Oru Kayak COAST XT User manual

STERN
(back)
Stern
fairing
Bow
fairing
BOW
(front)
Handle
Cockpit
handles
Cockpit
Coaming
(cockpit rim)
Deck
line
Bow Bulkhead
(inside) Cockpit
Bulkhead
(inside)
Deck
web
Seat
pad
Seat
back Zipper
channel
US PATENT NO. 8,316,788
THE COAST XT
Handle
Assembly Guide
HOW TO GET
STARTED
Read this entire Assembly Guide
before assembling your Oru Kayak.
Watch the instruction video:
www.orukayak.com/pages/assembly
Be patient! With practice your
assembly time will get to 15 minutes.
WE’RE HERE TO HELP!
If you have questions, email us at [e-mail]
Stern
Bulkhead
(inside)
Thigh
braces

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 –
this will become 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 float bags and our 4-piece paddle.
B
A
23456789101
B
1 ORU KAYAK | ASSEMBLY GUIDE

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1
2
3
4
57
6
Parts: Loose components
1
SHOULDER
STRAP
STERN (back)
BULKHEAD
SPARE PARTS
KIT
64
BACKREST
5
SEAT PAD
TOP
TOP
TOP
2
ZIPPER
CHANNELS
x6
TOP
Shoulder strap: Used to carry
the kayak when in box form.
Stow behind the backrest while
kayaking.
Zipper channels: These seal
the deck seam.
Cockpit (large) bulkhead:
Provides structural rigidity
behind the cockpit.
Stern (back) bulkhead:
Provides structural rigidity
in the kayak’s stern.
Backrest: Combines back
support and structural rigidity.
Seat pad: Tucks under the
bungee in the oorboard.
Spare parts kit: Extra
hardware and lubricant for
repairs and upkeep.
7
7
3
COCKPIT (large)
BULKHEAD
TOP

Step 2: Unfold the box
Unclip side straps that are
keeping the kayak closed on
both sides.
Hold the two folds at the
orange stickers. Pull as
indicated in the illustration
(left) to open. The skin will
be stiff.
Push the ends apart to
extend the box into a long
sheet.
Pop the hull flat with your
hands as you extend it,
pushing down the inverted
folds, creating a bowl shape.
A
B
C
C
NOTE
Orange stickers will
help guide you through
your first assembly.
34567891012
A
A
B
B
C
3 ORU KAYAK | ASSEMBLY GUIDE
PULL UP
PULL UP
D
PUSH DOWN
SIDES POP UP TO
CREATE BOWL SHAPE
D
D
PROFILE VIEW

BOW
(front)
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Fairings: These finish the boat at
the bow and stern and include
handles for carrying the kayak.
Tension strap: Provides additional
rigidity to the hull of the kayak.
Bow and stern bulkheads: These
provide structural rigidity.
Adjustable footrest: Keeps your
legs in a comfortable position
and gives you greater
control of the
kayak.
1
5
6
2
3
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.
STERN
(back)
3
Coaming: The rim around
the cockpit can hold the Oru
Kayak spray skirt as well as
any 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 only.)
Foam plugs: Keeps out any
water that gets through the
fairings.
Bulkhead channels: For
placing the bulkheads
3
7
7
4
8
8
BOW
(front)
3
5
6
5
2
4
1
6

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 bungee:
The seat pad tucks under
the bungee 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
bungee
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)
5 ORU KAYAK | ASSEMBLY GUIDE

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Step 3: Insert the floorboard
2 4 5 6 7 8 9 101 3
Ensure that the floorboard backrest plate is
on the stern side of the kayak.
AB
C
NOTE
Handle goes into
groove on the
coaming. Rotate
the cockpit handle
to lock into the
coaming, as shown.
Make sure straps
are not caught
under floorboard.
The floorboard adds structure to the cockpit area. The floorboard handles lock into the coaming
(this is around the rim of the cockpit) to hold the floorboard in place.
After locking in both sides and
pushing down in the center of
the floorboard, you’ll find that the
kayak retains its “boat shape.”
B
C
SEE THIS IN MOTION IN THE ASSEMBLY VIDEO:
www.orukayak.com/pages/assembly
Prop the kayak on its side, and
align the floorboard handle with
the ridge in the coaming. Rotate
down and inward, until you hear
a “snap.” See note. Flip kayak and
repeat on the other side.
FLIP AND REPEAT ON
OTHER SIDE
A
STERN
FLOORBOARD
COAMING
PUSH DOWN

7 ORU KAYAK | ASSEMBLY GUIDE
STERN
(back)
Step 4: Attach footrest
On both sides, attach the footrest
buckles to the corresponding buckles
on the coaming (see close up).
A B
Adjust the footrest straps to provide simple, adjustable comfort.
2 3 5 6 7 8 9 101 4
A
BOW
(front)
CLOSE-UP
Connect the buckles
on both sides of the
cockpit.
NOTE
The back buckles are used for
the backrest NOT the footrest.
A
Move the deckline into the cockpit so it
is out of the way during the next steps.
(Make sure the deckline is ABOVE the
footrest bungee.)
B

Step 5: Tighten end straps/insert bulkheads
The end straps help seal the bow and stern while the bulkheads
provide rigidity to the hull.
Make sure the ends of the
bow and stern are inverted.
Tighten the bow and stern
using the end straps (see
note). This will begin to
shape the kayak and make it
easier to install the zipper.
Make sure the foam plug
stays on the outside.
Insert the bow, stern and
cockpit bulkheads into the
bulkhead channels on the
floor of the kayak. Make sure
they are properly placed.
A
B
end
strap
A
B
BOW
(front)
STERN
(back)
end
strap
B
A
NOTE
The end strap will tighten
just under the openings
on the bow and stern.
NOTE
Make sure ends are
inverted and the foam
plugs are on the out-
side before tightening
end straps.
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2 4 6 7 8 9 101 35
A
foam
plug
foam
plug
B
INCORRECT CORRECT
B
TOP
TOP

