Bike Friday New World Tourist Manual Download Page 2

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www.bikefriday.com

800-777-0258 • +1-541-687-0487

Extra Accessories

We also sell an extensive (and growing!) line of bicycle and travel

accessories. Whether you are riding the local back roads or ventur-

ing into foreign lands we have the gear you need. Call us for info on

spare tires & tubes, replacement parts, fenders, racks, bags, or other

items to complete your Travel System.

Congratulations!

You have just purchased the finest travel bicycle available today.

Your bike has been carefully designed and constructed for your

personal travel needs. All of our bikes are manufactured in our

Eugene, Oregon factory by real cyclists who care about our custom-

ers and our products.
Please take your time reviewing this manual and, if possible, watch

the video before you assemble your new Bike Friday travel bicycle.

You will find your new bicycle 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 web site at www.bikefriday.com. Or

just call us at 800-777-0258.
Blue skies and happy trails from the gang at Green Gear Cycling.

If You Need Help . . .

If you need technical assistance with any Green Gear

Cycling

product, or are unclear on the proper operation of your Bike Friday

travel bicycle, please call us and a Service Technician will help you

get back on the road. Our toll-free number in the US and Canada

is 800-777-0258, international is +1-541-687-0487. Normal business

hours are 8 a.m. to 5 p.m. Monday through Friday, and 9 a.m. to 4

p.m. Saturdays, Pacific Standard Time. You can also email service

questions to [email protected].
Because we understand the needs of world travelers, we offer

24-hour technical support in emergencies. If necessary, please call

our regular number and our answering service can forward you to

a Service Technician on call.

Summary of Contents for New World Tourist

Page 1: ...ompanion Sport Expedition Pocket 8 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 7 16 10 Pocket Llama owners Nina Tartakoff Richard Kemnitz escape the winter freeze of hometown Fairbanks AK and head for Mexico ...

Page 2: ...ble 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 web site at www bikefriday com Or just call us at 800 777 0258 Blue skies and happy trails from the gang at Green Gear Cycling If You Need Help If you need technical assistance with any Green Gear Cycling...

Page 3: ...Brake 15 Install Front Wheel 16 Install Stem 17 Handlebars 19 Seat Post Saddle 20 Install Pedals 21 Packing Pedals Seat Post 22 Remove Front Wheel 23 Remove Handlebars 24 Remove Stem 25 Fold Frame 26 Place Bike in Case 27 Handlebars 28 Wheels 29 Accessories 30 Quick Fold 32 Accessories TravelTrailer 36 Rear Rack 40 Front Rack 42 Fenders 44 Fit Stem 45 DualDrive Hub 46 Trouble Shooting 51 Bike Frid...

Page 4: ...tion 5 6mm S wrench that is attached to your water bottle cage This wrench should get your new bike on the road along with your own pedal wrench Leave it in your bottle cage so that you always have it handy All bikes ordered with a TravelCase suitcase also come with a tool pouch In the tool pouch you will find some cotton gloves to keep your hands clean a folding tool set a combination headset and...

Page 5: ...at Mast Hinge Cassette Cogs Rim Rear Derailleur Chain Stays Mono Stay Bottom Bracket Mono Tube Stem Riser Stem Collar Clamp Handlebars Stem Brake Levers Shift Levers Head Set upper Head Tube Fork Bottom Bracket Hinge Crank Arm Chain Ring Kick Stand Front Derailleur Adjustable Stem Clamp optional Head Set lower Front Brake Frame between cranks on bottom bracket shell ...

Page 6: ... operation PLEASE study these directions carefully If you are still unclear on their operation call us or contact your favorite local bike shop before you ride Using a Quick Release 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...

Page 7: ...rame or the frame joint closed position the QR lever so that it is in line with the axle Then turn the knurled nut on the other side clock wise until it is snug When the QR is properly adjusted you should be able to freely swing the QR lever for the first half of its arc at which point the lever should offer resistance Fig 1 Quick release operation 2 Continue Closing QR Using the palm of your hand...

Page 8: ...r acces sories and we encourage you to experiment If you discover a particularly good way doing things let us know Some of our best ideas have come from members of the Bike Friday family If you encounter difficulties assembling your bike and the manual and video do not help please call us Our goal is to get you on the road so that you can enjoy your custom made Bike Friday bicycle Illustrated Acce...

