DAHON Bike Service Manual Download | Manualshive

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Instructions

Service

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Summary of Contents for Bike

Page 1: ...Instructions Service ...

Page 2: ...Contents 02 Dealer Pre delivery Checklist 03 VRO Stem 07 Flat Pak Stem 08 Handlepost Hinge 10 Headset 12 Frame Latch 13 LockJaw Hinge Adjustment 17 Kore I Beam 22 Dahon Neos Derailleur 23 ...

Page 3: ...ess Bike Information Model Year Serial Mechanic Information Signature Name Date of check Please fill out the pre delivery checklist to activate the warranty This following pre delivery checklist information should be filled out by a qualified bicycle mechanic If the mechanic is unclear of the requirements and process needed to carry out any checklist item he she should seek the appropriate assista...

Page 4: ...hain guard Moves freely and accurately through all gear selections Correctly aligned with all gears Cable locking nut is secure Excess cable should be tied cut reasonable length and capped Mechanism s is securely fixed to the handlebars Free of physical defect or damage Correctly positioned Retaining nuts are secure The chain is correctly wired between the front and rear sprockets chain is free fr...

Page 5: ...t is correct forward and level Ability to fold your frame efficiently For bikes fitted with suspension seatposts Functioning and operating properly Wheels Wheel rims bearings and spokes do not have any physical damage or defect Wheel nuts and spoke nipples are tight Front and rear wheels are securely fastened do not foul the brake blocks mudguards or anything else Item Description Remarks OK Brake...

Page 6: ... that both reflectors are present and securely fastened to your front and rear wheels Check that the bell is present and securely fastened to the handlebar Mudguards racks kickstands and supports are firmly attached to your bicycle All supports are in place and tightly fastened Support brackets function properly Magnetix correctly aligned Bike folds properly The bike stands firmly when folded Bike...

Page 7: ...red riding position Move the VRO clamp within the window of adjustment front backwards up and down Step 4 When you have established your desired position proceed to tighten the bolts of the VRO clamps using a torque of 10 Nm Step 2 Using a 5mm Allen key loosen the bolts of theVRO clamps NOTE Check to see that the angle of the handlebar allows immediate access to the brake levers WARNING If you are...

Page 8: ...om riding position open the lock lever on top of the Flat Pak stem by pulling it towards you Flat Pak Stem Adjustment Overview Front Lock Lever Lock Lever The newly developed Flat Pak stem allows easy adjustment of the handlebar in any direction through two quick release levers By adjusting the handlebar s angle riders can change their riding position whether upright for leisurely riding or forwar...

Page 9: ...reach the brake levers Step 4 After the handlebar has been placed in the desired position close front lock lever tightly NOTE Check that the angle of the handlebar will allow immediate access to the brake levers NOTE To avoid rust regularly apply grease to the joints Flat For folding To achieve your preferred riding position you can adjust the height and position of the Flat Pak stem Here are some...

Page 10: ... A closed handle post hinge with a properly adjusted and secured latch should not have side to side movement Periodically inspect the handle post to ensure that it is properly adjusted Several versions of handlepost can be found on different Dahon models With a slight difference the adjustment of the hinge latch is virtually the same Check the handlepost hinge to find out which version is used the...

Page 11: ...not available Radius to make adjustments use an 8mm wrench to tighten or loosen An adjustable wrench or small pliers can also be used if an 8mm wrench is not available Vybe to make adjustments use a 6mm wrench to tighten or loosen An adjustable wrench or small pliers can also be used if a 6mm wrench is not available Adjust the latch bolt until the latch is able to open and close with a 29 49 Nm fo...

Page 12: ...it clockwise Tighten the screw with a torque of 11 3 Nm Step 4 Before you continue to tighten the clamp screw check again to make sure that the handlepost and handlebar are in the correct alignment Also check to make sure that they are perpendicular to the front wheel as shown in the picture above Step 3 Periodically apply Loctite 222 Loctite 242 is also acceptable to the clamp screw Take out the ...

Page 13: ...mark point on handle post should just be visible In this situation the stem has the best folding effect WARNING Do not extend the telescope stem beyond the safety line when adjusting handlebar height Check that the safety line is not visible before riding Telescope stem A telescope stem allows for convenient adjustment of the handlebar height Operation is exlained in the steps below 13 MIN INSERTI...

Page 14: ...rench 6 mm Allen key FRAME HINGE CLOSED FRAME HINGE OPEN The most important part of a folding bicycle is frame hinge Special care should be taken to check that the hinge is adjusted correctly before each ride Use a 6mm wrench an adjustable wrench or small pliers to tighten or loosen the hinge Adjust the hinge bolt for the hinge to open and close with the correct force 49 59 Nm for aluminum frames ...

Page 15: ...is being used and apply the appropriate instructions to the correct V clamp version Adjust the hinge bolt to allow the hinge to open and close with the same amount of force 39 88 Nm The hinge clamp is located completely in the front of the frame with the adjusting nut on the outside To adjust use a 6mm Allen key Open hinge before you do any adjustments Proceed to loosen the lock nut with a 10mm wr...

