Bike Friday Haul-a-Day Manual Download Page 2

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Table of Contents

The story behind Haul-a-Day

The growth of Haul-a-Day

Anatomy of a Bike Friday Haul-a-Day

Anatomy of a Bike Friday Haul-a-Day: Closeup

Congratulations / If You Need Help

A Word on Safety / Your Tools

Unpacking your Haul-a-Day

Assembly: Connect Frame

11-12

Installing Seatmast

Using a Quick Release

14-15

Assembly: Install Front Wheel, V-Brake

Reconnect Linear Pull / V-Brake

Install Front Wheel, Disc Brake

Adding Brake Cable Slack

Stem Safety Check

Mount the Stem Riser

Double Check Steering

Install Pedals

Double Check Your Bike Friday

Adjusting your Haul-a-Day

Saddle Height

Handlebar Height

24-25

Quill Stem Handlebars

Main Frame: Gravity Technique

26-27

Adjusting Headset

28-31

Bike Friday Service Overhauls

Bike Friday Service

More Maintenance Tips and Information

34-36

Airport and Travel Tips

Warranty Information

38-39

Summary of Contents for Haul-a-Day

Page 1: ...7 0258 1 541 687 0487 Using Your Bike Friday Haul a Day Green Gear Cycling Inc 3364 W 11th Ave Eugene OR 97402 800 777 0258 USA Canada 1 541 687 0487 Int l 1 541 687 0403 Fax www bikefriday com info bikefriday com version 7 15 16 ...

Page 2: ...ease 14 15 Assembly Install Front Wheel V Brake 16 Reconnect Linear Pull V Brake 17 Install Front Wheel Disc Brake 18 Adding Brake Cable Slack 19 Stem Safety Check 19 Mount the Stem Riser 20 Double Check Steering 20 Install Pedals 21 Double Check Your Bike Friday 22 Adjusting your Haul a Day 23 Saddle Height 23 Handlebar Height 24 25 Quill Stem Handlebars 25 Main Frame Gravity Technique 26 27 Adju...

Page 3: ...3 www bikefriday com 800 777 0258 1 541 687 0487 Versatile Light for a Cargo Bike Fits on a Portland Bus Rack Hangs on Amtrak Works on a Car Rack Sky s the limit so add on Ready for real work ...

Page 4: ...That idea simmered in my head for awhile Then our local Safe Routes to School Coordinator Shane MacRhodes stopped by to have a conversation with Alan The school program teaches kids to ride safely and uses fleet bicycles Fitting bikes to a class of middle schoolers of various sizes and shapes created a challenge and those two ideas came together in our OSATA When Shane needed a bike for the class ...

Page 5: ...address those needs Building custom bikes to fit an individual s needs and body has been the cornerstone of Bike Friday since 1992 and the versatility of the Haul a Day reflects that commitment to deliver the perfect bike for you All Haul a Days have multi person fit capability and come at Bike Friday s affordable prices starting less than 1 000 for a DIY Frame Kit with wheels The growth of Haul a...

Page 6: ...6 www bikefriday com 800 777 0258 1 541 687 0487 Anatomy of an Haul a Day ...

Page 7: ...7 www bikefriday com 800 777 0258 1 541 687 0487 Anatomy Closeups ...

Page 8: ...icycle to be simple and reliable anywhere you go More Information To check out our products find other useful information discover Bike Friday events and Yak with other Bike Friday owners on the bulletin board go to our main website at www bikefriday com Blue skies and happy trails from Green Gear Cycling If You Need Help If you need technical assistance with any Green Gear Cycling product or are ...

Page 9: ...your tire pressure before every ride Make sure all quick releases are secure Have your bicycle routinely serviced for trouble free travels Your Tools Your Haul a Day was delivered with a combination 5 6mm S wrench and 5 16mm wrench right These wrenches should get your new bike on the road along with your own pedal wrench We also sell more extensive tool kits for home repair work See large photo be...

Page 10: ...ecause your bicycle was built for you you might discover that your bike was packed at the factory slightly different than the one in this manual Your Haul a Day should only require minimal assembly It will take approximately 30 60 minutes and require a basic level of technical skill You will need a 5 6mm hex wrench 5 16mm hex wrench a 15mm open pedal wrench and a pair of scissors or bet ter yet wi...

Page 11: ...e arm to the outside of the chaining If the chain was on the chainring it will pull the front end backward creating tension and making the process more difficult By placing the chain on the side of the crankarm to the outside of the chainring it will take up some of the slack of the chain and hold it in place for the purpose of affixing the rear end to the mid section Line up the bolt holes and ha...

Page 12: ...n its rear end front section pointing upward Fig 5 Insert the front section male into the mid section female opening Depress the spring loaded mainframe button to allow the front section to settle into one of the four holes in the mid section Fig 6 Tighten the main frame pinch bolts with a 5mm hex wrench Fig 7 Assembling your Haul a Day Fig 7 Tighten pinch bolts ...

