Rio Mobility Dragonfly Instructions for use

Dragonfly
TM
Handcycle
User Instruction and Maintenance Manua l
Part Number 25
Rev A, 12/11/2007
(PLEAS E PRINT OUT AT 100% SIZE – NO SCALING)

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Dealer: This manual must be given to the user of the handcycle.
User: Before using this handcycle, read this manual and save it for
future reference; it has installation and maintenance instructions along
with warranty information.
For more information regarding Rio Mobility products, parts, and
services, please contact Rio Mobility, a Daedalus Wings, Inc. company,
at www.riomobility.com.
You can also visit our retail store, conveniently located at 56 Tehama
Street in downtown San Francisco, CA 94105.
We would like to acknowledge the National Science Foundation for
their support of the development of the Dragonfly
T M
handcycle.
© 2007 Daedalus Wings, Inc.

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-Table of Contents-
1. Product Registration/Warranty Form ………………..5
2. Limited Warranty…………………………………….6
3. Introduction to Handcycling …………………………8
4. Dragonfly
T M
Guidelines……………………………...9
5. What Comes in the Box ……………………………14
6. Initial Installation Instructions ...……………………16
7. Routine Attachment and Removal………………….27
8. Safety Checklist and Maintenance Instructions…….29
9. Replacement Parts…………………………………..31
10. Troubleshooting Guide ……………………………..32
11. Contact Information………………………………...33

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-WARNING-
DO NOT OPERATE THIS EQUIPMENT WITHOUT FIRST
READING AND UNDERSTANDING THIS MANUAL. IF
YOU ARE UNABLE TO UNDERSTAND THE WARNINGS,
CAUTIONS, AND INSTRUCTIONS, CONTACT
CUSTOMER SERVICE AT [e-mail]
BEFORE ATTEMPTING TO USE THIS EQUIPMENT –
OTHERWISE INJURY OR DAMAGE MAY RESULT.
IT IS RECOMMENDED THAT INITIAL SETUP OF THIS
HANDCYCLE BE PERFORMED BY A QUALIFIED
TECHNICIAN, SUCH AS A BICYCLE OR WHEELCHAIR
MECHANIC.

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-1. Product Registration/Warranty Form-
Please complete and mail or fax this form to: Rio M obility
56 Tehama Street
San Francisco, CA 94105
[phone] (f)
Name: _____________________________________________
Address: _____________________________________________
City: _____________________________________________
State/Province: _____________________________________________
Zip/Postal Code: _____________________________________________
Email: _____________________________________________
Phone #: _____________________________________________
Rio Mobility M odel #: _____________________________________________
Serial #: _____________________________________________
Purchased from: _____________________________________________
Date of Purchase: _____________________________________________
This product was purchased for use by (circle one):
Self Parent Spouse Child Other: _______________________
Product was purchased for use at (circle one):
Home Facility Other: _______________________
I purchased this product because (circle one):
Price Features Other: _______________________
Who referred you to this product (circle one)?
Doctor Therapist Friend Relative No Referral Other: _______________
Advertisement: TV Radio Magazine Newspaper Internet: _______________
What additional features, if any, would you like on this product?
______________________________________________________________________________
Would you like to receive information via mail or email about other Rio M obility products?
Do you have any suggestions for the RioM obility.com website?
To find out more about Rio M obility products, please visit our website, www.riomobility.com, or
visit our showroom at 56 Tehama Street, San Francisco, CA 94105.

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-2. Limited Warranty-
All handcycle parts (excluding tires and tubes) are warrantied free of defects in material and
workmanship for 90 days from date of purchase. The handcycle structural frame is warrantied
free of defects in material and workmanship for 1 year from date of purchase.
This warranty is only available for the original owner or purchaser and is non-transferable.
Said warranty does not cover mechanical or structural failure due to improper assembly,
improper usage, or damage involving accidents of any kind. Warranty also does not cover
normal wear and tear. Also not included under this warranty is the loss of purchased product,
damage from exceeding the normal payloads of handcycle product, damage due to buyer/driver
mechanical negligence, or damage due to lack of preventative and routine maintenance.
Rio M obility is to do all warranty work if deemed necessary. One way shipping costs are the
sole responsibility of the buyer, return shipping costs will the responsibility of Rio Mobility. Rio
Mobility is not responsible for damages incurred to product during product return shipping. All
returns must be pre-approved and receive an official Return Authorization number from Rio
Mobility. In some special cases, if requested, the buyer can pay for the repainting of product.
This warranty will become invalid if:
-The frame number is removed or altered.
-The handcycle is used in any competitive event.
-The handcycle is used in stunt riding, jumping, or similar activity.
-The handcycle is ridden with more than one person at a time.
-The handcycle is used in a manner contrary to the instructions in the Owner’s Manual.
The warranty applies to U.S.A customers only.
Our product is to not be copied or modified under any circumstances.

