Final Assembly Instructions: Bikes with Threadless Headsets Thank you for buying your new bicycle from L.L.Bean. Read these instructions carefully before beginning the final assembly. Prior to shipping, our expert cycling technicians completely assembled and tuned your bicycle to ensure that all components are functioning properly. However, for shipping purposes we have to partially disassemble your bicycle. Although this bicycle has been factory pre-assembled, some loosening may have occurred during shipping and handling. WARNING: BEFORE ATTEMPTING TO RIDE THIS BICYCLE, read the enclosed Owner’s Manual thoroughly. The Owner’s Manual includes important information on customizing your bike for an optimal fit. Tools required for final assembly: ∞ Cutting-type pliers – for removal of packaging materials, including “zip-ties” ∞ 5mm & 6mm Allen wrench – for tightening stem bolt ∞ 15mm wrench or adjustable wrench – for tightening pedals ∞ Phillips head screwdriver – may be needed to tighten reflector BEFORE GETTING STARTED: PLEASE REMOVE BICYCLE FROM BOX AND REMOVE PACKAGING MATERIAL. Recommended tool – diagonal cutting pliers, wire cutter, heavy duty shears, or multi-tool wire cutter. FYI - Your bicycle may appear different from those in photos. Assembly Instructions QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 3/10/08 specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. EST. pg. 1 1. FRONT WHEEL AND FORK Head tube To fit your bike into the shipping box, the front fork may have been reversed and the front wheel has been removed. Brakes must be in front of the fork as seen here. If you find the brakes behind the fork, spin the fork 180 degrees. Spin so the brake cable does not wrap around the head tube. In proper position, the fork ends will face forward and brakes will be in front of the fork. Correct brake position The brake cable may have been connected for shipping. It will need to be disconnected to install the wheel. To disconnect, hold the brake arms together and remove the silver insert from the cable stop. To reconnect after wheel is on, hold the brake arms together and insert the silver insert into the cable stop as show in the photo or as seen on the rear brake of your bike. Disconnected Properly brake cable connected brake cable Cable stop Silver insert Silver insert connected to cable stop To install the quick-release front wheel: Remove the quick-release front skewer from the parts box. Check for the tread direction on the tire sidewall (if the tread is directional there will be an arrow on the sidewall). With the tire in the correct direction, insert the wheel between the fork blades so that the axle seats firmly at the top of the slots, which are at the tips of the fork blades (the fork dropouts). Remove adjusting nut from skewer and slide skewer through the fork and axle. Quick- There should be a spring on each end of the skewer. Both should be facing with release the small end into the fork (refer to pictures below). While holding the wheel in correct firmly to the top of the slots in the fork dropout and at the same time centering closed the wheel rim in the fork, tension and secure the quick release lever. position QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 3/10/08 specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. EST. pg. 2 Note direction of springs Correctly installed skewer Correct quick-release tensioning: 1. Turn the lever to the open position so that the curved part faces away from the bicycle. 2. While holding the lever in one hand, tighten the adjusting nut until it stops. 3. Pivot the lever towards the closed position. When the lever is halfway closed, there must be firm resistance to turn it beyond that point. If resistance is not firm, open the lever and tighten the adjusting nut in a clockwise direction. 4. Continue to pivot the lever all the way to the closed position so that the curved part faces the bicycle. Note: If you can fully close the quick release without wrapping your fingers around the fork for leverage, and the lever does not leave a clear imprint in the palm of your hand, the tension is insufficient. Open the lever, turn the adjustment nut and try again. Continue until quick release lever closes properly. Reconnect the brake cable as explained above. Please refer to the Owner’s Manual for additional information. 2. INSTALL HANDLEBAR AND STEM. Required tool – 5 mm Allen wrench The stem may have been reversed for packing. If the stem is not facing the same direction as the brakes (as in photo A), follows steps A-C. If the stem and brakes are facing the same direction, begin with step D. Stem Stem Bolts reversed for Brakes packing facing forward A) Out of the box – remove packaging B) Using a 5mm Allen wrench, loosen the two material. bolts. QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 3/10/08 specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. EST. pg. 3 C) Swing stem clockwise to the forward D) Using a 5mm Allen wrench, remove the two position and align with the front wheel. bolts from the head of the stem (remove plate). Tighten bolts firmly. E) Place handlebar in position and install plate using the two 5mm bolts. Tighten bolts firmly. F) Tighten all stem bolts firmly. To check Cables should be in brackets and routed in smooth tightness, brace front wheel between your knees, then rounded paths (not pinched or bent). try to turn the handlebar left and right. The stem should not move. The handlebar should be aligned square to the tire, if NOTE: After completing Step 2, Install not, slightly loosen the stem bolts, adjust square and Handlebar and Stem, your bike should look like retighten. this – handlebar and stem facing forward. ∞ For road bikes with dropped handlebars, set flat part of drop parallel with the ground initially, and then adjust for personal preference. Note: Do not adjust the screw on top of the steering tube on bikes with threadless headsets. It is a headset bearing adjustment screw, and not part of basic assembly. QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 3/10/08 specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. EST. pg. 4 3. INSTALL PEDALS. Required tool – 15mm open-end wrench, or adjustable wrench. CAUTION: The right pedal has right-hand threads and must be installed in the right crankarm, tightening in a clockwise direction. The left pedal has left-hand threads and must be installed in the left crankarm, tightening in a counter-clockwise direction. To avoid cross-threading, carefully start and tighten pedals by hand. Then tighten securely with a 15mm wrench. Pedals are marked “L” and Place right pedal into right Insert left pedal into left “R” on their spindles. crankarm and turn crankarm and turn counter- clockwise. clockwise. 4. INSTALL SADDLE AND ADJUST SADDLE HEIGHT. If the seat and seat post were removed for shipping, insert the seat post into the seat post tube. WARNING: The seatpost may be raised or lowered for comfort, but it should never be raised above the “minimum insertion line” marked on the seatpost. To raise or lower seatpost, To determine proper saddle Adjust saddle height if open and close quick-release height, position right pedal at necessary and repeat. Now lever as shown. If not the bottom of its revolution, place the ball of your foot equipped with quick-release, aligned with the seat tube. directly over the center of the loosen and tighten flathead While sitting on saddle, place pedal (normal riding position). bolt. your heel on right pedal. Your This should result in the leg should be fully extended. correct bend at the knee. Generally, you do not want to raise your saddle higher than determined by this method. If you have to rock your hips to reach the bottom of the pedal stroke, then your saddle is too high. However, if while riding your bicycle, this position doesn’t feel comfortable to you, adjust as necessary. NOTE: For additional maintenance and safety tips, be sure to read your Owner’s Manual thoroughly. Custom Fitting your Handlebar (adjustable stems only) QUESTIONS: Should you have any questions during the final assembly of your new bicycle, please call our product 3/10/08 specialists at 800-226-7552 any day between 8:00 a.m. and 10:00 p.m. EST. pg. 5 Some bikes have an adjustable “riser” stem. You may be able to raise or lower it, as well as move it farther away from you. If you’d like to be sitting more upright, you can move it up and back towards you. If you feel that your riding position is too upright, you can move it lower and out away from you. Riser adjusted fully down and forward. Riser adjusted fully upright and back. Rotating the adjustable riser bar gives you more adjustment. To do this you need to loosen the riser “through” bolt (see below) a few turns using Allen wrenches (you might need two, one for each side). If there is a “clamp” bolt, loosen the riser “clamp” bolt at the front of the riser (see below), holding the clamp away with your finger to disengage the teeth.