AmTryke JT2000 Assembly Instructions

AmTryke Adult Recumbent Model JT2000 #50-FC-2000

TOOLS Needed for Assembly

5 mm Allen Wrench

8 mm Socket or Wrench
10 mm Socket or Wrench
14 mm Socket or Wrench
15 mm Socket or Wrench

22 mm Socket or Adjustable Wrench

Needle Nose Pliers W/ Side Cutters

Phillips Screw Driver

Revise Date: 8/06/09 1 of 29

Table of Contents

Rear Deck Assembly Page 3

Front Tire Installation Page 5

Attaching Rear Deck to Main Frame Page 6

Leg Supports Page 7

Main Steering Installation Page 8

Attaching Seat Frame to Main Frame Page 10

Attaching Seat Cover Page 12

Front Reflector Page 13

Front Brake Page 14

Cable Retainer Page 16

Wheel Reflectors Page 18

Maintenance Page 19

Revise Date: 8/06/09 2 of 29

Rear Deck Assembly

1) Remove the 22mm nuts & flat washers from both ends of axle, slide wheel over each side, pay attention
to tire.

directional arrow.

2) Slide flat washer over each side and then thread a 22mm nut on each side. Tighten using a 22mm socket or
adjustable wrench, do not over tighten as wheel bearing we be damaged.

3) Install black round caps on each side, lightly tap to secure in place.

Revise Date: 8/06/09 3 of 29

4) Install red reflector on bracket for rear deck using Phillips screw driver, bracket will have B-2 stamped on it.

B – 2
stamped

Clamping
Screw

5) Using Phillips head screw driver remove clamping screw from bracket, open clamp and install on rear, thread
clamping screw and tighten.

6) Install seat support bracket to rear deck using two 5mm Allen bolts & nuts. Use a 10mm Socket or Wrench & a 5
mm Allen Wrench to tighten.

Revise Date: 8/06/09 4 of 29

Front Tire Installation

1) Remove two black plastic thread protectors located on each end of axle.

2) Using the thin black quick release axle, remove the thumb nut from one side and one spring.

3) Place front tire in front fork.

4) Slide shaft of quick release axle through center of

rim.

5) Install spring on other side with narrow end pointing inwards, thread thumb nut back on and tighten.

Revise Date: 8/06/09 5 of 29

Attaching Rear Deck to Main Frame

1) Slide rear deck into main frame.

2) Using four large lag bolts, 4 large flat washers and four large nuts attach rear deck to main frame, use a 15mm

socket or wrench to tighten nuts. Do not tighten up completely at this point.

3) Install chain from main hub to rear axle sprocket.

Rear Axle
Sprocket

Main Hub

4) Using a pair of needle nose pliers snap the master link in place.

5) Pull back on the rear deck to tighten the chain, while pulling back tighten the four 15mm nuts using a 15mm

socket or wrench.

6) Install two upper support Allen bolts, washers and nuts using a 5mm Allen wrench & 13mm wrench. There is

one on each side of the rear deck.

Upper Support
Allen Bolt

Rear Deck

Main Frame

Master Link

Revise Date: 8/06/09 6 of 29

Leg Supports

1) The leg supports are already installed. Due to constraints in packaging you will need to position them.

2) First, remove the tube from the right leg support. Pivot the leg so it is 90 degrees to the main frame of the

tricycle. Replace the tube.

3) Rotate the left side leg support to a similar position.

4) Don’t tighten until final set-up.

Pivot
Downward

Remove
Tube

Insert Tube

Initial Appearance

Tighten

Main Steering Installation

1) Slide the hand crank steering tube over the steering stem of the main frame, note location of chain guides before

installing. Inside chain guide fits underneath bolt for tightening steering tube to stem. Outside chain is just
above holes in leg support bracket.

Revise Date: 8/06/09 7 of 29

Steering
Stem

2) Pivot leg support bracket so the hole in support bracket aligns with hole in main steering tube.

Leg Support Bracket

Hole not
aligned

3) Thread the 1” 5mm Allen head bolt with flat washer through the center steering stem hole.

Chain guides
location

Hole aligned

Chain
Guide

4) Insert 6mm 3 ½” bolt through the support bracket and

through the main steering tube and out the other side,
install one flat washer and thread 13mm nut, tighten
using 13mm socket or wrench and 6mm Allen wrench

Revise Date: 8/06/09 8 of 29

5) Install handgrips, shift/rear brake goes on the right side, while the front hand brake is positioned on the left, the

6) Install the steering linkage; remove the two nuts and flat washers already installed.

