3333 WS Rudder Kit A Instructions (Tarpon).indd

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RUDDER KIT INSTRUCTIONS
TARPON 120/140/160/160i
The Tarpon series is designed as a high performance
sit-on-top kayak tailored for the sport paddler. Our rudder
system is designed to fit the original design profile and is
able to stow securely and efficiently on the deck when not
needed yet can be deployed very quickly when required.
The addition of a rudder to a kayak results in additional
control and efficiency, especially in certain sea and wind
conditions. The presence of a rudder is by no means essential,
nor does it mean it must be deployed at all times. A rudder
is not a substitute or replacement for paddling experience or
talent.
CAUTION: All possible steps have been taken to provide for a
successful instillation of your new rudder but installation does
require permanent alteration of your kayak. Please read all
instructions prior to beginning the process. Be safe, measure
twice before proceeding with any step requiring drilling or
cutting of your hull. If you are uncomfortable with any part
of this process, we suggest you contact your local dealer for
support and advice. It is possible they will undertake this
installation for you at a modest cost.
All directions included in these instructions reference
starboard (right), Port (left), forward, stern, etc., are given as if
you are standing behind your kayak looking forward.
Call our Customer Service Line: 1(800)390-0819 should
REVISION
DATE
additional assistance be required.
1.0
4/20/05
ADDITIONAL TOOLS & MATERIALS NEEDED
Phillips Head Screwdriver
Cable Cutters
Drill with 5/32” & 5mm Drill Bit
11/32” Wrench
Cigarette Lighter
Small Tube of Lexel, or
(equivalent marine sealant)
Deep 7/16” Socket
Measuring Tape or Ruler
Crimpers
Scissors
Non-permanent marker
Rivet Gun
INSTALLING THE RUDDER SYSTEM
INSTALLING THE RUDDER
The rudder system consists of the rudder assembly, rudder
mounting bracket, rudder rest to secure the rudder blade when
stowed on deck, rudder uphaul line to provide for deployment
and retrieval of the rudder blade, and the steering system to allow
rudder to be angled right or left to guide kayak.
Step 1-4
STEP 1: INSTALLING THE RUDDER BRACKET
1
Remove the two filler screws from the stern of the kayak
and discard.
2
Remove the split ring from the rudder pin and remove the
bracket assembly from the rudder.
3
Install a lock washer on both hex head bolts and slide the
bolts into the rudder bracket, placing a small amount of
Loctite® adhesive on the bolt threads.
4
Step 2-1
With the stop pin of the rudder bracket facing upwards,
start the bolts into the stern (Illustration 1-4). Tighten the
bolts securely using a 7/16” deep well socket, making sure
the bracket is flush against the stern and straight up and
down.
STEP 2: INSTALLING THE CARRYING HANDLE AND
RUDDER REST
1
There are three different carry handle systems used on
Tarpons. The hardware for either installation is provided.
An illustration of the each style of handle is shown at right
(Illustrations 2-1).
Tarpon 120, 140: Back out screws holding existing carry
handle at stern of kayak. Replace with provided carry
handle included with kit (#3290-0120) that has addition
of bungee cord loop. Use existing hardware to install
replacement carry handle, making sure that bungee loop
faces forward. To secure rudder blade in stowed position,
flip blade onto deck and secure under bungee loop.
120/140/160i
Step 2-1
160
Tarpon 160i: Measure 11 1/2” forward from stern along
center line of deck and locate raised circle molded in deck.
Drill 5mm hole at indent in center of circle. Secure round
pad eye with assembled loop of 3/16” bungee to deck
with 10/32 x ¾” screw and nylon lock nut. Orient so that
bungee loop faces towards bow of kayak.
Tarpon 160: Locate raised flat mounting panel on deck
between stern and carry handle. Center V-block rudder rest
on panel so that center notch will contain rudder blade and
mark 2 mounting holes in base of rudder rest on hull. Drill
2 5mm mounting holes through deck. Secure V-block with
rivets provided. To secure blade in rest, flip blade forward
so that it rests in center notch of V-block and secure with
bungee over blade.
Step 3-4
STEP 3: INSTALLING THE RUDDER UP HAUL LINE
1
Insert rudder assembly in mounting bracket (does not
have to be secured at this time). Position the rudder in the
KAYAK KARRIER
The uphaul line allows you to raise and lower the rudder and
will be routed along the top of the deck along the right side of
the kayak. It will run from the rudder to a ?tting near the cockpit,
guided by a number of round pad eyes. (Illustration 3)
REVISION
1.0
DATE
4/20/05
INSTALLING STEERING SYSTEM
stowed (on deck) position and secure in a centered position
under the rudder rest bungee or in V-block.
