Zinc 332/2280 User manual

Maintenance Guide
Important – Please read these tips fully.
These instructions contain important information that will help you get the best from your bike,
ensuring safe and correct maintenance.
If you need help or have damaged or missing parts, call the Customer Helpline on 0871 226 2034
ZINC 16 inch Bike
Dec 2011
Instruction Manual
Important - Please take time to read the instructions carefully
332/2280
332/2228

Contents
2
Customer Helpline 0871 226 2034
In the Box .........................................................................................................................................................5
Parts .............................................................................................................................................................5
Tools .............................................................................................................................................................5
Assembly ..........................................................................................................................................................6
Step 1 ...........................................................................................................................................................6
Step 2 ...........................................................................................................................................................7
Step 3 ...........................................................................................................................................................9
Step 4 .........................................................................................................................................................10
Step 5 .........................................................................................................................................................11
Step 6 .........................................................................................................................................................14
Riding Advice .................................................................................................................................................15
Before Riding..............................................................................................................................................15
Riding in Bad Weather...............................................................................................................................16
Riding in the Dark ......................................................................................................................................16
Riding Using Personal Music Players.......................................................................................................16

Safety Information Customer Helpline 0871 226 2034
Important – Please read these instructions fully before starting assembly
3
WARNING! This Bike has been designed, assembled and tested in accordance with the BS EN
14765:2005 standard to ensure your safety. To make sure the bike remains safe, it should only
be used for recreational use. Under no circumstances should it be used for competitive cycling,
stunting, jumping or acrobatic manoeuvres. These types of cycling may result in serious personal
injury and damage to the bike.
WARNING! Always wear a cycle helmet when riding the bike. The helmet should be the correct size
for your head and must conform to the European Standard EN1078:1997.
WARNING! When riding in the dark, always make sure that the bike is tted with suitable reectors
and use a white front light and a red rear light.
WARNING! Always take extra care when riding in wet, foggy, windy or icy conditions. The brakes
may not be as effective and the braking distances may be increased.
WARNING! Always wear suitable cycling clothing when riding the bike. Loose clothing which may
get caught in moving parts should be avoided.
WARNING! This bike is only suitable for use by riders (including any panniers and/or luggage) with
total weight including the bike of 60 kg (132 lb) or less.
WARNING! When assembling the handlebars and stem to the bike frame, make sure the forks
are facing in the correct direction. If the forks are assembled correctly, the brakes should be facing
forwards. Failure to observe this warning may prevent their correct operation and may lead to
personal injury and damage to the bike.
WARNING! When assembling the handlebars and stem, make sure it is inserted beyond the
minimum insert mark. Failure to observe this warning may lead to a potentially unstable bike and
may result in serous personal injury.
WARNING! When assembling the seat post, make sure it is inserted beyond the minimum insert
mark. Failure to observe this warning may lead to a potentially unstable seat post and may result in
serous personal injury.
WARNING! The front and rear tyres must be fully inated before attempting to ride the bike. Under
no circumstances should the tyres be inated above the maximum pressure stated on the side of
the tyres.
WARNING! Only inate the front and rear tyres of the bike using a bicycle pump. Do not attempt to
use another type of pump to inate the tyres.
WARNING! As with all mechanical components, the bike is subjected to wear and high stresses.
Different materials and components may react to wear, stress or fatigue in different ways. If the
design life of a component has been exceeded, it may suddenly fail, possibly causing injuries to the
rider. Any form of crack, scratches or change of colouring in highly stressed areas indicate that the
life of the component has been reached and it should be replaced.
WARNING! Ensure only genuine replacement parts are used, especially for safety critical parts.

