Schwinn SW76193-4 Brake and Derailleur Cable Repair Set

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Manual Schwinn SW76193-4 Brake and Derailleur Cable Repair Set.pdf

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SCHWINN®
Bike Cable Ki~ Instructions
Model #: SW76193-4
Parts: ·th SIS
1. Two 2 double ended ge~r) cables w1 rear
. (Index compatible) housing – 1 fro~t, ~ using
2. Two double ended brake cables with o
3. Eight ferrules
4_ Four cable end caps
Tools
1 Bike stand or assistant
2. Look at nut and bolts on your brakes.
· W hes may be: 4mm or 5mm hex wrench /
renc 6″ d. ·t bl h Bmm, 9mm, 1 Qmm box wrench / a JUS, a e wrenc
3. Sharp diagonal pliers or cable cutter
4. Awl or ice pick
5. “Third hand” brake tool or an assistant
6. White lithium grease
Gear Cable Installation . .
Note: Both front and rear derailleur use springs and cable
tension. The spring moves the derailleur as the cable tension
is deceased.
The cable moves the derailleur in the opposite direction as
cable tension is increased. There are usually two limit screws
that stop the derailleur form moving to far either direction.
1. Before loosening any gear cables, turn handle bars as until they
are close to the top tube. If the cables are tight you will need to
increase the length of the housing.
2. Move shift levers until both front and rear derailleur cables ·are
not under tension.
3. Loosen cables (gear wires) on both front and rear
derailleurs (shifters).
4. Remove gear cab/es. The short..ene is-the front cable.
The longer one is the rear derailleur cable.
5. Match the cable heads. Then cut off the non-matching head.
6. Lay the able housing on a flat surface and lay the new housing
next to it. If the cables were tight when the handle bars were
turned in step # 1 hold cable to bike and add length.
7. Use an awl or ice pick to open cable housing ends.
8. Route gear housing like originals.
9. Add ferrules per originals.
10. ·Lightly grease cable (gear wires) and insert them in housing.
11. Pull cable to cable anchor bolt. Make sure derailleurs are in
most relaxed position. Tighten cables.
12. Front derailleur – either suspend the bike or have a friend hold
the rear wheel up. Turn the pedals and move the front shift
lever. Front derailleurs can be either shift small to big chain
wheel or big to small chain wheels. Watch the cage on the front
chain wheels. Either way the limit screws determine how far the
cage will move. Push on the cage to determine which way it
moves. It will move in that direction when’tension is applied to
the cable.
Rear derailteur – with bike still suspended or rear wheel held up
move rear shift lever to relaxed position. The chain should be ·
on the smallest outside cog. If it is on next inner cog, loosen
limit screw with wheel turning until chain moves on to
smallest cog.
13. With the pedals turning move both shift levers one at time.
The chain must not fall off the small or big chain wheels. The
chain must not bypass the biggest rear cog and go into the
spokes or fall off the smallest outer cog. There may be some
minor chain rub when the chain is in maximum cross-ave~ .
position. The best solution is to select another gear combination.
14. The cable should be tight enough not to dip. There will be
housing compression. The cable tension will need to be
adjusted several times.
15. Use cable cutters or diagonal pliers to trim excess gear c~ble.
Leave 1 ½” of extra cable. Crimp on cable end cap with pilers.
SCHWINN®
Bike Cable Kit Instructions .
Model #: SW76193-4 continued …
Front and Rear brakes
1. Before loosening any brake cables, turn handle bars as until
they are close to the top tube. If the cables are tight you will
need to increase the length of the housing.
2. Brakes use springs to open and cables (brake wires) to close.
3. Loosen cables (brake Wires) on both front and rear
brakes (shifters).
4. Remove brake cables. The short one is the front cable. The
longer one is the rear derailleur cable.
5. Match the cable heads. Then cut off the non-matching head.
6. Lay the cable housing on a flat surface and lay the new housing
next to it. If the cables were tight when the handle bars were
turned in step #1 hold cable to bike and add length.
7. Use an Awl or ice pick to open cable housing ends.
8. Route brake housing like originals.
9. Add ferrules per originals.
1 o. Lightly grease cable (brake wires) and insert them in housing.
11. Pull cable to cable anchor bolt. Make sure brakes are in most
relaxed position. Squeeze brake calipers to make sure they
open easily.
12. Squeeze brake arms until brake shoes touch rims. Use third
hand brake tool or have your assistant hold brake arms.
13. Tighten cable at anchor bolt.
14. Squeeze brake lever. The brake shoes should be close but not
touch the rim. Re-adjust cable as necessary.
15. Cable housing will compress under normal use. Check brake
adjustment often.
16. Make sure the brake shoes do not rub on tire.
17. Use cable cutters or diagonal pliers to trim excess brake cable.
Leave 1 ½- of extra cable. Crimp on cable end cap with pliers.

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