2007 Montague Owners Manual FINAL.indd

TABLE OF CONTENTS

1. Introduction 1

2. Owner’s Responsibility 2

3. Parts of Your Bicycle & Location of Quick Releases 3

4. Assembly and Adjustment 4-11

Packing List 4

Operation of Quick Release Levers 5-6

Installing the Seat Post 7

Installing the Pedals 8

V-Brake Assembly 9

Front Wheel Assembly 10-11

5. Before Every Ride Checklist 12-13

6. Folding the Montague Bike 14-16

7. Unfolding the Montague Bike 17-18

8. Road Safety 19-20

9. Operation of the Gear System 21-22

10. Adjustment of Handlebars & Seat 23-24

11. Scheduled Maintenance 25

12. Inspection and Maintenance 26-31

Tools Needed, General Inspection 26

Control Cables, Steering 26

Brakes 27

Wheels 28

Chain, Cranks, Pedals and Reﬂ ectors 29

Front Derailleur 30

Rear Derailleur 31

14. Accessories For Your Montague 32

15. Montague Corporation Limited Warranty 33

Full-size, High-performance bicycles that fold

Bicycle

Owner’s Manual

for Montague

, SwissBike

and Paratrooper

Bicycles

1. INTRODUCTION

CONGRATULATIONS on the purchase of your new MONTAGUE. This manual

is designed to give you the information you need for the safe operation and

maintenance of your new bicycle. Please read it thoroughly before riding your

bicycle.

Your bicycle’s serial number is stamped on the underside of the bottom bracket

shell. Record the serial number in this manual in the event that your bicycle

is lost or stolen. You may also want to register your serial number with your

local police department.

MODEL NAME

COLOR

SERIAL NUMBER

DATE OF PURCHASE

PLACE OF PURCHASE

Since all the components on your Montague are industry standard, repairs or

replacements can be performed at virtually any retail bicycle dealer.

If you have any questions about your Montague after reading this manual,

or encounter any problems when folding or unfolding your bike, please

call Montague’s Customer Support Team toll free at (800) 736-5348. A

knowledgeable representative will be happy to answer any questions and

help you to fully enjoy your new Montague.

2. OWNER’S RESPONSIBILITY

Before riding your Montague, carefully follow all assembly instructions.

Ensure your bike is the correct size for your comfort and safety. When

standing over the frame (straddle frame) you should have a minimum of 1.0”

clearance between the boom tube and your body. Personal adjustment of

the saddle is also necessary to assure maximum safety and comfort. Open

the quick release lever on the seat tube and adjust the height of the saddle.

When seated, your leg should be fully extended with the knee slightly bent

and the ball of the foot on the pedal at the lowest pedal position.

All of the X-Bike’s quick releases must be securely fastened before riding

the bicycle. The quick releases are pictured on the following page in Fig.

1. They are: the front wheel quick release lever (#23), the seat post quick

release lever (#8), the boom tube quick release lever (#9) and, the rear wheel

quick release lever (#30, not on all models). For instructions on operating

the quick release levers, see pages 5-6.

Double check to ensure all bolts and screws are tight.

Make sure that anyone to whom you loan your Montague understands

how to work the quick release levers and how to fold and unfold the X-Bike

properly.

The owner is responsible for required normal maintenance services, such

as those listed in the “Maintenance” sections of this booklet (pages 28-31) in

order to keep the bicycle in good operating condition.

Damage or injury resulting from negligence, improper operation, improper

or unauthorized repair or from maintenance, environmental inﬂ uences,

and improper use are not warranted by Montague Corporation. Montague

Corporation excludes incidental and consequential damages.

WARNING

Make sure to read this complete manual before riding your bike. Failure

to do so, or failure to follow its guidelines could lead to serious injury or

death.

4. ASSEMBLY AND ADJUSTMENT

Although your Montague is 99% assembled, there are a few steps that must

be completed before it is ready to ride. If you have questions or concerns

about any of these steps, please see a bicycle dealer or contact Montague’s

Customer Support Team toll free at (800) 736-5348.

Carefully follow the “Final Assembly Instructions” attached to your bike.

Once you have completed the assembly, read the remainder of this Owner’s

Manual.

NEVER ATTEMPT TO RIDE A BICYCLE THAT IS NOT PROPERLY

ASSEMBLED.

Inside your box you will ﬁ nd:

• 1 99% Assembled Bicycle, folded with rear wheel attached

• 1 Saddle with seat post

• 1 Front Wheel

• 1 Small Parts Box which includes:

• 2 Pedals (Right and Left)

• 1 Front Wheel Quick Release

• 1 15 mm Pedal Wrench

Carefully remove the bicycle and all accessories from the box to avoid

scratching the frame. Check the carton for loose parts before discarding.

3. FIG. 1: PARTS OF YOUR BICYCLE AND LOCATION OF QUICK RELEASES

1. shift levers

2. handlebar

3. brake lever

4. stem

5. saddle

6. head set

7. seat post

8. seat post quick

release

9. boom tube quick

release

10. reﬂ ectors (front

& rear)

11. boom tube

12. spoke reﬂ ectors

(front & rear)

13. tire (front & rear)

14. water bottle mounts

15. seat tube

16. rear brake

17. front brake

18. down tube

19. crank arm

20. seat stay

21. cassette

22. front derailleur

23. front wheel quick

release

24. quick release drop box

25. chainstay 28. pedal 30. rear wheel quick release

26. chain wheel 29. rim (front & rear)

27. rear derailleur

3. 4.