Page 13: ...e seatmast The Haul a Day bicycle mod els have a sleeved seatmast that telescopes out of the lower seat tube Install the seatmast into the seat tube Note The minimum insertion mark is etched at 4 from the bottom on the mast This is the minimum amount of the mast that must be inserted overlapped in the frame Fig 8 ...

Page 14: ...miliar with their operation PLEASE study these direc tions carefully If you are still unclear on their operation call us or contact your favorite local bike shop before you ride Quick Release Operation A quick release is a simple cam with a lever that swings through an arc that is square to the axle As the lever moves the cam clamps the wheel to the frame or secures the frame joint It is not a win...

Page 15: ...line with the axle Then turn the knurled nut on the other side clockwise until it is snug When the quick release is properly adjusted you should be able to freely swing the quick release lever for the first half of its arc at which point the lever should offer resistance Fig 9 Quick release operation Continue Closing QR Using the palm of your hand press the quick release lever through the rest of ...

Page 16: ...toward the center of the hub Loosely thread on the knurled nut for now Fig 12 Front Wheel QR Mechanic s Tip If you are ever unsure of the proper direction of the front tire looking down at the tire the tread should be oriented so that it is pointing for ward Often the tread is in a arrow ish pattern and this makes it easy to point it in the forward direction The quick release levers front and back...

Page 17: ... the brake cable may need to be loosened a bit See the next step for instructions to add some slack to the cable Repeat this procedure on the rear brake Mechanic s Tip Sometimes the cable housing can come unseated either where it enters the noodle or where the housing enters the brake lever barrel adjuster If the housing is unseated it will not be possible insert the noodle tip into the noodle hol...

Page 18: ...veral possible configurations of front brakes The Haul a Day is available with disc V brake or linear pull front only Please read directions specific to the brake type that appear on the following pages Disc Brakes When inserting the front wheel into the fork ensure the disc rotor on wheel fits nicely into the slot on the caliper installed on fork You will want to avoid the rotor getting hung up o...

Page 19: ...tch from use unscrew the barrel adjuster away from the brake lever Note Some models may have a lock nut on the adjuster which will need to be loosened first ALWAYS DOUBLE CHECK YOUR BRAKES BEFORE RIDING Fig 20 Brake barrel adjuster Barrel Adjuster Assembling your Haul a Day Fig 21 Stem pin Stem Safety Check If you look carefully at the base of your stem from the underside you will see a pin hidden...

Page 20: ...Once the lower stem riser is in place tighten lower stem riser bolt NOTE Do not adjust the locking headset spacer Assembling your Haul a Day Fig 22 Lower stem riser Upper Stem Riser Bolt Lower Stem Riser Bolt Locking Headset Spacer Double Check Your Steering System Integrity Now is a good time to double check your steering system Try standing in front of your bike with your front wheel between you...

Page 21: ...engagement with your hands instead of a wrench see below so use this tip as a practical way to know which way to begin threading the pedals Thread in the Pedals Using your finger start the pedal threads into the proper crank arm Be careful not to cross thread the pedals Once the pedal threads are started you may use a wrench to fin ish threading them in and then tighten securely Mechanic s Tip The...

Page 22: ... tube bottle cage for quick roadside adjustments If you have the folding tool take it with you You will probably want to stop and adjust saddle height and the angle as well as per haps adjust a few other items during your first ride or two Mechanic s Tip Grease is your friend Be sure to keep a light film of grease on any intersecting bike parts This will help to prevent corrosion facilitate disass...

Page 23: ...le Height Proper saddle height is important in prevent ing injuries as well as increasing riding efficiency and com fort A rough rule of thumb method for determining proper saddle height is when the pedal is in the 6 o clock position your leg should have a slight bend in it with the ball of your foot centered on the pedal your knee almost fully extended but not quite A quick way of achieving this ...

Page 24: ... a few positions just be sure to try them out for more than a few minutes because that initial period may feel awkward but possibly because you have acclimated to incorrect sizing The beauty of the Haul a Day is the ability to try and use a wide range of positions on the bike Adjusting Handlebar Fig 28 Loosen lower stem riser Upper Stem Riser Bolt Lower Stem Riser Bolt Locking Headset Spacer Locki...

Page 25: ...ill Stem Adjustments NOTE For customers that have a quill style stem you have an extra set of height adjustments with the quill stem To loosen the quill stem loosen the main bolt You are likely going to have to un wedge the internal wedge in the quill stem This can be done in one of two ways Stand in front of the bike with your legs surrounding the front wheel to prevent it from turning turn the h...

Page 26: ... of hands can help Insert a 5mm hex wrench into the two Haul a Day pinch bolts clamping the female mid section to the main front section Loosen both of the bolts Fig 37 Fig 37 Loosen pinch bolts Stand the bike on end with front wheel directly above the rear wheel You may wish to have a piece of cardboard to set the rear end of the bike on to prevent paint scuffing Do be aware of the possibility of...

