Falcon CYCLES Product information sheet

NMD 11-04

INSTRUCTION

LEAFLET

AND

GUARANTEE

RIGID FRAME AND FORKS – LIFETIME

All rigid frames and forks (with the exception of suspension forks, suspension

frames and rear shocks) - lifetime warranty.

COMPONENT PARTS – 1 YEAR

All other components (including suspension forks, suspension frames and rear

shocks) - 1 year warranty.

All the above warranties apply, provided the bicycle has been properly cared

for, maintained and used, and are warranted against manufacturing or material

defects for the warranty period stated. This warranty is applicable from the date of

purchase for the original owner only, who must produce proof of purchase in order

to validate any claim. Claims must be submitted through your retailer. This warranty

does not include labour and transportation charge. The company can accept no

responsibility for consequential or special damage. This warranty applies only in

the case of defective components and does not cover the effects of normal wear

and tear or damage caused by accident, abuse, excessive loads, neglect, improper

assembly, alteration of original specification, improper maintenance or the addition

of any item inconsistent with the original intended use of the cycle.

No bicycle is indestructible and no claims will be accepted for damage caused

by improper use, competition use, stunt riding, ramp jumping, leaping or

similar activities. Our bicycles conform to BS 6102: Part 1: 1992 as set by the

British Institute Testing Services. We reserve the right to change or amend any

specifications within this brochure without notice. All information and specifications

within this brochure are correct at the time of going to press.

NOTICE

In offering this warranty, Falcon Cycles Ltd in no way seeks to diminish the

statutory rights of the consumer.

Please refer to our website for the latest information.

http://www.falconcycles.co.uk

FALCON CYCLES LTD, P.O. BOX 3, BRIDGE STREET, BRIGG,

NORTH LINCOLNSHIRE, DN20 8PB

TEL: (01652) 656000 FAX: (01652) 650040

CYCLES LTD

Complete this Section and keep it in a safe place. In the event of your machine being

lost or stolen this information should be passed on to the police.

Name ...........................................................................................................................................

Address .......................................................................................................................................

.....................................................................................................................................................

Model Name & Type ...................................................................................................................

Serial No....................................Frame Size & Colour................................................................

Extras and Identifying Marks .....................................................................................................

...................................................................................................................................................

..................................................................................................................................................

FALCON CYCLES LTD

This bike has been designed, developed and sourced fully built by Falcon Cycles Ltd. North

Lincolnshire.

Falcon has carefully selected and developed the product with some of the best suppliers throughout

the world. These suppliers have satisfied the exacting quality standards that have been developed by

Falcon, a company with over a century long reputation for quality and craftsmanship.

All Falcon Cycles Ltd are built to conform to British Standards.

Suspension frames and forks and rear shock absorbers are covered by a separate guarantee.

Included in this manual are details on how to prepare your bicycle for riding, how to maintain your

bicycle to keep it roadworthy, information on accessories and recommendations and tips for a safe and

correct riding position.

Please ensure that the Bicycle Log Sheet below is completed at the time of purchase. The details will

be of value to the police in the unfortunate event of your bicycle ever being lost or stolen. They also act

as a record of your guarantee.

FRAME NUMBER

The frame number is located on the BS6102 label

at the bottom of the seat tube or stamped on the

bottom bracket shell or seat tube. We strongly

recommend that you have either the frame number

or your post code stamped on to your bicycle.

xxxxxx

Dealerʼs Address or Stamp Date of purchase

Service

Dealer Stamp:

Date:

Dealer Stamp:

Date:

Dealer Stamp:

Date:

Dealer Stamp:

Date:

Highly Recommended for safety & support of warranty claims. At 6-monthly

intervals or more frequently if high mileage or subject to heavy use.

YOUR BICYCLE — OWNERʼS RESPONSIBILITY

In this leaflet we describe and illustrate how to ride safely and keep your bicycle in a safe

trouble free operating condition.

Ownerʼs Responsibility and Important Points

Point 1 Carefully and thoroughly read this leaflet and follow the instructions.

Point 2 Any major service or adjustments on your bicycle should be carried out by a

professional repairer; however if this service is not available and you wish to make

adjustments yourself, this manual contains important tips on how to do it.

