Xtracycle LEAP Manual de usuario

LEAP ASSEMBLY MANUAL

Rev 1A

in the box

BE MOVED

Congratulations on purchasing an Xtracycle Leap DIY Cargo Bike Kit, and being one of

the visionaries using the Leap to create your dream cargo- or passenger hauling bicycle.

This guide well help you set up the Leap on your bicycle safely and easily.

For Attaching the LEAP:

• Metric open-end or

box wrenches: 10, 17mm

• Metric allen wrenches: 3, 4, 5, 6mm

• Cable + housing cutters

• Needle nose pliers

• Bicycle grease

(Park Tool PPL-1 or similar)

• Medium strength thread locking

compound (Blue Loctite or similar)

TOOLS & MATERIALS REQUIRED

Other Tools Required:

You will need all of the tools and

materials required to:

• Remove and install your rear wheel

• Remove, install, and adjust your rear

derailleur (if present)

• Remove, install, and adjust your rear

disc brake

• Separate your chain

• Install a new, longer rear derailleur

cable and housing

• Install a new, longer rear brake

cable and housing (mechanical) or

hose (hydraulic)

Please refer to the component’s

manufacturer instructions for the

tools needed for each operation.

BICYCLE PREPARATION

Bicycle Inspection

Before undertaking the LEAP

conversion, check to make sure that

your bicycle is in good working order.

Make sure that the frame is sound and

has no damage, cracks, or

misalignment. Check all components

for damage or wear and replace worn

out components as needed.

•

Disassembly

• Remove the rear wheel from the bike.

Separate the chain and remove it from

the bike.

• Disconnect the rear derailleur cable

and rear brake cable (if present).

• Remove rear derailleur and rear brake

from the bike.

get ready

Install chainstay clamping plates

step 1

1A: Decide where you are going to place the extension tube clamping

plates on the chainstays.

1B: Once you have decided on

proper placement, assemble the

clamping hardware on the longer

M10 carriage bolt as shown.

1A 1B

1C: Install the chainstay clamping plates with the wider side facing the rear

dropouts. This puts the notched lower piece correctly toward the drive side of

the bike. Tighten the nut to 15-20 N-m using a 17mm wrench. As you tighten,

check two things:

• That the square head of the carriage bolt is fully seated in the square

hole on the extension tube bracket

• That the chainstay clamping plates are centered and clamp straight across

the chain stays, and the extension tube bracket is lined up with the

centerline of the bike.

If your front derailleur cable rubs the plate, you may mount the plate as far

back as possible while avoiding cable rub. Alternately, place a section of thin

plastic tube over the cable to avoid rubbing. Jagwire housing liner would work.

Assemble Leap Frame

step 2

2A: Lightly grease the extension tube where it inserts

into the boom tube, the extension tube clamp bolts,

and the inside face of the extension tube clamp.

2B: Assemble as shown.

• Check that the clamp is fully seated onto the

extension tube and that the security cable

attachment faces up.

• Do not tighten the bolts yet.

2C: Insert the dropout xing bolts into the

holes on the Leap frame, with the dome

nuts and lock washers facing outwards,

and the dropout spacer on the inside of the

frame.

Note: There are two mounting positions for

the dropout xing bolts on the Leap frame.

The forward position will give the nished

bike a longer overall wheelbase for more

stability, greater clearance between the

rider and passengers/cargo on bikes with

short chainstays, and less potential for

interference between the bike frame and

Leap frame.

The rearward position will give the nished

bike a shorter overall wheelbase for more

maneuverability/ease of parking, will move

the passengers/cargo closer to the rider

on bikes that have long chainstays, and

will provide even greater stiffness to the

already-stiff Leap mounting.

Install dropout xing bolts

step 3

3A: Attach the Leap frame to the bike frame, by

inserting the dropout xing bolts into the rear

dropouts of the bicycle as shown.

The curved side of the dropout insertion tab needs

to be placed into the dropout. You can get it to sit

the opposite way but it will not seat fully causing

issues.

• Check that the tabs on the dropout xing bolt

heads can fully seat into the dropout.

Note: This step may be easiest to accomplish with

the bike upside down.

3A 3A

3B: Adjust the length

of the extension tube

until it aligns with the

extension tube bracket

on the clamping plates.

• Temporarily place

the shorter M10

carriage bolt through

the bracket and

extension tube as a

pin to hold in place.

3B 3C: Use a 17mm

wrench to tighten both

dropout xing bolts to

30-40 N-m.

Note: If you turned the

bicycle upside down,

you may now turn it

right side up again.

Dropout

Carriage

Bolt

Cont’d: Install dropout xing bolts

step 3

3D: Remove and re-assemble

the shorter M10 carriage bolt

on the extension tube bracket.

