DAHON - 2010 Service Instructions Manual Download

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Part

Item to Check

Passed Remarks

Chain

The chain is correctly tensioned between the front and rear sprockets, free from physical

defects and rust.

Chain and gear

selector assembly

Moves freely and correctly through the gear selections, and are correctly aligned in all

gears.

Derailleur(s)/hub

actuator

Cable locking nut is secure.

Any excess cable should be tied or cut to a sensible length and capped.

Gear selection

Mechanism is securely fixed to the handlebars.

Chain guard

Is free from physical defect or damage, is correctly positioned. Retaining nuts are secure.

Handlebar and

handlepost

Are free from physical defect or damage.

Handlepost, stem,

handlebar

All bolts are secure and correctly tightened.

Headset

Is correctly tightened and adjusted.

Handlepost hinge

Opens and closes freely.

Is free from all play when locked.

Safety lock operates correctly.

Saddle and

seatpost

All seat bolts, saddle bolts, and seat quick releases are correctly tightened and adjusted.

Saddle

Saddle alignment is correct (forward and level)

Seatpost

Slides freely and smoothly in the frame for folding.

(For bikes fitted with PostPumps or suspension seatposts) Functioning and operating

correctly.

Summary of Contents for - 2010

Page 1: ...SERVICE INSTRUCTIONS ...

Page 2: ...09 DS EN Contents Dealer Pre Delivery Checklist 3 Dahon F I T Stem 7 Axis Stem 8 VRO Stem 12 Andros Stem 13 Handlepost Hinge 15 Headset 17 Frame Latch 18 LockJaw Hinge Adjustment 22 Kore I Beam Saddle 27 Neos Derailleur 28 2 ...

Page 3: ...e as required Customer Information Name _________________________ Email _________________________ Address _________________________ _________________________ Dealer Information stamp Name _________________________ Email _________________________ Address _________________________ _________________________ Bike Information Model ___________________________ Year ___________________________ Serial ___...

Page 4: ...h front and rear Brake Levers Moves and returns freely with the brake cable seated correctly within the lever Brake Cables Calipers can move freely are free from damage and the cable locking nut is secure Any excess cable should be tied or cut to a sensible length and capped Brake Blocks Are correctly positioned to make contact with the rim Retaining nuts are secure Brake Calipers Front and rear c...

Page 5: ...guard Is free from physical defect or damage is correctly positioned Retaining nuts are secure Handlebar and handlepost Are free from physical defect or damage Handlepost stem handlebar All bolts are secure and correctly tightened Headset Is correctly tightened and adjusted Handlepost hinge Opens and closes freely Is free from all play when locked Safety lock operates correctly Saddle and seatpost...

Page 6: ...rings Are correctly adjusted Reflectors Are both present and securely fastened to the front and rear wheels at the front of the bike and at the rear of the bike Bell Is present and securely fastened to the handlebar Accessories Mudguards racks kickstands and supports are firmly attached to the bodywork all supports are in place and tight Lights Lights and wiring are firmly attached and functioning...

Page 7: ...xactly what height he has adjusted his handlebars WARNING If you are in any way unsure of how to make these adjustments take your bike to a qualified bicycle technician for professional adjustment 5mm 5mm Step 1 Loosen the bolt with a 5 mm Allen key WARNING Do not loosen the top cap Step 2 Adjust the stem to the desired height WARNING Do not raise the stem over the stem s top cap 5mm 5mm Step 3 Ti...

Page 8: ...andlebars have been adjusted Additionally a second groove in the stem makes it possible to take off the stem and handlebar reposition it 90 degrees and put it back onto the handlepost In this way the stem and handlebar can be securely attached to the bike when it is folded and stored instead of dangling loosely from the bike WARNING If you are in any way unsure of how to make these adjustments tak...

Page 9: ... handlebar can be rotated Adjust Handlebar Angle Tools Needed 4 mm Allen Key 5 mm Allen Key Step 2 Adjust the stem to the desired angle Step 5 Adjust the handlebar to desired position The angle should allow your fingers to easily reach the brake levers Step 3 Retighten the angle adjustment bolt to a torque of 10 Nm 4mm Step 6 Tighten the plate bolts with a 4 mm Allen key Tighten to a torque of 8 N...

