Retrospec SULLY User manual

ASSEMBLY INSTRUCTIONS
SULLY
TOOLS 1
STEP 1 - UNPACK YOUR BIKE
STEP 2 - SADDLE
STEP 3 - HANDLEBARS
WARNING
Using the bike with the minimum insertion line on the lower
portion of the seat post showing above the frame could result
in a failure of the seat post and/or the frame causing a loss of
control with potential injury to rider. Such failures are not
covered by warranty as it is improper use of the product.
WARNING
WARNING
Using the bike with the minimum insertion line on the lower portion of the seat post showing above the
frame could result in a failure of the seat post and/or the frame causing a loss of control with potential
injury to rider. Such failures are not covered by warranty as it is improper use of the product.
The minimum insertion line must NOT show above the seat tube (Fig. 6)
What we give you: 3 Hex Wrenches (4mm, 5mm, & 6mm), a 10-function multi-tool.(fig. 2)
What you need: Scissors, Phillips Screwdriver, 15mm wrench or crescent wrench.
Cut the shipping straps on the outside of the box.
Remove the box staples as these are sharp and can cut you as you access the bike. Lift bike out by frame and rear wheel.
Rotate the fork so that it is facing forward of the bike (Fig. 1). Place the bike on the ground, so it’s standing upright on the fork dropouts and rear tire.
Cut all of the packing zip ties.
Separate the front wheel from the bike by carefully slipping it away from the crank arm, which is resting within the spokes.
Remove the accessory box (Fig. 2) and set it aside.
Examine your new bike for any visible damage that may have occurred during shipping.
Special Note: For tightening all fasteners, please refer to Appendix D in the back of your owner’s manual for all fastener torque specifications.
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The seat post will come attached to the saddle from the factory.
Remove the plastic shipping plug from the top of the seat tube (Fig.3).
Use the included hex wrench to loosen the seat post clamp at the top of the frame seat tube.
Slide the red rear reflector onto and up the seat post, lightly tighten (red rear reflector is factory installed on some
production runs).
RECOMMENDED: Apply a thin layer of grease to the inside of the frame seat tube.
Insert the seat post/saddle assembly into the frame seat tube of the frame to at least the minimum insertion line of the
seat post. Adjust the seat to your desired height, align/center seat with frame top tube. (Fig.4)
Face red rear reflector rearwards and center align with rear wheel – securely tighten (Fig.5).
Note: You can make the final adjustment to the height of the seat as needed after the bike is assembled.
The stem will be secured onto fork steer tube from the factory.
Using a hex wrench, remove the 4 bolts/washers of the handlebar clamp on the front/face of the stem (Fig.7).
Untwist the handlebar and brake cable and face the handlebar forward (reflector facing forward).
Make sure that the fork is facing forward (Fig.1).
Place the handlebar in the stem and the stem front clamp over the handlebar. Center the handlebar in the stem. Install
the 4 stem bolts. Tighten each bolt a little at a time to ensure even pressure on all four corners using a cross pattern
(Fig.7).
The front white reflector should already be installed on the handlebar from the factory. You may need to position the
reflector forward and then tighten the bracket (Fig.8).
FRONT
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45
6 7
Pedals
5-6
4
3
10 function
multi-tool
rear-reflector
stem compression
bolt converter
seat post
rear reflector
min. insert line
frame seat tube
stem
stem front
clamp
PLASTIC
SHIPPING
PLUG
REAR
REFLECTOR
BRACKET
MIN INSERT
25.4
MIN INSERT
25.4

