Owner`s Manual 3201 John Joanis Dr. • Stevens

Owner’s Manual

3201 John Joanis Dr. • Stevens Point, WI 54482

PH: 715-340-1133 • FAX: 715-341-7414

www.volaerecumbents.com • [email protected]

2

2013

ContentS

Chapter 1 IntroDuCtIon

1-1 Thank You ................................................3

1-2 Overview ..................................................4

Chapter 2 SetuP & ASSembly

2-1 Unpacking ................................................5

2-2 Assembly .................................................5

2-3 Chain Routing (Single).............................5

Chapter 3 ADJuStmentS

3-1 Adjusting Boom (Single) ..........................6

3-2 Adjusting Boom - Tandem .......................6

3-3 Handlebar/Stem/Riser System ................6

3-4 Stem Length, Rider Arm Position

& Adjustable Boom ..................................6

3-5 Idlers, Idler Placement

& Cassette Size .......................................8

3-6 Carbon Seat .............................................8

3-7 Fitting 10

3-8 Tire Pressure ......................................... 11

3-9 Weight Limits ......................................... 11

3-10 Final Inspection ...................................... 11

Chapter 4 trAVel FrAmeS

4-1 ES Frame (Travel Single Frame) ...........12

4-2 S&S Couplers (Travel Tandem Frame) .12

Chapter 5 rIDIng your VolAe

5-1 Starting ..................................................13

5-2 Stopping .................................................14

5-3 Riding/Handling .....................................14

5-4 Muscles ..................................................15

5-5 Pedals ....................................................15

5-6 Descending ............................................15

5-7 Transporting Your Volae ........................15

Chapter 6 tAnDem

6-1 Load Limit ..............................................16

6-2 Chain Routing ........................................16

6-3 Tandem Setup Adjustment .....................16

6-4 Boom & Timing Chain Adjustment .........17

6-5 Steering System ....................................17

6-6 S&S Couplers ........................................18

6-7 Descending on a Volae Tandem ............18

Chapter 7 WArrAnty & SerIAl number

7-1 Volae, LLC. Warranty .............................19

7-2 Serial Number Location .........................20

Warranty registration Card ........................................21

Chapter 1

IntroDuCtIon

1-1 tHAnK you For CHooSIng A VolAe reCumbent!

Proudly made in the U.S.A., Volae recumbents are designed to out-perform the best upright road racing machines while providing incredible comfort. Please take a few minutes to fill out your warranty registration card and to read these important points about recumbents and bike riding in general.

AlWAyS WeAr An AnSI or Snell APProVeD Helmet

Wearing a modern bicycle helmet may save your life or prevent serious head injuries if you are involved in an accident.

CHeCK your bIKe CAreFully beFore eACH rIDe

Spend a few moments before each ride inspecting your Volae for problems.

• Check all nuts, bolts and other fasteners to make sure none are loose.

• The tires should be inflated to no more than the pressure molded on the sidewall.

• Tires should not be excessively worn and be free of cuts or imperfections.

• The wheel rims should be straight. Spin the wheel and observe the gap between the rim and one of the brake pads. There should be very little wobble as the wheel rotates.

• Squeeze each brake lever to make sure there is no binding and the brake pads press hard enough on the rims or the disc brakes contact the rotor to stop the bike. The brake pads should be centered on the rim and not touching the tire.

• Sitting on the bike, swing the handlebars from side to side checking for binding or interference. Check to make sure the stem bolts are tight.

• If you are unsure of the condition of your Volae recumbent, DO NOT RIDE IT until the problem has been corrected. If you have any questions, contact your Volae dealer or take it to your local professional bike shop.

• The wheel and seat quick release skewers should be clamped shut with at least 20 lbs (14kgf) of force, and a sharp blow to the top of the tire should not knock the wheel loose. Study the wheel/seat skewer operation diagram below.

To adjust the skewer to the proper tightness, open the skewer handle, adjust

(tighten or loosen) the skewer nut slightly, then close the skewer handle. It should take 20-45 lbs of force to close the handle as shown.

gloVeS Are reCommenDeD

With its low center of gravity, you don’t fall very far on a recumbent, but your hand will often touch down first. A set of bicycling gloves will protect your skin.

ProteCt your eyeS

Recumbents position your head to look forward. Uprights position your head to look forward and down. Keeping the sun out of your eyes on a recumbent requires a different visor than is provided on standard helmets. We recommend the “Bent Ray Visor”, available at the Hostel Shoppe, to help keep the sun out of your eyes. Sunglasses help keep bugs, dirt and sun out of your eyes making it easier to avoid obstacles.

PrACtICe rIDIng your VolAe

Before you mix it up with traffic, spend enough time on your recumbent in an empty parking lot, driveway or other open area to get used to its unique riding position. See “Riding Your Volae” for more important riding tips.

neVer rIDe At nIgHt WItHout reFleCtorS AnD A Front AnD reAr lIgHt!

eXPerIment WItH DIFFerent SeAt PoSItIonS AnD SeAt AngleS DurIng your PrACtICe PerIoD

Your Volae recumbent has many adjustments and special features that fit the bike to you. A more reclined seat, sport position

(Fig. 3-9)

, may make balance and handling more difficult at first. Start with the seat a little more upright, recreational position

(Fig. 3-8)

, and gradually recline it as you become more comfortable with the handling.

be CAreFul WHen rIDIng In Wet ConDItIonS

No rim brakes work as effectively in wet weather as they do in dry. It takes longer to stop in wet conditions. Also, ride slower through corners since tires will skid more easily on wet pavement.

