Assembly Guide Pilot`s Handbook Technical Illustration

Assembly Guide
Pilot’s Handbook
Technical Illustration
&
Parts List
www.TerraTrike.com - 800.945.9910
4460 40th St SE. Grand Rapids MI, 49512
USA
Table of Contents
Assembly Guide - Pg 1-15
Pg 1 - Serial Number & Boom Installation
Pg 2 - Rear Wheel Installation & Hubmount (Axle) Installation
Pg 3 - Idler Wheel Installation
Pg 4 - Steering Brace Installation & Tie Rod Installation
Pg 5 - Front Wheel Installation & Handlebar Installation
Pg 6 - Brake Caliper Installation
Pg 7-9 - Alignment
Pg 10 - Align Rear Derailleur Hanger & Rear Derailleur
Installation and Setup
Pg 11 - Front Derailleur Setup & Pedal Installation
Pg 12 - Chain Installation
Pg 13 - Handlebar Cable Housing Routing & Installation
Pg 14 - Seat Clamp Installation
Pg 15 - Seat Installation and Reflector Installation
Owners Information - Pg 16-17
Pg 16 - Welcome, Unpackaging, Cautions/Safety, Riding Tips
Pg 17 - Warranty Information
Technical Drawing & Parts List - Pg 18-20
Pg 18 - Tour II Technical Drawing w/Part Numbers
Pg 19 - Tour II Parts List
Pg 20 - Seat Clamp Technical Drawing w/Part Numbers,
Seat Clamp Parts List
Boom Size Chart - Pg 21
Company Information - Pg 22
Assembly Guide
Dark Grey = Installation/Adjustment
PLEASE NOTE: Make sure you’re greasing bolts before installing them. Failure
to do so can cause “galling” to occur (heat and friction will fuse (weld) the fasteners
together). Adjustment will be impossible and not covered under warranty.
1
Locate/Record Serial Number
Number is located under
the underside of the frame.
2
Boom Installation
Boom must be slid all of the way
onto the boom receiver tube so that
none of the non-painted surface is
showing
Torque Spec: 100-125
in lbs
1
3
Rear Wheel Installation
4
Hubmount Installation
Tighten hubmount bolts completely. If
the hubmounts cannot rotate on the
kingpin easily, loosen bolts slightly
until they do. Failure to do so can
result in poor steering performance.
2
WARNING: please check the kingpins periodically.
Road vibration will cause them to loosen over time!
5
Idler Wheel Installation
LEFT SIDE
OF TRIKE
Front Idler
Assembly
Rear Idler
Assembly
Front Idler Assembly
Idler Spacers
Idler Spacer
Trike Frame
M8 x90 Bolt
RIGHT SIDE
OF TRIKE
M8 Lock Nut
Idler Wheel
Idler L Bracket
Chain Routing - under both Idlers
Rear Idler Assembly
Idler L Bracket
Chain Routing - over outside Idler
Idler Spacer
Trike Frame
M8 Lock Nut
M8 x90 Bolt
PLEASE NOTE: An Additional M8 washer (illustrated in white) may
be required for proper Idler spacing between “L” bracket and Idler.
IMPORTANT: Drive portion of chain must be routed on
the idlers closest (inside idlers) to the frame; “return”
portion of chain is routed on the outer idlers.
M8 Flat
Washer
Idler Wheel
Chain Routing - under inside Idler
3
6
7
Hubmount
Steering Brace Installation
Tie Rod Installation
Use M8 washers on the under side of the
steering brace tongue. Install between
steering tongue and tie rod end. THERE
ARE NO WASHERS ON 2011 TOURS
Make sure lines on tie rods are attached as
pictured. This will make alignment easier.
“L” Bracket (computer
sensor mount)
4
8
Front Wheel Installation
Apply grease to
axle bolts before
installing!
Install Axle Bolts
Tighten to 325 in lbs
9
Handle Bar Installation
Tighten handlebar
clamp bolts uniformly
Handlebar Adjustment
Your handlebars are adjustable:
1) The Tour II stiffness/ease of steering can be adjusted - you can make your Tour II harder or easier to steer by
adjusting your “steeing brace lock nut.” (number 28 in the technical illustration).
2) Your Tour II handlebars can rotate forward or backward.
