TRAK Kayaks T-1600 Assembly And Disassembly Manual
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TRAK Kayaks T-1600 Assembly And Disassembly Manual

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Assembly and
Disassembly Guide
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Summary of Contents for TRAK Kayaks T-1600

  • Page 1 Assembly and Disassembly Guide...

  • Page 2: Table Of Contents

    Table of Contents: Unpacking your TRAK kayak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Getting to know your TRAK .

  • Page 3: Unpacking Your Trak Kayak

    Unpacking your TRAK kayak: Parts checklist: 1 x Spray Skirt 1 x Command Seat 3 x Jacks (Tri-active Performance System™) 1 x Bow Frame Section (Stern) 1 x Stern Frame Section (Bow) 1 x PolyTRAK Shell™ 1 x Coaming 2 x Gear/Float Bags 1 x Pack...

  • Page 4: Getting To Know Your Trak

    Getting to know your TRAK: Top profile: Deck Coaming Coaming Tri-active Performance Rigging Seal System Jacks (3) Tow Handle Keder Keder Seat Keel Strip Deck Rigging Grab Line Tow Handle Handle Side profile: Stern Keel Deck Hull...
  • Page 5 Components: 1 Bow plate 11 Keel tube 2 Keel tube 12 Rib D 3 Rib A 13 Stern plate 4 Foot brace 14 Foot brace 5 Gunwales tube 15 Opening for coaming 6 Keel jack (TPS) 16 Gunwale jack (TPS) 7 Rib B 17 Seat 8 Gunwale jack (TPS)
  • Page 6 About the Tri-active Performance System™ (TPS) What is so amazing about TPS? TPS is what allows TRAK to perform like no other kayak ever created . First, RigiTEK™ Rigidity Technology creates a rigid, hydrodynamic skeleton over which the PolyTRAK Shell™ is tightly formed .
  • Page 7 Straight trim Adjusted trim Every pull on the gunwale jacks adjusts the arc (trim) of your TRAK . Depending on which side you adjust, the boat will pull in that direction at your command . This technological advancement has its roots in aircraft technology and works on the same principal as the wing of an airplane .

  • Page 8: Instructions: From Pack To Water

    Instructions: from pack to water TEN-&-IN Portability: 7 steps, 8 pieces, 10 minutes, no joke. Owning the world’s first performance folding kayak means that you can enjoy unsurpassed performance, adaptability, durability and portability . To get the most out of your kayak’s portability, the design team at TRAK has made the assembly process as quick and easy as possible .

  • Page 9: Frame Assembly: Bow And Stern Sections

    Frame assembly: bow and stern sections Each half of the frame is completely connected. • You can start with either the bow or stern section. • All sections of the frame are shock corded together. • There are no loose pieces on the bow or stern section of the frame . • On the top middle tube of the bow frame is a spring- pin . • PRESS the spring-pin so that it can slide under the outer tube . • Then MOVE it under the hole in the outer tube until it POPS back out into place . • This spring-pin helps hold the tubes together.
  • Page 10 Connect the ribs to the frames, starting with the STERN (rear) section. • Each frame section has two ribs. Small rib: • Each rib is attached to the frame with a single ball stud bungee . Use this bungee connection as your corners starting point . • START with the SMALLER rib on each section. Connect the smaller rib, starting with the bungee connected corner.
  • Page 11 Now assemble the BOW (front) section. • ASSEMBLE same as stern section, beginning with the smallest rib. • When attaching the larger rib, first SLIDE the bottom tube into place, past the spring pin. • Then ATTACH the ball studs into their respective holes. CHECKPOINT: Both sections of the frame are assembled. Bow section Stern section...