Page 27: ...rk Grasp the front section by the fork or stem riser Fig 39 The Gravity method Making the Frame Larger Depress the spring loaded button Use your right foot to hold the rear section down on the ground Place your left hand on the backside of the fork above the tire below the headset With your left hand push You may need to wiggle the front section a bit side to side to make it easier for it to slide...

Page 28: ...t can be adjusted into one of three states Loose When you grasp the front brake and try to move the front wheel forward and backward you feel play or slop in this connection This suggests the bearings are loose Adjusting the Headset Fig 39 Headset Anatomy Locking Headset Spacer Tight While raising the bicycle in the air with the front wheel lower than the back wheel very lightly turn the stem to o...

Page 29: ...rings if applicable from the steerer tube let them hang beside the bike Loosen the locking headset spacer note with this clamp loose the fork and headset can easily fall apart unexpect edly It should be just loose enough to turn with your fin gers but not any looser Remove excess space between the headset pieces Do this by lifting the fork a few inches off the ground with one hand on the fork leg ...

Page 30: ... block of wood and hammer Tighten the headset fixed clamp install the stem riser fully tightening the bolts and check headset adjust ment Repeat as necessary Fig 44 Strike Seatmast Adjusting Haul a Day Headset Fig 45 Headset Press Tool Remove the stem riser and O rings if applicable from the steerer tube Let them hang beside the bike Loosen the headset fixed clamp Haul a Day Headset Press Tool ava...

Page 31: ...It is helpful to evaluate the headset adjustment with the tool still in place Fully tighten the locking head set spacer Fig 48 Fig 46 Headset Press Tool Remove the washer and nut from the bottom of the tool Fig 46 Slide the rest of the tool from the top allowing the 1 tubing to cover the portion of exposed steerer tube Fig 47 Haul a Day Headset Press Tool cont Fig 47Headset PressSetup Fig 48 Heads...

Page 32: ...heck all components for wear and recommendations on replacements Strip frame and clean components optional solvent tank option Clean and optional alignment of the frame Replace stickers New cables and housing New bar tape where applicable Test ride and packing Don t hesitate to call Bike Friday s Customer Service Depart ment for help 1 800 777 0258 U S or 1 541 687 0487 world or email Service bike...

Page 33: ...ility it provides Then at least once a year and before any major tour take your bike back to your local shop for another tune up to be sure that it runs smoothly After a few years of use and a few thousand miles of riding you might notice that the decals on your bike are starting to look worn and the paint has some scratches Perhaps your bike doesn t ride as smoothly as it used to and the local bi...

Page 34: ...http www parktool com repair The Initial Break in Period It is reasonable to expect that a new bicycle will have an initial break in period where adjustments will need to be made after a hundred ish miles The following items may occur or need at tention during this break in period Brake and derailleur cables may stretch You can perceive this as you squeeze the brake lever and you have to squeeze f...

Page 35: ...e brake adjustment is proper Areas Requiring the Occasional Application of Grease In the steerer tube where the stem fits in At least once a year ideally twice a year A light film of grease on the out side unpainted and exposed part of the steerer tube is also recommended Inside the Easy Pack seat tube Inside the seat mast where the seatpost fits in Inside the tandem joints where the mid tubes of ...

Page 36: ... replace those parts on a bike that wear out with use Tires When a smooth bald spot begins to appear on the riding surface When you are getting consistent flats The sidewalls appear to no longer be structurally sounds dry rot slashes etc Rims For bikes with rim brakes when the braking surface of the rim feels concave Some rims have a trench running on the braking surface this is the wear line When...

Page 37: ...When traveling by air you might consider not over packing your TravelCase With some practice it is quite possible to get a tre mendous amount of gear into your TravelCase however this only obscures the inspector s view and they will deconstruct your care fully packed case Consider using extra straps bungee cords or toe straps etc to bundle the packed bike together as one unit instead of multiple s...

Page 38: ...ork for you and in order for your bicycle to work well it should fit We ll need some help from you to ensure that your new Bike Friday fits you well specifically by providing us with the measurements of your best fitting bike if you own a bike that fits well and a description of how you feel on this bike Additionally you will be asked for some per sonal measurements with a required accuracy within...

Page 39: ...able Claims must be made through Green Gear Cycling or an authorized dealer Proof of purchase is required This warranty covers bicycles and components purchased outside of the United States only if purchased through an authorized Green Gear Cycling dealer This warranty does not cover normal wear and tear improper assembly or maintenance or installation of parts or accessories not originally in ten...

Page 40: ...ly re ceiving the bike We must receive it within 35 calendar days of you taking delivery of the bike We also accept returns on parts within 30 days as long as the part is unused and undamaged Processing your refund usually takes 2 6 weeks from the time that we receive back your returned item s The sizing of the pre owned bicycles are limited by their cur rent construction Bike Friday will as part ...

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