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

Transcription

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

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

3 G. Wheels H. Lubrication I. Cleaning J. Storage K. Baby your Fezzari FEZZARI LIMITED WARRANTY A. Warranty Information TORQUE MEASUREMENT TABLES A. Technical Torque Measurements SUPPORT A. Fezzari Contact Information INDEX TABLE OF FIGURES INDEX OF TABLES... 47

4 1 - Overview 1. OVERVIEW A. Thank You Thank you for purchasing a Fezzari. Fezzari bicycles are handmade of the finest components. Fezzari was founded on the premise that discerning customers will embrace products of superior performance, quality, and value. We hope you appreciate your Fezzari experience. We want this to be the most rewarding purchase you have ever made. If you have any feedback, comments, or questions, we look forward to hearing from you. New information will be made available on the Fezzari website ( as it is available. Assembly and adjustments of your Fezzari take special tools and skills, so please read carefully. C. Important Symbols and Terms Bicycling can be a hazardous activity even under the best of circumstances. Properly maintaining your Fezzari is your responsibility and will help reduce the risk of injury. This manual contains many symbols, terms, and formatting to call attention to warnings and cautions. B. General Warning In order to use and enjoy your Fezzari bicycle 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

5 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, wide tires, and are designed for road and off-road riding (see Figure 2). Figure 2 Mountain Bike 4

6 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

7 2- Unpacking 2. UNPACKING A. Box Contents Following is a list of all packaging contents shipped with your Fezzari: Fezzari Bicycle Frame (with rear wheel attached) Saddle and Seatpost Handlebars Front Wheel Box containing: o Pedals (left and right) o Front Wheel Axle 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 B. Initial Inspection All major parts are identified in Figure 3 (road bikes) and Figure 4 (mountain bikes). Please familiarize yourself with these parts prior to assembling or riding your Fezzari. Please check your Fezzari along with the parts and components thoroughly for any damage that may have been sustained during shipping. Be careful to avoid scratching the frame when untying or unpacking the bicycle and components. If you find that something is missing or damaged, please contact the Fezzari Customer Support Team at (888)

8 2- Unpacking Figure 3 - Names and Locations of Parts on Road Bike 7

9 2- Unpacking Figure 4 - Names and Locations of Parts on Mountain Bike 8

10 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

11 2- Unpacking Figure 6 - Names of Frame Parts on Mountain Bike 10

12 2- Unpacking C. Registration The serial number of your bicycle frame is attached to the underside of the down tube or underneath the bottom bracket 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 Your Fezzari must be registered before a warranty claim can be processed. 11

13 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) or visit 12

14 3 - Assembly: Overview Figure 7 Quick Assembly Overview Road Bikes 13

15 3 - Assembly: Overview Figure 8 Quick Assembly Overview Mountain Bikes 14

16 3 - Assembly: Step 1 - Attach Front Wheel B. Step 1 - Attach Front Wheel (1) Put quick release axel in wheel (See Figure 9). (Note: if you have a 15 mm axel on a mountain bike, it will screw into place through the wheel and fork.) Unscrew Cap on end of Rod and remove one spring. Slide Rod through center of wheel. Slide second spring onto Rod (fat end of springs should be away from wheel on both sides). Screw on Cap 1-2 turns (keep it loose at this point). (2) Slide wheel into front fork (See Figure 10). With the steering fork facing forward (angling away from bike), insert the wheel between the fork blades so that it firmly touches the inside of the fork ends. The quick-release lever should be on the left side of the bike. On some mountain bikes, make sure that the disk brake slides into the disk brake pad housing. Figure 9 Quick Release Axel Installation 15 Figure 10 Slide Wheel into Fork

