2008 Dahon User Manual en
2008 Dahon User Manual en
2008 Dahon User Manual en
1. Wheel
2. Rear Derailleur
3. Chain
4. Crank Set
5. Pedal
6. Seat Post
7. Saddle
8. Bolts for Bottle Cage
9. Frame
10. Head Set
11. Handlepost
12. Handlebars
13. Brake Lever
14. Fork
15. Brakes
2
Contents
First.................................................................................... 4 How an Internal Gear Hub Drive Train Works.......................... 11
Bike Fit.......................................................................................4 Shifting Internal Hub Gears.................................................. 11
Safety First.................................................................................4 What Gear Should I Be In?.................................................. 11
This Manual................................................................................4 Special Dahon Service Instructions:.........................................12
Luggage Mounting Bracket Installation................................12
Safety................................................................................. 5
Handlepost Latch Adjustment Instructions...........................13
The Basics..................................................................................5
Headset Adjustment Instructions..........................................14
Riding Safety..............................................................................5
Frame Latch Adjustment Instructions...................................15
Wet Weather Riding...................................................................5
Adjusting Dahon Infinite Adjustable Stem............................16
Night Riding................................................................................6
Kore I-Beam Seat Adjustment..............................................17
Fit....................................................................................... 7 VRO Stem Adjustment.........................................................18
Saddle Position..........................................................................7 Cadenza Offset Bottom Bracket...........................................19
Handlebar Height and Angle......................................................7 Replaceable Derailleur Hanger............................................19
Tech................................................................................... 8 Transporting Your Bike.........................................................20
Wheels.......................................................................................8 Chains......................................................................................21
Installing A Quick Release Front Wheel.................................8 Pedals......................................................................................21
Installing A Quick Release Rear Wheel..................................8 Service............................................................................. 22
Brakes: Rim Brakes & Disc Brakes............................................9 Service Intervals.......................................................................22
Brake Controls and Features.................................................9 Break-in Period.....................................................................22
How Brakes Work...................................................................9 After Every Long Hard Ride.................................................22
Shifting Gears...........................................................................10 After Every Long Hard Ride or After 10 to 20 Hours of Riding..22
How a Derailleur Drive Train Works.....................................10
Warranty.......................................................................... 24
Shifting Gears.......................................................................10
Shifting the Rear Derailleur..................................................10 Torque Values................................................................. 25
Shifting the Front Derailleur..................................................10
What Gear Should I Be In?.................................................. 11
3
you may be able to adjust their angle and • Handlebar and Saddle Alignment: Make
First reach.
• Do you fully understand how to operate your
sure the saddle and handlebar stem are
parallel to the bike’s centerline and clamped
new bicycle? If not, before your first ride, tight enough so that you can’t twist them out
have your dealer explain any functions or of alignment.
All folding bicycles and P.A.Q. mini-bikes are
features that you do not understand. • Handlebar Ends: Make sure the handlebar
intended for use on paved roads only. P.A.Q.
grips are secure and in good condition. If
mountain bikes are intended for use on hard-
not, have your dealer replace them. Make
packed trails only, and are not intended for
sure the handlebar ends and extensions
jumps, stunts or other extreme sports. Safety First are plugged. If not, have your dealer plug
them before you ride. If the handlebars
Make sure your bicycle is used for its intended • Always wear an approved helmet when rid- have bar-end extensions, make sure they
purpose as the misuse may lead to the failure ing your bike, and follow the helmet manu- are clamped tight enough so you can’t twist
of some component or part. facturer’s instructions for fit, use and care. them. Please note that with the installa-
• Do you have all the other required and tion of some TT bars, criterium, aero bars,
recommended safety equipment? It’s your bar ends or a triathlon style clip-on, your
Bike Fit responsibility to familiarize yourself with response time for braking and steering may
the laws of the area where you ride, and to have been adversely affected.
• Is your bike the right size? If your bicycle is comply with all applicable laws.
too large or too small for you, you may lose • Rider’s weight and luggage should not ex-
control and fall. If your new bike is not the ceed 105kg (230lbs).
right size, ask your dealer to exchange it • Do you know how to correctly operate your
This Manual
before you ride it. wheel quick releases? Check Section 4.A.1
This manual is not intended as a comprehen-
• Is the saddle at the right height? To check, and 4.A.2 to make sure. Riding with an
sive guide to bicycling and maintenance. It
see Section 3.A. If you adjust your saddle improperly adjusted wheel quick release can
cannot teach you all the mechanical skills you
height, follow the Minimum Insertion instruc- cause the wheel to wobble or disengage
need to repair a bicycle nor can it teach you all
tions in Section 3.A. from the bicycle, and cause serious injury
the skills you will need to ride a bicycle. This
• Are the saddle and seat post securely or death.
manual has a great number of tips and advice
clamped? A correctly tightened saddle will • Are your wheel rims clean and undamaged? for the specific bikes it comes with. If you are
allow no saddle movement in any direction. Make sure the rims are clean and undam- ever unsure of how to maintain your bike, visit
See Section 3.A. aged along the braking surface, and check a dealer and ask for advice.
