Owner’s Operator and Maintenance Manual ® Recumbent Handcycle Series Top End XLT™ Top End XLT Jr. Top End XLT Pro Top End XLT Gold Top End Force™ DEALER: This manual MUST be given to the user of the handcycle. USER: BEFORE using this handcycle, read this manual and save for future reference. For more information regarding Invacare products, parts, and services, please visit www.invacare.
WARNING DO NOT USE THIS PRODUCT OR ANY AVAILABLE OPTIONAL EQUIPMENT WITHOUT FIRST COMPLETELY READING AND UNDERSTANDING THESE INSTRUCTIONS AND ANY ADDITIONAL INSTRUCTIONAL MATERIAL SUCH AS OWNER’S MANUALS, SERVICE MANUALS OR INSTRUCTION SHEETS SUPPLIED WITH THIS PRODUCT OR OPTIONAL EQUIPMENT. IF YOU ARE UNABLE TO UNDERSTAND THE WARNINGS, CAUTIONS OR INSTRUCTIONS, CONTACT A HEALTHCARE PROFESSIONAL, DEALER OR TECHNICAL PERSONNEL BEFORE ATTEMPTING TO USE THIS EQUIPMENT - OTHERWISE, INJURY OR DAMAGE MAY OCCUR.
TABLE OF CONTENTS TABLE OF CONTENTS REGISTER YOUR PRODUCT ............................................................... 7 DEALER/TECHNICIAN INFORMATION ............................................... 8 SPECIAL NOTES ................................................................................ 8 TYPICAL PRODUCT PARAMETERS .................................................. 10 SECTION 1—GENERAL GUIDELINES ................................................. 12 Proper Fit ....................................
TABLE OF CONTENTS TABLE OF CONTENTS SECTION 5—OPERATION ................................................................ 26 Riding the Handcycle ...............................................................................................................................26 Shifting Gears.............................................................................................................................................27 Seven Speed Hub ..............................................................
TABLE OF CONTENTS TABLE OF CONTENTS SECTION 8—SERVICE PROCEDURES ................................................. 46 Replacing the Fork/Crank Assembly ....................................................................................................46 Replacing the Crank Arms - XLT Gold, XLT PRO and Top End Force .....................................49 Replacing the Left Side Crank Arms................................................................................................
TABLE OF CONTENTS TABLE OF CONTENTS SECTION 9—OPTIONS ..................................................................... 60 Installing Rear Safety Light......................................................................................................................60 Batteries .................................................................................................................................................60 Mounting the Safety Light....................................................
REGISTER YOUR PRODUCT For Models Made After 7/12/07 .......................................................................................................65 Installing Gloves ........................................................................................................................................66 Mountain Drive Transmission Option.................................................................................................66 Switching to Mountain Drive Transmission Option ...............
DEALER/TECHNICIAN INFORMATION DEALER/TECHNICIAN INFORMATION The term ʺqualified technicianʺ in this manual refers to an Invacare qualified technician or a Shimano® certified bicycle repair technician. SPECIAL NOTES Signal words are used in this manual and apply to hazards or unsafe practices which could result in personal injury or property damage. Refer to the table below for definitions of the signal words.
SPECIAL NOTES WARNING ALWAYS wear your seat positioning strap. Inasmuch as the seat positioning strap is an option on this handcycle (you may order with or without the seat positioning strap), Invacare strongly recommends ordering the seat positioning strap as an additional safeguard for the handcycle user. The seat positioning strap is a positioning belt only. It is not designed for use as a safety device withstanding high stress loads such as auto or aircraft safety belts.
TYPICAL PRODUCT PARAMETERS TYPICAL PRODUCT PARAMETERS TOP END XLT TOP END XLT JR Seat Width: 14 to 20 inches 14 inches Seat Depth: 15 inches 15 inches Seat-to-Floor (approx.
TYPICAL PRODUCT PARAMETERS TOP END XLT PRO TOP END XLT GOLD Seat Width: 14 to 18 inches 14 to 18 inches Seat Depth: 15 inches 15 inches Seat-to-Floor (approx.
SECTION 1—GENERAL GUIDELINES SECTION 1—GENERAL GUIDELINES WARNING SECTION 1 - GENERAL GUIDELINES contains important information for the safe operation and use of this product. Proper Fit The handcycle MUST be adjusted to fit the rider. For a proper fit: • The rider MUST be able to see over the hand crank. • The rider MUST have a slightly bent elbow when the hand pedals are toward the front of the handcycle (farthest from the riderʹs face).