4. ASSEMBLY AND ADJUSTMENT

OPERATION OF QUICK RELEASES (FIG. 2):

Since your Montague relies on quick releases for folding and general assembly

and adjustment, it is crucial that you fully understand how to operate the

levers.

Great care should be taken when locking the quick release levers on the

bicycle. Failure to properly tighten the quick release levers for the

wheels, seatpost, or frame can result in loss of control and may result

in serious injury or death. If you do not fully understand how to operate

the quick release levers, ask a bicycle mechanic for assistance, or call

Montague’s Customer Support Team toll free at (800) 736-5348. Do not ride

your bicycle without all quick releases securely locked.

The quick releases are (See Fig. 1):

CLIX Wheel Release System (standard front wheel quick release

found on bike models prior to 2007) (#23)

The seatpost quick release lever (#8)

The boom tube quick release lever (#9)

The rear wheel quick release lever (#30, not on all models)

1. To release a quick release lever, pull it away from the bike

and towards you until it turns over 180º and the word “open”

is visible facing the outside, away from the bicycle. If your

quick release lever is not marked “open” and “closed”, it is

open when the lever curves away from the bicycle.

The tightness of the lever is adjusted with the nut opposite the

release lever and by rotating the quick release lever. Turn the nut

by hand to adjust the tension while holding the lever stable (Fig. 2).

3. To lock the release lever, push lever up and over towards

the bike frame until it turns over 180º and the word “open”

is no longer visible (Fig. 2), or the lever curves toward the

bicycle. The lever is securely tightened when it leaves an

imprint on the palm of your hand from pushing it closed.

4. ASSEMBLY AND ADJUSTMENT

4. Once the lever is securely closed, you should not be able to move it

unless you open it again, Step 1. If you can easily move it, open the

quick release lever again and tighten the nut another half turn clockwise.

Continue with Step 3.

5. If you have adjusted the nut too tightly and cannot push the lever to the

“close” position, open the quick release lever again and turn the nut a

half turn counterclockwise. Continue with Step 3.

5. 6.

Use extreme care when operating Quick Release Levers. Your personal

safety depends on proper and secure operation of the Quick Release

Levers.

WARNING

Adjusting Nut

1. Tightening

the Adjusting

Nut

Quick Release Lever

2. Locking the Quick

Release Lever

Fig. 2: Operation of Quick Release Levers

4. ASSEMBLY AND ADJUSTMENT

INSTALLING OR ADJUSTING THE SEAT:

1. Loosen seatpost quick release lever (Fig. 3).

2. Insert the seatpost into the seat at least to the minimum insertion line.

CAUTION: Do not raise seat post beyond the minimum insertion line.

To maintain rider safety, at least 2½” of seat post must be in the frame

at all times (Fig. 4).

3. To adjust seat height, loosen the seat post quick release lever (see page

5 for proper operation of quick release levers). Raise or lower the seat

post accordingly. Retighten the quick release lever securely so that

when the quick release lever is closed, the seat post cannot be rotated

in the frame.

Adjust for comfort of the rider. The saddle is properly adjusted when you can

sit on the saddle, and with your knee only slightly bent (approx. 15º), reach the

pedal at its lowest point with the ball of your foot.

4. ASSEMBLY AND ADJUSTMENT

INSTALLING THE PEDALS (FIG. 5):

You will ﬁ nd a pair of pedals in your small parts box. The pedals have different

threads and are stamped “R” for Right and “L” for Left, on the ends of the axle

shaft to differentiate between right and left. Do not try to insert the wrong

pedal into the crank arm as it will strip the threads in the crank.

1. Align the pedal axle with the threaded hole in the respective crank arm

and secure the pedal in the crank by hand.

• The right pedal is installed by turning the pedal axle

clock-wise.

• The left pedal is installed by turning the pedal axle

counterclockwise.

2. After the pedals can no longer be turned by hand, use the 15 mm pedal

wrench (included) and tighten the pedals securely. The shoulder of each

pedal should ﬁ t tightly against the crank arm.

CAUTION: Always start threading the pedals into the crank by hand to

prevent stripping the threads. Do not ride the bike if pedals are loose.

Fig. 3: Seat Post Installation

Fig. 4: Insertion Line

Min.

Insertion

Line

Fig. 5: Pedal Assembly

7. 8.

NOTE: Left and right are determined from riding position on the bicycle.

4. ASSEMBLY AND ADJUSTMENT

V-BRAKES (FIG. 6):

To release the brakes:

1. Pinch the brake arches together

with one hand.

2. Pull the cable guide out and up

while pushing the cable hook

unit down.

3. Release the brake arches,

allowing them to fall open on

either side of the wheel.

To attach the brakes:

Use one hand to pinch the brake arches together and level the cable hook unit.

With the other hand, squeeze the end cap into the hook unit.

Release the brake arches and the hook unit will lock into place

Squeeze the brake lever a few times to ensure the brakes are secured in

place.

Brakes and Gear System: The brakes and gear system are factory set.

However, new brake and gear cables may stretch. Therefore, please check

brakes and gear system before riding your bicycle. If necessary, adjustments

to brakes and gear system can be made by you (refer to the “Operation of

Gear System’ and “Inspection and Maintenance” sections of this manual ) or

by a bicycle mechanic.

4. ASSEMBLY AND ADJUSTMENT

Front Wheel Installation (FIG. 7):

1. Remove the front wheel quick release unit from the small parts box.

2. Unscrew the adjusting nut from the quick release unit, and remove it and

the corresponding spring from the quick release axle.