• Insert the cupped spacers

between the extension tube

and the inside of the

extension tube bracket. The

cups should face outwards.

• Slide the M10 carriage bolt

back through the bracket,

spacers, and extension tube,

checking to make sure that

the head of the carriage bolt

fully seats in the square hole

on the bracket.

• Thread the other M10 nyloc

nut onto the carriage bolt

and use a 17mm wrench to

tighten it to 30-40 N-m.

3D 3E: Use a 4mm allen wrench to

tighten the bolts on the extension

tube clamp to 6 N-m.

After a caterpillar buries itself inside its cocoon, it waits to morph into a buttery. The caterpillar doesn’t simply shrink a bit

and sprout wings. Instead, it sort of disintegrates into a puddle of ooze within the cocoon. New cells are called imaginal

cells start popping up and they are so completely different from the original ooze cells that they are thought to be a virus or

some other form of enemy so the ooze cells begin attacking the imaginal cells. However, even though the imaginal cells are

being killed off for not tting in, they still keep showing up, more and more of them. Eventually, the imaginal cells begin to

nd each other and cluster together. Like attracts like, and the clusters begin to join up with other clusters. Eventually, the

imaginal cells get to be a large enough community and they switch gears from simply being a group of like-minded cells into

the programming cells of the buttery. Some imaginal cells start changing into wing cells, some start changing into antenna

cells, some start changing into digestive tract cells, and so on. Imaginal cells transform into buttery anatomy cells. As we all

know, if left alone to do his thing, the buttery eventually emerges as a completely new entity from the original caterpillar.

Assemble Security Cable

step 4

4: Assemble the security cable on the extension tube clamp.

• The security cable is similar to a brake cable, with a short

length of housing.

• Cut security cable housing to length such that it loops around

the left chainstay as tightly as possible and fully seats into

stops on extension tube clamp.

• Place a ferrule on the cut end.

• Pass security cable through extension tube clamp, through

housing, around left chainstay, and back through extension

tube clamp.

• Pull tight and clamp with the M5 bolt.

• Cut off excess cable and crimp on a cable end cap.

Assemble Rest of LEAP Frame

5A: Install the

rear wheel in the

Leap Frame.

step 5

5B: Attach the

tailpiece with 4

M6 bolts, wash-

ers, and nyloc

nuts.

Do not tighten

the bolts yet.

Cont’d: Assemble Rest of LEAP Frame

step 5

5C: Prep the V-Racks and RackLocks

• Grease the M4 bolts on the RackLocks,

and the ends of the V-Racks where they

insert into the Leap Frame.

• RackLocks have 3 pieces: outer collar,

o-ring, and inner collar. Slide them onto the

ends of the V-racks in this order.

5D: Install V-Racks

• Insert the V-Racks into the Leap Frame

and check that they are fully seated.

• Slide the RackLocks down the V-Racks

until the bottom edge of the outer collar

is even with the bottom edge of the inner

collar and both are fully seated on the

Leap Frame.

• Tighten the RackLock bolts to 4 N-m.

5F: With V-Racks and U-Tubes (if present) in-

stalled, tighten the 4 M5 bolts on the tailpiece

to 5 N-m, by holding the bolt head with a

4mm allen wrench and tightening the nut on

the backside with a 10mm wrench.

5E: If U-Tubes are being installed, install them

now. See the U-Tube LT2 Assembly Guide for

more information.

Note: Leap U-Tubes are Leap-specic and are

not width adjustable.

Reassemble Drivetrain and Rear Brake

step 6

6A: Install the rear brake caliper on the Leap frame.

Check that the rear brake caliper is properly spaced for

the rear rotor being used (minimum rotor size is 180mm).

For some disk brakes, the shape/size of the caliper

body causes intereference with the leap frame when

using a 160mm rotor. Take note when installing. You

must switch to 180mm rotor and post mount adapter

if your caliper touches the frame. Do not risk lowering

the braking capacity by adding spacers to make the

160mm rotor work. Also, with cargo bikes, your braking

needs increase signicantly and thus it is highly

recommended that you use 180mm rotors minimum.

6C: Install longer rear derailleur and brake cable and housing (if rear brake is

mechanical). If rear brake is hydraulic, refer to manufacturer instructions for

running a longer hose to the brake.

Notes:

• The housing can run continuously from the rearmost housing stop on the

bike frame to the derailleur or brake, or the full length from the lever if no

stops are present on the frame.

• The derailleur housing should be run under the forward bar of the Leap

frame to avoid interference with the chain. There is a welded-on cable guide

for the derailleur cable ahead of the dropout.

• There are three bolt-on cable guides for the rear brake cable or hose

included. Use as many as you need to secure the rear brake cable while also

providing for a smooth cable path into the rear caliper.

6B: Install the derailleur on the Leap frame.

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