Bicycle is a one of most economical and popular transport mechanism in world. However Paddle crank failure was identified as a most critical failure point of bicycle. The analysis and optimization of a bicycle pedal crank using manual calculation and Finite Element Analysis (FEA) is a proposed procedure in this research. All manual calculations based on applied mechanics for maximum load case from vertical direction and found greatest principal stress (Equivalent or Von-Mises) and total deflection. The pedal crank was modeled using design modeler and validation of model was done by using equivalent stresses and directional deflection of the crank and pedal. Geometry was refined by using method of body sizing till receive converged result of maximum stress. This research paper proposed improvements of designs with regard to minimize the weight, cost and optimum factor of safety.