Sun Bicycles EZ-1 User manual

Notice:
This bicycle is partially assembled. It is intended to be sold in fully assembled and fully adjusted condition.
Final assembly and adjustment are to be performed by your SUN BICYCLE dealer.
TABLE OF CONTENTS
General Rules...................1
Night Riding.....................1
Recumbent Riding Tips...2
Fitting Your Recumbent..3
Assembly....................4-11
EZ Rider .........................12
EZ Speedster ...................13
EZ-3 USX.....................14
Maintenance.............15-19
Limited Warranty........20-21
Specifications.............22-27
EST.
1971
BICYCLESBI CYCLESBICYCLESBI CYCLES
EZ-Series Owners Manual

RECUMBENT SAFETY AND RIDING TIPS
General Rules for Safe Recumbent Riding
1. Always wear a CPSC approved helmet and some form of eye protection.
2. Always ride with a rear view mirror attached to your helmet or mounted on the recumbent.
3. Obey all traffic rules and regulations, signs and signals.
4. Ride on the side of the road, going in the same direction as the traffic and in single file.
5. Use proper hand signals when turning or stopping.
6. Be alert at all times, especially watch for cars pulling out into traffic or for opening doors.
7. Inspect your Sun Recumbent before every ride. Make sure all nuts and bolts are securely tightened. Check your brakes by applying
them and rock your Sun Recumbent forward and back to make sure they are engaging properly. Check your tires for proper air pressure
as indicated on the sidewall of the tires. Make sure the quick release levers on wheels and seat are secure. Also check for any
other possible mechanical problems.
9. Do not "stunt ride" or hitch a ride on other vehicles.
10. Do not ride carelessly.
11. Use extreme caution when riding in wet, icy or otherwise hazardous conditions.
WARNING:J&B Importers, Inc. is not responsible for accidents resulting from failure to comply with all bicycling safety laws. Contact your
local authorities for more specific information about such laws.
Night Riding Tips
1. Your Sun Recumbent is equipped with front, rear, wheel and pedal reflectors. They should be kept clean at all times, and never be
removed from your recumbent.
2. Always use an appropriate lighting system when riding at night.
3. Ride with extreme caution. Be alert for cars, pedestrians, runners and other bicyclists. Ride defensively and watch for road hazards.
4. Wear light colored clothing and use reflective tape on clothing or helmets to help make you more visible at night.
WARNING:Reflectors alone are not adequate for night visibility. Use a high quality front and rear lighting system for greater visibility.
Page 1

Wet Weather Caution
When rims and brakes are wet due to muddy, wet or icy road conditions the distance needed to stop safely increases. You must, therefore,
anticipate the additional distance needed to stop in such circumstances. Reduce your speed and take corners slowly and carefully. Hard appli-
cation of the brakes on wet or icy pavement (or on loose gravel or debris) can cause the wheel(s) to lock up and skid, resulting in possible
loss of control. Slowly apply brakes in a gradual, controlled manner to avoid skidding or loss of control.
Recumbent Riding Tips
There are some unique features to be aware of that will help you enjoy riding your Sun Recumbent. You may find it helpful to practice riding
in an open area, such as a paved, empty parking lot or a traffic-free road. Before riding your Sun Recumbent, please carefully read this
manual. This will enable you to familiarize yourself with the mechanical operations.
1. Relax the upper body.
2. Do not pull on the handlebars or tense the shoulders as this leads to over-steering the recumbent.
3. Ride with relaxed pressure on the handlebars.
4. When starting to ride, be sure the recumbent is in a low gear.
5. Get comfortable in the seat, and place both feet on the ground (see Seat Installation, Removal and Adjustment on page-10).
6. While sitting comfortably on your Sun Recumbent, with both feet on the ground, try propelling the recumbent slowly with your feet on
the ground. Like walking; left, right, left, right... while gently steering a little to the left and right. Keep walking the recumbent with your
feet until you can pick both feet up off the ground an inch and be able to balance yourself and steer comfortably. When you feel comfort
able, then you can try pedalling.
7. Stabilize the recumbent by applying the brake, put one of your feet on the pedal and back pedal until the crank is at the top in a vertical
position.
8. With firm pressure, push on the pedal; lift the other foot off the ground, as you release the brake and place the other foot on the other
pedal.
9. Lean back into the seatback and pedal confidently in an appropriate gear. Propel yourself at a safe and reasonable speed.
10. When riding on level ground or going downhill, lean back and relax. Up hill it sometimes helps to lean forward a little.
11. Before coming to a stop, gear down (while spinning the pedals in a forward motion); this will enable you to start again in a low gear.
Page 2

