Warning: Please read this entire manual before riding your Fezzari. Failure to do so could result in serious injury or even death.

Contents

1. OVERVIEW ...... 3 A. Thank You ...... 3 B. General Warning ...... 3 C. Important Symbols and Terms ...... 3 D. Related Manuals ...... 5 2. UNPACKING ...... 6 A. Box Contents ...... 6 B. Initial Inspection ...... 6 C. Registration ...... 11 3. ASSEMBLY ...... 12 A. Quick Assembly Overview ...... 12 B. Step 1 - Attach Front Wheel ...... 15 C. Step 2 - Attach Handlebar ...... 17 D. Step 3 - Attach Pedals...... 22 E. Step 4 - Inflate Tires ...... 23 F. Step 5 - Attach Seat ...... 24 G. Step 6 - Attach Additional Reflectors ...... 27 4. OPERATION ...... 28 A. Before Riding – Important Safety Information ...... 28 5. MAINTENANCE ...... 30 A. Inspecting ...... 30 B. Brake Adjustments ...... 30 C. Gears ...... 32 D. Suspension Fork Adjustment & Maintenance ...... 33 E. Rear Shock Adjustment & Maintenance ...... 35 F. Pedals ...... 38

G. Wheels ...... 38 H. Lubrication ...... 39 I. Cleaning ...... 39 J. Storage ...... 40 K. Baby your Fezzari ...... 40 6. FEZZARI LIMITED WARRANTY ...... 41 A. Warranty Information ...... 41 7. TORQUE MEASUREMENT TABLES ...... 42 A. Technical Torque Measurements ...... 42 8. SUPPORT ...... 44 A. Fezzari Contact Information ...... 44 9. INDEX ...... 45 10. TABLE OF FIGURES ...... 46 11. INDEX OF TABLES ...... 47 1 - Overview

1. OVERVIEW New information will be made available on the Fezzari website (www.fezzari.com) as it is available.

A. Thank You Assembly and adjustments of your Fezzari take special tools and skills, so please read carefully. Thank you for purchasing a Fezzari®. Fezzari are handmade of the finest components. Fezzari was C. Important Symbols and Terms founded on the premise that discerning customers will embrace products of superior performance, quality, Bicycling can be a hazardous activity even under and value. We hope you appreciate your Fezzari the best of circumstances. Properly maintaining experience. We want this to be the most rewarding your Fezzari is your responsibility and will help purchase you have ever made. If you have any reduce the risk of injury. This manual contains feedback, comments, or questions, we look forward to many symbols, terms, and formatting to call hearing from you. attention to warnings and cautions.

B. General Warning

In order to use and enjoy your Fezzari safely and to get the best durability and performance from your Fezzari, please read this manual carefully and thoroughly before riding.

The information contained in this manual is to be used as a guideline for safe operation and is not intended to replace any safety rules or laws that may be in force in your area.

Even if you have ridden a bicycle for years, it is important for every person to read this manual before you ride your new bicycle.

3 1 - Overview

The Warning sign indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

The Caution sign indicates a potentially hazardous situation that, if not avoided, could result in minor or moderate injury.

The Note sign indicates text that provides helpful or other

important information. Figure 1 – Road Bike

BOLD Bold lettering indicates important text and points to note.

Please read and follow all Warnings and Cautions in this manual.

Throughout this manual, we refer to different types of bikes – road bikes and mountain bikes:

Road bikes have drop handlebars, narrow tires, and are designed for road riding (see Figure 1).

Mountain bikes have straight handlebars, Figure 2 – wide tires, and are designed for road and off-road riding (see Figure 2).

4 1 - Overview

If no distinction is made between the two bikes, then the comments and procedures outlined in the manual are the same for both bikes.

D. Related Manuals

Many of the Fezzari components have separate manuals that provide additional information. These manuals were included with your Fezzari. Please read and follow the information in these manuals.

5 2- Unpacking

2. UNPACKING B. Initial Inspection A. Box Contents All major parts are identified in Figure 3 (road bikes) and Following is a list of all packaging contents shipped Figure 4 (mountain bikes). Please familiarize yourself with your Fezzari: with these parts prior to assembling or riding your Fezzari. Please check your Fezzari along with the parts  Fezzari (with rear wheel and components thoroughly for any damage that may attached) have been sustained during shipping. Be careful to  Saddle and avoid scratching the frame when untying or unpacking  Handlebars the bicycle and components.  Front Wheel  Box containing: If you find that something is missing or damaged, o Pedals (left and right) please contact the Fezzari Customer Support o Front Wheel Axle Team at (888) 833-9927. o Tools needed to assemble your Fezzari . 4mm, 5mm, and 6mm Allen Wrenches (for installing and adjusting handlebars, brakes, and seatpost) . 15mm Wrench (for attaching pedals) o Component manuals o Additional reflectors

6 2- Unpacking

Figure 3 - Names and Locations of Parts on Road Bike

7 2- Unpacking

Figure 4 - Names and Locations of Parts on Mountain Bike

8 2- Unpacking

For your information, Figure 5 and Figure 6 reference commonly-used terms for the frame parts of your Fezzari.

Figure 5 - Names of Frame Parts on Road Bike

9 2- Unpacking

Figure 6 - Names of Frame Parts on Mountain Bike

10 2- Unpacking

C. Registration

The serial number of your bicycle frame is attached to the underside of the down tube or underneath the shell (see Figure 5 and Figure 6).This information is required for you to register your bike. We must have this registration before we can process a warranty claim. Please fill out the warranty registration form included with this manual (or register online at www.fezzari.com). Your Fezzari must be registered before a warranty claim can be processed.