  • Page 12: Insert Frames Into Shell

    Insert frames into shell: Lay out the shell. stern • SPREAD OUT the shell, deck side up (colored side up) . • Try to FLATTEN out the shell as much as possible. Open Keder. pull • Make sure the Keder is PULLED BACK all the way towards the tip of the stern (so that the back “flaps” on the shell are accessible) . Insert front frame section (bow) into Bow section the shell.
  • Page 13 • From the cockpit INSERT the bow section into the shell . • LINE UP the keel tube (bottom tube) with the inner keel strip keel strip (the center white strip that runs the length of the bottom of the kayak) . • Use a SLIDE/LIFT motion . • PUSH the frame in as far in as it will go by bracing one hand on the shell and the other on the rib .
  • Page 14 Insert back frame section (stern) into Stern section the shell. • The stern section is the shorter of the two. • INSERT in same manner as bow section . • The frame will not go all the way at this point. CHECKPOINT: Both sections of the frame are inside the shell but are not connected.

  • Page 15: Connect The Coaming

    Connect the coaming: Click the coaming into place. • HOLD the coaming in one hand with the tip or bill facing forward toward the front or bow section of the kayak, and PUSH it into the opening slot on top of rib .

  • Page 16: Inserting The Tri-Active Performance System™ (Tps) Jacks

    Inserting the Tri-active Performance System™ (TPS) jacks About the TPS system: • All three jacks are exactly the same, and can be used interchangeably . TPS switch “release” position: • If the jacks are in release position inside the kayak, there will be no tension on the frame . • When the valve is set to release (as in the photo) the piston can be manually adjusted . Release TPS switch “ready” position: • When the valve is set to “ready” (as in the photo) the jack is ready to be used .
  • Page 17 Before inserting the TPS jacks into the frame: • Ensure each valve is in release position. • Then manually INSERT the extending tube into the housing . NOTE: Practice adjusting the jack switch from Ready to Release and extending and compressing the jack piston so you get used to how it works. Connect the keel (center) jack first: • The jack handle should be facing toward the front of the kayak .
  • Page 18 Insert the jack into the bow end: • Next, you’ll INSERT the front (handle) end of the centre jack into the bow frame section . NOTE: You may not be able to easily spread the frames apart enough to fit the keel jack into place. Don’t worry! You can let the jack do this for you.
  • Page 19 Insert the side (gunwale) TPS jacks: • The handle on the jack should be facing to the front of the kayak (the same direction of the keel TPS jack) . • INSERT jack into the gunwale tube . • If it does not slide easily or there is not enough room to insert it, simply ADD more TENSION to the keel (center) jack until it fits .
  • Page 20 Tuck the coaming seal (shell) into the coaming grooves: • Starting at the front of the coaming, TUCK the coaming seal into the grooves in the coaming, if this is not already the case . • There will be some space between the coaming closure seal and the coaming .
  • Page 21 CHECKPOINT: TPS jacks are in place, and the coaming seal is secured around the cockpit.

  • Page 22: Install The Command Seat

    Install the Command Seat. Connect the seat pillars: • To connect the seat pillars SLIDE both ends of the black tube into the frame tubes of the stern (back) section at the same time . • SLIDE the top of the seat pillar into the groove on the bottom of the coaming .
  • Page 23 Install the seat: • PLACE the seat into the cockpit . • ALIGN the seat rails with the slots on the seat posts . • SLIDE the seat backwards into the grooves on the seat pillars .
  • Page 24 • PUSH the seat down once to ensure it is locked in place . • The seat is now in place.
  • Page 25 Adjust seat back for comfort: • The cords attached to the seat are to adjust the seat back for comfort . • The end of the cord goes in BETwEEN the shell and the seat pillars (behind the pillars) . • Make sure the seat back is locked into the grooves in the seat bottom . • Take the end of the cord and PULL it through the cleat on the edge of the coaming . This will lock it in place .

  • Page 26: Close The Keder

    Close the Keder System. Slide the Keder handle towards the coaming: • Begin closing with no tension in jacks (ready position) . • If it feels too tight ADD tension in gunwale jacks . • To decrease the “bunching” of the material close to the Keder, add tension (6 - 10 jacks) on each gunwale jack until the Keder closing is lined up . • DROP the pin on the Keder strip into the hole at the back of the coaming to lock in place .

