Owner’s Operator and Maintenance Manual
®
Recumbent
Handcycle Series
Top End XLT™
Top End XLT Jr.
Top End XLT Pro
Top End XLT Gold
Top End Force™
DEALER: This manual MUST be given to
the user of the handcycle.
USER: BEFORE using this handcycle, read
this manual and save for future reference.
For more information regarding
Invacare products, parts, and services,
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TABLE OF CONTENTS
TABLE OF CONTENTS
Tire Pressure.............................................................................................................................................14
Inspect/Adjust Initially.........................................................................................................................18
Maintenance...............................................................................................................................................21
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TABLE OF CONTENTS
TABLE OF CONTENTS
Using Parking Brake.................................................................................................................................30
Replacing/Adjusting Leg Guard.........................................................................................................32
Using/Replacing Footrest Strap.............................................................................................................33
Using Footrest Strap...........................................................................................................................33
Replacing Footrest Strap....................................................................................................................33
Adjusting Hand Crank.............................................................................................................................34
Adjusting Seat Height - All Models Except XLT Gold and Top End Force................................38
Adjusting Back Angle - All Models Except XLT Gold and Top End Force.................................39
Replacing Tire/Tube and Tuning/Replacement of Spokes...............................................................43
Tire Pressure.............................................................................................................................................43
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TABLE OF CONTENTS
TABLE OF CONTENTS
Replacing the Fork/Crank Assembly....................................................................................................46
Replacing the Right Side Crank Arms.............................................................................................49
Installing/Removing/Adjusting the Road Crown Compensator.....................................................50
Installing/Removing/Adjusting the Steering Dampener -
For Top End XLT Gold and Force Only.............................................................................................52
Removing Steering Dampener..........................................................................................................52
Seven Speed Hub Chain Installation................................................................................................54
Adjusting Seven Speed Hub Chain...................................................................................................55
Adjusting Twenty-Seven Speed Cassette Chain...........................................................................56
Replacing the Parking Brake..............................................................................................................57
Replacing Seat Upholstery......................................................................................................................58
Replacing Back Upholstery.....................................................................................................................59
Replacing Narrow Back Upholstery................................................................................................59
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TABLE OF CONTENTS
TABLE OF CONTENTS
Installing Rear Safety Light......................................................................................................................60
Batteries.................................................................................................................................................60
Operating the Safety Light.................................................................................................................60
Installing the Water Bottle.....................................................................................................................61
Installing/Using the Tow Bar..................................................................................................................61
Installing the Draft Bumper....................................................................................................................62
Installing Seat Positioning Strap.............................................................................................................63
Vertical Handles ...................................................................................................................................64
V or S Crank Handles.........................................................................................................................64
Installing V/S Crankarm Handles...........................................................................................................64
For Models Made Before 7/12/07 ....................................................................................................64
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REGISTER YOUR PRODUCT
For Models Made After 7/12/07.......................................................................................................65
Installing Gloves........................................................................................................................................66
Removing/Installing the Fork - Travel Ready XLT PRO Equipped
with Road Crown Compensator..........................................................................................................68
Removing the Fork..............................................................................................................................68
with Steering Dampener.........................................................................................................................69
Removing the Fork..............................................................................................................................69
Installing the Fork.................................................................................................................................69
Removing the Front Wheel...............................................................................................................70
Assembling the Handcycle Rack.......................................................................................................71
LIMITED WARRANTY ..................................................................... 75
REGISTER YOUR PRODUCT
The benefits of registering include:
1. Safeguarding your investment.
2. Ensuring long-term maintenance and servicing of your product.
3. Receiving updates with product information, maintenance tips and industry news.
Register ONLINE at warranty.invacare.com
Please have your model number and purchase date available to complete your registration.
Any registration information you submit will only be used by Invacare Corporation and protected
as required by applicable laws and regulations.
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Excelerator™XLT Handcycle Series
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DEALER/TECHNICIAN INFORMATION
DEALER/TECHNICIAN
INFORMATION
The term ʺqualified technicianʺ in this manual refers to an Invacare qualified technician
or a Shimano® certified bicycle repair technician.
SPECIAL NOTES
Signal words are used in this manual and apply to hazards or unsafe practices which
could result in personal injury or property damage. Refer to the table below for
definitions of the signal words.
SIGNAL WORD
MEANING
Danger indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
DANGER
Warning indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
WARNING
CAUTION
Caution indicates a potentially hazardous situation which, if not avoided,
may result in property damage.
NOTICE
THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO
CHANGE WITHOUT NOTICE.
HANDCYCLE USER
As a manufacturer of handcycles, Invacare endeavors to supply a handcycle to meet
many needs of the end user. However, final selection of a handcycle to be used by an
individual rests solely with the user and his/her health care professional capable of
making such a selection.
HANDCYCLE TIE-DOWN RESTRAINTS AND SEAT POSITIONING STRAPS
Invacare recommends that handcycle users NOT be transported in vehicles of any
kind while in a handcycle. As of this date, the Department of Transportation has not
approved any tie-down systems for transportation of a user while in a handcycle, in
a moving vehicle of any type.
As regards restraints - seat positioning straps - it is the obligation of the DME
dealer, therapists and other health care professionals to determine if a seating
positioning strap is required to ensure the safe operation of this equipment by the
user. Serious injury can occur in the event of a fall from a handcycle.
Invacare products are specifically designed and manufactured for use in conjunction
with Invacare accessories. Accessories designed by other manufacturers have not
been tested by Invacare and are not recommended for use with Invacare products.
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SPECIAL NOTES
ꢀ WARNING
ALWAYS wear your seat positioning strap. Inasmuch as the seat positioning strap is
an option on this handcycle (you may order with or without the seat positioning
strap), Invacare strongly recommends ordering the seat positioning strap as an
additional safeguard for the handcycle user. The seat positioning strap is a position-
ing belt only. It is not designed for use as a safety device withstanding high stress
loads such as auto or aircraft safety belts. If signs of wear appear, belt MUST be
replaced immediately.
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TYPICAL PRODUCT PARAMETERS
TYPICAL PRODUCT PARAMETERS
TOP END XLT
TOP END XLT JR
Seat Width:
Seat Depth:
14 to 20 inches
15 inches
14 inches
15 inches
Seat-to-Floor (approx.): 12, 13, or 14 inches
12, 13, or 14 inches
Back Style:
Adjustable Back Angle 90° - 110°
Adjustable Back Angle 90° - 110°
Back Height Fixed/
Adjustable Angle:
11-14 inches (Wide)
20 inches (Narrow, Tall)
11-14 inches (Wide)
16½ inches (Narrow, Tall)
Footrest:
Adjustable Fore and Aft
Adjustable Fore and Aft
2 inches - 2½ inches
Quick-Release
Side - Wheel Clearance: 2 inches - * 2½ inches
Rear Axle:
Quick-Release or Threaded
15° - Standard
Rear Wheel Camber:
Wheels/Tires:
15° - Standard
26-inch Spoke High Performance
24-inch Cruiser or *Knobby
20-inch Cruiser
Brakes:
Internal reversing drum brakes and
parking brake
Internal reversing drum brakes and parking
brake
Handles:
Ergonomic, Vertical foam covered or
Delrin®
Ergonomic, Vertical foam covered or
Horizontal foam covered
Crankset:
Hub:
Alloy Crankset
Alloy Crankset
FRONT - Shimano Nexus® 7 Speed Hub FRONT - Shimano Nexus 7 Speed Hub
REAR - Precision Black Anodized REAR - Precision Black Anodized w/½-inch
w/½-inch Quick Release Stainless Axles Quick Release Stainless Axles
Spokes:
14 Gauge Stainless
Shimano
14 Gauge Stainless
Shimano
Shift Levers:
Gears:
7 Speed
7 Speed
Seat Cushion:
Upholstery:
Weight:
Foam Insert - Optional
Nylon
Foam Insert - Optional
Nylon
35 lbs
30-35 lbs
Shipping Weight:
Weight Limitation:
Options:
65 lbs
65 lbs
250 lbs
250 lbs
Mirror, Backpack Hydration System,
Computer, Tow Bar, Horizontal Han-
Cordless Computer, Helmet, Quad Cuffs,
Quad Gloves, Seat Positioning Strap, Safety
dles, Safety Lights, Helmet and Flag, Seat Flag, Mirror, Safety Lights, Water Bottle and
Positioning Strap, Quad Cuffs, Quad
Gloves, Mountain Drive, Bike Rack,
Water Bottle and Cage, Tri-pin Quad
Handles, Threaded Axles, Leg Guard
Attachment, Alignment Gauge, Crutch
Holder, Indoor Training Roller
Cage, Leg Guard Attachment, Crutch
Holder, Bike Rack, Cushion, Towbar for
handcycle, Backpack Hydration System,
Alignment Gauge, Mountain Drive, Tri-pin
Quad Handles.
*NOTE: Knobby tires will reduce side wheel clearance to approximately 1‐inch.
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TYPICAL PRODUCT PARAMETERS
TOP END XLT PRO
TOP END XLT GOLD
14 to 18 inches
Seat Width:
Seat Depth:
14 to 18 inches
15 inches
15 inches
Seat-to-Floor (approx.): 12, 13 and 14 inches
9 inches
Back Style:
Adjustable Back Angle 90° - 110°
Adjustable Back Angle 50° - 90°
Back Height Fixed/
Adjustable Angle:
11-14 inches (Wide)
18½ inches (Narrow, Tall)
12 inches (Wide)
18 inches (Narrow, Tall)
Footrest:
Adjustable Fore and Aft
Adjustable Fore and Aft
2 inches - 2½ inches
Quick-Release or Threaded
9° - Standard
Side - Wheel Clearance: 2 inches - * 2½ inches
Rear Axle:
Quick-Release or Threaded
15° - Standard
Rear Wheel Camber:
Wheels/Tires:
26-inch Spoke High Performance
24-inch Cruiser or *Knobby
26-inch Spoke High Performance.
24-inch Cruiser or *Knobby
Brakes:
Rapid fire hands-on brake mounted on right Rapid fire hands-on brake mounted on
pedal. Parking brake on L frame
right pedal. Parking brake on L frame
Handles:
Ergonomic, Vertical, Ovalized Aluminum
mounted on Top End V crankset
Ergonomic, Vertical, Ovalized Aluminum
mounted on Top End S or V crankset
Crankset:
Hub:
Top End V Crankset
Top End S or V Crankset
FRONT - Shimano/Top End Components
w/ 27 Speed External Cassette
FRONT – Shimano/Top End Components
w/ 27 Speed External Cassette
REAR - Precision Black Anodized w/½-inch REAR - Precision Black Anodized
Quick Release Stainless or Threaded Axles w/½-inch Quick Release Stainless Axles or
Threaded Axles
Spokes:
14 Gauge Stainless
14 Gauge Stainless
Shift Levers:
Rapid fire hands-on shifter mounted on right Rapid fire hands-on shifter mounted on
handpedal for lower derailler, Manual shifter right handpedal for lower derailler, Manual
for upper derailler/chainrings.
shifter for upper derailler/chainrings.
Gears:
27 Speed
27 Speed
Seat Cushion:
Upholstery:
Weight:
Foam Insert - Optional
Foam Insert - Optional
Nylon
Nylon-Adjustable Tension
30 lbs
30 lbs
Shipping Weight:
Weight Limitation:
Options:
65 lbs
65 lbs
250 lbs
250 lbs
Computer, Tow Bar, Safety Lights,
Computer, Tow Bar, Safety Lights, Hel-
Helmet, Flag, Bike Rack, Water Bottle and met, Flag, Bike Rack, Water Bottle and
Cage, Carbon Fiber Wheels, Leg Guard
Attachment, Welded Seat, Travel Option,
Cage, Fixed seat frame, Alignment Gauge,
Backpack Hydration System, Carbon Fiber
Alignment Gauge, Backpack Hydration Sys- Wheels, Crutch Holder, Drafting Bumper,
tem, Crutch Holder,
Titanium Parts, Indoor Training Roller
Drafting Bumper, Indoor Training Roller
*NOTE: Knobby tires will reduce side wheel clearance to approximately 1‐inch.
