Optima Baron, Low Baron, Cobra, Dingo, Dolphin User Manual
...
Recumbent Bicycle
User’s Manual
‘Zen and the art of Recumbent Maintenance’
First published 2002
All Rights reserved, 2002
All images and text
Optima V.O.F.
We would like to extend special thanks to
Tim Biesemans, Mark Scherpenzeel and countless
other Optima customers whose many photos helped to
decorate the pages of this manual.
Congratulations and thank you, for buying an Optima!
About this manual
Why You Should Read This Manual
This manual was written to help you get the best of performance, comfort, enjoyment and
safety from your new Optima.
Whether you bought your Optima for running errands, commuting to work
or recreation and exercise, we welcome you to the effortless, comfortable
and fast world of
recumbent bicycling!
Before taking your bike out for a ride, we ask that you read this brochure
fully – we know you’re itching to go!
We would like to express many thanks to our customers who supplied
many of the photos included in this manual.
We hope that this manual will help you to enjoy your bicycle for many
years to come.
Caution! Whenever you see a grey box, be sure to read
it carefully. These boxes hold warnings and tips, some
crucial to the function or safety of your bicycle.
It is crucial that you fully understand your new recumbent bike; its features, characteristics
and operation, so that you get maximum enjoyment combined with maximum safety starting
with the rst ride. By reading this manual before you go out on your rst ride, you’ll know
how to get the most from your new Optima.
It is also important that your rst ride on a new bicycle is taken in a controlled environment,
away from cars, obstacles and other cyclists. This is especially important for individuals
who are not yet experienced in recumbent cycling, or for individuals riding a low slung
recumbent bicycle for the rst time. Do not overestimate your skills and potential. Riding
an unknown bike can lead to dangerous situations.
Optima strongly discourages riding your bicycle before reading the entire manual.
Warning! Bicycling can be a dangerous activity even in
‘optimal’ conditions. Proper maintenance of your recumbent
is your responsibility and it helps reduce the risk of injury
to yourself and others. This manual contains many Tips,
Warnings and Cautions which focus on important aspects
of your bicycle, its components and safe cycling. Many of
the Warnings and Cautions include text advising you of the
dangers which could “Lead to serious injury and damage to
your bicycle”.
Whenever any Warning! Or Caution! Boxes appear, keep
in mind that the following text is absent but applicable in all
cases:
Failure to follow this guideline could lead to a fall, damage to
your bicycle , serious injury and even to death.
We do not repeat this phrase everywhere because it would
give our manual a negative overtone. We all know how
much standard bicycle manufacturers warn you of the
dangers of cycling right? Keep in mind that this is true for a
recumbent, and that you have a reduced prole compared to
normal cyclists. Basically, be careful to ride with your head,
as well as your helmet, securely ON!
To the experienced Cyclist.
So you’ve been riding a bike all your life, know all the tips and tricks… you really don’t
need to read this manual, right?
WRONG.
Even if you’ve been riding a bike all your life, buying and riding a recumbent for the rst time
should be accompanied by an renewal of your cycling habits, knowledge and assumptions.
Why? Because bicycles are going through some pretty dramatic changes in the technology
which affects function, handing, comfort, performance and safety. A big example – the
difference between a standard upright bike and a recumbent! Please read this manual.
A point of attention for parents
It is a sobering fact that many cycling accidents involve children. Make sure that your
child always wears an approved bicycle helmet when riding. It is the responsibility
of a parent or guardian to ensure the safety of their child. This means that it is the parent
or guardian’s responsibility to ensure that their child can operate the bicycle, that it ts
the child properly and that it is well maintained. It is also your job to ensure your child
is educated in the laws of the road, common sense and trafc awareness, and wears
sufcient protective apparel. We strongly advise you read this manual if it is the manual
of your child’s bicycle.
