Page 1 BKE FRIDAY Sat R Day Instruction Manual For: Bike No

SEE DTN
Sat R Day Instruction Manual
For:
Bike No.:
www. bikefriday.com; email: [email protected]
3364 W 11th Ave, Eugene, OR 97402
Toll Free: 800-777-0258; 541-687-0487; Fax 541-687-0403
Congratulations!
You have just purchased one of the most exciting new products in the human powered world — a
practical recumbent! The SatRday has all the comfort and performance that recumbents are well
known for, and offers it in a package that is useful for every day living. The SatRday makes travel
a realistic option for recumbent enthusiasts everywhere.
The SatRday is the newest addition to Green Gear's stable of travel products. It joins the legacy
of the New World Tourist, the Air Friday and the Tandem Tuesday just to name a few. All of
those great products owe their current state of sophistication and elegance to ... you and the
cycling community.
You see, although Hanz and Alan Scholz made the Green Gear line of travel products happen, it
is our customer's feedback and suggestions that really evolved our line of products. By asking for
a better fit, easier travel, different colors, moving a set of water bottle bosses or just a different
type of component, you have made our products what they are today.
We would LOVE to hear from you, so please call, email or fax us; or drop into our Eugene,
Oregon factory for some bike talk. Tell us anytime what works for you, and what doesnt. What
you would like the next time you buy, or could use right now. We are here to listen to you.
So please let us know how we can make your SatRday better!
HOW DO YOU CONTACT GREEN GEAR?
Call us at 1 (800) 777 — 0258 Monday through Friday, 8am to 5pm Pacific Time.
Are you stuck and need after hours support? Just call the same number and listen to the voice
mail directory. Press 2, and you will be connected to one of our service technicians on call —
24hrs a day!
Are you outside the US? Dial the US country code and then (541) 687 — 0487.
Or email us at [email protected].
The fax works too, try 1 (888) 394 — 7797 in the US, and (541) 687 — 0403 outside the US.
Be sure to let us know when and what the best way to respond to you is!
Need a reason to call?
e Talk to your own salesperson for any of your needs. If they can't answer your
question, they will find someone who will.
* Our mechanics in Customer Support can walk you through any repair or other service
need.
e Hanz and Alan Scholz love to hear from the Green Gear community. That's night —
you can talk to the President or CEO for just about anything. Try that with Ford or
GM!
Our Marketing department would love to know how to get involved in your cycling
community — so let's plan a group ride sometime!
e Orjust call us to say hi! (We love postcards, too.)
This manual is a preliminary copy and was meant to accompany the SatRday assembly and
packing video. We will mail you an updated manual when one becomes available. Don't forget
to check our website for updates as well. We recommend that you watch the video first, before
you start to assemble, so that you can get an idea of the sequence. But if you are too impatient
to wait, go ahead and get started.
If you do not have a VCR/TV on which to watch the video this manual should be able to get you
on the road. Although there appear to be many loose pieces in the suitcase, don't panic! The
SatRday goes together smoothly with some logical thinking. If you have questions or trouble
assembling or packing your SatRday for the first time, call us! We want to help you get on the
road as soon as possible.
Here are a few tips to help you assemble your new SatRday for the first time:
Be sure to work in a quiet, sheltered, well lit area. You will discover that a bike in a
suitcase (let alone a recumbent) is going to attract public attention and lots of
questions. (Which can be good, depending on your demeanor.)
If you find yourself stuck, take a break and do something else for 10 minutes and
think about all the great places that you are going to ride to on your new SatRday.
If you are not confident in your mechanical skills, enlist the help of a cycling friend.
Give yourself plenty of time the first few times you pack and unpack your SatRday.
There is nothing worse than being rushed because your train is about to leave. An
hour should be enough..
If you can't get it all back into the suitcase and you have to catch a flight, there is
nothing wrong with carrying the front wheel in your hand!
AS you gain experience with your SatRday, you will probably think of a few extra things to bring
along. We recommend:
Some chain oil. There are many brands available, and all work well. Basic machine
oil works well in a pinch.
Keep some Tn-Flow with you as well. It is a little too thin for chains (It can wash out
easily), but it works great on sticky cables and housing.