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-WARNING-
The dragonfly is a recreational product. It is not a medical device nor is it intended as a primary
means of mobility. These handcycles are intended for outdoor recreational use on paths and
sidewalks. Required operating conditions are on flat, dry, paved surfaces during daylight hours.
The use of a flag or tall marker is highly suggested for maximum visibility. Do not operate
handcycles from dawn to dusk or in other low visibility conditions.
In most states, the use of wheelchairs on public roads is prohibited. Whether this is the case or
not, you should not operate your handcycle on roads, streets, or highways.
Your must have your anti-tip devices installed on your wheelchair to insure a safe ride.
Operating in or around a handcycle involves a certain level of risk and inherent danger of serious
bodily injury. These possible risks include, but are not limited to, permanent disability, neck and
head trauma, limb dismemberment and in extreme cases, even death.
Handcycle riders must ride these vehicles with the utmost care, caution, and safety in mind. It is
recommended that you inspect your chair and handcycle carefully before each ride.
Operate your handcycle with the same care and caution as you would any wheelchair or bicycle.
Follow all the instructions and recommendations indicated in your wheelchair users’ manual.
Rio M obility cannot be held responsible for any accidents that may occur from misuse.
Please refer to Operating Requirements for more details on safe use of the handcycle.

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-3. Introduction to Handcycling-
The Dragonfly
TM
will transform your wheelchair into a high performance machine, with the
potential to make you more mobile and physically fit. Just like many other exercises,
handcycling is an aerobic activity, so you should check with your physician before going for
your first ride or starting any handcycling on a regular basis.
If you’ve never ridden a handcycle before, you may feel soreness and fatigue in places you’ve
never felt it before. A little soreness is normal, but remember that overexertion can cause excess
soreness and potential injury, so be mindful of your limits. Be patient and reasonable with your
handcycling expectations; physical fitness takes time to achieve.
Most importantly, remember to have fun with your handcycle.
Enjoy the ride!

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-4. Dragonfly
T M
Guidelines-
Minimum Wheelchair Requirements
The Dragonfly
TM
is designed to accommodate most wheelchairs. There are specific
requirements that your chair must meet in order to safely attach and use the Dragonfly
TM
. Please
refer to the following table and associated pictures on the next page to determine if your
wheelchair meets the necessary specifications.
Chair
Configuration
Wheelchair must have pushrim wheels in the rear, castors in
front.
Wheelchair
Frame
The geometry of the tubes at the front of your wheelchair must be
similar to one of the 3 wheelchair frames shown in Figure 1
(page 10), specifically the regions where the clamps attach. If
your wheelchair is not similar, please contact Customer Service
at [e-mail].
Wheelchair
Frame Tube
Diameter
For our standard product your wheelchair frame tube size must
be 1 inch (25.4 mm) in diameter. To measure your tube
diameter, cut out the ruler on the bottom of the next page and
wrap it around your frame tubes at the 4 clamp locations for your
wheelchair frame shown in Figure 1 (page 10). Note where the
lines line up.
The tube should be straight (not curved) for the width of the
ruler.
For frame tube diameters of 1 ⅛inches (28.6 mm), 1.2 inches
(30.5 mm), and 1 ¼ inches (31.8 mm), order a set of 4 clamps for
the appropriate tube size.
Rear wheel
axle position
When seated in the wheelchair, your center of gravity must be far
enough forward of the rear axle so as to make “wheelies” or
tipping backward difficult – THIS IS VERY IM PORTANT. If
the chair is currently set up so that “wheelies” are very easy, it
will be very unstable and very unsafe when the handcycle is
attached, leading to possible serious injury to the head, neck, or
other parts of the body.
Anti-tips are also required.
Chair width Wheelchair seat width must be between 12” (305 mm) and 20”
(510 mm) wide.
Wheel Locks Wheelchair must have wheel locks installed.
Weight Combined wheelchair and user weight of less than 280 lb. (130
kg.); user weight no more than 250 lb. (115 kg.)

