AmTryke Adult Recumbent Model JT2000 #50-FC-2000 TOOLS Needed for Assembly 5 mm Allen Wrench 8 mm Socket or Wrench 10 mm Socket or Wrench 14 mm Socket or Wrench 15 mm Socket or Wrench 22 mm Socket or Adjustable Wrench Needle Nose Pliers W/ Side Cutters Phillips Screw Driver Revise Date: 8/06/09 1 of 29
Table of Contents Rear Deck Assembly Page 3 Front Tire Installation Page 5 Attaching Rear Deck to Main Frame Page 6 Leg Supports Page 7 Main Steering Installation Page 8 Attaching Seat Frame to Main Frame Page 10 Attaching Seat Cover Page 12 Front Reflector Page 13 Front Brake Page 14 Cable Retainer Page 16 Wheel Reflectors Page 18 Maintenance Page 19 Revise Date: 8/06/09 2 of 29
Rear Deck Assembly 6) Remove the 22mm nuts & flat washers from both ends of axle, slide wheel over each side, pay attention to tire directional arrow. 2) Slide flat washer over each side and then thread a 22mm nut on each side. Tighten using a 22mm socket or adjustable wrench, do not over tighten as wheel bearing we be damaged. 3) Install black round caps on each side, lightly tap to secure in place. Revise Date: 8/06/09 3 of 29
4) Install red reflector on bracket for rear deck using Phillips screw driver, bracket will have B-2 stamped on it. B 2 stamped Clamping Screw 5) Using Phillips head screw driver remove clamping screw from bracket, open clamp and install on rear, thread clamping screw and tighten. 6) Install seat support bracket to rear deck using two 5mm Allen bolts & nuts. Use a 10mm Socket or Wrench & a 5 mm Allen Wrench to tighten. Revise Date: 8/06/09 4 of 29
Front Tire Installation 1) Remove two black plastic thread protectors located on each end of axle. 2) Using the thin black quick release axle, remove the thumb nut from one side and one spring. 3) Place front tire in front fork. 4) Slide shaft of quick release axle through center of rim. 5) Install spring on other side with narrow end pointing inwards, thread thumb nut back on and tighten. Revise Date: 8/06/09 5 of 29
Attaching Rear Deck to Main Frame 1) Slide rear deck into main frame. 2) Using four large lag bolts, 4 large flat washers and four large nuts attach rear deck to main frame, use a 15mm socket or wrench to tighten nuts. Do not tighten up completely at this point. Upper Support Allen Bolt Rear Deck Main Frame 3) Install chain from main hub to rear axle sprocket. Rear Axle Sprocket Master Link Main Hub 4) Using a pair of needle nose pliers snap the master link in place. 5) Pull back on the rear deck to tighten the chain, while pulling back tighten the four 15mm nuts using a 15mm socket or wrench. 6) Install two upper support Allen bolts, washers and nuts using a 5mm Allen wrench & 13mm wrench. There is one on each side of the rear deck. Revise Date: 8/06/09 6 of 29
Leg Supports 1) The leg supports are already installed. Due to constraints in packaging you will need to position them. 2) First, remove the tube from the right leg support. Pivot the leg so it is 90 degrees to the main frame of the tricycle. Replace the tube. 3) Rotate the left side leg support to a similar position. 4) Don t tighten until final set-up. Pivot Downward Initial Appearance Remove Tube Insert Tube Tighten Main Steering Installation 1) Slide the hand crank steering tube over the steering stem of the main frame, note location of chain guides before installing. Inside chain guide fits underneath bolt for tightening steering tube to stem. Outside chain is just above holes in leg support bracket. Revise Date: 8/06/09 7 of 29
Steering Stem Chain guides location Chain Guide 2) Pivot leg support bracket so the hole in support bracket aligns with hole in main steering tube. Leg Support Bracket Hole aligned Hole not aligned 3) Thread the 1 5mm Allen head bolt with flat washer through the center steering stem hole. 4) Insert 6mm 3 ½ bolt through the support bracket and through the main steering tube and out the other side, install one flat washer and thread 13mm nut, tighten using 13mm socket or wrench and 6mm Allen wrench Revise Date: 8/06/09 8 of 29