SECTION 1—GENERAL GUIDELINES Top End XLT, XLT jr., and XLT Gold Models Only ‐ The parking brake of the handcycle MUST be engaged before attempting any transfer. Top End XLT Pro Model Only ‐ This model may be ordered with or without a parking brake. If ordered without a parking brake, the handcycle MUST be positioned securely against a stable object before any transfer is attempted. If ordered with the optional parking brake, the parking brake MUST be engaged before attempting any transfer.
SECTION 1—GENERAL GUIDELINES Tire Pressure 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 a flat or underinflated tires. Riding on flat or underinflated tires can cause injury, as well as, damage to the tire, tube and handcycle. Weight Limitation The Invacare Top End XLT handcycles have a weight limitation of 250 lbs.
SECTION 2—SAFETY AND HANDLING SECTION 2—SAFETY AND HANDLING Safety and Handling of the Handcycle Requires the close attention of the user as well as the assistant. This manual points out the most common procedures and techniques involved in the safe operation and maintenance of the handcycle. It is important to practice and master these safe techniques until you are comfortable in maneuvering the handcycle. Use this information only as a basic guide.
SECTION 2—SAFETY AND HANDLING Percentage of Weight Distribution Transferring in and out of the handcycle will cause a change to the normal balance, the center of gravity, and the weight distribution of the handcycle. To determine and establish your particular safety limits, practice transferring activities in several combinations in the presence of a qualified health care professional before attempting a transfer alone. Proper positioning is essential for your safety.
SECTION 2—SAFETY AND HANDLING NOTE: During independent transfer, little or no seat platform will be beneath you. Although it may be difficult to wedge the transfer board between the handcycle seat and the handcycle seat, use a transfer board if necessary. NOTE: Refer to STEPS A‐F in FIGURE 2.1 for details regarding transfer to/from a handcycle. 6. Shift body weight onto object while transferring. 7. Lift and place left leg past front frame across seat and over center tube.
SECTION 3—SAFETY INSPECTION SECTION 3—SAFETY INSPECTION Safety Inspection Checklist NOTE: Every six months, take your Top End XLT to a qualified technician for a thorough inspection and servicing. Regular cleaning will reveal loose or worn parts and enhance the smooth operation of your Top End XLT. For safe and proper operation, your handcycle MUST be cared for just like any other vehicle. Routine maintenance will extend the life and efficiency of your Top End XLT.
SECTION 3—SAFETY INSPECTION ❑ Inspect seat positioning strap for any signs of wear. Ensure buckle latches. Verify hardware that attaches strap to frame is secure and undamaged. Replace if necessary. ❑ Inspect upholstery for rips or sagging. ❑ Clean upholstery with light detergent and water. ❑ Check that all labels are present and legible. Replace if necessary. ❑ Ensure that casters are free of debris. Inspect/Adjust Weekly ❑ Inspect parking brake ‐ Adjust brake shoes to front rim.
SECTION 3—SAFETY INSPECTION Inspect/Adjust Monthly ❑ Inspect for bent or broken frame. ❑ Ensure that casters are free of debris. Inspect/Adjust Periodically ❑ Inspect for bent or broken frame. ❑ Inspect parking brake ‐ Adjust brake shoes to front rim. Check for worn or missing shoes. Check for wax or oil on rim. ❑ Ensure cable anchor is attached securely to brake arm. ❑ Ensure internal stopping brakes engages easily.
SECTION 3—SAFETY INSPECTION Troubleshooting VEERS VEERS RIGHT LEFT X X SLUGGISH WHEEL SQUEAKS LOOSENESS IN TURN OR FLUTTERS AND HANDCYCLE PERFORMANCE RATTLES X X SOLUTIONS Check tires for correct and equal pressure. X Check road crown compensator or XLT Gold dampener hardware and adjustment X X X X X X Check for loose axle nuts. X X Check spokes and nipples. X Check chain for proper tension and adjustment. X Check that goose neck fittings are secure.