  • Page 27: Rigging And Finishing

    Rigging and finishing. Release tension in the frame: • Release all three jacks into the neutral position, until a later step . Fasten rigging into place: • See photos. • Bow rigging.
  • Page 28 • Stern rigging. Inflate Gear/Float bags: • To provide flotation for the boat, you must inflate each of the Gear/Float bags . • Do this by twisting the cap counter clockwise. • Add air into the bag until it is mostly inflated. • Then tighten the cap clockwise. • If you are carrying gear, place your gear in the Gear/ Float bag, and insert into kayak before adding air . • This provides a dual benefit of a dry bag for gear and provides flotation for safety . NOTE: Never paddle your TRAK kayak without Gear/Float bags inflated or without using a Sea Sock.
  • Page 29 Adjust the position of the foot braces. • To adjust the foot braces, simply slide your hand under the tab and pull spring loaded lever on the backside of the foot brace to release the pin . • You can now slide the foot brace along the track to a comfortable position . • You can also adjust the foot braces from a sitting position inside the kayak using your feet . ONE FINAL STEP! Before paddling, ensure the SHELL is TIGHT.
  • Page 30 Adjustable Thigh Braces About your TRAK Adjustable Thigh Braces: • Thigh braces are used in kayaks for bracing and stability, and to assist in rolling the kayak. • Easy to remove hardware allows you to adjust the position of the braces along the underside of the coaming. • For a comfortable fit the braces are padded. • Attaching the outside column of the brace will result in a more aggressive style, while attaching the inside column of that same row will give you a slightly looser feel . • Alternatively, you can paddle without braces. • There are 32 unique positions for your thigh braces to be installed. • The thigh braces are designed to be interchangeable. Adjusting your Thigh Braces: Step 1: Determine the placement of the Thigh Braces Your thigh braces are currently set to a standard...
  • Page 31 Step 2: Remove the coaming from the kayak and place it upside down. Step 3: Remove Thigh Braces using a Philips screw driver. • Hold on to the screws as you will need them to re-attach the thigh braces . (Tool Required: Philips screwdriver)
  • Page 32 Step 4: Re-attach Thigh Braces to Coaming. • Place your thigh brace on the coaming in the desired position . • The grey padding is the underside of the brace. • Make sure that your position aligns with two of the brass inserts . • Using a Philips screwdriver, attach the thigh brace. • Two screws per brace are required for proper functioning . Repeat on other side. • Adjustment is complete. • Re-attach Coaming to kayak. • Your kayak is ready to paddle.

  • Page 34: Instructions: From Water To Pack

    Instructions: from water to pack TEN-&-IN Portability – 10 minutes from water to pack You can easily disassemble your kayak, going from water to pack in mere minutes . Your first time through will take a little extra time, but not much if you follow these instructions . And of course, if you have problems, we’re here .

  • Page 35: Disassembling The Cockpit

    Disassembling the cockpit: Release tension on all three TPS jacks. • SWITCH all valves from Ready to Release position. Release Ready Remove the seat back adjustment cord. • PULL cord INWARD to release from cleat. PULL cord out from between pillar and shell.
  • Page 36 Remove seat. • PLACE your hand on the rounded back edge of the seat, PULL UP and SLIDE the seat forward. • It will slide out from the pillars. Slide out seat pillars. • PULL UP the pillar lock (circled), then SLIDE the seat pillars forward so they are no longer attached to the coaming . • This will also disconnect the rod at the bottom from the frame tube.
  • Page 37 Remove TPS jacks. • Start with the keel (centre jack). • PUSH the jack towards the stern (rear) of the kayak until it can be REMOVED from the front (bow) keel frame tube . • Then LIFT and PULL the other end out of the frame tube. NOTE... Ensure the jack valves are set to the Release position. • REPEAT this process to remove both gunwale (side) jacks.
  • Page 38 Loosen the deck rigging. • REMOVE the clips to release tension in the rigging. You do not need to remove the rigging from the kayak. Open the Keder. • GRAB the Keder handle and pull UP and BACK. • SLIDE the Keder OPEN all the way to the stern tip. NOTE... The Keder remains attached to the shell.
  • Page 39 Release the coaming. • PLACE your hand under the front left edge of the coaming. FEEL for the metal LEVER underneath. NOTE... The lever is on the inside of Rib B and not visible from the cockpit. Lever is located inside Rib B . Press upward to release coaming . • PRESS UPWARD on the lever and PULL the coaming out. CHECKPOINT: The cockpit is now disassembled.