13mm nut with flat washer. Tighten 5) Install handgrips, shift/rear brake goes on the right side, while the front hand brake is positioned on the left, the right side threads in clockwise while the left side threads in counter clockwise. 6) Install the steering linkage; remove the two nuts and flat washers already installed. 7) Using a 5mm Allen wrench thread the screw through the steering stem attachment, slide one flat washer over the exposed thread and thread the 13mm nut, tighten. Stem attachment Steering Stem 13mm nut and flat washer Steering Linkage 13mm nut and flat washer 8) Slide flat washer over front screw and thread 13mm nut, use a 5mm Allen wrench and 13mm wrench or socket to tighten. 9) Once installed, adjust steering by turning black tube adjustment rod until satisfied tryke is positioned to steer straight ahead. Attach Seat Frame to Main Frame Revise Date: 8/06/09 9 of 29
1) Place main seat frame mounting bracket over main frame so that one hole in the seat bracket aligns with a hole in main frame. Remove thumb nut from silver cam lock lever and insert shaft through seat bracket and through main frame, thread thumb nut on and lock down lever. Seat Frame Bracket Main Frame Quick release with cam lock lever inserted through frame. 2) Install two short seat supports on back of main seat frame using two long shafted Allen bolts, two flat washers and two nuts. Tighten using a 10mm wrench or socket and 5mm Allen wrench. Seat Frame Short support mounts 10mm nut and 5mm Allen bolt Revise Date: 8/06/09 10 of 29
3) Slide long support bars inside of short support bars, align holes in each and insert in each one a clevis pin W/snap ring. Seat Support Bars. Clevis pin with snap ring NOTE: The angle of the seat is determined by adjusting the height of the support bars, the lower the adjust the greater the angle. By moving the main seat frame forward or backward to other holes in the main frame will either decrease or increase the arm/leg travel for either taller or shorter riders. Revise Date: 8/06/09 11 of 29
Attaching the Seat Cover 1) Along one edge of the seat cover are straps and the other edge are buckles. On the other two edges are pockets to slide the seat cover over the main seat frame. 2) Slide the seat cover over the main seat frame. Pocket in seat cover Main seat frame 3) Lace the straps through the buckles then tighten the straps by pulling them. The cover will conform to the seat frame. Lace strap through buckle as shown above. Pull on excess strap to tighten. Finished seat cover should look like this one. Revise Date: 8/06/09 12 of 29
1) Attach reflector to bracket, use Phillips head screw. Front Reflector Phillips head screw Bracket Reflector 2) Remove clamp screw, open clamp and place over steering stem tube. Clamp Screw Steering stem tube Reflector bracket Front Brake Revise Date: 8/06/09 13 of 29
V-Style Brakes If not already assembled, take the brake noodle from the parts box and slide the cable through the larger opening. The cable housing will then seat into the end of the noodle. Slide the cable through the cable lead on the end of the left brake boot arm; this will cause the noodle to fit into the lead. Slip the brake cable boot over the cable and position it between both brake arms. Next loosen the 5mm anchor bolt at the end of the right brake arm and slide the cable under the retaining washer. Pull the slack out of the cable making sure a distance of 39mm or more remains between the end of the lead and the start of the anchor bolt. Once the cable is secured to the brake arms, engage the brake lever several times, checking the position of the brake shoes at the rim. The brake shoes should be 1mm away from the rim when in a relaxed position. When the brake lever is engaged, the brake shoe should hit the rim flush (never the tire) with the front brake pad touching the rim slightly before the rear. This is called toeing-in your brake shoe. If this position is not achieved, adjustments to the brake shoe are required. Loosen the brake shoe hardware and reposition the brake shoe. It may take several shoe and cable adjustments before the required position is accomplished. V-Brake 1. If fitted with V-Brakes, insert the brake body into the center spring hole in the frame mounting boss, and then secure the brake body to the frame with the link fixing bolt. 2. While holding the shoe against the rim, adjust the amount of shoe protrusion by interchanging the position of the B washers (i.e. 6 mm and 3 mm) so that dimension A is kept at 39 mm or more. Revise 3. While Date: holding 8/06/09 the shoe against the rim, 5. Adjust the balance with the spring tension adjustment 14 of 29 tighten the shoe fixing nut. screws.