3

4

uSe CAutIon WHen negotIAtIng rougH roADS AnD unPAVeD roADS

Volae bicycles are road bicycles and are not designed to be ridden on unpaved surfaces. Sand or gravel may cause you to lose control and crash. Pavement covered with sand or gravel may also cause tires to skid. No road tire/wheel is designed to be ridden aggressively over rough roads, chuck holes or railroad track crossings. Slow down for the rough stuff. Your wheels and tires will last much longer and you may avoid an accident.

rePlACe your tIreS beFore tHey WeAr out

A flat tire may cause you to lose control and crash. Tires can be damaged from riding too fast over chuck holes or hitting objects on the road. Tires don’t always fail immediately. Inspect your tires regularly and replace them if they show any sign of damage or excess wear. Err on the side of replacing your tires too soon, rather than to late. This can reduce the chance of a blowout or flat.

get In tHe HAbIt oF WAtCHIng tHe roAD SurFACe For DebrIS

Your best protection against flats is to avoid riding over a sharp object. Glass and other sharp objects do not discriminate. They puncture new tires just as easily as old tires.

1-2 oVerVIeW

Chapter 2

SetuP & ASSembly

2-1 unPACKIng

Volae bicycles are shipped with the front wheel removed, the stem riser rotated sideways, the handlebars rotated down, the rear seat bracket disconnected and the pedals removed (if included with the bike). Please be sure to save the shipping carton and packing materials in the event that your Volae has sustained any shipping damage and needs to be returned.

2-2 ASSembly

(Your bike may be shipped with steps 3 & 4 already done for you)

1. Unpack your bike carefully and make sure that all parts are removed from the box. Tools required for reassembly include a pedal wrench and a 4mm & 5mm Allen wrench.

2. Install the front wheel

(Fig. 2-1)

. Detailed quick release skewer instructions are in Chapter 1.

3. Loosen handlebar stem face plate bolts and rotate handlebar to horizontal position

4. Attach rear seat mount to seat stays

(Fig. 2-3)

.

5. Install pedals: Be sure to grease threads before installing. The right pedal is

right-hand threaded (turn clock wise to install) and the left pedal is left-hand

threaded (turn counter-clock wise to install).

(Fig. 2-2)

.

0°

Fig. 2-1 Fig. 2-2

2-3 CHAIn routIng (SIngle)

Proper chain routing is shown in

(Fig. 2-4)

below. If you reinstall your chain at any time make sure that you use the chain routing shown below. Periodically check to make sure that your chain routing has not changed. It’s possible for chain routing to change without removing and re-installing the chain. This usually happens when transporting your Volae.

(Fig. 2-5)

and

(Fig. 2-6)

below show examples of improper chain routing that can result from a number of causes including, but not limited to, transporting your Volae and parking it in a bike rack next to other bikes .

InCorreCt CHAIn routIng #1

Fig. 2-3

CorreCt CHAIn routIng

Drive chain

(top chain)

Is under rear idler

Return chain

(bottom chain) is over front idler.

Fig. 2-4

InCorreCt CHAIn routIng #2

Return chain

(bottom chain) is caught on top of rear idler.

Fig. 2-5

Drive chain (top chain) is caught under front idler.

Fig. 2-6

5

6

3-1 ADJuStIng boom (SIngle)

Volae adjustable boom bikes also have adjustable seats. Thus, after the initial set up, adjusting the boom is usually not necessary. Your dealer should have the boom adjusted with the proper chain length when you get the bike and you should be able to make desired seat adjustments without adjusting the boom. Additional boom adjustments, if needed, should be done by a trained bicycle mechanic who knows how to check for proper chain length.

note: Failing to add chain when lengthening the boom may damage the bike and could cause an accident. As the boom is lengthened (moved out) the chain must be lengthened and as the boom is shortened (moved in) the chain should be shortened.

It’s better to have a little too much chain than not enough chain.

Recommended torque setting for the boom pinch bolts is 70 inch pounds. Make sure the threads of the pinch bolts are greased.

Align the boom by standing in front of the bike and checking to see that the chainrings are visually close to vertical. You will never get them perfectly vertical. Getting within 1.5° of vertical is close enough.

Handlebar

3-2 ADJuStIng boom (tAnDem)

See Chapter 5 on Tandems in this manual.

3-3 HAnDlebAr/Stem/rISer SyStem

SteerIng ASSembly ADJuStmentS

The Volae steering assembly consists of the handlebar, stem and riser

(Fig. 3-7)

. This design allows the rider a great amount of flexibility in customizing the steering assembly to fit his/her needs.

Stem riser

Fig. 3-7

3-4 Stem lengtH, rIDer Arm PoSItIon AnD boom ADJuStment

The Hostel Shoppe has a variety of stems available in different lengths to help you achieve the arm position you prefer. This allows you to choose the arm position that is most comfortable for your riding style.

In the recreational position, the arms have more of a bend at the elbows a slight bend at the elbows

(Fig. 3-9)

(Fig. 3-8)

. In the sport position, the arms should have

. We recommend riding in the sport position with a comfortable amount of bend at the elbows. This will cause the shoulders to be rounded slightly forward, which will make the contact between the upper back and the seat very comfortable on long rides. The sport position may feel a bit strange at first but after riding that way for a while most riders prefer it.

