for damage, and fix what you can. Then, when you get home, carefully
perform the maintenance procedure described this manual and check for any other damaged
parts. All bent, scored or discolored parts are suspect and should be replaced.
WARNING: A crash can put extraordinary stress on bicycle components, causing them to fatigue
prematurely. Components suffering from stress fatigue can fail suddenly and catastrophically, causing
loss of control, serious injury or death.
CAUTION: If you have any doubt about the condition of the bicycle or any of its parts, take it
to your dealer for a thorough check.
WET WEATHER RIDING
WARNING: Wet weather impairs traction, braking and visibility, both for the bicyclist and for other
vehicles sharing the road. The risk of accident is dramatically increased in wet conditions.
Under wet conditions, the stopping power of your brakes (as well as the brakes of other vehicles
sharing the road) is dramatically reduced and your tires don’t grip nearly as well. This makes it harder
to control speed and easier to lose control. To make sure that you can slow down and stop safely in
wet conditions, ride more slowly and apply your brakes earlier and more gradually than you would
under normal, dry conditions.
NIGHT RIDING
Riding a bicycle at night is many times more dangerous than riding during the day. Therefore,
children should never ride at dawn, at dusk or in the dark. Adults should not ride at dawn, at dusk or
at night unless it is absolutely necessary.
WARNING: Riding at dawn, at dusk, at night or at other times of poor visibility without a bicycle
lighting system which meets local and State laws and without reflectors is dangerous and can result in
serious injury or death.
Even if you have excellent night vision, many of the people with whom you’re sharing the road don’t.
A bicyclist is very difficult for motorists and pedestrians to see at dawn, at dusk, at night or at other
times of poor visibility. If you must ride under these conditions, check and be sure you comply with all
local laws about night riding: follow the Rules of the Road and of the Trail even more carefully; and
make sure to take the following additional precautions:
Before riding at dawn, at dusk, at night or at other times of poor visibility, take the following
steps to make yourself more visible:
•Make sure that your bicycle is equipped with correctly positioned and securely mounted
reflectors.
•Purchase and install an adequate battery or generator powered head and tail light.
•Wear light colored, reflective clothing and accessories, such as a reflective vest, reflective arm
and leg bands, reflective stripes on your helmet, flashing lights...any reflective device or light
source that moves will help you get the attention of approaching motorists, pedestrians and
other traffic.
•Make sure your clothing or anything you may be carrying on the bicycle does not obstruct a
reflector or light.
While riding at dawn, at dusk, at night or at other times of poor visibility:
•Ride slowly.

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•Avoid areas of heavy traffic, dark areas, and roads with speed limits over 35mph.
•Avoid road hazards.
BICYCLING IN TRAFFIC
Obey traffic signs
and signals –
bicycles must
drive like any
other vehicles if
they are to be
taken seriously by
the motorists.
Never ride against
traffic –motorists
aren’t looking for
bicyclists on the
wrong side of the
road.
Choose best way
to turn left –there
are two ways to
make left turn. 1.
Like a car –
signal, move into
the left lane and
turn left. 2. Like a
pedestrian –ride
straight to the far
side crosswalk.
Walks your bike
across.
Don’t pass on the
right –motorists
may not look for o
see a bicycle
passing on the
right.
Go slow on
sidewalks –
pedestrians have
the right of way.
By law, you must
give pedestrians
audible warning
when you pass.
Don’t cross
driveways or
intersections
without slowing to
a walker’s pace
and looking very
carefully for traffic
(especially traffic
turning right on a
green light).
Use hand signals
–hand signals,
using your left
arm, tell motorists
what you intend to
do. Signal as a
matter of law,
courtesy and
safety.
Ride in a straight
line –whenever
possible, ride in a
straight line, to the
right of traffic, but
about a car doors
width away from
parked cars.
Don’t weave
between parked
cars –don’t ride
out to the curb
between parked
cars unless they
are far apart.
Motorists may not
see you when you
try to move back
into traffic.
Ride in middle of
lane in slow traffic
–get in the
middle of the lane
at busy
intersections and
whenever you are
moving at the
same speed as
traffic.
Follow lane
markings –don’t
turn left from right
lane. Don’t go
straight in a lane
marked Right
Turn Only.