17 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 onequarter turn and try tightening the lever again. On road bikes, you may need to adjust the Brake Release Lever (refer to Figure 25 on page 31). If you can fully close the quick release lever without wrapping your fingers around the fork blade for leverage, and if the lever does not leave an imprint in the palm of your hand, then the tension is insufficient. Open the quick-release lever and turn the Tension Nut clockwise a quarter turn, and then try again. Figure 11 Fasten Wheel Securely in Fork (4) Test for proper installation. Spin the wheel to make sure that it is centered in the frame. Pick up the bike, and sharply hit the top of the tire with the heel of your hand. The wheel must not come off, be loose, or move from side to side. Failure to properly adjust the quick release mechanism can cause the wheel to wobble or disengage. This could cause you to lose control and fall, resulting in serious injury or death. 16

18 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 stem. (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

19 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: 18 Figure 15 Attaching Handlebar (Mountain)

20 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

21 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 a few turns on one side and then the other side, repeating until it is snug. Figure 18 Tighten Handlebar Clamp Bolts (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

22 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

23 3 - Assembly: Step 3 - Attach Pedals D. Step 3 - Attach Pedals The pedals have different threads based on which crank arm they should be connected to. The pedals are marked with L for left and R for right. Left and right are determined from the riding position on the bicycle. (2) After the pedals can no longer be turned by hand, use the 15mm wrench included in your tool kit and tighten the pedals securely. The shoulder of each pedal should fit against the crank arm. 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. (1) Align the pedal axle with the threaded hole in its respective crank arm. Secure the pedal in the crank by hand. The right pedal is installed by turning the pedal axle clockwise and the left pedal is installed by turning the pedal axle counter-clockwise. 22 Figure 19 Pedal Installation Sometimes noises coming from your pedals are because you have not sufficiently tightened the pedal onto the crank. Riding with a pedal not sufficiently tightened can damage your crank and pedals and could cause serious injury.

24 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 indicated on the tire sidewalls. Do not over-inflate. (1) Road Bike Tire Inflation (Presta Valve) (See Figure 20). Figure 21 Mountain Bike Tire Inflation (Either Presta or Schrader) For best results, use a pump with a built-in pressure gauge. Check for high 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

25 3 - Assembly: Step 5 - Attach Seat F. Step 5 - Attach Seat i. Seatpost Installation Install the seat post into the seat tube. To adjust the seat height: (1) Insert Seatpost into Seat Tube (see Figure 22). Make sure you insert the seatpost past the Seatpost Minimum Insertion Mark and Tighten securely. On bikes with Quick Release seatposts, you must use the full force of the cam action to clamp the seatpost securely. Turning the lever like a wing nut until it is tight will not clamp the seatpost safely. If you can fully close the quick release without wrapping your fingers around the seat post or a frame tube 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 tension adjusting nut clockwise a quarter turn, and then try again. 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

26 3 - Assembly: Step 5 - Attach Seat (2) Adjust Seatpost Height (Recommended) (See Figure 23). Exact saddle height is largely a matter of personal preference. Below is a recommended way to adjust seatpost height. i. Sit on the saddle in riding position without shoes while someone holds the bicycle upright. ii. Position the crank arms so they are parallel to the seat tube. iii. Loosen the seatpost binder bolt, or quickrelease. 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 quickrelease 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

27 3 - Assembly: Step 5 - Attach Seat ii. Saddle Adjustment Seat angle (tilt) and fore-aft positioning is largely a matter of preference. (1) Adjust Forward/Backward and Up/Down Position (See Figure 24). Loosen the Seat Fixing Bolt and adjust angle and fore-aft position. Most people prefer a horizontal saddle. Make sure to tighten completely. When properly tightened, the seat post cannot be rotated in the frame. Extended riding with a poorly adjusted saddle, or one that does not properly support your pelvic area, can cause short-term or long-term injury to your nerves and blood vessels. If your saddle causes pain or numbness, re-adjust the saddle position. If after adjustment your saddle still causes pain or numbness, try further positioning or replacing the saddle with one that fits you better. Full-suspension bikes have a markedly greater ground clearance than bikes without 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

28 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 for high quality lights and other accessories. 27