If you decide to adjust your Tour II handlebars, follow the below steps:
1) Loosen the 4 clamping bolts that secures your handlebar to the steering brace (number 26 in technical drawing).
2) Rotate handlebars to a comfortable position (you should sit on the trike for this adjustment).
3) Retighten clamp bolts uniformly and securely!
Remember: The handle bars are NOT load bearing elements of the trike and should NOT be used to get in and
out of the trike. Use the seat frame, tops of the tires or derailleur stub tube to enter and exit the trike. THERE IS
A “HOW TO” VIDEO FOR ENTERING AND EXITING THE TRIKE ON THE TERRATRIKE WEBSITE.
5
Brake Caliper Installation
10
Top
Mounted
Caliper
Bottom
Mounted
Caliper
Proper setup: you should see daylight on either side of the rotor with
bolt screws tightened down. See
below image for bolt location and
fastener layout.
Mounting
Bolts
Caliper Bolts
Hubmount
6
M6 washers OR Fender stay
Tire Pressure
Tire pressure is indicated on the side-wall of of each tire.
TIRE PRESSURE SHOULD BE CHECKED BEFORE EACH RIDE.
Front Wheel Alignment
11
Step 1: Make Handlebars Parallel to Outrigger Tubes
Inflate tires to proper PSI before alignment.
Distance = 4 3/4” or 120mm
1. Lock down Steering Brace Lock Nut - This will
prevent the handlebars from moving while
wheel alignment is completed. Loosen nut as
desired when steering setup is complete.
NUT IS ON THE UNDERSIDE OF THE FRAME.
7
Front Wheel Alignment (Cont.)
11
Step 2: Make Right Hand Wheel Parallel To Main Tube (Frame)
Rotate tie rod
to move wheel
8
14 7/8” or 378 mm
Front Wheel Alignment (cont.)
11
Step 3: Align Right Wheel To Left Wheel
Distance = 31 5/8” or 803mm
Rotate the opposite tie
rod to align the second
wheel to the first. Try
not to touch the first
tie rod already aligned.
BE SURE TO LOCK DOWN
BOTH TIE ROD HEX NUTS
AFTER ALIGNMENT.
Remember to loosen
Steering Brace lock
nut to desired resistance
after alignment is
completed.
IMPORTANT: Try to measure
to the center of each tire. Also,
keep the measuring device
level when measuring.
A millimeter of toe-in on the
front wheel is acceptable. This
may improve high speed
handling.
Double check all measurements before riding. Sometimes the
handle bar can move during the process which alters all other
measurements. An improperly aligned trike will wear tires prematurely. This improper setup will not be covered under our warranty.
9
Confirm Derailleur Hanger Alignment & Rear Derailleur Installation
12
Set Rear Derailleur High & Low Stops
13
Grease threads on derailleur before installing!
10
Set Front Derailleur High and Low Stops
14
Pedal Installation (tighten securely!)
15
Grease threads on pedals before installing!
11
Chain Installation and Routing
16
RIGHT SIDE
OF TRIKE
LEFT SIDE
OF TRIKE
Return Chain
Trike Frame
Front Idler Assembly
Return
Chain
Rear Idler Assembly
Drive Chain
Trike Frame
Drive
Chain
LEFT SIDE
OF TRIKE
12
RIGHT SIDE
OF TRIKE
Shifter and Brake Cable Routing
17
LEFT HAND SHIFTER (FOR
FRONT) - Rotate the shifter
so the barrel adjuster faces
backwards.
Left Hand Side of Trike w/Grip Shifter
Right Hand Side of Trike w/Grip Shifter
FOR TRIKES WITH GRIP SHIFTERS - Make FOR TRIKES WITH BAR END (thumb)
sure you route the brake cable behind
SHIFTERS: The brake cable housing
the shifter cables (Illustrated above).
doesn’t need to be routed behind the
shifter cable housing as shown above.
Don’t forget to crimp cable ends on cables. Cable ends have been provided in your trike kit.
13
18
Seat Clamp Installation
Some parts omitted for clarity
Rear of trike
Front of trike
19
Seat Mesh and Seat Installation
Install the seat mesh on the
seat frame. After the mesh
is installed on the seat
frame, tuck the excess strap
back up into the buckles.
