Steel Classic - Bike Puky - Free user manual and instructions

USER MANUAL Steel Classic Puky

Congratulations on the purchase of this PUKY play bicycle. You have acquired a quality product, which is certain to bring great joy. This User Manual contains information regarding the assembly, safe operation and maintenance of this new bicycle. Should you have any ques- tions or problems, please contact your dealer or contact us via our website: www.puky.de.

2. Parental responsibility

Risks during play are, for the most part, excluded when used in accordance with the intended purpose. However, please take into consideration that unforeseen situations and hazards may occur as a result of the natural need for movement and the temperament of young children and adolescents for which the manufacturer cannot be held liable. For this reason, instruct children and adolescents in the correct bicycle conduct whilst supervising them. At the same time, also draw their atten- tion to potential dangers.

The play bicycle is not suitable for sporting activities (e.g. jumps). The bicycle may only be used on paved paths and roads without obsta- cles. The bicycle is not suitable for jumps, tricks or cross-country use. When children are using the bicycle, it may not be ridden in the vicinity of stairs, slopes, steep terrain, swimming pools or other bodies of wa- ter. Stairs in the vicinity must be secured in such a way to prevent children from riding up or down them on their bicycle. The play bicycle may only be used in suitable areas and away from public roads. The bicycle does not comply with the requirements of German Road Traffic Regulations (StVZO) and may not be used on public roads. The relevant applicable national legal requirements are to be observed. The permissible total weight for this bike (bike + rider + baggage) is 60 kg. The load that may be placed on the luggage rack will depend on the version of the rack (see the embossing on the rack). For road safety reasons, we do not recommend using the rack of a play vehicle for carrying loads. Only the serial installed racks may be used. It is necessary to wear suitable clothing and closed shoes. PUKY recommends wearing a safety helmet (see PUKY Accessories). The bicycle is not suitable for mounting a child seat. Pay attention to potential trap hazards when using and maintaining. Play bicycle Mount supporting wheels in a secure and form-fitting manner to the rear when required as a learning aid (to maintain balance). The use of support wheels is only permitted during the course of a brief learning period, since with increased practice the support wheels may apply uncontrolled forces to the frame. Please pay attention to the reduced effect of the brakes on the front wheel when it is wet. Sudden, forceful braking with the rim brake should be avoided since the behaviour of the vehicle may suddenly change as a result which may end in a fall. On long slopes, long periods of braking with the back pedal brake are to be avoided (excess heat to the back pedal brake nave). The valve caps must be firmly tightened and kept out of reach of children (risk of choking). Subsequent additions or modifications to the bicycle (especially the braking systems) will change the behaviour of the vehicle and may pose a risk. 43820_kinderfahrrad_148x210.indd 11 13.09.2019 10:00:1512 Children‘s bike User Manual

4. Unpacking and scope of delivery

Do not use any sharp objects when opening the packaging and removing protective materi- al. If you were to do so, you may damage the paint or parts of the bike. Keep all packaging material out of reach of children.

• Remove all parts from the packaging.

• Remove the protective material.

• Examine the package for completeness and proper condition. If anything is missing, please contact your dealer before you con- tinue to assemble the bike. The delivery consists of (Figure A):

1. Bike preassembled

2. Handlebar preassembled

3. Pedals and User Manual in a plastic bag, for

3-gear models: Additional gear stick

5. Assembly and first use

Prepare for use by adjusting to the height of the child. The saddle is to be set so that at least the toes, preferably the ball of the foot, reach the ground in order to ensure balance can be achieved when at a standstill. In doing so, the marking showing the minimum insertion depth on the saddle post into the frame tube must be observed. For more information, see below. The handlebar, hand brake lever and bell must be easy for the child to reach from the set sad- dle position. In doing so, the marking showing the minimum insertion depth of the handlebar shaft must be observed. After adjusting the handlebar, tighten the clamping screws firmly. Use the following safety checklist to check the bicycle before using. When mounting the pedals, observe the right and left threads (labelled on the pedal axis with an R or L in the vicinity of the thread). The images for the assembly instructions can be found on the last pages of this manual. After assembly, please conduct a safety check in accordance with the safety checklist! During assembly, please note that some parts, such as pedal thread and clamping cone are lubricated. You will need the following tools for assembly (Figure B):

2. 5 mm Allen key (only for ZL 18-3 models)