2
3
Step 4-1 / 4-3
Unroll the cord attached to the rudder assembly and route it
forward along the right side of the hull. Straighten cord so
that both halves of loop run parallel to each other without
twists or tangles. Locate the pad eye on starboard (right) side
of hull just behind the cockpit. Loosen the stern most screw
halfway (do not remove fully). Remove the forward screw
completely and pass the end of the up haul loop under the
center of the pad eye. Make sure that there is one “turtle”
above the pad eye and one below. Retighten both pad eye
screws fully.
1
3
Locate any filler screws along the starboard (right) of the
kayak between the cockpit and the stern.
Step 4-6
Tarpon 120: does not have inserts. Measure 31” forward
from stern along angled side panel on starboard side of hull.
Mark location in line and about 3” aft of the “Tarpon 120”
logo. Drill 5/32” hole at mark.
6
Tarpon 140: will have two, located 8” and 24” in front of
stern.
Tarpon 160i: will have two, located 20” and 48” from
stern.
Tarpon 160: does not have inserts. Mark location
approximately 2 ½” below the center stern hatch strap in
line with up haul line. Mark second location 54” forward of
stern, again in line with up haul line. Drill both marks with
5/32” bit.
4
FOOTRAIL
d. Release the rudder from the rest and test the up haul
line’s functionality by pulling the lower turtle forward and
then top turtle forward causing rudder to deploy and then
raise to stowed position. There should be a slight amount of
tension in the line and the rudder should fully deploy and
fully stow on the deck. Pull the new knot out of the turtle
and cut the excess of the up haul line off just beyond the
knot. Slightly melt the knot with a lighter or match. The
knot will disappear into the fastener when released.
INSERTS: Remove filler screws and discard. Position a
round pad eye over the up haul cord above insert. Insert
10-32 x ¾” Phillips flat head screw through hole in center
of round pad eye and thread into insert. Make sure the up
haul cord runs parallel through cut-outs in base of pad eye.
Repeat the process at each insert, making sure to keep the
cords running parallel.
Tarpon 120, 160: Use 8-32 x 3/4” Phillips pan head screw
secured by neoprene faced washer and lock nut to secure
round pad eye as described above. (Refer to illustration 3-4
– shows Tarpon 120 installation)
5. There will likely be some slack in the uphaul line, particularly
with shorter boats. This should be removed. The uphaul line
should run fair with no or minimal drape or sag. To adjust
tension:
a. Position the rudder in the stowed position and make sure
it is centered. Take the top most of the two “turtles” in the
up haul line and slide it all the way forward and up against
the forward most uphaul line anchor nearest cockpit.
b. Pull the knot in the up haul line out of the top “turtle”
and pull line until desired tension is achieved without
repositioning the turtle. Tie off a new stopper knot at this
point.
c. Remove the slack in the “turtle” in the lower up haul line
following the same process.
STEP 1: INSTALLING THE STEERING SYSTEM
The rudder steering system consists of a pair of cables running
from the rudder up to and connecting with the foot pedals. The
cables are routed inside the hull of the kayak below the deck and
on each side of the seat.
1
Locate the stern rudder steering cable ports (the raised “frog
eyes” approximately 6” forward from the stern). (Illustration
4-1)
2
Remove the rudder assembly from the rudder bracket to
provide drilling access to frog eyes and set it aside.
3
Take great care in drilling! These steps are difficult to
correct! Angling the drill bit slightly in towards the center
keel line so you do not drill through the tapered forward
surface of the frog eye, drill a 5/32” hole through the flat
stern face. Reinstall the rudder unit after these holes are
drilled and install the split ring on the bottom of the rudder
assembly post. (Illustration 4-3)
REVISION
1.0
DATE
4/20/05
INSTALLING THE RUDDER SYSTEM
4
Remove the hatch covers and internal bags to provide access
to the kayak interior.
5
Remove the existing foot brace assemblies and discard
them. It may be necessary to reach inside via the hatches
and the forward storage compartment to remove these
components.
6
7
8
9
10
backed washer (neoprene side against hull) and nylon lock
nut. Access these mounting points through hatches. The
use of box head wrench is recommended and securing the
lock nut in wrench with a piece of masking tape across the
back side will make installation easier.
Drill a 5/32” hole centered in the forward-facing vertical
triangular panel at the stern end of the foot brace mounting
panels on each side of the boat. (See illustration #4-6).
On both sides, feed the straight (un-flared) end of the nylon
tubing forward starting at frogeye cable ports, reaching
through the stern hatch to pull the tubing forward towards
the seating area. It is very important that the tubes are
routed between the sides of the hull and any of the scupper
(drain) holes. The straighter the tubes run the smoother the
rudder will perform.