Safety Information Customer Helpline 0871 226 2034
Important – Please read these instructions fully before starting assembly
4
CAUTION! Only use suitable tools to assemble the bike. The use of unsuitable tools may lead to
personal injury and damage to the bike.
CAUTION! Always ensure all packaging is removed from the bike before assembly and use. Failure to
remove the packaging may prevent the correct operation and may lead to personal injury and damage
to the bike.
CAUTION! The safety and smooth running of the bike can only be preserved with regular
maintenance. Always ensure the bike is maintained in accordance with the supplied maintenance
manual.
CAUTION! Before attaching the handlebar assembly, make sure all the cables are free to move
and are not tangled. Failure to observe this caution may prevent correct operation and may lead to
personal injury and damage to the bike.
IMPORTANT! Before assembling the bike, check all the parts indicated in the manual are in the
box. Inspect the parts for signs of damage. Do not assemble the bike if you observe any damaged
components.
IMPORTANT! Always take care when removing the packaging to prevent damage to the bike.
NOTE! Always recycle the packaging in accordance with local recycling schemes.
NOTE! The pedals and crank arms have colour coded stickers to indicate which pedal matches which
Crank Arm.
NOTE! The threads on the left and right pedals are different. To prevent damage to the threads, only
tighten the pedals in the direction indicated on the stickers.
NOTE! The left and right sides of the bike are determined by sitting correctly on the bike.
While assembling the bike, it is recommended that, where possible, a torque wrench is used to tighten
nuts and bolts. The table below provides a list of torque settings for the various nuts and bolts.
Recommended Tightening Information
Front Wheel Nuts
Rear Wheel Nuts
Seat Binding Nut
Seat Pillar Clamp Nut
Brake Anchor Nut
Handle Bar Clamp Nut
Head Stem Expander Bolt
Crank Cotter Pin Nuts
Brake Centre Bolt
Pedals
22 - 27 Newton Metres
24 - 29 Newton Metres
12 - 17 Newton Metres
4 - 19 Newton Metres
7 - 11 Newton Metres
5 - 19 Newton Metres
17 - 19 Newton Metres
5 - 10 Newton Metres
5 - 7 Newton Metres
35 - 40 Newton Metres
NOTE

5
Customer Helpline 0871 226 2034In the Box
Parts
Tools
ABike (supplied with rear wheel assembled)
BHandlebar and stem
CSeat post and saddle
DFront wheel
EPedals (supplied in separate box)
B
E
D
C
Multitool (supplied in separate box) Hexagonal key (supplied in separate box)
A

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Customer Helpline 0871 226 2034
IMPORTANT! Before assembling the bike, check all the parts indicated in the manual are in the
box. Inspect the parts for signs of damage. Do not assemble the bike if you observe any damaged
components.
IMPORTANT! Always take care when removing the packaging to prevent damage to the bike.
1. Remove the bike from the box and carefully remove all packaging. The following types of
packaging are used to protect the bike during transit:
• Cardboard Wrapping - This is used to protect the painted surfaces of the bike frame.
• Bubble Wrapping - This is used to protect the painted surfaces of the bike frame.
• Cable Ties - These are used to secure loose parts to the partially assembled bike.
• Stem Caps - These are placed in unprotected ends of the bike frame.
• Axle Protectors - These are used to protect the outer edges of the front and rear wheel axles.
• Fork Protectors - These are used to prevent the suspension forks from bending or being
damaged.
2. The packaging should be retained until the bike is fully assembled. Use the box to store the
packaging during assembly.
NOTE! Always recycle the packaging in accordance with local recycling schemes.
Step 1
Assembly
NOTE

7
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2a Insert the Stem
WARNING! When assembling the handlebars and stem, make sure it is inserted beyond the
minimum insert mark. Failure to observe this warning may lead to a potentially unstable bike and
may result in serious personal injury.
If necessary, loosen the stem bolt at the top of the handlebars and stem Bto allow the wedge nut to
move freely.
Ensuring the wedge nut is correctly aligned, insert the lower end of the handlebars and stem Binto
the head tube of the bike A.
Step 2
Assembly
A
B
2a
Minimum
Insertion
Mark

