2010 Dahon Owner Manual en 21

8/3/2019 2010 Dahon Owner Manual en 21

1/20


2/20

Wheel1.

Rear Derailleur2.

Chain3.

Crank Set4.

Pedal5.

Seat Post6.

Saddle7.Bolts for Bottle Cage8.

Frame9.

Head Set10.

Handlepost11.

Handlebars12.

Brake Lever13.

Fork14.

Brakes15.

NOTE: This manual is not intended as a comprehensiveuse, service, repair or maintenance manual. Please seeyour dealer for all service, repairs or maintenance.

2


3/20

Contents

First...................................................................................4

Bike Fit ......................................................................................4

Safety First ................................................................................4This Manual ...............................................................................4

Safety................................................................................5

The Basics .................................................................................5

Riding Safety .............................................................................5

Wet Weather Riding ..................................................................5

Night Riding ...............................................................................6

Fit ......................................................................................7

Saddle Position .........................................................................7Handlebar Height and Angle .....................................................7

Tech ..................................................................................8

Wheels ......................................................................................8

Installing A Quick Release Front Wheel ................................8

Installing A Quick Release Rear Wheel .................................8

Brakes: Rim Brakes & Disc Brakes ...........................................9

Brake Controls and Features ................................................9

How Brakes Work ..................................................................9

Shifting Gears ..........................................................................10

How a Derailleur Drive Train Works ....................................10

Shifting Gears ......................................................................10

Shifting the Rear Derailleur .................................................10

Shifting the Front Derailleur .................................................10

What Gear Should I Be In? .................................................11

How an Internal Gear Hub Drive Train Works .........................11

Shifting Internal Hub Gears .................................................11

What Gear Should I Be In? .................................................11Chains .....................................................................................12

Pedals .....................................................................................12

Transporting Your Bike ............................................................13

Service............................................................................14

Service Intervals ......................................................................14

Break-in Period ....................................................................14

After Every Long Hard Ride ................................................14

After Every Long Hard Ride or After 10 to 20 Hours of Riding .14

Warranty .........................................................................16

Torque Values ................................................................17

3


4/20

All folding bicycles and P.A.Q. mini-bikes areintended for use on paved roads only. P.A.Q.

mountain bikes are intended for use on hard-packed trails only, and are not intended forjumps, stunts or other extreme sports.

Make sure your bicycle is used for its intendedpurpose as the misuse may lead to the failureof some component or part.

Bike Fit

Is your bike the right size? If your bicycle istoo large or too small for you, you may losecontrol and fall. If your new bike is not theright size, ask your dealer to exchange itbefore you ride it.

Is the saddle at the right height? To check,see Section 3.A. If you adjust your saddleheight, follow the Minimum Insertion instruc-tions in Section 3.A.

Are the saddle and seat post securely

clamped? A correctly tightened saddle willallow no saddle movement in any direction.See Section 3.A.

Are the stem and handlebars at the rightheight for you? If not, see Section 3.B. Canyou comfortably operate the brakes? If not,

you may be able to adjust their angle andreach.

Do you fully understand how to operate yournewbicycle?Ifnot,beforeyourrstride,have your dealer explain any functions orfeatures that you do not understand.

Safety First

Always wear an approved helmet when rid-ing your bike, and follow the helmet manu-facturersinstructionsfort,useandcare.

Do you have all the other required andrecommended safety equipment? Its yourresponsibility to familiarize yourself withthe laws of the area where you ride, and tocomply with all applicable laws.

Riders weight and luggage should not ex-ceed 105kg (230lbs).

Do you know how to correctly operate yourwheel quick releases? Check Section 4.A.1and 4.A.2 to make sure. Riding with animproperly adjusted wheel quick release cancause the wheel to wobble or disengagefrom the bicycle, and cause serious injuryor death.

Are your wheel rims clean and undamaged?Make sure the rims are clean and undam-aged along the braking surface, and checkfor excess rim wear. Periodically inspectyour rims for excessive wear and if youhave any question on whether or not yourrims are safe, have them inspected by abicycle dealer.