Reach through the round center hatch and pull the tubing
forward to and through the newly drilled hole at stern end
of foot brace mounting panel.
Grasp protruding end of tube and pull until slightly taut.
Hold tube with pliers at point where it exits hull and cut
tubing about ¼” in front of pliers. Lightly heat the end
of the tube so that it flares wide, similar to a mushroom
shape. Allow it to cool and harden before releasing pliers.
The flange will keep the tube from slipping back into the
hull. Holding tube with fingers, cut the excess length (about
¼” from the hull), then lightly torch the end with a lighter
so it swells, allowing it to cool and then releasing it.
Using the previous foot rail mounting holes and one insert
at seat end of rudder track, install new rudder foot pedal
tracks with the end with raised “stop” toward the bow of
the boat. To secure tracks to insert, use original mounting
screw. To secure tracks at mounting holes, insert screw
through footbrace track and into hull. Secure with neoprene
11
Uncoil the rudder cables. Remove split ring and pin from
rudder wings. Insert pin through eyelet on end of rudder
cable and then through rudder wing. Secure with split ring.
Cable eye should be on top of rudder wing.
12
Feed the cable through the tubing in both rear frog eyes
towards the front. Push cable forward until end protrudes
from tubing at cockpit and pull until cable becomes taut
back to rudder.
13
Slide the new rudder pedal/strap assembly onto the newly
installed foot pedal tracks.
14
Install the guide loop on the stern end of the foot pedal
tracks using the 5/8” length Phillips Truss screw and thread
the ring at end of foot strap through the guide loop.
15
Slide the rubber shrink tube followed by two copper ferrules
onto each rudder cable and slide until they contact hull.
16
Measure 5” from the point where the cable exits the rudder
cable tube. Mark this spot on the cable (this is where the
cable will contact the metal ring on the foot strap.) Measure
two inches beyond that mark and cut the cable.
17
Loop the cable through the metal ring on foot strap and
then slide the two ferrules over end of loop. Position
ferrules about ½” apart and crimp each firmly several times
to provide secure fit onto cable. Slide the shrink wrap up
and over both ferrules and heat to shrink in place.
18
Adjust tension in the rudder cable by releasing or tensioning
strap at the tabler buckle. Same procedure will also allow
you to adjust the foot pedal to desired position.
10
13
18
17
14
17
FULLY
ASSEMBLED
HULL
5”
15
17
2”
REVISION
1.0
DATE
4/20/05
TESTING THE RUDDER SYSTEM
TESTING THE RUDDER SYSTEM
STEP 1: SUPPORT THE BOAT BEFORE TESTING!
1
Situate the kayak so that it will safely bear your weight
and the rudder will not contact the floor or ground when
deployed. You may wish to set the kayak on a deck with the
stern extending over the edge or to put the kayak in calm
water to test its operation.
2
Remove the bungee cord holding the rudder to the rear
deck. Grasp the rudder actuation cords at the knots and pull
the lower knot forward and the upper knot aft to make the
rudder blade swing down freely. Pull in reverse directions to
raise the rudder, noting the position of the knots when the
rudder is stowed or deployed.
STEP 2: CHECK ALIGNMENT AND SMOOTHNESS OF
OPERATION
1
With the rudder deployed and the kayak safely supported,
get into the kayak and place your feet on the rudder pedals.
Pushing one pedal forward while relaxing pressure on the
other makes the rudder pivot freely to the side pushed.
Reversing the foot pressure makes the rudder swing easily
to the other side. If you experience a slight catch with either
leg fully extended, it may be necessary to remove any excess
glue securing the bow nut to the foot brace track.
2
With your legs equally extended, check to see that the
rudder is in a neutral position, aligned with the centerline
of the kayak.
STEP 3: USE EXTRA CAUTION WITH YOUR NEW RUDDER
1
Be aware that the presence of a rudder requires new
precautions when launching and landing your kayak. Keep
the rudder stowed on deck with the bungee cord released
as often as possible when launching or landing, since
underwater objects or the lake or sea bottom may bend the
rudder blades..
2
Use extra care to avoid personal injury when handling your
boat with a rudder installed. For example, be careful not
to bump into your rudder when your boat is stored or on
a roof rack, as the rudder is not quite as forgiving as the
unadorned hull of your kayak.
COMPLETED
ASSEMBLY
REVISION
1.0
DATE
4/20/05
G.
MF
.
INC
.007" Gap Fill
High Strength
Seals Refrigererants
NET 1 ml.
2N7
ON
4
R
HE
Item No. 342701
PARTS LIST
PART# 3580-7230
REVISION
1.0
DATE
4/20/05