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SECTION 1—GENERAL GUIDELINES
SECTION 1—GENERAL GUIDELINES
ꢀ WARNING
SECTION 1 - GENERAL GUIDELINES contains important information for the safe
operation and use of this product.
Proper Fit
The handcycle MUST be adjusted to fit the rider. For a proper fit:
• The rider MUST be able to see over the hand crank.
• The rider MUST have a slightly bent elbow when the hand pedals are toward the front
of the handcycle (farthest from the riderʹs face).
• The rider MUST have a slight bend at the knee when feet are in the footrests. Feet
should be flat against footrest hoop.
• XLT Series requires a 18ʹ turning radius. If leg touches tire during turn and user cannot
sense this, a leg guard attachment is recommended.
• The riderʹs knees MUST not obstruct hand crank operation.
Check the seat position, back angle, quick‐release on threaded axles, footrest fore/aft
position, hand crank height for proper fit and smooth operation of your handcycle.
Operating Information
Wear your helmet at all times when riding the handcycle.
Before riding your handcycle, check your brakes. Be sure that the brakes and all other
features of your handcycle are operating properly.
ALWAYS keep fingers or hands away from the chain while pedaling.
DO NOT let children play near the handcrank or the chain. Otherwise, injury or damage
may occur.
The user is responsible for normal upkeep and maintaining the handcycle in proper
operating condition.
The manufacturer is not responsible for failure, damage or injury caused by improper
operation or maintenance by the end‐user.
To determine and establish your particular safety limits, practice transferring activities in
the presence of a qualified health care professional before attempting active use of the
handcycle.
Before attempting to transfer in or out of the handcycle, every precaution should be taken
to reduce the gap distance. Position the handcycle on level ground and as close as possible
to the object you are transferring into or out of.
The object you are transferring into or out of MUST also be secured before attempting any
transfer.
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SECTION 1—GENERAL GUIDELINES
Top End XLT, XLT jr., and XLT Gold Models Only ‐ The parking brake of the handcycle
MUST be engaged before attempting any transfer.
Top End XLT Pro Model Only ‐ This model may be ordered with or without a parking
brake. If ordered without a parking brake, the handcycle MUST be positioned securely
against a stable object before any transfer is attempted. If ordered with the optional
parking brake, the parking brake MUST be engaged before attempting any transfer.
Care MUST be taken when operating on roads, streets or highways.
Operation of the handcycle is subject to all traffic rules and regulations. (This may include
the use of a safety lights and reflectors for dusk/night riding.)
Give pedestrians the right of way.
Slow down at all street intersections and observe to the left, to the right and back to left
again before proceeding.
Use proper hand signals when turning.
DO NOT attempt to move up or down an incline with an ice or oil film.
DO NOT attempt to ride over curbs or obstacles or speed bumps. Doing so may cause
your handcycle to ʺbottom outʺ and/or turn over and cause bodily harm or damage to the
handcycle.
Invacare products are specifically designed and manufactured for use in conjunction with
Invacare accessories. Accessories designed by other manufacturers have not been tested
by Invacare and are not recommended for use with Invacare products.
DO NOT attempt to lift the handcycle by any removable (detachable) parts. Lifting by
means of any removable (detachable) parts of an handcycle may result in injury to the
user or damage to the handcycle.
DO NOT stand on the seat or frame of the handcycle.
ALWAYS wear your seat positioning strap. Inasmuch as the seat positioning strap is an
option on this handcycle (you may order with or without the seat positioning strap),
Invacare strongly recommends ordering the seat positioning strap as an additional
safeguard for the handcycle user. The seat positioning strap is a positioning belt only. It is
not designed for use as a safety device withstanding high stress loads such as auto or
aircraft safety belts. If signs of wear appear, belt MUST be replaced immediately.
With regard to restraints – seat/chest positioning straps – it is the obligation of the DME
dealer, therapists and other healthcare professionals to determine if a seat/chest
positioning strap is required to ensure the save operation of this equipment by the user.
SERIOUS INJURY CAN OCCUR IN THE EVENT OF A FALL FROM A WHEELCHAIR.
Avoid all surface hazards.
DO NOT carry any riders.
DO NOT carry any items that may obstruct your view or prohibit you from operating the
handcycle properly.
DO NOT attempt to adjust or clean the internal gear hub with reversing drum brake. This
should only be performed by a bicycle professional.
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SECTION 1—GENERAL GUIDELINES
Tire Pressure
DO NOT use your handcycle unless it has the proper tire pressure (p.s.i.). DO NOT
overinflate the tires. Failure to follow these suggestions may cause the tire to explode and
cause bodily harm.
DO NOT ride on a flat or underinflated tires. Riding on flat or underinflated tires can
cause injury, as well as, damage to the tire, tube and handcycle.
Weight Limitation
The Invacare Top End XLT handcycles have a weight limitation of 250 lbs.
A weight limitation label is on the rear axle of the handcycle.
Top View
Weight
Capacity Label
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SECTION 2—SAFETY AND HANDLING
SECTION 2—SAFETY AND
HANDLING
Safety and Handling of the Handcycle
Requires the close attention of the user as well as the assistant. This manual points out the
most common procedures and techniques involved in the safe operation and
maintenance of the handcycle. It is important to practice and master these safe techniques
until you are comfortable in maneuvering the handcycle.
Use this information only as a basic guide. The techniques that are discussed on the
following pages have been used successfully by many.
Individual users often develop skills to deal with daily living activities that may differ
from those described in this manual. Invacare recognizes and encourages each individual
to try what works best for him/her in overcoming obstacles that they may encounter.
Techniques in this manual are a starting point for the new handcycle user and assistant
with safety as the most important consideration for all.
Stability and Balance
For stability and proper operation of your handcycle, you MUST at all times maintain
proper balance. Your handcycle should remain upright and stable during normal daily
activities when operated correctly.
Invacare recommends using seat positioning straps for additional safety.
A Note to Handcycle Assistants
When learning assistance techniques for the handcycle, have an experienced assistant
help you before attempting it alone.
When you are assisting with a transfer to/from the handcycle, remember to use good
body mechanics. Keep your back straight and bend your knees when lifting or
positioning the handcycle for the end‐user.
Also, be aware of detachable parts. These MUST NEVER be used for lifting supports or
to move the handcycle, as they may be inadvertently released, resulting in possible injury
to the user and/or assistant.
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SECTION 2—SAFETY AND HANDLING
Percentage of Weight Distribution
Transferring in and out of the handcycle will cause a change to the normal balance, the
center of gravity, and the weight distribution of the handcycle. To determine and establish
your particular safety limits, practice transferring activities in several combinations in the
presence of a qualified health care professional before attempting a transfer alone.
Proper positioning is essential for your safety.
Transferring Into/Out of the Handcycle
ꢀ WARNING
Before attempting to transfer in or out of the handcycle, every precaution should be
taken to reduce the gap distance. Position the XLT on level ground and as close as
possible to the object you are transferring into or out of.
The object you are transferring into or out of MUST also be secured before
attempting any transfer.
TOP END XLT, XLT JR. AND XLT GOLD MODELS ONLY - The parking brake of
the handcycle MUST be engaged before attempting any transfer.
TOP END XLT PRO MODEL ONLY - This model may be ordered with or without a
parking brake. If ordered without a parking brake, the handcycle MUST be
positioned securely against a stable object before any transfer is attempted. If
ordered with the optional parking brake, the parking brake MUST be engaged
before attempting any transfer.
CAUTION
When transferring, position yourself as far back as possible in the seat. This will pre-
vent damage to the upholstery.
NOTE: For this procedure, refer to FIGURE 2.1 on page 17.
NOTE: This activity may be performed independently provided you have adequate mobility and
upper body strength.
1. Position the handcycle on level ground and as close as possible along side the object
to/from which you are transferring.
2. If possible, position the handcycle at a 45° angle to the object to/from which you are
transferring.
3. If installed, apply the parking brake on the handcycle.
4. Position the handcycle handles as far forward as possible. This will create more room
to transfer.
NOTE: If necessary, lift the front wheel off the ground and rotate the front tire.
5. Secure object that you are transferring into or out of. Apply wheel locks (if installed)
if the object is a handcycle.
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SECTION 2—SAFETY AND HANDLING
NOTE: During independent transfer, little or no seat platform will be beneath you. Although it
may be difficult to wedge the transfer board between the handcycle seat and the handcycle seat, use
a transfer board if necessary.
6. Shift body weight onto object while transferring.
7. Lift and place left leg past front frame across seat and over center tube.
ꢀ WARNING
If installed, parking brake
MUST be secured.
STEP A: Shift body weight to the edge of the
wheelchair upholstery closest to the handcycle.
ꢀ WARNING
Wheel locks MUST be
engaged if installed.
STEP F: Place both legs onto
handcycle footrests and secure
safety straps.
Handcycle Pedals
(positionedtoward
the front of the
handcycle).
STEP B: Lift and
place LEFT leg past
front frame across
seat and over
center tube.
Footrest
Seat Frame
STEP E: Lift and shift weight
down into handcycle seat.
STEP C: Place LEFT hand on the left
side of handcycle seat frame, NOT on
hand crank.
STEP D: Place RIGHT
hand on the
wheelchair frame.
*NOTE: The steps in FIGURE 1 are specifically for transfer to/from a wheelchair and DO NOT
correspond to the steps in the procedure on the previous page. Follow a similar procedure to
transfer to/from an object other than a wheelchair. Refer to the steps on the previous page for
more information.
NOTE: Handcycle shown for clarity.
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SECTION 3—SAFETY INSPECTION
SECTION 3—SAFETY INSPECTION
Safety Inspection Checklist
NOTE: Every six months, take your Top End XLT to a qualified technician for a thorough
inspection and servicing. Regular cleaning will reveal loose or worn parts and enhance the smooth
operation of your Top End XLT. For safe and proper operation, your handcycle MUST be cared for
just like any other vehicle. Routine maintenance will extend the life and efficiency of your Top End
XLT.
NOTE: Invacare recommends that the following adjustments be performed by a qualified
technician. Initial adjustments should be made to suit your personal body structure and preference.
Thereafter follow these maintenance procedures.
Inspect/Adjust Initially
❑ Inspect for bent or broken frame.
❑ Inspect parking brake ‐ Adjust brake shoes to front rim. Check for worn or missing
shoes. Check for wax or oil on rim.
❑ Ensure cable anchor is attached securely to brake arm.
❑ Ensure internal stopping brakes engages easily.
CAUTION
As with any vehicle, the wheels/casters and tires should be checked periodically for
cracks, flat spots and wear, and should be replaced.
❑ Ensure axle nuts are tight. Wheel should be centered in fork. Keep wheel bearings
adjusted and keep spokes tight and wheel in proper alignment.
❑ Inspect rim and fork assembly for damage.
❑ Ensure axle nut and wheel mounting nuts are secure.
❑ Inspect wheels for excessive side movement or binding when lifted and spun.
❑ Inspect for flat spots, wear and proper inflation.
❑ Inspect chain/chain guard for damage, rust, tension and stretch. Adjust if necessary.
Lubricate each link (3‐in‐1 oil® or a quality bike lubricant). Check for damage or
looseness.
❑ Adjust shifter/brake cables according to shifter/brake manufacturerʹs instructions
(included with the handcycle).
❑ Inspect front fork. Keep tight and lubricate (All purpose grease).
❑ Inspect footrest mounting hardware is tight and footrest secure.
❑ Inspect footrest straps for wetness and/or damage.