3. Insert the quick release unit through the wheel hub with the lever on the

left side of the wheel.

Note: Left and right are determined from riding position on the

bicycle and can be found in one of the following ways:

• If an arrow is embossed or printed on the sidewall of the

tire, the wheel should be positioned so the arrow points in

the direction of rotation while riding the bicycle.

• If the manufacturer’s labels are on the tire, the wheel should

be positioned so they are on the right side of the tire.

4. Put the spring back on the quick release unit and loosely screw on the

adjusting nut, leaving room on either side of the hub for the axle to ﬁ t into

the front fork.

5. Position the wheel in the center of the front fork, keeping the opened

quick release lever on the left side of the bicycle.

6. Guide the axle into the fork slots, being careful not to knock the brake

shoes loose.

7. With axle inserted all the way into the fork slots, center the wheel between

the fork blades.

8. Tighten the adjusting nut until you feel a deﬁ nite resistance in the quick

release lever when you push it ½ the way to closed position.

9. Push the lever all the way to the closed position to lock the wheel

securely in place.

Fig. 6: Assembly of Front V-brakes

Brake

Arch

Metal Cable Guide

End Cap

Cable

Hook

Unit

9. 10.

Always inspect the brakes before riding to be sure they are function-

ing properly. If you are not comfortable with the assembly instructions,

please see a bicycle mechanic or call for assistance. Brakes that are not

properly adjusted may result in loss of control and serious personal injury

or death. NEVER ATTEMPT TO RIDE A BICYCLE WITHOUT PROPERLY

FUNCTIONING BRAKES.

WARNING

Riding with an improperly adjusted wheel quick release can allow the

wheel to wobble or disengage from the bike, causing damage to the

bicycle, and serious injury or death to the rider.

WARNING

4. ASSEMBLY AND ADJUSTMENT

10. Test the quick release lever. If you can rotate it up and down, it is too

loose.

11. If the quick release is too loose, re-open the lever and tighten the

adjusting nut until you can not rotate the lever in the locked position.

12. Re-engage the brakes (see page 9). Squeeze the brake lever tightly

few times and check that brakes are operating properly.

13. Tires should be inﬂ ated to the pressure indicated on the tire side wall.

If tire does not have enough air, inﬂ ate it using a regulated hand or foot

pump before riding. Do not ride with tires that are not properly inﬂ ated.

Removal:

1. Disengage the front brakes. (See page 9).

2. Open the hub quick release by pulling the lever away from the wheel

and turning it 180º.

3. Slip the wheel out of the fork. If the wheel does not slide out easily,

loosen the adjusting nut several turns. Do not force the wheel.

5. BEFORE EVERY RIDE - CHECKLIST

Your new Montague bike is designed and manufactured with the utmost care

and attention to detail. Montague utilizes high quality, industry standard

components to compliment our patented, FIT

frame. We are sure you will

ﬁ nd your bike not only meets your needs, but exceeds them.

If you wish to replace any parts or components on your Montague, you do so

at your own risk. Montague recommends that all modiﬁ cations to components

and parts be supervised by a trained bicycle technician.

Familiarize yourself with the use of all moving parts on your new bike, including

the wheels, chain and especially, your brakes. Montague has speciﬁ cally

chosen an appropriate breaking system for the design of our bikes. The

braking power (ability to stop) varies among different braking systems. If you

wish to change the braking system on your bike Montague recommends you

consult a bicycle dealer for appropriate options.

Practice riding your bike at slow speeds in an area with no-trafﬁ c, such as an

empty parking lot, your driveway, or back yard before you attempt to ride in

trafﬁ c, or on trails.

Fig. 7: Front Wheel Assembly

Front Fork

Wheel Hub

Adjusting Nut

Quick Release Lever

Tension Spring

Axle

11. 12.

Avoid contact between your foot or toe clip and the front wheel or fender of

your bike when turning. Doing so may cause loss of control and may result

in serious personal injury. If you experience a frame vibration or “shimmy”

slow your speed immediately and take your bike to a bicycle mechanic.

WARNING

This is not a comprehensive maintenance program. Montague recommends

that you have your bicycle tuned and safely checked by a bicycle technician

on a regular basis. If you notice any irregularities in your bike and/or its

performance take it to a bike dealer before attempting to ride. Overuse of

any brake system may cause loss of control resulting in personal injury.

WARNING

5. BEFORE EVERY RIDE - CHECKLIST

Ensure your bicycle is in proper working condition each and every time you

ride. Use the following checklist as a guide.

 Check your brakes. Press each hand lever to ensure the brakes are

moving freely and stop the bike. If your brakes are not working properly DO

NOT ride your bicycle. Practice braking at low speeds before taking your bike

out into high trafﬁ c areas or trails.

 Check the attachment of both wheels. Pick the front wheel off the

ground and apply force to the wheel in a downward motion, (Fig. 8). The wheel

should remain securely in place. Grab your wheel and try to move it from side

to side. If there is any movement of the wheel do not ride your bike. Take it

to a bike dealer for service.

When the quick release lever is properly adjusted and in the closed position

you should not be able to rotate the lever in a circular motion (parallel to the

wheel). This is different from the “ﬂ ipping” motion, used to open and close the

quick release lever. Repeat the same steps to check the rear wheel.

3 Test the security of the handlebar and stem by attempting to turn the

handlebars in the stem and by twisting them from side to side with the front

wheel locked between your knees (Fig. 9). Make sure that no cables are

stretched or pinched by rotating the handlebars.

