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Catrike EXPEDITION Technical Manual

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TECHNICAL MANUAL

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Summary of Contents for Catrike EXPEDITION

  • 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

    FRONT WHEEL INSTALL ..............................8-11 REAR WHEEL INSTALL ............................... 12 TIE ROD ADJUSTMENT ..............................13-14 HANDLEBARS ..................................15-16 BOOM ADJUSTMENT ................................17-18 CABLE ROUTING ................................. 19 CHAIN ROUTING ................................20 ECAT ....................................... 21-30 REAR FENDER ASSEMBLY ..............................31-33 EXPEDITION REV 12.18.24 Pg.3...

  • Page 5: Headset Assembly

    # 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 EXPEDITION REV 12.18.24 Pg.4...

  • Page 6: Spindles

    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) TORQUE 10Nm (88INLBS) M5 NYLOCK HEX NUT INSTALL INTO HEX POCKET EXPEDITION REV 12.18.24 Pg.5...
  • 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) EXPEDITION REV 12.18.24 Pg.6...

  • Page 8: Tie Rod

    TIE-ROD ASSEMBLY M8x35 BHCS MEDIUM TIE-ROD (ASSEMBLY) # BC1340 HARDWARE INCLUDED IN EACH ASSSEMBLY SLIM CONICAL SPACER M8 WASHER M8 NYLOCK HEX NUT RIGID SPINDLE # R: BC1243 / L: BC1244 EXPEDITION REV 12.18.24 Pg.7...

  • Page 9: Front Wheel Install

    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 DIRECTION IS CORRECT. EXPEDITION REV 12.18.24 Pg.8...
  • 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. EXPEDITION REV 12.18.24 Pg.9...
  • Page 11 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. CONICAL AXLE NUT AXLE SPRING (2x) QUICK RELEASE HANDLE AND SKEWER EXPEDITION REV 12.18.24 Pg.10...
  • Page 12 CLOSE THE QUICK RELEASE HANDLE SO THAT IT IS PAST PERPENDICULAR AND TIGHT. IF THE HANDLE IS NOT TIGHT WHEN CLOSED THEN TIGHTEN THE AXLE NUT SO THAT THE HANDLE LEAVES A MARK ON YOUR PALM WHEN CLOSED. EXPEDITION REV 12.18.24 Pg.11...

  • Page 13: Rear Wheel Install

    GREASE THREADS AND SHAFT TORQUE 10Nm STEP1 INSTALL DERAILLEUR HANGER. STEP3 INSTALL AND TIGHTEN THRU AXLE TO 10NM REAR DERAILLEUR NUT - THRU AXLE REAR DERAILLEUR HANGER - THRU AXLE # BC1353 # BC1352 TORQUE 17Nm GREASE THREADS EXPEDITION REV 12.18.24 Pg.12...

  • Page 14: Tie Rod Adjustment

    *ON BOTH SIDES OF TIE-ROD STEP 1 LOOSEN THE JAM NUTS ON BOTH SIDES OF THE TIE-ROD. JAM NUT - 14MM WRENCH NOTE THAT ONE SIDE OF THE TIE- ROD IS REVERSE THREADED. *ONE SIDE IS REVERSE THREADED EXPEDITION REV 12.18.24 Pg.13...
  • Page 15 WHEELS IN 2MM. IN OTHER WORDS THE MEASUREMENT FROM THE FRONT SHOULD POINTS CIRLCED BELOW. BE 2MM SMALLER THAN THE MEASUREMENT TAKEN FROM THE REAR OF THE RIM. AS RIDER WEIGHT IS APPLIED TO THE CATRIKE THE TOE WILL BECOME MORE EQUAL. REAR MEASUREMENT...

  • Page 16: Handlebars

    SRAM SERVICE HUB FOAM GRIP # 129 LOCKING BRAKE LEVER # BC1347-R LOCKOUT BUTTON POINTS OUTWARDS HANDLEBAR UPRIGHT GRIP - RIGHT # BC1006 HAND REST PAIR (RIGHT) # BC1249 HANDLEBAR LOWER HORIZONTAL SUPPORT - RIGHT # BC1004 EXPEDITION REV 12.18.24 Pg.15...
  • Page 17 # 129 HANDLEBAR UPRIGHT GRIP - LEFT # BC1007 LOCKING BRAKE LEVER # BC1347-L LOCKOUT BUTTON POINTS OUTWARDS MIRROR MOUNT LEFT # BC1252 HANDLEBAR LOWER HORIZONTAL SUPPORT - LEFT # BC1005 HAND REST PAIR (LEFT) # BC1249 EXPEDITION REV 12.18.24 Pg.16...

  • Page 18: Boom Adjustment

    BOOM CAN BE CUT FOR SHORTER RIDERS. CLIPLESS SHOES ARE STRONGLY RECCOMENDED SEE WARNING ON NEXT PAGE REGARDING MINIMUM BOOM INSERTION ONCE CLIPPED IN, THE EXTENDED LEG SHOULD NOW HAVE A SLIGHT BEND. BOOM ADJUSTMENT IS UP TO RIDER PREFERENCE. EXPEDITION REV 12.18.24 Pg.17...
  • Page 19 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 EXPEDITION REV 12.18.24 Pg.18...

  • Page 20: 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 EXPEDITION REV 12.18.24 Pg.19...

  • Page 21: Chain Routing

    CHAIN ROUTING DRIVE SIDE CHAIN TUBE ROUTED BELOW TIE-ROD AND ON TOP OF CROSS MEMBER TIE-ROD CROSS MEMBER RETURN SIDE CHAIN TUBE ROUTED BELOW CROSS MEMBER EXPEDITION REV 12.18.24 Pg.20...
  • Page 22 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 EXPEDITION REV 12.18.24 Pg.21...
  • Page 23 EKIT BATTERY CLAMP POSITION PLACE CLAMP BELOW THE CHAIN STAYS EXPEDITION REV 12.18.24 Pg.22...
  • Page 24 EKIT BATTERY RAIL POSITION PLACE RAIL IN CENTER POSITION FRONT OF TRIKE EXPEDITION REV 12.18.24 Pg.23...
  • Page 25 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 EXPEDITION REV 12.18.24 Pg.24...
  • Page 26 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 EXPEDITION REV 12.18.24 Pg.25...
  • Page 27 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 EXPEDITION REV 12.18.24 Pg.26...

  • Page 28: Ecat

    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 LEFT HANDLEBAR ASSEMBLY & GRIP EXPEDITION REV 12.18.24 Pg.27...
  • Page 29 EKIT FRONT LIGHT ASSEMBLY SUPERNOVA FRONT LIGHT ASSEMBLED M6x16 BHCS M6 SMALL OD WASHER EXPEDITION REV 12.18.24 Pg.28...
  • Page 30 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 EXPEDITION REV 12.18.24 Pg.29...
  • Page 31 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 EXPEDITION REV 12.18.24 Pg.30...
  • Page 32 FENDER TO FRAME INSTALLATION RUBBER WASHER FENDER MOUNT BRACKET - STRAIGHT M5 NYLOCK HEX NUT M5 WASHER M5x12 BHCS M5 WASHER MAINFRAME ENDCAP LONG 26” FENDER ASSEMBLY # BC1384 M5 WASHER M5x16 BHCS LIGHTLY GREASE THREADS RUBBER WASHER EXPEDITION REV 12.18.24 Pg.31...
  • Page 33 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 EXPEDITION REV 12.18.24 Pg.32...
  • Page 34 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 EXPEDITION REV 12.18.24 Pg.33...

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