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Your vehicle has been assembled and tuned. The front wheel, seat and handlebars may have been
disassembled for more compact shipment. There are a few items to reassemble, bolts to be tightened and
adjustments to be made. Your front wheel and other accessories may be in the cargo box or cargo pod on
your trike. Your control cables have been pre-stretched; however it is normal for the control cables to
stretch during use (a lot at first) and your shifters may need to be re-tuned after several miles of use.
If you use the Lightfoot Technical Manual to assemble and adjust your cycle, you will have learned in a few
hours the basics of what you need to know to keep it running efficiently and safely for a lifetime. This
chapter is designed to get you through reassembly so you can ride. The Lightfoot Tech manual is available
online at http://www.lightfootcycles.com/tech_man.php.
Lightfoot vehicles are all designed to be accessible to any qualified bicycle mechanic. As you put miles and
wear on the cycle, any bike shop should be able to troubleshoot and repair any mysterious behavior of
components or damage. Proper assembly, maintenance and adjustments will make your cycle safer and
more efficient to ride, and will avoid the potential frustration of trying to learn to ride on an improperly
assembled cycle. If in doubt as to your own ability to properly assemble this vehicle or some component of
If in doubt as to your own ability to properly assemble this vehicle or some component of
If in doubt as to your own ability to properly assemble this vehicle or some component of
If in doubt as to your own ability to properly assemble this vehicle or some component of
it, please use a qualified bicycle mechanic.
it, please use a qualified bicycle mechanic.
it, please use a qualified bicycle mechanic.
it, please use a qualified bicycle mechanic.
If damage has occurred during shipping, notify the shipping company imm
If damage has occurred during shipping, notify the shipping company immediately. Then, if anything appears
If damage has occurred during shipping, notify the shipping company imm
If damage has occurred during shipping, notify the shipping company imm
to be missing or damaged on a factory- - - - direct shipment, please call or e
to be missing or damaged on a factory
to be missing or damaged on a factory
to be missing or damaged on a factory
document the damage.
document the damage.
document the damage.
document the damage.
For future reference: All Lightfoot cycles have a serial number stamped on the frame. On bicycles, the serial
number is stamped on the left rear dropout. On trikes, it is stamped near the top of the upper separation
plate between the front and rear frame. The serial number may be difficult to read under the
powdercoating, but it is there.
TOOLS NEEDED
TO
OLS NEEDED
TO
TO
OLS NEEDED
OLS NEEDED
To adjust an assembled vehicle, you may need only a couple of tools. Bike shops will have all of these
tools. Also, you can buy these tools by the individual piece, or as part of a "home bicycle mechanic" set.
Certain vehicles or options may necessitate other tools. We recommend getting a portable bicyclist tool kit
(you will have most of the tools from the list above) for carrying with your vehicle as well as a home-
mechanic set for more extensive repairs.
1. Pliers to pull staples and cut wire ties.
2. Knife or scissors to cut tape.
3. Reversible hand held drill with a Phillips head driver bit for removing fork stabilizer.
4. Metric Allen wrench set. Specifically: an 8mm (crank arms), 6mm (shorty stem), 5mm (adjustable
stem and accessories), 4mm (seat and braces) and a 2.5 mm (Grip shifters). A 3mm wrench has
been supplied with your mirror. A Philips head screw driver is needed for some of the fender bolts.
5. 15mm pedal or open end box wrench for pedals on Bikes.
6. Grease for coating threads on pedals and freewheels, lubricating unsealed bearings, lubricating the
steerer tube. Phil Wood waterproof grease is one good choice. White Lightning is a good coating
for chains and cables.
7. Internal hub systems may require a wrench or small vise grip pliers, as well as a medium size flat
screwdriver.
8. A tire pump may be needed.
UNPACKING
UNPACKING A B
UNPACKING
UNPACKING
A B
A BIKE IN A CARTON
A B
IKE IN A CARTON: : : :
IKE IN A CARTON
IKE IN A CARTON
Technical Manual
direct shipment, please call or e
direct shipment, please call or e- - - - mail us.
direct shipment, please call or e
1- 1
RECEIVING YOUR CYCLE
RECEIVING YOUR CYCLE
RECEIVING YOUR CYCLE
RECEIVING YOUR CYCLE
ediately. Then, if anything appears
ediately. Then, if anything appears
ediately. Then, if anything appears
mail us. If at all possible photo
mail us.
mail us.
If at all possible photo
If at all possible photo
If at all possible photo

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Summary of Contents for Lightfoot Greenway

  • Page 1 (a lot at first) and your shifters may need to be re-tuned after several miles of use. If you use the Lightfoot Technical Manual to assemble and adjust your cycle, you will have learned in a few hours the basics of what you need to know to keep it running efficiently and safely for a lifetime.
  • Page 2 9. Sit on the cycle and adjust the handlebars to fit you. Align the handlebars, stem and fork. Tighten all bolts. 10. Unpack all optional components and be sure that there are none tucked away in packing materials. 11. Refer to the Lightfoot Technical Manual for further installation and maintenance instructions. UNPACKING A UNPACKING A...
  • Page 3 Install the front fork, wheel(s), seat, handlebars and pedals. Align handlebars and stem with the front wheel. Adjust to fit. Refer to the Lightfoot Technical Manual for further installation and maintenance instructions. FOR BOXED UNASSEMBLED TRIKES ONLY: FOR BOXED UNASSEMBLED TRIKES ONLY:...
  • Page 4: Initial Assembly