Handlebar and Saddle Alignment: Makesure the saddle and handlebar stem areparallel to the bikes centerline and clampedtight enough so that you cant twist them outof alignment.

Handlebar Ends: Make sure the handlebargrips are secure and in good condition. Ifnot, have your dealer replace them. Makesure the handlebar ends and extensionsare plugged. If not, have your dealer plugthem before you ride. If the handlebarshave bar-end extensions, make sure theyare clamped tight enough so you cant twistthem. Please note that with the installa-tion of some TT bars, criterium, aero bars,bar ends or a triathlon style clip-on, yourresponse time for braking and steering mayhave been adversely affected.

This Manual

This manual is not intended as a comprehen-sive guide to bicycling and maintenance. Itcannot teach you all the mechanical skills youneed to repair a bicycle nor can it teach you allthe skills you will need to ride a bicycle. Thismanual has a great number of tips and advice

forthespecicbikesitcomeswith.Ifyouareever unsure of how to maintain your bike, visita dealer and ask for advice.

First

4


5/20

The Basics

WARNING: It is your responsibility tofamiliarize yourself with the laws

where you ride and to comply with allapplicable laws, including properlyequipping yourself and your bike as the lawrequires.

Observe all local bicycle laws and regulations.Observe regulations about bicycle lighting,licensing of bicycles, riding on sidewalks, lawsregulating bike path and trail use, helmet laws,

childcarrierlaws,andspecialbicycletrafclaws. Its your responsibility to know and obeyyour countrys laws.

Always do check the safety of your bikebefore you ride it.

Be thoroughly familiar with the controls ofyour bicycle: brakes (Section 4.B); pedals(Section G); shifting (Section 4.C).

Be careful to keep body parts and otherobjects away from the sharp teeth of chainrings, the moving chain, the turning pedalsand cranks, and the spinning wheels of yourbicycle.

Riding Safety

You are sharing the road or the path withothers motorists, pedestrians and othercyclists. Respect their rights.

Ride defensively. Always assume that others

do not see you.Look ahead, and be ready to avoid:

Vehicles slowing or turning, entering theroad or your lane ahead of you, or com-ing up behind you.

Parked car doors opening.

Pedestrians stepping out.

Children or pets playing near the road.

Potholes, sewer grating, railroad tracks,expansion joints, road or sidewalk con-

struction, debris and other.The many other hazards and distractionswhich can occur on a bicycle ride.

Ride in designated bike lanes, on desig-nated bike paths or as close to the edge ofthe road as possible, in the direction of thetrafcoworasdirectedbylocalgoverninglaws.

Stopatstopsignsandtrafclights;slowdown and look both ways at street intersec-

tions. Remember that a bicycle always losesin a collision with a motor vehicle.

Use approved hand signals for turning andstopping.

Never ride with headphones.

Never carry a passenger.

Never hitch a ride by holding on to anothervehicle.

Dontweavethroughtrafcormakeunex-pected moves.

Observe and yield the right of way.

Neverrideyourbicyclewhileundertheinu-

ence of alcohol or drugs.If possible, avoid riding in bad weather,when visibility is obscured, at dawn, dusk orin the dark, or when extremely tired. Eachof these conditions increases the risk ofaccident.

Wet Weather Riding

WARNING: Wet weather impairstraction, braking and visibility, bothfor the bicyclist and for other vehiclessharing the road. The risk of an accident isdramatically increased in wet conditions.

Under wet conditions, the stopping power ofyour brakes (as well as the brakes of other ve-hicles sharing the road) is dramatically reducedand your tires dont grip nearly as well. Thismakes it harder to control speed and easier tolose control. To make sure that you can slowdown and stop safely in wet conditions, ridemore slowly and apply your brakes earlier andmore gradually than you would under normal,dry conditions. See also Section 4.B.