Page 9: ...ipped travel bicycle 2 Crush Protector The crush protector is a PVC dowel with a couple of flat caps on the ends This piece is a critical bit of packing material it spans the case so that luggage dropped on top of your bike is supported by the dowel and not your bike The caps are lightly pressed on just pull the top cap off Don t worry if the dowel comes out and the bottom cap is still in the case...

Page 10: ... bag with a cord around it Inside you should find a folding tool set with all of the Allen wrenches and screwdrivers you will need to assemble your bike a pair of cotton gloves to keep your hands clean and a 4mm ball end driver Note You will also find a combination 5 6mm S wrench attached to your water bottle cage for quick road side adjustments Fig 5 The tool pouch 6 Stand Up Bike Frame At this p...

Page 11: ...ly Unfolding 9 Secure Seat Mast With the seat mast upright close the quick release You may be concerned about hav ing a folding bicycle secured with one quick release how ever your Bike Friday bicycle has been carefully designed so that your weight tightens this joint The quick release simply makes the bike easier to carry Remove packing materials from frame Fig 9 Secure seat mast 8 Unfold Seat Ma...

Page 12: ... the lower seat tube If you bought a case with your bike the seat mast will be the painted tube except for titanium which is unpainted in a grey felt bag This configuration allows a great deal of adjustment in saddle height for different sized riders with the same bike However there is a minimum insertion mark on the seat mast at least the bottom four inches of the seat mast should always be insid...

Page 13: ...earings The fork legs slide up the grooved steerer until the steerer is flush with the bottom of the fork leg clamping collar Keep the fork legs roughly aligned with the wide part of the rubber dust sleeve Fig 14 Suspension fork Insert end of steerer to bottom of clamp 13 Install Wheel QR Now install the quick release from the fork spreader on the front wheel Make certain that there is only one sp...

Page 14: ...d with a side pull brake simply move the small lever to the up position Fig 17 Opening side pull brake 18 Operating V Brakes If your bike is equipped with V brakes start by pressing the brake arms together 16 Attach Dust Cover Once the fork clamp bolts are tight pull the rubber dust cover down and snap over the oval ring on the fork legs After the first ride check the tightness of these bolts Fig ...

Page 15: ...and then push the noodle holder down C There is a slot in the end of the noodle holder for the brake cable to slip out Fig 19 Pull out noodle from holder A A B C 21 Brake Barrel Adjuster To add some more brake cable slack you can turn the barrel adjuster on the brake lever The barrel adjuster is the knurled bolt that the cable housing goes through as it enters the brake lever Turn this adjuster cl...

Page 16: ...order of opening it Press both arms together A and insert the noodle B into the noodle holder C The end of the noodle has a bullet shaped tip that should be inside the holder but just sticking through the cable keyhole Fig 24 Close V brake A A C B 23 Reconnect Linear Pull Brake If you have a linear pull brake before closing it check to make certain that the hous ing is properly seated into its fer...

Page 17: ...per noodle tip position 27 Mount Stem Slide bottom of stem into the fork steerer tube keeping the stem s quick release assembly facing forward so that the hidden stem pin will engage the slot in the fork Gently press the stem all the way down Fig 27 Insert stem 26 Stem Safety If you look carefully at the base of your stem you will see a pin hidden under the clamping collar This pin must engage the...

Page 18: ...ly above the stem collar You may choose to precisely set the height once or vary it according to your riding needs in either case be certain this bolt is tight before riding your bike For fit stem instructions see the section on Accessories Fig 30 Adjustable stem Set bar height here Release stem for packing here 29 Pocket Gnu Stem If you purchased a Pocket Gnu bicycle your stem will be slightly di...

Page 19: ...amp has two bolts tighten both alternately Now is a good time to double check your steering system Try stand ing in front of your bike with the front wheel between your legs and then push pull and twist the bars and stem to make certain everything is secure Fig 33 Tighten handlebar clamp 32 Set Handlebars With the handlebars in the stem press them firmly together to ensure they are fully seated Cu...