4. Pass the inner cable through the inner cable lead. Set the cable with the clearance of 1mm between each brake pad and the rim, tighten the cable fixing bolt. 6. Depress the brake lever about 10 times as far as the grip to check that everything is operating correctly and that the shoe clearance is correct before using the brakes. Cable Retainer Revise Date: 8/06/09 15 of 29
1) Remove the Phillips head screw located on the steering stem tube. Phillips head screw on steering stem tube. 2) Put screw through lower eyelet of cable retainer and thread back into steering stem tube. Phillips head screw through lower eyelet of cable retainer. 3) Attach the cable retainer to upper chain guard bracket using a zip tie. Clip off excess zip tie. Cable retainer attached to upper chain guard bracket with zip tie. Revise Date: 8/06/09 16 of 29
4) Use a zip tie to attach the three cables to the retainer; this will prevent the cable from wrapping around the hand grips during pedaling. 5) Use the remaining zip ties and secure the cable to the steering stem tube. Gear shift cable and rear brake cable. Cable retainer secured to steering stem tube with screw. Rear brake, Front brake and Gear shift cables attached to the cable retainer with zip tie. Cable retainer attached to upper chain guard bracket with zip tie. Revise Date: 8/06/09 17 of 29
Wheel Reflectors 1) Place the reflector in an area on the rim behind a single spoke with two on the opposite side. Align the front spoke with the slot in the reflector. Reflector Reflector holding pin Single spoke 2) Insert the reflector holding pin with the slotted end going over the spoke into the hole in the reflector. Press firmly until you hear it click into place. Revise Date: 8/06/09 18 of 29
Maintenance As is with all other bikes and vehicles that use a chain for the drive line, the chain may come off the sprocket and need to be reinstalled. This next section will serve as a guide on how to reinstall the chain should it come off. 1) Remove the Phillips head screw on the front of the chain guard and the 8mm nut located behind it that secures the two halves of the chain guard together and holds the upper chain guard bracket in place. Remove Phillips head screw and 8mm nut located behind it. (not shown the 8mm nut) 2) The outer chain guard cover will easily remove by lifting up on it; let it rest on the hand grip. Outer chain guard cover removed chain and sprocket now exposed Revise Date: 8/06/09 19 of 29
3) Remove the outer chain from the lower outer pulley slot located at the base of the steering stem tube. Outer pulley at base of steering tube. 4) Use a screwdriver to lift the chain up in the front and turn the hand crank counter clockwise while doing so until it grabs the chain and pulls it outwards. Insert screw driver here and lift up on chain. Revise Date: 8/06/09 20 of 29
5) Place chain on front side of sprocket and rotate crank arm counter clockwise until chain is on sprocket completely. Front of Sprocket 6) Repeat steps 1, 2 & 3 in reverse to finish reinstalling the chain. Revise Date: 8/06/09 21 of 29
Seating Assembly Main Seat Frame (pages 10 to 12) Seat cover (Pages 10 to 12) Quick Release Seat support rods (Pages 10 to 12) Long support rod Allen bolts Clevis Pins Short support rods Short support rod Allen bolts Long support rods Seat mounting hardware (Pages 10 to 12) Revise Date: 8/06/09 22 of 29
Front Tire Front tire and quick release axle (Page 5) Quick release axle Revise Date: 8/06/09 23 of 29
Rear Deck Assembly Rear deck and mounting hardware (Pages 3 to 6) Rear deck frame Black round nut caps (page 3) Chain and master link (Page 6) Rear deck frame to main frame mounting hardware (Page 6) Revise Date: 8/06/09 24 of 29
Rear Tires Right and Left rear tires (Page 3) Tire direction must be followed Revise Date: 8/06/09 25 of 29
Main Frame Main frame (Pages 6 to 10) Hand cranks Seat position holes Main Steering Tube Front Fork Main hub Leg Supports Revise Date: 8/06/09 26 of 29
Hardware Leg support bolt, washers and nut (Page 9) Center steering stem bolt and washer (Page 8) Upper support Allen bolts, washers and nuts (Page 6) Brake noodle and cable cover (Pages 14 to 15) Cable Retainer (Pages 16 to 17) Revise Date: 8/06/09 27 of 29
Steering Linkage Steering Linkage (Page 9) Revise Date: 8/06/09 28 of 29
Reflectors Rear reflector and bracket (Page 4) Front reflector and bracket (Page 13) Wheel reflectors and spoke securing pins (Page 18) Revise Date: 8/06/09 29 of 29