Your handlebar and stem control your ability to steer your bike, therefore, if any

part of your handlebar or stem shows signs of damage or fatigue you should

not ride your bike. Once a month check the alignment of your handlebar and

stem with your front wheel. Ensure all stem bolts are tight.

6. FOLDING YOUR MONTAGUE BIKE

Your Montague bike is designed for quick folding and unfolding without the

use of tools. The following simple steps should be observed to ensure the

rider’s safety and to prevent damage or scratches when folding or unfolding

the bicycle.

1. Standing on the chain side of your bike, release the brake wire from

the front wheel brake (Fig. 10). To release the brakes, pinch the brake

arches together and swing the cable hook unit down. Push the end cap

and cable guide out of the hook unit. Release the arches.

2. To unlock the front wheel quick release lever swing the lever to the open

position. Hold the adjusting nut in place while turning the quick release

lever counter clockwise 5 or 6 times to release the wheel. Remove the

front wheel from the fork and set it aside (Fig. 11).

13.

14.

Fig. 8: Checking your Whee

Fig. 9: Checking your

Handlebar and Stem

Fig. 10: Release of Front Brake

Fig. 11: Removal of the Front Wheel

6. FOLDING YOUR MONTAGUE BIKE

3. Pull the bike up into the vertical position and stand on the chain side

with the rear tire on the ground between your feet. Open the quick

release lever on top of the boom tube (Fig. 12). Spin it counterclock-

wise 5 to 6 complete rotations, then with the heal of your hand press

and hold down the quick release to lower quick release nut out of

the quick release drop box while folding the bike with the handlebars

turned away from you so they fold into the rear wheel (Fig. 13). This

is best done by placing your other hand on top of the frame and

pushing away from you.

For extra compactness: open the quick release below the saddle and lower

the saddle all the way down. Then close the quick release below the saddle

(Fig. 14).

15. 16.

Fig. 12: Open Boom Tube Quick Release

Fig. 14: Final Folded Position of the Montague Bike

Fig. 13: Folding the Montague Bike

7. UNFOLDING YOUR MONTAGUE BIKE

1. To unfold the bike place the rear wheel ﬁ rmly on the ground, grasp the

rear wheel with one hand and the handlebar stem with the other and

unfold the bike. When the frame is almost completely unfolded, push

down on the opened boom tube quick release so the quick release nut

enters the quick release drop box. Secure the boom tube quick release

lever by rotating it in the open position clockwise 5 to 6 times (Fig. 15a

& 15b). Lock the quick release lever with the lever pointing towards the

saddle. Make sure the Quick Release End Nut is completely inside the

Quick Release Drop Box. See “Operation of Quick Releases”, page 5.

2. Put the front wheel on the bicycle, with the quick release lever positioned

on the non-chain side. Guide the axle into the fork slots and center

the wheel between the fork blades. Hold the quick release lever in the

open position and tighten the adjusting nut so that you feel resistance

half way when you are closing the quick release lever. Close the quick

release lever all the way over to lock the wheel securely. The quick

release should be tight enough that it leaves a mark on the palm of your

hand when closing it. If you can rotate the quick release lever it is too

loose. Reopen the quick release lever and tighten the adjusting nut until

you can’t rotate the lever up and down when the lever is in the locked

position (see page 10, Front Wheel Installation).

3. To attach the front brakes, pinch the brake arches together and swing

the hook unit up. Push the end cap and cable guide into the hook unit,

allowing the cable to feed through the end of the hook unit. Release the

brake arches and the hook unit will lock into place over the end cap (see

page 9, To Attach the Brakes).

17.

18.

7. UNFOLDING YOUR MONTAGUE BIKE

4. Adjust the saddle to proper height and lock the quick release lever. The

quick release should be tight enough so that it leaves a mark on the

palm of your hand when closing it (see page 7).

Boom Tube

Quick Release Lever

Quick Release

Drop Box

Quick

Release

End Nut

Safety Lip

Quick Release Axle

Fig. 15b: Boom Tube Quick Release

Do not use the quick release lever like a wing nut.

WARNING

If you do not fully understand any of the steps for unfolding your Montague

bike, be sure to ask your bicycle dealer for assistance, or call Montague’s

Customer Support Team toll free at (800) 736-5348.

DO NOT RIDE THE BICYCLE UNLESS ALL FOUR QUICK RELEASES

ARE SECURELY LOCKED!

NOTE: some models do not have rear wheel quick release.

WARNING

Fig. 15a: Quick Release Operation for Final Assembly

8. ROAD SAFETY

• For your safety, always wear a helmet that meets Snell or American

National Standards Institute (Ansi) Z290.4 requirements. In the

event of an accident a helmet can protect you from serious injury

and even death. A bicycle retailer will be happy to assist you in the

selection of a helmet and other useful accessories.

• Obey all trafﬁ c laws. Obey red and green lights, one-way streets,

stop signs, etc.

• Ride with the trafﬁ c, not against it. Ride single ﬁ le in a straight line.

• Have a satisfactory signaling device (bell, horn, etc.), to warn of

approach. RIDE DEFENSIVELY (expect the unexpected).

• Give pedestrians the right of way. Do not ride too close to

pedestrians and alert them if you intend to pass from behind.

• Slow down at all street intersections and look to the right and left

before crossing.

• Always use proper hand signals for turning and stopping. Give

signals 100 ft. before stopping or turning and always return both

hands to the handlebars before stopping or turning.

• Watch for cars pulling out into trafﬁ c and for sudden opening of car

doors.

• Avoid potholes, drainage grates or other road surface hazards.