Page 20: ...t thread directions The right pedal has a right hand thread and the left pedal has a left hand thread Thread the right pedal in a clock wise direction thread the left pedal in a counter clockwise direction Pedals are usually stamped with a R or L on the pedal axle near the threads A little grease is always a good idea on pedal threads Fig 36 Check pedals for threading 35 Tighten Seat Post Whenever...

Page 21: ...ure for proper inflation Under inflated tires not only wear faster and are more prone to flats but they also add drag Be sure to have at least the 5 6mm S wrench in the mono tube bottle cage for quick road side adjustments If you have the folding tool take it with you You will probably want to stop and adjust saddle height and perhaps a few other items during your first ride or two Tip Be sure to ...

Page 22: ...edal un threads in a counter clock wise direction and the left pedal un threads in a clock wise direction Remember that both pedals turn toward the rear of the bike Place both pedals in the light blue felt bag and set aside Fig 2 Remove pedals loosen in opposite direction for left pedal 3 Remove Seat Post Loosen the seat mast clamp ing collar and remove the seat post The saddle can remain attached...

Page 23: ... 5 Remove front wheel 4 Open Front Brake If you have a side pull brake simply flip up the small lever on the side of the brake If you have V brakes press the arms together A and then pull the elbow shaped noodle out and up B while pushing the noodle holder down C There is a slot in the end of the noodle holder for the brake cable to slip out Fig 4 Open brake arms V brake A A B C Packing Remove Fro...

Page 24: ...p bolt or two bolts Let the bars hang to the side for now On bicycles equipped with flat or H bars there will be a small button head screw in the center of the clamp Do not loosen or remove this screw It holds the black sleeve in the stem Fig 7 Remove handlebars 8 Pocket Gnu Bike Remove Fork If you own a Pocket Gnu bicycle you will need to remove the fork legs Lift the dust sleeve to expose the tw...

Page 25: ...ed accord ing to where they go Generally there is extra room in the case to accommodate some accessories such as shoes clothing and per haps a helmet As you travel with your bike and gain experience in your own customized packing process you may discover that some of the original pieces are unnecessary You may also feel that you may need some extra protection with new accessories Feel free to expe...

Page 26: ...he frame rather than fold forward Loosen the quick release remove seat mast and place the mast in the supplied grey felt bag and set aside Fig 13 Easy pack seat mast removal Packing Fold Frame 14 Fold Your Bike To fold your bike turn your fork to the left 90 degrees while picking up the bike by the mono tube With new bikes the rear end hinge may be a bit stiff and require either a light shaking of...

Page 27: ...he shorter yellow trailer axle bag behind the mono tube in the bottom of the case You will have to partially lift out the bike again as you slip in the trailer bag Fig 17 Add trailer axle bag Packing Place Bike in Case 16 Insert Trailer Tongue If you purchased a TravelTrailer with your bicy cle thread the trailer tongue in the long yellow felt sleeve into the case You will have to partially lift o...

Page 28: ...er wheel Packing Handlebars 18 Place Saddle Put the saddle in the front right corner of the case with the nose pointing up to 12 o clock and the large end of the saddle against the front of the case The seat post should slide under the rear wheel pointing at the cas sette cogs Check that the seat post is not lifting the frame Fig 18 Saddle and seat post position Saddle Seat Post 19 Place Handlebar...

Page 29: ... case Watch that the hub s axle does not rub against part of the rear end of your frame reposi tion if necessary Also make certain that the large end of the saddle does not push the wheel up too much Note Although it is not necessary to deflate tires prior to air travel large MTB tires may need to have some air let out for easier packing Fig 22 Front wheel placement 23 Second Trailer Wheel Now pla...

Page 30: ...he case Fig 24 Stem position Stem 25 GD Folding Rear Rack If you have a Bike Friday GD Folding Rear Rack fold the rack and put it in the yellow felt bag The rack should fit on edge along the left side of the case Fig 25 GD Folding Rear Rack 26 Front Rack If you have a front rack dis assemble the rack and put it in the yellow felt bag The front rack should lay flat on top of the bike to the left of...

Page 31: ...m bouncing around If you cannot close the lid check that the front wheel and trailer tires are properly positioned and are not too high Finally you should be able to feel that the crush protector is the highest point of the case Fig 29 Close TravelCase 27 Insert Crush Protector You should have placed one of the crush protector flanges into the bottom of the case soon after the bike was set in plac...

