Oru Kayak BAY ST User manual

For your first assembly, avoid common mistakes by reading this Assembly Guide or
watching the assembly video at www.orukayak.com/assembly
STERN
(back)
Stern
fairing
Bow
fairing
BOW
(front)
Handle
Handle
Cockpit
handles
Cockpit
Coaming
(cockpit rim)
Deck
line
Bulkhead
Bulkhead
Deck
web
Seat
pad
Seat
back Zipper
channel
PMS 1665
c=0
m=68
y=100
k=0
r=243
g=115
b=33
US PATENT NO. 8,316,788
BAYST
ASSEMBLY GUIDE
The

HOW TO GET STARTED
Read this entire Assembly Guide before
assembling your Oru Kayak.
Watch the instruction video:
www.orukayak.com/
assembly-guide-2017
Check out our Tips & Tricks:
www.orukayak.com/tips-and-tricks
PLEASE NOTE
Your first time assembling may take
20-30 minutes, but with practice
you’ll get closer to 5.
Be patient!
All Oru Kayak components have been
custom-engineered for a precise
fit. If a component seems difficult
to assemble, check the directions
instead of forcing a fit that might not
be correct.
WE’RE HERE TO HELP!
If you have questions, email us at
[e-mail].
Oru Kayak:
Explore outside the box.
With a few steps, the box you’re looking at will unfold into a twelve-
foot long kayak that’s beautiful, robust, swift, and smooth. It’s inspired
by the Japanese art of origami— and while it’s not quite as easy as
unfolding a piece of paper, your Oru Kayak is designed to be simple
and intuitive to assemble.
With a bit of practice, your Oru Kayak can be put together in five min-
utes—but the first time will take longer, as you learn the process and
the folds break in. Be patient and don’t force anything; components are
custom-engineered to fit together precisely. We recommend doing it at
home the first time, and also watching our assembly video.
You’ll be on the water in no time at all, and we can’t wait to hear about
your Oru Kayak journeys. Send your photos and videos to info@oru-
kayak.com or add #orukayak to share them with the communi-
ty.
Enjoy your adventures!
The Oru Kayak team

WWW.ORUKAYAK.COM 1
A
B
C
Loosen and slide the
shoulder strap off the
sides of the box. You will
not use it while kayaking,
but you will need it when
you fold the Oru Kayak
back into box form.
Unclip the two sets of box
buckles on both sides of
the orange lid. Lift the lid
off. (The lid
becomes the kayak’s
floorboard.)
Remove the loose kayak
components packed into
the box. See page 2 for
a list of the loose
components. Additional
components are
permanently attached to
the hull/deck.
Step 1: Open the Oru Kayak box
The box contains all the components needed for
assembly and includes space to store gear—such as
a personal flotation device (PFD) and a 4-piece paddle.
A
23456789101
B
B

2 ORU KAYAK | ASSEMBLY GUIDE
Shoulder strap: Used to
carry the kayak when in
box form. Stow behind the
backrest while kayaking.
Zipper Channels: These seal
the deck seam.
Stern (back) bulkhead:
Provides structural rigidity.
Backrest: Combines back
support and structural
rigidity.
Seat pad: Tucks under the
shock cord in the floorboard.
Maintenance kit: Extra
hardware and lubricant for
repairs and upkeep.
1
2
3
4
5 7
6
Parts: loose components
2
ZIPPER CHAN-
NELS
1
SHOULDER
STRAP
3
STERN
BULKHEAD
MAINTENANCE
KIT
6
4
BACKREST
5
SEAT PAD
TOP
TOP
TOP
x6
TOP

WWW.ORUKAYAK.COM 3
Step 2: Unfold the box
Unclip the center strap that
is keeping the kayak closed.
Hold the two folds at the
orange stickers. Pull as
indicated in the illustration
(at left) to open.
Push the ends apart to
extend the box into a long
sheet. Pop the hull flat with
your hands as you extend it.
A
B
C
C
NOTE: Removable
orange stickers will
help guide you through
your first assembly.
34567891012
A
AB
BC