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Watch for cars
pulling out –make
eye contact with
driver. Assume
they don’t see you
until you are sure
they do.
Scan the road
behind –learn to
look back over
your shoulder
without losing your
balance or
swerving left.
Some riders use
rear view mirrors.
Avoid road
hazards –watch
out for parallel
slat sewer grates,
slippery manhole
cover, oily
pavement, gravel
and ice. Cross
railroad tracks
carefully at right
angles. To get
better control as
you move across
bumps and other
hazards, stand up
on your pedals.
Keep both hands
ready to brake –
you may not stop
in time if you
brake one-
handed. Allow
extra distance for
stopping in the
rain, since brakes
are less efficient
when wet.
Watch for chasing
dogs –ignore
them or try a firm
No! if the dog
doesn’t stop,
dismount with
your bike between
you and the dog.
Dogs are
attracted to
spinning wheels
and feet.
ASSEMBLY, MAINTENANCE AND ADJUSTMENT
TOOLS / TECHNICAL SUPPORT
Your new bicycle was assembled and tuned in the factory and then partially disassembled for
shipping. You may have purchased the bicycle already full re-assembled and ready to ride OR in the
shipping carton in the partially disassembled form. The following instructions will enable you to prepare
your bicycle for years of enjoyable cycling. Please check that all parts referred to in the instructions
and shown in the diagram have been included, and that all tools needed are at your disposal. For
more details on inspections, lubrication, maintenance and adjustment of any area please refer to the
relevant sections in this manual. If you need replacement parts or have questions pertaining to
assembly of your bicycle, call HYPER direct at:
HYPER BICYCLES SERVICE AND TECHNICAL SUPPORT:
1.866.424.0500
Monday –Friday (10:00AM –8:00PM –EST)
Tools Required:
•Phillips head screw driver; 4mm, 5mm
•6mm & 8mm Allen keys; adjustable
•Adjustable wrench or a 9mm, 10mm, 14mm & 15mm
•Open and box end wrenches; and a
•Pliers with cable cutting ability.
To avoid injury, this product must be properly assembled before use. If your bicycle was obtained after
assembled, we strongly recommended that you review the complete assembly instructions and
maintenance checks specified in this manual before riding.

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REFLECTORS
Your bicycle is supplied with one front (white), one rear (red),
two wheel (white), and two pedal (orange) reflectors. These are
an important safety and legal requirement, and should remain
securely fitted and in good, clean conditions at all times.
Periodically, inspect all reflectors, brackets and mounting
hardware for signs of wear or damage. Replace immediately if
damage is found.
FRONT REFLECTOR BRACKET INSTALLATION
NOTICE: It is important to check and adjust the position of the
reflectors as you assemble your bike. The reflectors must
always be vertical (perpendicular to the ground) and pointed
toward the front and rear of the bike. Please make sure that the
adjustment is correct as a final step in the assembly of your
bike.
Attaching hardware to the handlebars
With the white reflector facing forward wrap the rear end of the
reflector bracket around the handlebar (A). Once the bracket is
in the correct position, and the fastening nut is in place
underneath the bracket, thread the screw down through the
top of the bracket. Tighten screw firmly with screwdriver (B).
REAR REFLECTOR INSTALLATION
1. Put the seat post mounted rear reflector in the correct position
by loosening the screws of the rear reflector bracket.
2. Make sure the rear reflector is vertical and points straight
toward the rear of the bicycle.
3. Make sure there are at least 3 inches of clearance between
the top of the seat and the top of the red rear reflector.
Operation and Maintenance
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.

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PEDALS INSTALLATION
All pedals have L or R stamped on the threaded spindle of each pedal.
1. Thread the pedal marked R clockwise into the right or chain
wheel side of the crank arm.
2. Thread the pedal marked L counter-clockwise into the left side
of the crank arm.
NOTE: Hand thread pedals into position without use of a wrench to
ensure threads are not crossed. Damage to crank arm will result from
crossed threads. When tightening with a wrench, make sure each
spindle is firmly seated against the crank arm. If jaws or wrench are
too thick, they may prevent proper tightening of pedal spindle against
crank arm.
SADDLE INSTALLATION
1. Insert the seat post into bicycle frame tube with small swaged
end up.
NOTE: Seat post must be inserted at least to the minimum
insertion mark stamped on the lower part of the post. If no
minimum insertion mark can be found, make sure at least 3 of
the post is inside the bicycle frame tube.
2. Tighten the seat post clamp nut securely. Recommended
torque is 120in/lb.
3. Loosen saddle clamp nut(s) so saddle clamp will fit down fully
onto top swaged end of seat post.
4. Tighten seat post bolt. Recommended torque is 150in/lbs.
SADDLE HEIGHT
1. Turn crank to place it in its lowest position.
2. Place heel of foot on pedal with foot parallel to the ground.
3. Position saddle so that toe of other foot can touch the ground.
Saddle should also be parallel to the ground and aligned
straight with the bicycle frame.
4. Tighten seat post bolt. Recommended torque is 150in/lbs.
NOTE: Seat post must be inserted at least to the minimum
insertion mark stamped on the seat post.

