DUTCH_instruc_man_GAKS2_2.9Uk.pdf

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Version
GAKS2_2.9UK
KS2 Recumbent Kit
This kit was designed and produced with great care. To turn it into a great
recumbent you will have to finish it with care and attention. Bad work here
can only lead to an unpleasant, noisy and wobbly bike that will bring you
little pleasure. So please give this project the attention and effort it
deserves. Finish all details careful and mount everything rattle-free. This
way you will make sure that you will have many enjoyable rides on you
Dutch Speed Bicycle. Good luck!
Version ......................................................................................................................... 2
Pictures ........................................................................................................................ 2
Important ! ....................................................................................................................2
Assumptions..................................................................................................................... 2
Skills ............................................................................................................................. 2
Left and right ................................................................................................................ 2
Front and rear .............................................................................................................. 2
Sizes ............................................................................................................................ 2
What is essential in the donor bike? ............................................................................ 2
Other requirements ...................................................................................................... 3
Recognising the type of Crankshaft ............................................................................. 3
What you will need: .......................................................................................................... 3
General tools ................................................................................................................ 3
Bicycle tools ................................................................................................................. 3
Very useful: .................................................................................................................. 4
You must buy ............................................................................................................... 4
Now for the real thing ....................................................................................................... 4
And now we start sawing ................................................................................................. 4
Rear frame ................................................................................................................... 4
Adjusting the crank shaft.............................................................................................. 4
Fitting the rear frame.................................................................................................... 4
The hole for the spring ................................................................................................. 5
Painting the rear frame................................................................................................. 5
The Seat.......................................................................................................................5
Sawing .........................................................................................................................5
Mounting the seat......................................................................................................... 6
Seat angle .................................................................................................................... 6
Sanding and painting ................................................................................................... 6
The foam seat cover .................................................................................................... 6
Fixing the foam............................................................................................................. 6
Mounting the headset................................................................................................... 7
The Fork .......................................................................................................................7
The crankshaft unit........................................................................................................... 7
Painting the crankshaft................................................................................................. 7
The supports ................................................................................................................ 7
The snap-off points ...................................................................................................... 7
Polishing....................................................................................................................... 8
Mounting the crankshaft unit ........................................................................................ 8
Mounting the gearing support (optional) ...................................................................... 8
Adjusting the crankshaft unit ........................................................................................ 9
The spring .................................................................................................................... 9
The suspension vibration isolator................................................................................. 9
Mounting the rear frame ................................................................................................. 10
Adjusting the vibration isolator ................................................................................... 10
The other side of the spring. ...................................................................................... 10
Before we go on ............................................................................................................. 10
The chain rolls ............................................................................................................ 10
Chain ..........................................................................................................................10
The chain tube ........................................................................................................... 10
Making an oblique entry cone (front ends)................................................................. 11
Mounting the lower tube............................................................................................. 11
Mounting the upper tube ............................................................................................ 11
The Handle bar. ......................................................................................................... 11
The handle bar conversion unit (improved “JOS” version)......................................... 12
The V-brake ............................................................................................................... 12
Caps ...........................................................................................................................12
Cables ........................................................................................................................ 12
Aligning the rear wheel............................................................................................... 13
Driving ............................................................................................................................ 13
Tips for beginners ...................................................................................................... 13
Changes ......................................................................................................................... 13
Alterations to the last version are in italic............................................................... 13
FAQ ................................................................................................................................ 13
Story ............................................................................................................................... 13
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Copyright Dutch Speed Bicycles
www.dutchbikes.nl
Version
GAKS2_2.9UK
KS2 Recumbent Kit
This instruction manual is intended for the Dutch Speed Bicycle KS2
recumbent kit
Version
This is version see above of the instruction manual for the KS2 recumbent kit.
Alterations to the last version are in italic
(Deze gebruiksaanwijzing is er ook in het Nederlands zie onze website.)
Pictures
Some details shown in the pictures may be different form what is supplied or
from what is shown on our site.
Important !
•
•
Check, before ordering the kit, whether or not the donor bike you intend
to use is suitable. Most bikes will be, but check nevertheless before you
take a saw to it!
Make sure you have downloaded the latest version of the instruction
manual. Should you need a different version (exceptional) this will be
mentioned on your delivery confirmation
Assumptions
Skills
We assume that you are familiar with working on a bike and that you have the
basic DIY skills and that your have only one left hand. Read a good book on
bicycle maintenance if you think that will help you.
Left and right
If we talk about left and right we assume to be looking from the rear to the
front of the recumbent.
Front and rear
Naming front and rear we observe the direction of travel.
Sizes
All non-bicycle specific parts we supply are metric.
A bolt of M6 x 70 means the thread is approximately 6 mm in diameter and
the length below the head is 70 mm. For a countersunk bolt the head is
included in the length.