• Are the stem and handlebars at the right for excess rim wear. Periodically inspect
height for you? If not, see Section 3.B. Can your rims for excessive wear and if you
you comfortably operate the brakes? If not, have any question on whether or not your
rims are safe, have them inspected by a
bicycle dealer.
4
Riding Safety • Never hitch a ride by holding on to another
Safety vehicle.
• Don’t weave through traffic or make unex-
• You are sharing the road or the path with
others — motorists, pedestrians and other pected moves.
cyclists. Respect their rights. • Observe and yield the right of way.
The Basics • Ride defensively. Always assume that others • Never ride your bicycle while under the influ-
do not see you. ence of alcohol or drugs.
WARNING: It is your responsibility to
familiarize yourself with the laws • Look ahead, and be ready to avoid: • If possible, avoid riding in bad weather,
where you ride and to comply with all »» Vehicles slowing or turning, entering the when visibility is obscured, at dawn, dusk or
applicable laws, including properly road or your lane ahead of you, or com- in the dark, or when extremely tired. Each
equipping yourself and your bike as the law ing up behind you. of these conditions increases the risk of
requires. accident.
»» Parked car doors opening.
Observe all local bicycle laws and regulations. »» Pedestrians stepping out.
Observe regulations about bicycle lighting, »» Children or pets playing near the road.
licensing of bicycles, riding on sidewalks, laws »» Potholes, sewer grating, railroad tracks, Wet Weather Riding
regulating bike path and trail use, helmet laws, expansion joints, road or sidewalk con-
child carrier laws, and special bicycle traffic struction, debris and other. WARNING: Wet weather impairs
laws. It’s your responsibility to know and obey traction, braking and visibility, both
»» The many other hazards and distractions
your country’s laws. for the bicyclist and for other vehicles
which can occur on a bicycle ride. sharing the road. The risk of an accident is
• Ride in designated bike lanes, on desig- dramatically increased in wet conditions.
• Always do check the safety of your bike nated bike paths or as close to the edge of
before you ride it. the road as possible, in the direction of the Under wet conditions, the stopping power of
• Be thoroughly familiar with the controls of traffic flow or as directed by local governing your brakes (as well as the brakes of other ve-
your bicycle: brakes (Section 4.B); pedals laws. hicles sharing the road) is dramatically reduced
(Section G); shifting (Section 4.C). • Stop at stop signs and traffic lights; slow and your tires don’t grip nearly as well. This
• Be careful to keep body parts and other down and look both ways at street intersec- makes it harder to control speed and easier to
objects away from the sharp teeth of chain tions. Remember that a bicycle always loses lose control. To make sure that you can slow
rings, the moving chain, the turning pedals in a collision with a motor vehicle. down and stop safely in wet conditions, ride
and cranks, and the spinning wheels of your • Use approved hand signals for turning and more slowly and apply your brakes earlier and
bicycle. stopping. more gradually than you would under normal,
dry conditions. See also Section 4.B.
• Never ride with headphones.
• Never carry a passenger.
5
Night Riding following strongly recommended additional
precautions:
Riding a bicycle at night is many times more
dangerous than riding during the day. A bicy- • Purchase and install a generator or battery
clist is very difficult for motorists and pedestri- powered head and taillight that meet all
ans to see. Therefore, children should never local regulatory requirements and provide
ride at dawn, at dusk or at night. Adults who adequate visibility.
choose to accept the greatly increased risk of • Wear light-colored, reflective clothing and
riding at dawn, at dusk or at night need to take accessories, such as a reflective vest, re-
extra care both riding and choosing special- flective arm and leg bands, reflective stripes
ized equipment that helps reduce that risk. on your helmet, flashing lights attached to
Consult your dealer about night riding safety your body and/or your bicycle.
equipment. • Make sure your clothing or anything you
may be carrying on the bicycle does not
WARNING: Reflectors are not a obstruct a reflector or light and securely
substitute for required lights. Riding mounted reflectors.
at dawn, at dusk, at night or at other times • Make sure that your bicycle is equipped cor-
of poor visibility without an adequate
rectly with reflectors.
