Warning: Please read this entire manual before riding your Fezzari.
Failure to do so could result in serious injury or even death.
Contents
1.
OVERVIEW ....................................................................................................................................... 3
A.
B.
C.
D.
2.
Thank You ....................................................................................................................................... 3
General Warning .............................................................................................................................. 3
Important Symbols and Terms ........................................................................................................... 3
Related Manuals ............................................................................................................................... 5
UNPACKING ..................................................................................................................................... 6
A.
B.
C.
3.
Box Contents ................................................................................................................................... 6
Initial Inspection .............................................................................................................................. 6
Registration ....................................................................................................................................11
ASSEMBLY ...................................................................................................................................... 12
A.
B.
C.
D.
E.
F.
G.
4.
Quick Assembly Overview .................................................................................................................12
Step 1 - Attach Front Wheel..............................................................................................................15
Step 2 - Attach Handlebar ................................................................................................................17
Step 3 - Attach Pedals......................................................................................................................22
Step 4 - Inflate Tires........................................................................................................................23
Step 5 - Attach Seat ........................................................................................................................24
Step 6 - Attach Additional Reflectors ..................................................................................................27
OPERATION .................................................................................................................................... 28
A.
5.
Before Riding – Important Safety Information .....................................................................................28
MAINTENANCE ............................................................................................................................... 30
A.
B.
C.
D.
E.
F.
Inspecting ......................................................................................................................................30
Brake Adjustments ..........................................................................................................................30
Gears .............................................................................................................................................32
Suspension Fork Adjustment & Maintenance .......................................................................................33
Rear Shock Adjustment & Maintenance ..............................................................................................35
Pedals ............................................................................................................................................38
G.
H.
I.
J.
K.
6.
Wheels ...........................................................................................................................................38
Lubrication .....................................................................................................................................39
Cleaning .........................................................................................................................................39
Storage ..........................................................................................................................................40
Baby your Fezzari ............................................................................................................................40
FEZZARI LIMITED WARRANTY ....................................................................................................... 41
A.
7.
Warranty Information ......................................................................................................................41
TORQUE MEASUREMENT TABLES .................................................................................................... 42
A.
8.
Technical Torque Measurements ........................................................................................................42
SUPPORT ........................................................................................................................................ 44
A.
Fezzari Contact Information ..............................................................................................................44
9.
INDEX ............................................................................................................................................ 45
10.
TABLE OF FIGURES ......................................................................................................................... 46
11.
INDEX OF TABLES .......................................................................................................................... 47
1 - Overview
1.
New information will be made available on the Fezzari
website (www.fezzari.com) as it is available.
OVERVIEW
A. Thank You
Assembly and adjustments of your Fezzari take special
tools and skills, so please read carefully.
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.
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
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.
BOLD
Figure 1 – Road Bike
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
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
2- Unpacking
2.
UNPACKING
B. Initial Inspection
A. Box Contents
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.
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
If you find that something is missing or damaged,
please contact the Fezzari Customer Support
Team at (888) 833-9927.
6
2- Unpacking
Figure 3 - Names and Locations of Parts on Road Bike
7
2- Unpacking
Figure 4 - Names and Locations of Parts on Mountain Bike
8
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
2- Unpacking
Figure 6 - Names of Frame Parts on Mountain Bike
10
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 www.fezzari.com). Your Fezzari must be registered before a warranty claim can be
processed.
11
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
Step
Step
Step
Step
Step
1
2
3
4
5
6
-
Attach
Attach
Attach
Inflate
Attach
Attach
Front Wheel
Handlebar
Pedals
Tires
Seat
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) 833-9927
or visit www.fezzari.com.
12
3 - Assembly: Overview
Figure 7 – Quick Assembly Overview – Road Bikes
13
3 - Assembly: Overview
Figure 8 – Quick Assembly Overview – Mountain Bikes
14
3 - Assembly: Step 1 - Attach Front Wheel
B. Step 1 - Attach Front Wheel
(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.
(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).
Figure 10 – Slide Wheel into Fork
Figure 9 – Quick Release Axel Installation
15
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.
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.
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.
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
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
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:
Figure 15 – Attaching Handlebar (Mountain)
18
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
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
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
3 - Assembly: Step 3 - Attach Pedals
(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.
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.
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.
Figure 19 – Pedal Installation
(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.
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.
22
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.
Figure 21 – Mountain Bike Tire Inflation (Either
Presta or Schrader)
Inflate tires only to the pressure
indicated on the tire sidewalls. Do not over-inflate.
For best results, use a pump with a built-in
pressure gauge. Check www.fezzari.com for high
quality pumps and other accessories.
(1) Road Bike Tire Inflation (Presta Valve)
(See Figure 20).
Figure 20 – Road Bike Tire Inflation
(Generally Presta Valves)
(2) Mountain Bike Tire Inflation (Generally
Schrader Valves) (See Figure 21).