4 ORU KAYAK | ASSEMBLY GUIDE
1
2
6
3
4
Fairings: These finish the
boat at the bow and stern,
and include handles for
carrying the kayak.
Tension strap: Provides
additional rigidty to the hull
of the kayak.
Bow (front) bulkhead: Like
the loose stern bulkhead,
this provides structural
rigidity.
Adjustable footrest: Keeps
your legs in a
comfortable position and
gives you greater control of
the kayak.
Coaming: The rim around
the cockpit can hold
a standard spray skirt (size:
medium) if desired.
Deck Lines: These lines
provide a secure grabbing
point during a rescue. (The
lines are orange in the
manual for instructional
purposes)
1
5
6
2
3
4
5
5
Parts: hull/deck The box becomes the hull and deck of the kayak. Several key parts are permanently
attached to the hull/deck. The bow (front) and stern (back) of the Oru Kayak are
different, so pay attention to orientation throughout the assembly process.
BOW
(front)
STERN
(back)

WWW.ORUKAYAK.COM 5
Handles: Lock into
coaming and provide
support when entering
or exiting the kayak.
Backrest plate: Holds the
backrest and column (see
Step 7).
Seat pad shock cord:
The seat pad tucks under
the shock cord in the
center of the floorboard (see
Step 10).
Box buckles: Two sets of
buckles hold the box closed,
but are not used when in
kayak form.
Backrest
plate
Right cockpit
handle
Left cockpit
handle
Seat pad
shock cord
Box
Buckles
1
1
1
2
3
4
3
4
2
Parts: floorboard The box lid becomes the floorboard. The floorboard is a crucial part of
the Oru Kayak assembly: it locks into the cockpit at the coaming, adding
structure, and holds the seat pad and backrest.
BOW
(front) STERN
(back)

6 ORU KAYAK | ASSEMBLY GUIDE
Step 3: Attach Footrest
Attach the female foot-
rest buckles to the male
buckles on the coaming (see
close up)
Move the deckline into the
cockpit so it is out of the
way during the next steps
A
A
BOW
CLOSE UP
Connect the
buckles on both
sides of the
cockpit.
STERN
2 4 5 6 7 8 9 101 3
A
B
B
NOTE
The buckles
with the orange
stiching are
used for the
seat NOT the
footrest.
The footrest buckles to adjusting straps to provide simple, adjustable comfort.
A

WWW.ORUKAYAK.COM 7
Step 4: Tighten End Straps/Insert Bulkheads
The end straps help seal the bow and stern while the bulkheads provide rigidity to the hull.
Tighten the Bow and Stern
of the kayak using the end
straps (see note). This will
begin to shape the kayak
and make it easier to install
the zipper.
Insert the bow and stern
bulkheads into the U-chan-
nels on the floor of the
kayak.
A
B
end
strap
A
B
BOW
STERN
2 3 5 6 7 8 9 101 4
end
strap
B
A
NOTE
The end strap
will tighten over
the openings
on the bow and
stern.

The zipper channels seal the deck of the kayak.
Step 5: Attach front zipper channel
Hook the front coaming
latch as shown in the upper
close-up A1.
Holding the bow of the kay-
ak, begin to guide the zipper
channel onto the deck trim.
Do not force the zipper on
as it may cause damage to
the kayak. (Make sure that
the bulkhead is inside of the
upper bulkhead channel).
Continue until all three
zippers are on the bow of
the kayak. Check to make
sure each zipper channel is
on correctly.
Finish closing the front
coaming latch as shown in
the upper close-up D.
A
B
B
A
before
zipper
STERN
BOW
8 ORU KAYAK | ASSEMBLY GUIDE
2 4 6 7 8 9 101 35
after
zipper
D
D
C
TIP
Applying some
downwards pressure
with your hand while
sliding the zippers will
help with installation
incorrect
correct
A1
BOW
C
C

