Hobie MAX RACE User manual

1
ASSEMBLY MANUAL
Last up-date : January 2005
HOBIE MAX RACE

2
Necessary tools
⇒ 2 spanners nr 17
⇒ 1 pair of niversal pliers
It is advisable to be at least two people to
assemble the Hobie Max
List of the parts
LIST OF THE PARTS
⇒ 2 hulls
⇒ 1 front crossbar with self-tacking jib
tracak
⇒ 1 rear crossbar (trampoline lacing
posts)
⇒ 1 Mast
⇒ 1 Boom
⇒ 1 one-piece trampoline with vectra
line + fibreglas rod
⇒ 1 part bag (wires)
⇒ 1 rigging bag
⇒ 1 ropes bag
⇒ 2 Rudder assemblies
⇒ 1 Tiller crossbar
⇒ 1 Tiller extension
⇒ 1 mainsail + battens (7)
⇒ 1 jib
⇒ 1 trumpet spi kit (composed of one
asymmetrical spinnaker, one
polyester trumpet, one spi bag, one
rigging kit + ropes)
CAUTION - DANGER
ALUMINIUM MAST - STAY AWAY
OF ELECTRICAL WIRES
TABLE OF CONTENT
List of the parts..............................2
Hull assembly................................5
Trampoline.................................6-7
Rudders, tiller and tiller extension.8
Preparation of the mast.................9
Spreader .....................................10
Mast assembly............................11
Stepping the mast.......................12
Trapezes.....................................13
Boom...........................................14
Mainsail.......................................15
Cunningham................................16
Jib................................................17
Jib self tacking system ...............18
Jib car control..............................19
Mainsheet...............................20-21
Spinnaker kit ...............................22

3
List of the parts
1 2 3 4
5 6
1
2
3 4 5
6
7
8
9
WIRES :
1. Shrouds
2. Bridles
3. Forestay + pigtail
4. Trapeze cable crew
5. Trapeze cable skipper
6. Rigid forestay
7. Kit trapeze handles skipper
8. Kit trapeze handles crew
9. Spreader wires
ROPES :
All ropes are labelled with ref.
number and name. Please check
carefully before using.
1. Mainsheet
2. Righting lline
3. Cunningham line (red)
4. Jib halyard
5. Jib line
6. Rotation line
Trumpet spi kit
1. Spinnaker sheet
2. Spinnaker halyard
3. Tack line
4. Pole fixation line
5. Trampoline rig
6. Trumpet screw
7. Single block for spi head
8. Sister block
9. Shackle 4 mm
10.& 11 2 pole blocks + 2 plastic springs + 2
shackles 6 mm.
1 2 3
4
5
6
7
8 9
10 11

4
List of the parts
Rigging bag
All pieces are labelled with name and reference number. Please carefully check the labels.
1. Spreader bars
2. Stay adjuster
3. Cunningham cam cleat (at tge mast base)
4. Heart block
5. Hull plugs
6. Shroud anchor bars and stay adjusters
7. Mainsheet fourfold block
8. Mainsheet threefold block
9. Silicone
10. Stop balls and hull screw caps
11. Shackles
12. Gooseneck vertex with pin and split ring
1
2
3
4
5
6
7
8
9 10
11
12

5
Fix the pole to the middle of the front crossbar
Hull Assembly
Position the hulls in parallel with the
inner sides fa-cing the ground.Lift
the right hull. One person straddles
the hull tohold it in place. The other
person applies the siliconesealant
(for waterproofing) around the screw
holes.
1
Take the front crossbar (with
dolphin striker). Place itin its
support so that the trampoline
track faces therear of the boat.
Insert the two bolts. Pass
yourhand through the inspection
port to position the nutsand
washers onto the screws photo).
2
Fasten loosely.
Apply silicone sealant around the screw holes at
theback of the hulls. Place the rear crossbar on the
rightside. Insert the bolts, washers and nuts as
shownfor the front crossbar. Do the same thing for
the leftside.Once the frame has been mounted,
tighten all thebolts fully and then install the lock nuts.
3
and place the other end on the
ground.
It is advisable to check the fastening of the
4
Do not forget to put the plugs before sailing. On
land take the plugs off to drain the water.

6
Unfold the trampoline. Note that the trampoline has side tension lines that are already pre-threaded.
Insert the front edge of the trampoline into the track at the left, rear side of the front crossbar. Continue
feeding the trampoline into the track and position it in the center. line up the grommet in the center of the
trampoline with the dolphin striker post to ensure it is centered.
Take one of the side tensioning lines and pass the line
through the pad-eye that is fixed to the front crossbar.
Then tie with a bowline knot the line onto the grommet of
the trampoline near where the rope exits the trampoline.
Repeat this step at the opposite side front corner.
Trampoline
1
2
Move to the rear of the trampoline. Very closely to where
the side tensioning line exits the rear of the trampoline tie
a loop. ensure you pull the side tensioning line firmly as to
tie the loop as closely to the trampoline where the rope
exits as possible. Tie a bowline or a similar loop in the
line which will be used for a 4:1 purchase of the side
tensioning lines. Repeat this step for the opposite side
rear corner.
Now take the tale of the side
tensioning line and pass the
rope through the pad-eye
mounted on the rear cross beam
closest to where the line exits
the trampoline. Then pass the
line back through the loop tied in
step3. Again go through the
pad-eye on the beam and back
through the loop. This will
provide a 4:1 purchase. Pull the
line slightly as to take some tension for the sides but do not
completely tension at this stage. Repeat this step for the opposite
side rear corner. Ensure that the trampoline is still centered.
3
4