GENERAL
SAFETY APPAREL 1
HELMETS 1
EYEWEAR 1
REFLECTORS 2
LIGHTS 2
MIRRORS 2
SUPPORT AND UPGRADING. 3
RESPONSIBLE CYCLING 4
GENERAL SAFETY MEASURES 4
WET WEATHER AND NIGHT TIME CYCLING 4
YOUR OPTIMA BICYCLE 5
SETTING UP YOUR BICYCLE 6
ASSEMBLING FROM THE BOX 6
1. INSTALLING THE WHEELS. 6
2. INSTALLING LINKAGE FRONT STEERING SYSTEMS 8
3. RIDER FRONT WHEEL ALIGNMENT 9
4. BRAKE ADJUSTMENT & BLEEDING 12
5. MOUNTING MUDGUARDS 13
6. FITTING THE SEAT AND RACK. 14
7. INSTALLING THE PEDALS 15
8. INSTALLING THE PEDAL BOOM 15
9. INSTALLING THE FRONT DERAILLEUR AND CABLES 16
10. TIRES AND CORRECT TIRE PRESSURE. 16
11. HANDLEBARS 16
12. SUSPENSION 17
13. CHAIN LINE AND PULLEYS 18
14. BRAKES. 19
15. MOUNTING THE AERODYNAMIC COWLING (BARON OPTION ONLY) 19
RIDING A RECUMBENT BICYCLE 22
BEFORE YOU RIDE 22
SHORT PRE-RIDE CHECKLIST. 22
THE FIRST RIDE 24
TRAVELLING ON YOUR RECUMBENT 25
COMFORT AND QUALITY ACCESSORIES FOR YOUR RECUMBENT 25
MAINTENANCE 27
RECOMMENDED PERIODIC MAINTENANCE 28
EACH TIME YOU RIDE 28
WEEKLY 28
QUARTERLY CHECKLIST. 28
TOOLS FOR MAINTENANCE 30
SERVICE TIPS 31
ADJUSTMENT OF THE HUBS. 31
HEADSET AND FRONT FORKS. 31
SPOKE TENSION 31
BOTTOM BRACKET AND CRANK 31
GEARS 31
STORAGE TIPS 32
TROUBLESHOOTING. 32
SUSPENSION
WHEELS AND TIRES
HUBS
CRANKS AND BOTTOM BRACKET
BRAKING
DERAILLEURS, CHAIN ROLLERS AND REAR CASSETTE
MISCELLANEOUS
FORKS AND HEADSET
PEDALS
OPTIMA BICYCLE MODELS 39
PERMITTED BICYCLE USAGE 40
RESOURCES 41
OPTIMA FACTORY 41
ACCESSORY LIST 41
WARRANTY 42
TERMS AND CONDITIONS OF GUARANTEE. 43
SERVICE RECORDS 45
WARRANTY FORM 51
General
Safety apparel
Many nations around the world, and their internal states, have strict requirements regarding
safety devices and their use in cycling. It is your soul responsibility to nd out what these
requirements are, in each and every state or nation you cycle and then follow them.
Helmets
‘If you don’t need a head, you don’t need a helmet’.
While not all nations and states require cyclists to wear approved protective headgear, we at
Optima strongly advise you to do so. Try to nd a helmet which complies to Snell, ANSI and
government safety requirements. Simple amoebic intelligence states that it is best to wear a
helmet (passed by these authorities) whilst cycling, whether the law requires it or not.
Many serious and fatal bicycle injuries could have been either reduced or avoided had the
cyclist been wearing a properly certied helmet. Your local bike store should have a range of,
or at least be able to order, helmets which suit your needs.
Caution! A correct helmet should t properly, and be fastened
securely according to the instructions of its manufacturer. A
good helmet will protect according to Snell, AISI or stringent
government regulations. Failure to wear a good helmet correctly
could lead to serious injuries or even death, which may have
otherwise been avoided.
For more information on helmets, please contact your dealer or a local bike store, they will
be happy to supply you with a helmet.
Eyewear
Any cycling involves airborne bugs, dirt and other objects that are just waiting to get at your
eyes. Higher speeds can also make ones’ eyes water and impair your vision. For this reason
we advise you wear sufcient eye protection, in the form of a quality set of glasses in all
conditions. Most sports and bicycle stores sell protective and fashionable eyewear.
Tip! To increase your vision in all weather conditions,
we suggest you buy a good pair of sports glasses, with
interchangeable lenses in at least one dark colored lens and at
1
least one amber, clear or yellow lens.
Reectors
Reectors are important safety features, which are an integral part of your bicycle.
Most authorities worldwide require bicycles to be tted with front, rear, wheel and pedal
reectors. The requirements of these reectors should be able to be found through your
local government. Reectors are designed to use other light sources – car headlights,
street lights and the such to increase your visibility to other road users.
Caution! Check your reectors are securely fastened to your bike
regularly. Clean your reectors often, as mud and grime picked up
will limit the amount of light that can enter and exit the reector,
reducing its effectiveness. Do not allow baggage or yourself to
conceal or cover a reector.
Do not remove any reector from your bicycle
Lights
If you ride your recumbent during or before dawn and dusk it must be equipped with a
lighting system approved by the local government. It is also prudent and advised to install
a lighting system if you ride during bad weather conditions as well. Your local bike store
or Optima dealer should be able to supply you with a good lighting set and advise you as
to the best choices.