WWW.ORUKAYAK.COM 9
A
STERN
9 ORU KAYAK | ASSEMBLY GUIDE
Step 6: Insert the floorboard
The floorboard adds structure to the cockpit area.
The handles rotate and clip onto the coaming
(cockpit rim) to hold the floorboard in place.
Fold the floorboard into a
U-shape, and insert it into
the cockpit. (The column
plate goes on the stern side
of the kayak.)
Flex the middle of the
floorboard upward, forming
a W-shape. Place the edge
of one handle into the
recessed groove in the
coaming.
While pushing the middle of
the floorboard down, rotate
the handle to lock it into
place; the handle will snap
in loudly when fully rotated.
Repeat with the other han-
dle. See close up.
A
B
C
NEED HELP WITH THIS STEP?
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NOTE
Handle goes into
groove on the
coaming.
Rotate the cockpit
handle to lock into
the coaming, as
shown.
C
B
2 4568 9 101 37

BOW
Step 7: Attach rear seat column
Closing the back of the kayak is
similar to closing the front (step 5).
You’ll install the backrest column, which
supports the rear cockpit area.
Slide the backrest column
into the slotted backrest
plate in the floorboard. Tilt
upward to lock the backrest
column in place.
Lock the top of the backrest
column into the two shiny
screws on the coaming of
the kayak (see close up).
B
A
A
CLOSE UP
How the backrest
column will look once
this step is complete.
This view shows
behind the backrest.
STERN
BOW
10 ORU KAYAK | ASSEMBLY GUIDE
NEED HELP WITH THIS STEP?
GO TO WWW.ORUKAYAK.COM/TIPSANDTRICKS
2 45678 101 3 9
DO NOT CLOSE
LATCH YET
B

.
WWW.ORUKAYAK.COM 11
Step 8: Attach rear zipper channel AHolding the stern of the
kayak, begin to guide the
zipper channel onto the deck
trim. Do not force the zipper
on as it may cause damage
to the kayak. (Make sure that
the bulkhead is inside of the
upper bulkhead channel).
Continue until all three
zippers are on the stern of
the kayak. Check to make
sure each zipper channel is
on correctly.
Close the rear coaming latch
behind the seat column.
B
C
B
STERN
BOW
2 3 4 5 6 7 9 101 8
CLOSE UP
Close the rear latch
behind the seat
column. Make sure
BOTH screws are
still inside the slots.
A
C
correct incorrect
TIP
Holding the coaming
while attaching the
rear zipper channels
will help keep the rear
column in place.

12 ORU KAYAK | ASSEMBLY GUIDE
Step 9: Tighten the tension strap
The tensions strap is locat-
ed inside the hull
underneath the bow coam-
ing latch.
Fasten the hook onto the
strap loop and tighten.
Make sure the strap is tight
(see diagrams)
Slip the seat pad under the
shock cord on the floor-
board.
A
B
C
A
CLOSE UP
Fasten the hook to
the strap loop.
23456781 10
Tightening the tension strap provides additional rigidity to the hull of the kayak.
B
incorrect
C
correct
C
9

WWW.ORUKAYAK.COM 13
Step 10: Add the finishing touches
Using the foam block
attached to the end straps,
plug the bow and stern of
the kayak.
Stretch the neoprene
fairings over the bow and
stern and clip the buckles
to the first deck buckles at
each end. Tighten the strap
until the deck lines are
tensioned.
Stretch the bungee across
the deck in front of the
cockpit. (Standard positions
shown. You may configure
the buckles as you see fit.)
Buckle the seat back straps
to the remaing straps on the
coaming (the straps with
orange stiching)
Slip the seat pad under the
shock cord on the floor-
board.
A
B
C
D
A
A
C
E
CLOSE UP
Step C and D
STERN
BOW
234567891 10
Just a few more things to get your Oru Kayak ready for the water!
DD
E
B
B