CAUTION: Any adjustments you make are entirely at your own risk.

Point 3 To use your bicycle for freestyle and stunt riding, competitive events, off-road use or

any similar activities can be dangerous and you are warned that you assume the risk

for personal injury, damages or losses incurred from such use. The Retailer shall not

be liable to the purchaser of the bicycle or to third parties for consequential or special

damages.

Point 4 Bicycles are built with a variety of equipment and accessories, and you should

familiarise yourself with their function and purpose, to make sure you can operate

them correctly.

LOCATION OF PARTS WITH

ROUTINE MAINTENANCE CHECKS AND LUBRICATION

Half Yearly — Remove and clean, lubricate chain, derailleur gears and all cables. Check and replace as required.

Refer to table of Recommended torque values - page 7.

NB — Wash cycle weekly with warm soapy water and polish dry with a soft cloth

A - Headset

Remove, clean and regrease

bearings yearly, checking if

replacements required.

B -

Stem Nuts

Ensure stem nuts and bolts are

tight. See page 7.

C -

Handlebars

Check handlebar bolt is tight.

Check brake levers securely

mounted to bars and brakes stop

smoothly and efficiently. See

page 7.

D -

Brakes

Lightly oil exposed cables

monthly. Maintain adjustment and

replace brake blocks when worn,

brake cables when frayed.

E -

Reflectors (front & rear)

Ensure reflectors are secure

and undamaged. Replace if

necessary.

F -

Front Suspension unit

(Dealer adjustment only)

G -

Tyres

Check for cuts and wear.

Maintain pressure indicated on

tyre wall for maximum efficiency.

H - Wheel

Reflectors

Check monthly. Securely fixed.

I -

Disc Brakes - Front

(Routine maintenance by your

dealer recommended.)

J -

Wheel Hubs

Grease bearings monthly. Adjust

cones to avoid free play from

side to side.

K - Pedals with Reflectors

Check all fittings are secure.

L - Cranks

Grease bearings monthly. Check

that axle bolts or cotterpin bolts

are tight. Check for free play in

bottom bracket.

Yearly, remove, clean and

regrease hub axles, bottom

bracket set and headset.

M - Chain

Keep lightly oiled weekly, clean

and lubricate half yearly.

N - Wheels

Check that axles are sealed

and secured properly. Rims

should be kept free from wax, oil,

grease and glue. Check for loose

or missing spokes.

O - Bottom Bracket

Clean, regrease yearly checking

for wear.

P -

Gears

Front and Rear — Lightly

oil moving parts. Maintain

adjustments of front and rear

derailleurs.

Q -

Disc Brake - Rear

(Routine maintenance by your

dealer recommended).

R - Seat and Stem Nuts

Be sure seat and

stem nuts are tight. See page 7.

S - Pedals

Lightly oil bearings monthly.

T - Frame Number

SAFE CYCLING AND SAFETY TIPS

Before you ride your bicycle at any time make sure it is in a safe operating condition. Particularly

check that your:-

• Bicycleʼs nuts, bolts and parts are tight and not worn or damaged.

• Riding position is comfortable.

• Brakes are operating effectively.

• Steering is free with no excessive play.

• Wheels run true and hub bearings are correctly adjusted.

• Wheels are properly secured and locked to frame/fork.

• Tyres are in good condition and inflated to correct pressure.

• Pedals are securely tightened to pedal cranks.

• Gears are correctly adjusted.

• All reflectors are in position.

After you have made any adjustments to your bicycle, check that all nuts and bolts are securely

tightened and cables are free from kinks and fixed securely to the bicycle frame.

Every six months (more frequently if high mileage or subject to heavy use) your bicycle should

be professionally checked to ensure that it is in correct and safe working order. A ʻService

Recordʼ is provided for your use.

Do Notʼs when riding

• Do not ride on same side of road as oncoming traffic.

• Do not ride two abreast.

• Do not carry a passenger unless cycle is equipped to do so.

• Do not swerve in and out of traffic.

• Do not hang items over the handlebars to impede steering or catch in the front wheel.

