The Tarpon series is designed as a high performance sit-on-top kayak tailored for the sport paddler. Our rudder system is designed to fi t the original design profi le and is able to stow securely and effi ciently 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 effi ciency, 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 additional assistance be required.

I N S T R U C T I O N S

RUDDER KIT INSTRUCTIONSTARPON 120/140/160/160i

A

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)

Measuring Tape or Ruler

Crimpers

Deep 7/16” Socket

Rivet GunScissors

Non-permanent marker

REVISION

1.0 4/20/05DATE

YAKRAK KAREI R

INSTALLING THE RUDDER SYSTEMStep 1-4

Step 2-1

120/140/160i 160Step 2-1

Step 3-4

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: INSTALLING THE RUDDER BRACKET

1 Remove the two fi ller 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 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 fl ush 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, fl ip blade onto deck and secure under bungee loop.

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 fl at 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, fl ip blade forward so that it rests in center notch of V-block and secure with bungee over blade.

STEP 3: INSTALLING THE RUDDER UP HAUL LINE

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)

1 Insert rudder assembly in mounting bracket (does not have to be secured at this time). Position the rudder in the REVISION

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INSTALLING STEERING SYSTEM

3

6

1

FOOTRAIL

Step 4-1 / 4-3

Step 4-6

stowed (on deck) position and secure in a centered position under the rudder rest bungee or in V-block.

2 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.

3 Locate any fi ller screws along the starboard (right) of the kayak between the cockpit and the stern.

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.

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 INSERTS: Remove fi ller screws and discard. Position a round pad eye over the up haul cord above insert. Insert 10-32 x ¾” Phillips fl at 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.

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.

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 diffi cult 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 fl at 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 4/20/05DATE

INSTALLING THE RUDDER SYSTEM4 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 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).

7 On both sides, feed the straight (un-fl ared) 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.

8 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.

9 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 fl ares wide, similar to a mushroom shape. Allow it to cool and harden before releasing pliers. The fl ange will keep the tube from slipping back into the hull. Holding tube with fi ngers, 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.

10 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

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.

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 fi rmly several times to provide secure fi t 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.

HULL5”

2”

FULLYASSEMBLED

10

13

14 17

17

18

15 17

REVISION

1.0 4/20/05DATE

TESTING THE RUDDER SYSTEMTESTING 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 fl oor 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.

COMPLETEDASSEMBLY

REVISION

1.0 4/20/05DATE

PARTS LIST

PART# 3580-7230

724 ONREHN

GFMI .

CN.

.007" Gap FillHigh StrengthSeals Refrigererants

107243 . oN

metIN

ET

.lm 1

REVISION

1.0 4/20/05DATE