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Catrike MAX Technical Manual

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TECHNICAL MANUAL

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June 14, 2025

My battery pops off when i hit a bump

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Summary of Contents for Catrike MAX

  • Page 1 TECHNICAL MANUAL...

  • Page 2: Safety Information

    Important: The microSHIFT parking brake actuator on the Catrike 700 • Boom for tightness should not be engaged while the Catrike is in motion. This is a parking brake Check for anything that may have worked its way loose like handlebars, •...

  • Page 3: Battery Safety

    •We recommend electric assist eCatrike users should be 16 and older or have extensive training and adult supervision. •Always disconnect the Bosch harness before folding the eCat Dumont, 5.5.9. or Trail. Folding a Catrike while the harness is connected can cause damage to the battery connection and harness. BATTERY SAFETY •Be sure to review the original Bosch operating instructions for charger and rechargeable...

  • Page 4: Table Of Contents

    HEADSET ASSEMBLY ................................4 SPINDLES ..................................... 5-6 TIE ROD ....................................7 FRONT WHEEL INSTALL ..............................8-11 REAR WHEEL INSTALL ............................... 12 TIE ROD ADJUSTMENT ..............................13-14 SUPPLEMENTAL TOE ADJUSTMENT INSTRUCTIONS ....................15 HANDLEBARS ..................................16-17 ASSIST BAR ADJUSTMENT .............................. 18-19 BOOM ADJUSTMENT ................................

  • Page 5: Headset Assembly

    HEADSET ASSEMBLY M6x35 SHCS TOP CAP DUST COVER 2MM HEADSET SPACER HANDLEBAR LOWER HORIZONTAL SUPPORT # R: BC1004 / L: BC1005 PTFE BEARING BOLTS FACE TOWARDS INSIDE OF TRIKE HEADSET CUPS (2x) HEADTUBE PRESSED INTO HEADTUBE AT FACTORY HEADSET BEARING 36x45 BLUE SEAL RIGID SPINDLE # R: BC1243 / L: BC1244 REV 12.18.24 Pg.4...

  • Page 6: Spindles

    RIGID SPINDLE MAIN ASSEMBLY LEFT FOR BRAKE AND CALIPER ADJUSTMENT VISIT SRAM SERVICE HUB SRAM BB7 FRONT BRAKES 20MM IS MOUNT FOR 160MM ROTOR TORQUE BOLTS TO 10Nm (88INLBS) M6 WASHER (2x) M5x16 BHCS DO NOT OVER TIGHTEN M6 WASHER COMPUTER SENSOR MOUNT # BC1443 BRAKE MOUNT BOLTS (2x)
  • Page 7 RIGID SPINDLE MAIN ASSEMBLY RIGHT FOR BRAKE AND CALIPER ADJUSTMENT VISIT SRAM SERVICE HUB SRAM BB7 FRONT BRAKES 20MM IS MOUNT FOR 160MM ROTOR TORQUE BOLTS TO 10Nm (88INLBS) BRAKE MOUNT BOLTS (2x) TORQUE 10Nm (88INLBS) M6 WASHER (2x) REV 12.18.24 Pg.6...

  • Page 8: Tie Rod

    TIE-ROD ASSEMBLY M8x35 BHCS M8 WASHER TALL CONICAL SPACER EXTRA LONG TIE-ROD (ASSEMBLY) # BC1466 HARDWARE INCLUDED IN ASSEMBLY RIGID SPINDLE M8 NYLOCK HEX NUT # R: BC1243 / L: BC1244 REV 12.18.24 Pg.7...

  • Page 9: Front Wheel Install

    WHEEL INSTALL STEP 1 MAKE SURE THAT THE BRAKE ROTOR GOES IN THE CALIPER OPENING WHEN INSTALLING THE WHEEL. PICK UP THE TRIKE AND ALIGN THE WHEEL HUB WITH THE BRAKE ROTOR FACING THE SPINDLE SO THE HIGHLIGHTED CIRCLES ARE CONCENTRIC. CHECK MARKINGS ON DISK BRAKE FACE AND WHEEL TO ENSURE THE WHEEL ROTATION...
  • Page 10 WHEEL INSTALL STEP 2 SLIDE THE 20MM AXLE INTO BOTH THE SPINDLE BORE AND THROUGH THE WHEEL HUB UNTIL FLUSH WITH SPINDLE SURFACE. THE TRIKE CAN NOW BE SET DOWN. REV 12.18.24 Pg.9...
  • Page 11 WHEEL INSTALL STEP 3 INSTALL A SPRING ON EACH SIDE OF THE AXLE ASSEMBLY. INSTALL THE QUICK RELEASE SKEWER SO THAT THE HANDLE IS ON THE INSIDE OF THE SPINDLE AND THE AXLE NUT IS ON THE OUTSIDE OF THE HUB.
  • Page 12 WHEEL INSTALL STEP 4 FOR YOUR SAFETY CLOSE THE QUICK RELEASE HANDLE SO THAT IT POINTS TO THE REAR OF THE TRIKE WITH THE QUICK RELEASE HANDLE ALL THE WAY OPEN TIGHTEN THE AXLE NUT ALL THE WAY UNTIL THERE IS SLIGHT RESISTANCE, THEN BACK IT OFF 1.5 TURNS.