29 4 - Operation 4. OPERATION A. Before Riding Important Safety Information The information contained in this manual is to be used as guidelines for safe operation and is not intended to replace any safety rules or laws that may be in force in your area. Make sure all of your quick releases are locked and secure. Make sure all parts, components, and accessories are in good working order. Here s a simple safety check that you should do every time before you ride your Fezzari: Frame Inspect thoroughly inspect frame for any signs of damage. Wheels Check Quick Release levers make sure they are secure and seated properly. (For wheel quick releases, see Figure 10 on page 15, and Figure 11 on page 16, and the accompanying text; for seat post quick releases, see Figure 22 on page 24 and the accompanying warning.) Check Tires & Tubes make sure they are inflated according to the pressure recommended on the tire sidewall. Check for any wear or tear. Replace damaged tires before riding. Note: tire pressure can decrease as much as 5 to 10 psi per week. Check tire pressure regularly. Ensure that the valve cap is installed correctly. (See Figure 20 and Figure 21 on page 23.) Check Rims and Spokes Inspect for damage. Saddle & Seatpost Check Height and Angle make sure they are adjusted correctly. (See Figure 23 on page 25, and Figure 24 on page 25, and the accompanying text.) Check Alignment make sure the saddle is parallel to the bike s center line and clamped tight enough so that you can t twist it out of alignment. Handlebars Check Alignment make sure handlebar stem is parallel to the bike s center line and clamped tight enough so that you can t twist it out of alignment. (See Figure 12 on page 17.) 28

30 4 - Operation Check Handlebar Grips Make sure the handlebar grips are secure and in good condition. Brakes Check Braking check for proper operation. Squeeze the brake levers. Are 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 with the rim? Do the brake pads touch the wheel rim within an inch of brake lever movement? Can you apply full braking force at the levers without having them touch the handlebar? If not, your brakes need adjustment. (See page 30, Brake Adjustments). New disk brakes will make some noise that will subside after the bike has been ridden a few times. Gears Check Shifting if gears don t shift smoothly or make clicking noises, they may need to be adjusted. (See page 31, Gears.) To understand how to shift the gears on your Fezzari better, please see the supplemental owners manual for the shifters. Note: for road bikes, the gears are generally integrated into the brake handles. Push the handles inward as you are pedaling to shift gears. For more information, visit Do not ride with your chain on either the smallest front gear and smallest rear gear, or with your chain on the largest front gear and largest rear gear. This can cause undue wear on the chain and gears, excess noise, and inefficient pedaling. Replace any worn or damaged parts before riding your bicycle. Riding with damaged parts could cause severed injury or even death. Always ride with a certified CPSCcertified bicycle helmet. Riding without a helmet can cause serious injury or death. 29

31 5 - Maintenance 5. MAINTENANCE Periodically, you may need to adjust some components on your Fezzari for safety and best performance. A. Inspecting Check the tightness of key components. Put a wrench on every important bolt and tighten it slightly to see if it has loosened: Check the seat and seatpost bolts Check the wheel quick releases Check the stem and handlebar bolts Check the brake and shift lever bolts Check spoke tension (look for loose spokes) Tighten pedal screws Tighten bolts that hold accessories (water bottle holders) B. Brake Adjustments i. Common Brake Adjustments Over time it is common for cables to stretch. There is a simple way to adjust your brakes. Your Fezzari has a handy device called a barrel adjuster. On road bikes you ll find the barrel adjuster near the brakes (see Figure 25); on mountain bikes you ll find the barrel adjuster near the brake levers (see Figure 26). Barrel adjusters have a knurled edge for gripping, and can be adjusted without tools. To use the barrel adjusters, turn the adjusting barrel counterclockwise by hand and check the setting by squeezing the levers. On mountain bikes, when the brakes feel comfortable, you can lock the barrel adjusters in position by turning the lockring (the second knurled piece) clockwise until it's tight against the lever. 30

32 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 Please go to 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 Figure 26 Mountain 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. When your brakes wear out, the barrel adjuster won t work. You ll need to turn the barrel adjusters all the 31