• Do not hold on to another vehicle.

• Do not ride too close behind another vehicle.

CAUTION: Wet Weather Riding No brakes work as well under wet or icy conditions as they do

under dry conditions. In wet weather special precautions must be taken to assure safe stopping.

Ride slower than normal and apply your brakes well in advance of anticipated stops.

CAUTION: Night Riding We recommend you minimise the time you ride after dark. If you

should have to be out on your bicycle at night you must to comply with the law, use a headlight

(white) and a taillight (red) on your bicycle in addition to the all-around reflectors that are

fitted. For added safety wear light coloured clothing with reflective stripes. Check that the

reflectors are firmly secured in their correct position and clean and not obscured. Damaged

reflectors must be replaced immediately.

CAUTION: Suspension Units Your cycle may be fitted with suspension units built into parts

of the frame and forks. We recommend these are serviced by your dealer as required. More

details may be found in the suspension manufacturerʼs handbook.

Front Suspension Unit

Frame Suspension Unit

Pre Load Adjustment

We recommend that Pre-Load load for optimum safe riding should be set as follows.

1 Pre-Load alters the amount of bottom bracket drop when seated on the saddle. We

strongly recommend you set Pre-Load so as to experience no more than 1" (25mm) of

sag. Measured as a decrease in bottom bracket height.

To adjust Pre-Load, grasp knurled adjuster (A) and spring, and either:

2 Increase Pre-Load by turning to compress the spring

3 Decrease Pre-Load by turning to allow spring extension.

Riding Position

It is important that you and your bicycle are fitted to each other, not only for comfort and riding

ease but for control and safety. Normally your Dealer will custom fit your bicycle to you but the

following few pages should help you to find your most comfortable, safe and efficient position.

Bottom Bracket Height

Pre Load Adjust

SEAT

Seat Adjustment

Loosen the nut on the seat-post clamp enough to allow the saddle to move forward and back.

The seat can then be aligned forward and back and the angle can also be adjusted (it is

recommended that the seat be parallel to the ground).

To adjust the seat up and down, loosen the binder-bolt on the seat tube, position the seat and

re-tighten the binder-bolt.

CAUTION: Insert the seat-post to a point above the insertion mark. The MINIMUM INSERTION

MARK should not be visible. Securely tighten the seat-post binder bolt/nut by using a 6 mm Allen

key or a 13 mm spanner. Test by grasping the seat and attempting to turn. Keep tightening until

the seat will no longer turn.Please refer to table of torque values Page 7

WARNING: Bicycle should not be ridden if seat adjustments are not properly tightened.

Allen head

Binder-bolt

Normal 13mm

Binder-bolt

Saddle Seat Post

Minimum

Insertion mark

Seat posts differ according to saddle types

and accordingly the procedure for fitting

varies. If in doubt consult your dealer.

Op en

Seat Forwards

or Backwards

Seat Angle

End of

Seat Pillar

Seat Pillar adjustment—

Suspension frames.Take care

when inserting seat pillar that the

protruding end cannot interfere

with the frame suspension unit

during use. If in doubt consult

you dealer about adjustment.

CYCLING POSITION — Seat

Saddle Angle

The seat should be horizontal or parallel with the ground. Slight variation around the horizontal

may suit individual comfort but if excessive angles are felt necessary check other aspects of your

position.

Saddle Height

The correct seat height is determined by sitting on the seat with your leg fully extended. Your

heel (in flat shoes) should just touch the pedal when it is positioned at its lowest point. When

riding normally with the ball of your foot on the pedal your knee should be slightly flexed at the

bottom of the pedal stroke (see diagram following).

Saddle Forwards/Backwards Position

With the ball of one foot on the pedal and the cranks parallel to the ground the saddle should

be adjusted backwards or forwards to a position whereby the pedal centre is directly below the

knee joint.

Very small changes in saddle position can have a substantial effect on performance and

comfort. Consequently, whenever you make a change to your saddle position, make only

one directional change at a time and make the changes in small increments, until you have

found the point at which you are most comfortable.