Cross railroad tracks at a right angle. Be careful when riding on soft

road edges, gravel, sand and uneven surfaces. Ride slowly and

avoid quick turns when riding on these surfaces.

8. ROAD SAFETY

• Never hitch on other vehicles, do not “Stunt” ride or race in trafﬁ c.

Don’t weave in and out of the trafﬁ c or swerve from side to side.

• Never carry other riders or packages, they may obstruct vision or

proper control of the bicycle.

• Before riding, check your brakes. Be sure they are operating

efﬁ ciently and that your bicycle is in perfect running condition.

• When riding at night, always use lights, clear light on front and

ﬂ ashing red light on rear, and wear light colored and/or reﬂ ective

clothing. Make sure your reﬂ ectors are intact and visible. Assume

motorists are unable to see you and ride in an appropriately

cautious manner.

• When braking always apply stronger braking pressure to the rear

wheel (right lever). If the front brake pressure (left lever) is applied

too strongly or quickly, the bicycle may ﬂ ip forward. Avoid strong

braking while turning.

CAUTION IN WET WEATHER RIDING

No brakes work as well under wet conditions as they do under dry conditions.

In rainy wet weather, special precautions must be taken to insure safety in

stopping. Proper adjustment and cable lubrication will help, but the major

precaution rests with you. Increased brake pressure is required in wet or

rainy weather and care must be exercised to maintain safety under these

conditions.

Ride slower than normal and apply your brakes sooner than normal

conditions would require.

A crash can put extraordinary stress on bicycle components, causing

them to fatigue prematurely. Components suffering from stress fatigue

can fail suddenly, causing loss of control, or serious injury.

19.

20.

Use your front brake properly to ensure safe, efﬁ cient stopping. To avoid

misuse and potential injury, do not apply sudden or excessive force on

your front brake. To do so may cause your rear wheel to lift off the ground

and/or, your front wheel to slip from under you.

WARNING

Your bicycle is equipped with reﬂ ectors, however, extreme caution is re-

quired when travelling at dusk or night. In addition to keeping your reﬂ ec-

tors clean, and properly afﬁ xed to your bicycle, you must use headlights

and taillights, in addition to wearing bright, reﬂ ective clothing when riding in

poor lighting conditions. Consult your local bike shop to ﬁ nd accessories

appropriate for your riding needs.

WARNING

9. OPERATION OF THE GEAR SYSTEM

The multi-gear system provides a means of maintaining a constant pedaling

rate, regardless of road level conditions. This is the most effective cycling

technique to prevent tiring over long distances.

The gears are activated by cables connecting the twist shifters or shift levers

located on the handlebar to the derailleurs.

If your bicycle is equipped with twist shifters, rotating the twist shifters towards

you moves the chain from one chainwheel (or sprocket) to the next larger

chainwheel (or sprocket). Rotating the twist shifters away from you moves

the chain from one chainwheel (or sprocket) to the next smaller chainwheel

(or sprocket).

If your bicycle is equipped with shift levers, pushing the thumb shift lever away

from you moves the chain from one chainring (or sprocket) to the next larger

chainring (or sprocket). Pulling the index ﬁ nger shift lever towards you moves

the chain to the next smaller chainring (or sprocket).

The left shifter controls the front derailleur and the right shifter lever controls

the rear derailleur . To shift, continue pedaling at a steady pace while operating

the shifters and engage the gear you ﬁ nd most comfortable.

For easiest pedaling (while going up-hill or slowly), position the chain over

the smallest chainring in front and the largest sprocket in back. For hardest

pedaling (while going down-hill, or quickly), position the chain over the largest

chainring in front and the smallest sprocket in back.

Pedals and wheels must be turning forward while shifting gears. Never pedal

backward while shifting gears and never force the twist shifters or shift

levers.

9. OPERATION OF THE GEAR SYSTEM

ADJUSTMENT OF THE CABLE TENSION:

If the gear system is not functioning properly, ensure that the rear derailleur

follows each shifting command of the right twist shifter/shift lever. Cable

stretching could affect the function after some time, so that synchronization

may no longer be assured. Check and adjust as follows:

1. Shift the chain to the center of the front chainwheel by turning the crank

forward and shifting the left twist shifter/shift lever.

2. Shift the chain to the outermost/smallest rear sprocket by turning the

right twist shifter all the way away from you, or moving the right shift

lever all the way towards you.

3. While turning the crank forward, rotate the right twist shifter or push the

right shift lever to the next position.

4. The chain should move to the second rear sprocket after a maximum of

one full turn of the wheel. If it stays on the ﬁ rst sprocket, the tension of

the shifting cable must be increased (proceed to Step 6).

5. If the chain jumps across the second sprocket or if it scratches the third

sprocket, the tension of the shifting cable must be decreased

(proceed to Step 6).

22.

21.

Fig. 16: Adjustment of Cable Tension

Cable adjusting

barrel

6. Cable tension is adjusted

by turning the Cable Adjusting

Barrel, which is located at the

junction of the cable and the

rear derailleur (Fig. 16).

To increase tension turn the

knurled knob counterclockwise,

to decrease tension, turn the

knob clockwise.

If the tension is adjusted according

to the above steps, the chain should

follow all shifting commands on the

twist shifters.

If the gear system still does not

function properly, please contact

a bicycle retailer for assistance.

10. ADJUSTMENT OF HANDLEBAR AND SEAT

HANDLEBAR STEM ADJUSTMENT:

Your handlebar’s primary function is to steer and control your bicycle,

therefore proper installation, adjustment and maintenance are crucial for your

enjoyment and safety.