Recumbent Riding Tips (continued)
Your body may require some adjustment to the riding position and muscle groups used that the Sun Recumbent promotes. This is natural;
adaptation to the new position will vary, depending on individual physiology and exercise regimes.
1. Take short rides on level or gently sloping terrain for a few days before attempting long distances or more aggressive riding.
2. Downshift and maintain a high RPM when climbing hills. Failure to do so can lead to possible knee irritation or injury.
3. If you feel tight or sore in some areas, you will benefit from a warm up and stretching routine before and after riding.
Fitting Your Sun Recumbent.
Your Sun Recumbent will accommodate most body sizes. In order to ride comfortably and safely, you
should adjust the Sun Recumbent to fit your body.
There are 3 adjustments that can be made to customize the fit of your Sun Recumbent:
a. Seat distance from the pedals
b. Seat back angle
c. Handlebar height and angle
1. When seated, your knee should be just slightly bent when the forward foot is in the farthest posi-
tion. This is adjusted by moving the seat along the length of the frame, moving you closer or
farther away from the pedals (see Seat Installation, Removal and Adjustment on page-10). For full
power, leg extension and the least stress on your knees, double check your seat to pedal position in
the following way: Try to touch the heel of your shoe to the pedal with your knee locked. You
should barely be able to reach the flat part of the pedal. Now when you put the ball of your foot on
the pedal. You should have the proper bend in your knees. (Fig. 3.1)
2. The handlebars should be at a height that is most comfortable for your hands and arms and that allows knee clearance when pedaling.
The handlebars are adjusted by raising or lowering the stem and adjusting the angle. (see Handlebar Adjustment and Alignment page-10).
Page 3
(Fig. 3.1)

ASSEMBLY
Your Sun Recumbent is 90% assembled at the factory, therefore is easily set up in a few minutes.
Tools Needed for Assembly (Not Included)
2, 4, 5 and 6 mm Hex wrench
15 mm open-ended wrench
Adjustable wrench
Flat blade screwdriver
Philips head screwdriver
Scissors/Diagonal Cutters
Unpack Carefully as Follows:
1. Carefully remove the recumbent by lifting it straight out of the box. Be careful not to scratch the recumbent or
yourself on the carton staples.
2. Carefully remove the packing material from the frame.
3. Carefully clip the plastic ties that secure the handle bar and front wheel to the recumbent during shipping.
4. Check and make sure parts box is included.
You are now ready to begin assembly. Please read carefully the following directions.
Handlebar and Front Wheel Installation
1. Loosen the 2 stem bolts with a 6mm hex wrench and position the stem down parallel to the handlebar. Tighten the
top stem bolt completely, then tighten the lower bolt securely (Fig. 4.1)
2. Apply a light coat of grease to the expander wedge.
3. Place the bottom end of the stem into the fork. Be sure that the minimum insertion line is not exposed. Tighten the
expander bolt with a 6mm hex wrench.
4. Remove the spacer from the front fork.
5. Open the front wheel quick-release lever. Loosen the QR nut a few turns.
6. Seat the wheel axle in the slot on the front fork dropouts. Make sure it is fully seated in the slot. Traditionally the
QR lever is on the left hand side from the seated position. (Fig. 4.2)
7. Make sure the front wheel is centered property between the fork blades.
Notice:
This recumbent is partially assembled. It is intended
to be sold in a fully assembled and fully adjusted
condition. Final assembly and adjustment are to be
performed by your SUN BICYCLES dealer..
Page 4
(Fig. 4.1)
(Fig. 4.2)