TIP
Apply downward
pressure and
push forward with
your hands while
sliding the zippers.
9 ORU KAYAK | ASSEMBLY GUIDE
The zipper channels seal the deck of the kayak.
Step 6: Attach front zipper channels
Hook the front coaming latch
as shown in close-up A.
Holding the bow of the
kayak, begin to guide the
zipper channel onto the deck
trim (see tip). 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
properly installed.
Finish closing the front
coaming latch as shown in
close-up D.
A
B
B
A
before
zipper
after
zipper
D
D
Cincorrect
correct
ABOW
C
C
2 4 5 68 9 101 37
STERN
(back)
BOW
(front)
B

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Step 7: Attach rear seat column
Closing the back of the kayak is
similar to closing the front (step 6).
You’ll install the backrest column, which
supports the rear cockpit area.
Insert 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 is behind
the backrest.
2 4 5 6 78 101 3 9
DO NOT CLOSE
LATCH YET
B
STERN
(back)
BOW
(front)
B

11 ORU KAYAK | ASSEMBLY GUIDE
Step 8: Attach rear zipper channels AHolding the stern of the
kayak, begin to guide the
zipper channel onto the deck
trim (see tip). Do not force
the zipper on as it may cause
damage to the kayak. Make
sure that the bulkheads are
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
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
Apply downward pressure
and push forward with
your hands while sliding
the zippers. See TIP and
drawing on Step 6B.
STERN
(back)
BOW
(front)
B
deck trim
deck trim
zipper channel

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Step 9: Tighten the tension strap
The tension strap is
located inside the hull
underneath the bow
coaming latch.
Fasten the hook onto the
strap loop and tighten.
Make sure the strap is
tight (see diagrams).
A
B
C
A
CLOSE-UP
Fasten the hook to
the strap loop located
under the deck.
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Tightening the tension strap provides additional rigidity to the hull of the kayak.
B
incorrect
C
correct
C
9

Step 10: Add the finishing touches
Stretch the bungee across
the deck in front of the
cockpit (standard positions
shown. You may configure
the clips as you see fit).
Buckle the seat back straps
to the stern-side straps on
the coaming.
Slip the seat pad under the
bungee on the floorboard.
A
B
C
D
A
A
C
E
CLOSE-UP
Step D and E
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Just a few more things to get your Oru Kayak ready for the water!
DD
E
B
B
13 ORU KAYAK | ASSEMBLY GUIDE
STERN
(back)
BOW
(front)
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 deckline buckles at each end.
Tighten the strap until the deck lines
are tensioned.
NOTE
If the fairings won’t stretch
over, make sure the ends
are inverted (see Step 5A).
NOTE
Use buckles to adjust
backrest and leave space
for more comfort.

Final adjustments
Stash water bottles,
spare paddles, and other
accessories under the
bungee deck web.
The coaming fits the Oru
Kayak spray skirt and all
standard spray skirts
(size medium), if desired.
B
A
B
ASSEMBLY
CHECKLIST
nZipper channels are
tight and no deck
trim is visible
underneath.
n The fairings cover
both ends.
n Coaming latches
are locked at the
front and back of the
cockpit.
n Both cockpit
handles are locked
onto the coaming.
Congratulations!
Your Oru Kayak is
ready for the water.
BEFORE YOU GET IN:
LOOSEN THE FOOTREST
This will allow easy entry.
ADJUST THE HEIGHT OF
THE BACKREST
Move the bungee up or
down the notched backrest
column to support your
lower back.
Pull on the seat back straps
to adjust the angle and
contour 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
loosening 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.
A
ONCE YOU’RE IN:
CHECK THE TENSION STRAP
Make sure the tension strap
is tightened, as it may have
loosened during assembly.
STERN
(back)
BOW
(front)
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0815 © 2017 ORU KAYAK, INC. ALL RIGHTS RESERVED
Disassembling the Oru Kayak is basically a 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.
Back on land: Folding your Oru Kayak into its box
Unclip the fairings and FULLY loosen
the end straps at bow and stern.
Remove the foam plugs.
Unhook the deckline clips and web.
IMPORTANT: Loosen and unhook the
tension strap before removing any
zipper channels.
Unlatch the front and rear coaming
latches.
Remove the zipper channels starting
with the ends of the kayak. (Remove
one channel at a time by placing your
palm on the zipper. Apply pressure
downward and out towards tip to
remove.)
1
2
4
3
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
Open the coaming latch. Remove the
rear seat column by unhooking it from
the coaming screw posts.
Unclip the footrest and remove the
stern bulkhead. Bow bulkhead stays in
the kayak and clipped to the bulkhead
keeper.
Remove the floorboard by swiftly pulling
up from the center.
Fold one end inward, compressing it like
an accordion (you can start with the bow
or stern).
Repeat with other end.
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.
7
6
8
5
9
11
Continue pushing, in a twisting motion,
until the arrows hit their targets.
Clip and tighten the two sets of
outside deck buckles on either side.
Stash loose components throughout
the box, making sure that they’re
safely positioned.
Place the floorboard over the top
of the box. Place and tighten the
shoulder strap loops over the box.
All packed up and ready to go!
12
10
13
15
16
14
TIP: Some water may collect inside the plastic
corrugated flutes. To let it escape, stand the assembled
kayak vertically for about 10 minutes to let it drain out. FOR STEP-BY-STEP VIDEO INSTRUCTION
WATCH THE ASSEMBLY VIDEO:
www.orukayak.com/pages/assembly
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