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Xtracycle STOKER Assembly Manual

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Summary of Contents for Xtracycle STOKER

  • Page 1 Manual Swoop assembly Manual RFA assembly Manual...
  • Page 2 Assembling the Stoker Tools needed - 3 mm Allen wrench - 4 mm Allen wrench - 5 mm Allen wrench - 6 mm Allen wrench - Snippers / scissors - 10 mm socket wrench - Pedal wrench or 15 mm wrench...
  • Page 3 Prebuild check Look over the box for signs of shipping damage. If damage is present, please take pictures in case a shipping damage report needs to be filed.
  • Page 4 Shimano key. The serial number is directly beneath the bar code next to "Frame No:". For the Stoker, this will start with STK. The key number is the directly beneath the bar...
  • Page 5 Open the box and inspect the contents and again look for any signs of shipping damage.
  • Page 6 Remove and set aside: - the small parts box - the KickBack 3 - front wheel and fender - u-tubes - saddle with post.
  • Page 7 If you have a stand, please secure the bike to the stand, otherwise with a friend, lift the bike out of the box and set it on your work surface.

  • Page 8: Charge The Battery

    CHARGE THE BATTERY Remove the battery keys secured to the handlebars.
  • Page 9 Unlock your battery and remove it by rotating it away from the bike.
  • Page 10 Find the battery charger and domestic power cable in the small parts box. Locate the charging port on the drive side of the battery. Pull back the rubber cover and plug in the charging cable.
  • Page 11 Make sure the charge indicator lights begin to blink green. A full charge will take a few hours but you will be able to use the battery with a partial charge by the time you are done setting up your bike.
  • Page 12 Install the KickBack 3 Remove the KickBack3 packaging and locate the included hardware kit consisting of two U-bolts, a rectangular mounting plate, four M6 washers & nuts, and an M5 set-screw.
  • Page 13 Under your bike find the kickstand mounting shelf and the threaded set-screw hole.
  • Page 14 Rest the back of the kickstand mounting plate on the mounting shelf and use a 3 mm Allen wrench to thread the M5 set screw in order to hold the kickstand in place.
  • Page 15 Install the first U-bolt on the drive side of the bike. Fit an M6 washer and nut onto the forward threads, until just finger-tight. Place another washer and nut on the other end of the U-bolt, and secure both nuts with a 10 mm socket tool, being mindful to tighten each end of the U-bolt evenly.
  • Page 16 Place the second U-Bolt on the non-drive side and position the small mounting mounting plate in place on the forward threads. Secure it with an M6 washer and nut. Secure the other end of the U-bolt with the remaining M6 washer and nut.
  • Page 17 Go back to all four nuts and tighten everything with the 10 mm socket tool.
  • Page 18 Install the front fender Carefully lift the front of the bike and deploy the kickstand. * You may want to add something weighted to the rear rack to keep the bike from tipping forward.
  • Page 19 Remove the thru axle with a 6mm hex wrench.
  • Page 20 The hardware for you fender is already installed in your fork. Please remove the M6 nyloc nut and L-bracket.
  • Page 21 Install your fender using the M6 bolt already in the fork. The order should be fender tab, L-bracket, washer, M6 nyloc.
  • Page 22 Usa a 4 mm Allen wrench to attach the outer support arms of the fender to the lower forkmounting points with the two M5 bolts.
  • Page 23 INSTALLING THE FRONT LIGHT Before you mount the light to the fender we have found that removing the light tab produces a more secure and stable lighting experience.
  • Page 24 REMOVAL OF THE LIGHT TAB Use a 1/4" drill bit to drill out the rivet from the underside of the fender. You'll only need to drill enough of the rivet to pop it out, though drilling all the way through is fine.
  • Page 25 Once the rivets are removed the tab should be free and you can discard it. Your fender should now look like this.
  • Page 26 You will be attaching the light through the forwardmost rivet hole. To receive the bolt, you can either drill out that hole a little bigger or use the bolt to open it up a little. Insert M6 bolt through the hole.
  • Page 27 Before you mount the light to the fender you should flip/rotate the piece of the light mount that attaches to the fender to look like the image here.
  • Page 28 Now you'll attach the light mount to the M6 bolt in the fender and secure with an M6 nyloc nut. Use a 5mm Allen wrench from the underside of the fender to tighten the bolt and nut securing your front light to your fender.
  • Page 29 Once the light is secure you're going to reconnect the connectors (from fender to light - red to black; black to black with gray stripe).
  • Page 30 Now you'll need to connect the light wires from the frame to the fender (red to red and black to black).
  • Page 31 Adjust your light position angle that fits your riding needs best. Secure the two mount joints with a 4mm Allen.
  • Page 32 INSTALLING YOUR FRONT WHEEL Remove the disc brake-pad spacer in your front brake caliper.
  • Page 33 Remove the packaging from the front wheel.
  • Page 34 **DOUBLE CHECK** Double check that the hub cap is not stuck to the plastic disc.
  • Page 35 Rotate your front wheel into position. Be mindful to seat the disc brake rotor neatly between the brake pads.
  • Page 36 Re-insert your thru-axel, and tighten with a 6 mm Allen wrench.
  • Page 37 INSTALL THE STABILIZER Locate the following hardware in the small parts box: eyebolt, flange nut, StabilizerSpring, and spring sleeve.
  • Page 38 Fully thread the eye-bolt through the flange nut.
  • Page 39 Thread the bolt through the threaded boss on the downtube. Tighten with a 8mm wrench, adjusting the eye bolt so it is aligned perpendicular to the bike.
  • Page 40 Hook the StabilizerSpring to the L-bracket on the fork.
  • Page 41 Use an Allen wrench or screwdriver to pull the other end through the eye-bolt.
  • Page 42 Slide the spring sleeve over the StabilizerSpring.