Warning! A good lighting system can never be substituted
for by reectors. It is your own responsibility to ensure your
bicycle is equipped with an acceptable lighting system, which
complies to the guidelines set up by your local authority. Failure
to follow this guideline may result in dangerous and fatal trafc
Battery lighting systems have the potential to be much more powerful than generator
systems, but they weigh more and have a limited battery life. Their constant illumination
is an advantage for the urban evening commuter, who remains visible all the time.
Caution! Be sure to install a WHITE front light and a RED rear
light on your bicycle. Failure to do so may violate local trafc
laws and will denitely compromise your safety.
situations.
Support and upgrading.
Although we strive to build ever higher quality products, your recumbent is not indestructible
and at some point something is bound to fail. With the constantly change and development of
the array of components available for bicycles, it is inevitable that at some point you will want
or have to replace a part or install a new one.
Caution! Replacing, changing and upgrading the componentry
on your recumbent may have an effect on the bicycles warranty.
To avoid any unpleasant surprises, consult your Optima dealer
before making any changes to the original equipment of the
manufacturer. (OEM)
If you do not have your new component installed by a professional and approved Optima
mechanic, then make sure to fully read the instructions of the new component and carefully
follow the manufacturer’s installation procedure. Also make sure to conrm that the new part is
completely compatible with your bicycle and its current (OEM) setup. Just because you have
the ‘mechanical touch’ does not mean that you will know everything about a new component,
especially if it is a new type of an existing product, or a completely new idea.
A popular upgrade nowadays is the installation of suspended forks. Finding a suitable
suspended fork for a 20 inch front wheel can be a tricky process, and we advise you contact
your dealer or Optima before making any decisions for their advice. Keep in mind that installing
suspension forks will change the geometry of your bicycle and in turn, your recumbent’s riding
characteristics.
Another popular upgrade is to install disk brakes. Realize that in installing a disk brake, you
are loading the bicycle’s forks differently and you may be reducing their service life. The extra
braking power provided by disk brakes also increases the loading on the frame.
If at any point you are worried about compatability and specic components or have any other
questions, contact your dealer and they will be able to help you. Your dealer is there to help
you in making decisions and provide you with the help of somebody whose profession it is to
know everything there is to know about these bikes and parts. Asking his opinion will allow you
to get the best out of your bike, and avoid unpleasant surprises after buying a component.
Generator lighting systems will never run out of power, but require the cyclist to be moving
for the lights to function. These systems are generally lighter than battery powered lights,
but the more powerful you want them to be, the more rolling resistance the system will
produce. Generators can be housed in the standard tire rollers, or in the front hub.
Mirrors
Looking behind you on a recumbent bicycle is trickier than doing so on a standard bike.
For this reason Optima strongly recommends that you install at least one rear view
mirror, preferably on the left hand side of your bicycle for countries where trafc drives
on the right, and the right for countries where you drive on the left.
2
3
Responsible cycling
Recumbent cycling, like all other sports has its thrills and exhilarations, but also its dangers.
A cyclist is in control of his or her own vehicle, and his safety is primarily in his or her
own hands. Dangerous or unusual situations should be met with cautious behavior and
preventative measures from the cyclist him or herself - the rst of which is to slow down.
Both Optima and the local government cannot therefore be held accountable for your
mistakes or misjudgements.
General safety Measures
Caution! Be sure to follow these guidelines to ensure your own safety.
· Always perform the pre ride checklist on page 18 before every ride
· Wear your helmet whenever you are on your bicycle
· Take care not to let the wheels, chainrings, chain, cables and other bicycle parts injure
you
· Recumbent pedals are higher than those of a normal bike, and are in a position that
your feet do not fall naturally, as they are on a standard bicycle. For this reason always
wear appropriate, fully closed shoes and buy a pair of ‘clipless’ pedals, to keep your
feet on the pedals. Do not use pedal straps.
· Know your bike and its controls.
· Control your speed. Speed is dangerous to you and strenuous to your bike.
· Stay rmly on the ground. Jumping a normal bicycle can be dangerous, but at least on
a normal bike you can move about to facilitate a safe landing. On recumbent bicycles
this is not the case. Do not jump whilst riding your bicycle.
· Wear highly visible clothing. Low swung recumbents, above all, should be ridden wearing
bright and visible colors to increase your chances of other road users seeing you.
· Ride as if you were invisible. Keep an eye on what is going on in the trafc around you.
The best way to avoid a collision is obviously to see it coming beforehand.
