Ice ICE B1 2008 Quick start guide

Inspired Cycle Engineering Ltd
2 0 0 8
I C E B 1
STEP-BY-STEP
ASSEMBLY INSTRUCTIONS
and
OWNERS MANUAL

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1.0 Introduction.
Congratulations on being a new ICE B1 owner. You have purchased one of the finest, most refined recumbent
bicycle available today; we hope it brings you many years of enjoyment.
This manual has been written to help you set up and use your bike. Recumbent bikes may be a little different
from the cycles you are familiar with, so please take a moment to read through this document. You will find the
latest version of this manual in a download-able PDF format on our website.
Throughout the manual, we have included some Tips, which have been learned from over 20 years of experience
building cycles. They are well worth taking special note of.
We hope you enjoy owning and riding your ICE B1 as much as we like making these great machines.
The ICE team
1.0 Introduction...........................................................................................2
1.1 Overview............................................................................................4
2.0 Assembling your ICE B1 ..........................................................................5
2.1 Unpacking...........................................................................................6
2.2 Fit the brake rotors and wheels..............................................................8
2.3 Adjusting the disc brakes......................................................................8
2.4a Assembling the seat – mesh seat..........................................................9
2.4b Assembling the seat – hard-shell seat ................................................. 10
2.5 Fit the seat .......................................................................................10
2.6 Fit the chainset..................................................................................11
2.7 Fit the pedals .................................................................................... 12
2.8 Adjust the seat angle..........................................................................12
2.9 Set the front boom.............................................................................12
2.10 Set the handlebars...........................................................................12
2.11 Install the front derailleur..................................................................13
2.12 Install and connect the rear derailleur.................................................14
2.13 Check the gear shifting .....................................................................19
2.14 Reflectors and bell............................................................................20
2.15 Check nuts and bolts ........................................................................ 20
3.0 Adjusting your ICE B1 ...........................................................................21
3.1 Tyre pressure....................................................................................21
3.2a Mesh seat cover...............................................................................21
3.2b Fitting the hard-shell seat to you........................................................21
3.3 Suspension adjustment....................................................................... 21
3.4 Seat angle adjustment........................................................................22
3.5 Leg length ........................................................................................ 22
4.0 ICE Optional Accessories........................................................................23
4.1 Lights...............................................................................................23
4.2 Extra water bottle mount ....................................................................23
4.3 Fitting Radical bags............................................................................24
4.4 Fitting the Wrap-around Handlebars ..................................................... 25
4.5 Fitting a Rohloff.................................................................................25
5.0 Riding your ICE B1................................................................................26
5.1 Getting on and off the bike..................................................................26
5.2 Initial test ride................................................................................... 26
5.3 Stopping in a low gear........................................................................ 26
5.4 Relax ...............................................................................................26
5.5 Cornering ......................................................................................... 27
5.6 Handling........................................................................................... 27
5.7 Brakes..............................................................................................27
5.8 Hill climbing...................................................................................... 27

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5.9 Descending a hill ...............................................................................27
5.10 Muscles ..........................................................................................27
5.11 Folding and unfolding the bike ...........................................................28
6.0 Maintenance ........................................................................................29
6.1 Lubrication........................................................................................ 29
6.2 Adjusting cables ................................................................................29
6.3 Disc brakes.......................................................................................29
6.4 Drivetrain .........................................................................................30
6.5 The frame.........................................................................................30
6.6 Tyres, tubes, & wheels .......................................................................31
6.7 Suspension .......................................................................................31
6.8 Storage ............................................................................................ 31
6.9 Serial Number ................................................................................... 32
6.10 Recommended minimum tools and spares ........................................... 32
7.0 Safety.................................................................................................33
8.0 Other Important Information..................................................................34
8.1 Recumbent/Bike forums on the Internet................................................34
8.2 Warranty Information......................................................................... 35
8.3 Liability Information ........................................................................... 35
8.4 Legal requirements ............................................................................35
8.5 Contacting us....................................................................................36
Appendix A: Tightening torques ...................................................................37
Appendix B: Elastomer limits ....................................................................... 38
Appendix C: Tyre Pressures.........................................................................38