14 ORU KAYAK | ASSEMBLY GUIDE
Final adjustments
Stash water bottles, spare
paddles, and other
accessories under the shock
cord deck web.
The coaming fits a
standard spray skirt
(size: medium) if desired.
B
A
B
ASSEMBLY
CHECKLIST
nZipper channes are
tight and no deck
trim is visible
underneath.
n The fairings cover
both ends.
n Coaming is locked at
the front and back of
the cockpit.
n Both cockpit han-
dles are locked onto
the coaming.
Congratulations!
Your Oru Kayak is
ready for the water.
BEFORE YOU GET IN:
ADJUST THE HEIGHT OF
THE BACKREST
Move the shock cord up and
down the notched backrest
column to
support your lower back.
Pull on the seat back straps
(with the orange stitching)
to adjust the reclining angle
of the seat. When properly
adjusted, there should be
a space between the seat
back and the rear of the
coaming, while seated in a
normal position.
ONCE YOU’RE IN:
ADJUST THE FOOTREST
From a seated position,
move the footrest by loos-
ening or tightening the left
and right buckles just below
the kayak deck, in front of
the cockpit handles.
The footrest should keep
your legs comfortably bent,
with your knees splayed
outward.
STERN
BOW
A
ONCE YOU’RE IN:
CHECK THE TENSION
STRAP
Make sure the tension strap
is tightened. It may have
loosened during assembly

Disassembling the Oru Kayak is basically
a simple reversal of the assembly.
However, there are a few tricks. Follow these
directions to learn how to pack your
Oru Kayak back into its box quickly and easily.
NOTE: Some water may collect inside the plastic
corrugations. To let it escape, stand the assem-
bled kayak vertically for about 10 minutes to let
it drain out, before moving on to Step 6.
The Oru Kayak box holds all the loose compo-
nents, and can also fit a paddle, PFD (personal
flotation device), and other accessories.
At first, the box may take some effort to close,
but with use, folding it up will become easier.
The shoulder strap makes it easy to carry the
Oru Kayak short distances; for longer trips we
recommend our Oru Pack, available at
www.orukayak.com.
Back on land: Folding your Oru Kayak into its box
WWW.ORUKAYAK.COM 15
Unclip the fairings and fully loosen the
end straps at bow and stern (as shown).
Remove the foam plug.
IMPORTANT: Loosen and unhook the ten-
sion strap before removing any
zipper channels.
Unlatch the front and rear coaming latches.
Unhook the deck web.
12
4
3

NEED HELP WITH THIS STEP?
GO TO WWW.ORUKAYAK.COM/TIPSANDTRICKS
The big fold
16 ORU KAYAK | ASSEMBLY GUIDE
DIAGONAL
CREASE
ORANGE
ARROW
Unclip the foot rest and remove both
bulkheads from the hull of the kayak.
7
Remove the rear seat column by
unhooking it from the coaming screw
posts.
6Remove the floorboard by lifting up in the
center as shown.
8
Remove the zipper channels starting with
ends of the kayak. (Remove one channel at
a time)
5
BLACK
TARGET

ORANGE
ARROW
ORANGE
TARGET
DIAGONAL
CREASE
Fold one end inward as shown,
compressing it like an accordion (you can
start with the bow or stern).
9
Fold the two accordioned ends towards
the middle, to slide past each other. Push
the orange arrow towards the orange
target and the black arrow towards the
black target.
11
WWW.ORUKAYAK.COM 17
NEED HELP WITH THIS STEP?
GO TO WWW.ORUKAYAK.COM/TIPSANDTRICKS
Continue pushing, in a twisting motion,
until the arrow hit their targets.
12
Repeat with other end.
10

CARING FOR YOUR ORU KAYAK
• Inspect your kayak before each use to
make sure it is not damaged, and that
all fasteners are tight.
• Rinse off your kayak with clean, fresh
water after each use, especially after
paddling in salt water.
• Make sure water does not collect
inside the kayak case after use.
• Some water may collect inside the
plastic corrugations. To let it escape,
flip the unfolded kayak upside down
to let it drain out.
• For additional cleaning, use general-
purpose cleaning spray with a soft,
non-abrasive rag or sponge.
• In case of serious damage or
punctures, email us at
[e-mail].
0815 © 2015 ORU KAYAK, INC. ALL RIGHTS RESERVED
Kneel on the folded box to compress it.
Clip and tighten the two sets of outside
deck buckles on either side.
Stash loose components in the box, along
with any extra gear. Place the floorboard
over the top of the box.
Place and tighten the shoulder strap loops
over the box as shown .
All packed up and ready to go!
13
Folding the Oru Kayak back into the box
STASH
ORU KAYAK
COMPONENTS
HERE
15 16
14