11 3 - Assembly:

3. ASSEMBLY

A. Quick Assembly Overview

All references to “left” and “right” in this manual are relative to riding position on the bicycle.

Your Fezzari comes with tools needed for assembly. Assembly is generally a 5 or 6 step process (note: you don’t necessarily need to do these in this order):

Step 1 - Attach Front Wheel Step 2 - Attach Handlebar Step 3 - Attach Pedals Step 4 - Inflate Tires Step 5 - Attach Seat Step 6 - Attach Additional Reflectors

Following is an overview of the steps for assembly, and then details of each step.

If you have any problems or questions with assembly

Call (888) 833-9927 or visit www.fezzari.com.

12 3 - Assembly: Overview

Figure 7 – Quick Assembly Overview – Road Bikes 13 3 - Assembly: Overview

Figure 8 – Quick Assembly Overview – Mountain Bikes 14 3 - Assembly: Step 1 - Attach Front Wheel

B. Step 1 - Attach Front Wheel (2) Slide wheel into front fork (See Figure 10). (1) Put quick release axel in wheel (See Figure With the steering fork facing forward (angling 9). (Note: if you have a 15 mm axel on a away from bike), insert the wheel between the mountain bike, it will screw into place through fork blades so that it firmly touches the inside the wheel and fork.) Unscrew Cap on end of of the fork ends. The quick-release lever Rod and remove one spring. Slide Rod through should be on the left side of the bike. On some center of wheel. Slide second spring onto Rod mountain bikes, make sure that the disk brake (fat end of springs should be away from wheel slides into the disk brake pad housing. on both sides). Screw on Cap 1-2 turns (keep it loose at this point).

Figure 9 – Quick Release Axel Installation Figure 10 – Slide Wheel into Fork 15 3 - Assembly: Step 1 - Attach Front Wheel

(3) Fasten wheel securely in fork (See Figure 11). Holding the quick-release lever in the OPEN position with your left hand, tighten the Cap until it is finger-tight. While pushing the wheel firmly to the top of the slots in the fork dropouts, and at the same time centering the wheel rim in the fork, rotate the quick-release lever upwards and push it into the CLOSED position. The lever should be parallel to the fork blade and curved toward the wheel. If the lever cannot be pushed all the way to a position parallel to the fork blade, return the lever to the OPEN position. Then turn the

tension adjusting nut counterclockwise one- Figure 11 – Fasten Wheel Securely in Fork quarter turn and try tightening the lever again. (4) Test for proper installation. Spin the wheel On road bikes, you may need to adjust the to make sure that it is centered in the frame. Brake Release Lever (refer to Figure 25 on Pick up the bike, and sharply hit the top of the page 31). tire with the heel of your hand. The wheel must not come off, be loose, or move from If you can fully close the quick release side to side. lever without wrapping your fingers around the fork blade for leverage, and if the lever does not Failure to properly adjust the quick leave an imprint in the palm of your hand, then the release mechanism can cause the wheel to wobble tension is insufficient. Open the quick-release lever or disengage. This could cause you to lose control and turn the Tension Nut clockwise a quarter turn, and fall, resulting in serious injury or death. and then try again.

16 3 - Assembly: Step 2 - Attach Handlebar

C. Step 2 - Attach Handlebar

Controls are mounted to handlebar and you will need to mount and align your handlebar to the front of the . (1) Make sure stem is aligned forward with fork angling away from bike frame (See Figure 12). If it is not, using the included Allen wrenches, loosen Steerer Clamp Bolts and align with fork. You may need to loosen the stem binder bolt also. Always loosen the Steerer Clamp Bolts before loosening the Stem Binder Bolt. When tightening, always tighten the Stem Binder Bolt before tightening the Steerer Clamp Bolts. Do not over-tighten the Stem Binder Bolt.

Figure 12 – Stem and Fork Alignment

17 3 - Assembly: Step 2 - Attach Handlebar

The stem’s Minimum Insertion Mark must not be visible above the top of the headset. If the stem is extended beyond the Minimum Insertion Mark the stem may break or damage the fork’s steerer tube, which could cause you to lose control and fall.

(2) Remove handlebar clamp bolts and Stem Clamp from the stem (See Figure 13).

Figure 14 – Attaching Handlebar (Road)

Figure 13 – Handlebar Clamp Bolt Removal

(3) Attach handlebar and finger-tighten (at this point) handlebar clamp bolts (See Figure 14 and Figure 15). Make sure cables aren’t twisted: Figure 15 – Attaching Handlebar (Mountain) 18 3 - Assembly: Step 2 - Attach Handlebar

(4) Position the handlebar to the desired angle (See Figure 16 and Figure 17). Make sure it is centered in the stem, and centered over front wheel. For mountain bikes, while standing over the bike as if you’re going to ride it, adjust handlebars so that brake handles are on the same plane as your arm while holding onto the handlebars. The brake and shifting controls are positioned on the handlebars where they work best for most people.

Figure 16 – Adjust angle of handlebar (Road Bike)

19 3 - Assembly: Step 2 - Attach Handlebar

Figure 17 – Adjust angle of handlebar (Mountain Bike)

(5) Tighten handlebar clamp bolts with the 5mm Allen Wrench (note: some clamp bolts require the 4mm Allen Wrench) (See Figure 18 – Tighten Handlebar Clamp Bolts Figure 18). Tighten a few turns on one side

and then the other side, repeating until it is snug. (6) Test for proper installation. i. Make sure stem is centered over wheel and Steerer Clamp Bolts are tight. ii. Make sure Handlebar is aligned properly and Handlebar Clamp Bolts are tightened. iii. Ensure that the front fork and stem will turn easily and smoothly from side to side without your handlebar slipping. 20 3 - Assembly: Step 2 - Attach Handlebar

If you do not fully understand any of the above steps or if you think the handlebar is not tightened properly, please contact the Fezzari Customer Support Team (see page 44).

