Barracuda Water Bike Owner’s Manual and Assembly Guide Models: BK 100 / BK 200 www.futurebeach.com At Future Beach, customer satisfaction is our top priority. For all inquiries and product support contact us at: 1-800-357-7837 y info@futurebeach.com Future Beach is publicly traded on the TSX Venture Exchange, symbol FBC Printed: April 2002 Future Beach Barracuda Owner’s Manual and Assembly Guide Congratulations on the purchase of your new Barracuda Water Bike. At Future Beach, we are proud of our world-class product designs, workmanship, and quality. The complete satisfaction of our customers is our primary concern. The Barracuda is the world’s finest and most durable water bike. This manual will detail your Barracuda’s assembly instructions, product care, safety issues, and limited warranty information. With proper care and consideration, your Barracuda will provide many years of safe and trouble-free enjoyment. For your optimum safety, pleasure, and satisfaction, we urge you to read this manual carefully and to follow its instructions and recommendations. Rediscover the beauty of your favorite lakeshore on your Barracuda Water Bike. With its body-contoured seats, you can cruise the lake or sea for hours at a time – alone or with a friend. The Barracuda Twin Water Bike is ideal for couples looking for a relaxing and comfortable ride on the water. With its independent drive and steering systems, you can sit back and relax while your partner takes you for a ride. If speed is what you are after, get together with friends and organize your own Barracuda race. With its hydrodynamic propeller blades and efficient drive system, your Barracuda can reach speeds of up to six miles an hour. Studies show the Barracuda to be an effective (and pleasurable) physical workout. Or, take your Barracuda on the high seas and go fishing. With its trimaran hull design, your Barracuda is so stable that you can actually stand upright on it and reel in your catch. CONTENTS Page I. Tools Required II. Barracuda Features III. Assembly Instructions A. Installing the Gearbox Cover B. Installing the Steering Column C. Installing the Steering Cables D. Installing your Barracuda Seat E. Unwrapping Plastic from Propeller IV. Leading-Edge Technology, Design, and Innovation V. Safety Recommendations and Warnings VI. Maintenance Tips A. Removing your Kevlar Belt B. Replacing the Transmission Belt C. Reconnecting Gearbox to Propeller Shaft D. Drainage Instructions E. Cleaning Instructions VII. Limited Warranty I. TOOLS REQUIRED 6 mm / ¼” Allen key with hexagon head – for draining water from the boat; Phillips screwdriver that fits 3/8” screws – for attaching cover to hull; ratchet that fits 3/8” hexagon head bolts – for connecting prop 1 2 2 2 3 3 3 3 4 5 6 6 6 7 7 7 8 1 Future Beach Barracuda Owner’s Manual and Assembly Guide II. BARRACUDA™ FEATURES All of the materials used to produce the Barracuda components are selected for their quality and performance characteristics. The smooth, sophisticated, and considerate lines of the hull design are simple and elegant. Many of the unique and innovative functions set a new standard for water bike design. III. ASSEMBLY INSTRUCTIONS *STEP (A) APPLIES ONLY IF BARRACUDA COMES PACKAGED IN A BOX *IF BARRACUDA COMES PACKAGED IN POLYBAG, REFER TO STEP (B) A) Installing the Gearbox Cover BK 200 • Length: 128 inches; 325 cm • Width: 50 inches; 127 cm • Height: 29 inches; 74 cm • Weight: 203 lbs; 92 kg • Capacity: 640 lbs; 290 kg 1. Lower the gearbox assembly in place (Fig. 1). Be sure that the bronze rod faces the rear of the craft. To connect bronze rod to propeller shaft, consult Step (c) on p.8 2. Lower the gearbox cover into place (Fig. 2). 3. Once the gearbox cover is firmly placed, use a Phillips screwdriver to attach it to the hull (Fig. 3). Fig. 1 Fig. 2 Fig. 3 BK 100 • Length: 128 inches; 325 cm • Width: 47 inches; 119 cm • Height: 29 inches; 74 cm • Weight: 134 lbs; 61 kg • Capacity: 340 lbs; 154 kg 2 Future Beach Barracuda Owner’s Manual and Assembly Guide B) Installing the Steering Column 1. Remove plastic wrapping from bottom of steering column to expose steering cable (Fig. 1A). Do not separate cable wires from the steering column. With Phillips screwdriver, temporarily unscrew the rubber stopper (Fig. 1B). 