MailStar Maintenance and Adjustment March 2002

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Beverly Clark
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1 MailStar Maintenance and Adjustment March 2002 The MailStar bicycle incorporates many new features to ease maintenance and improve handling and performance. The majority of components are similar to those used on the Millennium cycle and maintenance details can be found in Section of the current maintenance manual. The removal and re-fitting of many of the new components is simple and logical. These notes are issued on an interim basis until the MailStar maintenance section of the manual is available and covers those items with which you may not be familiar. The MailStar is a step-through cycle and is supplied in two sizes: Large-inside leg 1-0 inch Small-inside leg 27- inch The cycle is supplied with front carrier and rear pannier metal work. Until the MailStar front plastic insert part number 0077 is available (April 2002) continue to use the standard Millennium insert. Rear utility panniers are available from Swindon part number 0072.

2 Contents Page Headset Adjustment Brake Cable Adjustment Brake Shoe Replacement Removing and Refitting Rear Wheel , Chain Tensioner and Chain SRAM -Speed Gear Shifter Assembly / Gear Adjustment Lubrication

Headset Adjustment The MailStar is fitted with a locking top head locknut, part number 00709.

3 Headset Adjustment The MailStar is fitted with a locking top head locknut, part number The locknut is released by first loosening the two small grub screws located on either side of the locknut (use a 2.mm allen key), and then adjusting with a 2mm spanner. The headset is adjusted in the normal manner. When set, the grub screws can be lightly nipped up to hold the locknut in position and prevent it working loose. Do not overtighten the grub screws. The final tightening must be done with the handlebar stem in place, or else the fork steerer column may be deformed, preventing the handlebar from being fitted. 1. The caged balls should be replaced annually do not re-use the caged balls. 2. Inspect the races annually (any sign of indentation or other surface breakdown means a new race should be fitted).. Early MailStar cycles have a top head adjustable race with slots and adjustment is the same as the later non-slotted version. Retain this spacer for re-use Exploded view of headset assembly (Note orientation of bearings) 1

Brake Cable Adjustment The hub brakes fitted as standard to the MailStar combine consistent all-weather braking performance with low maintenance.

a b Front brake turn adjuster (a) anti-clockwise until brakes drag slightly. Turn locknut (b) clockwise to secure adjustment. N.B.

4 Brake Cable Adjustment The hub brakes fitted as standard to the MailStar combine consistent all-weather braking performance with low maintenance. Over time, the brake cables will need to be adjusted for pad wear as follows: Rear brake turn knurled nut clockwise until brakes drag slightly. a b Front brake turn adjuster (a) anti-clockwise until brakes drag slightly. Turn locknut (b) clockwise to secure adjustment. N.B. When fitting new cables, ensure that all adjusters are backed-off to their original position. Note: Both front & rear brake cables should be replaced every 2 years 2

Brake Shoe Replacement Remove the wheel from the bicycle and release the left hand lock nut (1mm on the front hub and 17mm on the rear) securing the brake plate to the hub assembly.

Clean the inside of the drum, using a degreaser if oil is present.

1 2 Place thrust washer () over axle onto adjusting cone (rear wheel only). 9 8 Slide the brake plate assembly over the axle.

5 Brake Shoe Replacement Remove the wheel from the bicycle and release the left hand lock nut (1mm on the front hub and 17mm on the rear) securing the brake plate to the hub assembly. The complete brake back plate can now be removed. If the brake pads are worn down, or oil has contaminated the linings, dispose of the whole unit. N.B. The brake linings are asbestos free. Clean the inside of the drum, using a degreaser if oil is present. Refitting back plate (see Fig on the right) Fit the new back plate, (or re-fit the old one if linings are not damaged) ensuring all washers and spacers are replaced in the correct order. 1 2 Place thrust washer () over axle onto adjusting cone (rear wheel only). 9 8 Slide the brake plate assembly over the axle. Fit washer () and spacing sleeve ( rear wheel only) and screw on lock nut (). Press lever (7) up to the stop and hold in order to centre the brake shoes in the brake drum whilst finally tightening lock nut () On the rear hub pay particular attention to the alignment of the back plate as this is critical for the correct attachment of cables and the torque arm to the P clip (9) on the chain stay. Fig

1) and pull the click box off the hub axle. Disengage the location sleeve (, Fig.

6 Removing / Refitting Rear Wheel Removal: Set handlebar gear shifter into 1st gear before removing / refitting the click box. Loosen the knurled screw (1, Fig.1) and pull the click box off the hub axle. Disengage the location sleeve (, Fig.) and pull it off. Withdraw the shift rod and shift tube (1/ 2, Fig. ) out of the axle bore. 2 1 Fig 1 Fig Fig Fig