An insufficiently tightened stem binder bolt, handlebar binder bolt, or bar end extension clamping bolt may compromise steering action, which could cause you to lose control and fall. Place the front wheel of the bicycle between your legs and attempt to twist the handlebar/stem assembly. If you can twist the stem in relation to the front wheel, turn the handlebars in relation to the stem, or turn the bar end extensions in relation to the handlebar, the bolts are insufficiently tightened.

Loose or damaged handlebar grips or extensions can cause you to lose control and fall.

Make sure all wires and cables are free from obstruction and not wrapped around the stem or front fork.

21 3 - Assembly: Step 3 - Attach Pedals

(2) After the pedals can no longer be turned by D. Step 3 - Attach Pedals hand, use the 15mm wrench included in your tool kit and tighten the pedals securely. The The pedals have different threads based on which shoulder of each pedal should fit against the crank arm they should be connected to. The pedals are crank arm. marked with “L” for left and “R” for right. Left and right are determined from the riding position on the bicycle.

Left and Right Pedals are threaded in opposite directions. Do not try to force the wrong pedal onto the crank arm as it will strip the threading.

Each pedal is marked with “L” for Left of “R” for Right.

Left and right are relative to riding position on your bike.

An easy way to remember how to tighten your pedals is to tighten both pedals towards the front of your bike. Figure 19 – Pedal Installation

(1) Align the pedal axle with the threaded hole in Sometimes noises coming from your its respective crank arm. Secure the pedal in pedals are because you have not sufficiently the crank by hand. The right pedal is installed tightened the pedal onto the crank. Riding with a by turning the pedal axle clockwise and the left pedal not sufficiently tightened can damage your pedal is installed by turning the pedal axle crank and pedals and could cause serious injury. counter-clockwise. 22 3 - Assembly: Step 4 - Inflate Tires

E. Step 4 - Inflate Tires

Check the inflation of the tires. Make sure that the tires are inflated according to the pressure indicated on the tire sidewall. Tire pressure should not exceed what is indicated on the sidewall.

Inflate tires only to the pressure Figure 21 – Mountain Bike Tire Inflation (Either indicated on the tire sidewalls. Do not over-inflate. Presta or Schrader)

For best results, use a pump with a built-in (1) Road Bike Tire Inflation (Presta Valve) pressure gauge. Check www.fezzari.com for high (See Figure 20). quality pumps and other accessories.

Figure 20 – Road Bike Tire Inflation (Generally Presta Valves)

(2) Mountain Bike Tire Inflation (Generally Schrader Valves) (See Figure 21).

23 3 - Assembly: Step 5 - Attach Seat

F. Step 5 - Attach Seat On bikes with Quick Release , you must use the full force of the cam action to clamp the seatpost securely. Turning the lever like i. Seatpost Installation a wing nut until it is tight will not clamp the seatpost safely. If you can fully close the quick Install the seat post into the seat tube. To adjust the release without wrapping your fingers around the seat height: seat post or a frame tube for leverage, and the lever does not leave a clear imprint in the palm of (1) Insert Seatpost into Seat Tube (see Figure your hand, the tension is insufficient. Open the 22). Make sure you insert the seatpost past lever, turn the tension adjusting nut clockwise a the Seatpost Minimum Insertion Mark and quarter turn, and then try again. Tighten securely.

Riding with an improperly tightened seat post can allow the saddle to turn or move and cause you to lose control and fall.

Figure 22 – Seatpost Installation 24 3 - Assembly: Step 5 - Attach Seat

i. Sit on the saddle in riding position without (2) Adjust Seatpost Height (Recommended) shoes while someone holds the bicycle (See Figure 23). Exact saddle height is largely upright. a matter of personal preference. Below is a recommended way to adjust seatpost height. ii. Position the crank arms so they are parallel to the seat tube. iii. Loosen the seatpost binder bolt, or quick- release. iv. Place your heel on the pedal and extend the seatpost until your leg is straight. For proper riding position, when wearing shoes and with the ball of your foot on the pedal, you should have a slight bend in your knee. v. Make sure the minimum insertion mark (See Figure 22) on the seatpost is not visible above the bike frame. A minimum of 2 1/2 inches (64 mm) of seatpost must remain in the frame. vi. Re-tighten the seatpost quick-release, or bolt. For a seatpost binder with a quick- release lever, the mechanism works the same as a wheel quick-release. Adjust the lever tension, and make sure it is in the closed position (see Figure 11 on page 16).

Figure 23 – Recommended Saddle Height Adjustment

25 3 - Assembly: Step 5 - Attach Seat

Extended riding with a poorly adjusted ii. Saddle Adjustment saddle, or one that does not properly support your pelvic area, can cause short-term or long-term Seat angle (tilt) and fore-aft positioning is largely a injury to your nerves and blood vessels. If your matter of preference. saddle causes pain or numbness, re-adjust the saddle position. If after adjustment your saddle (1) Adjust Forward/Backward and Up/Down still causes pain or numbness, try further Position (See Figure 24). Loosen the Seat positioning or replacing the saddle with one that Fixing Bolt and adjust angle and fore-aft fits you better. position. Most people prefer a horizontal saddle. Make sure to tighten completely. When Full-suspension bikes have a markedly properly tightened, the seat post cannot be greater ground clearance than bikes without rotated in the frame. springs. When the saddle is adjusted to its proper height, you will not be able to reach the floor with your feet. Set the saddle a little lower to begin with and practice getting on and off the saddle.

