Xtreme Rubicon 48V User manual

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Rubicon 48V / Sedona 48V
Santa Cruz 48V / Catalina 48V
Baja 48V
Rocky Road 48V
Owner’s Manual
www.ElectricBicycle.com

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PLEASE READ PRIOR TO RIDING
IMPORTANT INFORMATION
FULLY CHARGE BATTERIES BEFORE FIRST USE - Batteries should be fully charged immediately when they are received and immediately after
each use for the recommended charge times (see below)
• Li-Po4 Lithium Batteries: 4-6 hours
FACTORS TO MAXIMIZE THE RANGE OF YOUR ELECTRIC BICYCLE
RIDER INPUT - the more the rider pedals the further the distance traveled. Continuous riding, as opposed to frequent stopping and starting, will yield the
greatest range possible
ELEVATION GAIN - the flatter the road the further the distance traveled
 WEATHER - cold weather can adversely affect the battery capacity
TERRAIN - the smoother the terrain (roadways vs. fireroads, etc.) the further the distance traveled
RIDER WEIGHT - the lighter the rider, resulting in less drain on the batteries, the further distance traveled
RIDER BICYCLE MAINTENANCE - a properly maintained bicycle will yield the greatest range possible
RIDER TIRE PRESSURE - properly inflated tires have less rolling resistance and will be easier to pedal
BATTERIES - properly charged and maintained batteries will yield the greatest range possible. Batteries stored in cold areas (below 50 degrees Fahrenheit / 10
degrees Celsius) will show reduced range. Batteries that have not been kept in optimum condition will show reduced range and run time.

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TABLE OF CONTENTS
Important Information………………………………………………………………………………………….. 2
Table of Contents……………………………………………………………………………………………… 3
Terminology & Battery Systems………………………………………………………………………………… 4
Required Tools………………………………………………………………………………………………… 5
Before You Ride……………………………………………………………………………………………….. 6-8
Safety Checklist……………………………………………………………………………………………….... 9-10
Bicycle Care…………………………………………………………………………………………………… 10-13
Basic Maintenance………………………………………………………………………………………… 10
Throttle…………………………………………………………………………………………………… 11
Battery Care and Information……………………………………………………………………………….. 11-2
Charger……………………………………………………………………………………………………12-13
Bicycle Assembly……………………………………………………………………………………………… 13
Getting Started…………………………………………………………………………………………….. 13
Stem and Handlebars………………………………………………………………………………………. ….. 14-16
Front Forks………………………………………………………………………………………………....….. 17-19
Tektro Brakes…………………………………………………………………………………………….... …... 20-21
Shimano Altus Rear Derailleur……………………………………………………………………………..... …... 22-27
Kickstand…………………………………………………………………………………………………. ….. 27
Rear Suspension……………………………………………………………………………………………….. 28
Seat and Seat Post………………………………………………………………………………………….. …... 29
Installing Front Wheel…………………………………………………………………………………….. ….. 30
Drive Train…………………………………………………………………………………………………….. 31
Troubleshooting……………………………………………………………………………………………….... 32-33
Specifications…………………………………………………………………………………………………... 34
How To Guide………………………………………………………………………………………………….35-
How To Check Wire Terminals If Battery Not Charging Properly……………………………………………... 35
How To Adjust Brakes – Additional Information for Tektro Brakes…………………………………………… 35-36
How To Replace Brake Lever……………………………………………………………………………… 36
How To Adjust Derailleur – Additional Information for Shimano Altus……………………………………….. 36
How To Remove Rear Wheel……………………………………………………………………………… 36
How To Replace Pedal Shaft……………………………………………………………………………….. 37
General Information/Tech Support……………………………………………………………………………….. 38

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paRt
1 -
paRts
identi
F
ica
tion
Warning / important - t ake notice of this symbol throughout this manual and pay
particular attention to the instructions blocked off and preceded by this symbol.
TERMINOLOGY
POWER Systems
P AS – Pedal Assist - A sensor ring and pickup mounted near the bottom bracket allow the bicycle to sense forward pedaling and
apply power.
T AG – Twist and Go - A rider-controlled system, the motor activates only when the handlebar throttle is turned.
P AS / T A G – Pedal Assist or Twist and Go - A handlebar-mounted button allows selection of PAS or TAG modes.
BATTERY Systems
RTMB – Rack Top Mounted Battery with Lithium polymer cells - A single Li-Po battery pack lies horizontally inside the rack.
STB – Seat Tube Battery with Sealed Lead Acid (SLA) or Lithium Ion (Li- Po ) cells - A single battery pack is mounted behind the
seat tube.