23
3 - Assembly: Step 5 - Attach Seat
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.
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.
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
3 - Assembly: Step 5 - Attach Seat
i. Sit on the saddle in riding position without
shoes while someone holds the bicycle
upright.
(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.
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
3 - Assembly: Step 5 - Attach Seat
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.
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.
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
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
www.fezzari.com for high quality lights and other
accessories.
27
4 - Operation
4.
OPERATION
□
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.
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:
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.
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.)
Handlebars
□
28
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.)
4 - Operation
□
Check Handlebar Grips – Make sure the
handlebar grips are secure and in good
condition.
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 www.fezzari.com.
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).
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.
New disk brakes will make some noise that
will subside after the bike has been ridden a few
times.
Always ride with a certified CPSCcertified bicycle helmet. Riding without a helmet
can cause serious injury or death.
Gears
□
Check Shifting – if gears don’t shift
smoothly or make clicking noises, they
may need to be adjusted. (See page 31,
29
5 - Maintenance
5.
B. Brake Adjustments
MAINTENANCE
Periodically, you may need to adjust some components
on your Fezzari for safety and best performance.
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.
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
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.
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)
30
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 www.fezzari.com.
Please go to www.fezzari.com 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
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.
Figure 26 – Mountain Bike Brake Adjustments
When your brakes wear out, the barrel adjuster won’t
work. You’ll need to turn the barrel adjusters all the
31
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
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.
Figure 27 – Gear Barrel Adjuster (Front) –
Mountain Bike
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.
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.)
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
32
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 www.fezzari.com.
D. Suspension Fork Adjustment &
Maintenance
i. Generally
Please refer to the fork manufacturer’s owner’s manual
for suspension fork maintenance and adjustment.
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.
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.
Please go to www.fezzari.com for more
information on adjusting your derailleur and
maintaining optimum drivetrain performance.
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
5 - Maintenance
For optimal performance, your fork should be adjusted
to your weight and your intended riding purpose.
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.
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.
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.
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.
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.
Use caution and refer to the
supplemental fork manufacturer’s owners manual
before adjusting any screws.
Forks with air springs should be regularly
checked for air pressure.
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
5 - Maintenance
Before and after adjusting the fork, check
whether the adjusting mechanism at the top of
the upper fork tube is still tight.
E. Rear Shock Adjustment &
Maintenance
Make sure all screws and adjusting
mechanisms are secure before riding your Fezzari.
i. Generally
Please refer to the shock manufacturer’s owner’s
manual for rear shock maintenance and adjustment.
For more information on fork maintenance
and tips, visit www.fezzari.com.
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
5 - Maintenance
Lift your bike so that there is no weight on the
rear wheel.
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.
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.
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.
Turn the adjusting ring by one complete turn
clockwise to give the spring some initial
tension.
iii. Coil Shock Adjustments
Please refer to the supplemental
owner’s manual for your shock before changing
any settings or doing any maintenance.
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.
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.
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
5 - Maintenance
vi. Rear Shock 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.
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.
iv. Air Shock Adjustments
Check the screws on the swing arms to make
sure they are tight.
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.
Rear shocks constantly get sprayed with
water and dirt from the rear wheel. Make sure to
clean them after every ride.
You can increase the air pressure with a
shock pump or a standard floor pump with a
pressure gauge. For high quality pumps, visit
www.fezzari.com.
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
5 - Maintenance
G. Wheels
F. Pedals
i. Tires & Tubes
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.
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.
If your pedals develop squeaks, apply lubricant in the
moving parts and wipe off any excess, and make sure
that they are tightened.
Inflate tires to the tire manufacturer’s
recommended pressure, located on the tire’s
sidewall.
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.
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 www.fezzari.com.
An easy way to remember how to tighten
your pedals is to tighten both pedals towards the
front of your bike.
ii. Spokes and Wheels
For other pedal options and
recommendations, please visit www.fezzari.com.
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 www.fezzari.com for more information.
Loose spokes can cause a wheel to go
out of true and collapse, which could cause serious
injury or death.
38
5 - Maintenance
H. Lubrication
I. Cleaning
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:
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.
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.
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.
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.
Make sure to re-lubricate parts afterwards; otherwise
they may rust if left with water.
Pedals – if pedals seem stiff to rotate, or
make noise, apply lubricant in the moving
parts, and wipe off any excess.
You can use any liquid car wax on your Fezzari.
39
5 - Maintenance
K. Baby your Fezzari
J. Storage
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.
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.
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
www.fezzari.com 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
6 - Fezzari Limited Warranty
6.
NEGLIGENCE, PRODUCT LIABILITY, OR ANY OTHER
THEORY.
FEZZARI LIMITED WARRANTY
A. Warranty Information
EXCLUSIONS
FEZZARI BICYCLE LIMITED LIFETIME WARRANTY
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.