7) Using a 5mm Allen wrench thread the screw through the steering stem attachment, slide one flat washer over

8) Slide flat washer over front screw and thread 13mm nut, use a 5mm Allen wrench and 13mm wrench or socket

9) Once installed, adjust steering by turning black tube adjustment rod until satisfied tryke is positioned to steer

13mm nut with flat
washer.

Tighten

right side threads in clockwise while the left side threads in counter clockwise.

the exposed thread and thread the 13mm nut, tighten.

Stem
attachment

Steering Linkage

to tighten.

straight ahead.

13mm nut and flat
washer

Steering
Stem

13mm nut and
flat washer

Attach Seat Frame to Main Frame

Revise Date: 8/06/09 9 of 29

1) Place main seat frame mounting bracket over main frame so that one hole in the seat bracket aligns with a hole

in main frame. Remove thumb nut from silver cam lock lever and insert shaft through seat bracket and through
main frame, thread thumb nut on and lock down lever.

2) Install two short seat supports on back of main seat frame using two long shafted Allen bolts, two flat washers

and two nuts. Tighten using a 10mm wrench or socket and 5mm Allen wrench.

Seat
Frame

Short
support
mounts

Seat Frame
Bracket

Main Frame

Quick release with
cam lock lever
inserted through
frame.

10mm nut and
5mm Allen
bolt

Revise Date: 8/06/09 10 of 29

3) Slide long support bars inside of short support bars, align holes in each and insert in each one a clevis pin

W/snap ring.

Seat Support
Bars.

NOTE: The angle of the seat is determined by adjusting the height of the support bars, the lower the adjust the
greater the angle.
By moving the main seat frame forward or backward to other holes in the main frame will either decrease or
increase the arm/leg travel for either taller or shorter riders.

Clevis pin with snap ring

Revise Date: 8/06/09 11 of 29

Attaching the Seat Cover

1) Along one edge of the seat cover are straps and the other edge are buckles. On the other two edges are pockets

to slide the seat cover over the main seat frame.

2) Slide the seat cover over the main seat frame.

Pocket in
seat cover

Main seat
frame

3) Lace the straps through the buckles then tighten the straps by pulling them. The cover will conform to the seat

frame.

Lace strap through buckle
as shown above.

Finished seat cover
should look like this
one.

Pull on excess strap to
tighten.

Revise Date: 8/06/09 12 of 29

Front Reflector

1) Attach reflector to bracket, use Phillips head screw.

Phillips head
screw

Bracket

2) Remove clamp screw, open clamp and place over steering stem tube.

Clamp
Screw

Reflector

Steering stem
tube

Reflector
bracket

Front Brake

Revise Date: 8/06/09 13 of 29

V-Brake

1. If fitted with V-Brakes, insert the brake body
into the center spring hole in the frame mounting
boss, and then secure the brake body to the frame
with the link fixing bolt.

V-Style Brakes

If not already assembled, take the brake noodle from the parts box and
slide the cable through the larger opening. The cable housing will then
seat into the end of the noodle. Slide the cable through the cable lead on
the end of the left brake boot arm; this will cause the noodle to fit into the
lead. Slip the brake cable boot over the cable and position it between both
brake arms. Next loosen the 5mm anchor bolt at the end of the right
brake arm and slide the cable under the retaining washer. Pull the slack
out of the cable making sure a distance of 39mm or more remains
between the end of the lead and the start of the anchor bolt. Once the
cable is secured to the brake arms, engage the brake lever several times,
checking the position of the brake shoes at the rim. The brake shoes
should be 1mm away from the rim when in a relaxed position. When the
brake lever is engaged, the brake shoe should hit the rim flush (never the
tire) with the front brake pad touching the rim slightly before the rear.
This is called “toeing-in” your brake shoe. If this position is not achieved,
adjustments to the brake shoe are required. Loosen the brake shoe
hardware and reposition the brake shoe. It may take several shoe and
cable adjustments before the required position is accomplished.

2. While holding the shoe against the rim, adjust the amount
of shoe protrusion by interchanging the position of the B
washers (i.e. 6 mm and 3 mm) so that dimension A is kept at
39 mm or more.

3. While holding the shoe against the rim,

Revise Date: 8/06/09 14 of 29

tighten the shoe fixing nut.

5. Adjust the balance with the spring tension adjustment
screws.

4. Pass the inner cable through the inner cable lead. Set the
cable with the clearance of 1mm between each brake pad
and the rim, tighten the cable fixing bolt.