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Your new bicycle was partially assembled in the factory and then partially disassembled for shipping. You may have purchased the bicycle already
fully 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. For more details on inspection, lubrication, maintenance and adjustment of any area please refer to the
relevant sections in this manual. If you have questions about your ability to properly assemble this unit, please consult a qualified bicycle service
specialist before riding.
T YPICAL T OOLS REQUIRED:
• Phillips head screw driver
• 2.5mm, 3mm, 4mm, 5mm 6mm & 8mm Allen keys
• Adjustable wrench or a 8mm, 9mm, 10mm, 13mm, 14mm,
15mm & 17mm open/box end wrenches
• A pair of pliers with cable cutting ability
T o avoid injury, this product must be properly assembled before use. if your bicycle was obtained assembled, we strongly recommend
that you review the complete assembly instruction.

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PART
2 -
Beforeyou ride
R
ide
!
BEFORE YOU RIDE
ABOUT THIS MANUAL
It is important for you to understand your new bicycle. By reading this manual before you go out on your first ride, you’ll know how to get better performance, comfort,
and enjoyment from your new bicycle.
It is also important that your first ride on your new bicycle is taken in a controlled environment, away from cars, obstacles, and other distractions.
G ENER AL W AR NING
Bicycling can be a hazardous activity even under the best of circumstances. Proper maintenance of your bicycle is your responsibility as it helps reduce the risk of injury.
This manual contains many “Warnings” and “Cautions” concerning the consequences of failure to maintain or inspect your bicycle. Many of the warnings and cautions say
“you may lose control and fall.” Because any fall can result in serious injury or even death, we do not repeat the warning of possible injury or death where ever the risk of
falling is mentioned.
A SPECIAL NOTE FOR P ARENTS
It is a tragic fact that most bicycle accidents involve children. As a parent or guardian, you bear the responsibility for the activities and safety of your minor child. Among
these responsibilities are to make sure that the bicycle which your child is riding is properly fitted to the child; that it is in good repair and safe operating condition; that you
and your child have learned, understand and obey not only the applicable local motor vehicle, bicycle, and traffic laws, but also the common sense rules of safe and responsible
bicycling. As a parent, you should read this manual before letting your child ride the bicycle. Please make sure that your child always wears an ANSI, ASTM, SNELL
approved bicycle helmet when riding
CORRECT FRAME SIZE
When selecting a new bicycle, the correct choice of frame size is a very important safety consideration. Most full sized bicycles come in a range of frame sizes.
These sizes usually refer to the distance between the center of the bottom bracket and the top of the frame seat tube.
For safe and comfortable riding there should be clearance of no less than 1 - 2 inches between
the rider and the top tube of the bicycle frame, while the rider straddles the bicycle with both feet flat on the ground.
The ideal clearance will vary between types of bicycles and rider preference. This makes straddling the frame when you are off the seat easier and safer in situations
such as sudden traffic stops. Women can use a men’s style bicycle to determine the correct size women’s model.
The following chart and diagram will help you make the correct choice. Rider leg length refers to approximate pant inseam.

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RIDING POSITION
Seat H eight
In order to obtain the most comfortable riding position and offer the
best possible pedaling efficiency, the seat height should be set correctly in relation to
the rider’s leg length. The correct seat height should not allow leg strain from
over-extension, and the hips should not rock from side to side when pedaling. While
sitting on the bicycle with one pedal at its lowest point, place the ball of your foot on
that pedal. The correct seat height will allow the knee to be slightly bent in this
position. If the rider then places the heel of that foot on the pedal, the leg should be
almost straight.
Under no circumstances should the seat post project from the frame beyond its
“Minimum insertion” or “Maximum extension” mark. if your seat post
projects from the frame beyond these markings, the seat post or frame may
break. Prior to your first ride, be sure to tighten the seat clamp properly. a
loose seat clamp or seat post binder can cause damage to the bicycle or can
cause you to lose control and become injured. Periodically check to make
sure that the seat clamp is properly tightened
Reach
To obtain maximum comfort, the rider should not overextend his or her
reach when riding.
To adjust this distance, the position of the seat can be altered in relation to the seat
post. (Refer to page 29)
Maximum Height / Minimum
Insertion Mark (Should not be
visible)
Arms not over Extended
Handlebar stem
height about the
same as seat
height
Pedal at
Bottom Position