    INITIAL ASSEMBLY Modular frames should be bolted together firmly, as soon as possible. Do not fully tighten any bolts until all bolts are inserted and the nuts are on finger tight. Be careful not to put weight on the frame until all bolts are in and fully tightened;...
  • Page 5 Figure 2.3 Above. Installation of fork into head set. Figure 2.4 At right. Installing the stem. INSTALLING HANDLEBARS AND STEM Standard tiller steering includes a stem, either telescoping or fixed-length. If telescoping, make sure that at least 2” are inserted at maximum extension. If your vehicle is a bike or trike with the 12”...
  • Page 6: Parking Brake

    PARKING BRAKE Most Lightfoot trikes have a dual pull Figure 2.5a. Swept handlerbar and stem riser brake lever with a locking pin (see figure 2.5a). Some may also have an elastic band Parking Brake that holds the brake lever in the “on”...
  • Page 7 Most Lightfoot models are equipped with disc brakes. Use Gloves when handling brake rotor discs. Slide the wheels into place being careful to place the rotor between the brake pads.
  • Page 8 A word about maintenance: The hubs we use are not “sealed” but are “semi-sealed”. They come well lubed. The bottom bracket does not come apart; it is maintenance free. IF the threads start to "creak", back them out and grease them. They were well greased here. The hubs will need some maintenance.
  • Page 9 Tighten the nut and bolt so that the seat brace does not slip. Figure 2.12. Seat clamp on Greenway and RoadRunner trike Adjustment: Adjust the seat braces so that the seat bottom supports are roughly parallel to the ground.
  • Page 10 Release ALL 4 quick release bolts and/or pinch barrel bolts during adjustment, even if adjusting only one part of the seat. For Greenways and RoadRunners: The lower quick release bolt on the seat clamp should have a small wing nut on the chain side ( as shown in figure 2.12) and spacers to “shorten” the bolt on the left side of the trike.
  • Page 11 to the fender mount on the frame. Use two or more 1/4“ nuts as spacers between fender and frame if needed. Rear Fenders on Trikes 1.Place the fender on the rear wheel. Open the Stays to approximate Figure 6.8. Jackshaft, fender and brake setup width needed for mounting.
  • Page 12 WHEELS AND TRANSMISSIONS WHEELS AND TRANSMISS IONS WHEELS AND TRANSMISS WHEELS AND TRANSMISS IONS IONS MOUNTING TIRES ON WH MOUNTING TIRES ON WHEELS EELS MOUNTING TIRES ON WH MOUNTING TIRES ON WH EELS EELS Install a rim strip or rim tape; this protects the tube from punctures caused by the tips of the spokes and the spoke nipples.
  • Page 13 Contrary to some assumptions; single-wheel-drive on a trike (as Lightfoot Cycles uses it) with appropriate tires almost always provides plenty of traction, even in snowy or gravelly conditions.
  • Page 15: Routing The Cables

    recommend hairspray or any solvents that might damage the gel grip. You may have to trim the grips; they may be a bit too long to fit on some handlebars with certain components. Standard placement of the shifters connects the left grip shifter to the front triple chainring. The right grip shift controls the rear derailleur on bikes, or the mid-frame derailleur on trikes and quadracycles.
  • Page 18 Front derailleur adjustment is not an exact science. It requires a good eye and a bit of patience to get it right. When you apply power to the pedals, the power is transmitted to the rear sprockets by the upper run of the chain. The lower run of the chain is just the return path, and the only tension on the lower run is that applied by the spring in the rear derailleur.
  • Page 19 the inner and outer cage plates connect at the back. This made the derailleur match the curvature of the larger chainwheel, and allowed me to set it low enough to provide good chain control. This setup now works fine with an STI rig that doesn't permit "trimming" the front derailleur. Low-gear limit stop.
  • Page 20 Trimming means using the shifter to move the front derailleur cage sideways just a little bit, enough to stop the chain from rubbing, but not enough to make it shift to a different chainring. Older front derailleurs designed for friction shifters used to require trimming as a matter of course, but newer indexed systems can often be set up so that no trimming is necessary.
  • Page 21 Indicator marks for the front derailleur (even on index systems) do not accurately indicate what gear the front triple sprocket is in. This is not a problem, but you can take the time to adjust it as close as you wish. The shifter for the rear-most derailleur on a trike or Tandem is a "friction shifter".
  • Page 26 STEERING STEERING STEERING LINKAGE STEERING LINKAGE STEERING LINKAGE STEERING LINKAGE STEERING Lightfoot’s Linkage Steering System consists of these parts: 1. Handlebar and stem 2. Stem extension 3. Linkage Steerer Tube (inserts into bike frame) 4. Linkage Rod 5. Fork Steerer Tube Clamp/Cap 6.
  • Page 27 You may also want to make adjustments to the "quickness" of the steering. You may need to read the following paragraphs a couple times to make sense of these instructions. Adjustment is made in one of three ways. Fine toe-in adjustment is made by unbolting one end of the tie-rods and screwing the tie-rod-ends in or out.
  • Page 28: Options And Accessories

