United Bicycle Institute New Bike Assembly Check List

Transcription

1 United Bicycle Institute New Bike Assembly Check List Make/Model Size Color Inventory Number Bench Number Student 1 Student 2 Unpack Bike!" Remove inventory control number from carton and staple to front wheel, if available.!" Install seat post to maximum height line. Be sure to grease seat post and seat tube.!" Clamp bike in repair stand by seat post only.!" Grease and install quill stem to maximum height line, torque to: in. lbs (16-28Nm). If threadless, wait to install stem later.!" Carefully remove protective wrap and discard as directed by instructor.!" Check for damage and missing parts.!" Check carton for loose parts.!" Remove rear wheel from bicycle.!" Discard bike box as directed by instructor.!" Record serial number (found underneath bottom bracket shell): # Frame!" Check fork dropout alignment. If misaligned, consult instructor.!" Check rear dropout alignment. If misaligned, consult instructor.!" Check rear triangle alignment with Park Frame Alignment Gauge, if misaligned more than 2 mm, consult instructor.!" Measure rear dropout spacing and rear hub over locknut dimension, compare.!" Measure ft. dropout spacing and ft. hub over locknut dimension, compare.!" Discuss results with your instructor. Wheels!" Remove tires and tubes from both wheels.!" Remove "rubber band" style rim strips. If plastic, leave on wheel.!" If freewheel equipped, remove freewheel and grease threads then reinstall. If cassette equipped, torque lock-ring to: in. lbs (30-49 Nm).!" True front and rear wheels on truing stand using a tightly fitting spoke wrench. Check round, true, dish and spoke tension and remember to stress relieve. 1

2 !" Adjust hub bearings. For hollow axles, adjust for a small amount of play.!" Grease full length of quick release skewers (do not remove safety warnings) and install into axle.!" Check wheels in dropouts for final hub adjustment. Quick releases should be closed past vertical, readjust if necessary. When correct, remove wheels.!" Reinstall rim strips (if removed) and tubes and tires centering label over valve with label facing right, unless rotation direction on tire indicates otherwise.!" Check that tire bead is properly seated and inflate to maximum pressure as printed on the sidewall. Bottom Bracket!" Remove crank arm dust caps, if applicable.!" Remove crank bolts/nuts and washers. Make sure washers have been removed!!" Remove cranks using the appropriate crank extractor.!" Check chainring bolts for tightness, if applicable. If bicycle has a conventional loose ball, cup and cone bearing system do the following:!" Loosen lockring, but do not remove.!" Loosen adjustable cup and back out a few turns, do not remove.!" Grease threads on adjustable cup.!" Back out fixed cup a few turns and apply Loctite 242 (blue) or grease to fixed cup threads, per shop's specifications.!" Tighten fixed cup to appropriate torque: in. lbs. (68-79Nm).!" Adjust bearings, starting with extra play and adjusting until play barely disappears. If bicycle has sealed cartridge bottom bracket, do the following:!" Back out fixed cup a few turns and apply Loctite 242 (blue) or grease to fixed cup threads, per shop's specifications.!" Tighten fixed cup to appropriate torque: in. lbs. (49-69Nm). For all four sided spindle bottom brackets, do the following:!" Clean bottom bracket spindle flats and crankarm holes. They must be clean and dry. Use degreaser or rubbing alcohol with a clean rag.!" Install right crankarm, checking all four positions on spindle to find the most aligned position.!" Be sure to grease crankarm bolt or nut threads and washer, if applicable.!" Torque to the following: nut type in. lbs (34-40Nm); bolt type in. lbs (27-34 Nm); Shimano 8mm bolt in. lbs (34-43 Nm).!" Recheck bearing adjustment using right crank arm for leverage. For spline spindle bottom brackets, do the following:!" Lightly grease spindle flutes and then reinstall crank arms.!" Torque to: Shimano Octalink (34-49 Nm) or ISIS in. lbs (38-42 Nm). 2

3 All Bottom Brackets:!" Install left crank arm.!" Be sure to grease crank arm bolt or nut threads, grease washer, if applicable.!" Torque to the following: nut type in. lbs (34-40Nm); bolt type in. lbs (27-34 Nm); Shimano 8mm bolt in. lbs (34-43 Nm); Shimano Octalink (34-49 Nm) or ISIS in. lbs (38-42 Nm).!" If provided, install toe clips, straps and reflectors on pedals.!" Grease threads on pedals and install to proper torque in. lbs (34-40 Nm). Headset Turn fork slowly and check for abnormal roughness (possibility of improper assembly, or a bent or upside down bearing retainer). If bicycle has a conventional threaded headset, do the following:!" Remove headset locknut.!" Install cable hanger if provided.!" Grease threads and reinstall locknut.!" If not already installed, grease and install quill stem to maximum height line, torque to: in. lbs (16-28Nm).!" Adjust headset bearings, starting with play and adjusting until play barely disappears. If bicycle has a threadless headset, do the following:!" Clean outside portion of steerer tube that contacts stem, as well as inside of stem. Stem and steerer must be clean and dry, use degreaser or alcohol.!" Install cable hangers and spacers, if provided.!" Be sure fork is seated firmly in head tube, then seat stem firmly against headset spacers.!" Grease top cap bolt and install top cap into top of stem and steerer tube.!" Adjust headset bearings, align stem and tighten stem binder bolts to manufacturer's recommendation or 130 in. lbs. (15 Nm).!" If not already installed, install handlebars, brake and shift levers.!" If not already installed, install grips or tape, and bar ends, if provided. Setting Handlebar and Brake Lever Angles:!" Flat Mountain Handlebars: Set tipped slightly up and back from horizontal.!" Set brake levers at 45 degrees to ground.!" Upright Mountain Handlebars: Set tipped slightly forward from vertical.!" Set brake levers at 30 degrees from ground.!" Road Bike Handlebars: Set bottom of drops horizontal to ground.!" Align tips of road brake levers with bottom of drops and parallel to each other. 3