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Handlebar h eight
Maximum comfort is usually obtained when the handlebar height is
equal to or slightly higher than the height of the seat. You may wish to
try different heights to find the most comfortable position.
Handlebar Adjustment & Height
The stem’s “Minimum insertion” mark must not be visible above
the top of the headset. If the stem is extended beyond this mark,
the stem may break or damage the fork’s steering tube, which
could cause you to lose control and become injured.
Failure to properly tighten the stem binder bolt, the handlebar
binder bolt, or the bar end extension clamping bolts may
compromise steering action, which could cause you to lose control
and become injured. Place the front wheel of the bicycle between
your legs and attempt to twist the handlebar/stem assembly using
a reasonable amount of force. There should be no play or ability
to move the handlebars in relation to the wheel. If you can twist
the handlebars while the wheel remains in place, do not ride
until proper alignment and is obtained, then tighten all bolts
accordingly before use.
Handlebar
Binder Bolt
Exceeds 2 1/2”
(64mm)
Stem Wedge Bolt
Maximum Height/
Minimum
Insertion Mark

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SA F ETY CHEC K LIST
Before first initial ride and every ride after, it is important to carry out the following safety checks:
1. Brakes
Ensure front and rear brakes work properly.
Ensure brake calipers are not over worn and are correctly adjusted.
Ensure brake control cables are lubricated, correctly adjusted and display no obvious wear.
Ensure brake control levers are lubricated and tightly secured to the handlebar.
2. Wheels and t ires
Ensure tires are inflated to within the recommended limit as displayed on the tire sidewall.
Ensure tires have tread and have no bulges or excessive wear.
Ensure rims run true and have no obvious wobbles or kinks.
Ensure all wheel spokes are tight and not broken. You can use the include spoke wrench to ensure all spoke are tight.
Check that axle nuts are tight. If your bicycle is fitted with quick release axles, make sure locking levers are correctly tensioned and in the closed position.
3. S teering
Ensure handlebar and stem are correctly adjusted and tightened, and allow proper steering.
Ensure that the handlebars are set correctly in relation to the forks and the direction of travel.
Check that the headset locking mechanism is properly adjusted and tightened.
If the bicycle is fitted with handlebar end extensions, ensure they are properly positioned and tightened.
4. Chain
Ensure chain is oiled, clean and runs smoothly.
Extra care is required in wet or dusty conditions
5. Bearings
Ensure all non-sealed bearings are lubricated, run freely and display no excess movement, grinding or rattling.
Check headset, wheel bearings, pedal bearings and bottom bracket bearings.
6. Cranks and P edals
Ensure pedals are securely tightened to the cranks.
Ensure cranks are securely tightened to the axle and are not bent.
7. D erailleurs
Check that front and rear mechanisms are adjusted and function properly.
Ensure shift and brake levers are attached to the handlebar, shift and brake.
Ensure derailleurs, shift levers and shift and brake cables are properly lubricated.

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8. Frame and Fork
Check that the frame and fork are not bent or broken.
If either is bent or broken, they should be replaced.
9. Accessories
Ensure that all reflectors are properly fitted and not obscured.
Ensure all other fittings on the bike are properly and securely fastened, and functioning.
Ensure the rider is wearing a helmet.
10. Motor and Throttle
Ensure motor is functioning properly.
Ensure throttle is functioning properly.
11. Battery p ack
Ensure the batteries are in good operation condition and kept fully charged.
BICYCLE CARE
BASIC MAINTENANCE
The following procedures will help you maintain your hybrid electric bicycle for years of enjoyable riding.
1. After initial set up be sure to check wheel spokes to make sure they are properly fitted. Be sure to check again after a few rides to ensure proper break in.
Follow up with monthly checks.
2. Properly maintain the batteries by keeping them fully charged when not in use.
3. Do not ride your hybrid electrical bicycle in the water (damp roads, puddles, rain, streams, etc.) and never immerse it in water as the electrical system may be
damaged.
4. Periodically check the wiring and connectors to ensure there is no damage and the connectors have good continuity.
5. For painted frames, dust the surface and remove any loose dirt with a dry cloth. To clean, wipe with a damp cloth soaked in a mild detergent mixture. Dry with a cloth
and polish with car or furniture wax. Use soap and water to clean plastic parts and rubber tires. Chrome plated bikes should be wiped over with a rust preventative
fluid.
6. Store your bicycle under shelter. Avoid leaving it in the rain or exposed to corrosive materials.
7. Riding on the beach or in coastal areas exposes your bicycle to salt which is very corrosive. Wash your bicycle frequently and wipe or spray all unpainted parts with
an anti-rust treatment. Make sure wheel rims are dry so braking performance is not affected. After rain, dry your bicycle and apply anti-rust treatment.
8. If paint has become scratched or chipped to the metal, use touch up paint to prevent rust. Clear nail polish can also be used as a preventative measure.
9. Regularly clean and lubricate all moving parts, tighten components and make adjustments as required.
10. The use of alloy components and BED, SATIN and TITANIUM surface treatments minimizes the number of places where rust can surface

