Read Microsoft Word - Intrepid Tourer Owners Manual v 2 2008.doc text version

Intrepid Tourer

The Owner's Manual

Read me before you ride And save me for future reference



Do not operate this equipment without first reading and understanding this manual. If you are unable to understand the warnings, cautions, and instructions contact Intrepid Equipment at (800) 693-5082 or [email protected] before attempting to ride this equipment, otherwise injury or damage may result.

Congratulations on your new handcycle!

You want to get on the road. We want you to get on the road too. But read through this manual before riding to make sure you stay safe, and have the best time possible.

Important Safety Information

Handcycling is an inherently dangerous activity. Going fast will increase this risk. When you handcycle you assume this risk. Be safe, be smart, and always ride in control. Always handcycle wearing a helmet. Always have your orange safety flag attached at the back. At night always use your bike lights. Use extreme caution when getting in and out of the handcycle. Make sure that the handcycle is secure before attempting to get into the handcycle and that you are transferring from a stable location.


As a handcyclist, you are subject to the same traffic rules as bicyclists. Give pedestrians the right of way, use proper hand signals and extreme caution when cycling with other vehicles. If reflectors and lights are required for bicycles you must have them as well. Should you have special health needs, consult with your qualified medical professional before using this handcycle.


Assembly Instructions

You will have noted that your cycle came in two boxes, here's how to put your cycle together.

Follow these instructions carefully. Failure to follow these instructions could result in injury or damage to the handcycle.

First check that you have received all the parts for your handcycle. You should have: Assembled Front Half of Bike Rear Frame Three Wheels Left and Right Hand Cranks Seat Back Cushion Seat Base Cushion Foot Rest Straps (should be attached to footrests) Tool Kit(5mm allen, 6mm allen, 7/32" allen, 9/16" wrench) Coupler Wrench (note only with purchase of SNS coupler) Please note, when you remove your bike from the box, do so on a soft surface so as not to damage the paint.

You Will Need:

Various sizes of allen wrenches(included) High quality grease to lubricate various parts (as instructed). We recommend synthetic lithium grease, however any high quality grease will do. This should be readily available at any automotive or bicycle shop. If your bike is properly lubricated at assembly you should be able to go a year or so without lubricating the bike again. SNS coupler only: you will need to obtain Teflon Bearing Grease (note this is not the same as regular grease). We will have pre-lubricated the thread before shipment so you will not need to worry about this at the point of first assembly, but you should have Teflon Grease on hand in order to maintain the high tension necessary for the coupler and plan on lubricating as needed. Teflon bearing grease is special grease and cannot be substituted with ordinary grease. It is available through Intrepid Equipment; directly from Dupont; and other frame builders who use SNS couplers.

Attaching the wheels and seat

You will need: 6mm Allen wrench; 5mm Allen wrench. You will be working with the rear portion of the bike. 4

First install the rear wheels by removing the rubber plug from the hub and securely tightening the hub nut with a 6mm Allen wrench. Replace the rubber plug to protect the hub from dirt and grit build up.

Pull the seat back upright from its flat packed position, and insert its telescoping support tubes. Then secure the telescoping support tubes by tightening the clamp with a 5mm allen wrench.

Headset Assembly

Next you will need to assemble the headset. If your handcycle is equipped with the optional SNS coupler, then skip the headset installation since it is preinstalled for you. If your handcycle has the SNS coupler installed, then skip ahead to the SNS coupler installation instructions. To install the headset, remove the collar and first four pieces of the headset from the steerer. Ensure that the crown race, dust cover and lower bearing race are in their correct positions at the base of the steerer.

Lubricate the lower bearing race with synthetic lithium (or other high quality) grease.


Insert the steerer tube (front half) into the head tube (rear half).

Engage and tighten the nut that secures the rubber centering spring.

Insert the upper bearing race, dust cover, upper bearing seat and compression ring on to the steerer in that order (same order that they were removed).

Then slip the collar over the steerer and thread the compression bolt and head cap into the star-nut in the center of the steerer tube.

Tighten down the compression nut with a 5mm allen wrench with enough force to preload the bearings. This should require approximately 4Nm (35in lbs) of


torque. The rubber centering mount will compress slightly during tightening. Insufficient preload force will result in a loose headset and too much force will cause the bearings to bind. Either condition will cause premature bearing wear. Finally securely tighten the binding clamp on the steering collar to lock in the preload. It is essential that the steering collar is securely tightened to at least 7Nm (60in lbs) and can not slip. If it does slip it could result in damage to the handcycle and severe injury.