You should find a few spare spokes with your extra literature and information on your
SatRday. Keep them with you. Even if you do not feel comfortable repairing your
own wheels, your local mechanic will be thankful you have some of the right length.
Despite the protection of the cotton gloves, some hand cleaner is a good idea.
An old towel or rag can serve many purposes from dirt wiper to folding work bench.
Spare tubes and patches are a must. Don't forget to call us at 1 (800) 777 — 0258
and stock up before your next long tourt
On really long or remote trips a spare tire is an excellent idea as well.
A couple of spare brake and shift cables on long tours is recommend.
A few spare bolts are a good idea. The most common thread on bicycles (and your
SatRday) is 5mm x 0.8 or 10/32 in SAE sizes. Both are available everywhere in bike
shops or hardware stores, or call us.
And don't forget your referral cards! Our bikes attract attention and questions — be
prepared.
it is time to get started!
Green Gear Inc 1 (800) 777 — 0258 2
SatRday Beta 1/99 www. bikefriday.com
10.
Assembling Your SatRday Recumbent
Find a well lit, quiet area in which to assembly your SatRday. A good spot is near a VCR and
TV so that you can watch Hanz assemble a SatRday with you. Watch a segment of the
assembly or packing process first, then pause the video tape and try to complete that step
before you go on. Give yourself ample time to assemble or pack your SatRday for the first
time.
Open the suitcase. If you are unable to open the lock on the suitcase, check the
combination, it should be 000. To set a personal code, open the center latch and pivot it up
so you can see the back of the latch. You should see a silver colored metal plate with a tab
sticking out. Push the tab up and to the side so that it stays in place. Set your personal
three digit code on the front. Now push the tab over and back down to its original position.
Your new code has been set. Keep your number in a safe place and call Green Gear at 1
(800) 777 — 0258 and we will record it in your database file.
In the video you will notice that our prototype SatRday was packed with a Travel Trailer. It
consists of two trailer wheels and the trailer frame. If you did not order the Travel Trailer,
then disregard that part of the video. The packing of the rest of the bicycle does not change
when there is no Travel Trailer.
Pull out all of the loose pieces and accessories and set them aside. You want to isolate the
main part of the folded bicycle. Keep the accessories in a handy spot such as the opened lid
of the suitcase.
You will find a light blue felt bag folded in on itself. This is the tool kit, and has everything you
need to assemble your SatRday. Inside you will find a pair of cotton gloves, a combination
headset - pedal and 3x7 hub wrench, a 4mm Bondhus driver to mount racks and
accessories, an 8mm hex key (for crank arms) and a nifty folding tool. The folding tool has all
the common hex key wrenches you will need. You will also find a quick release in the tool
pouch for the seat frame.
If you ordered the Travel Trailer option, then remove the yellow bags from the case and set
them aside.
In another light blue felt bag you will find a loop of chain called the jack chain, put it aside for
now. This bag will also be used to store your pedals.
Carefully lift out the folded recumbent, holding the frame in the folded position. You will
notice that the handlebars are attached to the frame by their cables. Try not to kink or
damage these cables, as it will compromise shifting and braking.
Once the bicycle is on the ground, unfoid the front boom (the part supporting your crankams)
pivoting it forward. Then swing the rearend all the way back. You will notice that the rear
wheel is loose in the rear end, and not seated in the dropouts. This was done to facilitate
packing.
Seat the rear wheel in the rear dropouts. You may need to untangle any loops in the drive
chain as you guide the hub axie up into the dropouts.
Your SatRday is equipped with a Sachs 3x7 hub (pronounced “three by seven”). You will
notice that the rear hub does not have a quick release lever like in the video. The 3x7
has a solid axle and uses axle nuts to retain the wheel. This was done to allow for the
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SatRday Beta 1/99 www.bikefriday.com
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intemal shifting mechanism. The right side of the hub should have a long nut and the left
side just a plain nut.
There is also a washer that has a bent in tab on it. The washers need to go on the
outside of the dropouts (between the nut and the frame), with the bent in tab on the
bottom of the axle (towards the ground) and the little tab should face inwards (towards
the spokes).