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1.1 Overview

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2.0 Assembling your ICE B1
Assembly tools required:
3mm Hex Key Bicycle pump
4mm Hex Key 8mm wrench
5mm Hex Key 10mm wrench
6mm Hex Key 15mm wrench
8mm Hex Key Chain link remover
T25 torx Key Sharp knife
Cable cutter Small screwdriver
TIP – You will find it much easier to assemble the bike if you can
work on a bench or a table at waist height; this avoids too much
bending down. If you have to work on the ground, put down
some newspaper to avoid the chain, which is protected by
grease, from picking up dirt
Your bike has been assembled at our works and then partially disassembled and wrapped for safe and economic
shipment. First of all, open the box, unwrap and lay out the pieces.
You should have all the items in the enclosed packing list, as well as any accessories you have ordered.
Assembling your bike is quite simple, even if you have never done any bicycle assembly/work before. If you’re
uncertain about the work, any decent bike shop will be able to follow these instructions to assemble it for you.
It is a fairly short job to put your bike together, but don’t be tempted to rush through;
When assembling your bike, please refer to the table in the appendix for the proper tightening torques for all
fasteners. Do not over-tighten.
Adjusting and Closing Quick-releases
Open Closed
Quick-releases are used in a number of places on your bike; it is important that they are tightened correctly.
A quick-release that isn’t fully and properly closed can result in parts coming loose or moving while riding. This
could cause a serious accident.
A quick-release system consists of two basic parts: a lever that provides the clamping force and an adjusting nut
that alters the clamping tension.
With the part you are clamping located properly, adjust the quick-release by opening it, holding both ends and
turning one clockwise until, when you close the lever, you feel some resistance. At this point, try to close the
lever fully. The adjustment is correct when you can fully close the lever,but with some effort (the lever should
leave its impression in the palm of your hand). If you can only close the lever part way, open it, unscrew the
adjusting nut slightly and try again. If it closes too easily, tighten it up a tiny bit and try again. Do not try to
tighten the quick-release by winding the lever around; it will not tighten enough to be safe.
Right…… let’s begin assembly!

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2.1 Unpacking
Carefully unpack the contents of the box and inspect for any damage that may have occurred during shipping.
You should be able to unpack your bike without resorting to a knife; if you use one, be careful not to cut through
the parts or to mark the paintwork. Have a good look at the various packages and familiarize yourself with the
various parts. In addition to the main components shown below, there are other small packages of parts. Don’t
open them just yet; leave them sealed until you need them.
Main frame with assembled
rear section, and
handlebars
Chainset
Front Boom
Front Wheel and
Rear Wheel

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Rear and Front Derailleurs
Brake Rotors and Chain
Seat Mount
and fixing clips and quick
releases
Seat Cover and Frame
(mesh seat models)
Seat and Cover
(hard-shell seat models)

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2.2 Fit the brake rotors and wheels
First, the disc brake rotors must be mounted on the hub.
Place the disc rotor on the hub mounting surface. Be sure
that the arrow on the disc is pointing in the same direction
of the forward wheel rotation (the rotor is mounted on the
left side of the front wheel. Using a Torx T25 driver, install
then tighten the bolts to a torque of 6-7 Nm (4.5-5 ft-lbs).
Note: the bolts have what appears to be paint on their
threads. This is threadlocking adhesive, and it must not be
removed. If you remove and replace the rotor bolts, they
must be held in place with Loctite 243 Threadlocker or
equivalent.
Unclip the quick-release from the spokes of the front wheel and thread it through the centre of the axle. The
lever should be on the same side as the brake disc. Slip the front wheel into the fork, and tighten the quick
release. Be certain that the wheel is sitting fully into the dropouts, as this can affect the brake adjustment if it
isn’t.
Unclip the quick-release from the spokes of the rear wheel and thread it through the centre of the axle. The
lever should be on the side opposite the gears, on the same side as the brake disc. Fit the rear wheel to the rear
swingarm. You may find this easier if the Velcro restraining strap on the swingarm is fastened around the rear
section main tube.
2.3 Adjusting the disc brakes.
First, hook the Brake cables into the brake levers and connect the inner cable to the caliper actuation arm. The
brake calipers are already installed on the front and rear of your bicycle.
To adjust the calipers:
•To align the caliper, first turn the inboard (closest to the wheel) adjusting knob clockwise until it pushes the
rotor into the position shown. Note that the rotor should not be centred between the walls of the caliper
body.
•Turn the outboard pad adjustment knob until it is firmly squeezing the rotor against the inboard pad.
•The rotor should be offset to the outboard side of the rotor slot. The ideal ratio is 1/3 to 2/3.
•Tighten the two CPS bolts to the specified torque (10Nm)
•Turn both pad adjustment knobs counter clockwise until the pads clear the rotor (approx. 2 or 3 clicks), and
check that the wheels spin freely (without dragging)
Now sit down and read the instruction booklet that came with your brakes.
Warning: If you are not confident of installing your brakes
correctly, we strongly recommended that you have a
competent cycle mechanic install your disc brake system.