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T HROTTLE
TAG ( T WIST AND GO)
Before you begin riding, turn the main power switch on, then start riding as you would ride any regular, non motor
assisted bicycle. After you have begun to ride, slowly twist the throttle (on equipped models) towards you. The more you
twist the throttle, the more motor power will be applied to the wheels. You may feel the pedals get a “lighter” feel than
riding without the motor assisting you. Once you have twisted the throttle all the way, the motor will accelerate you to its
full speed of about 18-22mph (30-35km/h).
BATTERY CARE AND INFORMATION
Proper maintenance of batteries will maximize their lifespan and capacity. X-Treme Scooters warranties your new batteries from the date of purchase for 1 full
year when properly cared for. Visit http://support.x-tremescooters.com for more information.
Battery Care
Even with proper care, rechargeable batteries do not last forever. Every time the battery is discharged and subsequently recharged, its relative capacity decreases by
a small percentage. With proper care, the life span of your batteries is between 500-700 cycles. You can maximize the life of your battery by following the
instructions in this guide.
• Batteries should be fully charged immediately when they are received for the full recommended charge times.
LI-Po4 RECOMMENDED CHARGE TIME: 4-6 hours. For a complete, 100% charge, leave the battery on the charger for one full hour after the charger indicator
light turns green.
• Never charge batteries for longer than 8 hours.
• Li-Po4 batteries do not have a “memory.” Partial discharge/charge cycles will not harm the batteries’ capacity or
performance.
• The rated output capacity of a battery is measured at 77°F (25°C). Any variation in this temperature will alter the performance of the battery, and shorten its
expected life. High temperatures especially reduce overall battery life & run time.
• Always be sure to turn the bike/scooter power switch to “OFF” after each use. If you leave the power switch in the “ON” position, or your product has not been
charged for a long period of time, the batteries may reach a stage at which they will no longer hold a charge.
• Be friendly to the environment! Be sure to recycle your old batteries at a local battery-recycling center. Do not throw them
in the garbage!

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S TORAGE
When storing your batteries for a long period of time (longer than two months):
• Charge your batteries every 90 days to avoid capacity loss. Batteries slowly self-discharge when left unused for a long period of time; if the
battery cells are allowed to reach a critically low voltage, their lifespan and capacity will be permanently reduced.
• Always disconnect your charger from the wall outlet and battery before storing the battery.
• Avoid storing your batteries in extreme temperatures, whether hot or cold.
• Batteries are best kept in a cool, dry place. Do not allow batteries to accumulate condensation, as this could cause
shorting or corrosion.
• The recommended storage temperature is between 32-77 °F (0-25°C).
• Avoid exposing the battery to extreme heat (104°F or higher) for long periods of time.
F
A Q
Q: Do I need to “break-in” my batteries?
A: Yes, it is recommended that you perform a “break-in” cycle consisting of ~ three discharge/charge cycles to allow your batteries to reach optimum
performance. This involves three complete discharges and three complete recharges. After this initial “break-in” cycle the batteries will have maximum
possible performance and less line voltage fluctuations under load.
Q: Is it normal that the batteries get warm when recharging?
A: Yes, it is normal that the batteries will become warm to the touch during the recharging process. This is because the increase of internal resistance and less
energy conversion efficiency from electric energy to chemical energy.
Q: How long will my batteries last before needing replacement?
A: Average battery life depends on use and conditions. Even with proper care, rechargeable batteries do not last forever. Li-Po4 batteries will last
between 500-700 cycles. A partial charge/discharge counts fractionally against those numbers; running the battery down halfway then recharging it
completely uses up one half of a charge cycle.
“End of useful life” refers to the point at which a battery can no longer supply 80% of its original rated capacity in ampere- hours. After this point, the aging
process will accelerate and the battery will need to be replaced
C HARGER
The electric bicycle comes with its own "Smart Charger” that connects with an easy-access charger port for recharging the batteries. This charger unit has lights
that show the battery charge status. Refer to the instructions that appear on the charger unit and its instructions.
Batteries work best when they have a full charge, so always be sure to recharge them fully after each ride. If you leave them in a run-down condition, without
recharging them, it will shorten their life expectancy.
• Li-Po4 Lithium batteries - charge for 4-6 hours for full charge
The charger may get warm to the touch, so make sure you charge them in an open area and do not lay anything on the charger unit while charging.
Although you cannot over-charge the batteries, we recommend that you do not leave the charger plugged in for more than 24 hours.

