TRAK Kayaks T-1600 Assembly And Disassembly Manual Download Page 46

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Shell.

•  Place the shell in the pack.
•  Arrange the shell on TOP of the frames.
•  Place the WIDER end of the folded shell at the

BOTTOM of the pack .

Coaming.

•  Place the coaming in the pack.
•  Arrange the coaming on TOP of the shell.
•  Place the WIDER end of the coaming at the BOTTOM

of the pack .

TPS Jacks.

• Arrange the jacks along either side of the pack.

Seat.

• Ensure the seat back is disengaged so that it can lay

flat in the pack .

• Place the seat face down in the pack, inside the

perimeter of the coaming .

Summary of Contents for T-1600

Page 1: ...1 Assembly and Disassembly Guide ...

Page 2: ... 10 Connect the Coaming 13 Inserting the Tri active Performance System TPS jacks 14 Install the Command Seat 20 Close the Keder 24 Rigging and Finishing 25 Instructions from water to pack 34 47 Disassembling the cockpit 35 Removing frame from shell 40 Collapsing the frame sections 42 Folding the shell 44 Placing parts in the TRAK pack 45 February 2010 A B D C 1 1 2 2 3 3 4 4 5 5 6 7 ...

Page 3: ...ur TRAK kayak Parts checklist 1 x Spray Skirt 1 x Command Seat 3 x Jacks Tri active Performance System 1 x Bow Frame Section Stern 1 x Stern Frame Section Bow 1 x PolyTRAK Shell 1 x Coaming 2 x Gear Float Bags 1 x Pack ...

Page 4: ...know your TRAK Top profile Side profile Tow Handle Keder Keder Handle Seat Keel Strip Deck Rigging Grab Line Tow Handle Deck Rigging Coaming Coaming Seal Tri active Performance System Jacks 3 Stern Bow Keel Hull Deck ...

Page 5: ...l jack TPS 7 Rib B 8 Gunwale jack TPS 9 Seat Pillar 10 Rib C Components 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 4 11 Keel tube 12 Rib D 13 Stern plate 14 Foot brace 15 Opening for coaming 16 Gunwale jack TPS 17 Seat 18 Seat pillar 19 Coaming 20 Gunwales tube B ...

Page 6: ...TPS Jacks add rigidity to the PolyTRAK Shell Once the boat is rigid if you continue pulling on the TPS Jacks they begin to adjust the hull shape This is where it gets really interesting and fun VariTRAK Adjustable Rocker The TPS Jack in the keel allows you to adjust the rocker of your TRAK which increases or decreases its maneuverability and stability Every pull on the keel jack increases the rock...

Page 7: ...ack after the first two or three pulls remember the first few are used to tighten up the PolyTRAK shell will begin to change the shape either on the keel or gunwales of the kayak For example you could adjust the left gunwale TPS Jack with 4 pulls the keel TPS Jack 12 pulls and the right gunwale TPS Jack 3 pulls Any combination of the 3 TPS Jacks that gives you the desired hull shape you need for o...

Page 8: ...kayak is designed to go from pack to water or back again in 10 minutes or less There are only seven assembly steps to put your kayak together and only eight separate parts to the kayak To help you master the TEN IN assembly we ve included a simple play by play photo guide to make it even easier Yes it can easily be assembled in ten minutes even less but probably not on your first try Follow these ...

Page 9: ...the outer tube Then MOVE it under the hole in the outer tube until it POPS back out into place This spring pin helps hold the tubes together Frame assembly bow and stern sections 1 Shake out the frame to connect tubing HOLD the frame section by the bow or stern plate black end LIFT it up in the air and simply shake out each section of the frame the poles should begin to connect themselves CONNECT ...

Page 10: ...E the ball studs into the ribs as straightly as possible Follow the holes around the rib PUSHING each ball stud into its corresponding hole NOTE On the larger rib the top corner and keel tubes SLIDE into place instead of using ball studs 1 Small rib ball stud corners Connect the larger rib starting with the bungee connected corner SLIDE the top corner tubes and keel center tubes through the receiv...

Page 11: ...ction Stern section Now assemble the BOW front section ASSEMBLE same as stern section beginning with the smallest rib When attaching the larger rib first SLIDE the bottom tube into place past the spring pin 1 Then ATTACH the ball studs into their respective holes ...

Page 12: ... sure the Keder is pulled back all the way towards the tip of the stern so that the back flaps on the shell are accessible pull Insert front frame section bow into the shell The bow section has the footbraces and the seat pillars attached to it It is also the longer of the two frame sections Insert frames into shell bow stern Bow section ...