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,
WHAT YOU SHOULD DO
Contact Fezzari Customer Support at www.fezzari.com.
41
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
Disk Brake
Stem
Seat post
Bottle Cage
Screw connection
Caliper bolt (fixed to frame or fork)
Brake lever clamp screw
Disk (rotor) fixation bolt
Reservoir cover screw
Handlebar clamp screw M5
Handlebar clamp screw M6
Cone clamp screw in stem of fork
Headset clamp bolts
Saddle bolt (two bolt system)
Saddle bolt (one bolt system)
Saddle Clamp
Screws
*Nm = Newton meters
42
Torque (Nm)*
6
4
4
<1
10-12
14-16
19
10-16
9-11
16-19
12
5
7- Torque Measurement Tables
Table 2 - Recommended Torque Levels for Other Screwed Connections
Component
Crankset
Bottom bracket
Clipless pedal
Shoe
Brake
Rear gear changer
(Rear derailleur)
Front gear changer
(Front derailleur)
Brake- and gear-lever
Hub
Freewheel Hub
Screw Connection
Crank fixing bolt (grease-free square-head)
Crank fixing bolt (greased octalink)
chainwheel bolt
Sealed cartridge in housing
Fixed cup (cone) and lock ring
axle
Cleat screws
Spike
Fixing bolt on frame mounting (V-brake)
Pivot bolt Caliper brake
Cable anchor nut
Brake pad fixing bolt
Fastening bolt for cartridge brake pad lining
mounting bolt (hanger bolt)
Cable anchor bolt
Roller cage bolt
Mounting bolt
Cable anchor bolt
Mounting bracket bolt (Allen key)
Mounting bracket bolt (screwdriver)
Limit stop mounting bolt (frame! (screwdriver)
Shifter fastening bolt
Quick-release lever
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
43
Torque (Nm)
Shimano*
Campagnolo**
35 - 44
35 - 50
8 - 11
49 - 69
49 - 78
34
5-8
4
5-9
8 - 10
6-8
5-7
1-2
8 - 10
4-6
3-4
5-7
5-7
6-8
2.5 - 3
1 .5 - 2
2.5
9 - 12
10 - 25
35 - 49
35 - 44
29 - 49
32 - 38
70
40
10
5
8
15
6
3.5
5
8
15
6
8 - Support
8.
SUPPORT
A. Fezzari Contact Information
For all current contact information, please visit us at www.fezzari.com.
Questions? Problems?
For Customer Support,
Call (888) 833-9927
44
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
45
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
10 - Table of Figures
10. TABLE OF FIGURES
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1 – Road Bike .......................................................................................................................................4
2 – Mountain Bike .................................................................................................................................4
3 - Names and Locations of Parts on Road Bike ........................................................................................7
4 - Names and Locations of Parts on Mountain Bike...................................................................................8
5 - Names of Frame Parts on Road Bike ...................................................................................................9
6 - Names of Frame Parts on Mountain Bike ........................................................................................... 10
7 – Quick Assembly Overview – Road Bikes ........................................................................................... 13
8 – Quick Assembly Overview – Mountain Bikes ...................................................................................... 14
9 – Quick Release Axel Installation........................................................................................................ 15
10 – Slide Wheel into Fork ................................................................................................................... 15
11 – Fasten Wheel Securely in Fork....................................................................................................... 16
12 – Stem and Fork Alignment ............................................................................................................. 17
13 – Handlebar Clamp Bolt Removal ..................................................................................................... 18
14 – Attaching Handlebar (Road) .......................................................................................................... 18
15 – Attaching Handlebar (Mountain) .................................................................................................... 18
16 – Adjust angle of handlebar ............................................................................................................. 19
17 – Adjust angle of handlebar ............................................................................................................. 20
18 – Tighten Handlebar Clamp Bolts...................................................................................................... 20
19 – Pedal Installation ......................................................................................................................... 22
20 – Road Bike Tire Inflation ................................................................................................................ 23
21 – Mountain Bike Tire Inflation (Generally Schrader Valves) .................................................................. 23
22 – Seatpost Installation .................................................................................................................... 24
23 – Recommended Saddle Height Adjustment ....................................................................................... 25
24 – Saddle Adjustment ...................................................................................................................... 26
25 – Road Bike Brake Adjustments ....................................................................................................... 31
26 – Mountain Bike Brake Adjustments.................................................................................................. 31
27 – Gear Barrel Adjuster (Front) – Mountain Bikes ................................................................................ 32
28 – Gear Barrel Adjuster (Front) – Road Bikes ...................................................................................... 32
46
11 - Index of tables
11. INDEX OF TABLES
Table 1 – Maximum Torque Levels for Parts ..................................................................................................... 42
Table 2 - Recommended Torque Levels for Other Screwed Connections ............................................................... 43
47