Handlebar and Front Wheel Installation (continued)
8. Tighten the nut and close the quick-release lever with firm pressure (see Quick Release Lever Operations on page
16, for full operation instructions).
9. Align the handlebars perpendicular to the front wheel by standing with the front wheel between your legs. Look at
the alignment of the handlebars in relation to the front wheel. Then fully tighten the expander bolt. (Fig. 5.1)
10. To check for tightness, hold the front wheel between your legs and try to turn the handlebars.
11. Check for proper installation of the front wheel before each ride.
12. Be sure the quick-release lever is in the closed position.
13. Lift the recumbent off the ground and hit the wheel sharply from above to confirm that it is firmly attached.
Front Linear Pull Brake Installation / Front and Rear Linear Pull Brake Adjustment
1. Place brake cable nipple firmly into nipple slot on lever. (Fig. 5.2) Pass brake inner cable through grooves into
lever bracket.
2. Check brake pads, make sure they are aligned correctly on the rim, and there is a gap of 1mm between the top of
the rim and the top of the pad. Hold each pad against the rim (one at a time) & tighten mounting nut securely.
(Fig. 5.3)
3. Insert cable through cable guide pipe, cable protector and anchor-bolt. Slot cable guide pipe into holder and fit pro-
tector over guide pipe end. Set cable in anchor bolt so that combined pad rim clearance (A+B) is 2mm, then tight
en anchor bolt. (If clearance is not 1mm on each side, it will be balanced out in step 4). Crimp end cap onto cable
end. (Fig. 5.4)
4. Balance brake arms by turning spring-tension adjusters. Depress brake lever a few times while checking to see that
tension is equal for both arms. Pad/rim contact should occur at the same time on each side. Clearance should be
1mm on each side. Don't set tension too high. (Fig. 5.5)
Notes
1. Spring tension adjusters require a 2mm hex wrench. All other brake bolts use a 5mm hex wrench.
2. Pad/rim clearance can be further adjusted by turning the brake lever-adjusting barrel. (Fig. 5.6)
Caution: Linear pull brakes must be used with linear pull brake levers. Linear pull brakes offer considerable braking
power with little leverage force, and require practice at low speeds before normal use. J&B Importers, Inc. is not
responsible for damage or injury as a result of improper use or installation.
Page 5
(Fig. 5.6)
(Fig. 5.5)
(Fig. 5.4)
(Fig. 5.1)
(Fig. 5.3)
(Fig. 5.2)

SPECIAL CAUTION: Braking in wet weather conditions:
In wet weather conditions, you will need to increase the distance needed to stop safely. Anticipate the extra distance
you will need, ride slowly and carefully. Squeeze your brake levers slowly and with gradual pressure to avoid skidding
or loss of control. The same caution should be observed on loose gravel or dirt. Failure to be cautious during wet or
other severe road conditions may result in a serious accident.
Trike Rear Unit and Wheel Installation
1. Install loosely the two carriage bolts with their nuts and washers, to the two holes in the end of the trike frame stay.
The heads of the bolts are on the inside of the frame.
2. Slide the arms of assembled rear unit between rear frame stays, up to and between carriage bolt heads and frame
slot. Finger tighten nuts. (Fig 6.1)
3. Both wheels are the same. The hub flanges have three holes that fit the studs on the axle flange (Fig 6.2).
Install the drive wheel first, (right side). Add axle washer on the outside and tighten locking nut securely.
4. Now put the second wheel on left side. This wheel is the idler. First slip on the spacer (Fig 6.3), then the wheel,
followed by a washer and the locking nut until it touches the bearing. Now loosen 1/2 turn.
Do Not Over Tighten. Leave Some Side-To-Side Play (About 1 to 2mm).
Warning: Very Important: It is critical for the protection of the bearings, that you inform your customer that the idler
wheel requires a slight amount of play in order to prevent bearing damage.
5. Thread small 50 Link chain over welded sprocket on the drive hub unit and over the fixed sprocket on the rear
axle (Fig 6.4). Connect the connecting link, make sure both sprockets are aligned. If they need alignment, loosen
set screw on fixed sprocket, re-align, make sure axle key is positioned under set screw then re-tighten set screw.
6. Slowly pull unit towards end of trike until chain slack is taken up.
7. Tighten the two forward carriage bolts. (Fig 6.1)
8. Turn chainwheel and see if chain runs smoothly with no binding or excessive noise. If not, loosen bolts, move unit
slightly forward. Tighten bolts and check chain function again.
5. If chain now runs O.K. tighten all four carriage bolts securely, taking care that the unit does not shift.
Page 6
(Fig. 6.1)
(Fig. 6.2)
(Fig. 6.3)
(Fig. 6.4)

