Zinc 332/4037 Operating 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 assembly, use and maintenance.
If you need help or have damaged or missing parts, call the Customer Helpline on 01582 670100
ZINC 20 inch Dual Suspension Bike
Dec 2011
332/4037
332/4020

2
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
qualified bike repair technicians. Contact your local retailer for more information on bearing repairs.
A A
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 qualified bike
repair technicians. Contact your local retailer for more information on wheel repairs.
A
Inspecting and Maintaining the Wheels
Maintenance Instructions Customer Helpline 01582 670100

3
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, deflate 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 difficult 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.
B
C
C
NOTE
NOTE
B
C
CC
C
C
Changing the Inner Tube
Maintenance Instructions Customer Helpline 01582 670100

Maintenance Instructions Customer Helpline 01582 670100
4
1b. Remove the Inner Tube from the Tyre
Once the tyre is removed from one side of the wheel rim, carefully remove the inner tube starting with
the valve.
1c. Replace the Inner Tube into the Tyre
Check the inner surfaces of the tyre for any signs of damage or foreign matter i.e. thorns or small
stones.
Partially inflate the inner tube using a bicycle pump.
Carefully feed the inner tube into the tyre, starting with the valve. The valve must be repositioned
through the appropriate hole in the wheel rim.
1d. Refit the Tyre to the Wheel Rim
Using the thumb of one hand, refit the tyre to the wheel rim a small section at a time. When the tyre is
too tight to fit by hand, use the tyre levers to refit the last section.
Performing routine maintenance correctly on your bike will ensure you get years of trouble free use.
Please keep this manual safe for future reference.
It is recommended that the following maintenance schedule is adhered to. This will ensure the bike
operates correctly and is safe to use.
Is the saddle secure?
Are the front and rear tyres inflated correctly?
Are the pedals tight?
Do the brakes work?
Do the handlebars move?
Is the bike clean?
Check that the bike is clean and suitably lubricated.
Check that all parts of the bike are securely fitted.
Check that the tyres are in good condition.
Check that the wheel spokes are tight.
Check the frame and forks for signs of damage.
Check that the wheels are running true.
Check the condition of the brake pads.
Check the front and rear gears for signs of damage.
Check Before and
after each ride
Every
month
Every
six months
Routine Maintenance Schedule
Changing the Inner Tube (continued)

Adjusting the Rear Derailleur
Adjusting the Rear Derailleur – Step 1
.
1a
1b
1a. Select the Lowest Gear
NOTE! The lowest gear is always the largest cog.
While raising the rear of the bike and rotating the pedals by hand, use the right hand trigger shifter to
select the lowest gear (number 1 on the indicator).
1b. Set the Position of the Lower Limit Screw
The lower limit screw controls the position of the rear derailleur when the lowest gear is selected.
Using a suitable screwdriver, rotate the lower limit screw until the small gears of the derailleur are
vertically aligned below the lowest gear.
• Turn the lower limit screw clockwise to move the derailleur to the right (when viewed from the
back of the bike).
• Turn the lower limit screw anti-clockwise to move the derailleur to the left (when viewed from
the back of the bike).
While riding the bike, if the rear gears fail to work correctly and/or become noisy, the rear derailleur
should be adjusted. The following are a few examples of when to do this:
• If a grinding noise comes from the rear gears while peddling
• If the chain fails to move between the rear gears or jumps gears
• If the chain routinely jumps off the highest (smaller) gear.
NOTE! You will need a second person to help you adjust the front and rear derailleur.
D
D
D
D
D
5
Smallest
(6th gear)
Largest
(1st gear)
Maintenance Instructions Customer Helpline 01582 670100

