Xtracycle EdgeRunner Swoop User manual

EdgeRunner Swoop/Classic ASSEMBLY MANUAL
Rev 1A

getting started
This guide is designed to help you build an EdgeRunner Swoop or Classic as efficiently as pos-
sible. Please follow the assembly instructions in order. This guide covers most common acces-
sory variations and all models, with notes on common problems and troubleshooting. While
thorough, this guide is not exhaustive - you should already be familiar with all bike component
installation and adjustment procedures. If you are not, please refer to the component docu-
mentation to ensure correct installation and adjustment.
A note to the builder, before diving in:
As longtail cargo bike pioneers, we do things differently. This bike has unusual chain length, rear wheel dish,
steer tube length and rider t (not to mention all of our custom accessories).
1. The chain is intentionally 168 links. Longtail cargo bikes are unique - they have a wide gear range and an
extra long chain. When you check the shifting, particularly “big-big” cross-chain, the extreme derailleur
extension may look a little painful. However, in testing, we noticed the rear derailleur works better, the chain
bounces less and the drivetrain relaxes over time. Sometimes ddling with the B-tension screw can raise the
derailleur slightly.
2. Asymmetrical rear wheel dish. We redesigned our dropouts to create better chain/derailleur/tire clearance
which “shifted” the rear axle toward the drive side. The rear wheel is then dished back toward the non-drive
side. The result is a stronger load-bearing wheel that keeps the derailleur and chain clear of the tire.
3. We like our steer tubes long. Unlike traditional road and mountain bikes, cargo bikes benet from a much
more upright riding position. While it is always an option to cut down the steer tube, we recommend letting
the customer ride it for a while before making the decision to shorten it. If you chose to cut the steer tube
short, check to be sure that any stem-mounted lights will clear the porter rack, if applicable.
4. Help select stem/post kit for optimal rider t. In the separately-shipped accessory box, you should nd the
stem and seatpost kit ordered with this bike. Many shops will stock all three sizes so that the rider(s) can be
best accommodated. This is important when sharing the bike between differently sized riders (i.e. families or
demo bikes) and is a surprisingly effective way to customize t on upright bikes.
Warning:
Always use wheel protection like WheelSkirts or Xtracycle bags when riding with passengers or cargo.

Included
1. Large Box: Bike frame with assembled back wheel, derailleurs, tailpiece, V-Racks, and FlightDeck
(will need additional bolts depending on chosen accessories), assembled handlebars with brakes,
gears, and cables, the front fork, and front wheel. In addition, the accessory box will include pedals,
seat, owner’s manual, reflectors, headset and spacers, handlebar stabilizer, remaining deck bolts for
standard install, and front brake rotor.
2. Smaller Box with Sizing Kit: Will include: an Xtracycle seatpost and a stem. May include Xtra-
cycle Kickback 3, Herrmans lightset, Xtracycle bags or WheelSkirts, and other accessories you’ve
ordered.
NOTE:
To assemble an EdgeRunner
you’ll need two boxes - One
very large one containing the
bike, and another that will
include a sizing kit containing
the stem and seatpost, and
other accessories like
EdgeRunner WheelSkirts or
CargoBays, and a KickBack 3.
in the box

Unboxing the EdgeRunner
step 1
• Open the box
• Remove the accessory box from the back of the bike.
• Lift the bike out (team lift recommended) and set it
upright on the oor.
• Pull the seatpost out from the sizing kit, grease the
seat tube and insert the seatpost to the minimum
insert line. Torque the seatpost collar bolt to 5nM.
1A
• Fold the corner of the cardboard block closest to the
seat post back and out of the way, to make room for
the clamp.
• Lift the bike into the stand (team lift recommended)
and clamp it by the seat post.
1B

Remove the Fork and Front Wheel
step 2
Remove the fork from above the rear wheel - this
does not require removing the deck.
2A
Both the front wheel and the handlebars are attached
to the thick, protective cardboard “front wheel block.”
Remove the bars rst and zip tie them to the top tube
to avoid damaging the hoses or derailleur cables. Then
remove the block and front wheel.
Starting from
the back of the
bike, remove the
packaging.
3
2B
Remove the Packaging
step 3

Install the Fork
step 4
Find the headset and spacers in the included small
parts box, and the S/M/L sized stem (paired with
seatpost) in the separately-shipped accessory box.
4A
The headset includes a thin rubber seal that sits on the
lip of the crown race. Install this rst, then the lower
bearing (the lower bearing is larger than the upper).
Grease liberally.
4B
Slide the steerer tube up through the headtube,
taking care to make sure the hoses and housing are
routed correctly.
4C
Pro tip: Zip-tie or toe-strap the fork to the
down-tube to assist during stem/headset assem-
bly.
Note: The cable housing and hoses are routed
past the head tube on the same side as they
come up the down tube - don’t cross them under
the downtube!
*