  • Page 13: Rear Wheel Install

    THRU AXLE HUB & HANGER INSTALL TIP: STEP2 IF INSTALLED, SHIFT REAR INSTALL HUB IN TO REAR DERAILLEUR TO SMALLEST DROPOUTS. COG TO MAKE TIRE INSTALL AND REMOVAL EASIER THRU AXLE 12x167 # FB-M12 GREASE THREADS AND SHAFT TORQUE 10Nm STEP1 INSTALL DERAILLEUR HANGER.

  • Page 14: Tie Rod Adjustment

    TIE-ROD ADJUSTMENT THE PURPOSE OF SETTING THE CORRECT TOE IS TO OPTIMIZE TIRE LIFE AND HANDLING. IT IS RECOMMENDED TO MEASURE AND ADJUST THE TOE WHILE SITTING ON THE TRIKE. THIS WILL ENSURE THE PERFECT TOE SETTING. 11MM WRENCH FLATS *ON BOTH SIDES OF TIE-ROD STEP 1 LOOSEN THE JAM NUTS ON BOTH...
  • Page 15 TIE-ROD ADJUSTMENT CONTINUED STEP 3 STEP 2 COMPARE THE FRONT AND REAR MEASUREMENTS, ADJUST THE TIE-ROD BY WITH THE WHEELS POINTING AS STRAIGHT AS SPINNING THE MAIN BODY SO THAT THE FRONT AND REAR MEASUREMENT ARE POSSIBLE, USE THE CALIBRO OR A TAPE EQUAL WHILE SITTING ON THE TRIKE.

  • Page 16: Supplemental Toe Adjustment Instructions

    SUPPLEMENTAL TOE ADJUSTMENT INSTRUCTIONS MAX Toe-In Offset IF THE RIDER CAN NOT SIT ON THE TRIKE WHEN PERFORMING THE TOE ADJUSTMENT THEN FOLLOW THE STEPS TO APPROXIMATE THE CORRECT TOE FOR THE RIDERS WEIGHT: STEP 1 LOOSEN THE JAM NUTS ON THE TIE ROD.

  • Page 17: Handlebars

    TALL HANDLEBAR ASSEMBLY RIGHT 11 SPEED REAR BAR END SHIFTER SHIFTER SCREW TORQUE 5Nm (40INLBS) FOR BAR END SHIFTER ADJUSTMENT VISIT SRAM SERVICE HUB FOAM GRIP # 129 ASSIST BAR RIGHT LOCKING BRAKE LEVER LOCKOUT BUTTON FACES OUTWARDS HAND REST PAIR (RIGHT) # BC1249 FOR ASSIST BAR ADJUSTMENT...
  • Page 18 TALL HANDLEBAR ASSEMBLY LEFT TUBE PLUG E-CATS ONLY eCAT CONTROLLER MOUNT # BC1426 REPLACES TUBE PLUG FOR ASSIST BAR ADJUSTMENT VISIT PAGE 15 FOAM GRIP # 129 FOR BAR END SHIFTER LONG HANDLEBAR - LEFT ADJUSTMENT VISIT SRAM SERVICE HUB # BC1293 LOCKING BRAKE LEVER LOCKOUT BUTTON FACES OUTWARDS...

  • Page 19: Assist Bar Adjustment

    ASSIST BAR ADJUSTMENT ALIGN ASSIST BAR SO THAT IT IS VERTICAL AND LEAVES SPACE FOR THE RIDERS HAND AND THE BRAKE LEVER IF USING A FRONT FENDER, LEAVE CLEARANCE BETWEEN THE FENDER MOUNT BOTTOM AND THE ASSIST BAR BODY REV 12.18.24 Pg.18...
  • Page 20 ASSIST BAR ADJUSTMENT AND MIRROR INSTALL THE MIRROR BY REMOVING THE PLUG CAP AND INSTALLING MIRRYCLE MIRROR ON LEFT ASSIST BAR MIRRORS CAN BE PLACED ON BOTH ASSIST BARS IF DESIRED ADJUST THE ASSIST BAR TO A COMFORTABLE HEIGHT TO GET IN AND OUT OF THE TRIKE DO NOT EXTEND ASSIST BAR PAST...