This completes the headset assembly

Attaching the SNS coupler

You Will Need: Coupler Wrench(included) The thread will be pre-lubricated with Teflon Bearing Grease. You should have some grease on hand, however, for future use when the thread becomes dry. Please note: Teflon bearing grease is special grease and cannot be substituted with ordinary grease. It is available through Intrepid Equipment; directly from Dupont; and from other frame builders who use SNS couplers. One tube should last you a long time. The grease is very important since it will allow you to tighten the coupler sufficiently. Hold the front and rear halves of the handcycle together so that the main tube is lined up straight and the head tube is oriented vertically when viewed from the front of the hand cycle. At this point the teeth in the coupler should mate up. Grasp the coupler nut with your hand and get it started by turning it clockwise.


Using the coupler wrench tighten the coupler nut as much as possible. It is not possible to over-tighten the coupler using the 6in wrench with your hands (no extension bars) so it is preferable to get it tighter than the minimum torque. The nut should be tightened to a MINIMUM of 20 Nm (35 ft lbs). This corresponds to a minimum of 32 kg or 70lbs to the end of the 6in coupler wrench. This is very important since if the coupler is able to move it will wear which will change its geometry and cause it to loosen. This is an extremely dangerous condition. If you notice that your coupler has become worn, then contact Intrepid Equipment immediately for repair.

Attaching the secondary brake lever

The secondary brake lever which is hanging from a cable and attached to an aluminum stub, must be inserted into the front hole of either of the two side rails that form the seat. Make sure that the lever is securely located and securely tighten the clamp with a 5mm allen wrench.

Installing the hand grips

After you have unpacked your handgrips which come mounted on crank spindles, you are ready to attach them to the Crank arms. Notice that the black threaded portion of one of the spindles has a groove, and one does not. The one with a groove is the left-hand grip and the one without a groove is the right-hand grip. The spindles thread into the holes on the crank arms. NOTE: The lefthand grip spindle is REVERSE threaded. Using a 6mm Allen, tighten counterclockwise as shown. The right-hand grip is not reverse threaded, tighten it clockwise.

This completes the assembly.


Getting Ready to Ride

Important preliminary information about your handcycle


Proper Fit of the Handcycle

Adjust the seat back, footrests, and hand cranks so that you are comfortably seated in the handcycle. o You MUST be able to see over the hand cranks o Your legs should be comfortable and secure in the footrests.

When you adjust the hand cranks you can adjust them in a vertical or horizontal direction. To adjust the hand cranks vertically, loosen the clamp on the primary brake lever with a 5mm allen wrench (It is the one in front of you below the shifters), and loosen the 7 speed shifter with a 2.5 mm allen wrench. This will allow the tube on which it is mounted to telescope. Never have them adjusted so that they impede your view of the road. Then securely tighten the clamp on the brake lever and the shifter to lock it in position. To adjust the hand cranks horizontally, you will need to loosen the clamp connecting the cranks to the front upper fork with a 5mm allen wrench. This allows the tubes to telescope. Adjust the cranks to your preferred position and tighten the clamp. IMPORTANT: If you adjusted this by a significant amount you may need to either add or remove some links from the chain.


To add or remove links from the chain you will need a special chain tool. This can easily be done by your local bike shop.


Before You Ride

Make sure that the handcycle is in proper working order before you ride. This includes the brakes, cranks, wheels, shifters, and all other moving OR non-moving parts of the cycle. o ALWAYS keep your fingers away from the chain while pedaling o NEVER let children play around the hand crank or chain. Injury may result. ALWAYS Wear a helmet. It is also advisable to ride with a safety flag and bike lights attached to your handcycle. The user is responsible for proper upkeep and maintaining the handcycle in working condition. The manufacturer is not responsible for failure, damage, or injury caused by improper operation or maintenance by the end-user. DO NOT attempt to lift the handcycle by any removable (detachable) parts. Lifting by means of any removable (detachable) parts of the handcycle may result in injury to the user or damage to the handcycle. o DO NOT stand on the handcycle o DO NOT carry any other riders o DO NOT carry items that might obstruct your view. o DO NOT attempt to ride over curbs or obstacles or speed bumps. Doing so may cause your handcycle to bottom out and/or turn over and cause bodily harm or damage to the handcycle.

Upholstery must be inspected before each use. Exposure to moisture will damage fabric, fastening, and straps. DO NOT operate the handcycle if the upholstery is wet or damaged, otherwise severe injury may occur.


Weight Limitation Tire Pressure

The weight limitation on the Intrepid Tourer is 250 lbs.

Check the tire pressure each time you ride. Use a pressure gauge and inflate the tires to the pressure specified for the tires installed on your handcycle. This pressure can be found printed on the wall of the handcycle tire. DO NOT use your handcycle unless it has the proper tire pressure (p.s.i.).