If you have trouble getting the wheel seated in place, try removing the axie nuts and the
washers. Then slip the bare axle into the dropouts (the axle has no up or down). Now
add the washers to each side (checking their orientation as in the above paragraph) and
finally the nuts. Tighten the axle nuts down with the supplied combination tool. Make
sure the frame is all the way down on the axle when you do this.
Untangle the handlebars and the cables. If you ordered over the seat steering, ignore this
step (you will be shown how to mount your handlebars later). If you ordered under the seat
steering, remove the blue vinyl covers from under the seat boom. You will see a black
bracket with two tubes, side by side and a quick release. These two tubes are for your
handlebars. You will notice that one of the handlebars is slightly longer than the other (from
the grip to the weld). Slip the longer handlebar into the rearward tube from one side, and the
shorter one into the front tube from the other side. Roughly position the handlebars so that
the ends are parallel, and tighten the quick release. (Make certain that the quick release
lever is oriented on the top of the quick release cap — otherwise it may interfere with the
suspension.)
Now mount the right hand crank arm on the front boom. Set it so that it is opposite of the left
crank arm, and tighten down the crank arm bolt with the 8mm hex key. With the new style
Shimano splined crank ammns it is possible to accidentally misalign the crank arms ever so
slightly. If this happens loosen the crankarm bolt slightly and readjust the crankarms and
retighten the bolt. Check the tightness of this mounting bolt after the first 100 miles of riding.
Next install the jack chain. Drape the chain over the front chain ring. Then lift the boom so
that it is upright and slip the other end of the jack chain over the jackshaft (the small cog near
the hinge for the rear end). Start to lower the forward boom, but stop before the chain gets
tight. You should see a pivoting hook held in place by a spring (near the hinge for the
forward boom). Lift the hook over the chain. Now firmly push the boom all of the way
forward and down. As you push the boom down, the chain will get tight and then loosen a
little, as it “snaps” in-place. With the chain installed the bike should hold its form now, and the
rear end will not easily pivot back down.
Now we need to mount the seat. Remove the other blue vinyl covers on the seat boom. You
should see a black bracket in front with a slot in one side and a quick release lever, Alian the
slot in the bracket with the rail on the left side of the seat boom and slide it part of the way
back. Leave the quick release loose.
Now assemble the two halves of the black aluminum seat frame. On the seat back you
should see two extension tubes with a collar on each side. Pull one of the collars back so
that it is flush at the end of the tube. Keep the other one slightly extended. Plug one end of
the seat bottom into the seat clamp that you left slightly extended. Align the other side of the
seat bottom with the clamp you left flush and then pull the clamp down so that both halves of
the seat are held in place. The seat back should be joined to the seat bottom so that the flat
part of the seat is on the concave side of the seat back. Make certain that the clamps equally
span the joint on the two halves of the seat frame and the binder bolts are facing towards the
rear. Tighten the bolts with your folding tool.
Green Gear Inc 1 (800) 777 — 0258 4
SatRday Beta 1/99 www .bikefriday.com
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Select the quick release you took out of the tool bag and remove the nut. Set the seat frame
on the bike so that the mount (under the seat bottom) fits over the black bracket on the seat
boom and the holes are lined up. Slide the quick release through from left to right and add
the quick release nut again. Keep it loose for now.
The seat now rotates and pivots on the front seat mount, as well slides back and forth on the
seat boom. Behind the seat back is a pair of small fork tips that engage another quick
release bracket further back on the seat boom. Firmly set the fork tips into the mount and
tighten all of the quick releases on the seat assembly. Once the bike is ready to nde you will
need to experiment with the seat position for yourself. When you have the seat position just
right, keep the rear seat mount fixed in place next time you pack your SatRday. This way the
seat position will automatically reset itself properly.
Install the seat cushion by aligning the Velcro strip on the bottom of the cushion and the top
of the aluminum seat bottom. Then hook the two webbing pockets at the top of the backrest
over the top of the bars on the seat back. Now connect the buckles across the back of the
support brace on the seat back and tighten down securely. Adjust the tension as needed for
comfort.
If you ordered over the seat steering, then this step is for you. If you have not done so
already, turn the steering column and fork 180 degrees around to the right so that the fork is
facing forward. The steering column is already attached to the top of the fork's steerer tube.