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2.4a Assembling the seat – mesh seat
Find the seat frame and the bag with the seat cover in it.
Unfold the cover and identify which is the top, the
bottom, the front and the back. The top can be
identified by the cut-out just below a single strap. The
front can be identified by the wide smooth strips of fabric
running down the length of the cover, these should end
up on the inside touching a frame.
Before you begin assembly, locate the O-rings in the
cover pack. Each O-ring needs to be slipped onto a
strap on the cover, and pushed 8" (200mm) or more
down the strap. These O-rings are used to hold down
the loose tails of the straps after the seat has been
assembled.
Aligning the top of the cover with the top of the seat
frame, place the back of the cover against the frame.
Thread the top strap through the top buckle, and pull
snug. Thread the next strap down through its
corresponding buckle and pull snug. Make sure the seat
cover is centred on the seat frame and the top of the
cover is not to high or low. Work your way down the
seat frame, fastening up the straps snugly as you go.
Tight Loose
When you reach the bottom, check the cover for a
smooth, symmetrical fit. When you are happy with the
appearance of the seat, tighten the bottom 5 straps so
they are tight. If you’re got the optional seat foam, push
it between the seat bottom and the 5 bottom straps
before tightening. The rest of the straps can be adjusted
to your preference after you sit on the bike. A good
starting point is to slack off each strap in turn, and
retighten, pulling the strap gently between your thumb
and forefinger. Be careful about over-tightening the
straps on the back of the seat; too loose is more
comfortable than too tight. When all the straps are
adjusted, tuck the loose tails into the O-rings so they
don’t flap about.

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2.4b Assembling the seat – hard-shell seat
The hard-shell seat is supplied with 2 seat mounting
brackets, which have to be fastened to the seat. The
lower bracket is the wider one, and fastens
underneath through the pre-drilled holes. The upper
bracket is narrower, and should be mounted in the
lower position. The upper position should not be
used.
The flag mount bracket consists of 2 metal clips and a
short length of stainless steel tubing with one end
partially closed. The flag mount is positioned on the
back of the seat as shown in the photograph, with the
closed end facing down.
To install the breathable cover, remove the protection from the Double Faced Tape and stick the cover to the
seat.
2.5 Fit the seat
The seat is provided with 4 plastic SP-6 clamps. Two of these
clamps go around the bottom seat rail, and the other 2 go around
the top rail on the hard-shell seat or the 3rd rail (counting from the
bottom) on the mesh seat.
The 2 clips that go around the bottom rail are provided with quick-
release clamps. Place the clips on the bottom rail as shown in the
picture below, and then screw the quick-release into the clip. Do not
forget the small plastic spacer; the quick-release will not work
reliably without it.
The 2 clips that go on the upper rail are provided with M5 fasteners;
quick-releases are not necessary as the seat mount is held to the
frame with a quick-release. Clip the SP-6 clamps to the rail and
thread the bolts into place.