Fig. 3-8 Fig. 3-9

SHortenIng tHe rISer

As you ride you may find that you can lower the stem on the riser and still have adequate clearance between your shins and the handlebars.

(Fig. 3-10)

If you are consistently using a lower stem/handlebar position, you may want to trim off the excess riser that protrudes above the top of the stem.

(Fig. 3-11)

riser protruding above stem

Fig. 3-10

SHortenIng tHe rISer on All VolAeS:

(note: for professional bike mechanics only.)

1. Remove the Aheadset top cap.

2. Remove the stem.

3. Loosen the riser clamp.

(Fig. 3-12)

(Fig. 3-12)

4. Remove the shift cables and brake cables.

5. Slide the riser up and off of the fork steer tube.

6. Unscrew the Aheadset bolt extender assembly.

(Fig. 3-12)

7. Use a tubing cutter (available at your local hardware store) to cut the riser to the desired length.

8. Replace the Aheadset star nut extender assembly with the proper number of spacers.

9. Reassemble.

(Fig. 3-12)

Fig. 3-11

AheadSet top cap

AheadSet adjusting bolt

AheadSet adjusting bolt extender

glIDe FleX Stem InStAllAtIon

(tAnDem / SIngle VolAe moDIFICAtIon)

When using a Glide Flex you must make sure that the lip on the

Riser Clamp is snug to the bottom of the riser as shown in the

Diagram. When not using a Glide Flex, the Aheadset Adjusting

Assembly presses that Riser against the lip of the Riser Clamp during the headset adjustment process.

A cut away of the Riser Clamp, Riser and Fork Steer Tube is shown in

(Fig. 3-13)

. The Riser Clamp (Brown) clamps the

Riser (Blue) to the Steer Tube (Silver).

lip riser

Spacers threaded rod end of adjusting bolt extender

Star nut location

Fig. 3-12

Fig. 3-13

riser

Clamp riser

Clamp

7

8

boom ADJuStment

Use the following guidelines

(Fig. 3-14)

for the initial boom adjustment. Once the boom is adjusted you should be able to fine tune the fit with seat adjustments. Remember that chain length must be adjusted when adjusting the boom.

Carbon Seat:

1. Set the boom so the lower seat attachment skewer is over Buick Hole #2.

2. Ideal fore/aft weight distribution is achieved, for most riders, when the lower seat attachment skewer is close to

Buick Hole #2 position.

Mesh Seat:

1. Set the boom so the lower seat attachment skewer is over Buick Hole #3.

2. Ideal fore/aft weight distribution is achieved, for most riders, when the lower seat attachment skewer is close to

Buick Hole #3 position.

Carbon Seat Position (A)

4

3

2

1

Mesh Seat Position (B)

3-5 IDlerS, IDler PlACement

AnD CASSette SIze

All Volae bicycles are designed to provide proper clearance between the chain and the frame when used with cassette cog and chainring sizes as indicated in tables at right. Modifications to the idlers and/or idler positions may cause the chain to damage the frame, which can result in frame failure causing an accident, injury or death.

Any changes to the idlers or idler positions, other than replacing an idler with one of the same type and size, void your warranty with regard to damage caused by said changes. If you change either the idler or idler position you are solely responsible for determining that the changes do not cause the chain to damage the frame in any way as a result of riding in any and all gear combinations.

4

Fig. 3-14

3

2

1

Steel FrAme CASSette SIze

Description

Cassette - Large Cog

Size limit

≤ 36 teeth

Cassette - Small Cog

Chainring - Large

Chainring - Small

≥ 11 teeth

≤ 53 teeth

≥ 24 teeth

CArbon FrAme CASSette SIze

Description

Cassette - Large Cog

Cassette - Small Cog

Size limit

≤ 32 teeth

≥ 11 teeth

Chainring - Large

Chainring - Small

≤ 53 teeth

≥ 24 teeth

3-6 CArbon SeAt

AreAS oF tHe SeAt:

return (red): Returns area from shoulder up thru neck to head to a vertical enough position to prevent neck fatigue.

base (blue): Needs to be at correct angle to have some “front to back cup”.

Center (green): Supports middle of back.

the following is very important:

As you drop the seat angle back more of the weight is supported by the green area and pressure that is left on the blue (butt) area is evenly cupped from front to back.

ADJuStIng tHe VolAe SeAt

Important notes: Proper leg extension is achieved by moving the seat forward or backward and adjusting the seat back angle.

Adjustments to both the Seat Slider and the Seat back Angle will change your leg extension. Reclining the seat moves your butt away from the pedals. If your Volae is set up perfectly for leg extension and you decide to recline the seat more, you will have to move the seat base forward slightly to maintain correct leg extension. (Example: Drop the seat back down ½” means you should move the seat base forward about ½”).

The Volae seat position is programmable. Once you have selected the ideal seat slider position and the seat back angle, you can remove and re-install the seat without changing the seat position.

SeAt bACK Angle ADJuStment

The seat needs to be positioned in the proper recline angle range to be comfortable. The seat recline angle is measured on the flat spot at the top of the seat as shown in horizontal as shown in ( on either end.

