XR 200 Full Suspension

Mountain Bike

Bicycle Maintenance and Repair

Manual

Table of Contents
Introduction and Required Tools...................................................1
Safety Information..........................................................................2
Maintenance Schedule...................................................................3
Adjusting the Handlebars...............................................................4
Adjusting the Front Derailleur........................................................5
Adjusting the Rear Derailleur.........................................................6
Lubricating the Derailleurs.............................................................6
Adjusting the Seat...........................................................................7
Checking the Brakes.......................................................................8
Inflating Tires...................................................................................9
Changing a Flat Tire......................................................................10
Troubleshooting.................................................................11

Mongoose XR 200 Bicycle Maintenace and Repair Manual

Introduction and Required

Tools
This repair manual is designed to assist you with your Mongoose XR 200 mountain bike and is not a complete
or comprehensive manual of all aspects of maintenance and repair. This manual serves to provide you with
basic instructions on properly maintaining and repairing your bicycle for optimal performance. Consult a
bicycle specialist if you have doubts as to your ability to carry out the tasks outlined in this manual. Please
refer to the tools required for maintenance and repair, as well as Figure 1 below, which gives you a complete
listing of the parts that make up your Mongoose XR 200.

Tools Required:
A. Adjustable wrench
B. 4mm, 5mm, & 6mm Allen keys
C. A pair of pliers
D. Phillips head screwdriver
E. 9mm, 10mm, 14mm, & 15mm open end wrench

Figure 1:
Parts identification.

Mongoose XR 200 Bicycle Maintenance and Repair Manual

Safety Information
Important Safety Instructions
The caution symbol indicates that property damage or personal injury can result if
instructions are not followed properly. It is important to read through this repair manual
carefully to avoid risk of injury or damage to your bicycle.
The word note will appear in bold-face and followed by supplemental information to better assist you in
performing the maintenance or repair task correctly.

Caution! To avoid personal injury or damage to your bicycle, please do the following:
Brakes

Ensure front and rear brakes work properly

Ensure brake pads are not over worn and are correctly aligned with the rims
Ensure brake control cables are properly lubricated and correctly adjusted

Derailleurs

Check that the front and rear mechanisms are adjusted and working properly
Ensure derailleurs and control cables are properly lubricated

Steering

Ensure handlebar and stem are correctly adjusted and tightened

Check that the headset locking mechanism is properly adjusted and tightened

Wheels and Tires

Ensure that tires are inflated to within the recommended limit

Ensure tires have tread and have no bulges or excessive wear
Change out a flat tire as soon as possible

Mongoose XR 200 Bicycle Maintenace and Rapair Manual

Bike Maintenance Schedule

The more often you ride your bicycle, the more often it will require proper upkeep and maintenance to
minimize repair costs. The following schedule is a general guide to help you plan out maintenance tasks
according to usage.

eevery ride

(safety check)

Check tire pressure.

every month

(or 500 miles)

Clean bicycle frame

with cloth.

every six months

every year

(or 2500 miles) (or 6000 miles)

Clean and wax frame

to protect paint/
finish.

Check all bearing

systems: hubs,
bottom bracket,
headset, and brakes.
Check tread on both Check wheels for
Check tires for wear
Clean and check
tires for embedded
loose spokes and
and replace if there
wheels for signs of
debris.
replace them if
are any significant
wear such as worn
necessary.
cracks.
sidewalls or cracks.
Spin wheels to check Inspect and lube your Maintain and lube
Maintain and lube
for wobbles.
suspension.
your suspension
your suspension
components.
components.
Check over brake
Lube brake, derailleur, Check for worn brake Check all brake pads
pads to see that they and gear cables.
pads and replace if
and gear cables for
are in good condition
necessary.
fraying, breakage,
and that they touch
rust, or corrosion and
the rims.
replace if necessary.
Squeeze brakes to
Check brakes for
Check condition of
Check all bearing
make sure theyre
fraying and rusting
quick release parts
systems: hubs,
grabbing.
and replace if
and hubs and adjust brackets, pedals, etc.
necessary.
or tighten as needed.
Check that quick
Test the tightness
Clean drivetrain
Replace worn
release parts are tight of all moving and
(chain, chaining),
handlebar grips and
and secure.
connecting parts
front and rear
tape.
using a wrench.
derailleurs with
solvent and rags.
Wipe down bike chain Wipe down chain
Check chain for any
Wipe down chain and
and add chain lube if with cloth and
rust and replace if
replace chainrings.
it looks dry.
degreaser and re-lube necessary.
chain.

