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Catrike Villager Technical Manual

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TECHNICAL MANUAL

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Summary of Contents for Catrike Villager

  • 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 •...

  • Page 4: Table Of Contents

    TIE ROD ADJUSTMENT ..............................13-14 SUPPLEMENTAL TOE ADJUSTMENT INSTRUCTIONS ....................15 HANDLEBARS ..................................16-17 BOOM ADJUSTMENT ................................18-19 CABLE ROUTING ................................. 20 CHAIN ROUTING ................................21 ADJUSTABLE SEATBACK ..............................22-24 ECAT ....................................... 25-34 REAR FENDER ASSEMBLY ..............................35-37 VILLAGER 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 VILLAGER REV 12.18.24 Pg.4...
  • Page 6 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 VILLAGER 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) VILLAGER REV 12.18.24 Pg.6...

  • Page 8: Tie Rod

    TIE-ROD ASSEMBLY M8x35 BHCS LONG TIE-ROD (ASSEMBLY) # BC1278 HARDWARE INCLUDED IN EACH ASSSEMBLY SLIM CONICAL SPACER M8 WASHER M8 NYLOCK HEX NUT RIGID SPINDLE # R: BC1243 / L: BC1244 VILLAGER REV 12.18.24 Pg.7...
  • Page 9 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. VILLAGER 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. VILLAGER 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 VILLAGER 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. VILLAGER REV 12.18.24 Pg.11...
  • Page 13 CHECK THE TIGHTNESS OF THE STEP3 REAR WHEEL BEFORE EVERY RIDE WHILE PUSHING THE FRAME DOWN ON TO THE REAR WHEEL, TIGHTEN THE QUICK RELEASE NUT SO THAT WHEN CLOSING THE QUICK RELEASE HANDLE IT LEAVES AN IMPRINT IN PALM. VILLAGER 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 VILLAGER REV 12.18.24 Pg.13...
  • Page 15 IF IT IS NOT POSSIBLE TO SIT ON THE TRIKE WHILE ADJUSTING TOE, THEN REFER POINTS CIRLCED BELOW. TO THE SUPLEMENTAL INSTRUCTIONS ON THE FOLLOWING PAGE. REAR MEASUREMENT TIE-ROD BODY FRONT MEASUREMENT STEP 4 ONCE THE TIE-ROD HAS BEEN ADJUSTED TIGHTEN THE JAM NUTS AGAINST THE TIE- ROD BODY. VILLAGER REV 12.18.24 Pg.14...

  • Page 16: Supplemental Toe Adjustment Instructions

    SUPPLEMENTAL TOE ADJUSTMENT INSTRUCTIONS Villager 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 ADJUSTMENT VISIT SRAM SERVICE HUB FOAM GRIP # 129 LOCKING BRAKE LEVER LONG HANDLEBAR - RIGHT LOCKOUT BUTTON FACES OUTWARDS # BC1292 HAND REST PAIR (RIGHT) HANDLEBAR LOWER HORIZONTAL SUPPORT - RIGHT # BC1249 # BC1004 VILLAGER REV 12.18.24 Pg.16...
  • Page 18 ADJUSTMENT VISIT LONG HANDLEBAR - LEFT SRAM SERVICE HUB # BC1293 LOCKING BRAKE LEVER LOCKOUT BUTTON FACES OUTWARDS MIRROR MOUNT LEFT # BC1252 HAND REST PAIR (LEFT) HANDLEBAR LOWER HORIZONTAL SUPPORT - LEFT # BC1249 # BC1005 VILLAGER REV 12.18.24 Pg.17...

  • Page 19: 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. VILLAGER REV 12.18.24 Pg.18...
  • Page 20 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 VILLAGER REV 12.18.24 Pg.19...

  • Page 21: 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 VILLAGER REV 12.18.24 Pg.20...

  • Page 22: Chain Routing

    CHAIN ROUTING DRIVE SIDE CHAIN TUBE ROUTED ON TOP OF CROSS MEMBER CROSS MEMBER TIE-ROD RETURN SIDE CHAIN TUBE ROUTED BELOW TIE-ROD AND CROSS MEMBER VILLAGER REV 12.18.24 Pg.21...
  • Page 23 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 VILLAGER REV 12.18.24 Pg.22...

  • Page 24: Adjustable Seatback

    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 VILLAGER REV 12.18.24 Pg.23...
  • Page 25 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 VILLAGER REV 12.18.24 Pg.24...
  • Page 26 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 VILLAGER REV 12.18.24 Pg.25...
  • Page 27 EKIT BATTERY CLAMP POSITION PLACE CLAMP BETWEEN THE CHAIN STAYS AND SEAT STAYS VILLAGER REV 12.18.24 Pg.26...
  • Page 28 EKIT BATTERY RAIL POSITION PLACE RAIL IN REAR POSITION TO AVOID CONTACT WITH ADJUSTABLE SEATBACK DURING ADJUSTMENT FRONT OF TRIKE VILLAGER REV 12.18.24 Pg.27...
  • Page 29 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 VILLAGER REV 12.18.24 Pg.28...
  • Page 30 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 VILLAGER REV 12.18.24 Pg.29...
  • Page 31 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 VILLAGER REV 12.18.24 Pg.30...

  • Page 32: 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 VILLAGER REV 12.18.24 Pg.31...
  • Page 33 EKIT FRONT LIGHT ASSEMBLY SUPERNOVA FRONT LIGHT ASSEMBLED M6x16 BHCS M6 SMALL OD WASHER VILLAGER REV 12.18.24 Pg.32...
  • Page 34 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 VILLAGER REV 12.18.24 Pg.33...
  • Page 35 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 VILLAGER REV 12.18.24 Pg.34...
  • Page 36 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 VILLAGER REV 12.18.24 Pg.35...
  • Page 37 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 VILLAGER REV 12.18.24 Pg.36...
  • Page 38 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 VILLAGER REV 12.18.24 Pg.37...