HAMMERTRUCK RACK ASSEMBLY
 
Please Note: These assembly instructions are for installing the cargo rack system to a completely assembled HammerTruck bicycle. Please assemble your HammerTruck bicycle prior to attempting the installation of the cargo rack.
 
Tools needed for Assembly:
3/8” and 7/16” ratchet or nut driver
3/8” and 7/16” open end wrenches
5mm Allen Wrench
Masking Tape
Small round file
 
1. Open the bag of hardware and take inventory, check it against the pack list and photo #1.
2. Remove the 6mm bolt on the aft end of each side frame. Aft end of side frame is indicated by the 6mm bolt being 7.5” from the open end of the tube.
 
3. Determine left and right sling bags, this is indicated by the (very) small RANS label located on the aft end of each bag. Slip the front end of each sling bag over the aft end of each the side frame.
Hint: The bags will be tight, but there is a trick. Slide the bag up around each corner, then flex the ends of the side frame togethe. Then work the sleeves are around the corners, a little on each side at a time. The important part of this hint is to start with none of the bag pulled down around either corner.
 

Flex side frame after bag is slipped on past each corner, then work bag around each corner a little at a time.
 
4. Replace the previously removed bolts into the side frames and tighten snug. Do not over-tighten, or the tubing will crush.
 
5. A neat feature of the sling bags is the stow position. Place bag in stow position by pulling the flap around the bottom of the bag and attaching it to the Velcro strip on the back side. This will keep the bag out of the way for the rest of the assembly.
 
 
6. The side frames are now ready to assemble to bike. To prepare bike for assembly, apply loc TITE to the side frame attaching hard points on the bike.
 
 
7. Use 2 of the 1 1/2" x 1/4' bolts with a thin washer under the bolt head to bolt side frame to top hard points. Make sure you use the correct left or right frame and sling bag assembly. Do not tighten the bolts until the cargo rack is completely assembled.
 
8. Use one of the 1 3/4" x 1/4" bolts as an assembly aid as shown in photo #4 to hold the special I-nut in place. The I-nuts used in the front position have ¼” cross hole.
 
 
9. Of the 4 TC-1’s ( plastic saddles that insert into the ends of the tubes) two of them are cut off short, to create bolt clearance. Slip these into the bottom ends of the front of the side frames, and hold them in place with a small piece of tape.
 
 
10. Bolt the bottom ends of the side frames to the lower hard points.
 
11. Place thin 1/4" washer on the long 6mm bolts, slide though bracket on side frame. Place 2 plastic washers and brace onto bolt.
 
 
12. Tape brace in place to top of side frames.
 
 
13. Lift each side frame up to allow 70mm x 6mm bolt to slide into bushing on bike frame. Bolt with thin washer under nut. It may be a bit of a challenge to lift the side frame and not lift the bike too, try leaning over the seat, or have a friend sit on the bike. This slight amount of preload keeps the rack tight against all the hard points.
 
14. Using last 3/16” bolt with thin washer under head, bolt top brace in place using lock tight. Include brace in assembly as pictured below.
 
 
15. Take 2 of the 1/4" x 1 3/4" bolts, place a thin washer under the head, and apply lock tight. Use these bolts to install the forward 9BPHT0145) crossing tube (only the forward tube is marked), use 2-6mm x 70mm bolts to install the aft crossing tube (BPHT0148). Install the cross tubes with the snap buttons facing forward.
 
Optional Runner Installation
 
16. Test install the optional runner tubes: If snap buttons do not align, remove forward cross tube and flip upside down and reinstall. This also may apply to aft crossing tube.
Note: If buttons do not easily pop through the holes in the runners, file hole larger in the runner tubes.
 
17. Remove all masking tape from TC-1s.
 
18. To determine left and right covers, locate the small RANS label on aft top side of each cover. Label indicates aft end.
 
19. Slip the longer leg end of the runner tube into the aft end sleeve of the cover and slide cover around.
 
20. Once runners are installed pull covers around corners.
 
21. Pull flaps around tubes and lace straps to buckles as shown.
 
 
 
22. Check all bolts to snug but not crushing any tubes.
Note: Use stowing feature on the sling bags when riding without cargo.
 
 
Congratulations! Your HammerTruck sling bag and optional runners are ready for use. Check all bolts after a few miles to make sure they are tight. Please operate your HammerTruck within the weight limits and intent of the bike. Your HammerTruck is made for the long haul, but if you do damage any part of the cargo rack system is easy to replace individual parts. Enjoy, haul long, and ride safe.