2. Holding the steering column upright pass the steering cable though the steering column opening and into the steering channels (Fig. 2C). 3. Turn the steering column 90 degrees counter-clockwise to align the stop block (Fig. 3D) on the steering column with indentation (Fig. 3E). 4. Insert the steering column into the gearbox cover. Push down firmly on steering column so that it sits at the bottom of the opening (Fig. 4). 5. Once steering column is placed inside the opening, turn the handlebars 90 degrees clockwise, so that the handlebars are in the ready-to-use position (Fig. 5). Use a Phillips screwdriver to reinstall the rubber stopper. C) Installing the Steering Cable 2. Place both steering cables underneath the steering pulley (Fig. 2B). Put the two screws into the loops at the end of each cable. With one hand, hold the cables in place underneath steering pulley. Using other hand, thread the wing nuts onto the screws from the top and tighten securely. 1. Open the back hatch to access the steering cables and pulley system. Pass the two ends of the steering cable along the steering channels towards the rear of the craft. Be sure that the cables are passed underneath the rudder pulley (Fig. 1A), then cross the cables after the rudder pulley. To install seat, stand behind the Barracuda, and slide seat forward along rails. To adjust the seat position, lift the seat, slide it into place, and push into seat locks. The Barracuda’s propeller blades are wrapped in plastic to protect them during transport. Remove plastic wrapping before using your new Future Beach™ water bike. Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 1 Fig. 2 D) Installing the Barracuda Seat E) Unwrapping the Propeller A B Fig. 5 A B C D E 3 Future Beach Barracuda Owner’s Manual and Assembly Guide IV. LEADING-EDGE TECHNOLOGY, DESIGN, & INNOVATION Introduction Founded in 1992, Future Beach is focused on developing innovative, rugged, and feature-rich products, always expanding its comprehensive, modular product line. At Future Beach, we are not only extremely proud of the Barracuda’s aesthetic appeal, but the technology behind it. The major concern for the product designers at Future Beach is how technology translates into function. The technological features and functions of the Barracuda Water Bike are outlined below: Hull The hull of the Barracuda Water Bike is made from roto-molded polyethylene. Since polyethylene is a high density plastic, the hull of the Barracuda is extremely durable. Another great feature of the Barracuda’s polyethylene hull is that it is both 100 % UV-stable, and 100% salt-water resistant. The trimaran hull design of the Barracuda ensures tremendous stability in various wave and wind conditions. The sleek, contoured shape of the Barracuda yields excellent aerodynamic as well as exceptional hydrodynamic qualities. Seats The Barracuda’s contoured seats are ergonomically designed for excellent support of the human body. The placement of the seat in relation to the height of the pedal makes for the optimum low-profile angle at which to strike the water. The seats of the Barracuda are not only extremely easy to install, but to adjust as well. This flexibility allows for any sized person to achieve optimum levels of comfort and efficiency while pedaling. Transmission System Belt: The Barracuda has a Kevlar belt driven system. Future Beach designers chose Kevlar since it is one of the toughest materials available -- outperforming all others in harsh sand or salt-filled water environments. The Kevlar belt is 100% non-corroding. Gearbox: The gearbox contains 4 small gears with 8 stainless steel bearings, which give long life in corrosive water conditions. On the front of the gearbox is a tension adjusting screw, which allows the Barracuda user the ability to change the tension created from the belt on the flywheel. The gearbox has a flexible quality that complements the flexibility of the Kevlar belt. This means that the gearbox itself is not susceptible to breakage, even under the most heavy-duty commercial applications. Flywheel: Four belt retainers are positioned along the circumference of the flywheel, which act as a belt guide, preventing the belt from slipping of the flywheel. Aluminum Coupling: The gearbox and the propeller shaft are connected to one another by an aluminum coupling. This is a soft, flexible connection that provides excellent contact between the two components. Since the gearbox and propeller shaft are not directly connected, there is never the worry of creating any static energy or for any possible corrosion occurring. Bearings: The bearings of the gearbox are self-lubricated and self-cleaning. Each rotating piece in the gearbox has mini-paddles that channel water to every part of the gearbox, creating a fountain-like effect. This constant lubrication flushes out all sand and salt, thereby preventing any contamination that may occur to the product caused by contact with corrosive water environments. 