SECTION 3—SAFETY INSPECTION 3. If equipped, keep quick release axles free of dirt and lint to ensure positive locking and proper operation. Refer to Installing/Adjusting the Rear Wheel and Quick‐Release Axles on page 42. WARNING DO NOT use WD-40®, 3-in-1 oil, or other penetrating lubricants on quick-release axles. Otherwise, binding and/or damage to the handcycle may occur. 4. Clean/oil quick‐release axles once a week with a Teflon® lubricant. 5.
SECTION 4—INITIAL SETUP SECTION 4—INITIAL SETUP WARNING After any adjustments, repair or service and before use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result. DO NOT operate the handcycle if the hand crank obstructs your view. If the hand crank obstructs your view, adjust the hand crank height before using the handcycle - otherwise injury or damage may occur. Initial Setup NOTE: For this procedure, refer to FIGURE 4.1 on page 24 and FIGURE 4.
SECTION 4—INITIAL SETUP Top End XLT/XLT Jr. Back Hand Crank Assembly/ Reversing Drum Brake Seat Chain Rear Wheel Parking Brake Cable Shifter Location Footrest NOTE: Parking brake located on left side of seat frame. Top End XLT PRO Back Brake Cable Hand Crank Assembly Fork Mounted Shifters and Brakes Rear Wheel Chain Footrest Seat FIGURE 4.
SECTION 4—INITIAL SETUP Top End XLT Gold Rapid-Fire Hand Brake/Shifter Hand Crank Assembly Back Chain Rear Wheel Seat Footrest Top End Force Rapid-Fire Hand Brake/Shifter Hand Crank Assembly Chain Back Rear Wheel Seat Footrest FIGURE 4.
SECTION 5—OPERATION SECTION 5—OPERATION WARNING After any adjustments, repair or service and before use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result. Riding the Handcycle WARNING Before operating the handcycle, review the General Guidelines on page 12 in of this manual. DO NOT operate the handcycle if the hand crank obstructs your view.
SECTION 5—OPERATION 8. Rotate (pedal) the hand crank forward (toward the front) to propel the handcycle forward. 9. Top End XLT and XLT Jr. Models Only ‐ Rotate (pedal) the hand crank backward (toward the rear) to apply the brake and slow down or stop. NOTE: Top End XLT shown for clarity. Top End XLT and XLT Jr. ONLY Hand Crank (STEPS 3, 6, 8 and 9) Seat (STEP 5) Front of Handcycle Rear of Handcycle Footrest (STEP 4) FIGURE 5.
SECTION 5—OPERATION Hands-On Rapid Fire Shifter/Brake System: Twenty-seven Speeds NOTE: For this procedure, refer to FIGURE 5.3 on page 29. NOTE: This procedure applies to the Top End XLT Pro, XLT Gold, and Force ONLY. To shift gears, you MUST turn the crank forward with the chain under some tension while the bike is moving. DO NOT attempt to shift gears while bike is stationary. There are two shifters installed on the handcycle.
SECTION 5—OPERATION Shift Lever “B” Shift Lever “A” FIGURE 5.3 Shifting Gears - Hands-On Rapid Fire Shifter/Brake System: Twenty-seven Speeds - Hands-On Rapid Fire Shifter/Brake System: Twenty-seven Speeds Backing-Up Use the rear wheels (i.e. like a manual handcycle) to backup. When backing up, keep the front wheel straight. The weight of the hand crank may engage the reversing drum brakes (Top End XLT and XLT jr. models ONLY) while backing up. Lift the pedals up to avoid this problem.
SECTION 5—OPERATION Hand Brakes/Hands-On Brakes WARNING The twenty-seven speed cassette on the Top End XLT Pro, XLT Gold and Top End Force models use the hand brake as the primary brake. Reverse pedaling WILL NOT stop the bike. Handcycles equipped with Hand Brakes - In situations where caution is advised (heavy traffic, intersections, etc.) hands should be kept in the "ready" position to prepare for braking. NOTE: For this procedure, refer to FIGURE 5.4. 1.
SECTION 5—OPERATION • To Disengage the Parking Brake ‐ Squeeze and release the ratchet button. Parking Brake Location Slots or Hook and Loop Strap (Not Shown) Handle NOTE: Approximate location shown. Actual side of handcycle and location on seat frame may vary. FIGURE 5.5 Using Parking Brake Steering/Cornering WARNING DO NOT attempt to corner the handcycle at high speeds. This could result in a fall causing injury and/or damage to the handcycle. NOTE: For this procedure, refer to FIGURE 5.6.