bicycle lighting system and without
reflectors is dangerous and may result in
serious injury or death. While riding at dawn, at dusk or at night:
6
WARNING: If your seat post projects Handlebar Height and Angle
Fit from the frame beyond the Minimum
Insertion or Maximum Extension mark, the WARNING: The stem’s Minimum
seat post may break, which could cause Insertion Mark must not be visible
you to lose control and fall. above the top of the headset. If the stem is
Saddle Position extended beyond the Minimum Insertion
• Front and back adjustment. The saddle can Mark, the stem may break or damage the
Correct saddle adjustment is an important fac- be adjusted forward or backward to help fork’s steerer tube, which could cause you
tor in getting the most performance and comfort you get the optimal position on the bike. to lose control and fall.
from your bicycle. If the saddle position is not Ask your dealer to set the saddle for your
comfortable for you, see your dealer. optimal riding. Your dealer can also change the angle of the
• Saddle angle adjustment. Most people handlebar or bar-end extensions.
The saddle can be adjusted in three directions: prefer a horizontal saddle; but some riders
like the saddle nose angled up or down just WARNING: An insufficiently tightened
• Up and down adjustment. To check for cor- a little. Your dealer can adjust the saddle stem binder bolt, handlebar binder
rect saddle height: bolt or bar-end extension clamping bolt may
angle.
compromise steering action, which could
»» Sit on the saddle. cause you to lose control and fall. Place the
»» Place one heel on a pedal. NOTE: If your bicycle has a suspension seat front wheel of the bicycle between your legs
»» Rotate the crank until the pedal with your post, periodically ask your dealer to check it. and attempt to twist the handlebar/stem
heel on it is in the down position and the assembly. If you can twist the stem in
crank arm is parallel to the seat tube. Small changes in saddle position can have a relation to the front wheel, turn the handle-
substantial effect on performance and comfort. bars in relation to the stem, or turn the
To find your best saddle position, make only bar-end extensions in relation to the
If your leg is not completely straight, your handlebar, the bolts are insufficiently
one adjustment at a time.
saddle height needs to be adjusted. If your tightened.
hips must rock for the heel to reach the
pedal, the saddle is too high. If your leg is WARNING: After any saddle adjust-
ment, be sure that the saddle
bent at the knee with your heel on the pedal,
adjusting mechanism is properly tightened
the saddle is too low. before riding. A loose saddle clamp or seat
post binder can cause damage to the seat
Once the saddle is at the correct height, post, or can cause you to lose control and
make sure that the seat post does not fall. A correctly tightened saddle adjusting
project from the frame beyond its “Minimum mechanism will allow no saddle movement
Insertion” or “Maximum Extension” mark. in any direction. Periodically check to make
sure that the saddle adjusting mechanism is
properly tightened.
7
The lever should now be parallel to the fork Installing a Quick Release Rear Wheel
Tech blade and curved toward the wheel. With
the right amount of force, the lever should • Make sure that the rear derailleur is still in
make a clear embossed mark on the sur- its outermost, high-gear position.
face of the fork. • Pull the derailleur body back with your right
Wheels hand.
WARNING: Securely clamping the • Move the quick-release lever to the OPEN
front and rear wheels takes consider- position. The lever should be on the side of
Installing a Quick Release Front Wheel able force. If you can fully close the quick the wheel opposite the derailleur and free-
release without wrapping your fingers
wheel sprockets.
CAUTION: If your bike is equipped around the fork blade for leverage, and the
lever does not leave a clear embossed mark • Put the chain on top of the smallest free-
with disk brakes, be careful not to
damage the disk, caliper or brake pads in the surface of your fork, the tension is wheel sprocket. Then, insert the wheel up
when re-inserting the disk into the caliper. insufficient. Open the lever; turn the and back into the frame dropouts and pull it
Never activate a disk brake’s control lever tension-adjusting nut clockwise a quarter all the way in to the dropouts.
unless the disk is correctly inserted in the turn; then try again. • Tighten the quick-release adjusting nut until
caliper. See also Section 4.B. it is finger tight against the frame dropout;
• If the lever cannot be pushed all the way to then swing the lever toward the front of the
• Move the quick-release lever so that it a position parallel to the fork blade, return bike until it is parallel to the frame’s chain
curves away from the wheel. This is the the lever to the OPEN position. Then turn stay or seat stay and is curved toward the
OPEN position. the tension-adjusting nut counterclockwise wheel. To apply enough clamping force, you
• With the steering fork facing forward, insert one-quarter turn and try tightening the lever should have to wrap your fingers around
the wheel between the fork blades so that again. a frame tube for leverage, and the lever
the axle seats firmly at the top of the slots • Re-engage the brake quick-release mecha- should leave a clear embossed mark in the
that are at the tips of the fork blades — nism to restore correct brake pad-to-rim surface of your frame.
the fork dropouts. The quick-release lever clearance; spin the wheel to make sure that
should be on the left side of the bicycle. it is centered in the frame and clears the
• Holding the quick-release lever in the OPEN brake pads; then squeeze the brake levers
position with your right hand, tighten the and make sure that they work.
tension-adjusting nut with your left hand un-
til it is tight against the fork dropout.