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SECTION 3—SAFETY INSPECTION
❑ Inspect seat positioning strap for any signs of wear. Ensure buckle latches. Verify
hardware that attaches strap to frame is secure and undamaged. Replace if necessary.
❑ Inspect upholstery for rips or sagging.
❑ Clean upholstery with light detergent and water.
❑ Check that all labels are present and legible. Replace if necessary.
❑ Ensure that casters are free of debris.
Inspect/Adjust Weekly
❑ Inspect parking brake ‐ Adjust brake shoes to front rim. Check for worn or missing
shoes. Check for wax or oil on rim.
❑ Ensure cable anchor is attached securely to brake arm.
❑ Ensure internal stopping brakes engages easily.
CAUTION
As with any vehicle, the wheels/casters and tires should be checked periodically for
cracks, flat spots and wear, and should be replaced.
❑ Ensure axle nuts are tight. Wheel should be centered in fork. Keep wheel bearings
adjusted and keep spokes tight and wheel in proper alignment.
❑ Inspect rim and fork assembly for damage.
❑ Ensure axle nut and wheel mounting nuts are secure.
❑ Inspect wheels for excessive side movement or binding when lifted and spun.
❑ Inspect for flat spots, wear and proper inflation.
❑ Inspect chain/chain guard for damage, rust, tension and stretch. Adjust if necessary.
Lubricate each link (3‐in‐1 oil or a quality bike lubricant). Check for damage or
looseness.
❑ Adjust shifter/brake cables according to shifter/brake manufacturerʹs instructions
(included with the handcycle).
❑ Inspect front fork. Keep tight and lubricate (All purpose grease).
❑ Inspect footrest mounting hardware is tight and footrest secure.
❑ Inspect footrest straps for wetness and/or damage.
❑ Inspect seat positioning strap for any signs of wear. Ensure buckle latches. Verify
hardware that attaches strap to frame is secure and undamaged. Replace if necessary.
❑ Inspect upholstery for rips or sagging.
❑ Ensure that casters are free of debris.
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SECTION 3—SAFETY INSPECTION
Inspect/Adjust Monthly
❑ Inspect for bent or broken frame.
❑ Ensure that casters are free of debris.
Inspect/Adjust Periodically
❑ Inspect for bent or broken frame.
❑ Inspect parking brake ‐ Adjust brake shoes to front rim. Check for worn or missing
shoes. Check for wax or oil on rim.
❑ Ensure cable anchor is attached securely to brake arm.
❑ Ensure internal stopping brakes engages easily.
CAUTION
As with any vehicle, the wheels/casters and tires should be checked periodically for
cracks, flat spots and wear, and should be replaced.
❑ Ensure axle nuts are tight. Wheel should be centered in fork. Keep wheel bearings
adjusted and keep spokes tight and wheel in proper alignment.
❑ Inspect rim and fork assembly for damage.
❑ Ensure axle nut and wheel mounting nuts are secure.
❑ Inspect wheels for excessive side movement or binding when lifted and spun.
❑ Inspect for flat spots, wear and proper inflation.
❑ Inspect chain/chain guard for damage, rust, tension and stretch. Adjust if necessary.
Lubricate each link (3‐in‐1 oil or a quality bike lubricant). Check for damage or
looseness.
❑ Adjust shifter/brake cables according to shifter/brake manufacturerʹs instructions
(included with the handcycle).
❑ Inspect front fork. Keep tight and lubricate (All purpose grease).
❑ Inspect footrest mounting hardware is tight and footrest secure.
❑ Inspect footrest straps for wetness and/or damage.
❑ Inspect seat positioning strap for any signs of wear. Ensure buckle latches. Verify
hardware that attaches strap to frame is secure and undamaged. Replace if necessary.
❑ Inspect upholstery for rips or sagging.
❑ Clean upholstery with light detergent and water.
❑ Inspect hand grips for looseness. If loose, replace.
❑ Check that all labels are present and legible. Replace if necessary.
❑ Ensure that casters are free of debris.
20
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SECTION 3—SAFETY INSPECTION
Troubleshooting
VEERS VEERS
RIGHT LEFT
SLUGGISH
TURN OR
PERFORMANCE
WHEEL SQUEAKS LOOSENESS IN SOLUTIONS
FLUTTERS
AND
RATTLES
HANDCYCLE
Check tires for
correct and
X
X
X
X
X
X
equal pressure.
Check road
crown compen-
sator or XLT
Gold dampener
hardware and
adjustment
Check for loose
axle nuts.
X
X
X
X
X
X
X
Check spokes
and nipples.
Check chain for
proper tension
and adjustment.
X
X
X
Check that
goose neck fit-
tings are secure.
X
Maintenance
Maintenance Safety Precautions
ꢀ WARNING
After any adjustments, repair or service and before use, make sure all attaching
hardware is tightened securely - otherwise injury or damage may result.
CAUTION
DO NOT overtighten hardware attaching to the frame. This could cause damage to
the frame tubing.
Suggested Maintenance Procedures
1. Before using your handcycle, make sure all nuts and bolts are tight. Check all parts for
damage or wear and replace. Check all parts for proper adjustment.
2. Check parking brake cable and shifter adjustment cables for proper adjustment and
operation. Refer to Service Procedures on page 46.
21
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SECTION 3—SAFETY INSPECTION
3. If equipped, keep quick release axles free of dirt and lint to ensure positive locking and
ꢀ WARNING
DO NOT use WD-40®, 3-in-1 oil, or other penetrating lubricants on quick-release
axles. Otherwise, binding and/or damage to the handcycle may occur.
4. Clean/oil quick‐release axles once a week with a Teflon® lubricant.
5. Keep optional quick release levers on axle tubes free of dirt and lint to ensure positive
locking and proper operation.
ꢀ WARNING
DO NOT use the handcycle unless it has the proper tire pressure (p.s.i.). DO NOT
overinflate the tires. Failure to follow these suggestions may cause the tire to
explode and cause bodily harm.
6. Recommended tire pressure is listed on the side wall of the tire. If tire needs replaced,
see local bike shop.
CAUTION
As with any vehicle, the wheels and tires should be checked periodically for cracks
and wear, and should be replaced.
7. The wheels and tires should be checked periodically for cracks and wear, and should
be replaced if damaged.
9. Regularly check for loose spokes in the front and rear wheels. If loose, have them
aligned at your local bike shop.
10. Check road crown compensator and steering dampner for proper operation. Refer to
11. Check upholstery for sagging, rips or tears. Refer to Replacing Seat Upholstery on
12. Check alignment of front wheel. If it wobbles or takes too much effort to turn by hand,
have it aligned at your local bicycle shop.
22
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SECTION 4—INITIAL SETUP
SECTION 4—INITIAL SETUP
ꢀ WARNING
After any adjustments, repair or service and before use, make sure all attaching
hardware is tightened securely - otherwise injury or damage may result.
DO NOT operate the handcycle if the hand crank obstructs your view. If the hand
crank obstructs your view, adjust the hand crank height before using the
handcycle - otherwise injury or damage may occur.
Initial Setup
NOTE: For this procedure, refer to FIGURE 4.1 on page 24 and FIGURE 4.2 on page 25.
NOTE: Invacare recommends that the following procedures be performed by a qualified technician.
TOOLS REQUIRED:
Adjustable Wrench (10-12 inches)
5, 8 and 32 mm Wrench
3/16-inch Allen Wrench
1/4-inch Allen Wrench
1/2-inch Box Wrench
1/2-inch Socket Wrench
Medium Flat Screwdriver
Medium Phillips Screwdriver
Ensure quick‐release axles or threaded axles secure wheels to the handcycle.
there is a slight bend in the knee.
hand crank or if knees obstruct hand crank rotation.
6. Check brakes to make sure brakes work properly.
10. Check that all hardware is tight.
23
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SECTION 4—INITIAL SETUP
Top End XLT/XLT Jr.
Hand Crank Assembly/
Reversing Drum Brake
Seat
Back
Chain
Parking Brake Cable
Footrest
Rear Wheel
Shifter
Location
NOTE: Parking brake located
on left side of seat frame.
Top End XLT PRO
Brake Cable
Hand Crank Assembly
Back
Fork Mounted
Shifters and Brakes
Rear Wheel
Chain
Footrest
Seat
24
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SECTION 5—OPERATION
SECTION 5—OPERATION
ꢀ WARNING
After any adjustments, repair or service and before use, make sure all attaching
hardware is tightened securely - otherwise injury or damage may result.
Riding the Handcycle
ꢀ WARNING
Before operating the handcycle, review the General Guidelines on page 12 in of this
manual.
DO NOT operate the handcycle if the hand crank obstructs your view. If the hand
crank obstructs your view, adjust the height before using the handcycle -
otherwise injury or damage may occur.
NOTE: For this procedure, refer to FIGURE 5.1 on page 27.
NOTE: Footrest should be adjusted so that when seated with feet in the footrests, there is a slight
bend at the knee.
NOTE: Seat should be adjusted so that when seated with feet in the footrests, there is a slight bend
at the knee and a slight bend at the elbow when the hand crank is furthest away.
ꢀ WARNING
At least one hand MUST be on the hand crank assembly at all times. Otherwise,
injury or damage may occur.
7. Place at least one hand onto the hand crank pedals.
NOTE: The hand crank assembly is used for propelling and steering of the handcycle.
26
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SECTION 5—OPERATION
8. Rotate (pedal) the hand crank forward (toward the front) to propel the handcycle
forward.
9. Top End XLT and XLT Jr. Models Only ‐ Rotate (pedal) the hand crank backward
(toward the rear) to apply the brake and slow down or stop.
NOTE: Top End XLT shown for clarity.
Top End XLT and XLT
Jr. ONLY
Hand Crank (STEPS 3, 6, 8 and 9)
Seat (STEP 5)
Front of
Handcycle
Rear of
Handcycle
Footrest (STEP 4)
Shifting Gears
Seven Speed Hub
NOTE: For this procedure, refer to FIGURE 5.2.
NOTE: This procedure applies to the Top End XLT and XLT Jr. ONLY.
To shift gears while moving, hold onto the hand crank assembly with one hand, continue
pedaling, but ease pressure on the pedals and select the gear required with the other
hand. When the Top End XLT is stationary, simply select gear required.
1. Perform one of the following:
Upshift
Indicator
• Upshift ‐ Push the shifting lever
towards the indicator and release.
Repeat until the desired gear is
achieved.
Shifting
Lever
Downshift
• Downshift ‐ Push shifting lever
down and away from the indicator.
Repeat until the desired gear is
achieved.
27
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SECTION 5—OPERATION
Hands-On Rapid Fire Shifter/Brake System: Twenty-seven Speeds
NOTE: For this procedure, refer to FIGURE 5.3 on page 29.
NOTE: This procedure applies to the Top End XLT Pro, XLT Gold, and Force ONLY.
To shift gears, you MUST turn the crank forward with the chain under some tension while
the bike is moving. DO NOT attempt to shift gears while bike is stationary.
There are two shifters installed on the handcycle. The right shifter operates the nine gears
on the lower derailleur and the manual shifter operates the three chain rings on the upper
derailleur. Nine gears X three chain rings = Twenty‐seven speeds.
Shifting the chain on the lower derailleur towards the centerline of the handcycle is for
climbing/accelerating (easier cranking) (lever A) and is called a downshift. Moving the
chain on the lower derailleur out or away from the centerline of the handcycle is for speed
(harder cranking) (lever B) and is called an upshift.
Refer to the chart below for an explanation and use of the upper derailleur chain rings in
combination with the lower derailleur gears:
LOWER DERAILLEUR
GEARS (RIGHT SHIFTER)
UPPER DERAILLEUR CHAIN
RINGS (MANUAL SHIFTER)
USE
1 - 9
Smallest
Medium
Largest
Climbing Hills or Strong Headwinds
Flats or Gradual Rolling Terrain
Descending Hills or Strong Tailwinds
10 - 18
19 - 27
Each shifter has a large lever (brake handle), a medium lever (shifter lever “A”) and a
small lever (shifter lever “B”). The right and left shifters work in an opposite manner.