Your full-suspension mountain bike has been designed to compress with its shocks and still have optimum ground clearance. Just like a 4x4 vehicle, it is normal for a frame to ride higher on a full-suspension bicycle.

Figure 24 – Saddle Adjustment

26 3 - Assembly: Step 6 - Attach Additional Reflectors

G. Step 6 - Attach Additional Reflectors

Additional reflectors are included in the box for attaching to the handlebar and seatpost. Attach these to the middle of the front handlebar and on the seatpost so that they are visible to traffic.

If you ride on public roads, you must equip your Fezzari with the appropriate safety devices according to the laws of where you are riding. Consult your local community for bicycle riding laws, including lights, helmets, reflectors, where you can and can’t ride, and other rules you must follow.

Riding bicycles at night or at dusk can be extremely dangerous. You should ride on designated, well-lit bike paths. Reflectors alone are generally not adequate for night-riding. You should also get a front and rear light. See www.fezzari.com for high quality lights and other accessories.

27 4 - Operation

4. OPERATION □ Check Tires & Tubes – make sure they are inflated according to the pressure recommended on the tire sidewall. Check A. Before Riding – Important for any wear or tear. Replace damaged Safety Information tires before riding. Note: tire pressure can decrease as much as 5 to 10 psi per week. The information contained in this manual is Check tire pressure regularly. Ensure that to be used as guidelines for safe operation and is the valve cap is installed correctly. (See not intended to replace any safety rules or laws Figure 20 and Figure 21 on page 23.) that may be in force in your area. □ Check Rims and – Inspect for Make sure all of your quick releases are locked and damage. secure. Make sure all parts, components, and accessories are in good working order. Here’s a simple Saddle & Seatpost safety check that you should do every time before you □ Check Height and Angle – make sure ride your Fezzari: they are adjusted correctly. (See Figure 23 on page 25, and Figure 24 on page 25, and Frame the accompanying text.) □ Inspect – thoroughly inspect frame for □ Check Alignment – make sure the saddle any signs of damage. is parallel to the bike’s center line and clamped tight enough so that you can’t Wheels twist it out of alignment.

□ Check Quick Release levers – make Handlebars sure they are secure and seated properly. (For wheel quick releases, see Figure 10 □ Check Alignment – make sure handlebar on page 15, and Figure 11 on page 16, and stem is parallel to the bike’s center line the accompanying text; for seat post quick and clamped tight enough so that you releases, see Figure 22 on page 24 and the can’t twist it out of alignment. (See Figure accompanying warning.) 12 on page 17.)

28 4 - Operation

□ Check Handlebar Grips – Make sure the Gears.) To understand how to shift the handlebar grips are secure and in good gears on your Fezzari better, please see condition. the supplemental owners manual for the shifters. Note: for road bikes, the gears Brakes are generally integrated into the brake handles. Push the handles inward as you □ Check Braking – check for proper are pedaling to shift gears. For more operation. Squeeze the brake levers. Are information, visit www.fezzari.com. the brake quick-releases closed? Are control cables seated and securely engaged? Do the brake pads contact the wheel rim squarely and make full contact Do not ride with your chain on either with the rim? Do the brake pads touch the the smallest front gear and smallest rear gear, or wheel rim within an inch of brake lever with your chain on the largest front gear and movement? Can you apply full braking largest rear gear. This can cause undue wear on force at the levers without having them the chain and gears, excess noise, and inefficient touch the handlebar? If not, your brakes pedaling. need adjustment. (See page 30, Brake Adjustments). Replace any worn or damaged parts before riding your bicycle. Riding with damaged New disk brakes will make some noise that parts could cause severed injury or even death. will subside after the bike has been ridden a few times. Always ride with a certified CPSC- Gears certified bicycle helmet. Riding without a helmet can cause serious injury or death. □ Check Shifting – if gears don’t shift smoothly or make clicking noises, they may need to be adjusted. (See page 31,

29 5 - Maintenance

5. MAINTENANCE B. Brake Adjustments Periodically, you may need to adjust some components on your Fezzari for safety and best performance. i. Common Brake Adjustments Over time it is common for cables to stretch. There is a A. Inspecting simple way to adjust your brakes. Your Fezzari has a handy device called a barrel adjuster. On road bikes Check the tightness of key components. Put a wrench you’ll find the barrel adjuster near the brakes (see on every important bolt and tighten it slightly to see if Figure 25); on mountain bikes you’ll find the barrel it has loosened: adjuster near the brake levers (see Figure 26). Barrel adjusters have a knurled edge for gripping, and can be Check the seat and seatpost bolts adjusted without tools.

Check the wheel quick releases To use the barrel adjusters, turn the adjusting barrel Check the stem and handlebar bolts counterclockwise by hand and check the setting by Check the brake and shift lever bolts squeezing the levers. On mountain bikes, when the Check tension (look for loose spokes) brakes feel comfortable, you can lock the barrel adjusters in position by turning the lockring (the Tighten pedal screws second knurled piece) clockwise until it's tight against Tighten bolts that hold accessories (water the lever. bottle holders)

30 5 - Maintenance

way in (clockwise) and replace the brake pads. If the cable has stretched too far, you need to loosen the clamp bolt and tighten the cable.

For more information on adjusting and maintaining your brakes, please visit www.fezzari.com.

Please go to www.fezzari.com for more information on adjusting and maintaining your brakes.