• While pushing the wheel firmly to the top
of the slots in the fork dropouts, and at the
same time centering the wheel rim in the
fork, move the quick-release lever upwards
and swing it into the CLOSED position.
8
Brakes – Rim Brakes & Disc sure your hands can reach and squeeze the NOTE: Make sure that no oil or lubrication
brake levers. touches your brake pads or the bicycles rims’
Brakes braking surfaces. Please replace worn brake
NOTE: In the UK and Japan, the right lever shoes only with factory authorized brake
Riding with improperly adjusted brakes or worn controls the front brake while the left lever replacements.
brake pads is dangerous and can result in seri- controls the rear brake. All brakes should be
ous injury or death. adjusted according to local regulations.
9
Shifting Gears easier on a hill, make a downshift in one of two travel of the rear derailleur. Tightening the rear
ways: shift the chain down (the gear “steps” to derailleur high gear adjustment screw keeps
Your multi-speed bicycle will have a derailleur a smaller gear at the front) or shift the chain up the chain from shifting off the small (high) gear
drive train, an internal gear hub drive train or, in (the gear “steps” to a larger gear at the rear.) that is on the rear axle. Tightening the rear
some special cases, a combination of the two. So, at the rear gear cluster, what is called a derailleur low gear adjustment screw keeps the
downshift actually moves the chain up to a chain from shifting off the large (low) gear into
larger gear. The way to keep things straight is the rear wheel. Moving the chain from a smaller
to remember that shifting the chain in towards sprocket of the gear cluster to a larger sprocket
How a Derailleur Drive Train Works
the centerline of the bike is for accelerating and results in a downshift. Moving the chain from
climbing and is called a downshift. Moving the the smaller sprocket on the chain rings to a
If your bicycle has a derailleur drive train, the
chain out or away from the centerline of the larger sprocket results in what is called an
gear-changing mechanism will have:
bike is for speed and is called an upshift. “upshift.” In order for the derailleur to move the
chain from one sprocket to another, the rider
»» A rear cassette or freewheel sprocket
Whether upshifting or downshifting, the bicycle must be pedaling forward.
cluster.
derailleur system design requires that the drive
»» A rear derailleur. chain be moving forward and be under at least
»» Usually a front derailleur. some tension. A derailleur will shift only if you Shifting the Front Derailleur
»» One or two shifters. are pedaling forward.
»» One, two or three front sprockets called The front derailleur, which is controlled by the
chain rings. left shifter, shifts the chain between the larger
»» A drive chain. Shifting the Rear Derailleur and smaller chain rings. Shifting the chain onto
a smaller chain ring makes pedaling easier (a
The right shifter controls the rear derailleur. downshift). Shifting to a larger chain ring makes
pedaling harder (an upshift). There are 2 (two)
Shifting Gears The function of the rear derailleur is to move adjustment screws on the front derailleur: one
the drive chain from one gear sprocket to an- is to limit the travel of the front derailleur so
There are several different types and styles of
other. The smaller sprockets on the rear wheel that the chain can be shifted upwards towards
shifting controls: levers, twist grips, triggers,
gear cluster produce higher gear ratios. Pedal- the larger, higher or harder to pedal gears but
combination shift/brake controls and push
ing in the higher gears requires greater pedal- will not allow the chain to “overshift.” The other
buttons. Ask your dealer to explain the type of
ing effort, but takes you a greater distance with screw limits the travel of the front derailleur
shifting controls that are on your bike, and to
each revolution of the pedal cranks. The larger towards the smaller or easier-to-pedal chain-
show you how they work.
sprockets produce lower gear ratios. Using wheel. By limiting travel, it prevents the chain
them requires less pedaling effort, but takes from “undershifting” and keeps the chain from
A downshift is a shift to a “lower” or “slower”
you a shorter distance with each pedal crank falling off the chainwheel onto the frame.
gear, one that is easier to pedal. An upshift is
revolution. There are two set screws or limit
a shift to a “higher” or “faster”, harder to pedal
screws on the rear derailleur body that limit the
gear. To select a gear that will make pedaling
10
WARNING: Never shift a derailleur How an Internal Gear Hub
onto the largest or the smallest
sprocket if the derailleur is not shifting Drive Train Works
smoothly. The derailleur may be out of
adjustment and the chain could jam, If your bicycle has an internal gear hub drive
causing you to lose control and fall. train, the gear changing mechanism will consist
of:
11
Special Dahon Ser-
vice Instruction
Step 1.2 Use an Allen wrench to Step 1.4 To install the luggage Step 1.6 With the luggage bracket
unscrew the bolt holding the light bracket, screw in the bolts that installed, you are free to attach
onto the apex of the front fork. were supplied with the bracket us- a number of baskets or cases
ing an Allen wrench. that are available from various
companies.