Upper seat clamp bolt needs to be tight
enough to allow seat frame mounting
tabs to fit over sliding seat clamp, use
detent ring pins to secure seat stays
together.
14
Tighten seat frame bolts before
tightening seat clamp bolts!
Seating Position Adjustment
Your Tour II’s seat is adjustable on two different planes: fore/aft position at the base and incline/recline
angle of the seat back. Your seating position can adjust anywhere from 40-70 degrees depending on
where the seat clamp is located on the frame.
1) Fore/Aft Seat PositionTo move the base of your seat, loosen the two lower clamping bolts, move the seat, and tighten the
bolts. Your Tour II seat has approximately 6” of total fore/aft movement on the main frame. MAKE
SURE THAT THE SEAT IS CLAMPED SECURELY OR IT WILL ROTATE ON THE MAIN TUBE OF THE
FRAME. THIS CAN LEAD TO LOSS OF CONTROL WHICH CAN RESULT IN SERIOUS INJURY OR
DEATH.
2) Incline/Recline PositionTo adjust the incline/recline position (sitting up-right or laying back), pull the “seat stay pins” (number 3
in technical illustration) from the “seat stays” (number 4 in the technical illustration). You can now adjust
your angle of recline (seat back angle). When you have a seating position you feel comfortable with,
align the holes in the “seat stays” and reinstall your “seat stay pins” MAKE SURE THE HOLES IN THE
SEAT STAYS LINE-UP WHEN YOU REINSTALL YOUR SEAT STAY PINS
2
Seat Bracket
1
20
Rear frame section
Reflector Installation
Rear Reflector on Seat Stay Support
Front reflector on front derailleur
stub tube.
15
Welcome to our growing Family!
First Things First...Please read the information below BEFORE you go riding. It discusses everything
from unpackaging your trike to trike maintenance to riding tips. We want our customers to be safe and
enjoy their trikes for years to come. Thank you for supporting our company, dealers and families by
choosing TerraTrike.
Unpacking
When your TerraTrike arrives, carefully unpack the contents and inspect for any damage that may have
occurred during shipping. Notify your delivery person of ANY damage on the outside of the box. If
anything is amiss, contact the TerraTrike Sales Office immediately at (616) 455-5988. Note: The tires
may have little or no air in them. This is our normal shipping procedure to avoid damage from extreme
altitude fluctuations.
It’s a good idea to flatten and save all boxes and packing materials. You may need them if you ever
need warranty service or want to ship your TerraTrike.
Cautions/Safety
Stop! Make sure to read and understand this manual completely before riding your TerraTrike. We want
to keep you riding safely for endless miles and years to come. So, always follow these safety precautions for each ride:
•Inspect your TerraTrike before each ride. Check the tires for proper pressure and any damage. Ensure
that the brakes are functioning at their full capacity.
•Please remember a helmet is your most important piece of safety equipment. Wear one!
•If you ride at night make sure you have a white headlight visible from a distance of at least 500 feet, and
a red rear taillight.
•Look behind you! We strongly recommend the use of a rear view mirror. Also make sure to turn your
head and look before turning or changing lanes.
•Use caution when cornering. Learn to use safe speeds for negotiating corners and going down hills.
•Lean into turns when cornering at speed. Your TerraTrike can be “rolled” if turned too sharply for a
given speed. Rule of thumb: rubber side down. :)
•The disc brakes and rotors will get very hot after braking. DO NOT touch them.
•Keep your feet securely on the pedals to prevent them from getting caught underneath your TerraTrike.
We recommend clipless pedals or Power Grip pedal straps.
•Brake evenly using both hands. Your TerraTrike is designed with front brakes only. You will experience
brake-steer if you brake only one side.
•Although your TerraTrike is suitable for riding on dirt roads if equipped with more rugged tires, it is not
designed for all-terrain, off-road use, or canyoneering.
•The unique look of your TerraTrike will attract much attention, so you’re more likely to be seen.
•Be sure you are not obstructed from view by other vehicles. Use of a flag is highly recommended.
•Remember, your first line of defense is always your own common sense. Ride as if you are invisible to
motorists.