    OPTIONS AND ACCESSORIES CANOPIES You will need a drill with 3/16" bit, screw driver, 3/8” wrench and (8+) 1 1/2" #10bolts and locknuts. Attach the Canopy pedestal to the fender platform with 1 ½” x ¼ “bolts and lock nuts. Position it on its center 17 1/2"...
  • Page 29: Chain Tubes

    It is important not to pedal backwards when chain tubes are on the cycle. If poorly adjusted, they may foul in the sprockets. CHAINRING GUARD The Lightfoot Chainring guard is made to install on the Truvativ Blaze Crankset. Slip the guard...
  • Page 30 DECALS Apply decals at 68 –75 degrees F. Clean the frame and your fingers with alcohol. Peel back off the decal keeping fingers off the adhesive; use tweezers if you have no fingernails. Position decal. Lay on frame. Use a credit card to “burnish” or set the decal working from center to outside, pushing any air bubbles as you go.
  • Page 31 When shifting, ease off of the throttle, so that the shift is smooth. If you have the assist in too high of a gear when starting up, it will surge or stall. FAIRING The fairing mounts with T-Block clamps with arms on the handlebars.
  • Page 32: Installation

    FENDERS Front Fenders All of our front fenders require that the left stay have a 30 degree bend 3” behind the fork mount loop to clear the brake caliper. On 20” front fenders, we trim the backside so it will not scrape going over curbs and bumps. The front fenders have single stays instead of double stays.
  • Page 33: Safety Flag

    KICKSTANDS Lightfoot cycles accept standard kickstands with a slight modification. Protect the frame with vinyl tape and install as shown in the photos below. Figure 1 Seat brace tab forward SAFETY FLAG Place frame protection tape on frame where you want the flag (the left rear side of the frame is a good visible spot).
  • Page 34: Handcrank Assembly

    HANDCRANK ASSEMBLY Tools needed: Metric hex set: 5mm, 7/16” open end wrench, ½” open end wrench Lift out of box TAKE CARE NOT TO CRIMP THE CABLES OR CABLE HOUSING! Unwrap lower portion, do not unwrap the crank yet. Plug lower stem into derailleur tube of trike with chain tubes on the right.
  • Page 35 Figure 2. Detail of lower clamp HEEL PLATES Install Heel Plates by unbolting or popping rear pedal reflector off with a flat screwdriver. Bolt heel plate onto pedal using reflector holes, L opening down. Place foot on pedal as normal. Slide heel cup up to heel.
  • Page 36 PARKING BRAKE PARKING BRAKE Lightfoot trikes have 2 simple parking brake systems. The first is the brake loop; a very simple low tech braking solution that comes with every cycle. Slip it over the grip, squeeze the brake lever. Pull the shock cord loop over the brake lever.
  • Page 37 • Spring tension adjustment: turn the spring tension adjustment screw with a 2.5 mm hex wrench. Turning the screw clockwise increases spring tension, which equals a harder lever pull. • Cable slack adjustment: use the barrel adjuster on the brake lever to remove cable slack. Turn the adjuster out until there is no free play in the lever, but not so far that the torque arm on the caliper is advanced.
  • Page 38 RIDING YOUR CYCLE RIDING YOUR CYCLE RIDING YOUR CYCLE RIDING YOUR CYCLE Any of our cycles will feel odd to the first-time recumbent rider. Two-wheel models will seem hard to balance at first, and clumsy to push or move around. Trikes and trucks will seem strange in every respect.
  • Page 39 Learn to use the mirror without turning your head. Make frequent checks of overtaking traffic by glancing at the mirror, moving only your eyes. Don't stare at it, just check and go. This continuously updated consciousness of what is behind you will make you much safer if you should need to make an emergency maneuver.
  • Page 40 When cargo trikes are loaded, they will be more stable than when unloaded. Enjoy your Lightfo Enjoy your Lightfoot! ot! ot! ot! Enjoy your Lightfo Enjoy your Lightfo...
  • Page 41 HOW TO RIDE SAFELY ON THE ROAD WITH CARS HOW TO RIDE SAFELY O N THE ROAD WITH CARS HOW TO RIDE SAFELY O HOW TO RIDE SAFELY O N THE ROAD WITH CARS N THE ROAD WITH CARS You can greatly reduce your chances of being in a bicycle accident by following some basic rules; rules which a majority of bicyclists break all too frequently.
  • Page 42 Rule: Wear a helmet. Rule: Wear a helmet. We, at Lightfoot Cycles, want you to enjoy your cycle for a very long time. If you have any sort of problem that you or your local bike shop cannot fix, please let us know.