SECTION 6—RIDING POSITION SECTION 6—RIDING POSITION WARNING After any adjustments, repair or service and before use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result. Replacing/Adjusting the Footrest and Leg Guard NOTE: For this procedure, refer to FIGURE 6.1. NOTE: If replacing footrest or leg guard, take note of current position. Replacing/Adjusting Footrest Footrest Replacement/Adjustment 1.
SECTION 6—RIDING POSITION Using/Replacing Footrest Strap WARNING Footrest straps MUST be inspected before each use. Exposure to moisture (i.e.- wet weather or puddles) will damage fastening strips. Footrest strap will not hold feet securely in footrest if fastening strips are damaged. DO NOT operate handcycle if footrest straps are wet or damaged, otherwise severe injury may occur. ALWAYS wear shoes and securely strap feet in using straps provided.
SECTION 6—RIDING POSITION Adjusting Hand Crank WARNING DO NOT operate the handcycle if the hand crank obstructs your view. If the hand crank obstructs your view, adjust the height before using the handcycle - otherwise injury or damage may occur. Adjusting Hand Crank Height - All Models Except Top End XLT Gold NOTE: For this procedure, refer to FIGURE 6.4. 1. Loosen, but DO NOT remove the two set screws securing the hand crank to the fork stem. Hand Crank 2.
SECTION 6—RIDING POSITION Adjusting Top End XLT Gold Hand Crank NOTE: For this procedure, refer to FIGURE 6.5. Adjusting Hand Crank Height 1. Loosen, but DO NOT remove the hex nut securing the hand crank to the fork stem. 2. Loosen, but DO NOT remove the two set screws for the upper clamp. 3. Move the hand crank assembly up or down in the fork neck until you are comfortable with the position for operational purposes.
SECTION 6—RIDING POSITION Adjusting Seat Fore/Aft - All Models Except XLT Gold and Top End Force NOTE: For this procedure, refer to FIGURE 6.6. NOTE: Seat should be adjusted so that when seated with feet in the footrests, there is a slight bend at the knee and a slight bend at the elbow when the hand crank is furthest away. 1. If installed, activate parking brake. 2. Loosen, but DO NOT remove the four rear socket screws that secure the rear seat frame to the handcycle frame. 3.
SECTION 6—RIDING POSITION Adjusting Seat Fore/Aft - XLT Gold and Top End Force Only NOTE: For this procedure, refer to FIGURE 6.7. NOTE: Seat should be adjusted so that when seated with feet in the footrests, there is a slight bend at the knee and a slight bend at the elbow when the hand pedal is furthest away. 1. Remove the seat upholstery. Refer to Replacing Seat Upholstery on page 58. 2. Loosen, but DO NOT remove the two mounting bolts and locknuts securing the two back clamps to the seat rails. 3.
SECTION 6—RIDING POSITION Adjusting Seat Height - All Models Except XLT Gold and Top End Force NOTE: For this procedure, refer to FIGURE 6.8. 1. Loosen, but DO NOT remove the four socket screws securing the rear of the seat to the handcycle frame. 2. Remove the two socket screws securing the front of the seat frame to the handcycle frame. 3. Align the seat height adjustment clamp with the desired height adjustment hole in the seat height adjustment bracket. 4.
SECTION 6—RIDING POSITION Adjusting Back Angle - All Models Except XLT Gold and Top End Force NOTE: For this procedure, refer to FIGURE 6.9. 1. If installed activate parking brake. 2. Loosen, but DO NOT remove the four rear socket screws that secure the seat frame to the handcycle frame. NOTE: There are two socket screws on the right and left side of the handcycle. 3. Loosen, but DO NOT remove the hex bolts and locknuts that secure the two seat angle adjustment clamps to the rear seat supports.
SECTION 6—RIDING POSITION Adjusting Back Angle - XLT Gold NOTE: For this procedure, refer to FIGURE 6.10. 1. Loosen, but DO NOT remove, the two socket screws located in the seat angle adjustment clamp. 2. Perform one of the following: • Increasing Back Angle ‐ While pushing down on the back support tube, push the back down to the desired position. • Decreasing Back Angle ‐ While lifting up on the back support tube, pull the back upward to the desired position. 3.