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If your charger shows a solid green light after charging for a short period of time, your battery may have been only partially dis- charged (short ride),
or this may be the sign of a partially worn out battery with reduced storage capacity. Continue charging for the full time, to cover all the bases. If the
battery still has not charged, you may need to replace it.
Even with proper care, a rechargeable battery does not last forever. Average battery life depends on use and conditions.
The charger and charger port should be regularly inspected for damage (cord, plug, enclosure, etc.).
if damage is found stop using the affected part until the it can be repaired or replaced.
Bicycle a ssembly
Assembly Guides
Follow the assembly guide contained within this manual or visit www.x-tremescooters.com/support/ for assistance.
Getting Started
Open the carton from the top and remove the bicycle. Remove the
straps and protective wrapping from the bicycle. Inspect the bicycle and all accessories and parts for
possible shortages. It is recommended that the threads and all moving parts in the parts package be
lubricated prior to installation. Do not discard packing materials until assembly is complete to
insure that no required parts are accidentally discarded.
**Note: Your bicycle may be equipped with different style components than the ones illustrated
within this manual.
We recommend that you contact X-Treme if you have doubts or concerns as to your experience or ability to properly assembly,
repair, or maintain your bicycle

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STEM AND HANDLEBARS (STANDARD QUILL-TYPE
1. Remove the protective shipping cap from the stem wedge.
2. Remove the Stem Plug from the stem. Loosen the Stem Bolt with a 6mm allen wrench or 13mm box wrench.
3. Insert the stem into the head tube of the bicycle. Ensure that the Minimum Insertion Line is below the top nut of
the headset.
4. Align the stem and handlebar so it is in line with the front wheel.
5. Tighten the Stem Bolt with a 6mm Allen wrench. Reinsert the Stem Plug into the stem.
6. Check the headset for smooth rotation and that the top nut is secured tightly.
7. Loosen the 6mm Binder Bolt and rotate the handlebar so the levers are at a 45 degree angle below the handlebar.
8. Retighten the Binder Bolt to ensure the handlebar does not rotate in the stem.

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!
W A R NIN G: M INI M U M INSE R TION LINE M UST B E HIDDEN W ITHIN
THE HEADTUBE OF THE BICYCLE. Stem should be inserted into
the top nut of stem bolt at least.
if the stem is not inserted into the top nut to at least the stem bolt.
NOTE: Some models of bicycles may be equipped with a stem that has an adjustable angle. In
addition to the normal assembly, these stems will require angling the stem to the desired position, and
securely tightening the 6mm Allen bolt located underneath the stem. Failure to do this may cause loss
of steering control.
Binder Bolt
Stem Bolt
Head Tube
Minimum
Insertion Mark
Top Nut
Wedge
!
Top Nut

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Stem Installation (should be assembled on the bike already)
1. Insert the compression bolt through the top cap and the stem. Begin
threading into the star nut.
2. Tighten compression bolt so it removes all play from the fork, but allows
the fork to rotate smoothly.
3. Align the stem with the front wheel. Tighten the stem clamp bolts to
secure the stem to the steering tube.
Handlebar Installation
1. Remove the stem cap bolts and stem cap.
2. Insert handlebar into the stem cap.
3. Tighten the stem cap bolts equally. Note the distance between the stem and
stem cap "A" should be equal on the top and bottom of the stem cap
.
Wedge
Head Tube
Compression Bolt
Top Cap
Stem Clamp Bolts
Spacer
Bearing Race
Bearing Retainer
Upper Headset Cup
Bearing Retainer
Headset Wedge
Bearing Dust Cover
Star Nut
(Inside Steer Tube)
Headtube
Lower Headset Cup
Bearing Dust Cover
Headset Crown Race
Handlebar
Stem Cap Bolt
Cap
Bolts