  • Page 40: Removing Frame From Shell

    Removing frame from shell: Remove the stern (rear) section of the frame from the shell. • HOLD the stern tip of the kayak. You will feel a rigid piece inside. • TWIST the tip from side to side. This will begin to release the frame from the shell. We call this “breaking the nose”, which is essential to remove the frames from the shell . • From the cockpit, PULL the stern section of the frame out of the shell. TIP... Brace one hand against the bottom of the shell while pulling the frame with your other hand. • The stern section of the frame is now removed.
  • Page 41 Remove the bow (front) section of the frame from the shell. • HOLD the bow tip of the kayak. You will feel a rigid piece inside. • TWIST the tip from side to side. This will begin to release the frame from the shell. • From the cockpit, PULL the bow section of the frame out of the shell. TIP. . . Brace one hand against the bottom of the shell while pulling the frame with your other hand. CHECKPOINT: Both bow and stern frame sections are removed from the shell.

  • Page 42: Collapsing The Frame Sections

    Collapsing the frame sections: Remove the frame tubes from the ribs. TIP... It is much easier if you disassemble the larger rib before the smaller rib on each frame section. BOw FRAME SET: • To remove ball-joined frame tubes, BRACE one hand or thumb on the rib and PULL the frame tube until it pops off the rib. • To remove the keel (bottom) frame tube, BRACE one hand on the rib and SLIDE the tube out of the hole in the rib, past the spring-pin . STERN FRAME SET: • To remove the Stern frame pieces, remove ball-joints, then SLIDE out corner and keel tubes.
  • Page 43 Fold up both frame sections. • Once all frame tubes are removed from the ribs, you will then fold up the frame sections. • Remember, the tubes are all shock-corded together. • PULL each tube piece apart and FOLD over. • PRESS and release spring pins where required. • Then completely COLLAPSE each frame section into a compact bundle. CHECKPOINT: Both bow and stern frame sections are collapsed for storage in the pack.

  • Page 44: Folding The Shell

    Folding the shell: • Begin by FOLDING the entire shell in half along its length. The coloured deck folds to the INSIDE; the hull is OUTSIDE. TIP: Line up the black trim that runs around the perimeter of the shell . NOTE: There should be very little of the deck visible once folded . • Starting at the stern end, make your first FOLD, using the Keeder as your measurement for the length of the fold. • PLACE your hand at the inside end of the keeder and FOLD the tip of the shell OVER your hand. • REPEAT this process for the second and third folds. NOTE: One end of the folded shell is wider than the other . The wider end goes inside the bottom of the TRAK pack . Fold to length of Keeder .

  • Page 45: Placing Parts In The Trak Pack

    Placing parts in the TRAK pack: Get the pack ready. • UNZIP the pack and LAY it flat. Frame sections (bow and stern). • Place both frame sections in the pack, side by side. • Arrange the frames so that the RIBS are on the BOTTOM. • LAY them as FLAT as possible.
  • Page 46 Shell. TPS Jacks. • Place the shell in the pack. • Arrange the jacks along either side of the pack. • Arrange the shell on TOP of the frames. • Place the WIDER end of the folded shell at the BOTTOM of the pack . Seat. • Ensure the seat back is disengaged so that it can lay flat in the pack . Coaming. • Place the seat face down in the pack, inside the perimeter of the coaming . • Place the coaming in the pack. • Arrange the coaming on TOP of the shell. • Place the WIDER end of the coaming at the BOTTOM of the pack .
  • Page 47 Gear/Float Bags and Sprayskirt. • Place the Gear/Float bags and Sprayskirt in the pack. Close the pack. • If the zipper seems tight, first connect the buckles on the straps and cinch them together. The zipper will close more easily . Congratulations! Disassembly is complete.
  • Page 48 www.RethinkKayak.com 1.888.35.KAYAK sales@RethinkKayak.com...

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