4 Brakes Cantilever Brakes Only:!" Remove each brake arch.!" Clean any paint or rust from brake post then grease.!" If thread lock agent is not visible on fixing bolt threads, apply Loctite 242 (blue) to threads.!" Reinstall each brake arch onto brake posts with spring in middle spring tension hole.!" Tighten mounting bolts to in. lbs (5-7 Nm). Do not over tighten! All Brakes:!" Turn lever and/or caliper barrel adjuster threads out a few turns and grease the threads.!" Thread barrel adjusters all the way back in or leave 2 threads showing.!" Install wheels with quick releases properly tightened.!" Seat wheels properly in dropouts and center in frame.!" If cables are pre-installed, carefully remove cables from housing, leave attached to brake levers.!" Shorten all brake housing to minimum length necessary to allow a smooth arc without binding.!" Grease brake cables and reinstall into housing.!" Set up brakes according to manufacturer's instructions.!" Be sure to grease all threaded fixing bolts and nuts. Linear Pull Only:!" Install accordion cable cover.!" Verify brake arms are parallel. If not, switch brake pad post spacers accordingly.!" Check for recommended noodle carrier to brake arm distance of 39-65mm. Be sure to adhere to the following guidelines when setting up brake pads:!" Pad Height: Pad should contact rim so there is a 1 mm gap between top of pad and top of rim or sidewall of tire.!" Pad Toe-in: There should be a mm gap at the rear of the pad just as the front makes contact with the rim.!" Pad Angle: Pad should contact rim squarely so that 100% of pad material touches the rim when brake is fully engaged.!" Pad Symmetry: Pad should contact rim squarely and equally at all four corners of pad. Final Brake Check and Failure Test:!" Pre-stretch cables and seat the housing system by squeezing the brake levers several times. This will ensure that all fixing bolts are tightened properly and there are no flaws in the system.!" When finished pre-stretching, lever travel should not exceed two thirds of its full travel to the handlebars.!" Check pad to rim clearance, pads should be 1-2 mm from rim on each side.!" Brakes should be centered and both brakes feel the same at the lever. 4

5 Derailleurs!" If cables are pre-installed, carefully remove cables from housing, leave attached to shift levers.!" Shorten front-of-bike derailleur housing to minimum length necessary to allow a smooth arc without binding.!" Grease derailleur cables and reinstall into housing. Do not tighten into derailleur cable fixing bolt yet!!" Make sure shift levers are in their neutral position. Cable protrusion from housing ends should be at the maximum.!" Hold each cable end while shifting through all lever indexes, making sure cable moves freely without drag. If derailleur cables and housing are routed along down tube:!" Route the front and rear derailleur housing according to shop policy. Routing around the head tube allows cables to cross under down tube.!" The left/front derailleur cable and housing should route to the right down tube housing stop.!" The right/rear derailleur cable and housing should route to the left down tube housing stop.!" Cross cables under the down tube and route through the appropriate bottom bracket cable guides. Do not install into derailleur yet! If derailleur cables and housing are routed along top tube:!" Route the front and rear derailleur housing around the head tube to provide the smoothest arc possible.!" Compare top tube cable stops with rear triangle cable stops to choose the best routing. Do not install into derailleur yet! All Derailleurs:!" Remove front derailleur clamp bolt and grease the threads and reinstall.!" Check and adjust front derailleur cage height and angle.!" Bottom of outside cage should be 1-3 mm above highest point of large chainring.!" Cage angle should be parallel to large chainring.!" Torque front derailleur clamp bolt to in. lbs (4-7 Nm).!" Remove the rear derailleur.!" Using the derailleur hanger alignment tool, check against the wheel for misalignment. If misaligned, discuss with instructor.!" Grease hanger bolt threads and reinstall. Torque bolt to in. lbs (8-10 Nm). Avoid trapping "B" tension screw against face of derailleur hanger. Rear Derailleur!" Install rear derailleur cable behind cable fixing washer. Do not install front cable yet.!" Grease cable fixing bolt threads and seat cable in groove under the cable-fixing washer.!" Torque cable fixing bolt to manufacturers specifications, in. lbs (4-7 Nm).!" Adjust rear derailleur high limit screw so the guide pulley is aligned under the outside face of the smallest rear cog. 5