Fig. 3-15)

and

(Fig. 3-15)

(Fig. 3-16)

. A good starting point for seat recline angle is between 64° to 70° from

. However, some riders may find the seat comfortable outside of this range

Seat too upright:

Too much of your weight is supported by the base of the seat and you are likely to experience butt discomfort. Additionally, you lose some aerodynamic advantage and don’t recruit the strongest muscle group.

Seat too laid back:

This is more an issue of personal preference. However, reclining the seat below 64° doesn’t appreciably improve aerodynamics and may cause neck strain. Some people also find balance to be more difficult when the seat is too reclined.

To adjust the seat back angle:

1. Loosen the screws on the two seat stay collars.

(Fig. 3-17)

2. Adjust the seat to the desired angle.

3. Tighten the seat stay collar screws. These bolts need to be snug enough to keep the seat from sliding when you ride.

Caution: Repeatedly over tightening these screws can cause the threads to strip out.

Seat in reclined position.

Seat in upright position.

Seat Stay

Collars

Approx.

64 degrees level level

70 degrees

Fig. 3-15 Fig. 3-16

Fig. 3-17

9

10

3-7 FIttIng leg eXtenSIon ADJuStment

Your position on the seat usually shifts forward slightly when you start riding and settle into the seat. We accommodate this shift forward in the following method by allowing ½” to accommodate “settling in.

1. Start by adjusting the seat so the heel of your foot is 1/2” from the pedal in its most forward position, with a straight leg

(Fig. 3-18)

. This should result in a slight bend at the knee when the ball of your foot is placed on the pedal after you start

(Fig. 3-19).

riding and settle into the seat

2. Fine-tune the seat adjustment, after riding, to make sure that you still have a slight bend in the knee at the forward most pedaling position.

3. Pointing your toes to reach the pedals “Ankling”

(Fig. 3-20)

is not recommended.

Proper foot position.

toe pointed too much. “Ankling”

Fig. 3-18 Fig. 3-19

Most forward pedal position

Fig. 3-20

SeAt SlIDer ADJuStment

The seat slider mechanism has a front and rear position as well as a forward and backward orientation. The front position uses holes 1 and 2 and the rear position uses holes 2 and 3. backward orientation is shown in

(Fig. 3-23)

.

(Fig. 3-21)

The forward orientation is shown in

(Fig. 3-22)

and the

Adjust the slider position and orientation to get the proper leg extension. The seat slider is adjusted by loosening the two quick adjust levers that attach the slider to the frame. Most riders will find the proper seat position and not need to adjust these levers again. The seat slider levers are not used to remove and reattach the seat.

Some riders will need to frequently adjust the seat to accommodate different family members or friends.

1

2

3

Fig. 3-21

4

Forward orientation

Fig. 3-22

backward orientation

Fig. 3-23

toP HAt nut For SeAt AttACHment

PurPoSe oF toP HAt nut

This special nut is designed to keep the seat from coming off when riding even if the seat attachment skewer is not properly tightened. Of course, you should always tighten the seat attachment skewer but if you forget this gives you an extra margin of safety.

ProPer InStAllAtIon oF toP HAt nut

Shoulder

(A)

on Top Hat Nut needs to fit into slotted hole

(b)

in right side of seat mount.

(Fig. 3-24)

note: When reversing the seat slider orientation the seat attachment skewer needs to be reversed as well to keep the top hat nut on the right side of the bike. The shoulder

(C)

of the top hat nut needs to be to the inside (towards seat slider) as shown in

(Fig. 3-25)

(Right side is to the right as you are sitting on the bike.)

(Fig. 3-26)

b

C

Seat

Slider

A

Fig. 3-25

Fig. 3-24

Fig. 3-26

3-8 tIre PreSSure tIre & WHeel InFormAtIon

Front: Tour, Century, Venture - 20”, 406mm bead seat diameter

Expedition, Expedition Pro - 26”, 559mm bead seat diameter

Club, Team - 650c, 571mm bead seat diameter

rear: Tour, Century, Venture - 26”, 559mm bead seat diameter

Expedition, Expedition Pro - 26”, 559mm bead seat diameter

Club, Team - 650c, 571mm bead seat diameter

Inflation Pressures: Inflate to the pressure molded on tire sidewall. Check your pressure every ride.

Carbon Fiber

Skewer Plate

3-9 WeIgHt lImItS

Steel FrAme WItH or WItHout ADJuStAble boom

The combined rider/gear load limit, on a Volae Steel single frame (not including ES Frames) , is 250 lbs.*

Steel FrAme eS moDelS (tAKe-A-PArt SIngle bIKeS)

The combined rider/gear load limit, on Volae ES frames is 230 lbs.*

CArbon FrAmeS

The combined rider/gear load limit, on Volae Carbon frames is 230 lbs.*

tAnDem

The combined rider/gear load limit, on a Volae tandem, is 500 lbs.*

Captain weight limit: 250 lbs.

Stoker weight limit: 230 lbs.

Handling may be adversely affected by a stoker that is heavier than the captain.

*Note: You can be under these weight limits and still have problems with overheating rims and brakes on long steep descents.

3-10 FInAl InSPeCtIon

Before each ride inspect the fasteners on the bike, looking for any parts that may have loosened. Check the alignment of the wheels, and inspect the brakes to make sure the shoes contact the rims squarely and bikes with disc brakes contact the rotor to stop the bike. The handlebars should be aligned and able to turn from side to side without binding or interference. Check that the wheel skewers are secure, and that a sharp blow on the wheel while you hold the bike off the ground, will not jar the wheel loose.