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Figure 1. Wheelchair Frame Configurations
RULER MUS T BE PRINTED AT 100% - NO S CALING, RULER IS 6” (152 mm) LONG
Frame
with Swing
-
Away Footrests
(balls facing inward)
F
rame with
No Horizontal Bottom
Tube
Available
(balls facing outward)
Frame with Horizontal Bottom Tube Available
(balls facing outward)
S
T
A
R
T
H
E
R
E
1”
1 ⅛”
1.2”
1 ¼”
CUT ALONG DASHED LINE,
WRAP AROUND CHAIR FRAM E
FRAM E MUST BE
STRAIGHT FOR
WIDTH OF RULER

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Proper Fit of Your Handcycle
•You must be able to see over the hand crank and chain guard.
•When seated in the wheelchair, your center of gravity must be far enough forward of the rear
axle so as to make “wheelies” or tipping backward difficult – THIS IS VERY IM PORTANT.
•When riding the handcycle, your arms should never be straight; ideally elbows should be
slightly bent when the pedals are farthest away from you.
•The hand crank must be clear of your knees at the lowest crank position – the Dragonfly
TM
has coaster brakes, which are operated by rotating the cranks in the reverse direction. YOU
MUST BE ABLE TO PULL THE CRANKS BACK FREELY TO SLOW DOWN AND
STOP!
•Your feet or footrest should not contact the front tire either when it is straight or turning – the
handcycle must be adjusted to prevent this.
Before You Ride
•The handcycle transforms your chair into a highly maneuverable exercise device, so
ALWAYS WEAR A HELMET.
•Make sure reflectors are installed, oriented properly, and not covered with dirt or dust.
•The use of safety belts is recommended when operating your handcycle.
•Always engage the wheel locks on your wheelchair before attaching or detaching the
handcycle.
•Secure your legs or feet so that they don’t fall off the footrest when riding.
•ALWAYS check to make sure that your 4 ball sockets attachments to your wheelchair are
fully engaged before operating your handcycle.
•Check to make sure all nuts and bolts are tight and all latches are secured before riding.
•Make sure both the coaster and the emergency hand brake work properly before riding your
handcycle.
•Do not add any parts or accessories not authorized by Rio Mobility to your handcycle, or you
will void your warranty.
•Follow the maintenance procedures to keep your handcycle in good shape, and you’ll enjoy it
for a long time.
Operating Instructions
•Operate your handcycle with the same care and caution as you would any wheelchair or
bicycle.
•Mind your fingers and hands when using your handcycle – keep them and any loose hair or
jewelry away from the chain, sprocket, and the wing attachment points.
•When moving slowly or in tight spaces, use the pushrims to propel and steer your
wheelchair, as you normally would – the Dragonfly
TM
won’t interfere with that.
•Be very careful going over bumps and curbs over 1” (25 mm) high. Your front castors may
contact theses surfaces, making you unstable. Use your pushrims to get over these bumps,
NOT the handcycle. You should approach bumps and curbs straight on and at very low

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speeds to avoid damage to your wheelchair and injury to you – your return spring should
keep the front wheel straight, freeing up your hands for the pushrims.
•Be aware of the road surface, especially on inclines or declines. Watch out for water, ice, and
oil films.
•Always mind your speed, especially when turning; you should have full control of your
wheelchair at all times. Do not exceed the maximum allowable speed recommended by your
wheelchair manufacturer.
•This handcycle is meant for recreational use only, and it is not intended for use in
competition.
•Keep children away from your handcycle to avoid maladjustment and possible injury to both
you and the child.
•Always watch out for traffic and pedestrians when riding on the road and sidewalk – follow
traffic regulations.
•Follow any and all local regulations which apply to bicycles, as these now apply to you as
well.
•Do not carry any riders.
•Do not carry anything that obstructs your view or interferes with the hand crank operation.
•Do not lift your wheelchair by the handcycle.
•Do not put weight on the wings – this includes weight due to objects and people.
•Rio M obility is not responsible for any damage or injury due to misuse of your handcycle.
Tire Pressure
• All tires – including those on your current chair – have the pressure range printed on the
sidewall. Lower pressures in the Dragonfly
TM
tire result in greater traction and a better ride.
Weight Limits
•The Dragonfly
TM
is designed for a maximum rider weight of 250 lbs. (114 kg.) and a
maximum combined weight of rider and wheelchair of 280 lbs. (130 kg.) Exceeding this
limit will greatly void the warranty and reduce the lifespan and increase the amount of
maintenance necessary for this handcycle.
Stability and Balance Notes
•Three wheeled vehicles are inherently unstable in turns, so be careful to keep all three wheels
on the ground and moderate your speed when approaching curves.
•Be very careful when reaching and leaning left or right from your wheelchair with your
handcycle attached – the longer wheelbase makes it less stable in sideways leans than your
normal wheelchair.
•Narrow wheelchairs are less stable, so be extra careful if your wheelchair is narrow.