DO NOT overinflate the tires. Failure to follow these suggestions may cause the tire to explode and cause bodily harm. DO NOT ride on flat or underinflated tires. Riding on flat or underinflated tires can cause injury, as well as damage to the tire, tube and handcycle.

Getting Into Your Handcycle

Transferring should be done with extreme caution. Position the handcycle on level ground and as close as possible to the object you are transferring into or out of. The object you are transferring into or out of MUST also be secured before attempting any transfer.

o Before attempting to transfer in or out of the handcycle, every precaution should be taken to reduce the gap distance. Position the Tourer on level ground and as close as possible to the object you are transferring into or out of. The object you are transferring into or out of MUST also be secured before attempting any transfer. You MUST engage the secondary brake (at the side of the seat) using the provided loop before transferring into the handcycle. The handcycle MUST be positioned securely against a stable object before any transfer is attempted.

o o

o o

You may do this on your own if you have sufficient mobility and strength. If you do not, always seek assistance. To determine and establish your particular safety limits, practice transferring in the presence of a qualified health care professional before attempting active use of the handcycle.


Riding Your Handcycle

You are in the cycle, now what you've really been waiting for...


Going Forward

When the cranks are above their center line push them away from you, and when they are below the center line pull them towards your body. Be aware of the location of your brake lever in front of you, and always ride so that you can engage the brakes quickly in case you need to stop. Also be aware of the secondary brake attached to the seat rail (see the diagram below)



The upper shifter operates the derailleur at the crank set. The lower shifter operates the derailleur at the 7 speed cassette. Twist each shifter while pedaling to engage the desired gear combination. It might be necessary to shift to an easier gear in anticipation of a change in gradient of the riding surface. This way the risk of stalling on an incline is minimized. In the event that you are unable to shift in time for a hill and stall on the hill, apply the brake and check for traffic, pedestrians and other cyclists, then grasp the rear wheels with one hand and push down. This will allow you to shift into a low gear and continue riding.




Do not try to corner at high speeds as this could result in a fall causing injury or damage to the handcycle.

To turn your handcycle while you are moving forward, push the cranks sideways in the direction in which you wish to turn. For example: if you wish to turn to the left push the cranks sideways to the left. Some find it easier to turn while the hand cranks are in their up most position. Be aware that the handcycle might tip over while cornering. To minimize this risk always ride cautiously, and if you are able, shift your weight to the side in which direction you wish to turn. At first do not attempt to peddle and corner at the same time. After some practice, you should be able to both turn and peddle simultaneously. Be aware that this handcycle has a wide turning radius. Take this into account when maneuvering the handcycle.


Backing Up

Reach behind you with one hand and pull on the rear wheels. Keep the other hand ready on the brake lever in case you need to stop. Make sure that the path behind you is clear and safe. Be aware that the hand cranks will always rotate backwards while the handcycle is going backwards. Keep your body and all other objects clear of the hand cranks to avoid damage or injury.



Your Intrepid Tourer handcycle is equipped with two separate brakes: A disc brake and a caliper rim brake. The lever for the disc brake is located next to the shifters directly in front of you. The location of the other brake lever that operates the caliper rim brake is on the seat rail. Make your self familiar with both brake levers and practice using them. Allow plenty of time to stop under all circumstances, but especially in wet conditions. The efficiency of both brakes, but especially the rim brake will deteriorate in wet conditions. Take this into account when riding.


Maintaining your handcycle

Before riding your handcycle make sure that all nuts and bolts and screws are tight. Check all parts for damage or wear and replace as necessary. Check all parts for proper adjustment. Check frame and footrests for damage, dents and cracks before you ride. If damage is found do not ride the cycle. Call Intrepid Equipment for repair. Check brake cables and shifter cables for proper adjustment and operation. Ensure that quick release axles are kept free of dirt and lint to ensure that they engage and lock positively with the frame. Lubricate your chain, quick release axles, and derailleur with Teflon based dry lubricant once a week. Check your tire pressure. The correct tire pressure is printed on the wall of your tires. Check your tires for damage, cracks, and wear and replace if necessary. Regularly check your front and rear wheels for loose or broken spokes. If loose have them aligned at you local bike shop. If broken call Intrepid Equipment for correct spoke length information or replacement spokes. Check the rubber centering compensator, for cracks and damage and replace if necessary. Check the alignment of the front wheel. If it wobbles excessively, have it aligned at a local bike shop. If you have any questions about maintenance, customer service is available M-F 9-5 Pacific Standard Time. Please call (800) 693-5082 or email [email protected] We will be glad to assist you.

Parts and service

Intrepid Equipment keeps a complete stock of reasonably priced spare parts available for immediate shipment. Many of the parts used on your handcycle are standard bicycle components and are also available from your local bike shop.



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Microsoft Word - Intrepid Tourer Owners Manual v 2 2008.doc