SECTION 6—RIDING POSITION Adjusting Back Height - Wide Back Option Only NOTE: For this procedure, refer to FIGURE 6.11. NOTE: This procedure applies to Top End XLT models with wide back option only. 1. Remove the back upholstery from the handcycle. Refer to Replacing Back Upholstery on page 59. WARNING Push pin MUST protrude through hole in back cane. Ensure that both back cane inserts are at the same height before reassembling the chair. 2.
SECTION 7—WHEELS SECTION 7—WHEELS WARNING After any adjustments, repair or service and before use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result. Installing/Adjusting the Rear Wheel and Quick-Release Axles NOTE: For this procedure, refer to FIGURE 7.1. 1. Make sure that the axle receiver hex nut is securely tightened before installing the rear wheels. Axle Receiver Hex Nut Quick-release Axle Locknut 2.
SECTION 7—WHEELS Installing the Rear Wheels with Threaded Axles NOTE: For this procedure, refer to FIGURE 7.2. 1. Apply a small amount of grease onto the axle. 2. Insert the axle into the axle mounting hole on the handcycle frame. 3. Securely tighten the axle to the frame. Axle Mounting Hole ¼-inch Allen Wrench Frame Rear Wheel Axle FIGURE 7.
SECTION 7—WHEELS Determining/Adjusting Toe In/Toe Out NOTE: For this procedure, refer to FIGURE 7.3. Determining Toe In/Toe Out 1. Inflate all pneumatic tires to recommended tire pressures (listed on the sidewall of the tire). 2. Measure the distance between the center lines at the rear and front of the rear wheels at approximately 12 inches from the ground/floor. Front of handcycle Toe-out Toe-in NOTE: For optimum accuracy, perform STEP 2 with the handcycle occupied.
SECTION 7—WHEELS Adjusting Toe In/Toe Out 1. Loosen, but DO NOT remove the socket screws and clamps that secure camber inserts to the camber bar (Detail ʺAʺ). 2. Slowly rotate the camber insert until the rear wheels are approximately in a straight line. 3. Securely tighten the socket screws and clamps that secure the camber inserts to the camber bar. 4. Measure the distance between the center lines at the rear and front of the rear wheels at approximately 12 inches from the ground/floor.
SECTION 8—SERVICE PROCEDURES SECTION 8—SERVICE PROCEDURES WARNING After any adjustments, repair or service and before use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result. Replacing the Fork/Crank Assembly NOTE: For this procedure, refer to FIGURE 8.1 on page 48. NOTE: Invacare recommends that the following procedure be performed by a qualified technician. 1. Note the position of the crank handles. 2.
SECTION 8—SERVICE PROCEDURES 19. Slide the bottom bearing onto the new fork. Refer to FIGURE 8.1 for correct orientation. 20. Slide the new fork into the frame. 21. Position the o‐ring and bearing on the new fork. Refer to FIGURE 8.1 for correct orientation. 22. Install the two nuts onto the new fork and tighten securely. Refer to FIGURE 8.1 for correct orientation. 23. Position the footrest clamps on the new frame. 24.
SECTION 8—SERVICE PROCEDURES STEPS 1, 2, 3, 36, 37 STEPS 6, 7, 34 Fork Socket Screws Fork Brake Assembly Hardware Socket Nut Crank Handle STEPS 8, 31 Steering Dampener Road Crown Compensator STEPS 12, 13, 26, 27, 28, 29 STEPS 10, 11, 30, 31 Non-Turn Washer-Must Be Installed as Shown Locknut Brake Arm Clamp Hex Bolt Brake Arm Cap Nuts Fork Washer Front Wheel STEPS 5, 17, 18, 19, 20, 21, 22, 35 STEPS 15, 16, 23, 24 Top Nuts Fork Crank Handle Bearing O-Ring Frame Hex Bolts, Locknuts and
SECTION 8—SERVICE PROCEDURES Replacing the Crank Arms - XLT Gold, XLT PRO and Top End Force NOTE: For this procedure, refer to FIGURE 8.2 on page 50. NOTE: Right and left determined from as if seated on the handcycle. Replacing the Left Side Crank Arms 1. Remove the two socket screws from the existing crank arm clamp. 2. Remove socket screw and cap from the spindle. 3. Remove the existing crank arm from the spindle. 4.
