Final Assembly Instructions Portside Cruiser

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Neil Pearson
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Final Assembly Instructions Portside Cruiser Thank you for buying your new bicycle from L.L.Bean. Read these instructions carefully before beginning the final assembly.

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.

1 Final Assembly Instructions Portside Cruiser 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 6mm hex wrenches for tightening stem bolt 15mm wrench or adjustable wrench for tightening pedals & installing front fender Phillips head screwdriver for tightening the front reflector & front fender 8mm wrench or adjustable wrench for tightening front fender 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. pg.1

1. INSTALL HANDLEBAR AND STEM Required tool 6mm hex wrench The front wheel has been removed and the fork may have been reversed for shipping.

In proper position, brakes will face away from the frame (1-A).

Cables should be in brackets and routed in smooth rounded paths (not pinched or bent). Insert stem into head tube. You may need to loosen the stem bolt slightly (1-B).

2 1. INSTALL HANDLEBAR AND STEM Required tool 6mm hex wrench The front wheel has been removed and the fork may have been reversed for shipping. If you find the brakes facing toward the frame, spin the fork 180 degrees. Spin so the brake cable does not wrap around the head tube. In proper position, brakes will face away from the frame (1-A). Head tube Correct brake position 1-A If there is a protective plastic cap on the end of the stem, remove and discard it before inserting the stem into the head tube. Cables should be in brackets and routed in smooth rounded paths (not pinched or bent). Insert stem into head tube. You may need to loosen the stem bolt slightly (1-B). Snug the stem bolt. Instructions for proper alignment will be given later. Tighten and loosen the stem bolt with a 6mm hex wrench. Turn clockwise to tighten, counter clockwise to loosen 1-B Stem bolt head Stem Minimum insertion line 1-C The stem bolt works by drawing this wedged piece up until it locks the stem in place. Head tube pg.2

2. ATTACHMENT OF FRONT FENDER Tools required 10mm & 8mm wrenches or adjustable wrench Using a 10mm wrench or an adjustable wrench, remove the locknut from the front

Position the fender with the brake mounting bolt through the fender mount (2-B). Carefully thread the locknut onto the brake mounting bolt.

Locknut Fender mount Brake mounting bolt mounting bolt 2-A 2-B Fender strut Brake caliper Using an 8mm wrench or an adjustable wrench, remove the fender mounting bolts

FRONT WHEEL INSTALLATION Tool required 15mm wrench or adjustable wrench Loosen the outer silver nuts on each side of the wheel axle enough for the fork to fit over the

3 2. ATTACHMENT OF FRONT FENDER Tools required 10mm & 8mm wrenches or adjustable wrench Using a 10mm wrench or an adjustable wrench, remove the locknut from the front brake mounting bolt, this is the thicker nut on the end (2-A). Insert the fender through the rear of the fork and the brake caliper. Position the fender with the brake mounting bolt through the fender mount (2-B). Carefully thread the locknut onto the brake mounting bolt. While holding the brake caliper in position, tighten the locknut. Locknut Fender mount Brake mounting bolt mounting bolt 2-A 2-B Fender strut Brake caliper Using an 8mm wrench or an adjustable wrench, remove the fender mounting bolts (3-A) on the fork and use them to attach the fender struts. 3. FRONT WHEEL INSTALLATION Tool required 15mm wrench or adjustable wrench Loosen the outer silver nuts on each side of the wheel axle enough for the fork to fit over the axle with a silver nut and washer on the outside of the fork on each side (3-B). With the tire tread in the same direction as the rear wheel, center the tire between the brake pads and push the tire through the brake. Position the wheel axle between the fork blades so that the axle seats firmly at the top of the slots of the fork dropouts (3-A). Fork dropout Fender mounting 3-A bolt 3-B Silver nut and washer on the outside of the fork pg.3

With the front wheel held off of the ground, ensure that the wheel can spin freely and the wheel is centered between the brake pads.

The rim should be centered between the brake pads.

You may need to hold the fender in place as this is being done. Fender mount adjustment 3-C 3-D 4.

slightly loosen the stem bolt, adjust square and retighten (4-A). Tighten stem bolt firmly.

4 With the front wheel held off of the ground, ensure that the wheel can spin freely and the wheel is centered between the brake pads. If the tire is rubbing on the fender, you may need to raise the fender at the fender mount (3-C). The rim should be centered between the brake pads. If the brake pads are not centered, grasp the brake caliper and rotate the brake to a centered position (3-D). You may need to hold the fender in place as this is being done. Fender mount adjustment 3-C 3-D 4. HANDLEBAR AND STEM ALINGMENT Tools required - 6mm and 5mm hex wrench The handlebar should be aligned square to the tire, if not, slightly loosen the stem bolt, adjust square and retighten (4-A). Tighten stem bolt firmly. To check tightness, brace front wheel between your knees, then try to turn the handlebar left and right. The stem should not move. Brakes are to the front of the fork. 4-B Stem bolt Stem bolt NOTE: After completing Step 4, Handlebar and Stem Alignment, your bike should look like this (4-B) handlebar and stem facing forward with front brakes located in front of fork. 4-A pg.4

Handlebar clamp bolt The handlebar may have been rotated for shipping.