  • Page 43: Install The Pedals

    Install the pedals Apply a small amount of grease to the threads on each pedal, marked Left and Right.
  • Page 44 With the right pedal, start threading the pedal bolt into the crank arm. Once initially threaded you can backpedal while holding the pedal bolt in place. The left pedal has a reverse thread so you will need to turn the pedal bolt counter clockwise to tighten it. Use a 15 mm pedal wrench to tighten the pedals.

  • Page 45: Install The Seat

    Install the seat Apply a modest amount of grease to the inside of the seat tube.
  • Page 46 Lower your seatpost into your desired position and tighten the collar with a 5 mm Allen wrench.

  • Page 47: Install Handlebars

    Install handlebars Remove your top cap and remove the cardboard spacer from fork steerer. Install your stem with your handlebars forward and the shifter on the drive side of the bike. Thread your topcap and secure until just before snug.

  • Page 48: Adjust Handlebars

    Adjust handlebars Remove the rubber plug on the top-cap, and use a 5mm Allen wrench to loosen the bolt. Use a 4 mm Allen wrench to loosen the two bolts holding your handlebar stem in place.
  • Page 49 Align your handlebars with your front wheel. Re-tighten the two stem bolts, and the top-cap bolt and replace the rubber plug.
  • Page 50 Use a 4 mm Allen to loosen the faceplate on the front of your stem, and center the positioning target. Then retighten the faceplate.
  • Page 51 Use a 3 mm Allen wrench to loosen the paddle grips. Reposition them so they are level with the ground. Then retighten them.
  • Page 52 Use the provided Shimano lead-connector tool from the small parts box to insert the display cable into the small port under the display. You should feel a securing click when the connection is made.
  • Page 53 Replace your battery by sliding it into the cradle and rotating towards the bike frame until it clicks into place.
  • Page 54 Install the U-Tubes Before installing the U-Tubes, please note that the rear insertion end on each U-Tube is slightly longer than the insertion end on the front end of the U-Tube. Front insertion Rear insertion...
  • Page 55 Determine if you would like to have the U-tubes installed in the wide setting (shown on the left side of the bike pictured below) or the narrow setting (shown on the right side). In the wide setting, the U-tubes will extend 6"...
  • Page 56 The U-tubes should easily slide into the mounting holes. But it is possible an adjustment will be needed if the fit the alignment is not perfect. If no adjustment is needed skip to step 62.
  • Page 57 Four bolts secure the tailpiece in place. Loosen these four bolts using a 10 mm socket wrench and a 5 mm Allen wrench.
  • Page 58 Push or pull the tailpiece into a place where you can easily insert the U-tube. Do not tighten the tailpiece yet.
  • Page 59 Insert the U-tube into the frame, pushing in on the spring pin button so that the button slides into the frame as well. Insert the U-tube far enough for the spring pin to pop out into the hole on the bike frame. (Optional: You can apply grease to the portion of the U-tube being inserted.)
  • Page 60 Insert the remaining U-Tube on the other side of the frame.
  • Page 61 If you loosened the tailpiece to install the U-tubes, tighten the tailpiece into place.
  • Page 62 Complete assembly Tie down the two hook and loop straps on the bottom of the FreeLoader Too bags to the bike frame.
  • Page 63 The Stoker assembly is complete and you are ready to ride!
  • Page 64 Looking to install additional accessories on your Stoker? Please refer to the following page on the Xtracycle wesbite for links to additional installation manuals: https://www.xtracycle.com/product-manuals...
  • Page 65 Manual Swoop assembly Manual RFA assembly Manual...

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Stoker e