It telescopes up and down by loosening the quick release in the middle of the column. The
two handlebar halves fit into each other and can slide quite a ways together. Join the
handlebars in the middle of the clamp at the top of the steering column and set a comfortable
position for yourself. Tighten the knurled clamp at the top. You may have to readjust the
handlebar position on your first ride.
Install your pedals on the cranks. The right hand pedal should be labeled with an R and
threads in with a clockwise motion. The left pedal should be labeled with an L and threads in
with a counter-clockwise motion. Tighten both pedals securely.
To install your front wheel you will need to open your front V-brake by squeezing together the
two brake arms while pulling the elbow shaped cable tube out and up from its carrier. The
brake arms should now be wide open and loose.
Install the front wheel in the SatRday fork. The quick release in your front wheel is a very
powerful cam, not a wrench. Adjust the nut on the quick release shaft so that with the wheel
in the fork, you can swing the quick release arm only half way through its movement. The
quick release should begin to get tight when the lever is in a straight line with the hub and
axie. Then stop adjusting the nut and push the quick release over the rest of the way
securing your front wheel. BE SURE YOU UNDERSTAND HOW TO USE A QUICK
RELEASE PROPERLY BEFORE YOU RIDE. IF YOU DO NOT UNDERSTAND HOW TO
PROPERLY SECURE YOUR WHEELS, PLEASE CALL US ANYTIME DAY OR NIGHT
FOR ASSISTANCE.
Now close the front V-brake. Pinch both arms together so that the brake shoes contact the
rim on the wheel. Then guide the elbow shaped tube back into its carrier. Test the brake by
squeezing the lever. You should have adequate braking power. If the brakes feels soft or do
not contact the rim, inspect the routing of the brake cables and housing to make certain that it
IS properly seated everywhere. Please call us if you have questions about your brakes.
Close the rear brake ams in the same fashion. ‘
You will need to hook up your 3x7 shift cable to the rear wheel. You should see a small chain
and ribbed bar coming out of the right side of your rear wheel's axie nut, called an indicator
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chain. This is what controls the intemal shifting. There will be a slack cable with a black
plastic piece (called a cable anchor) hanging off of your frame on the night rear side that
connects to the indicator chain. To properly connect and adjust the cable anchor to the
indicator chain:
« Pedal one tum backwards so that the hub can shift into the high (or overdrive) gear.
This is the default setting in the hub.
* Move your left shift lever so that all of the cable is extended out of it.
« Then slip the end of the cable anchor over the end of the indicator chain until there is
no slack left in the shift cable. Don't go so far as to pull the spring loaded indicator
chain out of the hub, but do remove any slack.
« If, on a test ride, you are unable to engage the lower or climbing gear in your 3x7
hub, then tighten the cable anchor one or two clicks by pushing it further on the
indicator chain.
If you cannot return to the high gear or downhill gear, then the cable is too tight and
you must loosen the cable anchor one or two clicks by pressing on the little metal tab
on the back of the cable anchor briefly.
о For more information on your 3x7 hub, see the enclosed pamphlet or call us.
26. Mount any extra accessories you desire such as racks or water bottle cages. Check your tire
pressure and don't forget a helmet. On our first ride, take along the folding tool just in case
you have any last minute adjustments to your new SatRday.
27. Have fun and good luck!
Green Gear Inc 1 (800) 777 — 0258 6
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To Quick Fold Your SatRday Recumbent
A quick fold is whenever you need to take advantage the space saving virtues of the SatRday,
but do not need to put it back into its Travel Case. There are varying degrees of quick folding for
your daily needs. You can make it very small with a little extra effort, but if you only need to put it
into the trunk of your car then the first kind will be small enough. Experiment for yourself. Let us
know if you have any better ideas.
The Quick, Quick fold:
1. If you have over the seat steering, turn the whole steering column and front wheel around
180 degrees to the left. If you have under the seat steering, skip this step.
2. Fold the forward boom back so that it rests in the seat.
3. Then lift the SatRday so that the rearend can swing forward and under the frame.
4. Done, that's it!
If you need to make your SatRday even smaller so it will fit into our Travel Bag, then:
1. Open both quick releases on the seat boom and fold the seat forward. Leave the seat
mounts tight on the seat boom if you can. (If you have over the seat steering, then you would
have folded the steering column all of the way forward as well.)
