Johnny Loco Cargo Coupe User manual

Assembly manual
cargo coupé

2
Assembly of the Cargo Coupé bike
This manual will guide you through the assembly of the
Cargo Coupé bike from 85% to 100% assembled. This
will be done in the following steps:
- Assembly of the handlebar
- Assembly of the kickstand
- Assembly of the box frame
- Assembly of the soft pod
Required tools for assembly:
- Allen key 3, 5 and 6 mm
- Spanner 10 and 13 mm
- Spanner with ratchet ring spanner end
- A pair of pliers
Assembly of the handlebar
The handlebar of the Cargo Coupé is assembled the
same way a normal bicycle handlebar is assembled
Important! Make sure the brake and shifter cables re-
main on the outside of the box.

3
Assembly of the kickstand
Position the center part of the kickstand as shown in the
image. Make sure the connection plates are orientated in
the same direction as in the picture.
Important!
If connection plate orientation is the other way around the
kickstand will not function as designed.
The turning points need to be greased the guarantee
proper functioning
connection plate
Connect the center tube of the kickstand with 2 M8
bolts to the connection tube of the frame. The bolts
need to have a non threaded neck. The bolts need to be
tightened completely. The non threaded part of the bolt
will function as the axle of the kickstand
When the center tube is connected to the frame the
connection plate should point slightly to the front of the
bicycle.
With the center tube in place, the positioning rod can be
connected.
Put mounting grease on all connections and sliding points
before assembly!
Put the positioning rod through the sliding plates in the
center of slot underneath the spring.
Put the positioning rod all the way through and position
as in picture in the below right corner.
The positioning rod can now be connected to the center
tube with M5 bolts and lock nuts. Make sure to put a
washer between center tube and positioning rod when
mounting. The bolt must not be completely tightened,
leave some clearance for smooth operation
These connection point need grease to!
Operating the kickstand:
Lift the positioning rod with your foot and push the bike
forward at the same time. The kickstand will be released.
Lift the kickstand with your foot until the positioning rod
slides into the rear position in the slot.

4
short
Assembly of the frame
The box consists of two tubes running along the top and
two tubes connecting top and bottom. The tubes for the
top construction are different for left and right.
Connect the top and side tubes make sure the position-
ing edge of the top tube fits in the hole in the side tube.
The bolt should not be completely tightened, leave some
freedom for easier installation.
long
identical
Left and right
version
The now assembled sub frame can be connected to the
center frame of the bike.
Important! The sub frames tubes are alloy. To ensure the
bolts not cutting and pressing through put washers on
every bolt.
Bolts can be asserted into the slots cutout of the side
frame and nuts can be connected.
Connecting the subframes to the bike
Position the sub frame to the center frame. Slide the nuts
in to the centerframe and push all connection down.
Make sure tubes are properly aligned.
Check alignment and adjust if necessary
Tighten the bolts using the ratchet ring spanner.
Important! The sub frame is a construction part of the
total frame, This will only add stiffness to the bike when all
connections are properly tightened.

5
After all connections are proper the center connection
can be tightened.
Installing the floor
The flooring of the box consists of a alloy floor board.
This needs to be connected with 4 Allen bolts to the bike
frame, with the curved side to the front of the bike.
Important! Put grease on all bolts and insert all bolts
before tightening.
When all four bolts with washer are in place tighten them.

6
Assembly of the soft pod
The soft pod consists of a center piece and two side
pieces.
Inside and outside are different. The inside is a soft mate-
rial, the outside a waterproof tarp. For extra protection
the floor of the pod is also constructed with the smooth
plastic sheet material.
Important! All zippers are double functioning, when con-
nection make sure both runners are held together when
inserting the zip.
Zip the parts of the soft pod together and put it in the
bike, with the small window facing forward.
Form the soft pod around the steering tube.
Important! The parts of the soft pod should never be
folded. Folding the soft pod parts will damage the mate-
rial.
After positioning the pod the Velcro straps should be
used to connect the soft pod to the frame..
The bucklle is positioned on top of the frame, the strap
goes around the from from below through the buckle.
And then can be attached with the velcro.

7
Installing the seats
Adjust the frame of the seats as displayed. When in posi-
tion thighten the adjust ment screws
To accomodate larger children the position of hte seat
can be changed.
Tip: A seat without canvas can function as a support for
childseat.
The seats can be positioned forward and backward and
are able to slide backwards and forwards. When the seat
are positioned opposite of each other, one facing forward
and one facing backward, the shoulders of the children
will not be aligned and there will be more room for taller
children
When the desired position of the seats is Chosen they
can be attached to the floor board. First slide the thread-
pint throught the pod and floorboard in th eright position.
Screw on the wingnuts and tighten them
The locknuts are only installed to make sure the wingnuts
cannot fall of, they do not need te bee tightened com-
pletely
Important! During use the resilience of the foam material
will become less and the wing nuts need further tighten-
ing. Check if this is necessary regularly.

8
Assembling the roof
The roof consists of four parts, the center piece, the two
sides and the roof frame.
Inside and outside of the roof are made from different ma-
terials. Make sure to put the soft side on the inside and
the smooth watertight side on the outside.
The roof frame has an extra hinge point. This hinge point
makes it possible to fold the frame and store it inside the
pod. When unfolding the frame secure the position with
the Velcro strap
Zipp all parts together
Important! These zippers are all double functioning
zippers. When inserting the zipper into the runner make
sure both runner are positioned at the start and pressed
together.
The roof frame can be attached to the roof with the velcro
Important! Ports of the soft pod should never be folded.
Folding the material will damage the soft inner material.

9
The roof can now be placed on the soft pod.
Slide the roof frame into the sleeves on the side of the
pod.
Attach the sides of the roof to the Velcro connection
straps of the pod as shown in the picture.
When parking in bad weather and strong wind it is rec-
ommended to attach all straps.
To allow the children to get out or in, both roof zippers
can be undone from the front up onto the frame.
When the soft pod lower zippers are partly undone from
the front, children are able to enter en exit the soft pod
underneath the top tube on their own.