•Your TerraTrike is strong enough for most riding conditions. That is not a license to ride in a hazardous
or abusive manner! Anyone can damage their TerraTrike if they try hard enough. Use common sense.
•Take care of yourself. We like our customers, and we want to keep them around.
Riding Tips
Shifting: Simply twist the shifter up or down to find the desired gear. Sturmey Archer (internally geared)
hubs should be shifted when you ARE NOT pedalling. External drive trains (derailleur systems) require
pedaling while shifting.
16
•Steering: All of the steering parts tend to settle in after the first 100 miles or so. This may require some
tightening of nuts and bolts. •Cleaning: Your TerraTrike will operate for years to come if you keep it regularly cleaned and lubed! Water and soap won’t hurt your TerraTrike, provided you dry and lubricate right after cleaning. If you need
to wash the seat mesh, remove it from the seat frame, wash it in the gentle cycle and let it air dry. If you
ride in inclement weather, immediately clean and lube your TerraTrike after your ride. Road salt, over
time, will cause significant damage to your TerraTrike. Clean it off immediately! Likewise, salty air will
corrode your TerraTrike. It’s a good idea to wax the frame occasionally with a good quality car wax. We
do use stainless steel nuts and bolts.
17
18
11
27
22
25
27
33
11
27
26
24
27
22
29
31
30
32
Tour II Technical Illustration
&
Parts List
Part Number
Tour II Parts Description
Quantity
1
Seat End Cap
2
2
M5x30 Bolt
2
3
Seat Stay Pin
2
4
M5 Lock Nut
2
5
Seat Stay, Upper
2
6
Seat Stay, Lower
2
7
M5 Flat Washers
4
8
M5x12 Bolt SHCS
2
9
Rear Idler Assembly - see pg. 3 for part names
-
10
M8x30 Bolt
4
11
M8 Flat Washer
10
12
Tie Rod End (left hand)
2
13
M8 Hex Nut (left hand)
2
14
Tie Rod
2
15
M8 Nyloc Nut
10
16
M8 Hex Nut (right hand)
2
17
Tie Rod End (right hand)
2
18
Axle Bolt (Socket Plug)
2
19
Wheel Bearing, 20mm (Pressed into hub)
6
20
Wheel hub, (20mm) Front
2
21
Hubmount (1 right hand, 1 left hand)
22
M8x16 BHCS
4
23
“L” Bracket
4
24
Handle Bar
1
25
Seat Frame
1
26
Steering Brace Clamp
1
27
Bushings, 12mm
6
28
Steering Brace Nyloc Nut
1
29
M5x12 BHCS
2
30
Front Idler Assembly - See pg 3 for part names
-
31
Boom
1
32
M8x40 SHCS
1
33
Steering Brace
1
1 Set
19
20
2
1
3
Seat Clamp
Technical Drawing
4
M8 Lock Nut
Seat Clamp Shims
Seat Clamp (Left Side)
M8 Flat Washer
M8x40 Socket Head Cap Screw
2
3
4
5
6
Sportster Seat Clamp Part Description
Seat Clamp (Right Side)
1
Part Number
5
6
3
3
1
2
3
1
Quantity
Boom Lengths
18”
Long Boom
Boom Size
X-seam Range
Short
36” - 42”
Medium
38” - 44”
Long
40” - 46”
Boom Size
Boom Size
Short
14”
Medium
16”
Long
18”
Boom Size
Chain Length
Short
138”
Medium
142”
Long
146”
16”
Medium Boom
14”
Short Boom
Chain Length includes
master link.
Range of fore/aft seat movement: approx. 6”
21
COMPANY INFORMATION:
TerraTrike (WizWheelz Inc.)