The tools are not part of the scope of delivery. Assembly must be carried out with great cau- tion and by an adult, to avoid any potential sub- sequent accidents or injuries. Please take your time when assembling the bike. In some cases, it is necessary to tighten screws with a pre- scribed torque. The torque value is stated in Newton metres (e.g. 2 Nm). If the torque with which a screw is tightened is too low, the con- nection may still be too loose and therefore unsafe. If the torque is too high, screws and other parts may be damaged or destroyed. Please contact your dealer or a workshop if you have any questions. First remove the plastic protective caps from the cap nuts of the front and rear axle as well as from the cantilever brakes at the front. Also remove the plastic foil which has been used to protect the cranks. 43820_kinderfahrrad_148x210.indd 12 13.09.2019 10:00:1613 Children‘s bike User Manual GB Remove the handlebar padding from the han- dlebar and unscrew (with just a few rotations) the underlying screw at the stem with the aid of a 6 mm Allen key (ZL models) or a 13 mm spanner (Z models). Now you can remove the plastic cover that protects the clamping cone at the lower end of the stem shaft. Figure 1: Insert the handlebar into the steer tube (1). If this proves to be difficult, unscrew the handlebar a bit further. Adjust the handle- bar to the desired height, align at right angles to the front wheel and lock it by pulling the screw at the stem (2) with the aid of a 6 mm Allen key (ZL models) or a 13 mm spanner (Z model) (15 Nm). Please pay attention to the marking of the mini- mum insertion depth of the stem shaft. Now reattach the handlebar padding back onto the handlebar. Figure 2: Take the loose end of the brake ca- ble and insert the wedge into the predefined recess on the brake handle (1). Then, carefully pull the outer cover of the brake cable to en- gage the end stop into the adjustment screw of the brake handle (2). When assembling the brake cable, please make sure that the knurled screw of the brake cable is situated straight in the holder of the front light. Otherwise, the brakes cannot be assembled correctly. Setting the handlebar height for models with ahead stem: The handlebar has been set at the factory to the highest position, thus, all spacers are locat- ed under the stem. If required, remove the stem and adjust the spacers to lower the handlebar height. Figure 3: First undo and remove the ahead cap (1). Then undo the two steerer tube clamp- ing screws (2). Now the stem can be removed from the steerer tube (3). Now set the handle- bar height according to requirement. Possible positions are:

• All spacers located under the stem (highest handlebar position, set at the factory)

• Spacers over the stem and under (medium handlebar position)

• All spacers above the stem (lowest handlebar position) No spacers may be removed! Figure 4: After rearranging the spacers, fit the ahead cap again, align the handlebars to be straight in the direction of travel and set the play of the control bearing correctly. To do this, use the setting screw in the ahead cap (1). Cor- rect setting: The handlebars must be easy to turn without play in the control bearing. Now tighten up the steerer tube clamping screws of the stem with the correct torque (2). The torque for the clamping of the stem on the steerer tube shaft: 5-6 Nm. Make sure that the stem is firmly mounted to the steerer tube and cannot rotate. Adjusting the brakes (Cantilever): Figure 5: On the front wheel, press the right cantilever brake in the direction of the rim (1). Now you can insert the wedge of the brake cable into the predefined recess of the brake (2). If this is not possible, reduce the tension of the brake cable at the tensioning screw of the left brake arm in the direction of travel (see Figure 6 / Position 2) and then tighten the ten- sioning screw again. Figure 6: Make sure that the brake pads are parallel to each other and that they are properly aligned with the rim. This means that the brake pads should rest 1 mm below the top edge of the rim. If these settings are not correct, loosen the fastening nut of the brake pad (1) with a 5 mm 43820_kinderfahrrad_148x210.indd 13 13.09.2019 10:00:1614 Children‘s bike User Manual Allen key and align as described above. To do so, pull the brake lever and re-tighten the fas- tening nut (5-8 Nm). Figure 7: Rotating the adjustment screw enables you to now centre the brake arms, i.e. the distance from the brake pad <-> rim should be identical both on the right and the left. You will need a crosstip screwdriver for this. By turning the screw in, you move the appropriate brake arm away from the rim, turning the screw out moves the screw to- wards the rim. It is important that the brake levers are actu- ated several times so that the tension of the brake arms is evenly distributed to both sides and the settings take effect. The brake/rim contact must be identical on both sides. Again Figure 6: Brake cable tension is adjusted at the anchor nut (2) so that each brake pad maintains a distance of 1.5 mm to the rim. If an adjust- ment needs to be made, the protruding wire end should then be refastened to the brake. Figure 8: With a slight degree of wear to the brake blocks, you can remove them by un- screwing the knurled screw above the front reflector and position both blocks closer to the rim. Adjust the screw so that the each brake pad is set at a distance of approximate- ly 1.5 cm from the rim. Before each journey, please check whether the brakes are functioning properly. If, during the course of the use of the product, renewed adjustment of the brakes is required, please follow the steps detailed above. Adjusting the brakes: The bicycle has two calliper brakes. The left brake lever operates the brake on the front wheel, the right brake lever operates the brake on the rear wheel. Depending on the model, the bicycle may also have a back ped- al brake for the rear wheel. Figure 9: Centre the brake arms (1) by turning the adjusting screw. The gap between the brake pad <-> rim should be identical on both right and left and the contact between brake pad/rim should be applied simultaneously on both sides when you brake. You will need a cross-headed screwdriver. By turning the screw in, you move the appropriate brake arm away from the rim, turning the screw out moves the screw towards the rim. It is important that the brake levers are actuat- ed several times so that the tension of the brake arms is evenly distributed to both sides and the settings take effect. Figure 10: The handle distance (distance of brake lever to handlebar) can be adjusted indi- vidually using an cross-headed screwdriver on the brake handle. Please remember that brak- ing must taken effect before the brake lever reaches the handlebar! Figure 11: The tension can be set on the brake handle using the knurled screw. The brake is set correctly if the brake pads are all approximately 1.5 mm from the rims. Replacing the brake pads Figure 12: Undo the fastening nut of the brake pad using an Allen key sized 5 mm (1) and re- place the brake pads. This means that the brake pads should rest 1 mm below the top edge of the rim (2). If these settings are not correct, loosen the fastening nut of the brake pad (1) with a 5 mm Allen key and align as described above. To do so, pull the brake lever and re-tighten the fastening nut (5-8 Nm). The tension is to be set so that the brake pads are all approximately 1.5 mm from the rims. If subsequent adjustment is necessary, undo the 43820_kinderfahrrad_148x210.indd 14 13.09.2019 10:00:1615 Children‘s bike User Manual GB tensioning screw (3) and adjust the tension (tighten the tensioning screw back up using 6-8 Nm!) or carry out the step described in Figure