2a
2b
2a. Select the Highest Gear
NOTE! The highest gear is always the smallest.
While raising the rear of the bike and rotating the pedals by hand, use the right hand trigger shifter to
select the lowest gear (number 6 on the indicator).
2b. Set the Position of the Lower Limit Screw
The upper limit screw controls the position of the rear derailleur when the highest gear is selected.
Using a suitable screwdriver, rotate the upper limit screw until the small gears of the derailleur are
vertically aligned below the upper gear.
• Turn the upper limit screw clockwise to move the derailleur to the right (when viewed from the
back of the bike).
• Turn the upper limit screw anti-clockwise to move the derailleur to the left (when viewed from
the back of the bike).
E
E
E
E
E
Adjusting the Rear Derailleur – Step 2
6
Smallest
(6th gear)
Largest
(1st gear)
Maintenance Instructions Customer Helpline 01582 670100

Adjusting the Rear Derailleur – Step 3
3a. Check the Gear Change
While raising the rear of the bike and rotating the pedals by hand, use the right hand trigger shifter to
change from the highest (smallest) gear to the lowest (largest) gear one at time. If the rear derailleur is
tuned correctly, the gears should change quickly without any grinding noises.
If the gears still do not operate correctly, carry out step 3b.
3b. Check the Cable Tension
If the gears change correctly between the highest and lowest gears but not between the lowest and
highest gears, the cable tension should be increased.
Rotate the barrel adjuster a quarter of a turn anti-clockwise.
Check the gear change by repeating step 3a.
Keep checking the gear change and slowly increasing the cable tension a quarter of a turn at a time
until they operate correctly.
F
F
F
7
Maintenance Instructions Customer Helpline 01582 670100

Maintenance Instructions Customer Helpline 01582 670100
8
Adjusting Rear Suspension
6 Adjusting the rear suspension
Adjust the strength of the springs so that when you put your weight on the saddle, the bike sinks
down or sags about thirty per cent of the total spring travel. That is the total distance that the rear of
the frame will move.
Measure the sag on the rear suspension with your weight on the saddle.
The most convenient place to measure is usually between the centres of the mounting bolts at each
end of the suspension unit.
Rear suspension sag can be reduced by turning the adjustable spring seat clockwise. Or
increased by turning the spring seat anti-clockwise. Keep testing and adjusting the spring until you
get the amount of sag right.
When you have completed the adjustment process, the bike should sag equally front and rear. If it
doesn’t, re-adjust the rear unit as required. But the real test is riding the bike and working out how to
set it up to suit your own personal style.
The heart of the rear suspension is the pivot. It pays to keep the pivot area free of dust and mud, and
also lubricate it with bike lube occasionally.
G
G
Loosen
Tighten
G

Maintenance Instructions Customer Helpline 01582 670100
9
Adjusting V-Brakes
H
H
I
Throughout the life of your bike, the front and rear v-brakes may need adjusting if the brake cable
has stretched or the brake arms have been knocked during use.
Adjusting V-Brake Cable Tension
1a. Adjust the Brake Cable
The brake cable must be adjusted to ensure that the brakes are as close as possible to the wheel
rim when no pressure is applied to the brake lever.
Using a suitable spanner or socket, loosen the cable pinch bolt until the brake cable is free to
move.
Pull the brake cable until the brake pads are approximately 2mm/ 0.16”inch from the wheel rim.
Retighten the cable pinch bolt while holding the brake cable in position.
H I
I
H
1a
2mm 2mm

Maintenance Instructions Customer Helpline 01582 670100
10
Adjusting V-Brake Cable Tension (continued)
J
I
K
1b. Fine Tune the Cable Tension
If the brake pads are too close or too far away from the wheel rim once the brake cable has been
adjusted in step 1a, fine tune the cable tension as described below.
Unscrew the barrel adjuster locking nut by turning it anti-clockwise.
Turn the barrel adjuster bolt to increase or decrease the cable tension. This will fine tune the position of
the brakes.
• To increase the tension on the brake cable and move the brakes towards the wheel rim, turn the
barrel adjuster bolt anti-clockwise.
• To decrease the tension on the brake cable and move the brakes away from the wheel rim,
turn the barrel adjuster bolt clockwise.
Once the cable tension is correct, retighten the barrel adjuster locking nut .
J
K
I
K
J