  • Page 21: Boom Adjustment

    BOOM ADJUSTMENT CLOSE BOOM CLAMP BY TIGHTENING THE QUICK RELEASE NUTS ON BOTH LEVERS AND FULLY CLAMPING EACH HANDLE. THE BOOM SHOULDN’T ROTATE WHILE PEDALING. WHILE SITTING, SLIDE BOOM UP TO HEEL OF FULLY EXTENDED LEG. BOOM CAN BE CUT FOR SHORTER RIDERS.
  • Page 22 BOOM INSERTION MINIMUM BOOM INSERTION IS 6” FROM THE FRONT OF THE TRIKE. IF BOOM POSITION IS PAST THIS POINT, SEVERE DAMAGE CAN VIEW FROM OCCUR TO THE FRAME UNDERNEATH TRIKE PEACE BOOM REV 12.18.24 Pg.21...

  • Page 23: Cable Routing

    CABLE ROUTING REAR DERAILLEUR CABLE RUN CABLE UNDERNEATH SEAT TUBE AND THROUGH BOTTOM OF SEAT MESH TO THE REAR OF THE TRIKE. LEAVE SLACK AND DO NOT KINK CABLE USE CABLE CLIPS TO ATTACH TO SIDE OF CHAIN STAY REV 12.18.24 Pg.22...

  • Page 24: Chain Routing

    CHAIN ROUTING DRIVE SIDE CHAIN TUBE ROUTED ON TOP OF CROSS MEMBER CROSS MEMBER TIE-ROD RETURN SIDE CHAIN TUBE ROUTED ON TOP OF TIE-ROD AND BELOW CROSS MEMBER IF A CHAIN TENSIONER IS INSTALLED THEN ROUTE CHAIN SLIDE RETURN SIDE CHAIN TUBE TUBE BELOW TIE-ROD ALL THE WAY FORWARD TO AVOID CHAIN RUB ON CROSS MEMBER...
  • Page 25 STRAIGHT ADJUSTABLE SEATBACK ASSEMBLY LEFT LEFT SIDE SHOWN, RIGHT SIDE MIRRORED STRAIGHT SEATBACK RIGHT TRIKE FRAME M8x22 BARREL 8x8.5MM NORGLIDE BUSHING M6 WASHER M6x10 BHCS M8 NYLON WASHER .75” OD x .062”THICK MEDIUM THREADLOCKER REV 12.18.24 Pg.24...

  • Page 26: Adjustable Seatback

    ADJUSTABLE SEATBACK FORK ASSEMBLY M6x10 BHCS (2x) MEDIUM THREADLOCKER M6 WASHER (2x) M8X16 BARREL (2x) M8 NYLON WASHER .5” OD x .03” THICK (2x) 8x8.5MM NORGLIDE BUSHING (2x) ADJUSTABLE SEAT BRACKET (2x) # BC1200 NESTING FEATURES FACING OUTSIDE OF TRIKE REV 12.18.24 Pg.25...
  • Page 27 ADJUSTABLE SEATBACK ADJUSTMENT STEP1 OPEN THE SEATBACK QUICK RELEASE AND LOOSEN THE QUICK RELEASE NUT UNTIL THE SEATBACK FORKS CAN MOVE FREELY STEP2 SLIDE THE SEAT INTO ONE OF THE FOUR POSITIONS ON THE ADJUSTMENT FORK STEP3 TIGHTEN QUICK RELEASE NUT SO THAT WHEN CLOSING THE QUICK RELEASE HANDLE THE SEATBACK DOES NOT MOVE REV 12.18.24 Pg.26...
  • Page 28 EKIT BATTERY CLAMP ASSEMBLY DO NOT TIGHTEN BOLTS ALL THE WAY YET BATTERY MOUNT CLAMP WELDED # BC1419 BATTERY MOUNT CLAMP SHIM # BC1423 WRAP AROUND MAINFRAME TUBE BATTERY MOUNT OUTER CLAMP # BC1420 M6 SMALL OD WASHER (2x) M6x25 SHCS (2x) LIGHTLY GREASE THREADS REV 12.18.24 Pg.27...
  • Page 29 EKIT BATTERY CLAMP POSITION PLACE CLAMP BETWEEN THE CHAIN STAYS AND SEAT STAYS REV 12.18.24 Pg.28...
  • Page 30 EKIT BATTERY RAIL POSITION PLACE RAIL IN REAR POSITION TO AVOID CONTACT WITH ADJUSTABLE SEATBACK DURING ADJUSTMENT FRONT OF TRIKE REV 12.18.24 Pg.29...
  • Page 31 EKIT BATTERY RAIL ASSEMBLY DO NOT TIGHTEN BOLTS ALL THE WAY YET UNLESS SPECIFIED M6 SMALL OD WASHER (2x) M6x16 BHCS (2x) M6x16 BHCS (2x) LIGHTLY GREASE THREADS LIGHTLY GREASE THREADS M6x16 FHCS (2x) TORQUE 5Nm (40INLBS) BATTERY MOUNT PLATE WELDED # BC1421 BATTERY RAIL ASSEMBLY REV 12.18.24 Pg.30...
  • Page 32 EKIT BATTERY CLAMP LEVEL TIGHTEN LEVEL EACH OF THE SHOWN AXIS 5Nm (40INLBS) FOR THE BATTERY CLAMP AND BRACKET BEFORE TIGHTENING THE RESPECTIVE BOLTS TIGHTEN 5Nm (40INLBS) ENSURE EVEN GAP ON CLAMP WHEN TIGHTENING REV 12.18.24 Pg.31...
  • Page 33 EKIT SPEED SENSOR ASSEMBLY LEFT SPINDLE COMPUTER SENSOR MOUNT # BC1443 M5 NYLOCK NUT BOSCH SPEED SENSOR ZIP TIE CABLE ALONG TIE ROD TO DRIVE UNIT M5x12 BHCS SPEED SENSOR RUBBER PLUG REV 12.18.24 Pg.32...