7 Removing / Refitting Rear Wheel Installation: (see Fig 1-, Page ) Fit the anti-rotation washer ( Fig.2 ) on both sides so that the small teeth bear against the dropout and the prongs engage in the dropout slot below the axle. The axle must be positioned snugly against the top of the drop out slot. No additional washers or accessories are permitted on the sprocket side of the axle. Fit the guard on the sprocket side (its front end rests on the chain stay. (, Fig.1). Tighten axle nuts securely. 1-2 turns of the axle thread must be visible at the axle nut. (2, Fig.1) Slip the shift rod (1, Fig ) into the shift tube (2, Fig ) (parts lightly oiled) and push them home into the axle bore. Turn slot (, Fig ) of shift tube into a visible position. Slip the location sleeve (, Fig ) with its guiding rib (, Fig ) foremost onto the hub axle, taking care to run the inner lug (, Fig ) in the shift tube slot (, Fig ) until it sensibly snaps in. Turn the location sleeve (, Fig ) so that the guiding rib (, Fig ) is uppermost. Slide the click box (, Fig 1) home onto the hub axle. At this point, the guiding rib (, Fig ) must be fully seated in the click box housing groove. Tighten knurled screw (1, Fig 1) by hand. Connect the brake torque arm to the P clip (9, Fig ) on the chain stay. Ensure that there is no play in the clip when the bolt is tightened. For Royal Mail version of the drum brake hub with special lever (10, Fig ) only use original Royal Mail brake cables. Fork unit (8, Fig ) is not suitable for use with Royal Mail cables.

Chain Tensioner and Chain The MailStar is fitted with a chain tensioner to eliminate the regular adjustment of rear wheel position to maintain chain tension.

The tensioner is secured to the frame by means of a M8 nut at the rear of the assembly.

As fitted, the roller will face to the rear, and moving the roller to its normal operating position will tension the spring.

8 Chain Tensioner and Chain The MailStar is fitted with a chain tensioner to eliminate the regular adjustment of rear wheel position to maintain chain tension. The unit is pre-greased at the factory, but check occasionally to ensure the spring is working correctly, and the chain passes freely through the roller. The tensioner is secured to the frame by means of a M8 nut at the rear of the assembly. When fitting the chain tensioner, ensure the spring tab at the rear is located in the slot in the tensioner mount section of the right hand drop out. As fitted, the roller will face to the rear, and moving the roller to its normal operating position will tension the spring. The MailStar chain uses a snap-lock type connector (recognisable by the bright dimpled pins in the photo) but can be removed by using a conventional chain rivet extractor tool, available from Swindon part number It is easier to clean and lubricate the chain on the bike. You should only need to remove the chain if it is going to be replaced. The combination of the chain tensioner and regular cleaning and lubrication will enhance chain life. Only use chain with two-piece (snap-lock) connectors on this cycle. Do not use three-piece (spring-link) connectors as they will foul the chain roller.

9 SRAM -Speed Gear Shifter Assembly / Gear Adjustment Assembly Shifter Spectro Grip Slide shifter (1, Fig ) onto handlebar. Add two thrust washers (2, Fig ). Mount Fixed grip (, Fig ) onto end of the handlebar. Without applying pressure, slide shifter against fixed grip. Adjust shifter on handlebar and tighten bolt (, Fig ) adequately. Check: The shifter and brake lever function properly and are unobstructed, realign if necessary. Fixed grips (left & right) provide an axial safety function. For this reason, they should be mounted in such a way as to make sure they do not slip off the handlebar. Never use lubricants or solvents to install fixed grips. Cycles must not be ridden without fixed grips. The turning grip could loosen from housing and slip from handlebar resulting in severe injury. The shifter should not be forced as this can damage other parts of the system. If the gear change becomes stiff, remove the clickbox from the rear axle and check for free movement of the cable by twisting the control. If the cable moves freely check the free movement of the shift rod. 1 2 Fig Gear Shift Adjustment For correct function of the gear change, the correct assembly of the shift rod, shift tube and location sleeve is criticial. See pages &. After replacing the clickbox and tightening the knurled screw, shift the gears from 1st up through to th and then drop back down to rd gear. Turn the adjustment barrel (, Fig ) so that the arrow marks in the clickbox window align. Check setting from time to time and readjust if necessary. Note: The twist grip, right hand fixed grip,two thruster washers, gear cable and clickbox are a complete unit. Treat this assembly as no user serviceable parts Part number

10 1 2 Lubrication Notes 1. Brake lever bearing occasional application of dry lubricant spray. 2. Headset bearings pack with lithium grease when replacing.. Handlebar stem and seat pillar lightly grease lower section when re-fitting.. Gear hub bearings may need re-greasing (six-month check). Hub mechanism is permanently lubricated, and is normally maintenance free.. Chain clean regularly with spray degreaser and apply dry lubricant spray.. Pedal axle threads grease lightly when replacing. The front hub and bottom bracket cassette unit are fitted with sealed bearings. Pedals are pre-lubricated, and cannot be adjusted. Gear and brake cables are lined and pre-lubricated. Exposed inner cable may be lightly sprayed with dry lubricant spray, but take care not to over spray other components. Avoid the use of oil, as this attracts dirt. Never use a high pressure water hose to clean the bicycle, as this can force lubricant out of bearings. Lubricants and Cleaners These are the cycle manufacturers list of approved lubricants and supplier details: Part No Weldtite lithium grease PWL Swindon (general purpose water resistant grease) SRAM gear grease PWL Swindon Weldtite cycle oil PWL Swindon Weldtite CD1 citrus degreaser spray CPC via Buck and Hickman (natural based cleaner for chains and general cleaning) Weldtite TF2 dry spray lubricant CPC via Buck and Hickman (combination water dispersant and dry lubricant spray) Weldtite graphite penetrating oil spray CPC via Buck and Hickman 8

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