Page 13: ...s it will go by bracing one hand on the shell and the other on the rib Push on both top and bottom of the rib simultaneously NOTES You may have to straighten out the tip of the shell midway to allow the frame to slide in easier You may want to stand inside the cockpit to push the frame in The frame will not go all the way at this point Leave the end of the top frame tube exposed to approximately f...

Page 14: ...frame are inside the shell but are not connected Stern section Insert back frame section stern into the shell The stern section is the shorter of the two Insert in same manner as bow section The frame will not go all the way at this point ...

Page 15: ... secure if you take your hand off it and it remains in place The coaming will not appear secure as it is only connected to the front of the frame It will eventually rest on the stern section of the kayak at a later step Wrap the coaming seal skin around the coaming so it is ready to be fully assembled 3 Connect the coaming CHECKPOINT The coaming is secured to the bow section of the frame resting o...

Page 16: ...cks are in release position inside the kayak there will be no tension on the frame When the valve is set to release as in the photo the piston can be manually adjusted TPS switch ready position When the valve is set to ready as in the photo the jack is ready to be used When the handle is pulled upward the piston will extend and this will increase the tension in the kayak Release Ready ...

Page 17: ...sing the jack piston so you get used to how it works Connect the keel center jack first The jack handle should be facing toward the front of the kayak Start with the back stern end First PLACE the back end of the jack AGAINST the rib of the stern frame NOTE Before inserting the jack in the keel tube you will simply place it against the ribs and use the jack to spread the ribs apart This will then ...

Page 18: ...l extend the jack and spread the frames apart When the jack has extended enough so that there is room to easily maneuver it into the bow keel tube set the jack switch to Release Then simply insert the front end of the jack into the keel tube of the bow frame section And INSERT the back end of the jack into the keel tube of the stern frame section Set the jack switch to Ready and pull it several ti...

Page 19: ... of the keel TPS jack Insert jack into the gunwale tube If it does not slide easily or there is not enough room to insert it simply add more tension to the keel center jack until it fits Switch the valve position on the gunwale jack to Ready Pull the handle several times to secure it in place Repeat on the opposite gunwale ...

Page 20: ...hell into the coaming grooves Starting at the front of the coaming tuck the coaming seal into the grooves in the coaming if this is not already the case There will be some space between the coaming closure seal and the coaming 4 ...

Page 21: ...21 CHECKPOINT TPS jacks are in place and the coaming seal is secured around the cockpit 4 ...

Page 22: ...ottom of the coaming Apply light pressure on the top of the coaming as you SLIDE the pillar into the locking system circled The locking system will push up automatically as you slide and lock the pillar into place Use the gunwale jacks to increase tension if they don t line up Continue pushing the pillar all of the way in until it locks in place Repeat on the other side of the kayak 5 Install the ...

Page 23: ...23 5 Install the seat Place the seat into the cockpit Align the seat rails with the slots on the seat posts Slide the seat backwards into the grooves on the seat pillars ...

Page 24: ...24 5 push the seat down once to ensure it is locked in place The seat is now in place ...

Page 25: ...k for comfort The end of the cord goes in between the shell and the seat pillars behind the pillars Make sure the seat back is locked into the grooves in the seat bottom Take the end of the cord and pull it through the cleat on the edge of the coaming This will lock it in place Adjust to desired length for seat back comfort ...

Page 26: ... tight ADD tension in gunwale jacks To decrease the bunching of the material close to the Keder add tension 6 10 jacks on each gunwale jack until the Keder closing is lined up Drop the pin on the Keder strip into the hole at the back of the coaming to lock in place 6 Close the Keder System CHECKPOINT Keder is closed ...

Page 27: ...27 Release tension in the frame Release all three jacks into the neutral position until a later step 7 Rigging and finishing Fasten rigging into place See photos Bow rigging ...

Page 28: ...ise Add air into the bag until it is mostly inflated Then tighten the cap clockwise If you are carrying gear place your gear in the Gear Float bag and insert into kayak before adding air This provides a dual benefit of a dry bag for gear and provides flotation for safety NOTE Never paddle your TRAK kayak without Gear Float bags inflated or without using a Sea Sock ...

Page 29: ... is TIGHT For optimum performance there should be no slack particularly on the sides of the shell The TPS jacks are already in place Now PULL each GUNWALE Jack 3 5 times until shell is very taut It should be rigid particularly around the cockpit Now PULL the KEEL jack the number of times required for desired ROCKER at put in 3 5x NOTE As long as you adjust the gunwale jacks evenly it simply adds r...

Page 30: ...ned the same way on each side When you feel comfortable mark their position on the coaming with a pencil About your TRAK Adjustable Thigh Braces Thigh braces are used in kayaks for bracing and stability and to assist in rolling the kayak Easy to remove hardware allows you to adjust the position of the braces along the underside of the coaming For a comfortable fit the braces are padded Attaching t...

