Old Town Loon 160T Rudder(Before 2000) - Manual

Old Town Canoe Co
LOON 160T RUDDER KIT INSTRUCTIONS – FOR KAYAKS PRODUCED BEFORE NOVEMBER 2000
Kit Contents: (1) Rudder assembly: Includes rudder, pivot bolt, split ring, and cord – E0359
(2) Cable assemblies: Consisting of cable and cable tube
(1) 11”raising cord bungee with cord lock
(1) M Block –1331.3143
(2) Foot pedals w/ long straps (4) Lg. Washers– 1574
(2) Barrel Nuts-E1792 (4) Swages –E0355
(2) 48” Foot Tracks-E0973 (5) Cable clamps –E0354
(2) Stamped washers–E3000 (1) Jam cleat–E0353
(1) Tube Aqua Seal–E1226 (2) 3/8”lock nuts–E1585
(3) Sm. Washers –E1568 (9) Rivets–E1571
(2) 1” bolts (small) – E1569 (4) 5/8” Locknut-E0149
(4) 1” bolts (large)-E1603 (2) 3/4" (1/2”) bolts-
E1607
THIS IS A GOOD TIME TO SORT OUT ALL THE PARTS AND SEPARATE THEM FOR EASY
ACCESS DURING ASSEMBLY. PLEASE READ INSTRUCTIONS THOROUGHLY BEFORE
BEGINNING THE RUDDER ASSEMBLY.
Required
tools: 3/16” Drill bit 3/8” wrench
1/4” Drill bit 7/16” wrench
Vice grips Tape Measure
Pop rivet tool Black Marker
Phillips head driver
Procedure
1. Install the rudder assembly by sliding the pivot bolt through the holes in the aluminum
casting. Secure the rudder by placing the split ring through the small hole in the end of the
pivot bolt. (Illustration #1)
2. On each side, approximately 8” forward from the stern end are the rudder cable entrance
points. Drill 1/4” holes into these entrance points with the holes angling down toward the
front of the boat. (Illustration #2 and #3)
3. Push the straight end of the rudder cable and the black carrier tube through the hole you
just drilled. Keep feeding the black carrier tube through until only 2 1/4” of the black
carrier tube remains outside the hull. Place a small amount of aqua seal around the black
carrier tube, then slowly slide the black carrier tube into the hole until 1 ” of the black
carrier tube is left. Place a cable clamp around the black carrier tube 1” from the end and
make a mark through the hole in the cable clamp, move the cable clamp slightly and drill a
3/16” hole. Anchor the cable clamp to the deck with a rivet, then dab a small amount of
aqua seal onto the head of the rivet. Repeat for the other rudder cable and black carrier
tube assembly. (Illustration #3 and #4)
4. Measure 6 1/2” from the stern end of the kayak and center the rear edge of the M block so
that the rudder can rest between the V notch of the M block when it is in the raised position.
Mark the location of the four holes on the deck; drill 3/16” holes and rivet the M block into
place. (NOTE: M Block cannot be used to anchor kayak during transportation.)
(Illustration #2)
5. Remove the nuts from the rear bolts of the seat tubing using the 3/8” wrench and the Phillips
head screwdriver. Put a cable clamp on each carrier tube, and then install the cable clamp
on the underside of the seat tube using the seat bolts. The cables should run to the outside of
the kayak. Reinstall the washer and lock nuts that hold the seat in place. (Illustration #5)