To change the handlebar height, loosen the stem expander bolt two to three

turns, then tap the top of the stem handlebars to the desired height, and

retighten very tightly (175-260 lb.

in or 19.8-29.4Nm). MAKE SURE THE

MINIMUM INSERTION LINE IS NOT SHOWING ABOVE THE HEADSET.

Some bikes are equipped with a stem that has an adjustable rise, or angle.

These bikes require that you tighten the angle adjusting bolt to 150-170 lb.in

(17-20.3 Nm) after ﬁ rst making sure the teeth are correctly engaged with the

corresponding teeth entered between the teeth of the mating part.

Note: Some bikes are equipped with handlebar stems that are not adjustable

in height.

Test the security of the handlebars in the stem and the stem in the frame, by

attempting to twist the handlebars in the stem and by attempting to turn them

from side to side with the front wheel locked between your knees (Fig. 17). Make

sure there are no cables stretched or pinched by rotating the handlebars.

10. ADJUSTMENT OF HANDLEBAR AND SEAT

SEAT ADJUSTMENT:

Your seat and seatpost are the primary means of support for the rider.

Proper adjustment is important for your comfort and pedaling efﬁ ciency.

Ensure your seat and seatpost are securely tightened in a comfortable

position for your riding style.

Ensure that the seat is secure by attempting to turn the seat and seatpost

in the frame. Grabbing the saddle, attempt to move the front of the saddle

up and down and side to side. If it rotates, is loose, or moves up and down,

tighten the quick release and repeat the test until there is no movement.

(see page 5 for Operation of Quick Release Levers).

Your seat post has a “Minimum Insertion Mark” 2 1/2 inches above the

bottom. When you adjust the height, always make sure this mark is inside

the frame and NOT showing.

23.

24.

If you are unsure of the safety of your handlebar system, do not attempt

to ride your bike. Never ride your bicycle with the stem raised above the

minimum insertion mark as this may cause loss of control resulting in

personal injury or death. A minimum of 2 3/4 inches (70mm) of the stem

must always remain in the frame.

WARNING

When adjusting the seatpost ensure the minimum insertion mark remains

inside the frame. A minimum of 2 1/2 inches (64mm) of seatpost must

remain in the frame. Riding with the seat raised above this height may

cause loss of control resulting in personal injury or damage to your bike.

WARNING

Fig. 17: Hold Wheel and Try to

Turn Handlebar

11. SCHEDULED MAINTENANCE

We recommend that you take your bicycle in to an authorized bicycle dealer

before riding it and then once a year for maintenance so that you can enjoy

your Montague bike for as long as possible. Maintenance of your bicycle

should include the following:

Maintenance service by a dealer

1. Crank set: check play, adjust and retighten if necessary.

2. Head set assembly: check play, adjust and tighten if necessary.

3. Brake system: replace brake cables, check brake pads and replace

if necessary, adjust lever play.

4. Gear system: grease shifting cables, check and adjust setting and

indexing function.

5. Wheels: check alignment, realign if necessary. Check and adjust air

pressure.

6. Chain: check, replace if necessary.

7. Tighten mounting bolts on handlebar, saddle, brakes and hubs.

8. Boom Tube quick release box: keep free of debris.

9. Quick releases: check function.

Regular performance of these maintenance services will afford carefree

enjoyment of your Montague bike.

12. INSPECTION AND MAINTENANCE

Regular care preserves the value and safety of your bicycle. You can carry

out the following care and inspection procedures yourself or bring the bicycle

to a dealer for maintenance. We recommend that you do take your bicycle in

to a dealer once a year for maintenance so you can enjoy your Montague for

as long as possible.

TOOLS NEEDED FOR MAINTENANCE OF YOUR MONTAGUE BIKE:

• Small adjustable wrench

• Large adjustable wrench

• Set of 4, 5, 6 mm Allen keys

• Medium Phillips screwdriver

• Slip-joint pliers

• Flat thin open end wrench 15mm

• Air pump

• Tire levers

GENERAL INSPECTION: Every week or two tighten all nuts and bolts.

Check all hardware to see that no parts are worn or damaged, that there

is correct fork and frame alignment, and that all components are seated in

proper position.

CLEANING: Clean the frame and all parts regularly with a moist cloth or

sponge. Bicycle shops offer special cleaning agents for easy care.

REFLECTORS: Reﬂ ectors should be kept clean, securely fastened and

positioned for bicycle identiﬁ cation at night from front, rear and lateral visibility.

Damaged units should be promptly replaced.

CONTROL CABLES: Replace worn or damaged cables. Do not kink cables.

Cables stretch with use; adjust accordingly. Keep control cable lubricated.

HANDLEBAR/STEERING: On some models, the handlebar stem may be

adjusted for your comfort. The bearing of the fork in the frame (headset)

should rotate easily without play. Adjustment of the headset requires special

tools and should be performed by a bicycle mechanic.

GRIPS: Replace worn grips. Make sure they ﬁ t snugly.

25.

26.

Failure to properly maintain your bicycle may lead to damage to the bi-

cycle, or a loss of control resulting in personal injury.

WARNING

12. INSPECTION AND MAINTENANCE

BRAKES: The brake levers should be easy to operate without too much play.

Too much play will cause insufﬁ cient braking power. The play is properly

adjusted if the brake pads meet the rim fully when the brake lever is pulled

one third of the way.

Adjust the brake play by turning the adjusting nuts located at the junction

of the brake cable and brake lever. When you have determined the proper

setting, turn the knurled knob at the shaft of the adjusting bolt all the way

down to the brake lever to lock the brake setting in place.