Check that all seat and wheel skewers are secure. See Chapter One for more details.

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12

Chapter 4 trAVel FrAmeS

4-1 eS FrAme (travel Single Frame)

Some travel bikes compromise performance to make the bike extremely compactable for traveling. The cleverly engineered

Volae frame separates in the middle to facilitate packing in a standard bike travel case while preserving the high performance that you demand.

1

4

Important: Use only the Carbon paste provided to lube the frame joint to insure easy assembly and

secure coupling. To assemble your ES frame, line up the two ends of the frame. Be careful to not bend the prongs on the male end. The slot should line up with the seat slider quick releases.

2

Rotate the frame until it stops, the Volae logo and seat slider should line up, and tighten the two pinch bolts** and the anti-rotate bolt. This insures proper wheel alignment. Connect the shifting and brake cables, attach the seat and you are ready to ride.

** Make sure the pinch bolts are inserted through the non-drive side (no threads) of the clamp and into the threaded side of the clamp.

** Pinch bolts do not have to be removed to take the frame apart.

Slide the frame together slowly to make sure the slots line up and engage properly.

3

When the frame is pushed together the Volae logo should be about 45 degrees from the seat slider.

The ES frames come with end caps for use on the exposed frame ends so damage does not occur when the bike is in transit.

Take the frame apart occasionally and lube the joint with the provided paste to prevent the tubes from seizing together.

4-2 S&S CouPlerS (travel tandem Frame)

Volae tandems are available with either two or four S&S Couplers.

(Fig. 4-1)

For your safety it’s imperative that you read the

Users Guide at

http://www.sandsmachine.com/. Look for Users Guide on the front page of the website and read it carefully. If you have trouble finding it or have any questions please contact Volae for help.

Fig. 4-1

Chapter 5 rIDIng your VolAe

Learning to ride a Volae recumbent takes a little practice but is not difficult for most riders. This chapter covers some of the things that will make your transition to recumbents easier.

First, be sure to read Chapter 2 and 3 about setting up and adjusting your bike. It’s helpful to be sure that your Volae is adjusted to fit you properly. First time recumbent riders may find it helpful to have the seat a little more upright. Later, you can recline the seat as needed.

It is essential to wear a helmet whenever you ride. Also, we recommend wearing gloves for two reasons. Gloves help protect your hands if you fall and they make shifting easier when you have sweaty hands. Protective eye wear is also helpful. Protection from dust, pollen and flying insects is important on a recumbent. Recumbent specific cycling shorts and jerseys make you even more comfortable.

Bike shoes with clipless pedals are highly recommended. We especially recommend them on the dual 650c wheel models.

With your feet higher than the seat, it can be an effort to keep your feet on the pedals.

ride a while with regular shoes to get

confident with the balance before switching to a good set of clipless pedals and shoes. Contact the Hostel Shoppe for suggestions about shoes and pedals.

5-1 StArtIng rollIng StArt

Preparation:

1. Find an empty parking lot or lightly traveled road.

2. Position the seat more upright than it would normally be used. This provides the rider, new to recumbents, with a seating position that is easier for an upright bike rider to relate to. Adjust the seat as shown in for proper leg extension.

(Fig. 9)

to get you in the ball park

Four steps to make learning to ride easier:

1. While sitting completely upright on the seat push off and coast to get the feeling of the steering and the bike. Keep your feet just off the ground.

(Fig. 5-1)

2. Do the same thing as step #1, but now lean back on the seat (which is adjusted to be fairly upright). Keep your feet just off the ground. Do this for awhile until you feel comfortable with the balance and handling.

(Fig. 5-2)

3. When you feel fairly confident with the handling, put your feet up and start peddling. Don’t stop peddling for awhile. Your confidence and ability to handle the bike should improve significantly in the first five minutes. (

Fig. 5-3)

4. Start reclining the seat a little at a time and ride a few minutes at each recline angle until you have reclined the seat to the point where you don’t feel that you are sliding off the front of the seat. As you recline the seat you will have to move the seat slightly ahead to keep your leg extension in the proper range.

Fig. 5-1 Fig. 5-2 Fig. 5-3

13

StAtIonAry StArt

(Try this after you have ridden enough to feel somewhat confident with the balance and handling.)

PuSH AnD CoASt eXerCISe

Find a place with a slight downhill grade and plenty of room and make sure the bike is pointed downhill. Empty parking lots are usually good spots for this.

1. Make sure to put the bike in a lower gear like the middle chainring and one of the bigger (lower) gears on the cassette.

2. Shoulders are back against the seat

3. Hands and arms are relaxed

4. Push off with one leg while holding the other foot just off the ground and coast.

(Fig. 5-4)

5. Repeat until you feel you can hold a fairly straight line when coasting.

6. Then, while coasting, put the other leg up and start peddling.

(Fig. 5-5)

7. This breaks the starting process down into two parts as follows:

- The push and coast

- Putting the second foot up on the pedal.

In time it will seem like one fluid motion but keeping it separated into two parts, in your mind, prevents you from rushing to get the second foot on the pedal. Rushing to get the second foot up is responsible for most of the problems with starting.

note: You may find the Rolling Start to be helpful when you stop suddenly and forget to shift down.