Page 10: ...ep 2 Lift the stem off the handlepost turn it counter clockwise by 90 and put it back onto the handlepost Step 5 Adjust the handlebar downwards Handlebar and front wheel should now be parallel to each other Step 6 Retighten the angle adjustment bolt so that the stem is secure Step 3 Retighten the height adjustment bolt at the back of the stem with a 5 mm Allen key so that the stem is secure Stem a...

Page 11: ... position Position Stem for Unfolding Tools Needed 5 mm Allen Key Step 2 Adjust the handlebar upwards Step 6 Retighten the height adjustment bolt at the back of the stem with a 5 mm Allen key Tighten it to a torque of 10 Nm Step 3 Retighten the angle adjustment bolt Tighten it to a torque of 10 Nm Handlebar and front wheel should now be perpendicular to each other Step 4 Loosen the height adjustme...

Page 12: ... for professional adjustment NOTE Make sure that the angle of the handlebar allows you easy access to the brake levers Step 1 Loosen the bolts of the VRO clamps with a 5 mm Allen key Step 2 Adjust the height and position of the handlebar to achieve your preferred riding position Move the VRO clamp within the window of adjustment front backwards up and down Step 3 After establishing the desired pos...

Page 13: ...stem allows the handlebar to be easily adjusted in seconds without the use of tools to fit a rider s height or desired riding position With the stem the handlebar can also be placed in a flat position when folding the bike Step 1 Open the safety lock on top of the Andros stem by sliding it to the right when facing the stem from behind NOTE You have to push down on the lock lever slightly when you ...

Page 14: ...ow of adjustment Some suggested riding positions Step 5 After the handlebar has been placed in the desired position close the lock lever until the safety lock closes with an audible click NOTE Make sure that the angle of the handlebar allows easy access to the brake levers NOTE Make sure that the safety lock is closed when you cycle NOTE Regularly apply grease to the joints to avoid rust WARNING M...

Page 15: ... latch needs to be adjusted WARNING If you are in any way unsure of how to make these adjustments take your bike to a qualified bicycle technician for professional adjustment Different versions of the handlepost hinge can be found on Dahon bikes They look slightly different but the adjustment of the hinge latch is basically the same for both versions Please check the handlepost hinge to find out w...

Page 16: ...djustable wrench or small pliers can be used if an 8 mm wrench is unavailable The Eco Handlepost Hinge can be adjusted tightened or loosened with a 6 mm wrench An adjustable wrench or small pliers can be used if a 6 mm wrench is unavailable Adjust the latch bolt until the latch opens and closes with 29 49 N of force WARNING If the hinge is over tightened the tension can cause damage to the hinge A...

Page 17: ... a 6 mm Allen key by turning it counter clockwise as indicated by the arrow Step 4 After the adjustment and before you tighten the clamp screw again please check again to make sure that the handlepost and handlebar are in correct alignment and that they are perpendicular to the front wheel as shown in the picture above Step 2 Tighten the headset screw with a 10 mm Allen key Turn the headset screw ...

Page 18: ...o NOT cycle with a loose frame hinge Dahon uses a variety of frame hinges on its bikes Please check your bike to see which of the following instructions is applicable The ViseGrip Hinge also applies to the Eco frame s hinge Use a 6mm wrench if you do not have the right sized wrench you can also use an adjustable wrench or small pliers to tighten or loosen the hinge Adjust the hinge bolt so that th...

Page 19: ...E Adjust in 1 16 turn increments only otherwise you will quickly over tighten or over loosen the V Clamp hinge WARNING If the hinge is over tightened the tension can cause damage to the frame Hinge clamp on the frame s back half Open the hinge to adjust it Use an 8 mm wrench to adjust Version A Hinge clamp on the frame s front half Open the hinge to adjust itttt Use an 8 mm wrench to adjust Versio...

Page 20: ...crew downwards Loosen Turn the hinge clamp bolt clockwise as indicated by the arrow facing the hinge turn the screw upwards Version A Version B Adjust the hinge bolt so that the hinge opens and closes with the correct amount of force which is 39 88 N NOTE Adjust in 1 16 turn increments only otherwise you will quickly over tighten or over loosen the V Clamp hinge WARNING If the hinge is over tighte...