2. On under the seat steering equipped SatRdays, open the quick release that clamps the
handlebars and slide the handlebars towards each other. Point the left handlebar end
towards the ground.
3. Now rotate the seat to the left and let it hang face down on the left side of the recumbent.
The left side handlebar that you pointed towards the ground should now clear the seat (under
the seat steering only).
5. On SatRdays equipped with over the seat steering, narrow the handlebars by loosening the
handlebar clamp and pushing the handlebars in towards each other. Then tum the whole
steering column and front wheel around 180 degrees to the left.
4. Fold the forward boom (and the steering column, if you have over the seat steering) all the
way back. It should rest nearly flush with the top of the SatRday.
5. Lift the recumbent and swing the rearend under the bicycle.
6. You now have a very compact recumbent. There is a shock cord attached to the forward
boom that you can use to keep it all together. Unhook one end of the shock cord from the
forward boom and pull it over the top of the frame and hook it around the rear derailleur
assembly.
7. Done!
To unfold your SatRday:
1. Unhook the shock cord from the rear derailleur and string it along the forward boom.
2. Swing the rearend around first. If you try to unfold the forward boom first, you will not be able
to swing the rearend around because the jack chain will be too tight.
3. After you have the rearend unfolded, pivot the forward boom over and “snap” down.
4. If you have over the seat steering lift the steering column and tum the handlebars and front
wheel back around to the right — in the opposite direction you turned when you folded the
bike. (If you continue totum the handlebars in the same direction as when you folded the
Oe. you will tangle up the cables around your fork and head tube!) Reset the handlebar
width.
Swing the seat up and onto the forward boom so that it is out of your way.
If you have under the seat steering pull the handlebars apart and reset their position.
Now pivot the seat back until it engages the rear quick release on the seat boom. Since you
left the position of the rear seat clamp intact when you folded it, your seat position has not
changed.
8. Make certain all quick releases and clamps are tight!
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Ln
Packing Your SatRday
Just like when you assembled your SatRday recumbent for the first time, look for a quiet, well lit
area in which to work and give yourself plenty of time. With a little practice you should be able to
pack your recumbent in about 15 minutes, but give yourself about an hour the first time. Since
you probably dont remember how the bike was packed or oriented in the suitcase when you
assembled it (kind of like Christmas moming?) you may need to pay close attention to the video
and pause on critical moments. Please call us with questions anytime!
Packing your SatRday can be done in more than one way, so please experiment. Let us know if
you have some good ideas.
1. Remove the jack chain. Pivot the forward boom back part way to loosen the jack chain and
unhook it from the chain guide, the chainring and the jackshaft. Place it in the light blue felt
bag and set aside.
2. Remove the left pedal using your headset-pedal wrench. Since it is a left-hand thread, tum
the pedal spindle clockwise. The pedal can fit into the light blue felt bag along with the jack
chain.
3. Remove the right crank. Use your supplied 8mm hex key wrench to loosen the crankamm
bolt. It will come loose readily, but it will then appear to tighten again as you continue to tum
it counter-clockwise. Despite this, keep tuming the bolt and the crankarm will come off. You
can leave the right pedal on the crankarm and place both in the dark blue felt bag.
4. Loosen the quick releases on the seat mounts. The front quick release that serves as the
front seat hinge should be removed and placed in the tool kit. Although you will need to
loosen the quick release that holds the fork tips on the back of the seat, leave the rear seat
mount tight on the seat boom, this way your seat position is set in place. Put the seat aside
for now. Slide the front seat mount as far back as you can to help in packing. Cover the
mounts with the blue vinyl packing pieces.
5. Loosen the rear wheel using the small end of your headset-pedal wrench. You do not need
to disconnect the Sachs 3x7 shift cable from the indicator chain.
6. Open the rear brake by squeezing together the two brake ams while pulling the elbow
shaped cable tube out and up from its carrier. The brake arms should now be wide open and
loose. Leave the rear wheel in place for now.