Install the Headset & Stem
step 5
Slide on the upper bearing, top race, split bushing, bearing cap, spacers, and the stem.
5A
Install the stem cap and bolt to hold things in place,
but do not adjust at this point.
5B

Install Handlebar
step 6
• Remove the faceplate with
integrated light mount from
the stem, and install the
handlebars so that the ends
of the bars will lie parallel to
the ground. Torque the stem
faceplate bolts to 6nM.
• Angle the shifter/brake lever
down 45 degrees.
6
Adjust the Headset
step 7
Tension the headset bolt to adjust the headset. You
may now release the zip-tie or toe-strap that was
holding the fork.
7A
Tighten the stem clamp bolts to 6nM to lock in the
adjustment.
7B

Bolt Brakes to Fork
step 8
The front brake and its
bolts are attached to
the handlebars - bolt
the brake to the fork per
the included shimano
instructions, but do not
torque it down yet.
8
Install the Rotor
step 9
The 180mm front rotor is
in the accessory box - at-
tach it to the front wheel,
this requires a 16-notch
external bottom bracket
tool to tighten the center
lock nut.
9

Install Front Wheel & Adjust Brakes
step 10
Remove cardboard from thru axle. Install the front
wheel, and secure the thru-axle.
10A
Now adjust the front brake.
10B
step 11
11
Install Front Wheel & Adjust Brakes
Adjust the Rear Brake
step 12
12
Adjust the Derailleurs
Pro tip: If you are installing U-Tubes, now is a good time to do it - refer to the U-Tube documentation, found on the Xtracycle Support page, for details.
*

step 13
Check RackLocks & V-Racks
Make sure the RackLocks and
V-Racks are seated correctly: The
racks should be fully inserted
into the uprights and the Rack-
Locks should be pushed all the
way down on the uprights and
the outer clamp should fully
cover the inner collar.Torque all
bolts to 5nM.
13
step 14
14
Check Tailpiece Bolts
Make sure the tailpiece bolts are
tight, use a wrench on the back-
ing nut to keep it from spinning.
Torque to 6nm.

Install the EdgeRunner WheelSkirts, these
should be tight enough to keep anything
from pushing it into the wheel - you may
need to loosen the bolts holding the deck
on to slip the straps between the deck and
V-Racks.
15a
Installing the WheelSkirts
step 15
On the lower straps, make sure not to
wrap straps around the derailleur cable.
Note: If you are installing a Hooptie, now is
a great time to do it. You may need to loosen
the WeddingRings that connect the seat stays
to the racks.
*Pro Tip: If you are installing bags, the
WheelSkirts are not necessary. This is the
right time to install Xtracycle bags.
*
15b

Bolt Down the Deck
step 16
If you’ve already installed your Hooptie handrails
(optional) secure the deck by tightening the four bolts
already in the deck and installing the four long bolts
and nylock nuts provided into the empty bosses on
the V-Rack - two in the front and two in the rear.
Note: The larger thicker washer goes between the
deck and the V-Rack.
16
Note: If you are having a hard time
aligning the holes in the deck to the
holes in the rack bosses, loosen the
WeddingRings so that you can move
the V-Racks slightly.

Finally, apply some blue
loctite to the threads of the
WeddingRings, and tighten
them to a more harmonious
union - take out the slack,
then add a full turn for ten-
sion.
17
Adjust the WeddingRings
step 17 step 18
18a
Install Handlebar Stabilizer
Use pliers to thread the spring. Install protective cover over stabilizer spring.
18b

KickBack Installation
step 19
Refer to Kickback instructional
manual.
19
step 20
20a
Install The Front Light
Remove the black nut and bolt holding the light to its bracket. Note that the nut will t into a hexagonal pocket
on one side of the bracket, so you won’t need to hold it by hand/wrench.
Hold the back of the light and pull forwards on the clear plastic tab to remove the light’s cover.
Install the provided batteries, then reinstall the bracket with the black bolt and nut.
(Skip to step 21 if your model didn’t come with a front light)

Attach the bracket to the mounting eyelets on
the stem using the shorter silver bolt and match-
ing nut. The semi-spherical washers should go
on either side of the eyelets, pointing inwards.
This bolt should be tightened enough that the
light will stay in place if the front end of the bike
is bounced on the ground.
Note: It is possible to ip the stem’s faceplate
to lift the light above cargo on the PorterRack.
20b
Install the Front Light Cont’d
step 20 Cont’d step 21
Pedals, Seat, and Air
Install the pedals, drop the bike out of the stand, install the seat and adjust the seat
height, air up the tires and take the bike for a test ride!