CAUTION
DO NOT press both shifter levers down at the same time. Doing so may damage
the shifter and will void the warranty. The gears WILL NOT shift when both levers
are pressed simultaneously.
DO NOT use excessive force. This may damage the shifter and void the warranty.
Lower Derailleur (Right Side Shifter)
• Shifting from Harder Gears to Easier Gears (Downshift) ‐ Push shift lever “B” and
release. Repeat until the desired gear is achieved.
• Shifting from Easier Gears to Harder Gears (Upshift) ‐ Pull shift lever “A ” and
release. Repeat until the desired gear is achieved.
Upper Derailleur (Manual Shifter)
• Shifting from Easier or Smaller Chainring to Harder or Larger Chainring (Upshift)
‐ Push lever up until chain runs smoothly over the chain ring teeth while the
handcycle is moving.
• Shifting from Harder or Larger Chainring to Easier or Smaller Chainring
(Downshift) ‐ Push lever down until chain runs smoothly over the chain ring teeth
while the handcycle is moving.
28
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SECTION 5—OPERATION
Shift Lever “B”
Shift Lever “A”
Backing-Up
Use the rear wheels (i.e. like a manual handcycle) to backup. When backing up, keep the
front wheel straight. The weight of the hand crank may engage the reversing drum brakes
(Top End XLT and XLT jr. models ONLY) while backing up. Lift the pedals up to avoid
this problem.
CAUTION
If backing up in the XLT PRO, XLT Gold and Force models, take care not to tangle
the cables.
Braking
Top End XLT Handcycles have either internal gearing (7 speeds) or external gearing (24
or 27 speeds). Internal geared handcycles (7 speeds) are equipped with reversing drum
brakes. External geared handcycles (24 or 27 speeds) have hand brakes.
Reversing Drum Brakes
NOTE: Top End XLT and XLT Jr. with the seven speed hub have reversing drum brakes.
Use the brakes intermittently on your handcycle to bring it to a complete stop. Apply by
pedaling in reverse.
29
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SECTION 5—OPERATION
Hand Brakes/Hands-On Brakes
ꢀ WARNING
The twenty-seven speed cassette on the Top End XLT Pro, XLT Gold and Top End
Force models use the hand brake as the primary brake. Reverse pedaling WILL
NOT stop the bike.
Handcycles equipped with Hand Brakes - In situations where caution is advised
(heavy traffic, intersections, etc.) hands should be kept in the "ready" position to
prepare for braking.
NOTE: For this procedure, refer to FIGURE 5.4.
1. Squeeze brake handle(s) as needed to slow or come to a complete stop.
2. Release when desired speed is achieved.
Rapid-Fire Hands-On
Brakes
Squeeze Brake
Handle
Using Parking Brake
ꢀ WARNING
Before attempting to transfer in or out of the handcycle, every precaution should be
taken to reduce the gap distance. Position the handcycle on level ground and as
close as possible to the object you are transferring into or out of.
The object you are transferring into or out of MUST also be secured before
attempting any transfer.
The parking brake of the handcycle MUST be engaged before attempting any transfer.
NOTE: For this procedure, refer to FIGURE 5.5.
• To Engage the Parking Brake ‐ Squeeze the handle and push the ratchet lever and
lift until the handle locks in place.
30
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SECTION 5—OPERATION
• To Disengage the Parking Brake ‐ Squeeze and release the ratchet button.
Parking Brake Location
Slots or Hook and Loop Strap (Not
Shown)
Handle
NOTE: Approximate location shown. Actual side
of handcycle and location on seat frame may vary.
Steering/Cornering
ꢀ WARNING
DO NOT attempt to corner the handcycle at high speeds. This could result in a fall
causing injury and/or damage to the handcycle.
NOTE: For this procedure, refer to FIGURE 5.6.
To steer the handcycle, use the hand crank to direct the front fork and wheel assembly in
the direction you intend to go (straight, right, or left).
• Steering can be done while rotating the hand crank (pedaling) or coasting.
• When cornering, it is recommended that you slow the handcycle, stop pedaling,
steer the handcycle and coast through the turn. Hands should be up in the crank
cycle (at approximately between the 11 and 2 oʹclock position).
Handle UP
31
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SECTION 6—RIDING POSITION
SECTION 6—RIDING POSITION
ꢀ WARNING
After any adjustments, repair or service and before use, make sure all attaching
hardware is tightened securely - otherwise injury or damage may result.
Replacing/Adjusting the Footrest and Leg Guard
NOTE: For this procedure, refer to FIGURE 6.1.
NOTE: If replacing footrest or leg guard, take note of current position.
Replacing/Adjusting Footrest
Footrest Replacement/Adjustment
1. Remove the hex bolt and locknut that
secure the footrest to the fork.
Footrest
2. If replacing footrest perform the
following:
Fork
A. Remove existing footrest from
clamp.
B. Insert new footrest into clamp.
Clamp, Hex,
Bolt and
Locknut
3. Slide footrest to desired position.
4. Reinstall hex bolt and locknut. Tighten
Leg Guard Replacement/Adjustment
securely.
5. Repeat STEPS 1‐5 for the opposite
Fork
footrest, if necessary.
Rear of
Front Tire
Replacing/Adjusting Leg Guard
NOTE: This procedure is for Top End XLT,
XLT Jr., and XLT Pro ONLY.
Brake Cable
Allen
1. Loosen the two allen screws on each
mounting clamp.
Screws
2. If replacing leg guard, preform the
following:
Mounting
Clamp
Leg Guard
3. Remove existing leg guard from
clamps.
4. Insert new leg guard into clamps.
5. Position each mounting clamp onto the fork under the brake cable.
NOTE: The leg guard should surround, but not touch, the rear of the front tire.
6. Adjust leg guard to desired position.
7. Tighten the two allen screws on each mounting clamp securely.
32
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SECTION 6—RIDING POSITION
Using/Replacing Footrest Strap
ꢀ WARNING
Footrest straps MUST be inspected before each use. Exposure to moisture (i.e.- wet
weather or puddles) will damage fastening strips. Footrest strap will not hold feet
securely in footrest if fastening strips are damaged. DO NOT operate handcycle if
footrest straps are wet or damaged, otherwise severe injury may occur.
ALWAYS wear shoes and securely strap feet in using straps provided. Severe injury
may occur if feet are not secured while the handcycle is in motion.
Using Footrest Strap
NOTE: For this procedure, refer to
Footrest
Fastening Straps
1. Place feet in footrests.
Footrest
Strap
2. Secure feet to footrest strap using small
fastening straps.
Replacing Footrest Strap
NOTE: For this procedure, refer to
DETAIL “A”
End of Footrest Straps (STEP 4)
Footrest Strap
Loop Portion
(STEP 3)
1. Pull apart fastening straps securing
existing footrest strap to footrest.
Footrest
Strap Hoo
Portion
Small Fastening
Straps
NOTE: The small fastening straps should face
up.
(STEP 3)
2. Wrap end of footrest strap over and
around the inner footrest tube and
firmly connect the hook and loop
portions of the footrest strap
(Detail ʺAʺ).
Inner Footrest
Tube
Outer
Footrest
Tube
DETAIL “B”
End of Footrest Straps (STEP 4 AND 5)
3. Wrap end of footrest strap over and
around the outer footrest tube and
under the inner footrest tube and
firmly connect the hook and loop
portions of the footrest strap (Details
ʺAʺ and “B”).
Inner
Footrest
Tube
Outer Footrest
Tube
Loop Fastening
Strip (STEP 6)
4. Ensure the footrest strap is firmly
attached to the loop fastening strip on
the outer footrest tube.
33
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SECTION 6—RIDING POSITION
Adjusting Hand Crank
ꢀ WARNING
DO NOT operate the handcycle if the hand crank obstructs your view. If the hand
crank obstructs your view, adjust the height before using the handcycle - otherwise
injury or damage may occur.
Adjusting Hand Crank Height - All Models Except Top End XLT Gold
NOTE: For this procedure, refer to FIGURE 6.4.
1. Loosen, but DO NOT remove the two
Hand Crank
set screws securing the hand crank to
the fork stem.
2. Move the hand crank assembly up or
down on the fork stem until you are
comfortable with the position for
Set Screws
operational purposes.
Fork Stem
NOTE: The hand crank should be positioned so
that when the hand is toward the front of the
handcycle, the arm is slightly bent. The arm
should NEVER be fully extended (locked) at
any point while cranking.
3. Tighten the hex nut to secure the hand crank in the desired position.
34
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SECTION 6—RIDING POSITION
Adjusting Top End XLT Gold Hand Crank
NOTE: For this procedure, refer to FIGURE 6.5.
Adjusting Hand Crank Height
1. Loosen, but DO NOT remove the hex nut securing the hand crank to the fork stem.
2. Loosen, but DO NOT remove the two set screws for the upper clamp.
3. Move the hand crank assembly up or down in the fork neck until you are comfortable
with the position for operational purposes.
NOTE: The hand crank should be positioned so that when the hand is toward the front of the
handcycle, the arm is slightly bent. The arm should NEVER be fully extended (locked) at any point
while cranking.
4. Tighten the hex nut to secure the hand crank in the desired position.
5. Tighten the two set screws on the upper clamp.
Hex
Nut
Fork Neck
Upper Clamp
and Set
Screws
Hand Crank
(Gear and Chain Not Shown)
35
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SECTION 6—RIDING POSITION
Adjusting Seat Fore/Aft - All Models Except XLT Gold
and Top End Force
NOTE: For this procedure, refer to FIGURE 6.6.
NOTE: Seat should be adjusted so that when seated with feet in the footrests, there is a slight bend
at the knee and a slight bend at the elbow when the hand crank is furthest away.
1. If installed, activate parking brake.
2. Loosen, but DO NOT remove the four rear socket screws that secure the rear seat
frame to the handcycle frame.
3. Loosen, but DO NOT remove the two front socket screws that secure the front of the
seat frame to the handcycle frame.
NOTE: There are socket screws on the right and left side of the handcycle.
4. Loosen, but DO NOT remove the hex bolts and locknuts that secure the two seat angle
adjustment clamps to the rear seat supports.
NOTE: There is one clamp on the right and left side of the handcycle.
5. Perform one of the following:
• Moving the Seat Rearward ‐ While lifting up on the back support tubes, push the
seat rearward to the desired position.
• Moving the Seat Forward ‐ While pushing down on the back support tubes, pull
the seat forward to the desired position.
6. Tighten the six socket screws that secure the seat frame to the handcycle frame
securely.
7. Tighten the hex bolts and locknuts that secure the two seat angle adjustment clamps
to the rear seat supports securely.
Back Support Tube
Seat Angle
Adjustment
Clamps
Height Adjustment Clamp
Front Socket Screw
Height Adjustment Bracket
Handcycle
Seat Frame
Frame
Rear Socket Screws
36
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SECTION 6—RIDING POSITION
Adjusting Seat Fore/Aft - XLT Gold and Top End Force
Only
NOTE: For this procedure, refer to FIGURE 6.7.
NOTE: Seat should be adjusted so that when seated with feet in the footrests, there is a slight bend
at the knee and a slight bend at the elbow when the hand pedal is furthest away.
2. Loosen, but DO NOT remove the two mounting bolts and locknuts securing the two
back clamps to the seat rails.
3. Slide back clamps for (forward) or aft (rearward) along the seat rails to desired seat
position.
4. Securely tighten the two mounting bolts and locknuts securing the two back clamps
to the seat rails.
6. If necessary adjust the back angle.
Mounting Bolt
and Locknut
Seat Rails
Back Clamp
37
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SECTION 6—RIDING POSITION
Adjusting Seat Height - All Models Except XLT Gold
and Top End Force
NOTE: For this procedure, refer to FIGURE 6.8.
