1. General Safety Information. Silvio V2.2 Assembly Instructions Assembly. Adjust to the rider.
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1 Silvio V. Assembly Instructions General Safety Information WARNING to avoid serious injuries:. If you are unsure about fitting, testing and adjusting brakes or gearing on a bicycle, you should take your bicycle to a professional bicycle mechanic for adjustment. Improperly adjusted brakes or drivetrain components could cause severe injury or death.. If you are unsure of the frame assembly instructions, you should take your bicycle to a professional bicycle mechanic for assembly. An improperly assembled frame could cause severe injury or death.. After adjusting the position of the crank to fit the rider, ensure the front (flexible) chainstay is straight, not held in a curved position. An improperly adjusted frame could be damaged by riding and cause severe injury or death. Assembly This instruction set describes the assembly sequence but there may be minor differences in specification of your model. Preassembled steps are printed in grey. Thank you for purchasing your new Silvio. You have one of the most beautiful, innovative, advanced and safe bicycle designs ever developed. Beutiful in its single mainframe hydroformed tube design. Innovative in its front-wheel direct-drive system. Advanced in allowing full body engagement with the frame like no other recumbent format, letting you put your heart and soul into the ride. Safe in its outstanding braking performance, in preventing back and soft tissue injuries as well as lessening the chance of head and collar bone injuries. On this bike, you will perform as you never have before. Ride well, ride safe! John Tolhurst Design Director, Cruzbike Inc. SilvioAssemblyNotesV.0 Adjust to the rider Adjust to the rider, before fitting brake and gear cables. Sight along the Front Chainstay to verify that it is straight, not held in a curved position. Important! Adding components Adding components is done to component manufacturer s instructions. This document does not describe how to fit components, however the Silvio frame provides standard mounting points for standard road bike components. Adding components can be easier if you have a bike workstand and the best place to clamp the frame is on the slider tube. Silvio Assembly Manual Page
2 . Preparation These are the instructions for Silvio edition. and contain minor updates on headrest mounting from Silvio.0. Attend to the following before commencing assembly: Unpack the items and unwrap them, except for tube protection which may be retained until the bicycle is ready to be ridden. Identify the headset bearings, (do not unpack them yet). Identify the frameset is complete, by reference to the parts diagrams on this and the following pages. If you do not have all the parts, stop and contact and provide the part number. Obtain a set of metric hex head wrenchs (also known as allen keys) in sizes 5mm, 4mm, mm and.5mm. Avoid overtightening bolts, hold the allen key in your fingers. If this document has been printed, greater detail may be visible by downloading the manual from cruzbike and zooming in. Go to cruzbike.com/silvio 5 4 ITEM NO. PART NUMBER QTY. Main Frame Rear Triangle Seat Pan 4 Seat Back 5 Headrest tube Headrest Cushion If the details of Aheadsets are new to you, two of many useful links explaining them are Sheldon Brown s authoritative glossary and this general description with diagrams that describe the Integrated Headset as found on Silvio. Silvio Assembly Manual Page
3 . Fit the Headrest Identification Identify the following parts: H Headrest Headrest Cushion Scissor Jacks assembly fitted within the Main Frame H Main Frame To insert the headrest legs inside the end of the Main Frame: Screw the scisso jack assembly bolts nearly all the way out. Slowly insert the headrest legs inside the endn of the Main Frame - push the scissor jack bolt heads in, use your fingers in the first hole to squeeze the jacks to allow the headrest tubes to pass. Keep inserting the headrest and squeezing the jack assembly as you go until it is past the second set of jacks. Tighten the bolts which will raise the jacks to apply outward pressure to the headrest tube and snugly secure it. Do not overtighten the jacks. Apply small pieces of velcro hook to the inside of the upper curve of the headrest tubes. This connects with velcro on the inside of the headrest cushion. SECTION H-H Fit the headrest cushion over the headrest and secure the velcro. ITEM NO. PART NUMBER QTY. ISO 0 - M5 x 5 Barrel Nut Wing 4 Silvio Assembly Manual Page