  • Page 34: Ecat

    EKIT CONTROLLER ASSEMBLY CONTROLLER CABLE IS ROUTED THROUGH HANDLEBAR GRIP TO DRIVE UNIT eCAT CONTROLLER MOUNT ECAT PURION CONTROLLER # BC1426 ECAT CONTROLLER CLAMP BOLT SLIDE ECAT CONTROLLER ONTO CONTROLLER MOUNT AND ADJUST FOR VIEWING COMFORT THEN TIGHTEN THE ECAT CONTROLLER CLAMP BOLT TO LOCK INTO PLACE *BOLT IS CAPTURED, REMOVED FOR ILLUSTRATION...
  • Page 35 EKIT FRONT LIGHT ASSEMBLY SUPERNOVA FRONT LIGHT ASSEMBLED M6x16 BHCS M6 SMALL OD WASHER REV 12.18.24 Pg.34...
  • Page 36 EKIT REAR LIGHT ASSEMBLY ROUTE BRAKE LIGHT CABLE THROUGH SEAT MESH TO DRIVE UNIT PLACE BRAKE LIGHT ON HIGHTEST POINT OF TRIKE OR WHERE EVER MOST VISIBLE TO REAR TRAFFIC WRAP RUBBER BAND AROUND ANY 1” TUBE SECTION REV 12.18.24 Pg.35...
  • Page 37 EKIT CABLE ROUTING ZIP TIE CABLES TO TIE ROD AND SPEED SENSOR CABLE ENSURE THEY DON’T SNAG UNDER FULL CONTROLLER CABLE STEERING LOCK BRAKE LIGHT CABLE BATTERY CABLE W/ DISCONNECT ZIP TIE CABLE CLUSTER TO BOOM AND BOOM CLAMP LOOP & ZIP TIE EXCESS POWER CABLE UNDER SEAT MESH...
  • Page 38 FENDER TO FRAME INSTALLATION RUBBER WASHER FENDER MOUNT BRACKET - 90 DEG M5 NYLOCK HEX NUT M5 WASHER M5x12 BHCS M5 WASHER M5x12 BHCS LIGHTLY GREASE THREADS M5 WASHER SHORT 20” FENDER ASSEMBLY # BC1387 RUBBER WASHER MAINFRAME ENDCAP REV 12.18.24 Pg.37...
  • Page 39 FENDER TO DROP OUT INSTALLATION LEFT DROP OUT RIGHT DROP OUT FENDER STAY (4x) M5x12 SHCS (3x) M5 WASHER (4x) M5x14 SHCS INCLUDED WITH FLAG MOUNT FLAG MOUNT # BC1265 REV 12.18.24 Pg.38...
  • Page 40 FENDER STAYS & FINAL INSTALLATION TIGHTEN ALL 4 FENDER STAYS TO LOCK FENDER ASSEMBLY IN PLACE ADJUST REAR FENDER SO THERE IS AN EVEN GAP AROUND THE REAR WHEEL RUBBER CAP M6 NYLOCK NUT EYELET BOLT FENDER STAY REV 12.18.24 Pg.39...