Knees slightly

bent

Handlebar Stem

approximately level

with seat or slightly

lower

Pedal at bottom

position

Loosen saddle from seat

pillar to adjust forwards

or backwards. Tighten

when set correctly

The saddle should be moved forwards or backwards so that the

knee is directly above the pedal when the crank is parallel to

the ground.

HANDLEBARS AND STEMS

As your cycle may be fitted with a standard ʻquillʼ stem or an A-Head stem, you must always check

that all the bolts are tight before cycling.

STANDARD STEM: Loosen expander bolt so that expander wedge is not tight in bottom of

handlebar stem. Gently tap the top of the expander bolt to further loosen the wedge if necessary.

When the expander wedge is loose, move the handlebars up or down until you find the optimum

height at which you can easily reach the brake levers and comfortably grasp the handlebars. Usually

this height is level with, or slightly lower than, the top of the saddle. Be sure the stem is in line with

the front wheel.

CAUTION: A minimum insertion ring is marked on the handlebar stem and this marking

should remain in the head tube. Under no circumstances should the minimum height

insertion mark be visible on the handlebar stem. It must be down in the head tube.

When desirable height has been achieved, align the handlebar with the front wheel and securely

tighten expander bolt. It is extremely important to tighten the expander bolt sufficiently, so that when

the wheel is held between your legs and the handlebars are twisted, the handlebars do not move.

Do not over tighten, as it may increase risk of injury to the rider. Position grip portion of handlebars

horizontally and securely tighten the binder bolt.

Note: On models equipped with stem mounted gear levers the levers may be moved up or down to

the riderʼs most comfortable position. When moving them, be certain that the levers face upwards

and that the cables are not twisted.

Refer to table of recommended torque values on page 7.

Note: Whenever the handlebar stem is removed from the head tube then the expander bolt should

be lightly greased.

Note: On some ATB’s raising the stem requires brake cable adjustment. Do not attempt this if low

profile brakes are fitted with a stem mounted cable stop.

A-HEAD STEM: Has 2 steerer clamp bolts on the back of the stem, which clamp around the

steerer tube. Loosen these bolts to align the stem with the front wheel. Re-tighten the steerer

clamp bolts.

CAUTION: Do not adjust the top compression bolt, this should be pre-set to eliminate bearing

play, overtightening will cause premature wear.

Contact your retailer for service.

Handlebar Position

The position of the handlebar should be set to allow a comfortable and easy reach of gear control

and brake levers.

When riding, your weight should be so balanced that your hands rest lightly on the handlebars.

This prevents strain on wrists and forearms when pedalling. If you alter the riding position,

remember to tighten all nuts and bolts securely.

Refer to table of recommended torque values - page 7.

CAUTION:

NEVER EXTEND THE HANDLEBAR STEM OR SEAT POST ABOVE THE MINIMUM INSERTION

MARK AS THIS IS DANGEROUS

6mm Allen Key

Handlebar

Stem Expander Bolt

(Allen Head)

Recessed Type

Minimum

Insertion

Mark

Stem

Binder

Bolt

Stem Expander

bolt

Standard Stem

Steerer

Clamp Bolts

A-Head Type

Compression Bolt Compression Cap

Extension

Spacers

Bearing Seat

Top cup with Bearings

inside

5 Star Washer

Stem Binder

Bolts

COTTERLESS CRANKS ADJUSTMENT

IMPORTANT

Please check if the chainwheel and cranks of your new bicycle are of the cotter less type

as illustrated on page 3.

If so, to ensure trouble free operation it is important that the nuts securing these item to the

bottom bracket axle are tightened as securely as possible.

It is strongly recommended that the tightness of the nuts be checked after the first two

weeks of use and a maximum of three monthly intervals thereafter.

BRAKES

WARNING

For safe riding it is important to completely understand the operation of your bicycleʼs

brake system. Improper use of your bicycleʼs brake system may result in a loss of control or

an accident, which could lead to severe injury. Because each bicycle may handle differently,

be sure to learn the proper braking technique (including brake lever pressure and bicycle

control characteristics) and operation of your bicycle. This can be done by consulting your

professional bicycle dealer and this ownerʼs manual, and by practicing your riding and

braking technique.