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FRONT FORK (SR SUNTOUR Models XCT26”/700C)
NOTE: We strongly suggest that your SUNTOUR forks to be installed or replaced by a skilled and qualified
bicycle mechanic as knowledge and specialized tools are needed to complete. Should you attempt to install
the forks on your own, we request you consult X-TREME SCOOTERS for assistance or seek Tech Support from
the professionals at a local bike store. Please note that incorrect installation is extremely dangerous and can
cause damage to your bicycle and/or possible injury or death to the rider.
DO NOT ATTEMPT TO DISASSEMBLE A SUSPENSION FORK YOURSELF. Consult
X-Treme E-Bikes for assistance.
SAG SETTINGS
The SAG is the compression created by the impact from rider's weight and gravity. Different riders will have
different weights so therefore you need to know about the PELOAD function to achieve the correct settings for
riding according to your weight.
To increase the PRELOAD of the forks turn the PRELOAD button clockwise located at the position No. 2 in
the illustration.
Model Max Rotor Travel SAG
Diameter (mm)
XCT/M Series 160 mm 80 mm 15% - 20%
80mm refers to the limit of Travel length of the forks. Please note these forks are designed only for casual riding on city road surfaces or off road on mountains or dirt
roads, but not for stunt movements or downhill racing!
These forks feature a LOCK function. When pedaling on flat surface road, lock the forks to save energy when braking to starting pedaling again. You should unlock
forks while climbing or descending on bumpy mountain roads to protect your hand or wrist from being injured from the impact. CAUTION! NEVER REACH FOR
THE LOCK BUTTON BY LEANING FORWARD DURING PEDALING AS THIS MOVE MAY CAUSE A SEVERE ACCIDENT, INJURY OR DEATH.
FOR YOUR OWN SAFETY, BE SURE TO STOP AND GET OFF OF THE BIKE TO LOCK OR UNLOCK FORKS!

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Very Important Information
WARNING!
Be sure to read carefully the instructions below before using your suspension fork. Inappropriate usage of your suspension fork may cause damage to the
product and/or injuries or death to the rider.
1. Suspension forks contain fluid and gas under extreme pressure. Warnings included in these instructions must be followed in order to reduce the possibility of injuries
and possible death. Never try to open any SR SUNTOUR cartridge, as stated above they contain fluids and gases under high pressure. Opening any SR SUNTOUR
cartridge risks serious injury.
2. Only use genuine SR SUNTOUR parts. The use of aftermarket replacement and spare parts will void any warranty and may cause failure to the fork. Failure could
result in an accident, injury or even death.
3. SR SUNTOUR suspension forks are designed for the usage by a single rider.
4. Always be equipped with proper safety gear. This includes a properly fitted and fastened helmet. According to your riding style you should use additional safety
protection. Make sure your equipment is in flawless condition to ensure adequate protection in the event of an accident.
5. When using a bike carrier always fully release the quick release fastener. Not properly unfastening the quick release may result in bending, breaking, or other
structural damage while removing your bike of the bike carrier. If your bike has fallen off the carrier please do not ride until it has been inspected by a qualified bike
mechanic. When using a bike carrier that secures the bike by clamping the fork’s dropouts, make sure to fasten rear wheel as well. An inaccurate fastened rear wheel
could allow the bike to jiggle which may result in breakage of the dropouts.
INSTALLATION INSTRUCTIONS
1. Remove the existing fork from your bike. Afterwards remove the crown race from the fork.
2. Measure the length of your old fork's steer tube against the length of the SR SUNTOUR fork steer (stem). SR SUNTOUR suspension forks are delivered with a
standard steer tube length of 255mm. Therefore the steer tube may need cutting to the proper length.
3. In order to define the proper length of your steer tube you can apply the following formula:
FRAME'S HEADS TUBE (GOOSE NECK) + HEAD SET STACK HEIGHT + STEM'S CLAMP HEIGHT - 3mm CLEARANCE
Warning!
IF YOUR SR SUNTOUR FORKS DOES COME WITH A THREADLESS STEERER TUBE DO NOT ADD A THREAD TO IT.
SUNTOUR'S FORK STEERERS ARE A ONE TIME PRESS FIT WHICH CAN NOT BE REMOVED. DO NOT TRY TO REPLACE THE
STEERER TUBE WITH A THREADED STEERER. THIS WILL RESULT IN FAILURE OF THE PRODUCT AND/OR CAUSE SERIOUS
INJURIES OR EVEN DEATH TO THE RIDER.
!
!