1. Loosen, but DO NOT remove the four socket screws securing the rear of the seat to the
handcycle frame.
2. Remove the two socket screws securing the front of the seat frame to the handcycle
frame.
3. Align the seat height adjustment clamp with the desired height adjustment hole in the
seat height adjustment bracket.
4. Install the two socket screws to secure the front of the seat frame to the handcycle
frame.
Back Support Tube
Seat Angle
Adjustment
Clamps
Height Adjustment Clamp
Front Socket Screw
Height Adjustment Bracket
Handcycle
Seat Frame
Frame
Rear Socket Screws
38
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SECTION 6—RIDING POSITION
Adjusting Back Angle - All Models Except XLT Gold and
Top End Force
NOTE: For this procedure, refer to FIGURE 6.9.
1. If installed activate parking brake.
2. Loosen, but DO NOT remove the four rear socket screws that secure the seat frame to
the handcycle frame.
NOTE: There are two socket screws on the right and left side of the handcycle.
3. Loosen, but DO NOT remove the hex bolts and locknuts that secure the two seat angle
adjustment clamps to the rear seat supports.
NOTE: There is one clamp on the right and left side of the handcycle.
4. Perform one of the following:
• Increasing Back Angle ‐ While lifting up on the back support tubes, pull the seat
upward to the desired position.
• Decreasing Back Angle ‐ While pushing down on the back support tubes, push the
seat down to the desired position.
5. Tighten the four socket screws that secure the seat frame to the handcycle frame
securely.
6. Tighten the hex bolts and locknuts that secure the two seat angle adjustment clamps
to the rear seat supports securely.
Back Support Tube
Seat Angle Adjustment Clamps
Handcycle Frame
Rear Socket Screws
39
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SECTION 6—RIDING POSITION
Adjusting Back Angle - XLT Gold
NOTE: For this procedure, refer to FIGURE 6.10.
1. Loosen, but DO NOT remove, the two socket screws located in the seat angle
adjustment clamp.
2. Perform one of the following:
• Increasing Back Angle ‐ While pushing down on the back support tube, push the
back down to the desired position.
• Decreasing Back Angle ‐ While lifting up on the back support tube, pull the back
upward to the desired position.
3. Securely tighten the two socket screws located in the seat angle adjustment clamp.
Back Support Tube
Socket
Screw
Adjustment Holes
NOTE: Wheel not shown for clarity.
40
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SECTION 6—RIDING POSITION
Adjusting Back Height - Wide Back Option Only
NOTE: For this procedure, refer to FIGURE 6.11.
NOTE: This procedure applies to Top End XLT models with wide back option only.
ꢀ WARNING
Push pin MUST protrude through hole in back cane.
Ensure that both back cane inserts are at the same height before reassembling the
chair.
2. Press the push pin on the back cane insert tube in and adjust the back height to one of
three heights depending on original back height.
Back Cane
Push Pin
Back Cane Insert
41
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SECTION 7—WHEELS
SECTION 7—WHEELS
ꢀ WARNING
After any adjustments, repair or service and before use, make sure all attaching
hardware is tightened securely - otherwise injury or damage may result.
Installing/Adjusting the Rear Wheel and Quick-Release
Axles
NOTE: For this procedure, refer to FIGURE 7.1.
1. Make sure that the axle receiver hex nut
Quick-release
Locknut
Axle Receiver
Hex Nut
is securely tightened before installing
the rear wheels.
Axle
2. Depress detent pin in the quick‐release
axle and slide axle through the axle
receiver.
3. Release detent pin ensuring that the
locking pins are fully released.
Locking
Pins
Detent
Pin
Axle Receiver
NOTE: Locking pins MUST protrude past the
end of the axle receiver to fully release. Any
excessive play MUST also be eliminated.
4. Increase or decrease end play by adjusting the locknut on the end of the quick‐release
axle.
ꢀ WARNING
Make sure detent pin is fully released before operating the handcycle.
Keep locking pins clean.
5. Reinstall rear wheel on the handcycle.
6. Tilt handcycle onto either rear wheel and spin raised wheel. It should spin freely with
no excessive drag.
7. Repeat procedure for opposite rear wheel.
NOTE: If drag to either side occurs, repeat the procedure until the handcycle rolls correctly.
42
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SECTION 7—WHEELS
Installing the Rear Wheels with Threaded Axles
NOTE: For this procedure, refer to FIGURE 7.2.
1. Apply a small amount of grease onto the axle.
2. Insert the axle into the axle mounting hole on the handcycle frame.
3. Securely tighten the axle to the frame.
Axle
Mounting
Hole
¼-inch Allen
Wrench
Frame
Rear Wheel
Axle
Replacing Tire/Tube and Tuning/Replacement of
Spokes
NOTE: Invacare recommends that these procedures be performed by a qualified technician.
Tire Pressure
ꢀ WARNING
DO NOT use the handcycle unless it has the proper tire pressure (p.s.i.). DO NOT
overinflate the tires. Failure to follow these suggestions may cause the tire to
explode and cause bodily harm. Tire p.s.i. is printed on the tire wall.
43
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SECTION 7—WHEELS
Determining/Adjusting Toe In/Toe Out
NOTE: For this procedure, refer to FIGURE 7.3.
Determining Toe In/Toe Out
1. Inflate all pneumatic tires to recommended tire pressures (listed on the sidewall of the
tire).
2. Measure the distance between the
Front of handcycle
center lines at the rear and front of the
Toe-out
rear wheels at approximately 12 inches
from the ground/floor.
Toe-in
NOTE: For optimum accuracy, perform STEP
2 with the handcycle occupied.
NOTE: Step 2 may be performed with using
alignment gauge (available as an option for the
handcycle). Refer to Using the Alignment
Top View of
handcycle
3. Determine the difference between the
two measurements. If the difference
between the two measurements is
greater than 1/8‐inch (for maximum
rollability), one of two conditions exists:
• If the back centerline measurement
of the rear wheels is smaller than
the front centerline measurement of
the rear wheels, a toe‐out condition
exists.
Smaller Than
Front
Larger Than Front
DETAIL “A”
• If the back centerline measurement
of the rear wheels is LARGER than
the front centerline measurement of
the rear wheels, a toe‐in condition
exists.
Clamp
4. If the difference between the
measurements is greater than 1/8‐inch,
correct the toe‐in/toe‐out condition.
Camber Bar
Camber
Insert
Socket Screw
44
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SECTION 7—WHEELS
Adjusting Toe In/Toe Out
1. Loosen, but DO NOT remove the socket screws and clamps that secure camber inserts
to the camber bar (Detail ʺAʺ).
2. Slowly rotate the camber insert until the rear wheels are approximately in a straight
line.
3. Securely tighten the socket screws and clamps that secure the camber inserts to the
camber bar.
4. Measure the distance between the center lines at the rear and front of the rear wheels
at approximately 12 inches from the ground/floor. Refer to Determining Toe In/Toe
5. Repeat STEPS 1‐4 until the toe in/toe out measurement is less than 1/8‐inch (for
maximum rollability).
Replacing Camber Inserts
NOTE: For this procedure, refer to FIGURE 7.4.
1. Loosen, but DO NOT remove the socket screws and clamps that secure the camber
inserts to the camber bar.
2. Remove the existing camber insert from the camber bar.
3. Install the new camber insert into the camber bar.
Clamp
Frame
Camber Bar
Camber
Insert
Socket Screw
45
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SECTION 8—SERVICE PROCEDURES
SECTION 8—SERVICE PROCEDURES
ꢀ WARNING
After any adjustments, repair or service and before use, make sure all attaching
hardware is tightened securely - otherwise injury or damage may result.
Replacing the Fork/Crank Assembly
NOTE: For this procedure, refer to FIGURE 8.1 on page 48.
NOTE: Invacare recommends that the following procedure be performed by a qualified technician.
1. Note the position of the crank handles.
2. Loosen, but DO NOT remove the two socket screws that secure the crank handles to
the existing fork.
3. Slide the crank handles down towards the front wheel.
4. Remove the chain from the crank handles.
5. Remove the crank handles from the existing fork.
6. Remove the socket nut on the back of the existing fork that secures the brake assembly.
7. Note brake assembly hardware position and remove the brake assembly from the
existing fork.
8. Remove the road crown compensator or steering dampener from the existing fork.
9. Loosen, but DO NOT remove the socket screw that secures the shifting lever to the
seat frame.
10. Remove the hex bolt and locknut that secure the brake arm to the brake arm clamp.
11. Remove the brake arm clamp from the existing fork.
12. Loosen, but DO NOT remove the two cap nuts that secure the front wheel to the
existing fork.
13. Remove the front wheel from the existing fork.
14. Lay the chain flat.
NOTE: Laying the chain flat will prevent kinks in the chain.
15. Remove the two hex bolts, locknuts and clamps that secure the footrests to the existing
fork.
16. Note the position of the footrests and remove the footrests from the existing fork.
17. Remove the two top nuts that secure the existing fork to the frame.
18. Note the o‐ring and bearing position and remove the existing fork from the frame.
46
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SECTION 8—SERVICE PROCEDURES
19. Slide the bottom bearing onto the new fork. Refer to FIGURE 8.1 for correct
orientation.
20. Slide the new fork into the frame.
21. Position the o‐ring and bearing on the new fork. Refer to FIGURE 8.1 for correct
orientation.
22. Install the two nuts onto the new fork and tighten securely. Refer to FIGURE 8.1 for
correct orientation.
23. Position the footrest clamps on the new frame.
24. Install the footrests onto the new fork to the position noted in STEP 17 and secure with
the two hex bolts and locknuts.
25. Position the chain around the hub of the front wheel.
26. Install the front wheel onto the new fork.
NOTE: Make sure the washer and the non‐turn washer are on the outside of the new fork.
27. Line up the projecting ends of the non‐turn washer with the slot in the new fork.
28. Repeat STEPS 27‐28 until the projecting ends of the non‐turn washer line up with the
slot in the new fork.
29. Torque the two cap nuts 260‐390 in‐lbs.
30. Install the brake arm clamp onto the new fork.
31. Secure the brake arm to the brake arm clamp with the hex bolt and locknut. Torque to
22‐26 inch‐pounds.
32. Reinstall the shifting lever onto the seat frame and secure with the socket screw.
33. Install the road crown compensator or steering dampener onto the new fork. Refer to
34. Install the brake assembly onto the new fork. Refer to the hardware position noted in
STEP 8 and tighten securely with the socket nut.
35. Slide the crank handles onto the new fork.
NOTE: Make sure the sprocket on the crank handles is in line with the sprocket on the front wheel.
36. Reinstall the chain onto the crank handle sprocket.
37. Move the crank handle to the position determined in STEP 1 and tighen the two socket
screws securely.
47
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SECTION 8—SERVICE PROCEDURES
STEPS 1, 2, 3, 36, 37
STEPS 6, 7, 34
Brake
Assembly
Fork
Hardware
Socket
Screws
Fork
Socket
Nut
Crank Handle
STEPS 8, 31
Steering Dampener
Road Crown Compensator
STEPS 12, 13, 26, 27, 28, 29
STEPS 10, 11, 30, 31
Locknut
Non-Turn Washer-Must
Be Installed as Shown
Fork
Brake
Arm
Washer
Clamp
Hex
Bolt
Front
Brake Arm
Cap Nuts
Wheel
STEPS 5, 17, 18, 19, 20, 21, 22, 35
STEPS 15, 16, 23, 24
Crank Handle
Top Nuts
Fork
Bearing
O-Ring
Frame
Hex Bolts, Locknuts
and Footrest Clamps
Frame
Bottom Bearing
Fork
48
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SECTION 8—SERVICE PROCEDURES
Replacing the Crank Arms - XLT Gold, XLT PRO and
Top End Force
NOTE: For this procedure, refer to FIGURE 8.2 on page 50.