Cable Retainer

6. Depress the brake lever about 10 times as far as the
grip to check that everything is operating correctly and
that the shoe clearance is correct before using the
brakes.

Revise Date: 8/06/09 15 of 29

1) Remove the Phillips head screw located on the steering stem tube.

2) Put screw through lower eyelet of cable retainer and thread back into steering stem tube.

3) Attach the cable retainer to upper chain guard bracket using a zip tie. Clip off excess zip tie.

Phillips head screw on
steering stem tube.

Phillips head screw through
lower eyelet of cable retainer.

Cable retainer attached to upper
chain guard bracket with zip tie.

Revise Date: 8/06/09 16 of 29

4) Use a zip tie to attach the three cables to the retainer; this will prevent the cable from wrapping around the hand

grips during pedaling.

5) Use the remaining zip ties and secure the cable to the steering stem tube.

Gear shift cable and
rear brake cable.

Rear brake, Front brake and Gear
shift cables attached to the cable
retainer with zip tie.

Cable retainer secured to
steering stem tube with
screw.

Cable retainer attached to
upper chain guard bracket
with zip tie.

Revise Date: 8/06/09 17 of 29

Wheel Reflectors

1) Place the reflector in an area on the rim behind a single spoke with two on the opposite side. Align the front

spoke with the slot in the reflector.

Reflector

Single spoke

Reflector holding
pin

2) Insert the reflector holding pin with the slotted end going over the spoke into the hole in the reflector. Press

firmly until you hear it click into place.

Revise Date: 8/06/09 18 of 29

Maintenance

As is with all other bikes and vehicles that use a chain for the drive line, the chain may come off the sprocket and need
to be reinstalled. This next section will serve as a guide on how to reinstall the chain should it come off.

1) Remove the Phillips head screw on the front of the chain guard and the 8mm nut located behind it that secures the

two halves of the chain guard together and holds the upper chain guard bracket in place.

Remove Phillips head screw and
8mm nut located behind it. (not
shown the 8mm nut)

2) The outer chain guard cover will easily remove by lifting up on it; let it rest on th e hand grip.

Outer chain guard cover removed
chain and sprocket now exposed

Revise Date: 8/06/09 19 of 29

3) Remove the outer chain from the lower outer pulley slot located at the base of the steering stem tube.

Outer pulley at
base of steering
tube.

4) Use a screwdriver to lift the chain up in the front and turn the hand crank counter clockwise while doing so until it

grabs the chain and pulls it outwards.

Insert screw
driver here and
lift up on chain.

Revise Date: 8/06/09 20 of 29

5) Place chain on front side of sprocket and rotate crank arm counter clockwise until chain is on sprocket completely.

Front of Sprocket

6) Repeat steps 1, 2 & 3 in reverse to finish reinstalling the chain.

Revise Date: 8/06/09 21 of 29

Q

Seating Assembly

Main Seat Frame (pages 10 to 12)

Seat cover (Pages 10 to 12)

uick Release

Seat support rods (Pages 10 to 12)

Clevis Pins

Long support rod
Allen bolts

Short support rods

Short support rod Allen bolts

Long support rods

Seat mounting hardware (Pages 10 to 12)

Revise Date: 8/06/09 22 of 29

Front Tire

Front tire and quick release axle (Page 5)

Quick release axle

Revise Date: 8/06/09 23 of 29

Rear Deck Assembly

Rear deck and mounting hardware (Pages 3 to 6)

Rear deck frame

Black round nut caps (page 3)

Rear deck frame to main frame
mounting hardware (Page 6)

Chain and master
link (Page 6)

Revise Date: 8/06/09 24 of 29

Rear Tires

Right and Left rear tires (Page 3)

Tire direction must be followed

Revise Date: 8/06/09 25 of 29

Main Frame

Main frame (Pages 6 to 10)

Hand cranks

Seat position holes

Main hub

Main Steering Tube

Front Fork

Leg Supports

Revise Date: 8/06/09 26 of 29

Hardware

Leg support
bolt, washers
and nut (Page 9)

Center steering
stem bolt and
washer (Page 8)

Upper support Allen bolts,
washers and nuts (Page 6)

Cable Retainer (Pages 16 to 17)

Brake noodle and cable cover
(Pages 14 to 15)

Revise Date: 8/06/09 27 of 29

Steering Linkage

Steering Linkage (Page 9)

Revise Date: 8/06/09 28 of 29

Reflectors

Rear reflector and
bracket (Page 4)

Wheel reflectors and spoke securing pins (Page 18)

Front reflector and
bracket (Page 13)

Revise Date: 8/06/09 29 of 29