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FORWARDS AND BACKWARDS
1. Position crank arm parallel to the ground.
2. Place ball of foot on pedal with foot parallel to the ground.
3. Position the saddle so that an imaginary line drawn from the
center of your knee to the pedal spindle is vertical. Some
riders move the saddle slightly forward of this positon.
NOTE: Saddle should be horizontal and perfectly aligned with
the bicycle.
4. Tighten saddle clamp nut securely.
Please read and follow all directions in this manual.
Always wear a helmet when you ride.
BRAKE AND BRAKE CABLE INSTALLATION
1. Attach the upper cable to the brake lever by opening the brake
lever and placing the barrel end of the cable into the lever.
2. Feed brake cable through cable adjuster and through anchor
bolt. Secure anchor bolt firmly.
3. Fasten brake caliper to fork by sliding brake mount bolt
through center hole in fork. Secure brake mount bolt firmly.
4. Pull the link wire on the rear brake assembly until the brake
shoes are touching the rim wall and tighten the brake bolt.
5. Ensure that the brake shoes are positioned evenly with the
side surface of the rim.
Refer to the next section for Brake System Adjustments.

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ADJUSTING THE HANDLEBAR STEM AND HEADSET
NOTE: The handlebar stem and headset are an integrated system.
Both must be adjusted at the same time.
1. To adjust the headset or stem, first loosen the two stem binder
bolts, then the adjuster bolt in the top cap.
2. Align the handlebar stem with the front wheel.
3. To remove play from the headset, begin by tightening the
adjuster bolt in the top cap. This will tighten the headset and
remove side to side movement of the fork. If the fork fails to
rotate freely, the adjuster bolt is too tight and needs to be
loosened.
WARNING: Do not over tighten the adjuster bolt. Its function is
to adjust he headset. The stem binder bolts’function is to hold
the fork and stem in place.
4. Once the headset is adjusted, tighten the two stem binder bolts
to the recommended torque of 140 pounds per inch. Do not
over tighten these bolts.
WARNING: Do not over tighten the stem binder bolts and
handlebar binder bolts. Failure to properly tighten these
bolts may damage the handlebar and/or stem to fork
assembly. This may compromise the steering action,
causing you to possibly lose control, and possibly injure
yourself.
HANDLEBAR AND STEM
1. Assemble the stem to the fork: If necessary, assemble the stem to bolt (4), washer (5), and
wedge nut (2) to the stem (1). Turn the stem bolt only four revolutions into the wedge nut.
Turn the stem bolt only four revolutions into the wedge nut (2). Point the stem toward the front
of the bicycle and put it into the locknut (7). Put the stem at a comfortable height for the rider.
WARNING: To prevent steering system damage and possible loss of control, the MIN-IN
(minimum insertion) mark on the stem must be inside the locknut.
Make sure you cannot see the MIN-IN (minimum insertion) mark (3) on the stem above the
locknut.
Tighten the stem bolt just enough that the stem will not fall into the locknut.
2. Assemble the handlebar to the stem:
Put the handlebar (8) into the stem, but do not tighten the handlebar clamp (6) at this time.
Align the stem with the front wheel and tighten the stem bolt.