The bicycle is equipped with two independant brake mechanisms. One on the front wheel

and the other on the rear wheel. The brakes are operated by hand levers fastened to the

handlebars. The right lever controls the front brake and the left lever controls the rear brake.

To stop with safety:

1. Operate the rear brake (left lever) slightly before the front brake (right lever).

2. Apply firm pressure to both front and rear brake levers.

CAUTION: If the front brake is applied with too much pressure, the rider may be thrown off

the bicycle.

3. Never apply the front brake on a turn. This is especially dangerous when cornering or

riding on slippery or loose surface roads.

CAUTION: Brakes are less effective in wet weather. Ride slower and allow more distance

for stopping.

Note: Do not ride your bicycle if the braking system is not working correctly. If you are in

doubt, take your bicycle to your dealer.

TABLE OF RECOMMENDED TORQUE VALUES

DESCRIPTION TORQUE

1 Stem Expander Bolt 20Nm 15lb-ft

(where fitted)

1A A-Head Steerer Clamp Bolts 10Nm 8lb-ft

(where fitted)

2 Stem Binder Bolt 10Nm 8lb-ft

3 Brake Fixing Bolt (non disc) 5Nm 4lb-ft

Applies to both front and rear brake

4 Front Axle Nut 30Nm 22lb-ft

5 Chain Wheel Securing Bolt 38Nm 28lb-ft

6 Pedal 40Nm 30lb-ft

7 F/Derailleur Cable Fixing Bolt 4Nm 3lb-ft

8 R/Derailleur Cable Fixing Bolt 4Nm 3lb-ft

9 Rear Axle Nut 30Nm 22lb-ft

10 Seat Pin (Hexagonal Head) 10Nm 8lb-ft

Seat Pin (Allen Head) 10Nm 8lb-ft

11 Front and Rear 3Nm 2.5lb-ft

Reflector Mounting Nut

12 Saddle Clamp Bolt (Hexagonal Head) 15Nm 11lb-ft

12 13

BRAKE ADJUSTMENT PROCEDURE — Caliper brakes

The brakes on your bicycle should have been adjusted correctly by your dealer; however, as

cables do stretch, it is important to check the adjustment of your brakes after your first ride. Most

brakes will need some adjustments after being used the first few times. Your brakes are correctly

adjusted when there is a 1.5 mm gap between the brake blocks and the brake track of the wheel

rim.

Do not adjust brakes to allow brake blocks to contact wheel rim when brake levers are in the off

position. The fine adjustment of the brakes is made by the following procedure:

1. Turn adjustor A to set blocks C just clear of rim by 1.5 mm.

2. Ensure that the brake blocks meet the rim parallel and central to the rim brake tracks. Adjust

by nuts D if necessary, then tighten securely.

3. When all fine adjustment is taken up on adjustor A, it will be necessary to reset the cables as

follows:

a. Turn adjustor A all the way down as far as it will go into its mounting.

b. Loosen cable clamp bolt B. Press both brake shoes firmly against wheel rim.

c. Pull brake cable wire through its clamp bolt.

d. Tighten cable clamp bolt B securely.

Note: If one brake shoe is closer to the rim than the other first check that the wheel has been

centred between the forks then adjust the brakes as necessary.

To adjust brakes that have central Caliper adjuster simply turn screw as shown until brakes

centralise.

BRAKE MAINTENANCE — Caliper brakes

To maintain cable brakes in efficient working order, regularly check the brake adjustment and

lightly lubricate brake pivots and springs. Oil the exposed parts of the cable to prevent corrosion.

Slow or inefficient braking often indicates that the brake cables themselves require lubrication.

As this job requires the removal of the complete brake cable, we recommend strongly that this

service is done professionally.

Note: To assure smooth braking, wheels must run true and be correctly adjusted, with the rim

brake tracks free from dents and kinks. The brake blocks should be in correct alignment with the

rim brake track. See your dealer if you are in any doubt

regarding wheel and brake adjustment.

Protect yourself from frayed cable ends by maintaining the

end pieces fitted over the cable ends.

Brakes should function freely and release fully. If brakes bind,

first check for clean-liness and proper lubrication. If brakes

still bind, return your bicycle to your dealer for adjustment.