33 5 - Maintenance C. Gears If your gears are clicking unusually loud (as if the derailleur 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 shifter. (See Figure 27.) Figure 28 Gear Barrel Adjuster (Front) Road Bike Figure 27 Gear Barrel Adjuster (Front) Mountain Bike Road bikes: one barrel adjuster is located by the rear derailleur, and the other barrel adjuster is located close to the other end of the same cable at the top of the downtube. (See Figure 28.) 32 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. If the chain is skipping gears, then the tension needs to be decreased. You can decrease the tension by turning the barrel adjuster ¼ turn clockwise, repeating as necessary, until it shifts smoothly between the gears. If the chain is going beyond either the biggest gear or the smallest gear on the rear wheel, then the high and low gear limit screws may need to be adjusted. They

34 5 - Maintenance are two screws located on the rear derailleur labeled H and L. Counterclockwise turns allow it to move farther; clockwise turns limit it. More information on this simple adjustment and other shifting adjustments can be found at Do not ride with your chain on either the smallest front gear and smallest rear gear, or with your chain on the largest front gear and largest rear gear. This can cause undue wear on the chain and gears, excess noise, and inefficient pedaling. Please go to for more information on adjusting your derailleur and maintaining optimum drivetrain performance. D. Suspension Fork Adjustment & Maintenance i. Generally Please refer to the fork manufacturer s owner s manual for suspension fork maintenance and adjustment. For most suspension forks, a supplemental owners manual from the fork manufacturer is included with this manual. Please refer to that manual for adjustments and maintenance. OUR SUGGESTIONS BELOW DO NOT OVERRIDE ANYTHING STATED IN THOSE MANUALS. 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

35 5 - Maintenance For optimal performance, your fork should be adjusted to your weight and your intended riding purpose. Most forks have an adjustment mechanism to increase or decrease the tension. Generally, you can turn the adjustment screw ¼ turn to the + side (clockwise) to increase tension for a more firm ride, or ¼ turn to the - side (counter-clockwise) to decrease tension for a softer ride. Adjust again as necessary. These adjustments screws are generally at the top of the fork. Some forks may have a screw on each fork tube to adjust; other forks may have an adjustment at the top of one of the fork tubes that adjusts the tension for both fork tubes. Most suspension forks have adjustment 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 adjustment at the top of one of the fork tubes that adjusts the tension for both fork tubes. Use caution and refer to the supplemental fork manufacturer s owners manual before adjusting any screws. 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 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. iii. Maintenance Suspension forks require maintenance and care. Following are some recommendations for suspension fork maintenance: Make sure that the sliding surfaces of the upper fork tubes are clean. Clean the fork with water and a soft sponge after every ride. After washing your mountain bike, apply a very thin film of hydraulic oil or other bicycle lubricant. Regularly check all screwed connections on your fork with a torque wrench. Follow the recommendations in the supplemental fork manufacturer s owners manual for cleaning your fork. Forks with air springs should be regularly checked for air pressure.

36 5 - Maintenance Before and after adjusting the fork, check whether the adjusting mechanism at the top of the upper fork tube is still tight. Make sure all screws and adjusting mechanisms are secure before riding your Fezzari. For more information on fork maintenance and tips, visit E. Rear Shock Adjustment & Maintenance i. Generally Please refer to the shock manufacturer s owner s manual for rear shock maintenance and adjustment. 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

37 5 - Maintenance Full suspension bikes have a markedly greater ground clearance than bikes without springs, if 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. The rear shock should not reach the end of its travel. If it frequently hits the end of its travel it will become damaged and substantially decrease the usable life of your shock. iii. Coil Shock Adjustments Please refer to the supplemental owner s manual for your shock before changing any settings or doing any maintenance. Generally, your initial coil tension should be adjusted so that when you are sitting on the saddle, the coil yields about 10-30% of the total travel. Total travel for your model can be found in the supplemental shock manufacturer s owner s manual. You can determine actual travel by measuring the distance between the center of the rear wheel (at the quick release) to the lower edge of the saddle. Lift your bike so that there is no weight on the rear wheel. Turn the knurled ring counterclockwise until the spring has completely relaxed the rear shock. If you can t turn the ring on its own, take hold of the spring with your whole hand and turn it together with the knurled adjusting ring. Turn the adjusting ring by one complete turn clockwise to give the spring some initial tension. The maximum tensioning range from this position is four to six complete turns. If you turn the adjusting ring beyond this point, the coils of the spring will touch, and damage to the rear shock or its base may result. To increase the initial tension, turn the knurled adjusting ring on the steel spring clockwise. Adjust the initial spring tension so that when you are sitting on the saddle the bike yields by about 10% to 30% of the total spring travel. Following are general suggestions for adjusting a coil spring: 36