Fig. 5-4

5-2 StoPPIng

Fig. 5-5

Next, you should practice using the brakes. Stop and start a few times, getting the feel for how much pressure on the lever it takes to slow down or stop the bike. Remember to always use both brakes together, with gentle pressure at first to stop the bike smoothly.

Drop both your feet to the pavement while giving the brakes the final squeeze to stop the bike. Lean forward a bit and stand up, while reaching behind you for the seat to steady the bike. Practice stopping and dismounting, then starting off again.

You should also carefully investigate what happens to the bike with gradually increasing brake lever pressure, so you will be comfortable with quick decisions on the road.

5-3 rIDIng/HAnDlIng

AWKWArD

Everyone feels awkward at first. It’s common to think; “I’m riding and not crashing but I sure don’t feel comfortable and confident.” This sensation tends to go away fairly quickly. Most riders report that they feel much more confident after about fifty miles of riding. However, we have had customers who reported that it took five hundred miles before they felt really confident.

14

relAX

Riders new to recumbents tend to overuse their upper body. On an upright bike; hands, arms and shoulders must support the rider weight, help to put more force on the pedals and steer the bike. This tends to “carry over” into recumbent riding and results in riders (incorrectly) pulling on the handlebars. On a recumbents; hands, arms and shoulders are only used for steering. Work on relaxing your upper body. Never pull on the handlebars. When you are climbing think about pushing your back into the seat instead of pulling on the handlebars. Keep your hands and arms relaxed and you will find that fine control of the bike is easier when climbing. The handlebars and long risers on recumbents provide much more leverage and are not made to withstand aggressive pulling forces.

SPIn

Spinning smoothly through the pedal stroke noticeably improves riding efficiency. Clipless pedals and riding shoes are essential for spinning on a Volae. The main difference between “trudging” and “spinning” is that riders who trudge simply push on the pedals while spinners visualize their feet moving in a circle. Some riders find that it helps to start by thinking about pulling down and back on the non-pushing leg. The pushing leg will take care of itself. The one legged pedaling drill is a great way to learn to move your feet smoothly in a circle. Find an empty parking lot. With one foot clipped in and the other off the pedal ride in large circles pedaling with only one leg. Start with a slow cadence and work on keeping a consistent force on the pedal through the entire circle. Then, gradually increase your cadence while keeping it smooth. Be sure to do this with both legs.

CornerIng

At first you will do more steering and less leaning in the corners. However, as you gain confidence you will find you can lean into the corners more and steer less. Use caution, when the corner has sand, stones or debris on the pavement. In these cases you may need to slow down lean less and steer more.

Heel oVerlAP

It’s possible (on virtually all short wheelbase recumbents) for your heel to hit the front wheel during sharp turns. Heel strike is most likely to happen in slow-speed, sharp-steering maneuvers but never seems to happen under normal road riding conditions.

You will learn to avoid heel strike as you gain experience on your bike.

It’s common to feel wobbly at first. It may take fifty to one hundred miles of riding before you start to feel the same confidence that you are accustomed to on your upright. Avoid riding in traffic during this start up period. It’s also common to feel slightly weaker or slower at first because you may be using a muscle group that is not as well trained as the one you are used to.

HAnDlebAr/leg InterFerenCe

You may notice some contact between the handlebars and your leg in sharp turns. When making slow speed sharp turns it’s helpful to either take the inside leg off the pedal and hold it out like an outrigger or keep the inside leg straight and the pedal all the way forward while coasting through the turn. Remember how you had to keep the inside pedal of your upright bike up while coasting through a sharp turn? This is a similar situation.

5-4 muSCleS

SlIgHtly DIFFerent

You will be using a slightly different muscle group when riding your recumbent. Commit to riding your Volae. This muscle group will get stronger and you will get noticeably faster. It can take months or even a full season of riding to get the full benefit of the stronger muscle group.

5-5 PeDAlS

ClIPleSS & SHoeS

It’s impossible to spin on a Volae without Clipless pedals and bike shoes. We highly recommend a good quality bike shoe with a very stiff sole and a good set of Clipless pedals. Some Clipless pedals, like Speedplay and the new Shimano - Click’r are excellent choices for anyone that is concerned about getting quickly out of the pedals.

5-6 DeSCenDIng tAnDem rIDerS:

See “Descending on a Volae Tandem” under Tandems.

5-7 trAnSPortIng your VolAe

Removing the mesh or hardshell seat for transport is easy and does not effect your seat adjustment settings. The seat on your

Volae is designed to be removed by loosening two quick release skewers. The rear seat bracket is removed from the seat stays by loosening the quick release skewer lever and simply lifting the seat up.

(Fig. 5-6)

The seat is removed from the seat slider by loosening the quick release skewer lever and unscrewing the top hat enough to clear the safety indent in the seat base bracket.

(Fig. 5-7)

Be sure to remove the seat slider quick release lever and Top Hat nut if you transport your Volae on the outside of your vehicle with the seat on be sure to remove the seat foam on the hardshell seats. The seat foam is attached to the hard shell seat with hook and loop fasteners to make removal and reattachment easy.

Seat base bracket safety indent top hat

Seat slider quick release skewer

Fig. 5-6

Fig. 5-7

15

Chapter 6 tAnDem

6-1 loAD lImIt

See Chapter 3-8 on Load Limits.

note: You may be under this limit and still have problems with overheating rims and brakes on long steep descents.