Improperly adjusting your brakes could cause them to malfunction and could result in serious injury.

Figure 25 – Road Bike Brake Adjustments ii. Disk Brake Adjustments If your disk brake on your mountain bike is squeaking or needs adjustment, please consult the brake manufacturer’s manual that was included with your Fezzari for a simple adjustment. Please note however, that new disk brakes will make some noise that will subside after the bike has been ridden a few times.

New disk brakes will make some noise that will subside after the bike has been ridden a few times. Figure 26 – Mountain Bike Brake Adjustments

When your brakes wear out, the barrel adjuster won’t work. You’ll need to turn the barrel adjusters all the

31 5 - Maintenance

C. Gears

If your gears are clicking unusually loud (as if the is trying to shift to another gear), there is a simple adjustment. Similar to brakes, shifting cables also have barrel adjusters.

Mountain bikes: one barrel adjuster is located by the rear derailleur, and the other barrel adjuster is located at the other end of the same cable by the . (See Figure 27.) Figure 28 – Gear Barrel Adjuster (Front) – Road Bike

While turning the crank forward, shift the right shifter slowly through the gears. If it feels like it catches on any of the gears, twist the barrel adjuster ¼ turn counter-clockwise (this increases the tension). This should decrease the sound and cause the derailleur to shift smoothly between gears. Repeat as necessary adjusting ¼ turn counter-clockwise.

Figure 27 – Gear Barrel Adjuster (Front) – If the chain is skipping gears, then the tension needs Mountain Bike to be decreased. You can decrease the tension by turning the barrel adjuster ¼ turn clockwise, repeating Road bikes: one barrel adjuster is located by as necessary, until it shifts smoothly between the the rear derailleur, and the other barrel gears. adjuster is located close to the other end of the same cable at the top of the downtube. (See If the chain is going beyond either the biggest gear or Figure 28.) the smallest gear on the rear wheel, then the high and low gear limit screws may need to be adjusted. They 32 5 - Maintenance are two screws located on the rear derailleur labeled “H” and “L”. Counterclockwise turns allow it to move D. Suspension Fork Adjustment & farther; clockwise turns limit it. More information on Maintenance this simple adjustment and other shifting adjustments can be found at www.fezzari.com. i. Generally Do not ride with your chain on either Please refer to the fork manufacturer’s owner’s manual the smallest front gear and smallest rear gear, or for suspension fork maintenance and adjustment. with your chain on the largest front gear and largest rear gear. This can cause undue wear on For most suspension forks, a supplemental the chain and gears, excess noise, and inefficient owners manual from the fork manufacturer is pedaling. included with this manual. Please refer to that manual for adjustments and maintenance. OUR Please go to www.fezzari.com for more SUGGESTIONS BELOW DO NOT OVERRIDE information on adjusting your derailleur and ANYTHING STATED IN THOSE MANUALS. maintaining optimum drivetrain performance. Do not hang your mountain-bike upside down by both wheels because this may cause the oil in the front shock to separate.

ii. General Adjustment Suggestions

Please refer to the supplemental owner’s manual for your fork before changing any settings or doing any maintenance.

Your Fezzari suspension fork has already been adjusted for the average size rider and for normal riding conditions.

33 5 - Maintenance

For optimal performance, your fork should be adjusted Your full-suspension mountain bike has to your weight and your intended riding purpose. been designed to compress with its shocks and still have optimum ground clearance. Just like a 4x4 Most forks have an adjustment mechanism to increase vehicle, it is normal for a frame to ride higher on a or decrease the tension. Generally, you can turn the full-suspension bicycle. adjustment screw ¼ turn to the “+” side (clockwise) to increase tension for a more firm ride, or ¼ turn to the iii. Maintenance “-” side (counter-clockwise) to decrease tension for a Suspension forks require maintenance and care. softer ride. Adjust again as necessary. These Following are some recommendations for suspension adjustments screws are generally at the top of the fork. fork maintenance: Some forks may have a screw on each fork tube to adjust; other forks may have an adjustment at the top Make sure that the sliding surfaces of the of one of the fork tubes that adjusts the tension for upper fork tubes are clean. Clean the fork with both fork tubes. water and a soft sponge after every ride. After

washing your mountain bike, apply a very thin Most suspension forks have adjustment film of hydraulic oil or other bicycle lubricant. screws at the top of the fork to stiffen or soften the ride. Some forks may have a screw on top of each fork tube to adjust; other forks may have an Regularly check all screwed connections on adjustment at the top of one of the fork tubes that your fork with a torque wrench. adjusts the tension for both fork tubes. Follow the recommendations in the supplemental fork manufacturer’s owners Use caution and refer to the manual for cleaning your fork. supplemental fork manufacturer’s owners manual before adjusting any screws. Forks with air springs should be regularly

checked for air pressure. Do not ride if your fork hits the end of its travel. Increase the tension the fork by turning the adjustment dial in ¼ turn increments to the “+” side. 34 5 - Maintenance

Before and after adjusting the fork, check whether the adjusting mechanism at the top of E. Rear Shock Adjustment & the upper fork tube is still tight. Maintenance

Make sure all screws and adjusting i. Generally mechanisms are secure before riding your Fezzari. Please refer to the shock manufacturer’s owner’s For more information on fork maintenance manual for rear shock maintenance and adjustment. and tips, visit www.fezzari.com. For most rear shocks, a supplemental owners manual from the shock manufacturer was included with this manual. Please refer to that manual for adjustments and maintenance. OUR SUGGESTIONS BELOW DO NOT OVERRIDE ANYTHING STATED IN THOSE MANUALS.

ii. General Adjustment Suggestions Your Fezzari rear shock has already been adjusted for the average size rider and for normal riding conditions.