4 4. Prepare the Rear Triangle 0 Connect the stays together Bolt the Rear Stay to the Seat Stay with the raised areas of the Rear Stay facing up. Add the Suspension Link Bolt the Suspension Link to the top of the Seat Stay using the Seat Stay Link Plate 4 and four bolts. Place Link Buffer 0 between the Suspension Link and the Seat Stay Next Step The remaining plate, buffer and bolts are used on the next step. 9 ITEM NO. PART NUMBER QTY. Rear Stay Seat Stay Ti Link 4 Seat Stay Link Plate 5 Frame Link Plate ISO 0 - M5 x --- C CS Washer CS Bolt Male 9 CS Bolt Female 0 Link Buffer Silvio Assembly Manual Page 4
5 5. Fit the Rear Triangle to the Frame Wrap the Suspension Link in a shop rag to protect the frame paint.. Slide the Rear Stay to the Frame Slide the head of the Rear Stay into the mounting slot on the Frame, checking that the Suspension Link aligns with the Frame, then fit CS bolts. Tap the head of the Rear Stay into the slot with a rubber mallet, or protect it with cloth and use a piece of wood.. Fit the Suspension Link Place Link Buffer between the Suspension Link and the Frame. Bolt the Suspension Link to the Frame with the Frame Link Plate and four bolts. Rear Brake Warning The rear brake mounts to the forward side of the seat stays. Normally it mounts to the rear of the rear stays. Therefore the rear brake pads must be removed and swapped left to right. Make sure the retaining bolt on the brake pad housing is on the end that points backwards. When running disk brakes, run the brake cable over the brake bridge, fix with a cable tie as necessary. Silvio Assembly Manual Page 5
6 . Fit the Fork Note: Instead of a stem, Silvio uses its Pivot Clamp () to clamp the headstack. Note that a surplus star nut may be included in the headset bearings, however a star nut has already been pressed into the fork steerer. Fit the fork to the frame Assemble the bearing stack as follows: ) Place the lower stack onto the fork steerer ) Slide fork steerer into the frame ) Add top stack to the fork steerer (Tip: the dust seal is tight to go on, so lubricate the inside) 4) Add the Steering Spacer (4) to the fork steerer 5) Add the Pivot Clamp to the fork steerer ) Check the Pivot Clamp sits at least mm higher than the steerer ) Add the Steering Cap (5) and and tighten it down. Tighten the Steering Cap Bolt (), ensuring you can still rotate the Pivot Clamp, as you will need to align this with the front triangle. Make the two Pivot Clamp bolts finger tight. Front Suspension Adjustment Connect the shock pump to valve on the rear of the fork crown and adjust to 50psi, working range is 40 to 00psi. For detailed instructions on how to use the shock pump, see KindShockPumpOperation.pdf ITEM NO. PART NUMBER QTY. Pivot clamp Steering Cap Bolt Integrated Headset 4 Steering Spacer 5 Steering Cap 4 5 Top stack: Dust seal Thin washer Gold split ring Upper bearing Lower stack: Lower bearing Silver split ring Silvio Assembly Manual Page
7 . Assemble Chainstay & Boom Fit Chainstay to BB Clamp If you are fitting a Chainstay Extension (), attach it now to the Carboyoke Chainstay (). Slide the head of the Chainstay () into the slot on the BB Clamp () with holes aligned and with the raised areas of the Chainstay facing up, and fit the CS Bolts (,, 9). Fit Boom to the BB Clamps First, you must obtain the outboard bottom bracket bearing cups (0). These will come typically with your crankset. Important! First, position the end of the Boom ()between the rings of the BB Clamp. Thread the bottom bracket bearing cups (0) in each side, working through the rings of the BB Clamp. Slide the BB Clamp over to the right to tighten the left bearing cup. And vice versa. Tighten the bearing cups to manufacturer s specification. Make the BB Clamp bolts finger tight only. Back each bolt off half a turn. Important - this must be allowed to rotate when setting leg length! (Fully tighten the BB Clamp bolts after sizing adjustment.) Fit Dropouts to Chainstay Fit the CS Dropout Left and Right (4, 5) over the ends of the Chainstay and fit the CS Bolts. The RD hanger () sits inside the right Chainstay dropout, and is a press fit, which will become i ncreasing tight with the action of the hub quick release. Silvio Assembly Manual Page ITEM NO. PART NUMBER QTY. Carboyoke Chainstay BB Clamp Boom 4 CS Dropout Left 5 CS Dropout Right RD Hanger CS Bolt Male CS Bolt Female 9 CS Washer 0 Bearing cups CS Extension (optional) 9 5