Page 32: ... are still riding and coming to a stop anticipat ing a quick fold You will want the chain in the small cog in the rear If you have a front derailleur with two or more chain rings in front shift the chain into the small chain ring Fig 2 Shift into small cog 3 Set Crank Arms Level Turn your crank arms until the left crank arm is pointing forward and the cranks are level Fig 3 Left crank arm pointing...

Page 33: ...the stem so that it s loose but not out Fig 4 Loosen stem quick release 5 Open Frame QR Open the quick release on your frame Fig 5 Loosen frame quick release 6 Lift Bike Pick up your bike by the seat mast so that the rear end swings around and under the bike New bikes may be a bit stiff to fold You might have to lightly shake the bike or push the rear wheel down to start the fold Fig 6 Lift your B...

Page 34: ...ig 7 Fold frame 8 Remove Stem Your stem should just lift out of your frame with the quick release open Fig 8 Remove stem 9 Fold Seat Mast Fold the seat mast forward until it is next to the mono tube We use nylon water bottle cages so that you can gently bend the cage to the side to accommodate the seat mast Fig 9 Fold seat mast past bottle cage Quick Fold ...

Page 35: ...ng as you carry it If you have a TravelBag place the bike in it now and zip it shut Fig 11 Seat mast strap Quick Fold 12 Unfolding Your Bike Friday Bicycle Unfolding your bike into riding condition is just the reverse of these steps Before you ride your bike again double check to make cer tain that all of the quick releases are secure and that the alignment pin in the stem is properly engaged to t...

Page 36: ...ig 1 Travel Trailer parts 2 Connect Axles In the smaller yellow felt bag there should be two axles and a T bar Slip the open ends of the axles over the T of the T bar Each axle will have a threaded stud with a thumb nut and two flat washers Remove the thumb nuts and one of the washers from each stud leaving one washer over each stud post Fig 2 Assemble trailer axle 3 Attach Trailer Axle With the c...

Page 37: ...gue over T bar Accessories TravelTrailer 4 Add Thumb Nuts Place one of the flat washers over each threaded stud and then loosely thread on the thumb nuts do not tighten them yet Fig 4 Attach washers thumb nuts 6 Add Last Thumb Nut Place one flat washer over the threaded stud inside the case and add the last thumb nut Now securely finger tighten all three thumb nuts inside the case Each attachment ...

Page 38: ...ach trailer wheel has two bearings one is flush with the outside of the wheel and the other is recessed Slide the trailer wheel over the axle end with the recessed side down and the flush side up away from the trailer Fig 8 Mount trailer wheel Accessories TravelTrailer 9 Add Axle End Washers First install the rubber O ring so that it sits next to the wheel bearing Then install the flat washer over...

Page 39: ...e Fig 10 Insert clevis pin Accessories TravelTrailer 12 Ready To Go When you release the knurled collar the coupler should be secure and ready to go If the knurled collar becomes stiff and does not spring closed add some light lubricant such as TriFlow or WD 40 to the coupler Fig 12 Trailer hitch connected 11 Connect Trailer Hitch To attach the trailer hitch to your frame simply pull the knurled c...

Page 40: ...The GD rack is packed in a yellow felt bag and has two extra 5mm bolts for mounting it to your bike The other two required bolts are already in your frame Fig 1 GD Folding Rear Rack 2 Unfold Rack The two sets of main legs unfold down while the two black aluminum stays unfold over the top Fig 2 Unfold GD rack 3 Insert 5mm Bolts Let the holes in the main legs overlap at the bottom and then insert a ...

Page 41: ...o bolts on the sides of the wishbone The wishbone is the part of the frame that engages the frame quick release Reattach the two bolts through one of the two holes in the rack stays Experiment with which rack stay hole provides the most level rack position Fig 5 Attach rack stays to wish bone Accessories Rear Rack 6 Tighten Bolts Tighten all four mounting bolts securely If you would like to attach...

Page 42: ... side and loosely thread into the cross bar The rack should now resemble Figure 3 Fig 3 Attach other side of rack 1 Front Rack The front rack consists of two mirror image sides a long cross bar and assorted bolts and spacers The cross bar uses two 6mm bolts The lower mount uses two short 5mm bolts and spacers the upper mount uses two long 5mm bolts and spacers Look at the mounting eyelets on the r...