6-2 CHAIn routIng

Tandems have two chains. The Timing Chain (front chain) on the timing chain.

(Fig. 6-1)

and Drive Chain (rear chain)

(Fig. 6-2)

. Proper chain routing is shown in the pictures below. Note that the Volae Tandem does not have any idlers on the drive chain and only one idler

timing

Chain

Drive Chain

Fig. 6-1

6-3 tAnDem SetuP ADJuStment

The captain’s position has an adjustable boom, seat slider and seat recline angle. The boom is used to make major leg length adjustments. Fine leg length adjustments are done with the seat slider and seat recline angle adjustments. It’s helpful to set up the captain with the seat as far back as possible while still allowing some room for seat slider adjustment. Once the boom position is set where you want it, you shouldn’t have to change it again and we recommend sealing the slot near the adjusting screws with silicone to keep water out.

Start by setting the captain seat slider as shown in

(Fig. 6-3)

and then select the seat back angle you find comfortable. Next, set the boom to a position that gets you closest to the proper leg extension (See section 3-7). Now fine tune the leg extension with seat base and back adjustments.

Next put the stoker on the bike and adjust the seat.

(Fig. 6-4)

In the unlikely event that there is stoker foot or knee interference with the captain’s seat you may need to add a link or two of chain to the timing chain and move both the boom and the captain seat forward.

Reverse Orientation

Fig. 6-2

Range

Fig. 6-3

Middle of Range

Front of Bike

Stoker Seat Slider Adjustment Range

Fig. 6-4

The tandem is set up with 7 1/8” female seat stays for the stoker and 9 1/4” female seat stays for the captain

(Fig. 6-5)

. These seat stays can be interchanged if need be to accommodate seat recline angle for captain or stoker. (Very short stokers may need the longer seat stays in back.) It’s possible to get custom seat stays to accommodate special fit needs.

Female

Seat Stays

Fig. 6-5

6-4 boom & tImIng CHAIn ADJuStment

The boom is adjusted by adding or removing links from the timing chain.

Each link is one inch long. Since the chain is a loop, removing one link (inch) of chain changes the boom position by ½”. In some crank positions the timing chain will be slightly looser and in other positions it will be slightly tighter. This happens because chainrings are neither perfectly round nor perfectly concentric. Find the place where the chain is the tightest and adjust chain tightness so there is about ½” vertical movement in this position

(Fig. 6-6)

. The chain should never be drum tight as this will wear the bearings and create energy robbing friction.

Recommended torque setting for the boom pinch bolts is 70 inch pounds. Make sure the threads of the pinch bolts are greased.

boom

Fig. 6-6

½” vertical movement here when chain is tightest. Avoid having chain “drum” tight.

6-5 SteerIng SyStem

Terminology of the steering system is shown in

(Fig. 6-7)

.

Start with the top of the handlebar horizontal as shown in

Riders can change this slightly if desired.

(Fig. 2-2)

in

Chapter 2. This positions the grips properly for a neutral wrist position.

Stem glide

Flex riser riser Clamp

Fig. 6-7

17

18

6-6 S&S CouPlerS

Volae tandems are available with either two or four S&S

Couplers.

(Fig. 6-8)

For your safety it’s imperative that you read the Users Guide at http://www.sandsmachine.com/.

Look for Users Guide on the front page of the website and read it carefully. If you have trouble finding it or have any questions please contact Volae for help.

Fig. 6-8

6-7 DeSCenDIng on A VolAe tAnDem tHe Problem

Slowing down two riders with gear requires more friction (heat) than slowing down one rider with gear. The amount of heat produced is a determined by the weight, length of the descent, grade of the descent and speed of descent. Heavy riders, carrying a lot of gear, will produce more heat then light riders with little gear. Slower descents require more braking for a longer period of time without the benefit of wind resistance. We’re not recommending fast descents here but simply want to illustrate how various conditions effect heat build-up on brakes and wheels.

tHe reSult

Too much heat from using rim brakes may cause tire or wheel failure and a crash. We’ve seen a composite wheel, from an overloaded tandem (~600 lbs), where the rim actually came loose from the composite due to overheating the epoxy. On the other hand we’ve heard of disc brakes that were ruined after one 15 mile descent on an upright tandem in the mountains. In addition, rim brakes wear the braking surface of the rim. Too much rim wear results in thin sidewalls on the rim, which can cause rim failure and a serious accident. Recumbent tandems, with a 20” front wheel, which goes around more often, will have more wear on the front wheel rim from braking with rim brakes.

WHAt to Do About It

Err on the side of safety. Get to know your situation by stopping periodically when making long or steep descents to check how hot the brakes and/or rims are getting. An additional drag brake on the rear wheel is recommended for any tandem team that plans to do long or steep descents. However, depending on the drag brake, the weight and the descent, this may not be enough and stopping periodically to check how hot things are getting is essential. The ideal braking setup, for Volae tandem teams planning to ride in areas where heat build up from braking may be a problem, is a disc brake on the 20” front wheel and rim brake plus a drum drag brake on the rear wheel. Disc brakes on both wheels are sufficient for most tandem teams who do not ride in very hilly or steep terrain. If you are using rim brakes and making numerous descents you should have your wheels checked periodically for rim wear.