12
Handlepost Latch
Adjustment Instructions
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. 13
Headset Adjustment Step 3.3 (see Fig. 2) Tighten the Step 3.6 (see Fig. 1) Finally, tight-
Instructions Fig. 1 handlepost clamp screw with a en the headset screw completely
6mm Allen wrench and tighten to a with a 10mm Allen wrench and
If the handlepost is tightened cor- torque of 100 kg f/cm. By tighten- tighten to a torque of 150~200 kg
rectly, but there is still side-to-side ing this clamp screw, the handle- f/cm. Make sure that the handlebar
or front-to-back play, the headset post is secured to the fork steerer. and front wheel are perpendicular
may need to be adjusted. A tight When the headset screw is loos- to each other (see Step 1). If they
headset should keep the handle- ened, the handlepost will now be are not, please repeat steps 1~6
bars perfectly perpendicular to the kept in place by this handlepost again.
bike frame, while not allowing any base clamp screw.
lateral or front-to-back movement.
The following instructions explain Step 3.4 (see Fig. 1) Loosen the
Fig. 2 headset screw with a 10mm Allen
how to adjust the headset.
wrench.
WARNING: If you are in any way unsure of how to make these adjustments
14 yourself, take your bike to a qualified technician for professional adjustment.
Frame Latch Adjustment not insert grease into other areas
Instructions of the hinge or the handlepost
latch. Periodic lubrication on both
The frame latch is quite possible sides of the hinge lever is neces-
the most important part of a fold- sary to keep it working smoothly.
ing bicycle. Care should be taken If you are unsure about following
to check that the latch is adjusted these instructions or if your bicycle
correctly before each ride. A cor- is not functioning correctly, stop
rectly tightened latch will close with and do not use your bicycle. Da-
a strong seal, and the frame will hon recommends that you contact
feel solid. An incorrectly adjusted your local professional bicycle
frame latch will be loose, and the Step 4.2 Add a drop of Loctite 222 technician.
latch will close too easily. The fol- (Loctite 242 is fine) to the bolts
lowing instructions explain how to threads to prevent loosening.
adjust the latch.
WARNING: Do not add
Loctite to any other part of
the hinge. Loctite will be dry
enough to use in 10 minutes
and will be 100% dry in 24
hours. Please wait 10 minutes
for Loctite to be dry enough to
use.
WARNING: If you are in any way unsure of how to make these adjustments
16 yourself, take your bike to a qualified technician for professional adjustment.
Version A
If the hinge is too loose and you need If the hinge is too tight and you need
to tighten it turn the frame hinge bolt to loosen it, turn the frame hinge bolt
counter-clockwise (facing the hinge clockwise (facing the hinge turn the
turn the screw upwards). screw downwards).
Version B
If the hinge is too loose and you need If the hinge is too loose and you need
to tighten it turn the frame hinge bolt to tighten it turn the frame hinge bolt
counter-clockwise (facing the hinge counter-clockwise (facing the hinge
turn the screw downwards). turn the screw upwards).
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. 17
Adjusting Dahon F.I.T. Stem
Step 5.2 To adjust the height Step 5.4 Do not raise the stem
of the stem, loosen the steerer over the stem’s top cap.
tube binder bolt with a 5mm Allen
wrench.
WARNING: If you are in any way unsure of how to make these adjustments
18 yourself, take your bike to a qualified technician for professional adjustment.
Kore I-Beam Seat
Adjustment
Step 6.2 Fit the saddle onto the Step 6.4 Adjust the fore and aft
rails. position.
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. 19
VRO Stem Adjustment
Step 7.1 Loosen the two bolts Step 7.2 Adjust the VRO stem up Step 7.3 Progressively tighten
of the VRO clamps with a 5mm or down. each bolt of the two VRO clamps
Allen wrench to adjust the height until resistance is felt, making sure
and preferred riding position to the that the inside faces of the clamps
rider’s preference. are no more than 50mm apart from
each other. Then alternate tension-
ing the VRO clamps to 90 in/lbs
(10NM) making sure that the angle
of the brake levers allow the rider
easy access to them.
WARNING: If you are in any way unsure of how to make these adjustments
20 yourself, take your bike to a qualified technician for professional adjustment.