Full suspension bikes yield a little when you sit on the saddle. This causes the saddle to tilt slightly backwards. You may want to adjust the nose of the saddle slightly downward to compensate.

35 5 - Maintenance

Full suspension bikes have a markedly Lift your bike so that there is no weight on the greater ground clearance than bikes without rear wheel. springs, if the saddle is adjusted to its proper height, you will not be able to reach the floor with Turn the knurled ring counterclockwise until your feet. Set the saddle a little lower to begin with the spring has completely relaxed the rear and practice getting on and off the saddle. shock. If you can’t turn the ring on its own, take hold of the spring with your whole hand The rear shock should not reach the end of its travel. and turn it together with the knurled adjusting If it frequently hits the end of its travel it will become ring. damaged and substantially decrease the usable life of your shock. Turn the adjusting ring by one complete turn clockwise to give the spring some initial iii. Coil Shock Adjustments tension.

Please refer to the supplemental The maximum tensioning range from this owner’s manual for your shock before changing position is four to six complete turns. If you any settings or doing any maintenance. turn the adjusting ring beyond this point, the coils of the spring will touch, and damage to Generally, your initial coil tension should be adjusted the rear shock or its base may result. so that when you are sitting on the saddle, the coil yields about 10-30% of the total travel. Total travel for To increase the initial tension, turn the knurled your model can be found in the supplemental shock adjusting ring on the steel spring clockwise. manufacturer’s owner’s manual. You can determine actual travel by measuring the distance between the Adjust the initial spring tension so that when center of the rear wheel (at the quick release) to the you are sitting on the saddle the bike yields by lower edge of the saddle. about 10% to 30% of the total spring travel.

Following are general suggestions for adjusting a coil spring:

36 5 - Maintenance

Riding your Fezzari with the spring vi. Rear Shock Maintenance completely released will damage the thread of the Keep the rear shock clean. After washing your rear shock and can substantially decrease the bike (see page 39, Cleaning) apply a light usable life of your shock. bicycle lubricant to the bases and joints. This

prolongs the life of the shock and makes it quieter. iv. Air Shock Adjustments Air-cushioned rear shocks are adjustable via air Check the screws on the swing arms to make pressure. Use a suitable pump and observe the sure they are tight. recommended pressure values, either written on the shock or in the supplemental owner’s manual. Rear shocks constantly get sprayed with water and dirt from the rear wheel. Make sure to clean them after every ride. You can increase the air pressure with a shock pump or a standard floor pump with a pressure gauge. For high quality pumps, visit After cleaning, if you hear any noises from www.fezzari.com. the shock, apply a light bicycle lubricant spray to the area around the bearings and rear shock bases.

v. Rebound Adjustment Many shocks have Rebound Adjustment (the speed and force of the shock returning to its expanded state after being compressed). Please refer to the supplemental shock manufacturer’s owners manual for adjustment.

Generally, though, rebound can be adjusted by an external handwheel located on the shock. Rebound is generally considered satisfactory when the rear stays rebound once after descending from a high curb.

37 5 - Maintenance

G. Wheels F. Pedals i. Tires & Tubes Make sure that your pedals are securely fastened to the cranks. Remember that the left pedal is reverse- All bicycle tires are somewhat porous and allow air to threaded (counter-clockwise) and the right pedal is seep out over time. Low tire pressure makes riding threaded clockwise. more difficult, and can damage your rims, tires, and tubes. Low tire pressure also causes your tires to wear If your pedals develop squeaks, apply lubricant in the out quicker. Use a good pump with a built-in gauge moving parts and wipe off any excess, and make sure and inflate it to the tire manufacturer’s recommended that they are tightened. pressure, which is located on the sidewall of the tire.

Sometimes noises coming from your Inflate tires to the tire manufacturer’s pedals are because you have not sufficiently recommended pressure, located on the tire’s tightened the pedal onto the crank. Riding with a sidewall. pedal not sufficiently tightened can damage your crank and pedals and could cause injury. Tire pressure can decrease as much as 5 to 10 psi per week. Check tire pressure regularly. An easy way to remember how to tighten Ensure that the valve cap is installed correctly. For your pedals is to tighten both pedals towards the high quality pumps, visit www.fezzari.com. front of your bike. ii. Spokes and Wheels For other pedal options and recommendations, please visit www.fezzari.com. Check for loose spokes, which can cause a wheel to go out of true. To adjust spokes and wheels, take your

bicycle to a certified bicycle mechanic. You can also go to www.fezzari.com for more information.

Loose spokes can cause a wheel to go out of true and collapse, which could cause serious injury or death. 38 5 - Maintenance

H. Lubrication I. Cleaning A bicycle has several moving parts that must be lubricated regularly for optimal performance and to Regular and proper cleaning of your Fezzari will keep it prevent rust and excessive wear. Use a light bicycle looking newer longer, protect the finish, and make it lubricant (like TriFlow). Be careful to wipe off any perform better. If your Fezzari gets dirty or muddy excess lubricant, which can attract dirt and dust. You (as in the case of mountain bikes), prop your bike can easily lubricate the following yourself, and should upright and spray it down with a hose. DO NOT blast do it regularly: water sideways at the bicycle. This could cause water to get into the pedals, bottom bracket, or hubs, which Chain – while turning the crank backwards, could compromise the bearings, grease, and apply a light coat. Let it sit for a while, and components inside. Spray water from above the then wipe any excess off. The chain needs bicycle, and try not to spray directly on parts with lubricating if you hear it squeaking when grease. pedaling, or if the chain links appear bright and shiny. You can wash your bike with a bucket of warm water and mild dishwashing soap. Use a sponge, and for Any Pivots on and Brakes hard to reach spaces use a soft bristled brush, like a (places where parts move) – apply two to soft toothbrush. Dry the bike with a soft cloth three drops of lubricant on these places. Make afterwards. sure to wipe off any excess. Make sure to re-lubricate parts afterwards; otherwise Pedals – if pedals seem stiff to rotate, or they may rust if left with water. make noise, apply lubricant in the moving parts, and wipe off any excess. You can use any liquid car wax on your Fezzari.