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3. Assemble the brake lever to the handlebar: Loosen the clamp screw of each brake lever. If
necessary, move the handlebar to each side to install the brake levers put the brake levers on
the handlebar with the brake lever for the rear brake on the right side of handlebar. Do not
tighten the clamp screw of the brake levers at this time.
4. Tighten stem bolt and the handlebar clamp: Do not overtighten the stem bolt. Over
tightening the stem bolt can damage the steering and cause loss of control make sure the
stem is aligned with the front wheel and tighten stem bolt.
Put the handlebar in a comfortable position for the rider.
WARNING: If the handlebar clamp is not tight enough, the handlebar can slip in the stem. This can
cause loss of control.
Tighten the bolts of the handlebar clamp. If the handlebar clamp has more than one bolt, than tighten
the bolts equally.
5. Test the tightness of the stem: straddle the front wheel and hold it 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 front wheel.
Tighten the bolt tighter than you did before (about half a revolution only at a time).
Do this test again, until the handlebar and stem do not turn without turning the wheel.
6. Test the tightness of the handlebar: Hold the bicycle stationary and try to move the ends of the
handlebar forward or backward.
If the handlebar moves, loosen bolts of handlebar clamps. Put the handlebar in the correct
position.
Tighten the bolts of the handlebar clamp tighten 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.
FRONT WHEEL ASSEMBLY
Insert wheel into position making sure the axle (1) is aligned with the
fork dropout (2).
- Make sure the tab of each security washer (4) is in the hole
of the fork.
NOTE: Some models have a front fork with a built in wheel
retention feature. The security washers are not required and
will not fit on a fork with this feature.
- Using the two axle nuts (3) with serrations, tighten the axle
nuts and secure the front wheel.
WARNING: Do not use the nuts without serrations to attach
the front wheel.
NOTE: The recommended torque of 21 ft-lbs.

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BRAKES
BRAKE SYSTEM ADJUSTMENTS
WARNING: You must adjust the front brakes as written before you ride the bicycle.
1. Put the brake shoes in the correct position:
Loosen the nut (1) of each brake shoe. 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 shoes has arrows,
make sure the arrows point toward the rear of the bicycle. Hold each brake
shoe in position and tighten the nut.
2. 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.
3. Stretch the cable:
Hold both brake shoes against the rim. Loosen the cable clamp. Pull the
cable tight and tighten the cable clamp
WARNING: Do not overtighten the cable clamp. Overtightening the
cable clamp may cut the cable and cause injury to the rider or to
others.
Squeeze each brake lever firmly 20 times. Hold both brake shoes against
the rim and loosen the cable clamp. Pull the cable tight and tighten the
cable clamp.
The following sections describe final brake system adjustments required before riding. Determine
which style you have and follow the instructions.
1. Check tightness of caliper brake mounting nut or cantilever
mounting bolts (1):
Make sure each caliper brake mounting nut or cantilever mounting bolt is
tightened securely.
2. Center brake shoes on rim:
If you have a cantilever brake, turn the cable anchor bolt (6) on the
cantilever arm (4) to move the arm in or out so each brake shoe is the
same distance from the rim (3). If you have a caliper brake, hit downward
lightly on the return spring of the brake shoe (2) that is farther away from
the rim. Make sure both ends of the return spring stay hooked around the
inside edge or between the studs on the back of the caliper arms. Squeeze
the brake lever two times. Do this step again, until both brake shoes are
the same distance from the rim.
3. Put the brake shoes the correct distance from the rim (5):
Position each brake shoe 1/16 inch away from the rim. Turn the brake lever
adjusting barrel or caliper brake adjusting barrel in or out to make the
adjustment. If the brake shoes cannot be positioned the correct distance
from the rim, hold both brake shoes against the rim and loosen the cable
anchor bolt (6). Position each brake shoe 1/16 inch away from the rim. Pull
brake cable tight getting rid of any excess slack. Be careful not to pull
brake arm out of center. Tighten anchor bolt securely. Squeeze the brake
lever to check brake action.