Cadenza Offset Bottom Bracket ets, becomes important with the chain run- Replaceable Derailleur Hanger Installa-
ning on two sprockets. (With a multi-speed tion Instructions
WARNING: If you are in any way derailleur, one sprocket is in front and many
unsure of how to make these sprockets are in the rear. Chainline is al- If you have an alloy frame bicycle with the Da-
adjustments yourself, take your bike to a ways important, but derailleurs are forgiving hon Neos derailleur and want to install a longer
qualified technician for professional and single sprockets front or rear are not.) arm rear derailleur, you will need to install the
adjustment. You may need to overhaul the BB to place a extra derailleur hanger Dahon has supplied
thin spacer or spacers under the stationary with the bike. This instruction is designed to
The Cadenza frame comes with an eccentric cup of the BB set. advise you on how to install this simple frame
bottom bracket (BB) shell, which has an al-
replacement part. Please note the complexity
loy insert that is held stationary by 2 clamps. Use of the rotating eccentric BB shell to of this simple task, so be aware that there are
These 6mm screw threads should be lightly adjust chain tension both special tools and special bicycle mechani-
greased and tightened to 60-100 in./lbs. Loos-
cal knowledge necessary. If you are lacking
ening these screws allows the drive chain to be The eccentric BB insert can be rotated to in- either of these, Dahon strongly suggests
tightened or loosened. The BB (68 mm x 1.37” crease or decrease the chain tension. With you consult your local Dahon bicycle shop
x 24 tpi BSC) installation requires special tools the BB installed and the drivechain con- professional.
and special knowledge and if you lack either nected, loosen the Allen bolt and rotate the
of these, please consult your local Dahon bike eccentric BB with an adjustable pin spanner To replace your hanger derailleur, please go to
dealer. The adjustment of the eccentric BB wrench. In rotation of the chain, you find a your local Dahon dealer.
shell requires a pin spanner wrench, a 6mm Al- “tight spot” and a “loose spot.” Adjust the
len wrench, and perhaps a chain tool and some chain tension so that there is smooth rota-
extra links. tion on the tight spot and tighten and torque
the eccentric BB clamp screws.
Installing a rear wheel with a hub gear or
single-speed rear wheel
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. 21
Transporting Your Bike Rolling Travel Case
All 16- and 20-inch wheeled folding bicycles A much easier and more efficient method A semi-hard travel case is a perfect long
can be transported by the methods described to transport your 16 to 20-inch wheeled distance transportation solution for many
in sections a, b, c, and d below. Bikes with bicycles is to roll them on their wheels. Re- folding bicycles. They work well on any pub-
24- and 26-inch wheels, as well as road bikes member that the Jetstream fork and frame lic transportation system. Many travel cases
with 700c wheels, have limited carrying ability must be bound together so the wheels will are safe enough to withstand the most
and will not fit in public conveyance overhead roll. Raise the folded bikes seatpost and difficult luggage safety challenge, which is
compartments. Of course, using the methods saddle approximately 305 mm (12 inches) checking luggage in at the airport. You can
described in sections c and d below are no and tilt or angle the folded bike towards you. find travel cases large enough for most 16-,
problem. Our suggestion for commuting and Then simply push the bicycle forward. This 20-, and 24-inch wheeled bicycles. Howev-
medium distance travel is that it is best to use conveyance method is perfect for travel er, when carrying bikes with 26-inch wheels,
a nylon bag carry bag. For long distance travel, from parking lots to a bus, train or airplane the wheels must be removed.
the 24- and 26-inch wheeled bikes, and 700c terminal and transition from rough tarmac or
road bicycles, should be packed in a sturdy driveways to smooth granite or tile floors.
travel case.
Carrying Bag
Carrying a 16- to 20-inch wheeled folded This is a clean and efficient method of pack-
bicycle is quite easy for extra short to me- ing and carrying any of the many Dahon
dium distances. For Jetstream full suspen- bicycles. Simply place the folded, collapsed
sion bicycles, make sure you have the black or packed-away bicycle on the opened bag
nylon strap that came with your bike to bind that is lying on the floor. There are spacious
the wheels together. Simply grab the bicycle internal pockets for any parts that must be
and carry by the saddles edge. When cross- removed such as pedals and any tools that
ing a threshold, boarding a bus, train or you might need later. A nice neat package is
airplane or stowing the bike in an overhead visible when the sides of the bag are pulled
compartment, you will need to pick your bi- up tight and the handle/shoulder strap is
cycle up. When the occasion arises that you fastened. The entire operation takes only a
need to travel or commute and want your few seconds. It is perfect to carry your bike
bicycle with you, feel confident knowing your on any sort of public conveyance or to carry
bike is ready when you are. in a car. However, the bag is not approved
for airline check in.