SECTION 8—SERVICE PROCEDURES Mounting Bolts and Locknuts Crank Arm Clamp Chain Ring Disk Right Crank Arm (Tabs) Left Crank Arm Spindle, Socket Screw and Cap Spindle, Socket Screw and Cap Crank Arm Clamp and Socket Screws Socket Screws FIGURE 8.2 Replacing the Crank Arms - XLT Gold, XLT PRO and Top End Force Installing/Removing/Adjusting the Road Crown Compensator NOTE: For this procedure, refer to FIGURE 8.3 on page 51.
SECTION 8—SERVICE PROCEDURES Removing Road Crown Compensator 1. Remove the locknut securing the fork end of the road crown compensator to the fork bolt. 2. Remove the fork end of the road crown compensator from the fork bolt. 3. Remove the bolt and spacer securing the frame end of the road crown compensator to the frame. Adjusting Road Crown Compensator NOTE: This adjustment is made for handcycling on crowned roads or in heavy winds. 1.
SECTION 8—SERVICE PROCEDURES Installing/Removing/Adjusting the Steering Dampener For Top End XLT Gold and Force Only NOTE: For this procedure, refer to FIGURE 8.4 on page 53. NOTE: The steering dampener is designed to stabilize the handcycle during transfers and while riding and is not intended to keep the handcycle straight when pedaling but to keep the handcycle from leaning excessively to one side or another. Installing Steering Dampener 1.
SECTION 8—SERVICE PROCEDURES Top End XLT Gold ONLY Crank Assembly Tab Socket Screws (One Located on Both Sides of the Handcycle Frame) Upper Threaded Post and Locknut Steering Dampener Handcycle Frame Lower Threaded Post and Locknut Top End Force ONLY Dampener Clamp (Tab) Upper Threaded Post and Locknut Steering Dampener Dampener Clamp (Tab) Crank Assembly Tab Handcycle Frame FIGURE 8.
SECTION 8—SERVICE PROCEDURES Adjusting/Replacing Seven Speed Shifter Handcycles with seven speed shifters are equipped with SHIMANO hubs. If equipped with a SHIMANO hub, it MUST be serviced and adjusted by a qualified technician. NOTE: QUALIFIED TECHNICIANS ONLY ‐ Contact Invacare, 1‐800‐532‐8677 for complete SHIMANO hub instructions. It is recommended that you take your handcycle to a qualified technician for any shifter adjustment.
SECTION 8—SERVICE PROCEDURES Adjusting Seven Speed Hub Chain WARNING Chain MUST be tight. If the chain is noisy, loosen. After chain is assembled, start in first gear and on straightaway. NOTE: For this procedure, refer to FIGURE 8.7 on page 55. NOTE: This procedure applies to the Top End XLT and Top End XLT Jr. only. 1. Ensure the hand crank is adjusted to the proper height. Refer to Adjusting Hand Crank on page 34.
SECTION 8—SERVICE PROCEDURES 5. Run the chain around the bottom of the wheel sprocket and back up towards the hand crank sprocket. 6. Attach the chain together using the master link (w/clip) provided. 7. To tension chain, refer to Refer to Replacing the Fork/Crank Assembly on page 46. Hand Crank Sprocket Assembles STEP 5 Chain Derailleur and Wheel Sprockets STEP 4 STEP 3 FIGURE 8.
SECTION 8—SERVICE PROCEDURES Crank Handle Fork Clamps FIGURE 8.9 Adjusting Twenty-Seven Speed Cassette Chain Adjusting/Replacing the Parking Brake WARNING Before using your handcycle, inspect the parking brake for proper operation. NOTE: For this procedure, refer to FIGURE 8.10. Adjusting the Parking Brake Cable 1. Loosen the hex nut and turn the adjuster barrel clockwise (tighten) or counterclockwise (loosen) to adjust the cable. Retighten hex nut. Brake Pads 1.
SECTION 8—SERVICE PROCEDURES Parking Brake WARNING Replacement of the parking brake MUST be performed by a qualified technician. Adjuster Barrel Hex Nut Rim of Wheel Brake Pad Mounting Nut Stop Button FIGURE 8.10 Adjusting/Replacing the Parking Brake Replacing Seat Upholstery WARNING Upholstery MUST be inspected before each use. Exposure to moisture (i.e. - wet weather or puddles) will damage fastening straps/flaps/strips.