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Weight Distribution Notes
•When seated in the wheelchair, your center of gravity must be far enough forward of the rear
axle so as to make “wheelies” or tipping backward difficult – THIS IS VERY IMPORTANT.
If this is not the case, enough weight will not be on the front tire, and braking and stability
will be severely compromised.
Transfers
•DO NOT attempt to transfer into or out of your wheelchair with your handcycle attached –
you MUST detach the handcycle before attempting transfers.

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-5. What Comes in the Box-
The Dragonfly
TM
unit will arrive to you 90% assembled. You will need to install the pedals and
wings to the handcycle, the 4 clamps to your frame, and the reflectors to the wheel. The
following is what you should receive in the box (not shown to scale):
Item Description
1 Handcycle users manual (actually, it’s in your hand)
2 Wheel hub user’s manual (for 3 or 7-speed hubs only)
3 Handcycle assembly (wheel, fork, top tube, etc.)
4 Left and right wings
5 Four M 6 screws, 4 lock washers, 4 flat washers, and 4 nuts to attach wings
6 Hand crank pedals, marked left and right
7 Four clamps for 1” (25mm) wheelchair frame tube size, including 4 ball nuts, 4 M 10
socket screws, 4 lock washers, and 4 flat washers
8 5 mm and 8 mm hex wrenches (7-speed also comes with a 4 mm wrench)
9 ¾ inch (19 mm) and 10 mm open end wrench
10 2 cable ties to secure brake and shift cable housings (if necessary)
11 2 reflectors (attach to spokes)
12 2 blocks for lifting the front wheels for installation
If you are missing any of these items, please contact Rio M obility customer service
([e-mail]).

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On Your End
It is expected that you have the following tools for installation and setup of the Dragonfly
TM
:
1. Adjustable wrench
2. Pliers
3. Torque wrench
4. Tire pressure gauge
5. Bicycle pump
6. Philips head screwdriver (3-speed only)
The Parts of Your Handcycle
Figure 2 shows a handcycle. All the parts referred to in the instructions are labeled.
Figure 2
Crank
Pedal
Top-link
Wing (left)
Bottom-link
Wing Plate
Steering Plate
Parking/Emergency
Brake
Coupler
Crank Arm
Top Tube

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-6. Initial Installation Instructions-
Before You Get Started:
The Dragonfly
TM
is engineered to be highly adjustable to the rider and his or her wheelchair.
After working through the initial setup and making adjustments as you ride, your handcycle
should fit you like a glove.
Getting your handcycle just right takes time, but your patience will be rewarded with years of
fun and energizing rides.
So, get your tools out, we’ve got work to do!
Other Notes on Installation:
Since the Dragonfly
TM
is a highly customizable product, it REQUIRES TWO PEOPLE to setup
properly. Of course, once you’ve got it configured for your wheelchair, you won’t need any help
with it, but you will have to get some help from another individual to get it from the box to the
street the first time around.
If you are uncomfortable adjusting your wheelchair or have trouble with tasks requiring a high
degree of dexterity, such as assembly, tightening nuts and bolts, or gripping a wrench, then it is
recommended that you have a qualified technician do the initial installation of your Dragonfly
TM
handcycle for you.
Please refer to your local telephone directory to find a bicycle or wheelchair mechanic if you
wish to have someone else install your handcycle for you.
The following pages contain detailed information on how to adjust and setup your Dragonfly
TM
;
REM EM BER TO CHECK AND TIGHTEN ALL COMPONENTS AFTER SETUP!
Dragonfly
TM
Installation in Five Easy Steps:
A. Installing Clamps on Your Wheelchair
B. Assemble the Handcycle
C. Determining the Right Position of the Wheel and Crank
D. Adjusting the Wings and Top-Links to Lock Your Handcycle Into Position
E. Tightening It All Down and Doing a Final Check
F. Go for a ride!