8
Customer Helpline 0871 226 2034
Step 2 (continued)
Assembly
2b Align the Stem
WARNING! When assembling the handlebars and stem to the bike frame, make sure the forks are
facing in the correct direction. If the forks are assembled correctly, the front brake should be facing
forwards. Failure to observe this warning may prevent their correct operation and may lead to personal
injury and damage to the bike.
Adjust the handlebars and stem Bto the desired height and align with the forks . The forks must
be facing the right direction as shown.
2c Securing the Stem
Using the supplied hexagonal key, tighten the stem bolt rmly.
F
B
2b 2c
3a Insert the Seat Post and Saddle
WARNING! When assembling the seat post, make sure it is inserted beyond the minimum insert
mark. Failure to observe this warning may lead to a potentially unstable seat post and may result in
serous personal injury.
Insert the lower end of the seat post and saddle Cinto the seat tube of the bike A.
3b Securing the Seat Post
Using the supplied hexagonal key, tighten the seat post bolt H rmly.
Step 3
C
AH
3a 3b
90°90°
F
Minimum
Insertion
Mark
Loosen
Tighten
Loosen
Tighten

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Customer Helpline 0871 226 2034
Step 3 (continued)
3c Adjusting the Position of the Saddle
The angle of the saddle C should be adjusted so that it is horizontal to the oor. To adjust the tilt of
the saddle, loosen the saddle clamp nuts Ga quarter of a turn at a time using the multitool supplied
until the saddle can be moved.
Once the saddle Cis positioned correctly, retighten the saddle clamp nuts G.
3d Adjusting the Height of the Saddle
The height of the saddle Cshould be adjusted so that the Rider can comfortably touch the ground
with both feet. To adjust the height of the saddle C, loosen the seat post bolt Huntil the seat post
can move freely.
Once the saddle Cis positioned correctly, retighten the seat post bolt H.
WARNING! When assembling the seat post, make sure it is inserted beyond the minimum insert
mark. Failure to observe this warning may lead to a potentially unstable seat post and may result in
serous personal injury.
C
G
H
C
3c 3d
Assembly
Loosen
Tighten
Loosen
Tighten

10
Customer Helpline 0871 226 2034Assembly
NOTE! The pedals Eand crank arms Jhave colour coded stickers to indicate which pedal E
matches which crank arm J.
NOTE! The threads on the left and right pedals are different. To prevent damage to the threads, only
tighten the pedals in the direction indicated on the stickers.
4a Fitting the Right Hand Pedal
Locate the right hand pedal E. This will have a green sticker attached.
Locate the right hand crank arm Jon the bike A. This will also have a green sicker attached.
Remove the sticker from the right hand pedal E.
Insert the threaded shaft of the right hand pedal Einto the threaded hole of the right hand crank
arm J. Initially tighten the pedal using only your ngers in the direction indicated on the colour coded
stickers. Fully tighten using the multitool supplied.
4b Fitting the Left Hand Pedal
Locate the left hand pedal E. This will have a red sticker attached.
Locate the left hand crank arm Jon the bike A. This will also have a red sticker attached.
Remove the sticker from the left hand pedal E.
Insert the threaded shaft of the left hand pedal Einto the threaded hole of the left hand crank arm
J. Initially tighten the pedal using only your ngers in the direction indicated on the colour coded
stickers. Fully tighten using the multitool supplied.
Step 4
E
J
J
E
A
NOTE
Tighten
Clockwise
Tighten
AntiClockwise
Left Pedal (Red Sticker)
Right Pedal (Green Sticker)

11
Customer Helpline 0871 226 2034Assembly
Step 5
5a
5a Disconnect the Front Brake
Before the front wheel can be installed, the front brake must be disconnected. This allows the front
tyre to pass between the brake pads during assembly.
On the front brake arm, loosen the anchor nut and bolt.
K
P
L
M
N
O
Cable adjuster lock nut
Cable adjuster screw
Anchor bolt and nut
Brake Cable wire
Once anchor nut and bolt is loosened, the Brake Cable Wire will travel through allowing
the brake shoes to seperate.
N
N O N
P
K
D
Loosen
Tighten