Setting the chain tension (models with gear hub) The chain should have a vertical play of approximately 1.5 cm. The setting of the chain tension is carried out as follows: Figure 9: Undo both wheel nuts of the rear wheel. Adjust the chain tension by sliding the rear wheel at the dropout. Then tighten the wheel nuts back up again (torque 20 Nm). For models with derail- leur gears, the chain tension is regulated via the gears. Attention should be paid to ensure that the correct chain length is selected when replacing the chain. Figure 13: Please note that one pedal is equipped with a right-handed thread (for the right-handed driving direction) and the other pedal with a left-handed thread (for the left-handed direction). The pedals are labelled accordingly on the front face of the threaded axle with an "R" and an "L". Screw the pedals with the aid of a 15 mm span- ner to the cranks (20 Nm) – to do so, turn the Allen key on both sides in the direction of the front wheel. Setting the seating position Figure 14: Setting the height of the saddle: The saddle can be pulled out after releasing the saddle clamp with the aid of a 5mm Allen key. Set the saddle so that at least the toes, preferably the ball of the foot, reach the ground in order to ensure balance can be achieved when at a standstill. Please observe the following principles: Minimum height of the saddle as follows: Z2 / ZL 12: 45 cm Z6 / ZL 16: 49 cm Z8 / ZL18: 53 cm Maximum height of the saddle: The minimum insertion depth of the saddle post is 65 mm. There is an appropriate marking on the saddle post (see Figure 8). Then retighten the saddle clamp (torque 5-8 Nm). Setting the height of the handlebar: Adjust the seating position so that the child is seated up- right and a good overview is ensured. The han- dlebar, hand brake lever and bell must be easy for the child to reach. The torque for the clamping of the stem in the fork stem: 15 Nm. The torque for the clamping of the handlebar in the stem: 12 Nm. Setting the chain tension The chain should have a vertical play of ap- proximately 1.5 cm. The setting of the chain tension is carried out as follows: Figure 15: Undo both wheel nuts of the rear wheel Figure 16: Adjust the chain tension by sliding the rear wheel at the dropout. Then tighten the wheel nuts again (torque 10 Nm) 43820_kinderfahrrad_148x210.indd 15 13.09.2019 10:00:1616 Children‘s bike User Manual Setting the gear hub (only for 3-gear models)Installation of gear stick Figure 17: Take the gear stick out of the plas- tic bag and insert it as far as it will go, along with the black spring, into the right side of the rear axle (in driving direction).Figure 18: Then you can mount the gearbox onto the rear axle and tighten it with a 5 mm Allen key (3-5 Nm.) No further settings need to be made to the gearbox.If renewed adjustment must be made during the course of product use, proceed as follows: SET Switch the REVOSHIFT lever to 2. Then rotate the tension adjusting screw (A) in order to align the red line (D) on the push rod at the end (C) of the hub axis.COMMENTDuring the setting process, check both yellow lines from above using the window. Rotate the crank and switch the REVOSHIFT lever from 3 to 1 and then back to 3. Repeat this process two or three times and check to make sure that the gears are changed. Switch the REVOSHIFT lever from 1 to 2 again and make sure that the red line on the push rod at the end of the hub axis is aligned. If this is not the case, you must carry out the setting process again.After setting switch unit IV secure the tension adjusting screw using the tension adjusting nut (G). EINSTELLUNG Für Schalteinheit37 EINSTELLUNG Für Schalteinheit