SECTION 8—SERVICE PROCEDURES Replacing Back Upholstery WARNING Upholstery MUST be inspected before each use. Exposure to moisture (i.e. - wet weather or puddles) will damage fastening straps/flaps/strips. DO NOT operate handcycle if upholstery is wet or damaged, otherwise severe injury may occur. Replacing Wide Back Upholstery Back Upholstery NOTE: For this procedure, refer to FIGURE 8.12. 1. Unlatch the two fastening flaps that secure the bottom of existing back upholstery to the back canes.
SECTION 9—OPTIONS SECTION 9—OPTIONS WARNING After any adjustments, repair or service and before use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result. Installing Rear Safety Light Safety Light WARNING Operation of the handcycle is subject to all traffic rules and regulations. (This may include the use of a safety light and reflectors for dusk/night riding.) Lens Cover Clamp NOTE: For this procedure, refer to FIGURE 9.1. Batteries Rear Seat Post 1.
SECTION 9—OPTIONS Installing the Water Bottle NOTE: For this procedure, refer to FIGURE 9.2. 1. Secure the water bottle mounting tube to the seat frame using the hardware provided. NOTE: Make sure that the water bottle mounting bracket mounting holes are facing downward. 2. Attach the water bottle mounting bracket to the mounting tube using the hardware provided. 3. Push water bottle into mounting bracket until secure. Seat Frame Mounting Tube Water Bottle Mounting Bracket FIGURE 9.
SECTION 9—OPTIONS Installing the Draft Bumper WARNING DO NOT use if draft bumper extends past rear wheels. If draft bumper extends past the rear wheels, contact dealer. NOTE: For this procedure, refer to FIGURE 9.4. NOTE: The draft bumper can not be installed if the tow bar is installed. 1. Remove the four set screws on each mounting bracket. Mounting Brackets 2. Position the mounting brackets around the handcycle rear frame.
SECTION 9—OPTIONS Installing Seat Positioning Strap NOTE: For this procedure, refer to FIGURE 9.7. 1. Secure seat positioning strap to back canes using hardware provided. Back Canes Seat Positioning Strap FIGURE 9.7 Installing Seat Positioning Strap Installing the Computer NOTE: For this procedure, refer to FIGURE 9.8. 1. Install metal plug onto spoke of front wheel approximately 2 inches from wheel rim. 2. Align metal plug with fork assembly. 3. Secure sensor to fork using hardware provided.
SECTION 9—OPTIONS Installing Hand Crank Handles NOTE: For this procedure, refer to FIGURE 9.9. Horizontal Handles/Delrin Handles DETAIL “A” - HORIZONTAL HANDLES/DELRIN HANDLES Hand Crank 1. Secure handle to hand crank with the screw (Detail “A”). Horizontal Handle 2. Remove the screw to remove handle from handcrank. Screw Vertical Handles DETAIL “B” - VERTICAL HANDLES 1. Position handle onto crank (Detail “B”). 2. Tighten set screw to secure handle to crank. Hand Crank Set Screw 3.
SECTION 9—OPTIONS 2. Firmly tighten the bolt. NOTE: Handle should spin freely with minimal play. If handle does not spin freely make sure the spacer is firmly in place. If handle still does not spin freely, contact Invacare. Crankarm Housing Bearing Bolt Bearing Spacer Crankarm Handle FIGURE 9.
SECTION 9—OPTIONS Installing Gloves NOTE: For this procedure, refer to FIGURE 9.12 on page 66. 1. Wrap palm loop around horizontal handle (using top slot only) and secure to glove. 2. Run glove loop through bottom slot on palm and over back of hand until tight. Secure glove loop to back of glove. 3. Reattach glove strips to back of glove. Glove Palm Loop Secured to Glove Glove Loop Top Slot Glove Strip Glove Strip Palm Loop Horizontal Handle Bottom Slot FIGURE 9.
SECTION 9—OPTIONS Using the Travel Ready Option NOTE: For this procedure, refer to FIGURE 9.14 on page 67. NOTE: This procedure is for Top End XLT Pro, Gold, and Top End Force models only. The travel ready option allows the handcycle to be quickly and easily disassembled for travel. NOTE: Reverse the steps below to reassemble the handcycle. 1. Remove the rear wheels. Refer to Installing/Adjusting the Rear Wheel and Quick‐Release Axles on page 42. 2. Remove the camber bar.