4 Future Beach Barracuda Owner’s Manual and Assembly Guide Octopus propeller Future Beach has looked to nature in developing the Barracuda’s unique folding propeller. The octopus is a creature that has tremendously efficient hydrodynamic ability. Gliding slowly through the water, it can accelerate and pounce on its prey in the blink of an eye. The octopus-propeller (octo-prop, for short) is designed in such a way that three blades fold, much like the tentacles of an octopus. When the pedals are set into motion, the propeller blades reach their maximum diameter, allowing for great propulsion. When the user stops pedaling, the propeller automatically collapses, creating a low resistance shape allowing for prolonged gliding action, saving human energy for long distance excursions. The Barracuda’s octo-prop blades are made from extra-durable polypropylene – the same resilient material used to manufacture winter shovels. The pitch and diameter of the propeller gives an exact and effective workout. If you pedal very fast you apply more force and more revolutions per minute, and can achieve speeds of up to 6 mph. Likewise, if you choose to cruise on a low rotation you still create excellent propulsion. With the Barracuda’s intelligent octo-prop system, one can achieve exciting speeds without straining to pedal. Propeller Shaft: The Barracuda’s stainless steel ½ inch diameter rod is extremely durable, providing long- life performance without ever rusting. V. SAFETY INSTRUCTIONS Recommendations • Always wear a personal floatation device or lifejacket when operating any watercraft. • Plan your outings in accordance with the weather forecast. • Advise someone of your travel plans. • Stay in range of a safe harbor; beware of offshore winds that may make it difficult to return to shore. • Increase your visibility with other boaters by wearing bright colors. • Keep a whistle handy to alert other boaters in the case of an emergency. WARNINGS • Do not jump from a dock onto the Barracuda Water Bike. • Never let children operate a watercraft without adult supervision. • Do not dive off the Barracuda. • The Barracuda is not designed to be used in excessive wave conditions or in fast river currents. • Lay off the Barracuda pedals when coming into shore – allow the water bike to glide to a stop. • Do not pedal in water less than 30 inches deep. • Do not drag the Barracuda on the beach. 5 Future Beach Barracuda Owner’s Manual and Assembly Guide B) Replacing Transmission Belt Fig. 1 Fig.2 Fig. 3 Fig. 4 Fig. 1 Fig. 2 Fig. 3 Fig. 5 Fig. 6 Fig. 4 A B 1. Using a Phillips screwdriver, remove screws and washers from the gearbox cover (Fig. 1). Lift gearbox cover upwards to remove it from hull. 2. To detach gearbox from the propeller shaft, use a set of pliers to remove the second shear pin (Fig. 2A) from the aluminum coupling. Remove gearbox and flywheel from hull. 3. Using a Phillips screwdriver, remove at least two belt guides (Fig. 3B) from the circumference of the flywheel. 4. Slip the belt off the flywheel, and lift upwards to remove it from the gearbox (Fig. 4). A) Removing Gearbox Assembly from Hull REPLACING KEVLAR BELT VI. MAINTENANCE TIPS 6 4. The universal joint is ready to be engaged (Fig. 4). 5. Take universal joint, ensuring that bronze rod faces in opposite direction of white screw on gearbox, and place belt loop around the roller track (Fig. 5). 6. Ensuring that universal joint plates are aligned with the mating guides in gearbox, push universal joint into gearbox until it snaps into place (Fig. 6). 1. Squeeze belt together, ensuring that the teeth are facing each other (Fig. 1). 2. Lay gearbox on its side (white plastic screw facing up) and feed belt through gearbox (Fig. 2). 