39 5 - Maintenance

K. Baby your Fezzari J. Storage Your Fezzari was made with high performance Always store your Fezzari indoors. The indoor components, and is highly durable. You can ride hard, environment will protect the bike from moisture in but ride smart. Learn to ride with a light technique as outside air that over time will corrode the metal parts. some of the best bikers do and your Fezzari’s usable It will also protect your Fezzari from extended life will be extended. Experts ride softly so you barely exposure to sunlight, or salt if you live near an ocean. hear noise. This will save you time in maintenance, greatly reduce your chance of injury, and ensure that One of the easiest ways to store your Fezzari is with a your bike will run trouble free much longer. bicycle hook. You can hang it from the front wheel, or upside down by both wheels. You should not hang your mountain-bike upside down by both wheels because this may cause the oil in the front shock to separate.

Switch the gear to the smallest chainwheel and the smallest sprocket. This relaxes the cables and springs as much as possible.

Hang your bicycle indoors with a bicycle hook by the front wheel or by both wheels. See www.fezzari.com for bike hooks and other storage accessories.

Do not hang your mountain-bike upside down by both wheels because this may cause the oil in the front shock to separate.

40 6 - Fezzari Limited Warranty

6. FEZZARI LIMITED WARRANTY NEGLIGENCE, PRODUCT LIABILITY, OR ANY OTHER THEORY.

A. Warranty Information EXCLUSIONS

FEZZARI BICYCLE LIMITED LIFETIME WARRANTY THE ABOVE WARRANTY, OR ANY IMPLIED WARRANTY, DOES NOT COVER NORMAL WEAR AND TEAR. ALL Fezzari warrants the frame and rigid fork of each new WARRANTIES ARE VOID IF THE BICYCLE IS MODIFIED Fezzari brand bicycle and Fezzari brand frameset to be FROM ITS ORIGINAL CONDITION OR THE BICYCLE IS free from defects in material and workmanship for as USED FOR OTHER THAN NORMAL ACTIVITIES, long as the original purchaser owns the bicycle. Paint INCLUDING, BUT NOT LIMITED TO, FAILING TO finish and all other original components, and all Fezzari FOLLOW THE OWNER’S MANUAL OR USING THE brand repair parts, replacement parts, and accessories, BICYCLE FOR COMMERCIAL ACTIVITIES OR IN are warranted to be free from defects in material or COMPETITIVE EVENTS, INCLUDING BUT NOT LIMITED workmanship for a period of one year from the original TO BICYCLE RACING, BICYCLE MOTOCROSS RACING, date of purchase. STUNT RIDING, RAMP JUMPING OR SIMILAR ACTIVITIES, AND TRAINING FOR SUCH ACTIVITIES OR LIMITED REMEDY EVENTS. FEZZARI MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED. ALL IMPLIED WARRANTIES, Unless otherwise provided, the sole remedy under the INCLUDING THE WARRANTIES OF MERCHANTABILITY above warranty, or any implied warranty, is limited to AND FITNESS FOR A PARTICULAR PURPOSE, ARE the replacement of defective parts with those of equal LIMITED IN DURATION TO THAT OF THE EXPRESS or greater value at the sole discretion of Fezzari. You WARRANTIES STATED ABOVE. will be responsible for labor costs associated with warranty replacements. IN NO EVENT SHALL FEZZARI WHAT YOU SHOULD DO BE RESPONSIBLE FOR DIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, WITHOUT Contact Fezzari Customer Support at www.fezzari.com. LIMITATION, DAMAGES FOR PERSONAL INJURY, PROPERTY DAMAGE, OR ECONOMIC LOSSES, WHETHER BASED ON CONTRACT, WARRANTY,

41 7- Torque Measurement Tables

7. TORQUE MEASUREMENT TABLES

A. Technical Torque Measurements

Be careful to follow the directions in this manual and securely tighten each bolt. For reference, the following tables list recommended torque levels for various components when using a torque wrench:

Table 1 – Maximum Torque Levels for Parts Component Screw connection Torque (Nm)* Disk Brake Caliper bolt (fixed to frame or fork) 6 Brake lever clamp screw 4 Disk (rotor) fixation bolt 4 Reservoir cover screw <1 Stem Handlebar clamp screw M5 10-12 Handlebar clamp screw M6 14-16 Cone clamp screw in stem of fork 19 Headset clamp bolts 10-16 Seat post Saddle bolt (two bolt system) 9-11 Saddle bolt (one bolt system) 16-19 Saddle Clamp 12 Bottle Cage Screws 5