Safety

5


6/20

Night Riding

Riding a bicycle at night is many times moredangerous than riding during the day. A bicy-clistisverydifcultformotoristsandpedestri-ans to see. Therefore, children should neverride at dawn, at dusk or at night. Adults whochoose to accept the greatly increased risk ofriding at dawn, at dusk or at night need to takeextra care both r iding and choosing special-ized equipment that helps reduce that risk.Consult your dealer about night riding safetyequipment.

WARNING: Reectors are not asubstitute for required lights. Riding

at dawn, at dusk, at night or at other timesof poor visibility without an adequate

bicycle lighting system and withoutreectors is dangerous and may result inserious injury or death.

Bicyclereectorsaredesignedtopickupandreectcarlightsandstreetlightsinawaythatmay help you to be seen and recognized as amoving bicyclist.

CAUTION: Check reectors and theirmounting brackets regularly to make

sure that they are clean, straight, unbrokenand securely mounted. Have your dealerreplace damaged reectors and straightenor tighten any that are bent or loose.

If you choose to ride under conditions of poorvisibility, check and be sure you comply withall local laws about night riding, and take the

following strongly recommended additionalprecautions:

Purchase and install a generator or batterypowered head and taillight that meet alllocal regulatory requirements and provideadequate visibility.

Wearlight-colored,reectiveclothingandaccessories,suchasareectivevest,re-ectivearmandlegbands,reectivestripesonyourhelmet,ashinglightsattachedtoyour body and/or your bicycle.

Make sure your clothing or anything youmay be carrying on the bicycle does notobstructareectororlightandsecurelymountedreectors.

Make sure that your bicycle is equipped cor-

rectlywithreectors.

While riding at dawn, at dusk or at night:

Ride slowly.

Avoid dark areas and areas of heavy or fast-movingtrafc.

Avoid road hazards.

Ifridingintrafc:

Be predictable. Ride so that drivers can seeyou and predict your movements.

Be alert. Ride defensively and expect theunexpected.

Askyourdealerabouttrafcsafetyclassesoragoodbookonbicycletrafcsafety.

6


7/20

Saddle Position

Correct saddle adjustment is an important fac-tor in getting the most performance and comfortfrom your bicycle. If the saddle position is notcomfortable for you, see your dealer.

The saddle can be adjusted in three directions:

Up and down adjustment. To check for cor-rect saddle height:

Sit on the saddle.

Place one heel on a pedal.

Rotate the crank until the pedal with yourheel on it is in the down position and thecrank arm is parallel to the seat tube.

If your leg is not completely straight, yoursaddle height needs to be adjusted. If yourhips must rock for the heel to reach thepedal, the saddle is too high. If your leg isbent at the knee with your heel on the pedal,the saddle is too low.

Once the saddle is at the correct height,make sure that the seat post does notproject from the frame beyond its MinimumInsertion or Maximum Extension mark.

WARNING: If your seat post projectsfrom the frame beyond the Minimum

Insertion or Maximum Extension mark, theseat post may break, which could causeyou to lose control and fall.

Front and back adjustment. The saddle can

be adjusted forward or backward to helpyou get the optimal position on the bike.Ask your dealer to set the saddle for youroptimal riding.

Saddle angle adjustment. Most peopleprefer a horizontal saddle; but some riderslike the saddle nose angled up or down justa little. Your dealer can adjust the saddleangle.

NOTE: If your bicycle has a suspension seatpost, periodically ask your dealer to check it.

Small changes in saddle position can have asubstantial effect on performance and comfort.Tondyourbestsaddleposition,makeonlyone adjustment at a time.

WARNING: After any saddle adjust-ment, be sure that the saddle

adjusting mechanism is properly tightenedbefore riding. A loose saddle clamp or seatpost binder can cause damage to the seatpost, or can cause you to lose control andfall. A correctly tightened saddle adjustingmechanism will allow no saddle movementin any direction. Periodically check to makesure that the saddle adjusting mechanism isproperly tightened.