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A. Installing Clamps on Your Wheelchair
1. Remove any plastic covers, such as on the axle nuts, and packing materials.
2. Determine which wheelchair front tube configuration is similar to your wheelchair (Figure 1,
page 10). If none are similar, please contact customer service at [e-mail]
3. M easure the diameter of the tubes where the clamps will be installed (example locations are
shown in Figure 1, page 10) for the wheelchair frame configuration that is similar to your
wheelchair. Verify that you have the correct diameter clamps (instructions on page 9).
4. Install the clamps at the approximate locations shown in Figure 1 (page 10), paying special
attention to the orientation of the clamps and the direction the ball is facing. The ball should
face toward the outside of the wheelchair if possible, but for wide chairs, the ball may have
to face toward the center of the wheelchair. M ake sure the washers are in between the clamp
and the head of the screw (Figure 3). General guidelines for clamp location include:
•The clamps must be installed on a straight section of tube
at least ⅛” inch (3 mm) away from any curve, bend, or
weld in the tube, but if possible a ½” (12 mm) gap is best.
•The clamps should be in the approximate
location/orientation shown in Figure 1.
5. Tighten the clamp using the 8 mm Allen wrench to a tightness of approximately 10 ft-lbs
(13.6 N-m). This is approximately a force of 20 lb at 6 inches away from the screw (90 N at
15 cm away from the screw).
6. If you have difficulty with these steps, please contact customer service.
B. Assemble the Handcycle
Attach Handcycle Pedals
1. Your Dragonfly
TM
handcycle comes with a right hand pedal and a left hand pedal. The pedal
axles are marked (R for right, L for left on the top of the screw) and threaded in opposite
directions, so each pedal only fits into its specific crank arm. The right crank arm has a chain
ring attached to it; the left crank arm is free.
2. In order to keep the wheel still during pedal installation, you may apply the parking brake by
squeezing the brake lever and depressing the spring loaded pin next to it. Refer to Figure 4
on page 18. To release the parking brake, simple squeeze the brake lever again.
3. Thread the right pedal axle into the right crank arm in a clockwise direction. You should be
able to screw the axle into the crank arm completely by hand – if you encounter too much
resistance or it simply will not start, make sure the axle is properly aligned and the proper
pedal is in the correct crank arm.
Figure 3
Flat
Lock

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4. Thread the left pedal axle into the left crank arm in a counter-clockwise direction. You
should be able to screw the axle into the crank arm completely by hand – if you encounter
too much resistance or it simply will not start, make sure the axle is properly aligned and the
proper pedal is in the correct crank arm.
5. Completely tighten the pedal axles to the crank arms using an adjustable wrench to a
tightness of approximately 10 ft-lbs (13.5 N-m). This is approximately a force of 20 lb at 6
inches away from the screw (90 N at 15 cm away from the screw).
Install reflectors and secure loose cable housings
1. Your handcycle comes with two reflectors – a long one that should be mounted to the wheel
spokes and a small one that should be mounted to the top tube.
Extend Top Tube and Tension Chain (if required)
1. Your handcycle should come with the top tube extended and the chain pretensioned, but if
you need to readjust it, please move on to Step 2. Otherwise, skip ahead to Step 1 on page
20.
2. Using the included 5 mm hex wrench, loosen the clamping bolts on the brake clamp, the
shifter clamp, and the top tube clamp – the top tube clamp is pictured being loosened in
Figure 4.
Figure 4
3. Extend the top tube until the chain is fairly taut, with roughly ½” (13 mm) of side to side
play. The crank sprocket should be roughly aligned with the wheel sprocket. Slide the brake
down until it contacts the top tube clamp. With the top tube extended, apply tension to the
chain by gripping the top tube and pushing against the top of the brake clamp with your
thumb (Figure 5, page 19). Tighten the brake clamp. The chain should now be tensioned,
but the top tube should still rotate freely.
Parking brake
Lock pin

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Figure 5
4. Rotate the top tube so that the crank sprocket and the wheel sprocket are properly aligned,
and tighten the top tube clamp bolts to a tightness of 8 ft-lbs. (10.8 N-m). This is
approximately a force of 16 lb at 6 inches away from the screw (70 N at 15 cm away from
the screw).
5. M ove the shifter up the top tube so that the shifter clamp and brake clamp are a couple of
inches apart. Rotate the shifter so that the shifter lever is positioned about halfway between
the chain and the left crank arm and facing you (Figure 6). Tighten the shifter clamp.
Figure 6
6. Loosen the brake clamp, and rotate the brake so that the brake lever is positioned about
halfway between the chain and the left crank arm and facing AWAY from you, with the
crank in the down position (Figure 7, page 20). Tighten the brake clamp.

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Figure 7
Attach Wings
1. Attach the right wing to the handcycle using the M 6 screw supplied. Insert the screw
through the bottom hole of the wing plate and steering plate (Figure 8). M ake sure you
position the washers as shown. Tighten the nut down all the way, and then back it off one
full turn so that the wing can rotate. Do not install the screw in the top holes. Do the same
with the left wing.
`
Figure 8
Lock
w
asher
Flat
w
asher