Mongoose XR 200 Bicycle Maintenance and Repair Manual

Adjusting the Handlebars

In order to ride your bike for long distances comfortably, proper adjustment of the handlebars is necessary. As
with most mountain bikes, it is recommended that the handlebars should be lower than the seat to give you a
lower center of gravity and better balance when riding on different types of terrain.
1. Stand over the front wheel of your bike, and, while
holding it in place with your feet, loosen the top
nut around the stem with an adjustable wrench.
See Figure 1.
2. Twist handlebars from side to side until they turn
independently from the front fork and wheel.
3. Remove stem completely from head tube, wiping
it with a clean rag.
4. Reinsert the stem, adjusting it to the desired
position.
Caution. Possible personal
injury. Extending stem beyond
minimum insertion mark may
damage forks steerer tube,
which can cause you to lose
control and fall. Make sure that
stem is inserted to the proper
height without exceeding the
minimum insertion mark.

Figure 1:
Loosening the top nut with adjustable wrench.

5. Tighten the locknut once the stem is at the correct

height.

Adjusting the Handlebar Angle

1. Use an allen wrench to loosen binder bolt screws
at the top of the stem.
2. Push up or down on handlebars, making sure the
sweep of the handlebar angles back is in line with
your arms.
Note: You will want your elbows slightly bent while
riding so adjust the angle accordingly.
3. Tighten the binder bolt screws with the allen
wrench. Grab the handlebars with both hands and
twist side to side to ensure screws are secure.
Figure 2:
Loosening the binder bolt screws with an allen wrench.

Mongoose XR 200 Bicycle Maintenace and Rapair Manual

Adjusting the Front Derailleur

The front and rear derailleurs often need an adjustment when you notice that your bike switches gears
unexpectedly or doesnt shift correctly. Properly adjusting your derailleurs only requires a few hand tools and a
little tweaking to get the chain aligned correctly, so that you can shift gears with relative ease.
1. Put your bike in its lowest gear, making sure the
chain is on the largest cog in the back and the
smallest chain ring in the front.
2. Disconnect cable grip from front derailleur anchor
bolt with an adjustable wrench. See Figure 1.
3. Align the low end of your derailleur to the largest
cog in the rear.
4. Adjust the low limit screw, centering the chain in
the front derailleur cage.
5. Reconnect the cable, pulling any slack out. See
Figure 2.
6. Tighten the anchor bolt securely.
7. Shift the front shifter to the largest chainwheel.
8. Shift through every gear using the barrel adjusters
to fine tune each transition.

Figure 1:
Using an adjustable wrench to loosen anchor bolt.

Note: The barrel adjuster is located on the front

shifter where the barrel comes out of the shifter.
Note: Clockwise will loosen cable tension and
counter-clockwise will tighten cable tension.
Caution. Possible personal
injury. Riding a bike that is not
shifting properly can cause you
to lose control and fall. Make
sure your derailleur is properly
adjusted by shifting through
every gear before riding.

Figure 2:
Pulling the cable so its nice and taut before tightening the
anchor bolt.

Mongoose XR 200 Bicycle Maintenance and Repair Manual

Adjusting the Rear Derailleur

Adjusting your front and rear derailleurs is an important maintenance task to ensure that your drivetrain runs
smoothly. After an adjustment, it is recommended to lubricate the derailleurss screws and pivots, as well as
the chain itself, to prevent them from stiffening up or rusting.
1. Put your bike in the highest gear. See Figure 1.
2. Disconnect cable from rear derailleur anchor bolt,
placing the chain on the smallest cog.
3. Adjust the high limit screw so the guide pulley and
smallest cog are lined up vertically.
4. Reconnect the cable, pulling out any slack.
5. Tighten the anchor bolt securely.
6. Shift through every gear using the barrel adjusters
to fine tune each transition.
Note: Clockwise will loosen cable tension and
counter-clockwise will tighten cable tension.
7. Adjust low limit screw in quarter turn increments
until guide pulley and largest cog are aligned
vertically.