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WARNING: Do not overtighten the cable clamp. Overtightening the cable clamp may cut the
cable and cause injury to the rider or to others.
Do step 3 until the brake shoes are the correct distance from the rim. Turn the locknut(s) against the
brake lever and the caliper brake.
WARNING: Do not move the brake shoes away from a wheel rim that is not true (straight). This can
cause the caliper brake to be less effective and unsafe. To allow safe adjustment of the caliper brake,
have a bicycle service ship true the wheel.
4. Check sheath position:
Make sure both ends of the sheath are fully recessed in the brake lever, sheath stops (if equipped)
and brakes. If not, install sheath in correct position and do Step 3 again. Do this test again, until the
sheath is in the correct position.
5. Test the tightness of the cable clamp:
Squeeze each brake lever with firm pressure. Make sure the cable does not move in the cable clamp.
If the cable moves in the cable clamp, do Steps 3 and 4 again but tighten the cable clamp tighter than
before. Do this test again, until the cable does not move in the cable clamp.
6. Adjust the brake lever reach so the distance from the grip is comfortable to the rider.
Turn the adjustment screw (if equipped) to change the distance of the brake lever from the grip. Make
sure the back of each grip is no more than 3 inches from the front of each brake lever.
7. Test the travel of each brake lever:
Squeeze each brake lever with strong pressure. If the brake lever touches the grip, do Steps 1 through
7 again.
WARNING: After you do Steps 1 through 7 again, if either brake lever touches the grip or does not
work well, have a bicycle service shop repair or adjust the caliper or cantilever brakes.
Reducing Caliper Brake Noise (Caliper Brake Only)
It is common for caliper brakes to make noise or "squeak" when in use. This noise does not normally
indicate a brake problem. Following the instructions below may reduce the noise:
Make sure the caliper brakes are adjusted correctly. Using a small adjustable wrench, bend each
caliper arm so the front edge of each brake shoe is the first part to touch the rim.
WARNING: Bend each caliper only a small amount. If you bend the caliper arm too far, the caliper
brake can be damaged and performance of the caliper brake reduced.
BRAKE SYSTEM OPERATION
Operate the brakes as follows:
Squeeze the brake lever on the handlebar. The brake lever pulls on a cable that is attached to the
brake. The brake squeezes the rim between two brake shoes.
Operate the brakes by slowly and continuously squeezing both brake levers until you feel the braking
action. Make a habit of always using both brakes to stop the bicycle. You will stop in the shortest
distance by using both brakes.
WARNING: If you do not obey the following instructions, injury to the rider or to others can
occur:
Before you ride the bicycle for the first time, check and adjust the brakes as written in the
"Adjustments" section. Then test the brakes and practice using them at low speed in a large and level
area that is free of obstruction.
When correctly used, the brake system is very effective. But, if you apply the front brake too strongly,
you can be thrown off the bicycle. Make a habit of always using both brakes to stop the bicycle.
Always try to brake while going in a straight line. Apply brakes earlier in the following conditions: wet
pavement, sand, gravel, leaves, or if you need to brake while turning. To reduce the chance of
skidding apply brakes intermittently.

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If the rims are wet, start to brake earlier than normal because a longer distance to stop the bicycle will
be necessary.
Be careful when riding downhill or at a high speed because as your speed increases, a longer
distance to stop the bicycle will be necessary. Slow for curves because too much speed can force you
to make a turn too wide.
Keep wax, oil, grease, etc. off the rims and the brake shoes. These lubricants will reduce brake
performance and a longer distance to stop the bicycle will be necessary.
Check and adjust the brakes the first time they do not stop the bicycle quickly and smoothly, do not
stop the bicycle as well as they have in the past, or if either brake lever can touch the grip.
REAR DERAILLEUR ADJUSTMENT
The Low limit screw determines how far the rear derailleur will travel toward
the wheel of the bicycle, while the High limit screw determines how far the
cage will travel toward the frame.
1. Shift the rear shifter to the largest number indicated, disconnect the rear
derailleur cable from the cable anchor bolt and place the chain on the
smallest sprocket.
2. Adjust the High limit screw so the chain and the smallest sprocket are
lined up vertically. Remove any slack in the cable by pulling it taut, then
re-connect the cable and tighten the cable anchor bolt securely.
3. Shift up through the gears making sure that each gear is achieved
quietly and without hesitation.
If noise occurs, use the barrel adjuster clockwise will decrease cable
tension and allow the derailleur cage to move farther away from the
bicycle in small increments. Turning counter-clockwise will increase
cable tension and bring the cage closer to the bicycle. This will micro-
adjust the positioning of the derailleur cage in relation to the freewheel.
Simply put; turn the barrel adjuster the direction you want the chain to
go.
4. Shift the chain onto the largest sprocket; adjust the low limit screw so
the chain and the largest cog are lined up vertically. If you are unable to
get the chain to the largest cog, turning the Low limit screw counter-
clockwise will enable the chain to move towards the wheel.
5. Shift through the gears ensuring each gear is achieved quietly and
without hesitation.
NOTE: It may take several adjustments to achieve the desired
positioning.
TIRES
TIRE VALVES
The tire valve allows air to enter the tire’s inner tube under pressure, but doesn’t let it back out unless
you want it to.
There are primarily two kinds of bicycle tube valves (actually, there are other designs, but they are
seldom seen in the US anymore): The Schraeder Valve and the Presta Valve. The bicycle pump you
use must have the fitting appropriate to the valve stems on your bicycle.