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Customer Helpline 0871 226 2034
Step 5 (continued)
Assembly
Q
D
F
5b
5b Insert the Wheel
Loosen the wheel nuts Qon both ends of the front wheel Daxle.
Insert the axle of the front wheel Dinto the slots at the bottom of the forks F.
NOTE! The tyres may have a ‘Direction of Rotation’ arrow embossed on the side. When the front
wheel Dis assembled, the arrow should be pointing in the direction that the wheel will rotate.
While ensuring the wheel is centralised in the forks F, fully tighten the wheel nuts Qusing the
supplied multitool.
NOTE
Loosen
Tighten

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5c RettheFrontBrake
Squeeze the brake shoes together and using a pair of pliers, pull the inner brake cable tight.
Check the brake blocks make contact with the wheel rim and not the tyre.
Re-tighten the anchor nut and bolt .
Using the cable adjuster , adjust the brakes to give 1/16” or 2mm clearance between the brake
blocks and the wheel rim.
Tighten the cable adjuster lock nut.
Check that the front wheel Drotates freely. If it does not, the front wheel Dmay not be located
centrally between the forks F. Alternatively, the front brakes may need adjusting. Please refer to the
supplied Maintenance Manual.
Step 5 (continued)
Assembly
P
K
K
L
N
O
K
P
Cable adjuster lock nut
Cable adjuster screw
Anchor bolt and nut
Brake Cable wire
L
M
N
O

14
Customer Helpline 0871 226 2034Assembly
6 InatetheFrontandRearTyres
WARNING! The front and rear tyres must be fully inated before attempting to ride the bike.
Under no circumstances should the tyres be inated above the maximum pressure stated on the side
of the tyres.
WARNING! Only inate the front and rear tyres using a bicycle pump. Do not attempt to use another
type of pump to inate the tyres.
Before riding the bike, the front and rear tyres must be fully inated to the pressures indicated on the
side of the tyre.
Step 6

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You should perform the following checks before riding your bike to ensure it is safe to use and
operating correctly.
1. Is the Saddle Secure?
While standing next to the bike, try and move the saddle from side to side. If the saddle moves you
should retighten the seat post bolt or the saddle clamp nuts.
2. AretheFrontandRearTyresInatedCorrectly?
Squeeze the sides of the front and rear tyres. If they are soft they will need inating. Re-inate to the
pressure indicated on the sides of the tyres using an approved bicycle pump.
3. Are the Pedals Tight?
Using the supplied multitool, ensure both the left and right pedals are fully tight. Remember that the
threaded shafts of the left and right pedals tighten in different directions.
4. Do the Brakes Work?
Stand next to the bike and apply the front brake and push forwards. If the wheels move,
the front brake may not be working correctly. If required, adjust the front brake as described in the
Maintenance Manual.
Repeat the above check for the rear brake.
5. Do the Handlebars Move?
Hold the front wheel between your legs and try to move the handlebars. If the handlebars move, the
stem bolt may have become loose. Retighten the stem bolt.
6. Is the Bike Clean?
The bike should be cleaned and re-oiled regularly to ensure it operates correctly.
Before Riding
Riding Advice
The bike is tted with front and rear brakes to stop the bike effectively.
The brakes are operated using two brake levers mounted on the handle bars. The left hand brake
lever operates the rear brake and the right hand brake lever operates the front brake.
Using the Brakes

16
Customer Helpline 0871 226 2034
3322280/3322228/Nov2011
her
WARNING! When riding in the dark, always make sure that the bike is tted with suitable reectors
and a white front light and a red rear light.
It is essential that other road users can clearly see you when riding in the dark. Always wear bright,
reective clothing. Suitable reectors should be tted to the front and rear of the bike and if possible
the wheels. A white light must be tted to the front of the bike and a red light at the rear.
Before starting any journey in the dark or even twilight, ensure the lights are working correctly and are
turned on.
Clean lights and reectors regularly and make sure they can be seen from a distance.
WARNING! Always take extra care when riding in wet, foggy, windy or icy conditions. The brakes may
not be as effective and the braking distances may be increased.
When riding in bad weather i.e. wet, foggy, windy or icy, always wear bright, reective clothing which is
warm and waterproof.
You should always give other road users clear signals in plenty of time particularly when approaching
junctions. Always brake earlier than you would in the dry as the required braking distance will be
increased.
Be aware that all types of surface become greasy or slippery in bad weather. Do not turn or brake
suddenly.
It is recommended that personal music players are not used while riding a bike. These devices prevent
you from hearing approaching vehicles and may prove to be a distraction.
Riding in Bad Weather
Riding in the Dark
Riding Using Personal Music Players
Riding Advice