3. Pull belt until half of belt is on either side of gearbox (Fig. 3). Future Beach Barracuda Owner’s Manual and Assembly Guide 8. Spread belt open, take the flywheel and place it through belt. Rotate the belt 90 degrees counter- clockwise (if rotated clockwise, the craft will go backwards). Attach belt guides to circumference of the gearbox assembly (Fig. 8) 9. The unit is now ready to be connected to propeller shaft (Fig. 9). C) Reconnecting Gearbox to Propeller Shaft Fig. 7 Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 A B C Fig. 8 Fig. 9 1. To connect gearbox to propeller shaft, take the aluminum coupling (Fig. 1A) and place it at the end of bronze rod 2. Insert first pin (Fig. 2B) through appropriate hole in aluminum coupling and through appropriate hole in bronze rod. 3. Lower the flywheel and gearbox into the hull (Fig. 3). 4. Insert second pin (Fig. 4C) through aluminum coupling to attach propeller shaft. 5. Cover flywheel with housing unit and using Phillips screwdriver, fasten on securely with screws and washers provided (Fig. 5). D) Draining Water from the Barracuda On occasion, small amounts of water may collect in the hull due to condensation and other factors. If necessary, drain water from the Barracuda using an allen key to open the drain plug, located at the rear of the hull. Stand the Barracuda up against a wall to let the water drain from the hull. E) Washing Instructions The hull of your Barracuda water bike has been specially treated with UV-stabilizers. Clean the hull with soap and water, when necessary. Do not use harsh or abrasive cleaning solvents. 7 7. Pull belt upwards thereby tightening belt at bottom of gearbox (Fig. 7). Future Beach Barracuda Owner’s Manual and Assembly Guide VII. LIMITED WARRANTY Future Beach warrants the hull of your new Barracuda to be free from defect in materials and workmanship for a period of three (3) years from the date of retail sale, subject to the following terms and conditions: The Barracuda water bike components are covered for a period of one (1) year from the date of purchase. These components include the water bike’s steering column, steering cables, gearbox, gearbox covers, transmission belt, seat, rudder, flywheel, pedals, propeller, propeller shaft, as well as product accessories. The warranty is applicable to Future Beach products registered and normally operated in North America. Under this warranty, Future Beach Corporation is limited to the repair or replacement of the components. This warranty is non-transferable to a subsequent owner. What is not covered by warranty • Damage due to misuse, accident, collision, etc. • FBC shall have no liability whatsoever for any personal injury, accident or consequential damages • Wear-and-tear deterioration, discoloration, fading, etc. • Commercial use (refer to our commercial warranty) • Damage or surface corrosion caused by the environment • Damage caused by the use of aggressive chemical cleaning solvents • Any damage incurred to and from Future Beach due to transport • Any transportation charges to and from an Authorized repair facility For Service: If there is a problem with your new Barracuda water bike that is covered by our warranty, please: A) Visit our website at www.futurebeach.com/warrantyform.htm and fill in the required information. B) Fill in the information below and fax this page, along with a copy of the bill of sale to: Future Beach Corporation Attn: Customer Service (514) 694-9911 WARRANTY CARD Product__________________________ Name_________________________ Model___________________________ Street_________________________ Serial Number____________________ City, State_____________________ Dealer Name______________________ Zip / Postal Code_______________ Date of Purchase__________________ Telephone_____________________ E-mail________________________ C) (If you do not have access to a fax machine), fill in the information below and mail (with appropriate postage), along with original bill of sale to: Future Beach Corporation 181 Oneida Drive Pointe-Claire, QC Canada H9R 1A9 8 Future Beach Barracuda Owner’s Manual and Assembly Guide Future Beach Corporation, The World’s Beach Company 181 Oneida, Pointe-Claire, Québec, Canada H9R 1A9 T: 514-693-9600 (800) 357-7837 F: 514-694-9911 WWW.FUTUREBEACH.COM E-mail: info@futurebeach.com Future Beach is publicly traded on the TSX Venture Exchange, symbol FBC