Chapter 7

WArrAnty & SerIAl number

7-1 VolAe, llC. WArrAnty

Steel FrAmeS:

Volae, LLC warrants each new steel Volae bicycle frame, against defects in workmanship and materials for the lifetime of the original owner. Paint, decals, seat, fork and all original component parts are warranted for a period of one year from the date of purchase. This warranty is expressly limited to the repair or replacement of a defective frame, fork, seat or defective parts and is the sole remedy of the warranty. This warranty applies to the original owner and is not transferable.

Claims under this warranty are to be made through Volae, LLC. Proof of purchase is required. A Warranty Registration Card must be completed and received by Volae, LLC before warranty claims may be processed.

The warranty does not cover normal wear and tear, improper assembly or maintenance, or installation of parts or accessories not originally intended or compatible with the bicycle as sold.

The warranty does not apply to damage or failure due to accident, abuse or neglect.

Volae, LLC shall not be responsible for incidental or consequential damages. Labor charges are not covered by this warranty.

The user assumes the risk of any personal injury or damage to the bicycle or other losses if the bicycle is used in any competitive event including, but not limited to bicycle racing, triathlons or similar activities.

CArbon FIber CAre: InSPeCtIon oF ComPoSIte ForK, AnD ComPonentS

Cracks: Inspect for cracks, broken, or splintered areas. Any crack is serious. Do not ride any bicycle or component that has a crack of any size.

Delamination: Delamination is serious damage. Composites are made from layers of fabric. Delamination means that the layers of fabric are no longer bonded together. Do not ride any bicycle or component that has any delamination. These are some delamination clues:

• A cloudy or white area. This kind of area looks different from the ordinary undamaged areas. Undamaged areas will look glassy, shiny, or “deep,” as if one was looking into a clear liquid. Delaminated areas will look opaque and cloudy.

• Bulging or deformed shape. If delamination occurs, the surface shape may change. The surface may have a bump, a bulge, soft spot, or not be smooth and fair.

• A difference in sound when tapping the surface. If you gently tap the surface of an undamaged composite you will hear a consistent sound, usually a hard, sharp sound. If you then tap a delaminated area, you will hear a different sound, usually duller, less sharp.

unusual noises: Either a crack or delamination can cause creaking noises while riding. Think about such a noise as a serious warning signal. A well maintained bicycle will be very quiet and free of creaks and squeaks. Investigate and find the source of any noise. It may not be a crack or delamination, but whatever is causing the noise must be fixed before riding.

WArnIng: Do not ride a bicycle or component with any delamination or crack. Riding a delaminated or cracked frame, fork or other component could lead to complete failure, with risk of serious injury or death.

CArbon FIber FrAmeS by CAlFee DeSIgn:

Volae warrants to the original registered Volae owner that the Volae Carbon frame is free of manufacturer’s defects for a period of 10 years from the original date of purchase. If Volae determines a product defective, Volae will, at its sole option, either repair or replace the product free of charge. All build-up/break-down labor and shipping costs will be the sole responsibility of the owner. In order to obtain service under the Volae limited product warranty, the product must be returned to an Authorized

Volae Dealer along with the original bill of sale. All frames must be completely disassembled before being returned to Volae.

This warranty does not apply to normal wear and tear, defects or failures resulting from abuse, neglect, accidents, improper maintenance, or unauthorized modification.

Under no circumstances shall Volae be liable for any damages or injuries incurred by the use of its product. This includes, but is not limited to: lost profits, lost savings, and incidental or consequential damages or injuries arising from the use of, or inability to use this product. The limited warranty set forth in this agreement may not be extended or modified by any Volae Dealer, Agent or Employee. Volae does not assume any liability or make any warranty except as stated in this limited warranty. This warranty gives you specific legal rights, and you may also have other rights depending on your state. Some states do not allow limitations on the duration of implied warranties, or the limitation or exclusion of incidental or consequential damages; therefore, the limitations and exclusions set forth in this warranty may not apply to you.

19

20

7-2 SerIAl number loCAtIon

FrAme mAKer SIngle FrAme (non-adj boom) SIngle FrAme (adj boom)

AtP

Between chainstays on back of main frame.

(Fig. 7-1)

N/A

Waterford

Front of Bottom Bracket

(Fig. 7-2)

Between chainstays on back of main frame.

(Fig. 7-1)

Calfee Designs

Inside of right rear dropout

(Fig. 7-3)

N/A

tAnDem

N/A

Between chainstays on back of main frame.

(Fig. 7-1)

N/A

Fig. 7-1 Fig. 7-2 Fig. 7-3

Warranty registration Card

Name: ________________________________________________________________________________

Address: ______________________________________________________________________________

City: _______________________________________ State: ____________________ Zip: ___________

Phone: ___________________________________________________

Email: ____________________________________________________

Model Bought: _____________________________________________

Purchase Date: ______________________________

*Serial #: ___________________________________

Frame Color & Size: __________________________

How did you hear about us? _______________________________________________________________

______________________________________________________________________________________

Comments: ____________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

Please fold and mail back to Volae recumbents.

* Your serial # is stamped on the front of the bottom bracket and on your receipt.

21

22

Volae Recumbents

3201 John Joanis Drive

Stevens Point, WI 54482

Place

Stamp

Here

Fold

Fold