7. Open the front brake in the same manner and remove the front wheel. Set it aside.
8. On either type of steering system, loosen the handlebar clamp and separate the handlebar
halves. Let the handlebars hang loose by the cables. Compress the steering column on
SatRdays equipped with above the seat steering, and tum the steering column and front
wheel 180 degrees around to the left. If you have under the seat steering, leave the fork
facing forward.
9. Fold the forward boom back against the seat boom, and then lift the bicycle and swing the
rearend under the frame. Lay the bike down.
10. Prepare the Travel Case for packing. Empty any loose items from the case and then place
the two trailer wheels (if you ordered the Travel Trailer option) in the bottom of the case
towards the back and to the right. The trailer wheels should be side by side as in the video.
Keep packing materials you might need in the lid of the case for easy access.
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SatRday Beta 1/99 www. bikefriday.com
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The crush protector is the PVC dowel with the flanges at each end. It spans the middle of the
Travel Case and transfers luggage loads through the case and not through the bike. Put the
loose flange of the crush protector in the bottom of the case in the middle by the trailer
wheels.
Set the SatRday in the Travel Case with the rear derailleur up and towards the back, the fork
on the left side (with the fork dropouts in the back left corner), the forward boom and seat
boom along the front by the handle and the jackshaft towards the right. You will notice that it
won't quite fit in the case because of the rear wheel. Since you had loosened it earlier, just
push the rear wheel out of the dropouts towards the middle until the frame sets into the case.
Leave the handlebars hanging outside the case for now.
If you have the Travel Trailer option, make certain that the axie for the jackshaft is poking
through the spokes of the trailer wheels in the bottom of the case, and not resting on top of
the trailer wheel. Otherwise the bike may be too high in the suitcase.
Take apart the seat assembly. Remove the seat cushion, fold it and set aside. If you have a
water bottle cage attached to the seat frame, you will need to remove it. Loosen the clamp
bolts that secure the two halves of the seat frame and slide the clamps up and out of the way
onto the seat back. Then add the two clear vinyl tubes to cover the stubs on the seat bottom.
To pack the seat bottom, carefully slip the seat bottom upside down under the rear wheel in
the Travel Case. When the seat bottom is properly packed it should be upside down, the
vinyl covered stubs along the front of the suitcase (tucked around the frame) and the seat
bottom should be slightly to the right of the rear hub axle so that the rear wheel sits flat.
If you have the Travel Trailer option pack the longer yellow bag with the trailer tongue now. It
should fit in with the long straight part of the bag parallel to the front of the suitcase and the
“S” tum on the left side, under the rear wheel and the left side stub on the seat bottom should
hook over the yellow bag.
Cover the handlebars with the vinyl packing pieces and set them into the front left comer of
the suitcase. It is important to protect the cables from damage. There should be a pocket in
the front left comer of the suitcase to nest both handlebars together. :
Lay the front wheel on top of the bike in the right side of the Travel Case. Unlike other Bike
Fridays, you can leave the quick release lever in the wheel.
Select the seat back and cover the vertical tube on the right with a clear vinyl sleeve. Then
place the seat back, concave side down, over the rear wheel with the vinyl covered part along
the front of the suitcase. You will need to lift the drive chain slightly as you insert the seat
back.
If you ordered the Travel Trailer, the remaining short yellow bag with the trailer axles can be
placed along the rear of the suitcase, behind the front wheel.
Now add any remaining accessories such as the pedal bag, tool bag, crankarm bag or any
other miscellaneous items to the case. Try to group them together so they lock each other in
place.
Important: Lastly thread the dowel of the crush protector through the bicycle and into the
socket on the lower flange. You may have to fish for the lower flange a bit, and when you
have it, just press together. The crush protector is the single most important packing piece
you have after the Travel Case. The bicycle may be damaged without it.
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THIS 15 YOUR
DIKE FRIDAY
SAT R DAY
andle Bars
This is a photo of your bike with out the smaller items (i.e. stem, pedals, extra
tubes, etc.), so that you will be able to see where we put the major pieces. The page
is prelabeled, so if you don't have a rear rack or trailer on order, please disregard the
Crank "és Е TD AE R
FEE Front Wheel
LT
Seat Back |@
Trailer Kit
This is your bike, just add the seat pad and netting, and its ready to shut the case.