NOTE: Right and left determined from as if seated on the handcycle.
Replacing the Left Side Crank Arms
1. Remove the two socket screws from the existing crank arm clamp.
2. Remove socket screw and cap from the spindle.
3. Remove the existing crank arm from the spindle.
4. Position the new crank arm onto the spindle so that the new crank arm is evenly
aligned with the right side crank arm.
5. Re install the socket screw and cap from the spindle. DO NOT over tighten.
6. Using the two socket screws, secure the new crank arm clamp to the spindle. Securely
tighten.
Replacing the Right Side Crank Arms
1. Remove the two mounting bolts and locknuts securing the chain ring disk to the tabs
of the existing crank arm.
2. Remove the two socket screws from the existing crank arm clamp.
3. Remove socket screw and cap from the spindle.
4. Remove the existing crank arm from the spindle.
5. Position the new crank arm onto the spindle.
6. Using the two mounting bolts and locknuts, secure the tabs of the new crank arm to
the chain ring disk.
7. Ensure the new crank arm is evenly aligned with the left side crank arm.
8. Re install the socket screw and cap from the spindle. DO NOT over tighten.
9. Using the two socket screws, secure the new crank arm clamp to the spindle. Securely
tighten.
49
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SECTION 8—SERVICE PROCEDURES
Mounting Bolts
and Locknuts
Crank Arm Clamp
Left Crank Arm
Right Crank Arm (Tabs)
Chain
Ring Disk
Spindle, Socket
Screw and Cap
Spindle, Socket
Screw and Cap
Crank Arm Clamp and
Socket Screws
Socket Screws
Installing/Removing/Adjusting the Road Crown
Compensator
NOTE: For this procedure, refer to FIGURE 8.3 on page 51.
NOTE: The road crown compensator is designed to stabilize the handcycle during transfers and
while riding and is not intended to keep the handcycle straight when pedaling but to keep the
handcycle from leaning excessively to one side or another.
Installing Road Crown Compensator
1. Position the bolt through the frame end of the road crown compensator.
2. Position the spacer on the bolt.
3. Install the bolt with spacer and road crown compensator into the mounting hole on
the frame.
4. Rotate the fork to ensure the front wheel is pointing directly forward.
5. Position the fork end of the road crown compensator on the fork bolt.
NOTE: If necessary, lengthen or shorten the road crown compensator to position the fork end onto
the fork bolt. Refer to Adjusting Road Crown Compensator on page 51.
6. Secure the road crown compensator to the fork bolt with the locknut. Tighten securely.
50
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SECTION 8—SERVICE PROCEDURES
Removing Road Crown Compensator
1. Remove the locknut securing the fork end of the road crown compensator to the fork
bolt.
2. Remove the fork end of the road crown compensator from the fork bolt.
3. Remove the bolt and spacer securing the frame end of the road crown compensator to
the frame.
Adjusting Road Crown Compensator
NOTE: This adjustment is made for handcycling on crowned roads or in heavy winds.
1. Rotate the fork end of the road crown compensator to adjust the length. Clockwise ‐
shortens the road crown compensator and pulls the front wheel to the left.
Counterclockwise ‐ lengthens the road crown compensator and pushes the front
wheel to the right.
Adjustment
Road Crown Compensator
Removed
Fork End
Fork Bolt
Locknut
Frame
Installed
Mounting
Hole
Frame
Frame
Fork End
Road Crown
Compensator
Fork
Frame End
Bolt
Road Crown
Compensator
Spacer
51
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SECTION 8—SERVICE PROCEDURES
Installing/Removing/Adjusting the Steering Dampener -
For Top End XLT Gold and Force Only
NOTE: For this procedure, refer to FIGURE 8.4 on page 53.
NOTE: The steering dampener is designed to stabilize the handcycle during transfers and while
riding and is not intended to keep the handcycle straight when pedaling but to keep the handcycle
from leaning excessively to one side or another.
Installing Steering Dampener
1. Using a locknut, secure the upper threaded post of the steering dampener to the crank
assembly tab.
2. While inserting the lower threaded post into the tab, position the dampener clamp
around the handcycle frame.
3. Using two socket screws, loosely secure the dampener clamp to the handcycle frame.
4. Using a locknut, secure the steering dampener to the dampener clamp.
5. Ensuring the front wheel and dampener clamp are inline with the handcycle frame,
securely tighten the two socket screws securing the dampener clamp to the handcycle
frame.
6. Test drive handcycle, if handcycle pulls to the left or right adjust the steering
Removing Steering Dampener
1. Remove the locknut securing the steering dampener to the dampener clamp.
2. Remove the two socket screws securing the dampener clamp to the handcycle frame.
3. Remove the dampener clamp from the handcycle frame and the lower threaded post
of the steering dampener
4. Remove the locknut securing the upper threaded post of the steering dampener to the
crank assembly tab.
5. Remove the steering dampener from the crank assembly.
Adjusting Steering Dampener
1. Loosen, but DO NOT remove, the two socket screws securing the dampener clamp to
the handcycle frame.
2. Ensuring the front wheel and dampener clamp are inline with the handcycle frame,
securely tighten the two socket screws securing the dampener clamp to the handcycle
frame.
3. Test drive handcycle, if handcycle pulls to the left or right repeat STEPS 1‐3 until
handcycle drives straight.
52
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SECTION 8—SERVICE PROCEDURES
Top End
XLT Gold
ONLY
Crank
Assembly Tab
Socket Screws
(One Located on Both Sides
of the Handcycle Frame)
Upper Threaded
Post and Locknut
Steering
Dampener
Handcycle
Frame
Lower
Threaded
Post and
Locknut
Dampener
Clamp (Tab)
Top End
Force
ONLY
Upper Threaded Post and Locknut
Steering
Dampener
Dampener
Clamp (Tab)
Crank
Assembly Tab
Handcycle
Frame
Installing Seven Speed Shifter Cable
NOTE: For this procedure, refer to FIGURE 8.5.
NOTE: This procedure applies to the Top End XLT only.
NOTE: The seven speed Shifter Cable runs
from the right side of the front frame to its
Hand Crank
Assembly
Extension
Cable
mounting position on the hand crank assembly.
1. Run the cable from the right‐side of the
fork assembly to mounting position on
the left side just below the hand crank
assembly.
Shifter
2. Attach the seven speed shifter to the
hand crank assembly extension.
3. Secure with hardware provided.
53
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SECTION 8—SERVICE PROCEDURES
Adjusting/Replacing Seven Speed Shifter
Handcycles with seven speed shifters are equipped with SHIMANO hubs. If equipped
with a SHIMANO hub, it MUST be serviced and adjusted by a qualified technician.
NOTE: QUALIFIED TECHNICIANS ONLY ‐ Contact Invacare, 1‐800‐532‐8677 for complete
SHIMANO hub instructions.
It is recommended that you take your handcycle to a qualified technician for any shifter
adjustment.
Installing/Adjusting Seven Speed Hub Chain
Seven Speed Hub Chain Installation
ꢀ WARNING
Chain MUST be tight. If the chain is noisy, loosen. After chain is assembled, start in
first gear and on straightaway.
NOTE: For this procedure, refer to FIGURE 8.6 on page 54.
1. Spread the chain out flat and run it over the bottom chain tensioner upwards to the
hand crank sprocket assembly.
2. Position chain over the hand crank sprocket assembly.
NOTE: It may be necessary to turn the hand crank in a clockwise motion to position the chain on
the sprocket.
3. Run the chain over the top chain tensioner.
4. Position the chain around the wheel sprocket and back up towards the bottom chain
tensioner.
5. Place chain over the top of the bottom chain tensioner.
6. Attach the chain together using the master link (with clip) provided.
F
STEP 2
Hand Crank
Chain
Tensioners
Top
Chain
STEP 4
Bottom
Chain
Sprocket
Assembly
Wheel
Sprocket
54
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SECTION 8—SERVICE PROCEDURES
Adjusting Seven Speed Hub Chain
ꢀ WARNING
Chain MUST be tight. If the chain is noisy, loosen. After chain is assembled, start in
first gear and on straightaway.
NOTE: For this procedure, refer to FIGURE 8.7 on page 55.
NOTE: This procedure applies to the Top End XLT and Top End XLT Jr. only.
NOTE: Repositioning of the hand crank assembly loosens or tightens the chain in an up/down
position.
2. Loosen the hex screw securing the adjustable chain idler.
3. Adjust the tautness of the chain by moving the adjustable chain idler in or out as
shown in FIGURE 8.7.
4. Tighten the hex screw to secure the adjustable chain idler in place.
Hex Screw
Adjustable
Chain Idler
Installing/Adjusting Twenty-Seven Speed Cassette Chain
Installing Twenty-Seven Speed Cassette Chain
NOTE: For this procedure, refer to FIGURE 8.8 on page 56.
1. Spread the chain out flat and run it around the chain ring on the crank and the
sprocket on the hub.
NOTE: It may be necessary to turn the hand crank in a clockwise motion to position the chain on
the small sprocket.
2. Ensure that crank assembly is loosened and movable.
3. Lift up on the chain derailleur and thread the chain under the derailleur.
4. Thread the chain around the wheel sprocket.
55
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SECTION 8—SERVICE PROCEDURES
5. Run the chain around the bottom of the wheel sprocket and back up towards the hand
crank sprocket.
6. Attach the chain together using the master link (w/clip) provided.
Hand Crank Sprocket
Assembles
STEP 5
Chain Derailleur and Wheel Sprockets
STEP 3
STEP 4
Adjusting Twenty-Seven Speed Cassette Chain
NOTE: For this procedure, refer to FIGURE 8.9.
1. Loosen, but DO NOT remove the clamp that secure the crank handles to the fork.
2. Slide the crank handles up and/or down until the proper tension on the chain is
achieved.
NOTE: The proper chain tension will be approximately ½‐inch of chain slack.
NOTE: If crank is in desired position but chain tension is not correct, links MUST be added to or
removed from the chain to correct the tension. This should be performed by a qualified technician.
3. Tighten the clamp that secure the crank handles to the fork securely.
56
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SECTION 8—SERVICE PROCEDURES
Crank
Handle
Fork
Clamps
Adjusting/Replacing the Parking Brake
ꢀ WARNING
Before using your handcycle, inspect the parking brake for proper operation.
NOTE: For this procedure, refer to FIGURE 8.10.
Adjusting the Parking Brake
Cable
1. Loosen the hex nut and turn the adjuster barrel clockwise (tighten) or
counterclockwise (loosen) to adjust the cable. Retighten hex nut.
Brake Pads
1. Adjust the brake pad assembly so that when the parking brake is engaged the brake
pads rest solely on the rim of the wheel.
Replacing the Parking Brake
Brake Pads
1. Remove the mounting nuts and replace brake pads.
2. Secure with existing hardware and adjust.
57
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SECTION 8—SERVICE PROCEDURES
Parking Brake
ꢀ WARNING
Replacement of the parking brake MUST be performed by a qualified technician.
Adjuster Barrel
Hex Nut
Rim of Wheel
Brake Pad
Mounting Nut
Stop Button
Replacing Seat Upholstery
ꢀ WARNING
Upholstery MUST be inspected before each use. Exposure to moisture (i.e. - wet
weather or puddles) will damage fastening straps/flaps/strips. DO NOT operate
handcycle if upholstery is wet or damaged, otherwise severe injury may occur.
NOTE: For this procedure, refer to
Back
Upholstery
1. Remove seat cushion and back
upholstery from chair.
Large Strap
Toward
Rear of Seat
2. Unlatch the four fastening flaps that
secure the seat upholstery to the seat
frame.
Frame
3. Remove the existing seat upholstery.
4. Install the new seat upholstery making
sure that the three fastening flaps that
are in close proximity to one another
are to the rear of the seat frame.