• The right brake lever controls the rear brake. To tighten

brakes, turn the adjusting nut clockwise. To loosen brakes,

turn the adjusting nut counterclockwise.

• The left brake lever controls the front brake. To tighten

brakes, turn the adjusting nut counterclockwise. Too loosen, turn

the adjusting nut clockwise.

Note: Left and right controls are reversed on bicycles sold in some countries.

Check brake pads regularly for wear and make sure they are properly toed in.

Viewed from the side, the brake pads should be exactly at the height of the

rim and slightly toed in the direction of the rotation of the wheel. The brake

pads must display tread. When the tread is worn down, the brake pads must

be replaced.

For safety reasons, the brake cables must be replaced every 12 months. This

should be included in the annual maintenance service by a certiﬁ ed bicycle

repair and maintenance shop.

ALIGNMENT: If the bicycle does not align properly, immediately bring to a

bicycle mechanic or call Montague’s Customer Support Team toll free at (800)

736-5348.

12. INSPECTION AND MAINTENANCE

WHEELS: Make sure the quick release lever on the front wheel is properly

closed and the axle nuts, or quick release lever on the rear wheel are tight.

Wheels should be centered in fork or dropouts. Irregular noise from the wheels

or the brakes touching the rim indicates that the wheel requires maintenance.

Wheels should be checked regularly for spoke tightness and true alignment.

WHEEL ALIGNMENT: Wheels should rotate smoothly without wobbling from

side to side. Check the bearing play of the hubs by lifting the bicycle and

spinning the wheel. The wheel should continue to spin for several rotations

and ﬁ nally cease spinning. To check the play of the hubs: try to move the

rim from side to side between the fork. During this test, no substantial play

should exist. If you detect play or if the wheel is difﬁ cult to turn, the hub

bearings must be adjusted. Please contact a bicycle mechanic to have the

hub bearings adjusted.

RIMS: The rims must be smooth and without cracks, breaks, or bulges. Check

that they are smooth on the inside to prevent puncturing the inner tube.

SPOKES: Check spoke tension regularly. Approximately the same tension

should be applied to all spokes. If there is minor loosening of the spokes, you

may tighten the nipples, but it is recommended that you take the bicycle to a

bicycle mechanic. If you detect a loose spoke or if the rim has a side play of

more than 4mm, immediately have the wheel trued by a technician. Riding

with loose spokes may cause the wheel to fail, resulting in serious injury

or death.

TIRES: Maintaining proper inﬂ ation levels of your tires ensures a smooth,

efﬁ cient and safe ride. Make sure that the tires are inﬂ ated according to

pressure indicated on tire sidewall. Improper tire pressure will cause excessive

wear, causing premature replacement. A foot or frame pump should be used.

Pressurized, unregulated pumps should not be used.

The tire should be properly seated in the rim and the ﬁ tting of the tire bead

and rim bead should be checked. If the tube is pinched between the tire and

the rim, it will explode when inﬂ ated. Ensure that the tire is not cracked or

unevenly worn. Check for bulges. Check that the valve is straight in the rim.

Irregular tires should be replaced immediately.

27.

28.

12. INSPECTION AND MAINTENANCE

CHAIN: Check frequently for damage and stretch and replace if necessary.

Lubricate several times each season and after each washing or ride in the

rain. Use a lightweight, all-purpose oil, being careful to oil each link. Chain

speciﬁ c oil is available from any bicycle shop. The chain must be replaced

after a maximum of 1250 miles. This requires special tools and should be

performed by a certiﬁ ed bicycle mechanic.

CHAINRINGS: Replace if chainring teeth are bent or damaged. Keep

chainrings tight on crank.

CRANKS & PEDALS: Crank assembly should turn freely without side play.

Check the bearing play of the cranks by grasping the end of the crank near

the pedal thread and trying to wiggle it laterally. If you detect play, have it

corrected by a dealer.

Keep locknut tight and keep bearings clean and well adjusted. Check crank

bolt or nut (depending on axle type) regularly to make sure crank arms stay

tight.

Replace bent cranks immediately! Do not attempt to straighten.

Replace pedals if bearings are tight or frozen and if thread is lost or badly

worn. Keep pedal bearings lubricated.

REFLECTORS: Your reﬂ ectors are an important safety feature of your bike,

Do not remove them. Every three months, check the nuts and bolts holding the

front, rear, pedal and wheel reﬂ ectors and make sure that they are tight. Also

check the alignment of the front and rear reﬂ ectors, their reﬂ ective surfaces

should be perpendicular to the ground. The rear reﬂ ector should be at least

three inches below the top of the seat. KEEP REFLECTORS CLEAN AT ALL

TIMES.

12. INSPECTION AND MAINTENANCE

FRONT DERAILLEUR ADJUSTMENT: (FIG. 18)

The derailing cage must be positioned high enough to clear the chain

wheels while shifting. If an adjustment is necessary, loosen the frame clamp

and reposition accordingly. When re-tightening the frame clamp bolt, make

sure the curvature of the derailing cage is concentric to the curvature of the

chainwheel and that the derailing cage is in line with the chainwheel.

The front derailleur should shift smoothly and easily between the

chainwheels. If the front derailleur does not shift correctly, it can be adjusted

as follows:

1. Place left lever all the way forward, or twist shift all

the way back, and adjust screw “H” to center derailing

cage and chain over the large chainwheel.

