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Johnny Loco WOODY Assembly Manual

Cargo bike type 4
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ASSEMBLY MANUAL
CARGO BIKE TYPE 4 - WOODY
ASSEMBLING A JOHNNY LOCO
TYPE 4 CARGO WOODY BIKE

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Summary of Contents for Johnny Loco WOODY

  • Page 1 ASSEMBLY MANUAL CARGO BIKE TYPE 4 - WOODY ASSEMBLING A JOHNNY LOCO TYPE 4 CARGO WOODY BIKE...
  • Page 2 SUPPLIED: Cargo bike rear frame › Cargo bike triangle › Cargo bike wooden box parts with bench › Front bracket, front and rear LED lights › Cargo bike fenders and parts › Front connection part triangle › Front wheels (left and right) ›...
  • Page 3 SUSPENDING THE REAR FRAME To minimize the risk of damaging the bike › during installation we recommend a soft work floor. The cargo bike packaging is a good alternative. Make sure al metal clamps are removed from the box before placing parts on it.
  • Page 4 CONNECTING THE TRIANGLE triangle front connection Keep the headset of the frame elevated just › above ground for easy installation. Take the top and bottom bolt with washer out › of the headset and install triangle as shown in diagram. Leave the bottom bolt untightend (6 mm) to install front connection to the triangle later.
  • Page 5 ASSEMBLING THE WOODEN BOX Lay down the bottom part (A) and insert › the rear part (B) in the bottom part as shown. Place the 2 side plates (C) to the sides › of the bottom part (A) and rear part (B).

  • Page 6: Connecting The Box

    CONNECTING THE BOX Places where the bolts go through the triangle and the wooden side part Hoist the cargo frame in a straight position › Place the wooden box on the triangle › and connect the box to the triangle with (M6x25) bolts, washers and nuts.
  • Page 7 INSTALLING FRONT LIGHTS & BRACKET Place the front lights in the cut out of the wooden side › parts in the front. Make sure the handle of the front light is on the inside of › the wooden box, as shown in the picture Use a M6x20mm bolt, 2 washers and a lock nut per ›...
  • Page 8 front connection part 3 M6x25 bolts After the assembly of the front bracket and front lights is › complete, use 3 M6x25 bolts, washers and nuts to connect the front wooden part to the front connection Thighten all connections to the box and front connection ›...

  • Page 9: Installing The Wheels

    INSTALLING THE WHEELS The two front wheels are different, there › is a ‘left’ and ‘right’ version. Make sure the ‘right’ wheel is inserted on the right side and ‘left’ wheel on the left side of the box. If this is done incorrect, the thread on the axle can be damaged and the axle or triangle wil need replacement.
  • Page 10 MOUNTING THE BRAKES installed brake Loosen bolts as shown in picture below. › Mount the brakes as shown above. › Mount with supplied bolts on the frame check position. › take out before installing loosen 1 turn before installing (on both brake claws)
  • Page 11 CONNECTING AND ADJUSTING THE FRONT BRAKES Thighten outside pad of the › brake 1/4 turn. Squeeze the brake tight. › Thighten the cable in the brake. › Secure the brake to the › bracket. Losen the outside pad 1/4 › turn.
  • Page 12 INSERTING THE HANDLEBAR & BENCH Make sure the longer › version of the bench tube is at the bottom and the shorter tube is in top of the bench! Use 2 M6x20mm › bolts and washers to connect the bottom tube between the wooden side parts From the left to the right: M6x30m bolt, M6 washer, wooden side part, rubber washer,...
  • Page 13 MAKING THE SEATBELTS READY The top seatbelt parts (A) should be › connected properly to the bench by installing the handlebar (previous page) Connect the bottom seatbelt parts (B) › to the rear wooden part underneath the couch with M6x20mm bolts, washers and nuts Make sure the connections are ›...
  • Page 14 MOUNTING THE FENDERS PARTS front fender (2x) bolt M6x16 (4x) (preinstalled in triangle) › › front fender stay(4x) bolt M6x20 (2x) › › front fender rod (2x) washer M5 (12x) › › washer m6 (6x) bolt M5x16 (4x) › › bolt M5x12 (2x) ›...
  • Page 15 fender rod fender stay ducktail fender on cargo bike Position the fender on the › cargo box. Make sure the ducktail side is on the lower back of the cargo box. Connect fender tube to the › fender. Hold fender in place and ›...
  • Page 16 INSTALLING STEERING DAMPER Connect the steering damper to › frame and triangle as shown in picture. Check if the ‘extending rod’ side is mounted to the triangle. bottom Cargo box INSTALLING SAFETY BRACKET Position the safety › bracket as shown in drawing.
  • Page 17 HARNESSING THE CABLES NOTE! The Shimano Nexus cable should not be attached to the latest attachment on the bottom of the rear frame. Otherwise this cable will get damaged cause of to much tension while steering! So the attachment in the red circle should NOT get zipped! Hold the 3 cables together by hand ›...