38 5 - Maintenance Riding your Fezzari with the spring completely released will damage the thread of the rear shock and can substantially decrease the usable life of your shock. iv. Air Shock Adjustments Air-cushioned rear shocks are adjustable via air pressure. Use a suitable pump and observe the recommended pressure values, either written on the shock or in the supplemental owner s manual. You can increase the air pressure with a shock pump or a standard floor pump with a pressure gauge. For high quality pumps, visit vi. Rear Shock Maintenance Keep the rear shock clean. After washing your bike (see page 39, Cleaning) apply a light bicycle lubricant to the bases and joints. This prolongs the life of the shock and makes it quieter. Check the screws on the swing arms to make sure they are tight. Rear shocks constantly get sprayed with water and dirt from the rear wheel. Make sure to clean them after every ride. After cleaning, if you hear any noises from 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

39 5 - Maintenance F. Pedals Make sure that your pedals are securely fastened to the cranks. Remember that the left pedal is reversethreaded (counter-clockwise) and the right pedal is threaded clockwise. If your pedals develop squeaks, apply lubricant in the moving parts and wipe off any excess, and make sure that they are tightened. Sometimes noises coming from your pedals are because you have not sufficiently tightened the pedal onto the crank. Riding with a pedal not sufficiently tightened can damage your crank and pedals and could cause injury. An easy way to remember how to tighten your pedals is to tighten both pedals towards the front of your bike. For other pedal options and recommendations, please visit G. Wheels i. Tires & Tubes All bicycle tires are somewhat porous and allow air to seep out over time. Low tire pressure makes riding more difficult, and can damage your rims, tires, and tubes. Low tire pressure also causes your tires to wear out quicker. Use a good pump with a built-in gauge and inflate it to the tire manufacturer s recommended pressure, which is located on the sidewall of the tire. Inflate tires to the tire manufacturer s recommended pressure, located on the tire s sidewall. Tire pressure can decrease as much as 5 to 10 psi per week. Check tire pressure regularly. Ensure that the valve cap is installed correctly. For high quality pumps, visit ii. Spokes and Wheels 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 for more information. 38 Loose spokes can cause a wheel to go out of true and collapse, which could cause serious injury or death.

40 5 - Maintenance H. Lubrication A bicycle has several moving parts that must be lubricated regularly for optimal performance and to prevent rust and excessive wear. Use a light bicycle lubricant (like TriFlow). Be careful to wipe off any excess lubricant, which can attract dirt and dust. You can easily lubricate the following yourself, and should do it regularly: Chain while turning the crank backwards, apply a light coat. Let it sit for a while, and then wipe any excess off. The chain needs lubricating if you hear it squeaking when pedaling, or if the chain links appear bright and shiny. Any Pivots on Derailleurs and Brakes (places where parts move) apply two to three drops of lubricant on these places. Make sure to wipe off any excess. Pedals if pedals seem stiff to rotate, or make noise, apply lubricant in the moving parts, and wipe off any excess. I. Cleaning Regular and proper cleaning of your Fezzari will keep it looking newer longer, protect the finish, and make it perform better. If your Fezzari gets dirty or muddy (as in the case of mountain bikes), prop your bike upright and spray it down with a hose. DO NOT blast water sideways at the bicycle. This could cause water to get into the pedals, bottom bracket, or hubs, which could compromise the bearings, grease, and components inside. Spray water from above the bicycle, and try not to spray directly on parts with grease. You can wash your bike with a bucket of warm water and mild dishwashing soap. Use a sponge, and for hard to reach spaces use a soft bristled brush, like a soft toothbrush. Dry the bike with a soft cloth afterwards. Make sure to re-lubricate parts afterwards; otherwise they may rust if left with water. You can use any liquid car wax on your Fezzari. 39