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Set the 5 position upper seat mount in
the lowest position (see photo). There
is a quick-release skewer that goes
through the front hole on the top of the
rear section. Place the seat onto the
bike and fasten in place with the 4
plastic clips supplied (quick-release clips
on the bottom, and bolted clips on the
top) and then tighten the 2 lower quick-
releases. Tighten the upper seat mount
quick-release, and then tighten the 2
upper plastic clip bolts.
2.6 Fit the chainset
You now need to install the left and right sides of the chainset. Your bike is supplied with the bottom bracket
already installed. It is every important to follow these instructions exactly. If the chainset is not installed
correctly, it will develop play and annoying movement soon after being put into service.
Grease the inner bearing races as shown in the diagram. Grease is good… don’t be afraid of using too much. Slide the
right crankarm and spindle assembly through the bottom bracket until the left side splines come through the left
bottom bracket cup, and the spindle stops. There will be a gap of about 3mm between the right crankarm and the
bottom bracket.

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Assemble the left crankarm onto the bottom bracket spindle using an 8mm hex key and torque as shown. The left
crank arm will press against the bottom bracket with no gap. Check the assembly for play by pulling the crankarm
away from the boom, alternating back and forth. If the crank moves, tighten crankarm bolt until no play is detected.
If maximum torque has been reached, remove the crankarm from the spindle, apply additional grease, and repeat the
installation. It may take several installations to eliminate all play.
Note: the seals on the bottom bracket are designed to prevent contamination and
therefore must rub against their sealing surfaces. New seals will feel stiff when they are
first installed. This is normal. With use the seals will wear in and loosen up.
Warning: if you do not follow the instructions for installing the bottom bracket exactly,
then within a few miles the bottom bracket will develop play. It will feel much the same
as a bottom bracket with a bad or worn bearing. If this happens soon after you begin to
use the bike, retighten the bottom bracket.
2.7 Fit the pedals
(Your own if not ordered from us) – Note: the pedal threads are handed. The right hand pedal tightens in the
normal direction; the left-hand pedal has a left hand thread, and tightens in the opposite direction to normal.
Tighten the pedals to the torque shown in section 2.10
2.8 Adjust the seat angle
Sit on the bike (see section 5.1) and decide whether the seat angle suits you. The seat can be set more upright
(it was set to maximum recline in section 2.8) by simply opening the seat mount quick-release, sliding the seat
mount off the quick-release, and slotting it back over using a different set of slots. Please refer to section 3.4.
You may find a more upright position is initially better until you learn how the bike handles.
Do not use the handlebars to pull yourself out of the seat; they are not meant for
this purpose. Under normal use the handlebars will not slip in their clamps, they
will however move if subjected to an abnormal force.
There is also no need to pull on the handlebars when riding. The bike is easily
steered with a light grip of the fingers.
2.9 Set the front boom
Set the leg length by sitting on the bike and placing your heel on the pedal. Adjust the boom so that your leg is
almost straight when the pedal is at its furthest away from you. Set the front boom upright (by eye), and then
tighten the 2 clamp bolts.
Check the boom is not extended past its minimum insertion length. The end of the boom should not be visible in
the slot in the underside of the frame.
Obviously, this is a picture of a
trike, however, the principle is the
same.
As you won’t have the benefit of 3
wheels, you may need someone to
help hold you and the bike upright
while you check the boom length.
If you are doing this on your own,
try leaning against a wall while
checking the length. It’s important
that you are leaning back in the
seat in a proper riding position
when you are checking this
measurement.
2.10 Set the handlebars
The handlebars on your bike may need a small amount of adjustment. The main reason for adjusting the
handlebars is to ensure that you are comfortable and have adequate room for your knees when pedalling. The is
no ‘correct’ position, the best position is one that feels right to you.