· Never overtake in a corner. Never. Because you are so low, its likley that Vehicle drivers
will not to see you and will drive you off the road or into the gutter. (this hurts!)
Your Optima Bicycle
1. Seat
2. Upper adjustable seat
xture and upper rack
xture
3. Lower rack xture
4. Lower seat xture
5. Handlebars
6. Gear shifting levers (can
vary in position)
7. Stem
8. Brake levers
9. Bike computer mount
10. Pedal extension tube &
fastening bolts
11.
Front derailleur post
12. Front derailleur mounting
sheath
13. Bottom bracket
14. Crankset
1
15. Light xture (obscured by
chainwheels in photo)
16. Front chainwheels
17. Headset and Headtube
18. Front brake (rim brake)
19. Front (suspension) Forks
20. Hub
21. Wheel rim
22. Tire
24. Location of front disk brake
xture on the left side of bike
(not on all forks)
25. Valve stem
26. Mudguards
27. Rear suspension pivot point
28. Chain roller
29. Lower adjustable rear shock
mount
30. Rear brake (rim brake)
31. Wheel dropouts
32. Rear derailleur
33. Rear cog cassette /
Freewheel
34. Reector
35 Optima baggage rack
36. Chain
37. Rear shock absorber
38. Location of light generator
xture, left side. ( Not
on ‘Baron’, ‘Stinger’ or
‘Cobra’ )
39. Location of rear disk
brake xture, on left side
of bicycle.
Wet weather and night time cycling
Slow down in the rain and increase the distance between you and your fellow road users.
Avoid busy or dangerous roads. Realize you can be partially hidden in the spray following
vehicles. If you have lights, we suggest you turn them on in the rain. Ride in a restrained
fashion. Brake earlier, and more gently than when it is dry.
We strongly suggest you buy bright, reective cycling clothes for bad weather or night riding.
We also suggest you stick to routes you already know when conditions are bad, this way
you will have a better idea of what to expect. Keep this in mind when riding in the rain.
Caution! Precipitation signicantly increases your chances
of being involved in an accident. Wet weather reduces the
traction your bicycle has to the ground, it negatively effects
braking performance and it reduces visibility. These things
happen to you on your bicycle, and to all other road users.
4
Warning! Do not ride a bicycle that shows any sign of
malfunction or damage. Take your recumbent to a bicycle store
and do not ride the bike until the problem is xed.
1
For parts found only on linkage steering models, please see gure 9.1. For parts found only on
the ‘Rider’ please see gures 10.1 and 12.1
5
Setting up your Bicycle
Now that you have opened the box and unpacked your new bike – How do you get this thing
working?! Please follow the instructions and suggestions given in this chapter carefully, to
ensure you can start off your recumbent cycling addiction safely and securely.
Assembling from the Box
Your bike will arrive partially or fully assembled, depending on where you live. Now all you need
to do is follow the following steps in the order written, and you’ll be riding your recumbent in no
time! Some steps will only apply to certain models, in which case this will be clearly stated.
1. Installing the wheels.
For ease in construction and accessibility it is best to start by mounting the wheels. Optima
bikes come with either bolt on or quick release wheel fastenings, depending on the model
and specications.
The rear wheel is fastened using a quick release lever for standard
hubs and bolts for SRAM’s dual drive or 3x7 derailleur/hub gear
systems.
When removing or replacing any rear wheel, make sure the chain is
fed properly around the cogs on the wheel, as seen in gure 6.1.
Quick release fastening allow for fast installation and
removal of the wheels. Properly fastened quick release
wheels are in no way less safe than bolted wheels.
To install the wheel, simply pull the lever on the wheel
outward to the unlocked position (g 6.3). After unlocking
the mechanism, feed the wheel into the forks or the frame.
Ensure that the wheel is fully inserted in the frame, to prevent
the brakes dragging on the rim or disk. If the brakes drag
when the wheel is properly inserted, readjust the brakes.
Now press the lever to the closed position, as seen in gure
6.2. (The nut on the opposite side to the lever may need to
be tightened or loosened to allow for the closure of the lever
to clamp the forks properly). To remove the wheel, unlock the wheel by pulling the lever. You
may need to unscrew the bolt on the opposite side slightly to get the quick release skewer past
safety knobs on the dropouts. If you are not already experienced in the use of quick release
skewers, see the manufacturer’s procedures in the enclosed information package for proper
use. Otherwise ask the sales representative or a local bicycle store for assistance.
Warning! An improperly fastened quick release lever could lead
to the dislodging of the wheel during braking, leading to serious
injury and damage to your bicycle.