41 5 - Maintenance J. Storage Always store your Fezzari indoors. The indoor environment will protect the bike from moisture in outside air that over time will corrode the metal parts. It will also protect your Fezzari from extended exposure to sunlight, or salt if you live near an ocean. One of the easiest ways to store your Fezzari is with a 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. K. Baby your Fezzari Your Fezzari was made with high performance components, and is highly durable. You can ride hard, but ride smart. Learn to ride with a light technique as some of the best bikers do and your Fezzari s usable life will be extended. Experts ride softly so you barely hear noise. This will save you time in maintenance, greatly reduce your chance of injury, and ensure that your bike will run trouble free much longer. 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 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

42 6 - Fezzari Limited Warranty 6. FEZZARI LIMITED WARRANTY A. Warranty Information FEZZARI BICYCLE LIMITED LIFETIME WARRANTY Fezzari warrants the frame and rigid fork of each new Fezzari brand bicycle and Fezzari brand frameset to be free from defects in material and workmanship for as long as the original purchaser owns the bicycle. Paint finish and all other original components, and all Fezzari brand repair parts, replacement parts, and accessories, are warranted to be free from defects in material or workmanship for a period of one year from the original date of purchase. LIMITED REMEDY Unless otherwise provided, the sole remedy under the above warranty, or any implied warranty, is limited to the replacement of defective parts with those of equal or greater value at the sole discretion of Fezzari. You will be responsible for labor costs associated with warranty replacements. IN NO EVENT SHALL FEZZARI BE RESPONSIBLE FOR DIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, WITHOUT LIMITATION, DAMAGES FOR PERSONAL INJURY, PROPERTY DAMAGE, OR ECONOMIC LOSSES, WHETHER BASED ON CONTRACT, WARRANTY, NEGLIGENCE, PRODUCT LIABILITY, OR ANY OTHER THEORY. EXCLUSIONS THE ABOVE WARRANTY, OR ANY IMPLIED WARRANTY, DOES NOT COVER NORMAL WEAR AND TEAR. ALL WARRANTIES ARE VOID IF THE BICYCLE IS MODIFIED FROM ITS ORIGINAL CONDITION OR THE BICYCLE IS USED FOR OTHER THAN NORMAL ACTIVITIES, INCLUDING, BUT NOT LIMITED TO, FAILING TO FOLLOW THE OWNER S MANUAL OR USING THE BICYCLE FOR COMMERCIAL ACTIVITIES OR IN COMPETITIVE EVENTS, INCLUDING BUT NOT LIMITED TO BICYCLE RACING, BICYCLE MOTOCROSS RACING, STUNT RIDING, RAMP JUMPING OR SIMILAR ACTIVITIES, AND TRAINING FOR SUCH ACTIVITIES OR EVENTS. FEZZARI MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED. ALL IMPLIED WARRANTIES, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN DURATION TO THAT OF THE EXPRESS WARRANTIES STATED ABOVE. WHAT YOU SHOULD DO Contact Fezzari Customer Support at 41

43 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 M Handlebar clamp screw M Cone clamp screw in stem of fork 19 Headset clamp bolts Seat post Saddle bolt (two bolt system) 9-11 Saddle bolt (one bolt system) Saddle Clamp 12 Bottle Cage Screws 5 *Nm = Newton meters 42