Nach Einstellung von Schalteinheit IV sichern Sie die Zugeinstellschraube mit der Zugeinstellmutter (G) . (G) Zugeinstellmutter Anzugsmoment: 1,5 - 2,5 N•m (A) (B) (B)(B) (C) (E) (F) (E) (D) SET SET (G) (G) Tension adjusting nutTorque: 1.5 - 2.5 Nm 43820_kinderfahrrad_148x210.indd 16 13.09.2019 10:00:1617 Children‘s bike User Manual GB Safety checklist Saddle Firmly secured and cannot be rotated (5-8 Nm)* Minimum insertion depth marking observed Balls of feet reach the ground Handlebar Minimum insertion depth observed Handlebar shaft tube secured and cannot be rotated (15 Nm)* Handlebar cannot be rotated easy to reach, upright seating position Handles cannot be rotated Handbrakes Brake lever secure (2 Nm), easily accessible Functions perfectly Brake pad clean, grease-free, positioned correctly Back pedal brake Function checked Chain Chain tension is OK (play approximately 1.5 cm) Sufficient lubrication Chain guard is complete Tyres Sufficient profile Sufficient air pressure (air pressure to be maintained is on the tyre) Wheels Aligned Spokes evenly tightened Axle nuts firmly tightened (VR 12 Nm, HR 10 Nm)* Pedals Rotate easily Firmly fitted without excess play Bell Clear ring, easily reached Visual check Components without fault and all attached parts, such as protective guards and luggage rack, sufficiently well secured. (*Torques of screws in Newton metres) 43820_kinderfahrrad_148x210.indd 17 13.09.2019 10:00:16NL Gebruiksaanwijzing Kinderets Gebruiksaanwijzing

6. Maintenance and care

If the handbrake lever can be pulled more than half-way to the handlebar before the braking effect takes place, the brake must be adjusted. The braking surfaces must be clean, grease- free and the brake pads must be parallel to one another. Worn pads must be replaced immediately! When replacing, make sure you use original pads or ensure that they match the material of the rim at least (e.g. see the label: "Alloy / Alu" for aluminium rims). Caution in the event of rim wear Regularly check the state of the rims and pay special attention to the wear groove which sur- rounds the rim. Consult your specialist work- shop in good time (when the groove is almost worn away). Breakage and accident risks! Pay special attention to ensure that the handlebar and saddle do not rotate! Check the chain tension and adjust as neces- sary (if required, by loosening the rear wheel, aligning and tightening again). Pay attention to the correct air pressure (the prescribed pressure is indicated on the sides of the tyres). Do not repair damaged or deformed parts. Damaged or deformed parts must be replaced. Original replacement parts can be obtained from your PUKY dealer. Spare parts: Tyres (including tubes), rims, brake ca- ble, brake pads, chain, chain rings, handle cov- ers. All maintenance work requires specialist knowl- edge and you should consult your dealer for advice. Interested children may 'supervise' but should not do the work themselves. Cleanliness and corrosion protection All painted and metallic surfaces can be cleaned and protected using ordinary car care products. Only use environmentally friendly products and never use any aggressive deter- gents. Regularly oil the chain (chain or univer- sal oil) and clean when necessary. The flanks of the rims (braking surfaces) must be grease-free! The vehicle is to be protected from winter salt and long periods of storage in damp spaces (e.g. garage) are to be avoided. If you do store the bicycle in a damp environment, protect the surfaces of unpainted metal parts (screws, nuts etc.) with a suitable surface seal (e.g. spray wax). Hub and ball bearing should be checked from time to time by a specialist, adjusted and lubri- cated as required. The vehicle is to be protected from winter salt and long periods of storage in damp spaces (e.g. garage) are to be avoided. Do not use a pressure washer/power washer to clean the vehicle.

7. Statutory warranty

Statutory warranty covers defects. Damage resulting from improper use, use of force, lack of maintenance, or normal wear and tear, is excluded from such a statutory defect warranty. Enjoy your travels! 43820_kinderfahrrad_148x210.indd 18 13.09.2019 10:00:16NL Gebruiksaanwijzing