Three Seat Upholstery
Fastening Straps Towards
5. Secure the four fastening flaps together.
Towards Front of
6. Reinstall back upholstery and seat
cushion onto chair.
Rear of Seat Frame
Chair
58
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SECTION 8—SERVICE PROCEDURES
Replacing Back Upholstery
ꢀ WARNING
Upholstery MUST be inspected before each use. Exposure to moisture (i.e. - wet
weather or puddles) will damage fastening straps/flaps/strips. DO NOT operate
handcycle if upholstery is wet or damaged, otherwise severe injury may occur.
Replacing Wide Back Upholstery
Back Upholstery
NOTE: For this procedure, refer to
1. Unlatch the two fastening flaps that
secure the bottom of existing back
upholstery to the back canes.
Fastening
Flap
2. Unlatch the top of the existing back
upholstery.
Fastening
Flap
3. Lift up on the existing back upholstery
and remove from the handcycle.
Back Cane
4. Install the new back upholstery onto
the handcycle.
5. Securely latch the fastening flaps on the
bottom of the new back upholstery to
the back canes.
Replacing Narrow Back
Upholstery
Fixed Seat
Narrow Back
Fastening
Strips
NOTE: For this procedure, refer to
Back
Frame
NOTE: Pull the back cushion off the back
frame.
Back Cushion
1. Align the fastening strips on the back
frame with the fastening strips on the
new back cushion.
Fastening
Strips
1. Press the back cushion firmly against
the back frame to secure.
Back
Frame
Adjustable Seat
Narrow Back
59
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SECTION 9—OPTIONS
SECTION 9—OPTIONS
ꢀ WARNING
After any adjustments, repair or service and before use, make sure all attaching
hardware is tightened securely - otherwise injury or damage may result.
Installing Rear Safety Light
Safety Light
ꢀ WARNING
Operation of the handcycle is subject to
Lens
Cover
all traffic rules and regulations. (This
may include the use of a safety light and
reflectors for dusk/night riding.)
Clamp
NOTE: For this procedure, refer to
Batteries
Rear Seat Post
1. Remove the lens cover.
Set Screw
2. Insert the AAA batteries with correct
NOTE: Rear wheels removed for clarity.
polarity (+ or ‐).
3. Reinstall lens cover.
Mounting the Safety Light
1. Remove the set screw from the clamp on the safety light.
2. Position the clamp onto the rear seat post.
3. Install the set screw into the clamp and tighten securely.
Operating the Safety Light
1. Press GREY button to turn safety light on/off.
2. Remove lens cover and slide switch back and forth for pulse or constant mode.
60
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SECTION 9—OPTIONS
Installing the Water Bottle
NOTE: For this procedure, refer to FIGURE 9.2.
1. Secure the water bottle mounting tube to the seat frame using the hardware provided.
NOTE: Make sure that the water bottle mounting bracket mounting holes are facing downward.
2. Attach the water bottle mounting bracket to the mounting tube using the hardware
provided.
3. Push water bottle into mounting bracket until secure.
Mounting Tube
Seat Frame
Water
Bottle
Mounting
Bracket
Installing/Using the Tow Bar
NOTE: For this procedure, refer to FIGURE 9.3.
NOTE: The tow bar will not work with wheelchairs with swingaway front riggings. Only rigid
wheelchairs with a tubular style footrest can be towed using the tow bar.
1. Remove the two set screws on each mounting bracket.
2. Position the mounting brackets around the handcycle rear frame.
NOTE: Make sure that the tow bar is centered
Fastening Strip
Tow Bar
on the handcycle rear frame.
3. Using two set screws for each
Mounting
mounting bracket, secure the mounting
Bracket
brackets to the handcycle rear frame.
4. Secure the tow bar to the handcycle
Set Screws
with the mounting brackets and set
screws.
Handcycle
Rear Frame
5. Secure the wheelchair to the tow bar
with the fastening strips provided.
61
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SECTION 9—OPTIONS
Installing the Draft Bumper
ꢀ WARNING
DO NOT use if draft bumper extends past rear wheels. If draft bumper extends past
the rear wheels, contact dealer.
NOTE: For this procedure, refer to FIGURE 9.4.
NOTE: The draft bumper can not be installed if the tow bar is installed.
1. Remove the four set screws on each
Draft Bumper
Mounting Brackets
mounting bracket.
2. Position the mounting brackets around
the handcycle rear frame.
Handcycle
Rear Frame
Set
Screws
NOTE: Make sure that the draft bumper is
centered on the handcycle rear frame.
3. Using four set screws for each
mounting bracket, secure the mounting
brackets to the handcycle rear frame.
Mounting Brackets
Installing the Safety Flag
NOTE: For this procedure, refer to FIGURE 9.5.
1. Mount safety flag in holder secured to back tube on bike frame.
Back Tube
Holder
Safety Flag
Using Safety Helmet
NOTE: For this procedure, refer to
Helmet
1. Secure helmet using the chin strap.
2. Ensure proper fit.
62
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SECTION 9—OPTIONS
Installing Seat Positioning Strap
NOTE: For this procedure, refer to FIGURE 9.7.
1. Secure seat positioning strap to back canes using hardware provided.
Back Canes
Seat Positioning
Strap
Installing the Computer
NOTE: For this procedure, refer to FIGURE 9.8.
1. Install metal plug onto spoke of front wheel approximately 2 inches from wheel rim.
2. Align metal plug with fork assembly.
3. Secure sensor to fork using hardware provided.
NOTE: Slot in sensor MUST align with metal plug for mileage, etc. to be registered on the
computer.
4. Remove one of the chain guard screws and attach the computer mounting bracket.
5. Snap computer into mounting bracket.
Computer
Sensor
Mounting Bracket
Front Wheel Spoke
Metal Plug
63
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SECTION 9—OPTIONS
Installing Hand Crank Handles
NOTE: For this procedure, refer to FIGURE 9.9.
Horizontal Handles/Delrin
Handles
DETAIL “A” - HORIZONTAL
HANDLES/DELRIN HANDLES
1. Secure handle to hand crank with the
screw (Detail “A”).
Hand Crank
Screw
Horizontal Handle
2. Remove the screw to remove handle
from handcrank.
Vertical Handles
DETAIL “B” - VERTICAL HANDLES
1. Position handle onto crank (Detail “B”).
2. Tighten set screw to secure handle to
crank.
Hand Crank
Set Screw
3. Reverse STEPS 1‐2 to remove handle.
Tri-pin Quad Handles
Vertical Handle
1. Remove/install tri‐pin quad handles.
DETAIL “C” - TRI-PIN HANDLES
2. Loosen socket screws to adjust handle
position (Detail “C”).
3. Tighten socket screws to secure
handles in desired position.
V or S Crank Handles
Tri-Pin
Quad
Handle
Socket
Screw
Replacement/installation of V or S crank
handles should be done by a qualified
technician.
Installing V/S Crankarm Handles
For Models Made Before 7/12/07
ꢀ WARNING
Failure to install handle assembly properly could result in injury.
It is recommended to inspect this assembly prior to and after each use.
NOTE: For this procedure, refer to FIGURE 9.10 on page 65.
1. Secure the handle to the crankarm housing using the bolt, spacer, and two bearings.
64
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SECTION 9—OPTIONS
2. Firmly tighten the bolt.
NOTE: Handle should spin freely with minimal play. If handle does not spin freely make sure the
spacer is firmly in place. If handle still does not spin freely, contact Invacare.
Crankarm
Housing
Bearing
Bolt
Bearing
Spacer
Crankarm
Handle
For Models Made After 7/12/07
DETAIL “A” - HANDLE
Set
Screw
REPLACEMENT
Crankarm Housing
ꢀ WARNING
Failure to install handle assembly
properly could result in injury.
Handle
Locknut
It is recommended to inspect this
assembly prior to and after each use.
Crankarm
NOTE: For this procedure, refer to
DETAIL “B” - CRANKARM
Mounting
ORIENTATION
1. Secure the handle to the crankarm
Post
housing using the set screw and
Left
Handle
Right
Handle
locknut.
NOTE: Use the right handle, the handle with a
mounting post, with the right crankarm and
left with left crankarm. The right crankarm has
a flange at the base of the crankarm. The left
crankarm does not.
Flange
2. Firmly tighten the locknut.
NOTE: Handle should spin freely with
minimal play. If handle does not spin freely,
contact Invacare.
Right
Crankarm
Left
Crankarm
65
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SECTION 9—OPTIONS
Installing Gloves
NOTE: For this procedure, refer to FIGURE 9.12 on page 66.
1. Wrap palm loop around horizontal handle (using top slot only) and secure to glove.
2. Run glove loop through bottom slot on palm and over back of hand until tight. Secure
glove loop to back of glove.
3. Reattach glove strips to back of glove.
Palm Loop Secured to Glove
Top Slot
Glove Loop
Glove
Glove
Strip
Glove
Strip
Palm
Loop
Horizontal Handle
Bottom Slot
Mountain Drive Transmission Option
ꢀ WARNING
DO NOT shift the mountain drive transmission option under load (i.e. using a high
gear to start the handcycle in motion or to climb a hill, etc.). Shifting the mountain
drive transmission option under load will damage the internal workings of the
mountain drive option and will void the warranty.
NOTE: For this procedure, refer to FIGURE 9.13 on page 66.
Switching to Mountain Drive Transmission Option
1. Perform one of the following:
Hand
Crank
• Switching Mountain Drive
Transmission Option On ‐ Push in
the gear shift button in the middle
of the right side of the hand crank
while the option is under no load.
Gear Shift
Button
• Switching Mountain Drive
Transmission Option Off ‐ Push the
gear shift button on the left side of
the hand crank in while the option
is under no load.
Mountain Drive Transmission Option Maintenance
The mountain drive transmission option should be maintained by a qualified technician
according to the manufacturerʹs instructions included with the handcycle.
66
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SECTION 9—OPTIONS
Using the Travel Ready Option
NOTE: For this procedure, refer to FIGURE 9.14 on page 67.
NOTE: This procedure is for Top End XLT Pro, Gold, and Top End Force models only.
The travel ready option allows the handcycle to be quickly and easily disassembled for
travel.
NOTE: Reverse the steps below to reassemble the handcycle.
Removing/Installing the Camber Bar
NOTE: For this procedure, refer to FIGURE 9.14 on page 67.
NOTE: To install the camber bar, reverse the steps below.
1. Perform one of the following
• Adjustable Angle Seat on XLT Gold ‐ Seat support tube does not mount to camber
bar. Proceed to STEP 2.
• Adjustable Angle Seats Except XLT Gold ‐ Loosen, but DO NOT remove the two
hex screws securing the seat support clamps to the camber bar.
2. Loosen, but DO NOT remove the two hex screws securing the frame clamps to the
camber bar.
3. Slide the camber bar through the clamps.
Seat Support Clamp
Seat Support Clamp
(Not Present on XLT Gold)
(Not Present on XLT Gold)
Camber Bar
Socket
Screws
Socket
Screws
Frame Clamp
67
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SECTION 9—OPTIONS
Removing/Installing the Fork - Travel Ready XLT PRO
Equipped with Road Crown Compensator
NOTE: For this procedure, refer to FIGURE 9.15 on page 69.
Removing the Fork
1. Remove the nut securing the road crown compensator to the fork.
2. Remove the road crown compensator from the fork bolt.
3. Remove the two socket screws from each fork clamp.
4. Remove the plate from the top of the fork.
5. Remove the fork from the frame.
Installing the Fork
1. Position the fork onto the frame.
2. Position the plate on to the fork.
3. Secure the plate to the frame using the two clamps and four Socket screws.
4. Position the road crown compensator onto the fork bolt.
5. Secure the road crown compensator to the fork bolt using the nut.
7. Test drive handcycle, if handcycle pulls to the left or right adjust the road crown
68
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SECTION 9—OPTIONS
Fork Clamp
Socket
Screws
Plate
Fork
Clamp
Frame
Fork
Fork
Clamps
Nut
Fork Bolt
Road Crown Compensator
Removing/Installing the Fork - XLT Gold, and Top End
Force Equipped with Steering Dampener
NOTE: For this procedure, refer to FIGURE 9.16 on page 70.