TRIKE CAUTIONS: A trikes widest point is behind you, if the front goes by an obstacle there is no guarantee that the
rear wheels will also clear. When riding, you must give clearance to the edge of the road or sidewalk. Stay clear of pot-
holes and be aware that you can lose control if any wheels should drop into a hole.
A trike does not handle like a bicycle, therefore, you cannot lean into a turn. All wheels must be on the ground at all
times. Do not make sudden changes of direction, you could unbalance the trike and have an accident.
When beginning to ride, stay at a slow speed. You must acclimate yourself to handling and turning this three wheeler. If
you feel insecure, slow down, and proceed at a slower pace. With practice, you will get comfortable riding and stop-
ping.
The rear wheels on the EZ-3SX Recumbent trike only have braking on one wheel (the right hand or “drive” wheel)
Always use both hand brakes when stopping . If only the rear brake is applied, the trike could pull to the right and you
could loose control.If the drive wheel looses traction in a turning situation, with only the rear brake applied, your trike
will not stop and you could loose control.
The trike is made for one person only and the basket is not built to hold a passenger.
Weight capacity is 300 lbs. This trike is built for manual (non-motorized) use.
Rear Disc Brake Set-up and Adjustment (if equipped)
1. Lightly lubricate cable fixing bolt to prevent stripping the threads.
2. Loosen adjusting barrel and lock nut on the right hand brake lever so that the grooves on the adjusting barrel, lock
nut, and lever are aligned. Lightly lubricate cable with clear or white grease. Secure cable end into lever. Guide
cable through grooves, tighten the lock nut against the top of the adjusting barrel and screw the adjusting barrel
fully into the lever body. Slide cable through housing. Guide housing through cable guides on frame. Guide cable
through cable anchor. Cable should be between the cable anchor washer and the groove on the caliper action arm.
Snug cable fixing bolt
3. Tension cable without compressing caliper action arm. Cable should be tight with no sag. Secure cable fixing bolt
tightly. Squeeze lever firmly and hold for a few seconds. Re-tension the cable and tightly secure the cable fixing
bolt. Cut excess cable leaving approximately 2" (5cm) length. Install cable end cap and crimp tightly.
Page 7
(Fig. 7.1)
(Fig. 7.2)

Rear Disc Brake Set-up and Adjustment (if equipped) Continued
4. Spin hub in forward rotating direction. Rotor should run freely between brake pads. Some drag is normal prior to
first usage. Pads will wear down gradually with normal usage. As this occurs, loosen the cable fixing bolt and
retension the cable. Secure cable fixing bolt tightly before use.
5. If the rotor is contacting either brake pad, try the following: 1- realigning the caliper by loosening the mounting
bolts slightly and repositioning the caliper (side to side) so the rotor is in between the brake pads. Retighten
mounting bolts. [Locking torque 60 +/-5 kg-cm] 2- Using a 2mm allen wrench, loosen the nylock screw on the
top inside of the caliper shell. Using a 5mm allen wrench, slightly turn the pad adjusting plate on the backside of
the caliper. A clockwise (right) turn will decrease the clearance of the pads. A counterclockwise (left) turn will
increase the clearance of the pads. Retighten the nylock screw. [Locking torque 10-15 kg-cm]
Note: After the first few rides, re-tension the brake cable to take up the initial cable stretch that occurs. Do not use the
brake lever adjusting barrels. This will cause the brake modulation to change, resulting in decreased braking action.
Disc Brake Pad Replacement
Tools required (not included):
Needle-Nose Pliers
2mm and 5mm allen wrench
1. Check the brake pads for wear. At 0.5mm or less, the pads are worn and must be replaced for continued safe
braking.
2. Remove caliper from the frame.
3. Using a needle-nose pliers, clamp the tab of the outside brake pad [black] and pull towards the inside pad and
down to release. Loosen the nylock screw on the caliper. Using a 5mm allen wrench, remove the pad adjusting
plate. Push the blue pad out through the back of the caliper. Dispose of the old pads properly.
4. Insert the outside [black] pad into the caliper and align tab with slot. Insert the new blue pad through the caliper
and align tab with slot. Replace the pad adjusting plate, threading it into the caliper until the back of the tab
contacts the back of the slot. There should be approximately 3mm of space. Tighten the nylock screw securely.
5. Re-install caliper onto frame. Check for proper alignment.
Retighten mounting bolts. (Locking torque 60 +/-5 kg-cm).
6. Adjust as needed per installation instructions (See Rear Disc Brake Adjustment page-7).
Page 8
(Fig. 8.1)