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The usual procedure for adjustment is:
•Adjust the handlebar’s position forward and back. Sit on the bike. This position is changed by adjusting
the bolt located at the base of the stem at the pivot. Moving the bolt-stop in and out positions the
handlebars to stop in a comfortable position from your body.
•Adjust the height of the handlebars. This is done by loosening the clamp in the middle of the stem and
raising or lowering the bars to a comfortable position. Check that you have adequate clearance between
your knees and the handlebars and that your legs do not interfere with the steering.
•Adjust the angle of the handlebars. This is
done by loosening the handlebars where they
are held to the stem, and then rotating them
until the angle feels comfortable. Your hands
should fall naturally to the handlebars without
undue twisting of your wrists. Don’t worry
about the angle of the brake levers or shifters
at this time. Re-check the handlebar height
and position.
When you are happy with the adjustment of the
handlebars, loosen the brake levers and shifters and
adjust their position on the handlebars. Usually some
rotation is required. Make sure you can grip the brake
levers correctly, and that you can see the gear
numbers on the shifters. Tighten everything up.
2.11 Install the front derailleur
Next, the front derailleur needs to be installed. Its position is determined by the size of outer chainring. Attach
the front derailleur to the seat tube, and tighten the supplied M5 bolt lightly so you can adjust the position of
the derailleur. Adjust the position along the seat tube so that clearance between the front derailleur cage and
the large chainring is 1 – 3 mm.
At the same time, align the front derailleur cage outer plate to be parallel with the chainrings.
Tighten the 5 mm hex clamp bolt to 5 – 7 Nm (44 –62 in.lbs.).
Check that the front derailleur cage is positioned over the smallest chainring. Place the shifter in gear position
’1’. Turn the front shifter barrel adjuster clockwise fully into the shifter, then turn counter-clockwise 1 full turn.
Thread the front gear cable (left hand shifter) inner wire through the cable guide tube (chromed noodle). Pass
the cable guide up through the hole on the underside of the front boom, so that it just pokes out of the hole on
the top face of the boom, checking that it is seated correctly.

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Pull through any slack cable. While holding the cable taut, turn the shifter through its range of movement to
check the cable moves smoothly and that the cable is properly seated inside the shifter. Run the cable under the
cable anchor washer and hold taut. Tighten the 5 mm hex cable anchor bolt to 5 Nm (44 in.lbs.). Be careful not
to crush or deform the cable.
TIP - Do not trim any cables until you are happy with the various settings of front
boom and gears. The loose end of the cable can be tightly coiled so that it is out of
the way.
2.12 Install and connect the rear derailleur
Find the bag with the rear derailleur parts in it. Fit the rear derailleur to the rear dropout using a 5mm hex key,
making sure the B-tension washer tab / b-adjust screw is clear of the rear derailleur dropout tab. Tighten the 5
mm hex hanger bolt to 70 – 85 in.lbs. (8 – 10 Nm).

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View the rear derailleur and pulleys from behind
the rear wheel. Turn the limit screw marked ’H’
on the outer link of the derailleur to align the
upper guide pulley centre with the outboard
edge of the smallest cog. Then, push the rear
derailleur towards the larger cogs by hand.
Align the upper guide pulley under the largest
cog, centre to centre, by turning the limit screw
marked ’L’ on the outer link. The final
adjustment will take place once the chain is
installed.
Fit the long length of gear outer casing into the
rear derailleur.
Check that the rear derailleur is in the smallest
cog position. Rotate the rear shifter to the ‘9‘
position. Turn the rear shifter barrel adjust
clockwise fully into the shifter, then back it off 1
full turn.
Thread the rear derailleur cable through the
rear derailleur housing stop and through the
cable guide on the fin. Pull the cable tight and
position it under the cable anchor washer.
Tighten the 5 mm hex cable anchor bolt to 35 –
45 in.lbs. (4 – 5 Nm).

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TIP - Do not trim any cables until you are happy with the various settings of front
boom and gears. The loose end of the cable can be tightly coiled so that it is out of
the way.
2.13 Fit the chain
Find the chaintube and pulley assembly, and pulley bolt with 3 washers. Place the bolt through the pulley,
followed by the 3 washers, and then put the bolt through the hole in the middle of the pulley plate (the black
plate holding all the chaintubes together). Mount the chain tube assembly and pulley onto the frame. Ensure
that the cables run behind the pulley plate as shown in the photo below.
Twist the right hand rear shifter to the “1” position so that the rear derailleur lines up with the largest rear
sprocket. Twist the left hand front shifter to the “H” position so that the front derailleur lines up with the largest
front chainring.
Standard pulley set up
Full Chain Tube set up
TIP - make sure the chain is correctly routed through the rear derailleur cage
and goes the correct side of the tab on the derailleur cage between the two
jockey wheels.

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At the front of the bike, pass the chain under the idler pulley, then through the front derailleur cage, around the
large chain ring. Pass it thought the short length of chaintube under the pulley.
Now, checking that the chain is not twisted inside the chain tube, thread the bottom chain up through the
derailleur and over the largest cog of the cassette. Connect the bottom chain to the top chain using the quick
connect links supplied. Make sure that the chain is not twisted.