6 Rear Derailleur Index Adjustment:!" Beginning with the chain positioned in the smallest cog (in highest gear) shift into next position cog while turning cranks (one click at the shift lever). Guide pulley should now be centered directly under the next position cog.!" If shift lever clicks but chain does not shift, shift back to first cog, loosen fixing bolt, pull out cable slack and retighten fixing bolt. Shift again to the next position cog.!" If chain shifts, but makes noise on next position cog, derailleur is moving too far, turn barrel adjuster clockwise until noise disappears. Shift through rear cog set while pedaling. Use barrel adjuster to correct cable tension, if necessary, until derailleur shifts quietly and responsively.!" Shift to largest cog (in lowest gear) and adjust rear derailleur low limit screw so the guide pulley is centered under the largest rear cog.!" If chain is unable to get into large cog, check derailleur low limit screw for proper adjustment.!" If chain is unable to get back into the first cog, loosen barrel adjuster or cable fixing bolt and readjust and/or check derailleur high limit screw for proper adjustment.!" Shift again through all cogs and use barrel adjuster as needed. Front Derailleur!" Position chain in the lowest gear (large rear cog and small chainring). Chain should be all the way inboard on the bicycle.!" Adjust front derailleur low limit screw so there is a 1 mm gap between the inner cage plate of the derailleur and chain.!" Install front derailleur cable behind the cable fixing washer and passing over the cable guide "tab", if so designed.!" Grease cable fixing bolt threads and seat cable in groove under cable fixing washer.!" Torque cable fixing bolt to manufacturers specifications, in. lbs (4-7 Nm). Front Derailleur Index Adjustment:!" Starting with chain in lowest gear (large rear cog and small chainring), shift chain onto middle chainring by pushing on front lever one click while turning cranks.!" If shift lever clicks but chain does not shift, downshift, loosen cable fixing bolt, pull out excessive cable slack, and retighten.!" If chain shifts, but inner cage plate rubs chain, turn the barrel adjuster on the lever inward until rubbing just disappears. If cage doesn't move inboard, downshift into neutral position, loosen cable fixing bolt, turn crank to allow chain to drop onto small chainring. Check inner cage/ chain gap (1mm) and route of cable over guide tab. Retighten anchor bolt, then repeat the previous step.!" Shift rear derailleur so that chain is in smallest cog (high gear) and shift front derailleur from the middle chainring into the large chainring. Chain should not rub on outer cage plate.!" If chain is unable to shift into the large chainring, first check front derailleur high limit screw for proper adjustment, then check cable tension. There may be too much slack in the cable to allow full derailleur travel. Downshift to neutral position while pedaling and check for slack. Loosen cable-fixing bolt, pull slack from cable and reanchor cable, repeat the previous step. Readjust barrel adjuster as necessary.!" If problems persist, recheck to make certain you routed the cable properly over the cable guide "tab" if so designed. 6

7 !" Position chain in the highest gear. Chain should be all the way outboard on the bicycle.!" Adjust front derailleur high limit screw so there is a 1 mm gap between the inside of the outer cage plate and the chain. Final Derailleur Adjustment and Fine Tuning:!" Shift through all possible gear combinations and fine tune front and rear derailleur adjustments, if necessary.!" Fine tune limit screws as needed.!" Fine tune barrel adjustments and cable tension as needed. Finish!" Trim and solder or cap all cables.!" Install saddle so that saddle is level and centered on rails. Be certain seat rail binder bolt is greased and torque to in. lbs (8-17 Nm).!" Install all remaining reflectors supplied by the manufacturer. If rear reflector is seat post mounted, install at top.!" Install kickstand, if supplied.!" Perform a complete safety check on bicycle. Check brakes by firmly squeezing levers several times. Check tightness of stem, handlebars, control levers, seat post and saddle. Check tightness of front and rear quick release skewers and/or axle lock nuts!" Check bearing adjustment of hubs, bottom bracket and headset. Instructor Check: Test Ride!" Test ride bicycle.!" Shift through all gear combinations.!" Observe for handlebar alignment.!" Thoroughly test brakes for power and possible squeal. Do not ride off road! Keep the bike clean and new looking! After Test Ride!" Recheck all bearing adjustments and adjust as necessary.!" Re-torque crank bolts, handlebar and stem binder bolts.!" Readjust brakes and/or derailleurs if necessary.!" Recheck wheel trueness and roundness in the frame.!" Clean bicycle thoroughly using rubbing alcohol and a clean rag. 7

8 Call instructor for final inspection.!" Turn in bicycle owner's manual.!" Deliver bicycle to storage area, per directions from instructor.!" Turn in assembly checklist. Final Instructor Check: STUDENT COMMENTS: DO NOT WRITE BELOW THIS LINE. FOR INSTRUCTOR USE ONLY CHECKED BY: DATE: INSTRUCTOR EVALUATION: 8