22
Chains Pedals
Single-speed and three-speed bicycles as well • Toe clips and straps are a means to keep
as many IGH (Internal Geared Hubs) equipped your feet correctly positioned and engaged
bicycles use a “1/2 x 1/8” chain that has a with the pedals. The toe clip positions the
master link. ball of the foot over the pedal spindle,
which gives maximum pedaling power. The
To reinstall the “1/2 x 1/8” chain, turn the bi- toe strap, when tightened, keeps the foot
cycle upside down, and after reinstalling the engaged throughout the rotation cycle of
chain, pull the rear wheel axle in a rearward the pedal. Toe clips and straps work most
direction. With rotation of the chain, any “tight effectively with cycling shoes designed for
spot” and a “loose spot” are due to inconsistent use with toe clips. Care should be taken to
chain wheel roundness. Adjust the chain so become accustomed to the use of toe clips
there is no looseness when the chain is in one before riding in traffic.
of its “tight spots.” • Clipless pedals (sometimes called “step-in
pedals”) are another means to keep feet
Derailleur equipped bicycles use a narrower securely in the correct position for maximum
“1/2 x 3/32” chain that has no master link. With pedaling efficiency. They have a plate,
a “1/2 x 3/32” chain, it is necessary most of the called a “cleat,” on the sole of the shoe,
time to use a special tool to push a link pin out which clicks into a mating spring-loaded fix-
of a chain to separate and remove it. There are ture on the pedal. They only engage or dis-
many methods of measuring the chain to deter- engage with a very specific motion that must
mine if it is too worn. There are some excellent be practiced until it becomes instinctive.
chain wear indicators for sale at bike shops.
Since the chain rotates a lot more on the rear
wheel than the front, please note that replacing
any already badly worn chain may mean that
you might also need to replace the rear wheel
cassette or freewheel as well.
23
Service Intervals After Every Long or Hard Ride
Service If the bike has been exposed to water or grit,
Some service and maintenance can and should
be performed by the owner, and requires no or at least every 100 miles, clean it by wiping it
special tools or knowledge beyond what is pre- clean and lightly oil the chain with a dry Teflon
WARNING: Technological advances sented in this manual. lubrication or a synthetic based chain lube.
have made bicycles and bicycle Then, very importantly, wipe off excess oil.
components more complex, and the pace of Long lasting lubrication is a function of climate.
innovation is increasing. It is impossible for The following are examples of the type of
service you should perform yourself. All other (Hot or cold, wet or dry.) For general cycle
this manual to provide all the information
service, maintenance and repair should be per- lubrication, Dahon suggests using lightweight
required to properly repair and/or maintain
your bicycle. In order to help minimize the formed in a properly equipped facility by a qual- mineral based oil that is commonly available
chances of an accident and possible injury, ified bicycle mechanic, using the correct tools in most bike shops or hardware stores. If you
it is critical that you have any repair or and procedures specified by the manufacturer. have any questions, please talk to your dealer
maintenance that is not specifically as an incorrect lubricant can damage the
described in this manual performed by your painted surfaces.
dealer. Equally important is that your Break-in Period
individual maintenance requirements will be
determined by everything from your riding After Every Long or Hard Ride or After
style to geographic location. Consult your Your bike will last longer and work better if
dealer for help in determining your mainte- you break it in before riding it hard. Control Every 10 to 20 Hours of Riding
nance requirements. cables and wheel spokes may stretch or “seat”
when a new bike is first used and may require Squeeze the front brake and rock the bike
WARNING: Many bicycle service and readjustment by your dealer. Your Mechanical forward and back. If you feel a clunk with each
repair tasks require special knowl- Safety Check will help you identify some things forward or backward movement of the bike,
edge and tools. Do not begin any adjust- that need readjustment. But even if every- you probably have a loose headset. Have your
ments or service on your bicycle until you thing seems fine to you, it is best to take your dealer check it.
have learned from your dealer how to bike back to the dealer for a checkup. Dealers
properly complete them. Improper adjust- typically suggest you bring the bike in for a Lift the front wheel off the ground and swing
ment or service may result in damage to the 30-day checkup. Another way to judge when it it from side to side. If you feel any binding or
bicycle or in an accident that can cause is time for the first checkup is to bring the bike roughness in the steering, you may have a tight
serious injury or death. headset. Have your dealer check it.
in after three to five hours of hard off-road use,
or about 10 to 15 hours of on-road or more
casual off-road use. But if you think something Grab one pedal and rock it toward and away
is wrong with the bike, take it to your dealer from the centerline of the bike; then do the
before riding it again. same with the other pedal. Anything feel loose?
