ASSEMBLY INSTRUCTIONS
continued
STEP 2: HANDLEBAR ASSEMBLY
NOTE:
The stem has been pre-assembled to the handlebar at the factory. Prior to
assembly, check to be certain the handlebar is securely fastened to the stem.
1. Insert the handlebar stem (C) into the frame tube with the clamp portion, which holds
the handlebar in place, toward the front. The stem must be inserted far enough into the
frame tube to hide the minimum insertion line marked on the stem. (If necessary,
loosen the expander bolt to allow the stem to fit into the fork tube.)
2. Place a drop of oil under the head of the expander bolt (D). Tighten the expander
bolt just enough to hold the stem in place.
3. Raise or lower the handlebar stem until you have reached the desired height for the
user of the Co-Pilot and then position the handlebar so it is perpendicular (90 degrees)
to the front of the bike. Next, tighten the expander bolt to the required torque. Be sure
to have inserted the handlebar steering tube at least 2 1/2” (65mm), making certain the
minimum insertion line is no longer visible.
Torque 10-15 ft-lb / 13-20 N-m
WARNING: Assembler is cautioned against the danger of damaging the handlebar
stem assembly and possible injury to rider which can result from under-tightening
or over-tightening the expander bolt and expander wedge.
4. Slightly loosen the clamp bolts (E) to allow the handlebar (F) to
rotate easily. Rotate the handlebar into an upright position.
After you have achieved a comfortable handlebar position for the
intended user, then proceed to tighten all four clamp bolts to the
torque specified below. Tighten each bolt only a few turns at a time,
to get even clamping.
Torque 8-11 ft-lb / 11-15 N-m
C
E
F
D
TOP VIEW
FRONT VIEW
11