Maintenance Instructions Customer Helpline 01582 670100
11
1a &1b
1b. Fine Tune the Cable Tension
Over time, the brake arms can begin to lean to one side, making the distance between the
brake pads and the wheel rim uneven. This can be corrected by adjusting the spring tension of
the individual brake arm.
NOTE! When adjusting the spring tension, even adjustments should be made to both brake arms
until they are positioned evenly on either side of the wheel and rim.
1a. Adjusting the Spring Tension on the Right Hand Brake Arm.
If the brake arms lean to the right (when viewed from the front of the bike), the right hand brake
arm spring tension should be reduced. This can be achieved by turning the right spring tension
screw anti-clockwise.
If the brake arms lean to the left (when viewed from the front of the bike), the right hand brake
arm spring tension should be increased. This can be achieved by turning the right spring tension
screw clockwise.
1b. Adjusting the Spring Tension on the Left Hand Brake Arm.
If the brake arms lean to the right (when viewed from the front of the bike), the left hand brake
arm spring tension should be increased. This can be achieved by turning the left spring tension
screw clockwise.
If the brake arms lean to the left (when viewed from the front of the bike), the left hand brake arm
spring tension should be decreased. This can be achieved by turning the left spring tension screw
anti-clockwise.
J
L
M
L
M
L
N
L
N
Adjusting the V-Brake Spring Tension
L
N
M

Maintenance Instructions Customer Helpline 01582 670100
12
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 to move the saddle from side to side. If the saddle moves, you
should retighten the seat post bolt or the saddle clamp bolts.
2. Are the Front and Rear Tyres Inflated Correctly?
Squeeze the sides of the front and rear tyres. If they are soft, they will need inflating. Re-inflate, to the
pressure indicated on the sides of the tyres, using an approved bicycle pump.
3. Are the Pedals Tight?
Using the supplied multi-tool, 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 on pages 10-12.
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. Re-tighten the stem bolt.
6. Is the Bike Clean?
The bike should be cleaned and re-oiled regularly to ensure it operates correctly
You should perform the following checks once a month or after long rides.
1. Check that the bike is Clean and Suitably Lubricated.
Thoroughly clean and degrease your bike. Ensure the chain is adequately lubricated using a suitable
bicycle lubricant.
It is important to wipe off any excess lubricant as this will attract dirt and may prevent the bike from
operating correctly.
2. Check that all Parts of the Bike are Securely Fitted.
It is essential for your safety that the securing nuts and bolts are fully tightened and have not become
loose. Pay particular attention to the pedals, wheel nuts, seat post bolt and the stem bolt.
While holding the bike with one hand, vigorously rock the crank arms and wheels. If you notice any
movement, the bearings may be worn.
Repairing bearings requires specialist tools. It is recommended that all bearings are repaired by
qualified bike repair technicians. Contact your local retailer for more information on bearing repairs.
her
Every Month
Before and After Each Ride
Every Month

Maintenance Instructions Customer Helpline 01582 670100
13
3. Check that the Tyres are in Good Condition.
Check the outside of each tyre for signs of damage including cuts, deformation, excessive wear or
bald spots.
If you tyre shows any signs of damage, it must be replaced immediately. Do not attempt to ride the
bike with damaged tyres.
4. Check that the Wheel Spokes are Tight.
On each wheel check the tightness of the spokes. This can be done by gently squeezing two together
at time. If you notice any movement, the spokes may need tightening.
Repairing wheels and tightening spokes requires specialist tools. It is recommended that all wheel
spokes are tightened by qualified bike repair technicians. Contact your local retailer for more
information on wheel repairs.
1. Check the Frame and Forks for Signs of Damage.
Thoroughly check all the external surfaces of the frame for signs of damage.
This may include cracks, dents or bent mounting points.
If the frame damaged, do not attempt to ride the bike until it has been inspected by a qualified bicycle
technician.
2. Check that the Wheels are Running True.
Check the trueness of both the front and rear wheels as described on page 13.
3. Check the Condition of the Brake Pads.
Check all brake pads for signs of excessive wear. Replace badly worn brake pads immediately.
It is recommended that the bike is serviced by a suitably qualified bike technician every 12 months.
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her
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Every Month (continued)
Every Six Months
Every Twelve Months
Routine Maintenance