44 7- Torque Measurement Tables Table 2 - Recommended Torque Levels for Other Screwed Connections Torque (Nm) Component Screw Connection Shimano* Campagnolo** Crank fixing bolt (grease-free square-head) Crankset Crank fixing bolt (greased octalink) chainwheel bolt Bottom bracket Sealed cartridge in housing Fixed cup (cone) and lock ring Clipless pedal axle Shoe Cleat screws 5-8 Spike 4 Fixing bolt on frame mounting (V-brake) 5-9 Pivot bolt Caliper brake Brake Cable anchor nut Brake pad fixing bolt Rear gear changer (Rear derailleur) Front gear changer (Front derailleur) Brake- and gear-lever Hub Freewheel Hub Fastening bolt for cartridge brake pad lining 1-2 mounting bolt (hanger bolt) Cable anchor bolt Roller cage bolt Mounting bolt Cable anchor bolt Mounting bracket bolt (Allen key) 6-8 Mounting bracket bolt (screwdriver) Limit stop mounting bolt (frame! (screwdriver) Shifter fastening bolt 2.5 Quick-release lever 9-12 Locknut for adjusting quick-release hub bearing Freewheel body fixing bolt Freewheel body fixing nut Sprocket cluster lock ring *According to Shimano product information and tech tips **According to Campagnolo technical specifications

45 8 - Support 8. SUPPORT A. Fezzari Contact Information For all current contact information, please visit us at Questions? Problems? For Customer Support, Call (888)

46 10 - Table of Figures 9. INDEX Air Shock Adjustments, 37 Assembly Box Contents, 6 Barrel adjuster. See Brake Adjustments and Gear Adjustments Brakes Adjustments, 29, 30 Checking Brakes, 29 Disk, 31 Campagnolo Torque Levels, 43 Cleaning, 39 Coil Shock Adjustments, 36 Contact Information, 44 Derailleur. See Gears Fork, 33 Front Wheel Installation, 15 Gears Adjustments, 32 Handlebar Installation, 17 Handlebars Check Alignment, 28 Check Grips, 29 Inspecting, 30 Inspection Before Riding, 28 Initial, 6 Lubricant, 34, 37, 38, 39 Lubrication, 39 Maintenance, 30 Operation, 28 Pedals, 21, 38 Presta Valves. See Tire Inflation Rear Shock Adjustment & Maintenance, 35 Rear Shock Maintenance, 37 Rebound Adjustment, 37 Saddle Adjustment, 26 Safety Helmets, 29 Reflectors, 27 Safety check, 28 Schrader Valves, 23, See Tire Inflation Seatpost Height, 25 Seatpost Installation, 24 Shimano Torque Levels, 43 Shocks, 35 Air Shock Maintenance and Adjustment, 37 Coil Shock Adjustment and Maintenance, 36 Maintenance, 35 Rebound Adjustment, 37 Spokes, 38 Storage, 40 Suspension Fork & Rear Shock, 33 Suspension Fork Adjustment & Maintenance, 33 Tire Inflation Mountain Bike, 23 Presta Valves, 23 Road Bike, 23 Schrader Valves, 23 Tires, 38 Inflation, 23 Inspection, 28 Tools, 6, See Assembly Torque Levels, 42, 43 Tubes, 28, 38 Unpacking, 6 Warranty Registration, 11 Wheels, 38 Inspection, 28 45

47 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 Figure 7 Quick Assembly Overview Road Bikes Figure 8 Quick Assembly Overview Mountain Bikes Figure 9 Quick Release Axel Installation Figure 10 Slide Wheel into Fork Figure 11 Fasten Wheel Securely in Fork Figure 12 Stem and Fork Alignment Figure 13 Handlebar Clamp Bolt Removal Figure 14 Attaching Handlebar (Road) Figure 15 Attaching Handlebar (Mountain) Figure 16 Adjust angle of handlebar Figure 17 Adjust angle of handlebar Figure 18 Tighten Handlebar Clamp Bolts Figure 19 Pedal Installation Figure 20 Road Bike Tire Inflation Figure 21 Mountain Bike Tire Inflation (Generally Schrader Valves) Figure 22 Seatpost Installation Figure 23 Recommended Saddle Height Adjustment Figure 24 Saddle Adjustment Figure 25 Road Bike Brake Adjustments Figure 26 Mountain Bike Brake Adjustments Figure 27 Gear Barrel Adjuster (Front) Mountain Bikes Figure 28 Gear Barrel Adjuster (Front) Road Bikes

48 11 - Index of tables 11. INDEX OF TABLES Table 1 Maximum Torque Levels for Parts Table 2 - Recommended Torque Levels for Other Screwed Connections