*Nm = Newton meters

42 7- Torque Measurement Tables

Table 2 - Recommended Torque Levels for Other Screwed Connections Torque (Nm) Component Screw Connection * ** Crank fixing bolt (grease-free square-head) 35 - 44 32 - 38 Crankset Crank fixing bolt (greased octalink) 35 - 50 chainwheel bolt 8 - 11 Sealed cartridge in housing 49 - 69 70 Bottom bracket Fixed cup (cone) and lock ring 49 - 78 Clipless pedal axle 34 40 Cleat screws 5 - 8 Shoe Spike 4 Fixing bolt on frame mounting (V-brake) 5 - 9 Pivot bolt Caliper brake 8 - 10 10 Brake Cable anchor nut 6 - 8 5 Brake pad fixing bolt 5 - 7 8 Fastening bolt for cartridge brake pad lining 1 - 2 mounting bolt (hanger bolt) 8 - 10 1 5 Rear gear changer Cable anchor bolt 4 - 6 6 (Rear derailleur) Roller cage bolt 3 - 4 Front gear changer Mounting bolt 5 - 7 3.5 (Front derailleur) Cable anchor bolt 5 - 7 5 Mounting bracket bolt (Allen key) 6 - 8 8 Mounting bracket bolt (screwdriver) 2.5 - 3 Brake- and gear-lever Limit stop mounting bolt (frame! (screwdriver) 1 .5 - 2 Shifter fastening bolt 2.5 Quick-release lever 9 - 12 Hub Locknut for adjusting quick-release hub bearing 10 - 25 Freewheel body fixing bolt 35 - 49 1 5 Freewheel Hub Freewheel body fixing nut 35 - 44 6 Sprocket cluster lock ring 29 - 49

*According to Shimano product information and tech tips **According to Campagnolo technical specifications

43 8 - Support

8. SUPPORT

A. Fezzari Contact Information

For all current contact information, please visit us at www.fezzari.com.

Questions? Problems? For Customer Support, Call (888) 833-9927

44 10 - Table of Figures

9. INDEX

Air Shock Adjustments, 37 Before Riding, 28 Coil Shock Adjustment and Assembly Initial, 6 Maintenance, 36 Box Contents, 6 Lubricant, 34, 37, 38, 39 Maintenance, 35 Barrel adjuster. See Brake Lubrication, 39 Rebound Adjustment, 37 Adjustments and Gear Maintenance, 30 Spokes, 38 Adjustments Operation, 28 Storage, 40 Brakes Pedals, 21, 38 Suspension Fork & Rear Shock, Adjustments, 29, 30 Presta Valves. See Tire Inflation 33 Checking Brakes, 29 Rear Shock Adjustment & Suspension Fork Adjustment & Disk, 31 Maintenance, 35 Maintenance, 33 Campagnolo Rear Shock Maintenance, 37 Tire Inflation Torque Levels, 43 Rebound Adjustment, 37 Mountain Bike, 23 Cleaning, 39 Saddle Adjustment, 26 Presta Valves, 23 Coil Shock Adjustments, 36 Safety Road Bike, 23 Contact Information, 44 Helmets, 29 Schrader Valves, 23 Derailleur. See Gears Reflectors, 27 Tires, 38 Fork, 33 Safety check, 28 Inflation, 23 Front Wheel Installation, 15 Schrader Valves, 23, See Tire Inspection, 28 Gears Inflation Tools, 6, See Assembly Adjustments, 32 Seatpost Height, 25 Torque Levels, 42, 43 Handlebar Installation, 17 Seatpost Installation, 24 Tubes, 28, 38 Handlebars Shimano Unpacking, 6 Check Alignment, 28 Torque Levels, 43 Warranty Check Grips, 29 Shocks, 35 Registration, 11 Inspecting, 30 Air Shock Maintenance and Wheels, 38 Inspection Adjustment, 37 Inspection, 28

45 10 - Table of Figures

10. TABLE OF FIGURES

Figure 1 – Road Bike ...... 4 Figure 2 – Mountain Bike ...... 4 Figure 3 - Names and Locations of Parts on Road Bike ...... 7 Figure 4 - Names and Locations of Parts on Mountain Bike...... 8 Figure 5 - Names of Frame Parts on Road Bike ...... 9 Figure 6 - Names of Frame Parts on Mountain Bike ...... 10 Figure 7 – Quick Assembly Overview – Road Bikes ...... 13 Figure 8 – Quick Assembly Overview – Mountain Bikes ...... 14 Figure 9 – Quick Release Axel Installation...... 15 Figure 10 – Slide Wheel into Fork ...... 15 Figure 11 – Fasten Wheel Securely in Fork...... 16 Figure 12 – Stem and Fork Alignment ...... 17 Figure 13 – Handlebar Clamp Bolt Removal ...... 18 Figure 14 – Attaching Handlebar (Road) ...... 18 Figure 15 – Attaching Handlebar (Mountain) ...... 18 Figure 16 – Adjust angle of handlebar ...... 19 Figure 17 – Adjust angle of handlebar ...... 20 Figure 18 – Tighten Handlebar Clamp Bolts...... 20 Figure 19 – Pedal Installation ...... 22 Figure 20 – Road Bike Tire Inflation ...... 23 Figure 21 – Mountain Bike Tire Inflation (Generally Schrader Valves) ...... 23 Figure 22 – Seatpost Installation ...... 24 Figure 23 – Recommended Saddle Height Adjustment ...... 25 Figure 24 – Saddle Adjustment ...... 26 Figure 25 – Road Bike Brake Adjustments ...... 31 Figure 26 – Mountain Bike Brake Adjustments...... 31 Figure 27 – Gear Barrel Adjuster (Front) – Mountain Bikes ...... 32 Figure 28 – Gear Barrel Adjuster (Front) – Road Bikes ...... 32 46 11 - Index of tables

11. INDEX OF TABLES

Table 1 – Maximum Torque Levels for Parts ...... 42 Table 2 - Recommended Torque Levels for Other Screwed Connections ...... 43

47