Figure 1:
Putting the largest gear sprocket closest to the spokes.

8. Shift through every gear again using the barrel

adjusters to fine tune each transition.
Caution. Possible personal
injury. Failure to secure
bolts tightly can result
in chain separating from
derailleur, causing you to
lose control and fall. Make
sure all connecting bolts are
tightened properly before
riding.

Lubricating the Front and Rear Derailleurs

Lubricate the screws and pivots with chain lube to
ensure chain links do not sitffen up and affect smooth
shifting. Lubricate after any derailleur adjustment
and at least once a month to keep your drivetrain in
working order. See Figure 2.

Figure 2:
Using chain lube to keep derailleurs lubricated

Mongoose XR 200 Bicycle Maintenace and Rapair Manual

Adjusting the Seat

Along with properly positioning your handlebars, adjusting your bike seat to the right height and angle ensures
a comfortable ride.

Adjusting the Seat Height

1. Loosen the adjusting nut with allen wrench.
2. Move the quick release to the open position
to move the seat up and down to the desired
position. See Figure 1.
Note: When adjusting the seat height, you will want
to make sure that when the pedal is at the bottom,
your leg is almost straight.
3. Move the quick release lever to the closed
position.
4. Tighten the adjusting nut.
Caution. Possible personal
injury. Failure to securely
tighten the quick release
mechanism can cause you
to lose control while riding.
Make sure the quick release is
tightened properly to prevent
the seat from shift suddenly.

Figure 1:
Moving quick release to open position.

Adjusting the Seat Angle

1. Loosen the seat clamp underneath the seat. See
Figure 2.
2. Adjust the pitch of the seat up or down.
3. Slide the seat forward or backward to adjust the
horizontal position.
4. Tighten the seat clamp once the seat has been
adjusted to your desired position.

Figure 2:
Using an allen wrench to loosen the seat clamp

Mongoose XR 200 Bicycle Maintenance and Repair Manual

Checking the Brakes

It is important to have fully functioning brakes in order to ride safely. Brake pads that are worn or improperly
installed can prevent you from braking, which can be dangerous. Checking and lubricating your calipers, as well
as changing your brake pads when they become worn are essential for your brakes to work properly.

Checking Calipers
1. Check the brake pads for wear. See Figure 1.
Note: There should be a 1/4 inch of rubber between
the tire when the caliper is engaged.
2. Check the cables by squeezing the brake handles
to make sure the cable moves.
Note: You will want to make sure the caliper moves
when the cable pulls on it. If the cable moves, but
the caliber does not, the whole cable assembly will
have to be replaced.
3. Loosen the bolts that hold the caliper if only one
side is clamping against the wheel.
4. Work the bolt in and out to free up the
mechanism and lubricate the crevice if necessary.

Figure 1:

Checking the brake pads for wear.

5. Tighten bolts and squeeze brake handles again to

make sure both sides are now clamping against
the wheel.

Changing the Brake Pads

1. Remove the nut and washers from your old brake
pad. See Figure 2.
2. Pull the pad free from the caliper arm.
3. Toe the new pads in slightly so that the trailing
edge contacts the wheel first.
Note: Make sure the pad height is near the center of
the metal rim of the wheel.
4. Attach the nut and washers. Make sure they are
properly tightened.
Caution. Possible personal
injury. Mounting brake pads
too low may cause them
to slide off the rim and can
cause you to lose control
and risk injury. Align brake
pads correctly to prevent
loss of braking ability.

Mongoose XR 200 Bicycle Maintenace and Rapair Manual

Figure 2:
Removing the nut and washers from the old pad.

Inflating the Tires

Inflating your tires to their recommended PSIs is necessary for a smooth ride, especially when riding your
mountain bike along the most challenging of terrains. If your tires are not properly inflated, it can affect the
rest of the bike, putting undo stress on the rims over time.
1. Unscrew the rubber valve at the top of the
Schrader valve. See Figure 1.
Note: The recommended PSI is usually printed on
the side of your tires and will consist of a range. Do
not go below the lowest number listed there.
2. Using a bicycle pump, place the pump on the
valve, making sure its in the open position.
3. Snap the lever down into the closed position and
keep an eye on the PSI as the tire inflates.
4. Flip the lever back up while quickly returning the
rubber cap to the valve.