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STEP 4 - FRONT WHEEL
STEP 5 - PEDALS
8
Remove the plastic shipping protector from the fork dropouts and plastic axle protector(s).
Loosen the axle nuts on the front wheel and insert the front wheel into the fork dropouts. Insert the tab of the safety washers into the small holes on the outside of the fork dropouts. (Fig.9).
Inspect the wheel to make sure it is centered in the fork (Fig.10). Tighten each axle nut a little at a time with a 15mm wrench, alternating between sides, until each axle nut is properly tightened.
Right Pedal
Locate the pedal stamped “R” on the end of the spindle (this is the RIGHT pedal) (Fig. 11).
RECOMMENDED; Apply a thin layer of grease to the pedal threads prior to installation.
Carefully insert the Right pedal into the Right side crank arm (the side with the chain) and thread it Clockwise (Fig. 12). You should be able to thread the pedal in part of the way by hand with minor
resistance. If it seems dicult and binds, stop, remove the pedal, realign the threads and try again. Be sure you are turning the right pedal axle in a clockwise direction!
Tighten the pedal with a 15mm or adjustable wrench until the pedal is securely attached to the crank arm. The pedals need to be tightened with a considerable amount of force so that they do not come
lose.
Left Pedal
Locate the pedal stamped “L” on the end of the spindle (this is the LEFT pedal) (Fig. 11).
RECOMMENDED; apply a thin layer of grease to the pedal threads and insert your Left pedal into the Left side crank arm.
Thread it Counterclockwise and tighten with a 15mm or adjustable wrench following the instructions in step #3 above (Fig. 13).
NOTE: Be sure to tighten both pedals with an adjustable wrench or 15mm open end wrench to the recommended torque specification
otherwise they will unscrew while riding causing an unsafe condition for the rider and damaging the threads in the crank.
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11 13
9
SAFETY
WASHER
FORK DROPOUT
SMALL HOLE
.
FRONT
REFLECTOR
BRACKET
12

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BEFORE YOUR FIRST RIDE
STEP 7 - TIRES
We strongly recommend you take your bike to a professional bike shop and have them check
your work and fine tune the bike to ensure your bike is safe to ride.
SERIAL NUMBER
It is important that you locate and record the serial number of your bicycle in case of a recall or
if the bicycle is stolen. The serial number can be found under the crank bottom bracket stamped
into the frame (Fig.17).
Locate the tire manufacturer’s recommended inflation pressure found on the tire sidewall
(listed as “PSI”).
Using a hand or floor pump with a gauge, begin to inflate the tire to half its
recommended inflation pressure and check to see that the tire is properly seated
on the rim. Be sure to inspect both sides of the tire for proper fit.
If the tire is seated unevenly or bulges out along the rim, let some air out of the tire and
reposition the tire by hand so that it sits evenly on the rim.
Continue to inflate the tire to the manufacturer’s recommended pressure.
Do not exceed the recommended pressure as this will cause an unsafe condition potentially
causing the tire to unexpectedly explode.
Do not use a compressed air device to inflate your tires as the rapid inflation of the tire can
cause it to blow o the rim.
Tires and tubes are not warranted against damage caused by over-inflation or punctures
from road hazards.
F
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STEP 6 - BRAKES
Be sure that the brake pads are aligned with the curve of the rim and that they contact the rim
surface flat and evenly. The brake shoe angle and height can be adjusted by loosening the hex
bolt attaching the brake shoe to the brake arm. Notice that the brake shoe can articulate a certain
amount up and down and side to side. (Fig.14)
Loosen the brake cable anchor bolt on the brake arm held by a hex bolt allowing the brake cable to
freely glide through its anchor.
Squeeze the brake arms together until the brake shoes contact the rim surface. Pull the cable taught
through its anchor and tighten the cable anchor bolt. Make sure the brake cable housing is seated
properly at the cable stop ferrules before tightening the anchor bolt. (Fig.15)
Squeeze the brake lever hard several times to stretch the cable and make sure that it does not slip
through its anchor. If the cable tension is too tight to allow the brake shoes to retract and clear the
rim surface, loosen the anchor bolt and give the cable some slack. If the cable has too much slack
and you cannot apply enough stopping force to the rim, repeat procedure “2” and take the slack
out of the cable
Be sure that the brake arms are evenly spaced from the wheel and there is some clearance between
the brake pads and the rim surface. If the arms are not evenly spaced from the wheel, you can
balance the spacing by tightening or loosening the spring tension using the small screw located
at the lower side of each brake arm. (Fig.16)
Your Sully is equipped with a rear linear-pull brake which is factory installed and should be adjusted
from the factory. If adjustment is needed, use the following steps:
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16
BRAKE ARM
BRAKE SHOE
SPRING TENSION
SCREW
SPRING TENSION
SCREW
BRAKE ARMS
CABLE HOUSING
STOPS
CABLE
ANCHOR
BOLT