This Online manual contains information on how to properly adjust and operate your Lighting Handcycle for maximum comfort, safety, and performance. The recumbent position and rigid seat require alternate adjustment methods. Carefully follow the instructions, and after a short period of time, you will have the new skills needed to ride your Lightning cycle successfully. 

CONTENTS 

1.0   The Handcycle Assembly
2.0   Adjustments Before Riding
3.0   Riding
4.0   Maintenance 

 

 1.0 THE HANDCYCLE ASSEMBLY 

1.1 COMPLETE BIKE ASSEMBLY: 

A) Remove all items from the box and unwrap. You should have the following items: 

(1) Frame assembly
(1) Crankset assembly
(1) Steering assembly
(1) Chain
(1) 26" wheel, front
(2) 20" wheels, rear
(2) Hand-pedals 

Note: Insure that you cut the zip-ties that bind the Steering Damper and the Centering Elastomer before you begin assembly. 

B) Begin by mounting the upper pivot bolt of the steering assembly to the main tube just behind the seat, using the 5/16" Allen bolt [see Fig. 1-1). 

(Before 8/1/99 use C, after 8/1/99 use C.1)

C) Connect the swivel mount to the main tube (which is underneath the seat) with the hose clamp provided. Insure that the swivel mount is centered before tightening the hose clamp. Be sure that the hose clamp is mounted at the front of the swivel mount, towards the front of the cycle (see Fig. 1-2). Also be sure to fully tighten the hose clamp with a socket wrench. 

C.1) The pivot clamp is strapped in place. Remove the bolt from the pivot. Line up your handlebars and replace the bolt through the handlebars and screw the bolt back into the pivot you got it from. Be sure to use LockTight here.

D) Now attach the centering elastomers and the steering damper with the bolts provided (reference Fig. 1-1). To adjust the resistance of the steering dampener, just turn the knob at the bottom of the dampener clockwise. The further clockwise you turn the knob the stiffer the bike will be from left to right. The elastomers pins have threaded adjustment bolts at the top. The further down you spin these threaded bolts the stiffer your ride will be. However over-tightening these adjusting bolts will make sharp turns more difficult and require more force to achieve them.

E) Now take the time to attach the rear wheels. Press in the quick release.

F) (Bikes bought before 8/1/99 use F through H) The crankset will now need to be set into the head tube. Slide the bottom bracket assembly into the head tube, and install the hand-pedals. (Note: The left hand pedal has left hand threads.) Adjust the crank length and tighten (see Fig. 1-2). 

G) Install the front derailleur. Install the front wheel into the dropout and check the tire pressure. 

H) Install the chain according to figure 1-2. 

I) Install the warning flag into the small tube at the top of the seat back. 

 

 

 

 

 

2.0 ADJUSTMENTS BEFORE RIDING 

2.1 CRANK ADJUSTMENT: 

On Lighting cycles, the cranks are moved to accommodate individual body types. Adjust the cranks as follows: 

A) Loosen the two Allen head bolts atop the crank tube with a 5mm Allen wrench. 

B) Slide the cranks in or out until your arms are lightly bent at their furthest extension. It's better to have the cranks too close when making the initial adjustments than too far away. 

C) Verify the crank arms are vertical with respect to the crank tube, then tighten the two Allen head bolts. 

 

2.2 CHAIN ADJUSTMENT: 

A) The chain should be long enough to permit shifting onto the large rear chainwheel - large front sprocket combination, and not so long as to lose derailleur tension when shifted onto the small chainwheel - middle front sprocket combination. The derailleur does not have sufficient take-up to use the small chainwheel - small sprocket combination. 

B) Remove chain links as required to obtain the correct chain length as outlined in (A) above.

 

2.3 INSPECTION: 

A) Re-check the crankset, brakes, and derailleur for proper adjustment and operation. 

2.4 CYCLE CENTERING ADJUSTMENT: 

The two elastomer centering nuts are used to place the forward frame and front wheel in a vertical position (see Fig. 1-1).

A) Screw one adjusting nut down while at the same time screwing the other one up, until the front wheel is vertical. 

Note: For the cycle self-centering mechanism to work properly when riding, both adjusting nuts should be screwed down until they lightly touch the elastomers. Screwing the nuts further down than this, which compresses the elastomers, defeats the self-centering feature.

B) Verify the nuts are adjusted so that they lightly contact the elastomers. 

2.5 KNEE RESTRAINING STRAP: 

A) Determine the correct strap length needed for your body type. 

B) Cut any excess off of the fixed (non-loop) end of the strap. 

C) Reattach the cut end of the strap to the knee plate (see Fig. 2-1)

 

 

 

 

 

 

3.0 RIDING 

Find a straight, level road without much car traffic for learning how to ride. 

3.1 FIRST LEARNING TO RIDE: 

A) We recommend you ride slowly when first learning how to ride the Handcycle. The centering mechanism is designed so that a fair amount of leaning force is needed to initially cause the Handcycle to lean. However, one the lean is started, the cycle loans over fairly easily. Take the first turns slowly until you are used to the characteristics of the lean steering. 

B) The adjustment knob on the bottom of the steering clamper regulates how fast the cycle will lean over, and also helps to stabilize it and dampen out oscillations caused by uneven pedaling actions or road irregularities. We recommend the knob be placed in the middle of its adjustment range when first learning to ride. You may desire later on to increase the amount of damping (by turning the knob clockwise) for higher speeds or if you are a stronger rider. For quicker handling and maneuvering, turning the knob counterclockwise can decrease the damping. 

C) For maximum safety and control when cornering at higher speeds or when coasting down hills, we highly recommend you grab the handlebars located below and to both sides of the seat. 

3.2 ADJUSTING THE STEERING ANGLE FOR OPTIMUM HANDLING: 

The steering angle can be adjusted to suit your particular riding style, or changed depending on the type of terrain you ride in. To adjust the steering angle, perform the following: 

A) Referring to Fig. 1-2, loosen the hose clamp and the strut clamp bolts.

B) To decrease the steering angle for higher speeds, slide the handlebar and strut assembly forward. 

C) To increase the steering angle for slow speed tight turning, slide the handlebar and strut assembly rearward. 

D)  Retighten the strut clamp bolts and the hose clamp.

4.0 MAINTENANCE 

4.1 THE SEAT: 

The seat as received on new Lightning cycles is fairly tight. After an initial break-in period of riding, the seat will loosen up due to stretching of the material, The seat back should be tightened by taking the slack out of the string that runs along the sides. 

4.2 PAINT 

The paint on the frame is a very tough urethane coating, which is highly resistant to scratching. It also maintains its luster for a long time but can be waxed with ordinary auto type wax if desired. 

4.3 BIKE PARTS

All of the other parts are standard bicycle components, and can be easily serviced by your local bicycle shop. The chain should be oiled periodically. The bottom bracket and hubs should be cleaned, greased, and adjusted once a year. The brakes and control cables should be monitored and adjusted when necessary.

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