7
Trampoline
Again, take the side tensioning line and very
firmly pull the line. Once as tight as possible tie
off the line with an adequate knot. Repeat this
for the opposite side rear corner.
7
NB : It is important that the trampoline be strongly tightened.
Check the tension on a regular basis.
Find the trampoline rod and insert it
into the rear of the trampoline.
Commence lacing the rear of the
trampoline. The lacing line starts at the
left, rear lacing button on the rear
crossbar. Lace the rear of the
trampoline as tightly as possible as per
the photographs and diagrams
supplied. Continue across the rear
crossbar and tie off securely when
Début
5
6
Now, once the side tension line has
been tied off, using the long tail, pass it
back through the grommet at the rear
corner of the trampoline near where the side
tensioning line exits the trampoline. Then pass
the line through the pad-eye on the rear
crossbar. Again pass the tail through the
grommet on the trampoline and pull the line
firmly. Once the sides of the trampoline have
been further tightened, tie off the line and hide
the tail under the trampoline. Repeat this step
for the opposite side rear corner.
8

8
RUDDER
Identify the right rudder from the left rudder (green
sticker = right ; red sticker = left) As shown on the
picture, align the holes of the rudder castings onto
the gudgeons.
1
Rudder assembly Tiller bar
& Tiller extension
Insert the pin that is linked to the lower gudgeon in
order to ensure the rudders. This pin will avoid the
rudders to jump out of the gudgeons in case of
capsizing.
2
TILLER BAR
Take the tiller crossbar and insert the right
side into the right rudder arm and the left side
into the left rudder arm.
3
TILLER EXTENSION
Take the yoke connection of the tiller extension and fix
it into the middle of the tiller crossbar .
Then fix the tiller head into the yoke
connection as shown on the picture.
4
5

9
Mast set-up
Place the mast onto two supports (eg: two pieces of
polystyrene).
Unroll all the cables and fix them using a shackle to
the lower hole on the mast tang as shown on the
drawing.
1
NOTA : The spectra wires of the crew trapeze are
knotted on the shroud wires and the spectra wires of
the skipper’ trapeze are inserted directly in the
shackle pin.
2
Link the big stay adjuster to the forestay.
3
IMPORTANT : Do not forget to attach the jib
halyard rope to the small single block at the
end of the pigtail. Tie off the two ends of the
jib halyard near the base of the mast.
4
Spinnaker kit :
Attach the halyard block to the shackle on the upper part
of the mast. Insert the spi halyard in the block sheave as
shown on the picture.
5
1- Shrouds
2 - Crew trapeze
3 - Skipper trapeze
4 - Forestay and pigtail
1
2
3
4

10
Spreader bars
Slide the diamond Wires into the corresponding slots at
the end of the spreaders. Ensure the black plastic roller
is above the spreader arm. It may be necessary to
release tension from the diamond wire turnbuckle
adjuster near the base of the mast. Secure the
diamond wire with the thin wire supplied. Pass the wire
through the small hole near the spreader tip, bend the
wire and on one side of the spreader turn the wire
around the thicker diamond wires two or three times.
Do the same for the other side of the spreader. Cut off
the excess thin wire ensuring it is bent neatly onto the
diamond wires as to prevent the wire from tearing the
sails. Once secured, tape over the spreader tips to
further ensure there are no sharp edges.
Unroll the diamond wires.
Attach the joint end of the
diamond wires onto the
turnbuckle adjuster near the
base of the mast (level with the
security sticker) using the pin
and split ring.
Take the loose ends of the
diamond wires and hold tight to
adjust to the same length, using
the turnbuckle adjuster which is
located on the lower section of
one of the wires. Once they are
the same length, attach the two
wires to the shield plaes
situated on each side of the
mast under the mast tang.
3
1
Assemble the spreaders on the
centre of the mast. The spreader
root attaches to the front of the mast
section onto the one-piece stainless
steel strap. The spreader rake
adjuster barrel attaches on each
side to the individual fittings on both
sides of the mast nearer the sail
track. To adjust the spreader rake,
adjust the length of the barrel (by
winding in or out) and measure from
the wire positions at the tips of each
spreader.
Caution : do not try to adjust
spreader rake while diamond wires
are tensioned. Only adjust under no
diamond wire tension and screwing
the barrel by hand.
2