Page 21: ...Nut After adjusting the hinge use a 10 mm wrench to tighten the lock nut again Turn the wrench as indicated by the arrow NOTE Hold the adjustment nut tight with an Allen key while tightening the lock nut Adjust the hinge bolt so that the hinge opens and closes with the correct amount of force which is 39 88 N NOTE Adjust in 1 16 turn increments only otherwise you will quickly over tighten or over ...

Page 22: ...kJaw mechanism Pivot Bolt the actual hinge axle around which the two halves of the frame rotates The pivot bolt can be adjusted to tighten or loosen the hinge WARNING ONLY open the LockJaw hinge with the OC bolt WARNING As a general rule the pivot bolt will not need any user adjustment Do NOT try to open the LockJaw hinge with the pivot bolt ONLY adjust the tightness of the LockJaw hinge with the ...

Page 23: ...ke please refer to the included folding instructions To unlock the LockJaw hinge turn the OC bolt counter clockwise by 180º To lock the LockJaw hinge close the hinge and turn the OC bolt clockwise by 180º If the adjustment bolt is properly adjusted you should feel a slight click and the teeth of the LockJaw hinge will draw together 23 ...

Page 24: ...nality of the LockJaw and your safety Do not over loosen the adjustment bolt If it is too loose the LockJaw hinge will not close tightly which will result in a loose joint To tighten the adjustment bolt turn it as indicated by the arrow clockwise when looking at the bolt head on Adjust the Adjustment Bolt while the frame is closed To check the correct tightness of the LockJaw close and open the OC...

Page 25: ... turn it as indicated by the arrow clockwise when looking at the bolt head on Adjust the Adjustment Bolt while the frame is closed To check the correct tightness of the LockJaw close and open the OC bolt When the OC bolt closes with a click at the end the tightness is just right First open the OC Bolt turn 180º counter clockwise But DO NOT open the frame To loosen the adjustment bolt turn it as in...

Page 26: ...ntly affected the tightness of the pivot bolt while you were adjusting the adjustment bolt A 2 mm Allen key and a 6 mm Al len key are needed to adjust the pivot bolt The pivot bolt and its lock screw are on the bike s non chain side NOTE Only turn the pivot bolt in small increments e g a 1 8 turn each time otherwise you might over tighten or over loosen it Step 2 Loosen Turn the pivot bolt counter...

Page 27: ...tilt can be adjusted up or down as well Tools Needed 4 mm Allen Key WARNING If you are in any way unsure of how to make these adjustments take your bike to a qualified bicycle technician for professional adjustment Step 1 Loosen the Kore I Beam seat rail clamp with a 4mm Allen wrench Step 4 Adjust the fore and aft position Step 3 Adjust the tilt of the saddle Step 2 Fit the saddle onto the rails S...

Page 28: ...educed weight WARNING If you are in any way unsure of how to make these adjustments yourself take your bike to a qualified technician for professional adjustment Due to its special design the Dahon Neos derailleur s position differs from that of a conventional derailleur Compared to a conventional derailleur it is aligned in the opposite direction i e the adjustment screws and the wire adjustment ...

Page 29: ... 2009 DAHON BPSA 2009 09 DS EN High Adjustment Turn the top adjustment screw to adjust so that the guide pulley is below the outer line of the smallest sprocket when looking from the rear 29 ...

Page 30: ... 2009 DAHON BPSA 2009 09 DS EN Low Adjustment Turn the low adjustment screw so that the guide pulley moves to a position directly in line with the largest sprocket 30 ...

Page 31: ...justment bolt is tightened turned clockwise until noise occurs without the shifter being operated and then loosened turned counterclockwise 360 degrees from that point Operate shifter to change gears and check that no noise occurs in any of the gear positions If shifting to 2nd is not possible or shifting to 2nd occurs but noise of the chain contacting the largest sprocket is heard Change to 2nd a...

Page 32: ... DAHON BPSA 2009 09 EN Dahon California INC 833 Meridian Street Duarte CA 91010 1 800 442 3511 www dahon com Dahon TW 8F 8 6 Lane 609 Chung Hsin RD Sec 5 San Chung Taipei Hsien ROC 241 Taiwan 886 2 2999 5623 ...

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Summary of Contents for - 2010

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DAHON - 2010, Service Instructions Manual

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