Removing the Fork
1. Remove the locknut securing the steering dampener to the dampener clamp
(Detail ʺAʺ).
2. Remove the two socket screws securing the dampener clamp to the handcycle frame.
3. Remove the dampener clamp from the handcycle frame and the lower threaded post
of the steering dampener.
4. Remove the two socket screws from the fork clamp.
5. Remove the plate from the top of the fork.
6. Remove the fork from the frame.
Installing the Fork
1. Position the fork onto the frame.
2. Position the plate on to the fork.
69
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SECTION 9—OPTIONS
3. Using the fork clamp and two socket screws, secure the bottom of the plate to the
frame.
4. While inserting the lower threaded post into the tab, position the dampener clamp
around the handcycle frame.
5. Using two socket screws, loosely secure the dampener clamp to the handcycle frame.
6. Using a locknut, secure the steering dampener to the dampener clamp.
8. Ensuring the front wheel and dampener clamp are inline with the handcycle frame,
securely tighten the two socket screws securing the dampener clamp to the handcycle
frame.
9. Test drive handcycle, if handcycle pulls to the left or right adjust the steering
Dampener Clamp (Tab)
Lower Threaded Post of
Locknut
Steering Dampener
Dampener Clamp
Handcycle Frame
Socket Screws
Fork Clamp
Fork Clamp
Fork
Removing/Installing the Front Wheel - XLT Gold, XLT
Pro and XLT with Speed Cassette Chain
NOTE: For this procedure, refer to FIGURE 9.17 on page 71.
Removing the Front Wheel
1. Open the quick‐release lever securing the front wheel to the fork (Detail ʺAʺ).
2. Loosen the knob on the opposite side of the quick‐release lever.
3. Remove the wheel from the fork.
4. Remove the chain from the front wheel.
70
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SECTION 9—OPTIONS
Installing the Front Wheel
NOTE: For ease of installation, secure handcycle frame approximately 6 inches from the ground or
seek assistance.
1. Loop the chain over the front wheel sprocket.
2. Position the front wheel sprocket into the fork slots.
3. Tighten the knob on the opposite side of the quick‐release lever.
4. Secure the wheel to the fork with the quick‐release lever.
Sprocket
Front Wheel
Chain
DETAIL “A” - FRONT
WHEEL QUICK-RELEASE
LEVER
NOTE: Quick Release Lever is an
opposite side of wheel.
Quick-release
Lever
Fork
Assembling/Using/Adjusting the Handcycle Rack
NOTE: For this procedure, refer to FIGURE 9.18 on page 72.
Assembling the Handcycle Rack
1. Position the receiver with the bracket facing up.
2. Position the rear wheel bar with the wheel brackets facing up.
3. Remove the two large mounting bolts and locknuts from the receiver and set aside.
4. Remove the two small mounting bolts and locknuts from the receiver bracket and set
aside.
5. Secure the wheel tray to the receiver with the two large mounting bolts and locknuts.
6. Using two small mounting bolts and locknuts, secure the receiver bracket to the wheel
tray.
7. Remove the two mounting bolts and locknuts from the rear wheel bar and set aside.
71
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SECTION 9—OPTIONS
8. Using two mounting bolts and locknuts, secure the rear wheel bar to the wheel tray.
9. Install the receiver onto the trailer hitch of the vehicle, according to the vehicle
manufacturerʹs instructions.
Using the Handcycle Rack
1. Position the handcycle on the rack with the front wheel in the wheel tray bracket.
2. Adjust the handcycle rack so the wheel tray bracket sits against the front wheel and
the rear wheel bar brackets sit against the rear wheels. Refer to Adjusting the
3. Secure the front wheel to the wheel tray bracket using the strap provided.
4. Secure the rear wheels to the rear wheel bar using the straps provided.
Rear Wheel
Bar
Mounting Bolts
and Locknuts
Screws
Receiver
Small Mounting
Bolts and Locknuts
Large Mounting
Bolts and Locknuts
Bracket
Rear Wheel
Bar Bracket
Wheel Tray
Wheel Stop
Mounting Bolt
and Locknut
Wheel Stop
Mounting
Positions
Wheel Tray Bracket
Mounting Bolts
and Locknuts
72
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SECTION 9—OPTIONS
Adjusting the Handcycle Rack
Wheel Tray Bracket
NOTE: To properly secure the handcycle, the wheel tray bracket should be adjusted to sit against
the front wheel.
1. Remove the four mounting bolts and locknuts securing the wheel tray bracket to the
wheel tray.
2. Position the wheel tray bracket in the desired position.
3. Secure the wheel tray bracket to the wheel tray with the four mounting bolts and
locknuts.
4. If necessary, the wheel stop may be adjusted to one of three positions to sit against the
front wheel. To adjust the wheel stop, perform the following steps:
A. Remove the mounting bolt and locknut securing the wheel stop to the wheel tray
bracket.
B. Position the wheel stop in the desired mounting position.
C. Secure the wheel stop to the wheel tray bracket with the mounting bolt and
locknut.
Rear Wheel Bar Brackets
NOTE: To properly secure the handcycle, the rear wheel bar brackets should be adjusted to sit
against the rear wheels.
1. Loosen the two screws securing the rear wheel bar bracket to the rear wheel bar.
2. Adjust the rear wheel bar bracket in/out until they sit against the rear wheel.
3. Secure the rear wheel bar bracket to the rear wheel bar with the two screws.
4. Repeat STEPS 1‐3 for the opposite side if necessary.
Rear Wheel Bar
NOTE: To properly secure the handcycle, the rear wheel bar should be adjusted so the rear wheels
sit in the rear wheel bar brackets.
1. Remove the two mounting bolts and locknuts securing the rear wheel bar to the wheel
tray.
2. Position the rear wheel bar to one of three mounting positions on the wheel tray.
3. Secure the rear wheel bar to the wheel tray with the two mounting bolts and locknuts.
73
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SECTION 9—OPTIONS
Using the Alignment Gauge
NOTE: For this procedure, refer to FIGURE 9.19.
NOTE: The alignment gauge is used to determine toe in/toe out. Refer to Determining/Adjusting
1. Inflate all pneumatic tires to recommended tire pressures (listed on the sidewall of the
tire).
2. Place the handcycle and alignment gauge on a flat surface.
3. Position the alignment gauge near the rear of the rear tires.
4. Loosen the height adjustment screw.
5. Raise/lower the alignment bar so the bar is approximately 12 inches from the
ground/floor.
6. Tighten the height adjustment screw.
7. Loosen the alignment screw.
8. Position the alignment gauge between the rear of the rear tires.
9. Adjust the alignment bar so the alignment gauge fits snugly between the rear of the
rear tires.
10. Tighten the alignment screw to secure the alignment bar position.
11. Position the alignment gauge at the front of the rear tires.
12. Examine the gauge. Perform one of the following:
A. Alignment Gauge Fits Snugly Between the Front of the Rear Tires ‐ Wheels are
aligned. No toe in/toe out adjustment is needed.
B. There is Extra Space Between the Alignment Gauge and Rear Tires ‐ The tires have
a toe out condition. Refer to Adjusting Toe In/Toe Out on page 45.
C. Alignment Gauge Does Not Fit Between Rear Tires ‐ The tires have a toe in
Front of Handcycle
Alignment Gauge
Alignment Bar
Rear Tires
Alignment Screw
Front Measurement
Rear Measurement
Height Alignment
Screw
Rear of Handcycle
74
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LIMITED WARRANTY
LIMITED WARRANTY
PLEASE NOTE: THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH
FEDERAL LAW APPLICABLE TO PRODUCTS MANUFACTURED AFTER JULY 4, 1975.
This warranty is extended only to the original purchaser/user of our products.
This warranty gives you specific legal rights and you may also have other legal rights which vary
from state to state.
Invacare warrants the frame to be free from defects in materials and workmanship for a period
of three years from date of purchase; distributed parts and components including
compensators, forks, upholstery and miscellaneous bicycle components are warranted for a
period of one year from the date of purchase; except all tires, tubes, push handles grips, foam
parts, plastic coated parts, bushings, bearings and cables which are not warranted. The
Mountain Drive Option is not warranted. If within such warranty period any such product shall
be proven to be defective, such product shall be repaired or replaced, at Invacare's option. This
warranty does not include any labor or shipping charges incurred in replacement part
installation or repair of any such product. Invacare's sole obligation and your exclusive remedy
under this warranty shall be limited to such repair and/or replacemenT.
This warranty pertains to the Top End Series Only!
For warranty service, please contact the dealer from whom you purchased your Invacare
product. In the event you do not receive satisfactory warranty service, please write directly to
Invacare at the address at the bottom of the back cover. Provide dealer’s name, address, date
of purchase, indicate nature of the defect and, if the product is serialized, indicate the serial
number. DO NOT return products to our factory without our prior consent.
LIMITATIONS AND EXCLUSIONS: THE FOREGOING WARRANTY SHALL NOT APPLY
TO SERIAL NUMBERED PRODUCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR
DEFACED, PRODUCTS SUBJECTED TO NEGLIGENCE, ACCIDENT, IMPROPER
OPERATION, MAINTENANCE OR STORAGE, COMMERCIAL OR INSTITUTIONAL USE,
PRODUCTS MODIFIED WITHOUT INVACARE'S EXPRESS WRITTEN CONSENT
INCLUDING, BUT NOT LIMITED TO, MODIFICATION THROUGH THE USE OF
UNAUTHORIZED PARTS OR ATTACHMENTS; PRODUCTS DAMAGED BY REASON OF
REPAIRS MADE TO ANY COMPONENT WITHOUT THE SPECIFIC CONSENT OF
INVACARE, OR TO A PRODUCT DAMAGED BY CIRCUMSTANCES BEYOND INVACARE'S
CONTROL, AND SUCH EVALUATION WILL BE SOLELY DETERMINED BY INVACARE.
THE WARRANTY SHALL NOT APPLY TO PROBLEMS ARISING FROM NORMAL WEAR
OR FAILURE TO ADHERE TO THESE INSTRUCTIONS.
THE FOREGOING EXPRESS WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY OTHER
WARRANTIES WHATSOEVER, WHETHER EXPRESS OR IMPLIED, INCLUDING THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, AND THE SOLE REMEDY FOR VIOLATIONS OF ANY WARRANTY
WHATSOEVER, SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF THE DEFECTIVE
PRODUCT PURSUANT TO THE TERMS CONTAINED HEREIN. THE APPLICATION OF
ANY IMPLIED WARRANTY WHATSOEVER SHALL NOT EXTEND BEYOND THE
DURATION OF THE EXPRESS WARRANTY PROVIDED HEREIN. INVACARE SHALL NOT
BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES WHATSOEVER.
THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH STATE/PROVINCIAL
LAWS AND REQUIREMENTS.
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Invacare Corporation
USA
Canada
One Invacare Way
Elyria, Ohio USA
44036-2125
570 Matheson Blvd E Unit 8 All rights reserved. Trademarks are
Mississauga Ontario
L4Z 4G4 Canada
800-668-5324
identified by the symbols ™ and ®. All
trademarks are owned by or licensed to
Invacare Corporation unless otherwise
noted.
800-333-6900
Shimano, Nexus, and Ultegra are
registered trademarks of Shimano Inc.
3-in-1 and WD-40 are registered
trademarks of the WD-40 Company.
Delrin and Teflon are registered
trademarks of E.I. DuPont De Nemours
and Company.
Loctite 242 is a trademark of the Loctite
Corporation.
© 2007 Invacare Corporation
Part No 1114850
Rev D- 07/07
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