3x7 derailleur and hub gear system Installation and removal.
To install (or remove) the rear 3x7 wheel, rst put the left handlebar shifter to the lowest gear
(position on the grip 1). Feed the wheel into the frame ensuring that the cog cassette is on the
right hand side of the wheel, the same side as the rear derailleur. Now bolt the wheel to the
frame, using a 15 mm metric spanner. Once the wheel has been fastened, feed the shifting
linkage chain into the gear shifting roller and slide the shifting roller onto the hub axle stub
(g 7.1). You will hear and feel a positive click when it is properly engaged. Now track the link
chain around the roller.
The next step is to connect the shifting chains threaded stub with the shifting cable connection
unit. This is done easily, by simply feeding the stub into the unit, as seen in images 7.2 and 7.3.
Feed the connector unit onto the stub to the point at which most of the slack is gone from the
shifting cable and release the block. Now check that the handlebar shifter units can engage
all three gears. If the top gear cannot be engaged, you will need to loosen the connector unit
and allow a little more slack in the cable.
To move or remove the connection unit from the shifting chain stub you will need to pinch
the unit at it’s end, pressing the small square plate of brass in to release the ratchets which
prevent the unit from slipping (see g 7.2) To clamp the unit to the stub again, simply release
the button
Dual Drive derailleur and hub shifting system wheel installation and removal.
The hub will need to be bolted onto the frame using a 15mm spanner. Once bolted on you can
install the gear shifting linkage unit.
Start by putting the thumb lever on the handlebar shifting unit to the leftmost setting, with one
dot. When you look at the hub connection unit, the yellow indicator in the small window should
be as close to the axle hole as possible, (g.7.5). Next, you will need to press the black shaft
sticking out of the top of the connection unit in fully so that it sticks out of the bottom of the
unit. This will not be possible if the thumb shifter is not in position 1.
6
7
Once you have done this, feed the unit onto the protruding hub axle stub
on the right, derailleur hand side of the bike. Once you cannot push the
unit any further, reach your nger underneath the unit and push the shaft
back up as seen in gure 7.6. If the shaft will not move, remove and ip
over the unit and push the black lever inside the unit down towards the
unit’s base (as seen in g 8.1) and try again. It should now work.
Warning! Make sure that the gears work properly before
riding your bicycle. Badly adjusted gears could lead to the chain
skipping or jumping off the cogs resulting in frame and spoke
damage, and potentially dangerous trafc situations.
2. Installing linkage front steering systems 10.4
Setting up the steering linkage (All 2 and 3 wheel linkage steering models)
You will now need to connect the master to slave steering linkage. This may have already been
done, depending on where you live. You may however need to disconnect and connect the
linkage at some time anyway. To disconnect the linkage, pull the safety pin off the shaft (gs 8.2
and 8.3) and pull it out of the hole at the foot of the socket and shaft (g 10.4). To (re)connect
the linkage, make sure the safety pin is removed. Then push the linkage’s socket onto the
slave joint ball (seen bare in g 10.5) Once the socket is correctly around the ball joint, you will
be able to slide the safety pin back into the socket’s ange (g 10.7). If the pin will not go in,
the socket is not properly on the ball joint. This may require some force. If you cannot do it by
hand, give the socket moderated a tap with a rubber mallet to connect the joint properly. Once
properly on the ball joint, (Fig 8.7) replace the safety pin and clip it fully over the linkage shaft,
and it will snap itself closed. For instructions on aligning the steering system, please go to the
next page, and read the section entitled ‘Aligning linkage steering systems’.
3. Rider Front wheel alignment and installation
All export models of the ‘Rider’ are delivered without the front wheels fully assembled. Please
follow these instructions carefully to ensure you install the wheels properly. Failure to do so
may result in hub damage, breaking malfunction and serious resultant injuries.
Assemble the wheel to the
frame, in the order depicted
in gure 9.1, with the braking
slave unit on the front side
of the hub as in g 9.2. The
brakes will have been aligned
befor e shi pp in g so all you
ne ed to do is mou n t th e
wheel as shown in g 9.2 and
fasten the axle bolt tightly. If
the wheel bolt is not sufciently
tightened, the brakes will drag
and the wheel may work itself
loose.
While screwing the hubs in,
gently squeeze the brake levers a few times, to ensure that the hub shells are well centred.
If one or both of the brakes drag, you will need to adjust them. This should not be necessary
for the rst assembly. To see how to adjust the brakes, see section 4 on page 12, brake
adjustment & bleeding.
Fig
9.2,
rider
8
9
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