8 . Fit the Front Triangle Fit Slider to Pivot Clamp Insert the Slider Clamp (5) over the Slider Body () with the cable adjustor to the left side of the bike. Rotate the slider so the slot in the end and the bottle cage mount holes are facing downwards. Connect the Slider Clamp to the Pivot Clamp using the through pin. Add the Boom Clamp () to the end of the Slider. Then fit Boom & Chainstay 4 5 ITEM NO. PART NUMBER QTY. Slider Body Head Badge Handlebar clamp A 4 socket head cap screw 4 5 Slider clamp TL-0 Screw TL-0 Nut Boom clamp 9 socket head cap screw Insert the Boom into the Slider and place the dropouts over the lugs on the fork dropouts. Insert the DR hanger in between the fork and the Chainstay dropout - or retain until component assembly. Tighten: BB Clamp The Headset Cap bolt Pivot Clamp bolts Slider Clamp Boom Clamp Handlebar The handlebar fits to the top of the slider with two clamps () and four bolts (4). Important: Tighten the two Pivot Clamp bolts after the front triangle is added. Finishing touch 9 Optionally place headbadge in the traditional head tube location Note: The RD hanger will click fit into the chainstay dropout. After tightening the wheel skewer, the hanger will be very difficult to remove. Apply the Headbadge () to the headtube. Silvio Assembly Manual Page
9 9. Fit the seat Fit the Seat Shells The Main Frame comes with Velcro, as does the underside of the Seat. Bolt the seat pan and seat back together with the M4 bolts provided (, ). Place the seat pan and fit the two M5 bolts (9, 0) to the small wings of the frame. Then lay the seat down on the frame and press to engage the velcro. You can postpone mounting the HR Clamps (4, 5, ) that hold the seat to the headrest until after you are comfortable with the headrest adjustment, because being able to lift the seat makes it easier to adjust. Fit the Cushions Stick the velcro strips to the Seat Back and Seat Pan. Center to center distance for velcro on the seat pan is 4 cm and on the seat back is cm. 9 9 Suspension Block Screw the suspension Preload Adjustor () into the suspension tube on the underside of the mainframe. Screw from the underside of the frame until it is about.5 cm below the top of the frame. Insert the Elastomer block () into the suspension tube. Hold the Elastomer Mount () in place temporarily with a piece of tape ITEM NO. PART NUMBER QTY. Elastomer Mount Elastomer Preload Adjustor 4 HR Clamp 5 ISO 0 - M5 x C Nut M5 4 Nut M4 Screw M4 9 Screw M5 Silvio Assembly Manual Page 9
10 0. Components & Adjustment FD cable loop The front derailleur cable housing should feed into the cable stop on the FD stalk, then loop around the cable roller and connect to the FD. A barrel adjuster can be used in this cable stop, or on the threaded hole provided on the Slider Clamp. Disk Brake Rotor sizes Front 0mm* to 0mm Rear 40mm* to 0mm *Recommended Standard component assembly Adjust to the rider before running the cables. Important! If the wheel axles don t easily fit the dropouts, use a file to remove excess paint. All components should be assembled according to their manufacturer's instructions. Use a Mirror. Important! Using a stand If using a stand, place the clamp around the Slider, between the Slider Clamp and Boom Clamp, with the front of the bike up so that the back of the bike hangs down and does not swing. Gear Housing Loop over roller Cable to deraileur First, loosen the ring clamps and the skewer. Important! Loosen the boom clamp and adjust to create knee clearance; retighten. Loosen the slider clamp and pull slider so that the heal of an outstretched leg rests on the pedal; retighten. Note: Chainstay must be straight after adjustment. Important! Cable to shifter Barrel adjustor location A Optional cable adjuster position for either deraileur (recommended only after fully dialing in all adjustments). Rider adjustment For adjustment to the individual for arm reach and leg reach, the following are loosened and tightened as required: Ring Clamps Front wheel skewer Slider Clamp Boom Clamp Then retighten. Knee clearance Sitting on a chair, measure from the floor to the top of your knee (say 5 cm). Add your crank length (say cm) to this (5cm). Add 5cm for knee clearance (0cm) Adjust the boom clamp [] to make distance A. = 0cm. From now, adjust leg distance using the Slider clamp []. In this way both hand and leg distance move together, keeping the hands as far forward as practical. Any further and adjustments at the slider clamp [] will adjust leg length but won t affect the front derailleur adjustment. Fine tuning leg and arm reach adjustment can occur as the rider gains familiarity. Silvio Assembly Manual Page 0
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