4460 40th. St SE
Grand Rapids, MI 49512
USA
Email:
sales@terratrike.com - for Ordering & Customer Service
tech@terratrike.com - for Technical Assistance
shipping@terratrike.com - for Shipping Inquiries
Phone:
1-800-945-9910 or 1-616-455-5988
Fax:
1-616-455-6058
RESOURCES:
∙TerraTrike Forum - http://www.terratrike.com/forum/
∙TerraTrike Blog - http://terratrike.com/blog/
∙TerraTrike Facebook Page - http://www.facebook.com/terratrike
∙TerraTrike Twitter Page - http://www.twitter.com/terratrike
∙TerraTrike Youtube Channel - http://www.youtube.com/wizwheelzterratrike
∙TerraTrike Owners Group -http://sports.groups.yahoo.com/group/wwog/
∙Bentrider Online (BROL) - http://www.bentrideronline.com/
∙Recumbent Journal - http://www.recumbentjournal.com/
WARRANTY REGISTRATION:
Register your trike online at: http://www.terratrike.com/register.php
or
Call us to register your trike - 1-800-945-9910
22
WARRANTY
WizWheelz warrants to the original owner that all its trike frames, seat frames, and steering components are
free of defective materials and workmanship subject to the limitations contained in this warranty. This warranty
is limited to the lifetime of the original owner and is nontransferable. Warranty is conditioned upon the trike
being purchased through and assembled by WizWheelz or an authorized WizWheelz dealer, operated under
normal conditions, and maintained properly. Warranty does not apply to paint/finish, components attached to
the frame, or wear items such as tires, idler wheels, chain, etc. Attached components are subject to the
warranty, if any, of their original manufacturer.
Warranty claims must be presented to the place where the product was purchased whether that is an
authorized WizWheelz dealer or the WizWheelz factory. Proof of purchase must accompany all requests for
warranty coverage. WizWheelz reserves the sole discretion to repair or replace any parts covered by this
warranty. Replacement parts may be a newer version than those originally purchased. In the event that a
model has been discontinued or changed significantly, or if the part in question is no longer available for any
reason, some additional parts may need to be purchased by the customer in order to make the trike rideable
again due to compatibility issues. Original owner shall be responsible for all labor, shipping, and travel costs
related to repair or replacement of warranted parts.
This warranty does not apply to normal wear and tear, or any defects, malfunctions, or failures that result from
abuse, neglect, improper assembly, improper maintenance, overloading past specified load limit, alterations
(i.e. cutting, spreading, drilling, welding, etc.), collisions, accidents, or misuse.
WizWheelz shall not be liable for any special, indirect consequential, incidental or other similar damages
suffered by the purchaser or any third party, including, without limitation, damages for loss of profits or
business or damages resulting from use or performance of the product, whether in contract or in tort, even if
WizWheelz or its authorized representative has been advised of the possibility of such damages and
WizWheelz shall not be liable for any expenses, claims, or suits arising out of or relating to any of the
foregoing.
If you feel you have a warranty claim, contact us. We love our customers, and we want to keep you riding.
LIABILITY WAIVER
Riding a bike or trike can result in injury or death. By riding a WizWheelz trike, the rider is expressly assuming
the risk for any injury that may result from same.
The owner is responsible for any and all injuries and/or property damages caused by the owner or another
riding the owner's trike or any use of an accessory manufactured by, distributed, or sold by WizWheelz, Inc.
The owner of a TerraTrike (also known as a WizWheelz) or any related accessory shall indemnify WizWheelz
for any damage or financial loss incurred by WizWheelz as the result of an injury or property damage caused
by any use of the TerraTrike or accessory.
CHOICE OF LAW
Any person or entity that uses or utilizes any trike, accessory, equipment, tools, or other item that is
manufactured, distributed, or sold by WizWheelz, Inc. irrevocably and unconditionally agrees that he, she, or it
will not bring any action, litigation, or proceeding against any other party in any way arising from or relating to
said item in any forum other than the courts of the state of Michigan sitting in Kent County and any applicable
Michigan appellate court. Said person or entity irrevocably and unconditionally submits to the exclusive
jurisdiction of those courts and agrees to bring any such action, litigation, or proceeding only in those courts.
All terms, conditions, dispute, claim, action, litigation, contract term, etc. relating to any trike, accessory,
equipment, tools, or other item that is manufactured, distributed, or sold by WizWheelz, Inc. and all matters
arising out of or relating to the aforementioned will be governed by, and construed in accordance with, the laws
of the state of Michigan, United States of America, without regard to its conflict of laws provisions to the extent
that those principles or rules would require or permit the application of the laws of any jurisdiction other than
those of the state of Michigan. A rider or owner of a TerraTrike and/or the owner of any accessories thereto,
agrees that the United Nations Convention on Contracts for the International Sale of Goods does not apply.