Maintenance Guide
Important – Please read these tips fully.
These instructions contain important information that will help you get the best from your bike,
ensuring safe and correct maintenance.
If you need help or have damaged or missing parts, call the Customer Helpline on 0871 226 2034
ZINC 16 inch Bike

Safety Information Customer Helpline 0871 226 2034
Important – Please read these instructions fully before starting assembly
18
Adjusting The Brakes
Maintenance Instructions
K
F
Cable adjuster lock nut
Cable adjuster screw
Anchor bolt and nut
Brake Cable wire
L
M
N
O
Loosen
Tighten
1a.
Check the brake blocks make contact with the wheel rim and not the tyre.
Re-tighten the anchor nut and bolt .
Using the cable adjuster , adjust the brakes to give 1/16” or 2mm clearance between the brake
blocks and the wheel rim.
Tighten the cable adjuster lock nut.
Check that the front wheel Drotates freely. If it does not, the front wheel Dmay not be located
centrally between the forks F.
1a.
K
L
N
K

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Customer Helpline 0871 226 2034
1b. Inspect the Rim Wear
WARNING! If any section of the wheel rim wear grove is no longer visible, the wheel rim should
be replaced immediately. Do not attempt to ride the bike until the rim is replaced as the braking
performance could be affected.
Each wheel features a wear grove machined into the side of the rim. If the wear grove is no
longer visible, the wheel rim is worn and should be replaced immediately.
1c. Inspect the Wheel Bearings
Over the life of the bike, the wheel bearings may become loose and/or worn and will therefore need
servicing.
To check the condition of the wheel bearing, grab the tyre of either the front or rear wheel while holding
the bike securely. Vigorously move the tyre from side to side. If the wheel moves at the wheel hub (the
centre of the wheel), the bearings may be worn.
Repairing bearings requires specialist tools. It is recommended that all bearings are repaired by
qualied bike repair technicians. Contact your local retailer for more information on bearing repairs.
R R
her
It is essential that you regularly inspect and maintain your wheels, especially if your bike becomes
unstable or vibrates while riding.
1a. Inspect the Trueness of the Wheels
Over the life of the bike, the wheels may begin to run out of true, i.e. they may become buckled. This is
when the wheel rim moves from side to side.
To check the trueness of a wheel, lift the bike up and spin the wheel. If the wheel wobbles, it is out of
true and will need repairing.
Repairing wheels requires specialist tools. It is recommended that all wheels are trued by qualied bike
repair technicians. Contact your local retailer for more information on wheel repairs.
Inspecting and Maintaining the Wheels
Maintenance Instructions
R

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Customer Helpline 0871 226 2034
If you have a puncture, you will need to remove and repair the inner tube.
NOTE! To remove the inner tube you will need a set of tyre levers.
1a. Removing the Tyre from the Wheel Rim
Unscrew the valve nut from the inner tube valve. If required, deate the tyre fully. Using the thumb of
one hand, depress the tyre opposite to the inner tube valve.
CAUTION! Be careful not to trap the inner tube between the tyre levers and the wheel.
Insert a tyre lever between the wheel rim and the tyre wall.
Pull downwards on the tyre lever and hook onto the nearest spoke.
Insert and secure the remaining two tyre levers at suitable points around the wheel rim.
NOTE! Do not leave too much space between tyre levers as the tyre may prove difcult to remove.
If it is not possible to fully remove the tyre from one side of the wheel rim, use the tyre levers as
described above on another section of the wheel.
S
her
Changing an Inner Tube
Maintenance Instructions
T
T
NOTE
NOTE
S
T
TT
T
T