Page 16: ...open and close with the same amount of force 39 88 Nm VERSION A VERSION B TIGHTEN As indicated above face the hinge and turn the screw upwards counter clockwise As indicated above face the hinge and turn the screw downwards clockwise LOOSEN TOOLS NEEDED 8 mm wrench Use an 8 mm wrench you can also use an adjustable wrench or small pliers to adjust the hinge TIGHTEN As indicated above face the hinge...

Page 17: ...the same amount of force 39 88 Nm TOOLS NEEDED 10 mm wrench 6 mm Allen key Step 1 To loosen the Lock Nut Use a 10mm wrench Turn the wrench in the direction shown above Step 2 Close the hinge Do not close the latch in this process Step 4 Lock Nut Tightening After adjusting the hinge use 10mm wrench to tighten the lock nut Turn the wrench in the direction shown above To make sure the tightness of th...

Page 18: ...mm Allen key The Lockjaw hinge located on the top tube and on the down tube has three components each fulfilling a different function OC Bolt Allows the LockJaw hinge to open and close It is secured by a special Safety Screw Version B only Adjustment Bolt Adjusts the tension of the LockJaw mechanism Pivot Bolt Is the actual hinge axle where the two halves rotate on the frame The pivot bolt can be ...

Page 19: ...a LockJaw equipped bicycle Turning the OC bolt counter clockwise 180 will allow the LockJaw hinge to unlock See picture above To lock the LockJaw hinge simply close the hinge and turn the OC bolt clockwise 180 If you properly adjust the adjustment bolt you should feel a slight click The teeth of the LockJaw hinge will come together See picture above 19 ...

Page 20: ...ose joint Open OC Bolt and turn it counter clockwise 180 The LockJaw is exceptionally secure but will require periodic inspection and adjustment to ensure that it is properly working Adjust the LockJaw according to the following instructions DO NOT open frame To check for the correct tension of the LockJaw close and open the OC bolt When the OC bolt closes with a click at the end the tension is ju...

Page 21: ... If it is too loose the LockJaw hinge will not close securely which will result in a loose join To tighten the adjustment bolt turn it clockwise when looking at the bolt head on To loosen the adjustment bolt turn it counter clockwise when looking at the bolt head on Adjust the Adjustment Bolt while the frame is closed Checking for the correct tension of the LockJaw close and open the OC bolt If th...

Page 22: ...e pivot bolt At times it might be difficult to rotate the frame due to the pivot bolt being too tight This may be a direct result of adjusting the tension of the pivot bolt while adjusting the adjustment bolt A 2mm and a 6mm Allen key are needed to adjust the pivot bolt The pivot bolt and its lock screw are on the bike s non chain side Step 2 Tighten Use a 6mm Allen key to tighten the pivot bolt b...

Page 23: ...dle can be moved forward and backward on the rail while the tilt can be adjusted up or down Step 1 With a 4mm Allen wrench loosen the Kore I beam seat rail clamp Step 4 Adjust the fore and aft position Step 3 Adjust the tilt of the saddle Step 2 Fit the saddle to the rails Step 5 Tighten the pre greased bolts to 85 in lbs or 9 5 NM Tools Needed 4mm Allen key 23 Kore I Beam ...

Page 24: ... influence the locking efficiency Your seatpost is secured by a quick release that allows for easy height adjustment to the proper and most comfortable height 24 Seatpost WARNING Do not adjust the seatpost height beyond the Min Insertion or Max Insertion lines Remember to check that the position is inbetween these safety markers before riding Step 3 Lock quick release tightly Step 2 Move saddle to...

Page 25: ...body only projects 12mm from the chain stays and is much more protected than a standard derailleur which protrudes up to 40mm Due to its special design the Dahon Neos derailleur differs from that of a conventional derailleur The Neos is alligned in the opposite direction i e the adjustment screws and the wire adjustment bolt are facing forward but you can adjust it like any other derailleur Please...

Page 26: ...e rear turn the top adjustment screw to align the guide pulley with and below the outer line of the smallest sprocket Low Adjustment Turn the low adjustment screw for the guide pulley to move directly in line with the largest sprocket 26 ...

Page 27: ...use the shifter to move the derailleur to the largest sprocket Operate the shifter once more to move the derailleur to the 2nd gear sprocket Operate the shifter to the point of movement and then turn the crank arm 3 If shifting to 2nd is not possible or noises occur when the chain contacts the largest sprocket Simply move to 2nd gear and turn the screw counter clockwise until the noise is no longe...

Page 28: ...ope No 1 P O Box 17 Goliamokonarsko Shosse Str Tsaratsovo Village 4027 Bulgaria 359 32335 598 Headquarters Dahon North America INC 833 Meridian Street Duarte CA 91010 1 800 442 3511 Dahon Technologies Ltd Dahon Bldg Furong 6th Rd Shajing Shenzhen 518125 P R C 86 755 27249136 ...

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