Page 43: ... is generally not an issue If the interference is significant it is acceptable to lightly bend the noodle a bit tighter to help clear the rack Fig 6 Completed front rack 4 Mount Lower Eyelets Insert one of the short 5mm bolts through the recessed eyelet at the bottom of the rack Place one of the short spacers over the bolt on the inside of the rack Repeat with the other side Place the assembly ove...

Page 44: ...rward of the tab than the front fender The fender is attached to the rear end by the bolt in the wish bone Fig 2 Rear fender 1 Front Fender Your front fender has an alignment pin a small bolt through the aluminum tab beneath the mounting hole The fender is attached to the fork by the upper hole while the alignment pin keeps the fender from rotating Fig 1 Front fender ...

Page 45: ...in the supplied FedEx box along with the infor mation card The only essential details are your name address and bike color Once you have the stem boxed up and the card filled out call FedEx at 800 463 3339 to arrange a pick up It normally takes about two weeks to complete your new Custom Ultra light Stem If you need a quicker turnaround for a trip or event let us know on the card or call us to arr...

Page 46: ... ratios simplicity and durability As with a standard drive train there is no single best shifting order on a DualDrive equipped bicycle Experiment and find what works well for you A cyclist with a standard drive train must be conscious to avoid cross chaining which occurs when you shift into a small gear in front and a small one in back or a vice versa Cross chaining can cause excessive wear on yo...

Page 47: ...b into the lowest gear uphill icon or repeatedly press the small lever on STI shifters Fig 1 The click box 2 Attachment Button The small black button on the click box is used to attach the box to the axle In the up position the box is con nected To remove the click box press this button down until it is flush with the top of the box Fig 2 Click box button up connected 3 Remove Click Box With the b...

Page 48: ...the paragraph on hub maintenance for more information When screwing the shifting rod back into the hub be careful not to over tighten Just lightly tighten the shifting rod with a flat screw driver until snug Fig 4 Shifting Rod Loosen Tighten 5 Removing Rear Wheel With the click box removed loosen the two axle nuts with a 15mm wrench a crescent wrench or your pedal head set wrench in the tool pouch...

Page 49: ...d at the shift lever any cable stops and in the click box barrel adjuster Next to get the button down push the fork tip down toward the hole in the box with your finger while applying pres sure to the black button You may need to keep your finger on this button to keep it from popping up from cable movement Fig 6 Shifting fork down button down Fig 6a Shifting fork up button stuck 7 Mount Click Box...

Page 50: ...d barrel adjuster where the housing enters the click box Figure 8a until the needle is centered between the bars in the clear window It s that simple When you move the shift lever you can see the needle move to the different positions All new bikes will need some initial adjustment as parts wear in housing compresses and the cables stretch If your bike does not shift properly take it to your local...

Page 51: ...n thread sizes available today If you loose one of these small bolts you will most likely find replacement hardware locally The thread size for the rack water bottle cage derailleur and brake cable clamp bolts is a metric 5mm x 0 8mm A US standard thread of 10 32 can also be used The thread size for many of the frame parts and the front rack cross bar is a slightly larger 6mm x 1 0mm Every bike sh...

Page 52: ...t 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 may 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 bike shop c...

Page 53: ...t When traveling by air you might consider not over packing your TravelCase With some practice it is quite possible to get a tremendous amount of gear into your TravelCase however this only obscures the inspectors view and they will deconstruct your carefully packed case Consider using extra straps bungee cords or toe straps to bundle the packed bike This way an inspector can remove the bike as on...

Page 54: ...work 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 personal measurements with a required accuracy with i...

Page 55: ... 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 tended or comp...

Page 56: ... take advantage of this guarantee you must receive a Return Authorization Number from the Service Department 800 777 0258 service bikefriday com within 30 calendar days of your intent to return the bike and we must receive it within 35 calendar days of you taking delivery of the bike The sizing of the pre owned bicycles are limited by their current construction Bike Friday will as part of the purc...

Page 57: ...57 www bikefriday com 800 777 0258 1 541 687 0487 ...

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