What is essential in the donor bike?
Try to get a bike with good parts, like wheels and gears. Otherwise you'll find
yourself buying all kinds of new parts and spending more money. It's not a
problem if the paint is bad. It's repainted anyway. It should have a derailleur
type gearing.
•
The length (size a) of the saddle tube must be between 480 and 620 mm
If this is shorter the spring may also be attached on the seat post itself but
the spring should not be opposite of the seat post clamp. That would be v
hard to attach. ( the centreline of the spring is 470 mm above the
centreline of the crankshaft)
•
The length ( size b) of the bracket may not be larger than 85 mm
•
The length ( size c) of the crankshaft must be al least 115 mm
•
Rear wheel must be size 26, 27 or 28 inch = ETRTO size 559, 571, 594,
590, 622, 630 or 635 mm
•
For a bike with a 27" or 28" wheel (622, 630 or 635) angle
α
must be
between 60º and 72º
•
For a bike with a 26" wheel (559, 571, 584 or 590) angle
α
must be
between 63º and 71º
•
The lower beam of the rear frame should not be more than 500 long.
(form wheel-axis to crankshaft -axis) But around 450 mm is better.
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Copyright Dutch Speed Bicycles
www.dutchbikes.nl
Version
GAKS2_2.9UK
KS2 Recumbent Kit
Other requirements
•
•
•
•
The bike must have derailleur type gearing
Rear wheel in good condition ( you could consider buying a new one)
Do not use an ultra light racing bike, it will not be strong enough!
The bike must have a square spindle type (pegless /keyless) crankshaft.
If you donor bike does not meet this requirement you can still use it, but
you will need a crankshaft as well as a new set of cranks. You will not be
able to use the old ones.
Try to use a donorbike that has a lot of usable parts. This will be much
cheaper than buying all those parts new!
•
Recognising the type of Crankshaft
A) Pegless crankshaft. In the crank there is a plug or bolt along the axis of the
shaft. [left]
B ) Crank using a key. There is a bolt (the peg) perpendicular to the axis of
the crank.
There is absolutely no objection to using a worn crankshaft here. But there
must be an absolute absence of play. Otherwise the whole recumbent will feel
wobbly. Many crankshafts are adjustable. Adjust if necessary to remove the
play. If this means that there is some friction in the axis, don’t worry, this is no
problem. You must be able to turn the axis by hand though. If the axis cannot
be adjusted you must replace it..
What you will need:
General tools
•
•
Wrenches use open end wrenches [right] or better still, ring spanners
[left]. These won’t damage the nuts and bolts.
All the non-bicycle-specific stuff we supply is metric.
If you don’t have a fitting wrench you might use a adjustable wrench.
(bahco) [right] Never use waterpump pliers, this will damage or destroy
the nuts and bolds It is not nice to work with and it ruins the looks of your
recumbent
Set of socket head wrenches (hex key)
Metal saw (or right angle grinder)
Round and square file
Jig-saw, preferably a corded (electrical) jig-saw. But it can be done by
hand
An electric drilling machine,
Heat gun of burner. (gas cooker will do too)
a Ø7 or 6.5 mm steel drill (OPTIONAL: Ø 5,5 for the gear support and Ø
10 for the Rawl nuts)
Hammer
Safety goggles (only if you use the right angle grinder)
Measuring tape
Paintbrush
A pair of fine pliers
Some sanding paper fine and coarse
Sanding block
Cloth polishing wheel and polishing agent (a cloth and brass polish will do
fine too, it will just take longer.)
Can of Hammerite Hammered Paint (http://www.hammerite.com) 250 ml
=1/4 litre is sufficient.
Some paint stirring sticks
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Bicycle tools
•
Screw Type Chain Tool This is an inexpensive but very useful tool that
lets you remove chain rivets. This is also needed when adjusting a
recumbent to a much longer or shorter cyclist.
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Copyright Dutch Speed Bicycles
www.dutchbikes.nl
Version
•
GAKS2_2.9UK
KS2 Recumbent Kit
Crank arm puller for removing crank arm fixing bolts and nuts.
If no bolt is visible, remove dust caps. Turn hex wrench fitting or bolt or
nut head counter-clockwise and remove bolt or nut. Inspect inside arms
for washers, and remove washers if present. Before installing crank arm
puller into crank arm, turn puller nut away from internal driver as much as
possible. If puller nut happens to unthread from internal driver, thread it
back on only 3-4 turns. Thread nut of puller into arm, taking care not to
cross thread. Tighten puller nut into crank arm using wrench.
(some background info, for instance: http://www.parktool.com/)
•
Bicycle ball bearing grease
Very useful:
A workbench with a vice or a workmate
You must buy
•
•
Three lengths of chain
A front wheel to match you rear wheel. Size ERTO 406. (20”) You will
have to order this at you local bicycle shop. Ask for a wheel with 36
spokes made in the ATB (all terrain bike) fashion. Good kids ATB wheels
do just fine. Other 20” sizes should do as well.