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Now check that the length of the chain is correct. Set the chain to the correct length by removing a section of
chain from between the rear derailleur and the lower chain tube with a chain rivet tool as below. Move the chain
until one of the connecting links can be seen between the rear derailleur and the lower chain tube. Open the
link and then work out how much chain to remove.
Add 2 links (with the chain on both the largest sprocket and the largest chainring). This should leave just enough
slack so that the rear derailleur jockey wheels are pointing forward but so that they can still move up a fraction.
Then check that there is not too much slack when using the smallest chain ring and smallest cassette sprocket.
TIP – get an extra pair of hands to help with this. Make sure that any
links you alter with the chain link remover are not stiff on the rivets. If in
doubt, remove fewer links than you think as removing links is easier than
riveting links back in. Use the quick disconnect link to open the chain and
then punch out links and quick connect back together.
When you've finished adjusting the chain length, check at the pulley plate where the chain enters and leaves the
chain tubes. The plastic clips should be adjusted vertically so the chain is running centrally where it enters and
exits the chaintubes. This is also the position where the chain runs at it quietest.

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2.13 Check the gear shifting
While pedaling, shift the chain up and down the chainrings several times to take out initial slack in the cables.
Any slack can be removed by adjusting the barrel adjuster on the shifters.
Adjust the Front mech high limit screw
Set the chain to the smallest rear cog and
the largest front chainring. Adjust the high
limit screw so that clearance between the
front derailleur cage outer plate and the
chain is 0 – 0.5 mm.
Adjust the Front mech low limit screw
Place the chain on the largest rear cog and
the smallest front chainring. Adjust the low
limit screw so that the chain is positioned
close to the inner cage plate without actually
touching it. If the front mech will not move
to this position, it may be the cable that is
holding it. Loosen the cable clamp, adjust
the front mech, and then re-clamp the cable

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Rear mech ‘B’ adjust
Shift chain to the small chain ring. While turning the
crank, push the rear derailleur inboard by hand to the
largest cog. Hold the rear derailleur in this position
while making the following adjustment. Using a 2,5 /
3 mm hex wrench to turn the b-adjust screw until the
chain gap equals approximately 6 mm (1/4“) from tip
of the cog to tip of upper guide pulley. While
pedalling, release the derailleur and check the chain
gap throughout the cassette.
Setting the chain gap at this point of your installation
may be considered a rough estimate. Precision index
shifting may require small changes of the b-
adjustment while setting the proper cable tension. Do
not use the b-adjust screw to adjust the rear
derailleur to act as a chain-tensioning device or to
prevent chain suck. This increases the chain gap
causing poor shifting performance.
Shift the chain to the smallest cog. While turning the pedals, move the shifter up 1 click, to the “8” position. If
the chain hesitates or does not shift to the second cog, increase the cable tension by turning the shifter barrel
adjuster counter clockwise. If the chain shifts beyond the second cog, decrease the cable tension by turning the
shifter barrel adjuster clockwise.
Repeat the two former steps until shifting and cable tension is accurate.
It is not enough that the chain should run quietly in each gear, it should also move smartly from one sprocket to
the next, without clattering or jamming.
Now check for smooth changing up through the range, checking one pair of sprockets at a time (9-8, 8-7, etc.)
Make any minor adjustments by turning the shifter barrel adjuster. Finally, check that the chain cannot jump off
the cassette, either on the inside into the spokes, or on the outside onto the dropout. This is adjusted using the
high and low limits screws as shown in section 2.16
Cut the cable off leaving about 1.5” (40mm) past the cable clamp, and crimp the cable end cover onto the cable
end.
2.14 Reflectors and bell
Reflectors and a bell are supplied with your bike. The bell can be mounted anywhere on the handlebars where it
can be reached easily and doesn't interfere with steering the bike. The reflectors have brackets which allow the
front reflector to be mounted on the front derailleur post, and the rear reflector to be mounted on the top rail of
the seat.
2.15 Check nuts and bolts
Generally, check all nuts, bolts and quick-releases to make sure everything is tight.