Page 31: ... Thigh Braces using a Philips screw driver Hold on to the screws as you will need them to re attach the thigh braces Tool Required Philips screwdriver Step 2 Remove the coaming from the kayak and place it upside down 7 ...

Page 32: ...attach Thigh Braces to Coaming Place your thigh brace on the coaming in the desired position The grey padding is the underside of the brace Make sure that your position aligns with two of the brass inserts Using a Philips screwdriver attach the thigh brace Two screws per brace are required for proper functioning 7 ...

Page 33: ...33 ...

Page 34: ...ayak going from water to pack in mere minutes Your first time through will take a little extra time but not much if you follow these instructions And of course if you have problems we re here If you have suggestions for how we can improve we welcome your feedback Call us at 1 888 35 KAYAK or email info rethinkkayak com ...

Page 35: ...nsion on all three TPS jacks SWITCH all valves from Ready to Release position 1 Remove the seat back adjustment cord PULL cord INWARD to release from cleat PULL cord out from between pillar and shell a b Disassembling the cockpit ...

Page 36: ...L UP and SLIDE the seat forward It will slide out from the pillars Slide out seat pillars PULL UP the pillar lock circled then SLIDE the seat pillars forward so they are no longer attached to the coaming This will also disconnect the rod at the bottom from the frame tube c d ...

Page 37: ...k towards the stern rear of the kayak until it can be REMOVED from the front bow keel frame tube Then LIFT and PULL the other end out of the frame tube NOTE Ensure the jack valves are set to the Release position REPEAT this process to remove both gunwale side jacks e ...

Page 38: ...to release tension in the rigging You do not need to remove the rigging from the kayak Open the Keder GRAB the Keder handle and pull UP and BACK SLIDE the Keder OPEN all the way to the stern tip NOTE The Keder remains attached to the shell f g 1 ...

Page 39: ...aming FEEL for the metal LEVER underneath NOTE The lever is on the inside of Rib B and not visible from the cockpit CHECKPOINT The cockpit is now disassembled h Lever is located inside Rib B Press upward to release coaming PRESS UPWARD on the lever and PULL the coaming out 1 ...

Page 40: ...ll begin to release the frame from the shell We call this breaking the nose which is essential to remove the frames from the shell From the cockpit PULL the stern section of the frame out of the shell TIP Brace one hand against the bottom of the shell while pulling the frame with your other hand The stern section of the frame is now removed a Removing frame from shell ...

Page 41: ...ide TWIST the tip from side to side This will begin to release the frame from the shell CHECKPOINT Both bow and stern frame sections are removed from the shell From the cockpit PULL the bow section of the frame out of the shell TIP Brace one hand against the bottom of the shell while pulling the frame with your other hand b ...

Page 42: ...l joined frame tubes BRACE one hand or thumb on the rib and PULL the frame tube until it pops off the rib To remove the keel bottom frame tube BRACE one hand on the rib and SLIDE the tube out of the hole in the rib past the spring pin a STERN FRAME SET To remove the Stern frame pieces remove ball joints then SLIDE out corner and keel tubes Collapsing the frame sections ...

Page 43: ...e frame sections Remember the tubes are all shock corded together PULL each tube piece apart and FOLD over CHECKPOINT Both bow and stern frame sections are collapsed for storage in the pack PRESS and release spring pins where required Then completely COLLAPSE each frame section into a compact bundle b 3 ...

Page 44: ...arting at the stern end make your first FOLD using the Keeder as your measurement for the length of the fold PLACE your hand at the inside end of the keeder and FOLD the tip of the shell OVER your hand REPEAT this process for the second and third folds NOTE One end of the folded shell is wider than the other The wider end goes inside the bottom of the TRAK pack Fold to length of Keeder CHECKPOINT ...

Page 45: ...RAK pack 5 Get the pack ready UNZIP the pack and LAY it flat Frame sections bow and stern Place both frame sections in the pack side by side Arrange the frames so that the RIBS are on the BOTTOM LAY them as FLAT as possible a b ...

Page 46: ...aming Place the coaming in the pack Arrange the coaming on TOP of the shell Place the WIDER end of the coaming at the BOTTOM of the pack TPS Jacks Arrange the jacks along either side of the pack e Seat Ensure the seat back is disengaged so that it can lay flat in the pack Place the seat face down in the pack inside the perimeter of the coaming f 5 ...

Page 47: ...lace the Gear Float bags and Sprayskirt in the pack g Close the pack If the zipper seems tight first connect the buckles on the straps and cinch them together The zipper will close more easily h Congratulations Disassembly is complete 5 ...

Page 48: ...48 www RethinkKayak com 1 888 35 KAYAK sales RethinkKayak com ...

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