Now for the real thing
Take the donor bike apart:
•
Remove the saddle and the saddle pillar
•
Remove the chain
•
Remove the crank arms Use a puller, don’t use a hammer or other forms
of violence. Go see your friendly neighbour hood bicycle repair man if you
have to.
•
Remove the rear wheel
•
Remove the rear brakes
•
Remove the lock (if any)
•
Remove the luggage carrier
•
Remove the Derailleur
•
Remove the mud guards
•
And so on
•
In short remove everything form the rear part of the donor bike except the
crank shaft.
And now we start sawing
Rear frame
•
•
•
Cut the donor bike at points A and B. It is helpful if the frame can be
clamped in a vice or workmate.
Tool Metal saw and file (or right angle grinder) If you use the latter please
use safety goggles.
Finish the ends with a file or using the right angle grinder. If you use the
latter please use safety goggles.
The part you have now created will be referred to as “rear” frame
Adjusting the crank shaft.
There is absolutely no objection to using worn crankshaft here.
IMPORTANT: But there must be an absolute absence of play. See above
Fitting the rear frame
Before painting the rear frame you must check if it fits. Mount it with the U-
clamp. These must be mounted with self locking nuts (so they won't come off
with vibration) but for this testing please use the normal nuts supplied. So the
self locking nuts will not lose any of it's self locking properties. Use washers.
IMPORTANT: Never ride the recumbent wit ordinary nuts at this location.
IMPORTANT: Tighten the nuts only gently, they are heavily oversized
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Copyright Dutch Speed Bicycles
www.dutchbikes.nl
Version
GAKS2_2.9UK
KS2 Recumbent Kit
We advise to use the original cranckshaft bolts, use one or more rings
The hole for the spring
•
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•
Mark the proper location of the hole for the spring on the rear frame.
Putting a piece of adhesive tape at the approximate location can make
marking easier.
Mark a spot on the saddle tube of the rear frame that is on the same
distance from the crank shaft. Use a measuring tape to find the proper
spot. This must be accurate within 3 mm.
Prepare the spot for drilling, make a small dimple using a nail (or a
centre-punch) and a hammer. This will help keeping the drill al the proper
spot.
Drill a hole of 7 mm diameter.
IMPORTANT: This hole will be used for mounting the spring for the
suspension. So it must be opposite of the attachment point in the frame.
If you are sure you are not going to use a trailer (that needs a saddle pin)
on your recumbent, than you can cut away a bit more of the top of the
rear frame. But make sure the top of the saddle tube cut off straight,
otherwise the cap will not fit.
Painting the rear frame
Use black Hammerite. It is durable and needs no primer. It is easy to apply
and gives a professional finish weather you are a good painter or not. Also is
easy to retouch.
•
Make sure all parts except the crankshaft are removed.
•
If the frame is dirty clean it. Using a high pressure cleaner is the easiest
way. This will remove all grease and dirt form even the smallest corners.
(Many a Car-wash has a good high pressure cleaner).
IMPORTANT: don’t spray directly in to the crankshaft bearing.
•
Remove any loose paint.
•
Remove any rust with a steel brush. You don't have to remove completely
but get rid of the loose stuff at least.
•
If the frame's paint is still in good condition al you have to do is sand it
lightly with very fine sanding paper.
•
Degrease the frame with an ammonia solution (ammonia water) Do this
outside or in a well ventilated room. Wait untill the frame has dried.
•
Suspend the frame from a hook that you have attached to the ceiling. In
this manner you can paint the rear frame partly. Holding it by the
unpainted part you can hang it in a different position. In this fashion you
can paint the entire rear frame comfortably. Please note the transition
between the two sections you paint remain somewhat visible. So chose
these locations carefully.
•
You may paint the old crank shaft as well if you like.
•
Remember the new crank shaft needs some painting as well. This is a
good time to do it. See below
The Seat
The contours of the pre-formed seat are indicated with a pencil line. If you are
big or small you might decide to change the contours of the seat. It your legs
are not so long it is a good idea to make the seat somewhat narrower. This
will make it easier to get your feet to the ground. Also the length of the front in
important. A good approach is to test drive with an unfinished (unpainted)
seat. Once you are convinced this is good for you, you can paint it. Don't
expose the bike to too much rain while the seat is unpainted. And remember:
you can always make the seat smaller!
Sawing
Use a jig-saw to cut the contour in the desired shape. If you decide to use
your own shape, make sure you have drawn it smoothly and symmetrically
before you take the saw to it. You can fasten the seat temporarily to the
workbench by means of a screw. In this fashion you will have two hands
Page 5
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Copyright Dutch Speed Bicycles
www.dutchbikes.nl

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