To centre side pull brakes first slacken the retaining nut and then centre the brake using a

spanner on the front retaining nut.

CAUTION: Before riding, test your brakes. Make sure that the quick release mechanism is

returned to its normal correct position, otherwise your brakes will not operate effectively.

Calliper Arm

Tyre

Wheel Rim

Brake Shoe Brake Shoe

Quick Release

Mechanism

Return Spring

1. Pass the inner cable through the inner

cable lead, and after setting so that the total

of the clearances between the left and right

shoes and the rim is 2 mm, tighten the cable

fixing bolt.

To release the brake inner cable from the V brake, squeeze the two brake arms together until the

brake blocks contact the rim and remove the inner cable pipe from the cable end bracket.

To re-connect again squeeze the two brake arms together and relocate the inner cable pipe in

the cable end bracket.

INNER CABLE ADJUSTMENT

INNER CABLE QUICK RELEASE

ʻVʼ BRAKE SYSTEM

2. Adjust the balance with the spring tension adjustment screws.

BRAKE MAINTENANCE — Disc Brakes

Your cycle may arrive with factory fitted disc brakes — the latest technology in cycle braking!

If you have purchased your cycle from a professional cycle shop your brakes should have been

set up correctly. You will only have to do routine maintenance as the brake pads wear. (This is

described later on in this section).

If you purchased your cycle from a mail-order source you may have to set up the brakes before

you use your cycle.

The notes that follow are not exhaustive. If you need further assistance, please refer to the disc

brake leaflet that should accompany the cycle. If you do not have such a leaflet please take your

cycle to a professional cycle shop.

BRAKE LEVER AND BRAKE PAD TRAVEL ADJUSTMENT.

You can alter the amount of braking pressure by altering the travel of the brake lever and by the

proximity of the brake pads to the brake disc.

To alter the travel of the brake lever adjust screw A (see Fig.

1). Unscrewing screw A reduces the amount of lever travel

and by tightening it increases the lever travel. If you have fully

unscrewed screw A and the lever travel is still excessive you will

have to adjust the space between the pads and the disc.

Fig.1

Inner Cable Lead

Pipe

Cable End

Bracket

Cable Fixing

Bolt

3. Depress the brake lever about 10 times as in normal brake

operation and check that everything is operating correctly and

that the shoe clearance is correct before using the brakes.

Depress about

10 times

BRAKE BLOCK REPLACEMENT- Caliper and V Brakes

All brake blocks are provided with grooves that indicate the

wear on each block. When the grooves are worn down to a

flat surface, replace the blocks(in pairs) immediately.

Wear Indicator Groove

BRAKE LEVER AND BRAKE PAD TRAVEL ADJUSTMENT — cont.

Tighten screw A (Fig. 1) up to the brake lever. Go to Fig. 2 and insert a 2.5mm Allen key into

the smaller hole inside allen key hole B. Rotating the allen key clockwise pushes the outer

brake pad forward by approx. 0.8 mm. After each turn, check the brake travel, and the braking

Once the correct amount of travel has been reached, centre the brake Calliper on the disc by

adjusting screw C (Fig. 3). When the brake pads are centered on the disc the wheel should spin

freely, though there may be a slight amount of noise until the pads “bed” in.

If your cycle came from, or has recently been overhauled by a professional repair shop, you

Fig.2

Smaller

keyhole inside

main hole.

Fig.3

BRAKE PAD WEAR AND REPLACEMENT

When you check your brake pads due to

falling performance, check their thickness.

If they are less than 1 mm thick (Fig. 4) they

will need replacing.

1 mm

Min

Fig.4

To fit new pads, remove the brake Calliper

from the fork or frame by unscrewing allen

bolts D (Fig. 5). Unscrew, (anti-clockwise),

the smaller allen bolt inside allen bolt B

(Fig. 2). Lift up and pull the inner pad

downwards, using the protruding part E

(Fig. 6). Slide a thin slot screwdriver under

the outer pad (Fig. 7) and lift it up. Hold the

screwdriver in this position and remove the

pad with a pair of long-nosed pliers

Fig.5

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