2. Move left shift lever all the way back or twist shift all the way

forward and adjust limiting screw “L” so the derailing cage

and chain are centered over the smaller chainwheel.

3. Loosen the cable anchor nut and pull all slack out of the cable

through the anchor bolt. Re-tighten the cable anchor bolt securely.

These adjustments will limit the inward and outward movement of the

derailing cage so the chain will not derail to the left of the inside chainwheel

or to the right of the outside chainwheel.

Derailing

Cage

2.5 mm

Small Chainwheel

Frame

Clamp

Bolt

Limiting

Screw

“ H”

Cable Anchor

Nut

Fig. 18: Front Derailleur Adjustments

29. 30.

12 . INSPECTION AND MAINTENANCE

REAR DERAILLEUR ADJUSTMENT (FIG 19):

With the right shift lever all the way back or the twist shift all the way forward,

the rear derailleur should position the chain on the smallest rear sprocket

with no trace of slack in the control cable.

If the chain does not reach the smallest sprocket:

Adjust limiting screw “H” (moving it out, away from the derailleur housing)

allowing the necessary additional outward travel of the derailleur.

Once adjusted, limiting screw “H” should be moved to bottom against the

derailleur housing, stopping any additional outward travel of the derailleur

and preventing the chain from running off the smallest sprocket.

If there is slack in the cable:

Turn the barrel adjustment counterclockwise to remove slack. If the slack

is not taken up, or if the derailleur does not have a barrel adjuster, a cable

adjustment is necessary. Loosen the cable-ﬁ xing bolt freeing the cable. Pull

the cable tight and retighten bolt securely.

With the right shift lever all the way forward, or the twist shift all the way back,

the derailleur should position the chain on the largest rear sprocket.

If the chain does not reach the largest sprocket:

Adjust limiting screw “L” to allow for

this and position it to bottom against

the derailleur housing to prevent any

additional inward travel of the

rear derailleur. This will stop the

chain from running off the inside

of the large rear sprocket.

Fig 19: Rear Derailleur Adjustment

Cable

Adjusting

Barrel

Adjusting

Screw “L”

Tension Pulley

Adjusting

Screw “H”

Guide Pulley

Cable

ﬁ xing Bolt

13. ACCESSORIES FOR YOUR MONTAGUE

Optional Accessories:

Folding Pedals: Folding pedals will reduce the folded width of the bicycle

by four inches and are available to ﬁ t on all models.

Carrying Case: A water resistant 420 Denier nylon carrying case is

available. It has an over-the-shoulder strap and an inner pocket for the front

wheel. See your dealer for more details.

Additional Accessories: More custom Montague accessories are also

available, and since your Montague uses standard parts and components,

you can customize your bike in numerous ways. Check out your local bike

dealer’s selection of parts and accessories.

INSTALLATION OF RACKS: Montague does not manufacture rear racks,

but recommends you use a seat post mount rack. Contact your local

bicycle retailer for further details.

31. 32.

14. MONTAGUE CORPORATION LIMITED WARRANTY

Montague Corporation warrants each new Montague bicycle frame against

defects in workmanship and materials for the lifetime of the original owner.

Montague Corporation also warrants all original parts, excluding suspension

forks, for a period of one year from the date of purchase. Forks shall be

covered by the stated warranty of their original manufacturers. Paint and

decals are warranted for one year. This warranty is expressly limited to

the repair or replacement of a defective frame, fork, or defective part and is

the sole remedy of the warranty. This warranty is not transferable from the

original owner.

Claims must be made through an authorized Montague dealer. Proof

of purchase is required. In addition, a warranty registration card must be

completed and received by Montague Corporation before a warranty claim

may be processed.

This warranty does not cover normal wear and tear, improper assembly,

damage or failure due to accident, misuse, abuse or neglect, follow-up

maintenance, or installation of parts or accessories not originally intended

or compatible with the bicycle as it was sold. Modiﬁ cation of the frame or

components shall void this warranty.

Montague Corporation shall not be responsible for incidental or consequential

damages. Some states do not allow the exclusion of incidental or consequential

damages, so the above exclusion may not apply to you.

Labor charges for parts changeovers are not covered by the warranty.

This warranty gives the consumer speciﬁ c legal rights, and those rights may

vary from place to place. This warranty does not effect the statutory rights

of the consumer.

HUMMER and all related and distinctive vehicle model body and grille designs are General Motors

Trademarks used under license to Montague Corporation.

Montague Corporation.

Component speciﬁ cations vary by country and are subject to change without notice. All Montague bicycles

are covered under one or more patents or patents pending.

33.

Montague Corporation

P.O. Box 381118

Cambridge, MA 02238

Toll Free Phone # (800) 736-5348

International Customers Call (617) 491-7200

MONTAGUE BICYCLE WARRANTY REGISTRATION CARD

Name:

Mailing Address:

Place of Purchase:

Location - City: State: Date of Purchase / /

Purchase Price: Bicycle Color: Model Name:

Serial #: Frame Size: User’s Sex: M / F Age:

Used of Folded Montague Bicycle (if more than one applies, number by priority)

Store in home Commute Airline Travel Sailboat Powerboat

Car Trunk Private Plane RV Other:

Is use: Personal Government/Military Corporate

What type of riding do you mainly use your Montague Bicycle for?

City Bike Trails/paths Off-road Touring

How did you hear about Montague Bicycles?

Bicycle Dealer Consumer shows/Expos Friend Internet

Other:

Advertisement (specify where):

News Article (specify where):

Comments:

From:

MONTAGUE CORPORATION

P.O. Box 381118

Cambridge, MA 02238