Deflating the Tire

In the event that you want to deflate your tire, simply
press on the valve with a small tool until some or all
of the air escapes. See Figure 2.

Figure 1:
The Schrader valve before it has been unscrewed.

Figure 2:
Using a small tool to deflate a tire.

Mongoose XR 200 Bicycle Maintenance and Repair Manual

Changing A Flat Tire

If you notice that you have a flat tire, it should be patched up or replaced as soon as possible.
Caution. Property Damage. Riding your bicycle with a flat tire can cause
damage to your rims. Make sure you change out the flat tire prior to riding.

1. Remove the wheel from the bicycle.

2. Deflate the tire completely.
3. Loosen the tire bead by pushing it inward all the
way around. See Figure 1.
Note: Use tire levers instead of a screwdriver to
avoid damaging the rim.
4. Press one side of the tire bead up over the rim.
See Figure 2.
5. Remove the tube leaving the tire on the rim.
6. Patch the leaks using a tool repair kit or replace
the tube itself.
Note: Ensure the replacement tube matches the size
given on the tire sidewall.
7. Remove tire completely and inspect for nails,
pebbles, glass, etc. removing if located.
Note: Inspect inside rim to make sure there are no
protruding spokes and replace rim tape if necessary.
8. Remount one side of the tire onto the rim.
9. Inflate the tube with hand pump to give it some
shape.
10. Place the valve stem through hole in rim and work
the tube into the tire.
11. Remount the other side of the tire by pushing the
edge towards the center of the rim. Start on either
side of the valve and work around rim. See Figure
3.
12. Push valve up into the rim, making sure the tire
can sit squarely in position.
13. Fit the rest of the tire.
Note: Check that tube is not caught between rim and
tire bead.
14. Fully inflate tire to pressure marked on sidewall
using hand pump.
15. Replace wheel into frame, checking that all gears,
brakes, and quick release levers are properly
adjusted.

10

Mongoose XR 200 Bicycle Maintenace and Rapair Manual

Figure 1:
Push the bead tire into the center of the
rim.

Figure 2:
Remove tire bead from the rim.

Figure 3:
Pull tire back onto rim.

Troubleshooting
This section is in place to assist you with any issues that may arise while you are riding your bike.

problem

possible cause

Brakes not working effectively

solution

Brake pads worn down

Brake pads/rim greasy,
wet, or dirty
Brake cables are
stretched or damaged
Brakes out of adjustment
Brakes make a squealing or
Brake pads worn down
squeaking sound when applied Brake pads/rim dirty or
wet
Brake pads are loose
Knocking or shuddering when Brake mounting bolts
applying brakes
loose
Brakes out of adjustment
Fork loose in head tube

Replace brake pads

Clean pads and rims

Gear shifts not working

properly

Lubricate/tighten/replace
cables
Adjust derailleurs

Chain is slipping
Chain jumping off freewheel
sprocket

Steering is inaccurate

Tires keep getting punctured

Derailleur cables sticking/

stretched/damaged
Front or rear derailleur
not adjusted properly
Chain worn/frayed
Stiff link in chain
Chaining loose
Chaining teeth bent or
broken
Derailleur out of
adjustment
Wheels are not aligned
properly
Headset is loose
Front forks or frame is
bent
Inner tube is old
Tire tread/casing worn
Tire does not fit rim
properly

Clean/adjust/replace
cables
Center the brakes
Replace brake pads
Clean pads and rims
Tighten mounting bolts
Tighten mounting bolts
Center the brakes
Tighten the headset

Replace chain
Lubricate or replace link
Tighten mounting bolts
Repair or replace bike
chain
Adjust front and rear
derailleurs
Align wheels correctly
Adjust/tighten headset
Take bike to repair shop
for frame realignment
Replace inner tube
Replace tire
Replace with the correct
tire

Mongoose XR 200 Bicycle Maintenance and Repair Manual

11

Pacific Cycle, Inc.

4902 Hammersley Road

Madison, WI 53711
General Line: 1-800-666-8813
Corporate E-mail: info@pacific-cycle.com

PC-MO240A
Revised 11/24/2014