SECTION 9—OPTIONS Removing/Installing the Fork - Travel Ready XLT PRO Equipped with Road Crown Compensator NOTE: For this procedure, refer to FIGURE 9.15 on page 69. Removing the Fork 1. Remove the nut securing the road crown compensator to the fork. 2. Remove the road crown compensator from the fork bolt. 3. Remove the two socket screws from each fork clamp. 4. Remove the plate from the top of the fork. 5. Remove the fork from the frame. 6. Remove the front wheel from the fork.
SECTION 9—OPTIONS Socket Screws Fork Clamp Plate Fork Clamp Frame Fork Fork Clamps Nut Fork Bolt Road Crown Compensator FIGURE 9.15 Removing/Installing the Fork - Travel Ready XLT PRO Equipped with Road Crown Compensator Removing/Installing the Fork - XLT Gold, and Top End Force Equipped with Steering Dampener NOTE: For this procedure, refer to FIGURE 9.16 on page 70. Removing the Fork 1. Remove the locknut securing the steering dampener to the dampener clamp (Detail ʺAʺ). 2.
SECTION 9—OPTIONS 3. Using the fork clamp and two socket screws, secure the bottom of the plate to the frame. 4. While inserting the lower threaded post into the tab, position the dampener clamp around the handcycle frame. 5. Using two socket screws, loosely secure the dampener clamp to the handcycle frame. 6. Using a locknut, secure the steering dampener to the dampener clamp. 7. Install the front wheel. Refer to Installing the Front Wheel on page 71. 8.
SECTION 9—OPTIONS Installing the Front Wheel NOTE: For ease of installation, secure handcycle frame approximately 6 inches from the ground or seek assistance. 1. Loop the chain over the front wheel sprocket. 2. Position the front wheel sprocket into the fork slots. 3. Tighten the knob on the opposite side of the quick‐release lever. 4. Secure the wheel to the fork with the quick‐release lever.
SECTION 9—OPTIONS 8. Using two mounting bolts and locknuts, secure the rear wheel bar to the wheel tray. 9. Install the receiver onto the trailer hitch of the vehicle, according to the vehicle manufacturerʹs instructions. Using the Handcycle Rack 1. Position the handcycle on the rack with the front wheel in the wheel tray bracket. 2. Adjust the handcycle rack so the wheel tray bracket sits against the front wheel and the rear wheel bar brackets sit against the rear wheels.
SECTION 9—OPTIONS Adjusting the Handcycle Rack Wheel Tray Bracket NOTE: To properly secure the handcycle, the wheel tray bracket should be adjusted to sit against the front wheel. 1. Remove the four mounting bolts and locknuts securing the wheel tray bracket to the wheel tray. 2. Position the wheel tray bracket in the desired position. 3. Secure the wheel tray bracket to the wheel tray with the four mounting bolts and locknuts. 4.
SECTION 9—OPTIONS Using the Alignment Gauge NOTE: For this procedure, refer to FIGURE 9.19. NOTE: The alignment gauge is used to determine toe in/toe out. Refer to Determining/Adjusting Toe In/Toe Out on page 44 for more information. 1. Inflate all pneumatic tires to recommended tire pressures (listed on the sidewall of the tire). 2. Place the handcycle and alignment gauge on a flat surface. 3. Position the alignment gauge near the rear of the rear tires. 4. Loosen the height adjustment screw. 5.
LIMITED WARRANTY LIMITED WARRANTY PLEASE NOTE: THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLICABLE TO PRODUCTS MANUFACTURED AFTER JULY 4, 1975. This warranty is extended only to the original purchaser/user of our products. This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state.
Invacare Corporation www.invacare.com USA One Invacare Way Elyria, Ohio USA 44036-2125 800-333-6900 Canada 570 Matheson Blvd E Unit 8 Mississauga Ontario L4Z 4G4 Canada 800-668-5324 All rights reserved. Trademarks are identified by the symbols ™ and ®. All trademarks are owned by or licensed to Invacare Corporation unless otherwise noted. Shimano, Nexus, and Ultegra are registered trademarks of Shimano Inc. 3-in-1 and WD-40 are registered trademarks of the WD-40 Company.