If so, have your dealer check it.
24
Take a look at the brake pads. Starting to look es, cracks, fraying and discoloration are
worn or not hitting the wheel rim squarely? signs of stress-caused fatigue and indicate
Time to have the dealer adjust or replace them. that a part is at the end of its useful life and
needs to be replaced. While the materials
Carefully check the control cables and cable and workmanship of your bicycle or of
individual components may be covered by a
housings. Any rust? Kinks? Fraying? If so, have
warranty for a specified period of time by
your dealer replace them. the manufacturer, this is no guarantee that
the product will last the term of the
Squeeze each adjoining pair of spokes on warranty. Product life is often related to the
either side of each wheel between your thumb kind of riding you do and to the treatment to
and index finger. Do they all feel about the which you submit the bicycle. The bicycle’s
same? If any feel loose, have your dealer warranty is not meant to suggest that the
check the wheel. bicycle cannot be broken or will last forever.
It only means that the bicycle is covered
Check to make sure that all parts and acces- subject to the terms of the warranty.
sories are still secure, and tighten any that are
not. When replacement parts are necessary,
be sure to use factory authorized replacement
parts from your local authorized Dahon dealer.
25
Lifetime Warranty Upgrade Making a Warranty Claim
Warranty
The warranty on the frame, handlepost and You must at your own expense, deliver, mail
rigid fork may be upgraded to a lifetime war- or ship the damaged part, a photo of the de-
ranty if the original owner fills out the online fective part, and a description of the defect,
Dahon Five-Year Limited registration card. The warranty is activated together with both the original bill of sale and
Warranty when the bicycle is tuned and adjusted by a this limited warranty statement as proof of war-
professional mechanic before the owner’s first ranty coverage, to your place of purchase. A
Dahon warrants its bicycle frames, handle- ride. To activate your Dahon warranty and Life- warranty registration card must be completed
posts, and rigid forks to be free from defects in time Frame Warranty, please visit our On-line and received by Dahon before a warranty claim
materials and workmanship for a period of five Warranty Registration page. Go to www.dahon. can be processed. The retailer from whom
years. In addition, Dahon warrants all original com/registration.htm. Registering your Dahon you bought your bicycle will contact Dahon to
parts on the bicycle, excluding suspension serves as proof of original ownership for future determine if the necessary repairs are covered
forks and rear shocks, for a period of one year warranty issues. by the warranty.
from the date of purchase. Suspension forks
and rear shocks shall be covered by the war- *Exclusions from the Dahon Five-Year Lim- NOTE: This warranty does not affect the statu-
ranty of their original manufacturers. ited Warranty also apply to the lifetime frame tory rights of the consumer. Where applicable,
warranty. local laws will take precedent over this contract.
This warranty is limited to the repair or replace-
ment of a defective frame, fork, or defective
part and is the sole remedy of the warranty. Exclusions
This warranty applies only to the original owner
and is not transferable. This warranty only • For all city, road or trekking bikes, damage
covers bicycles and components purchased resulting from commercial use, accident,
through an authorized Dahon dealer and misuse, abuse, neglect or from anything
are only valid within the country in which the other than normal and ordinary use of the
bicycle was purchased. The warranty does product.
not cover normal wear and tear, improper as-
• For all mountain bikes, damage result-
sembly or follow-up maintenance, installation
ing from uses beyond cross-country and
of parts or accessories not originally intended
marathon riding or from anything other than
or compatible with the bicycle as sold, damage
normal and ordinary use of the product.
or failure due to accident, misuse or neglect, or
modification of the frame, fork or components.
26
Torque Values
Dahon large hex key headset screw (10mm) 52~87 6.8~11.3 60~100
Stem steer tube binder bolts; threadless headset 115~145 13~16.4 132~167
Dahon threadless infinite adjustable stem h/bar clamp 44~53 5~6 51~61
Dahon threadless infinite adjustable stem rear stem clamp 62~71 7~8 71~82
27
Brake-Rim and Disc and Brake Lever
Component in/lbs Newton Meters (Nm) kg f/cm
Brake lever - drop bar type (including STI & ERO types) 55~80 6.2~9 63~92
Crank bolt - including spline and square type spindles 300~395 33.9~44.6 345~454
28
Front and Rear Hubs; QR and Nutted Axles
Component in/lbs Newton Meters (Nm) kg f/cm
Rear axle nuts to frame (non-quick release type wheels) 260~390 29.4~44.1 299~449
Frame front or rear rack braze-on bolt torque 25~35 2.8~4 29~40
29
Notes
30
31
© 2008 DAHON, BPSA
2008.07.EN