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4. Install the head set crown race (30mm for 1 1/8") firmly against the top of your fork crown. Install the fork unit (headset, spacers and stem) back on the bike.
5. Install brake and make sure to adjust the brake pads properly. If you use a disc brake, only mount your brake to the original disc brake mounting holes. Only use
cantilever brakes which are intended to be used with a brace that does not have a hanger.
6. Re-install the wheel onto your bike. If you are using a quick release system to fasten your wheel, make sure that all fasteners and nuts are adjusted properly (four or
more threads need to be engaged in the nut when it is closed). If your fork comes with a through axel system, make sure that all fixing bolts are tightened with the
appropriate torque values.
TIRE CLEARANCE
The SR SUNTOUR suspension fork is designed to be used with 26" tires. Each tire has a different outer diameter (tire width and height) therefore the clearance between
your tire and fork must be checked to make sure that tire does not come in contact with any portion of the fork. Keep in mind that the narrowest part of your bike is
located at the brake.
WARNING!
Note! Using a tire which exceeds the maximum tire size suitable for your fork is very dangerous and could cause an accident and/or serious
injuries or even death to the rider.
To complete a tire clearance test, measure the distance between the top of your tire and the bottom of the fork crown. Make sure the gap is no less than 10mm. Exceeding
maximum tire size will cause the tire to rub against the bottom of the crown when fork is fully compressed.
Keep in mind that if you are using mudguard the clearance is limited! Repeat the tire clearance test again to make sure the gap is large enough. Every time you change
your tire you must repeat the test.
!

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TEKTRO BRAKES
INSTALLATION & ADJUSTMENT OF YOUR BRAKES
The Caliper and rotor for the front and rear of the bike are the same. The only difference between front and rear disc brakes is which adapter should be used to mount the
caliper to the bike. The adapter for the front fork is marked with an "F" and is designed to fit forks with international standard disc brake mounts. The rear adapter is
marked with an "R" and is designed to fit international mounts .The adapters for front and rear may be marked with "F.../R...", if so, check the brake rotor for diameter
(160) to determine front or rear adapter.
Mounting the Rotor to the Hub
1. Remove the wheel from the bike.
2. Attach the rotor to the hub with the supplied Allen bolts and tighten with Allen wrench.
3. Install the wheel onto the bike.
Note: The rotor must be installed with the "rotation" arrows pointing in the same direction as the forward rotation of the wheel.
Mounting the Adapter and Caliper
Note: Although front and rear caliper bodies are the same design, the adapter for the front is marked with an "F" and the adapter for the rear is marked with an "R".
1. Mount the relevant adapter to the caliper body. Insert 5mm bolts through the two adapter slots on the body and screw into the holes on the adapter. DO NOT TIGHTEN
YET.
2. Mount the caliper body and adapter to the frame/fork by placing the slot in the caliper body over the rotor. The mounting holes on the adapter should be behind the
frame/fork mounting holes (the hub side). Screw and tighten 5mm Allen bolts into the upper and lower holes in the frame/fork mount.
3. Check that the rotor is concerted between the disc brake pads and tighten the two bolts holding the caliper to the adapter. To re-adjust the caliper positioning, loosen
these two bolts and slide the caliper over until it is centered on the rotor and then re-tighten the bolts.
4. Attach the cable and housing to the brake lever. Route the cable along the frame/fork of the bike. Insert the cable through the cable adjuster barrel on the caliper
5. Making sure that the cable housing is firmly sealed within the cable adjuster barrel, insert the end of the cable through anchor bolt on the caliper. Take up slack in the
cable, then tighten cable anchor bolt.
6. Be sure no more 20mm excess cable beyond anchor bolt.
Adjusting the Pads and Caliper
Note: When your pads are worn, make sure to adjust both clearances between rotor and pad to be equal to 0.3mm. Adjusting only one side will cause braking failure.
1. Use 5mm Allen wrench to adjust the stationary caliper adjusting bolt at the back (hub) side of caliper (reach for the bolt with Allen wrench through space between
spokes).