The grips should be parallel to the ground.

4-C REMEMBER, the handlebar stem may be raised or lowered for comfort, but it should never be raised above the Minimum insertion line marked on

CAUTION: The right pedal has right-hand threads and must be installed in the right crankarm, tightening in a clockwise direction (5-B).

5 Handlebar clamp bolt The handlebar may have been rotated for shipping. To adjust, use a 6mm hex wrench to loosen the handlebar clamp bolt on the stem (4-C). Rotate to desired position and tighten the bolt. The grips should be parallel to the ground. The bolt should be tightened enough that there is no movement when firmly pushing against the handlebar. 4-C REMEMBER, the handlebar stem may be raised or lowered for comfort, but it should never be raised above the Minimum insertion line marked on the stem. 5. 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 (5-B). The left pedal has left-hand threads and must be installed in the left crankarm, tightening in a counter-clockwise direction (5-C). To avoid cross-threading, carefully start and tighten pedals by hand. Then tighten securely with a 15mm wrench. 5-A 5-B 5-C Pedals are marked L and R on their spindles. Insert right pedal into right crankarm and turn clockwise. Insert left pedal into left crankarm and turn counterclockwise. pg.5

6. ATTACHMENT OF SADDLE TO SETPOST Required tool- 13mm wrench or adjustable wrench Use a 13mm or adjustable wrench to loosen the seat clamp nut (6-A) enough to slide

Seat clamp 6-A Seat clamp nut 6-B To install the seat post to the bike, open the quick release seat clamp or loosen clamp bolt if not a quick release (6-C).

The saddle is adjustable forward and back along the saddle rails and can be angled up or down.

6 6. ATTACHMENT OF SADDLE TO SETPOST Required tool- 13mm wrench or adjustable wrench Use a 13mm or adjustable wrench to loosen the seat clamp nut (6-A) enough to slide the small end of the seat post into the seat clamp. Ensure that the smaller end of the seat post is fully inserted into the seat clamp (6-B). Snug the clamp nut. Seat clamp 6-A Seat clamp nut 6-B To install the seat post to the bike, open the quick release seat clamp or loosen clamp bolt if not a quick release (6-C). Insert the seat post into the bike s seat tube past the minimum insertion line, this line is embossed into the lower portion on the seatpost (6-C). The saddle is adjustable forward and back along the saddle rails and can be angled up or down. The best starting position is with the saddle horizontal and in the middle of the saddle rails (6-D). With the bike on the ground find this position and tighten the seat post clamp nuts. Minimum insertion line Saddle set horizontal Saddle mounted correctly 6-C 6-D pg.6

7. SADDLE HEIGHT ADJUSTMENT If the seat and seat post are not already installed, insert the seat post into the seat post tube.

7-A To raise or lower seatpost, open the quick-release lever as shown and close when adjusted. If not equipped with quick-release, loosen and tighten hex head bolt.

Your leg should be fully extended (7-B). Adjust saddle height if necessary and repeat. Now place the ball of your foot directly over the center of the pedal (normal riding position).

If you have to rock your hips to reach the bottom of the pedal stroke, then your saddle is too high.

7 7. SADDLE HEIGHT ADJUSTMENT If the seat and seat post are not already installed, 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. 7-A To raise or lower seatpost, open the quick-release lever as shown and close when adjusted. If not equipped with quick-release, loosen and tighten hex head bolt. 7-B 7-C To determine proper saddle height, position right pedal at the bottom of its revolution, aligned with the seat tube. While sitting on saddle, place your heel on right pedal. Your leg should be fully extended (7-B). Adjust saddle height if necessary and repeat. Now place the ball of your foot directly over the center of the pedal (normal riding position). This should result in the correct bend at the knee (7-C). 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. 8. ATTACH REFLECTOR Required tool Phillips head screwdriver The front reflector was not installed to prevent shipping damage. Your bike came with a handlebar-mounted front reflector (white). Remove the reflector mounting screw and gently open the bracket enough to slide over the handlebar on the left side of the stem. Position the reflector perpendicular to the ground and secure with the screw. Use care not to overtighten as the bracket may crack. Reflector mounting screw 8-A NOTE: For additional maintenance and safety tips, be sure to read your Owner s Manual thoroughly. pg.7

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Final Assembly Instructions Casco Bay Cruiser

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