Handlebar Height and Angle

WARNING: The stems MinimumInsertion Mark must not be visible

above the top of the headset. If the stem isextended beyond the Minimum InsertionMark, the stem may break or damage the

forks steerer tube, which could cause youto lose control and fall.

Your dealer can also change the angle of thehandlebar or bar-end extensions.

WARNING: An insufciently tightenedstem binder bolt, handlebar binder

bolt or bar-end extension clamping bolt maycompromise steering action, which couldcause you to lose control and fall. Place the

front wheel of the bicycle between your legsand attempt to twist the handlebar/stemassembly. If you can twist the stem inrelation to the front wheel, turn the handle-bars in relation to the stem, or turn thebar-end extensions in relation to thehandlebar, the bolts are insufcientlytightened.

Fit

7


8/20

Wheels

Installing a Quick Release Front Wheel

CAUTION: If your bike is equippedwith disk brakes, be careful not to

damage the disk, caliper or brake padswhen re-inserting the disk into the caliper.Never activate a disk brakes control leverunless the disk is correctly inserted in thecaliper. See also Section 4.B.

Move the quick-release lever so that itcurves away from the wheel. This is theOPEN position.

With the steering fork facing forward, insertthe wheel between the fork blades so thattheaxleseatsrmlyatthetopoftheslotsthat are at the tips of the fork blades the fork dropouts. The quick-release levershould be on the left side of the bicycle.

Holding the quick-release lever in the OPENposition with your right hand, tighten the

tension-adjusting nut with your left hand un-til it is tight against the fork dropout.

Whilepushingthewheelrmlytothetopof the slots in the fork dropouts, and at thesame time centering the wheel rim in thefork, move the quick-release lever upwardsand swing it into the CLOSED position.

The lever should now be parallel to the forkblade and curved toward the wheel. Withthe right amount of force, the lever shouldmake a clear embossed mark on the sur-face of the fork.

WARNING: Securely clamping the

front and rear wheels takes consider-able force. If you can fully close the quickrelease without wrapping your ngersaround the fork blade for leverage, and thelever does not leave a clear embossed markin the surface of your fork, the tension isinsufcient. Open the lever; turn thetension-adjusting nut clockwise a quarterturn; then try again.

If the lever cannot be pushed all the way to

a position parallel to the fork blade, returnthe lever to the OPEN position. Then turnthe tension-adjusting nut counterclockwiseone-quarter turn and try tightening the leveragain.

Re-engage the brake quick-release mecha-nism to restore correct brake pad-to-rimclearance; spin the wheel to make sure thatit is centered in the frame and clears thebrake pads; then squeeze the brake leversand make sure that they work.

Installing a Quick Release Rear Wheel

Make sure that the rear derailleur is still inits outermost, high-gear position.

Pull the derailleur body back with your righthand.

Move the quick-release lever to the OPENposition. The lever should be on the side ofthe wheel opposite the derailleur and free-wheel sprockets.

Put the chain on top of the smallest free-wheel sprocket. Then, insert the wheel upand back into the frame dropouts and pull itall the way in to the dropouts.

Tighten the quick-release adjusting nut untilitisngertightagainsttheframedropout;then swing the lever toward the front of the

bike until it is parallel to the frames chainstay or seat stay and is curved toward thewheel. To apply enough clamping force, youshouldhavetowrapyourngersarounda frame tube for leverage, and the levershould leave a clear embossed mark in thesurface of your frame.

Tech

8


9/20

Brakes Rim Brakes & DiscBrakes

Riding with improperly adjusted brakes or wornbrake pads is dangerous and can result in seri-ous injury or death.

Applying brakes too hard or too suddenly canlock up a wheel, which could cause you to losecontrol and fall. Sudden or excessive applica-tion of the front brake may pitch the rider overthe handlebars, which may result in injury ordeath.

Some bicycle brakes, such as disc brakes andlinear-pull brakes, are extremely powerful. Ex-ercise particular care when using them.

Disc brakes can get extremely hot with extend-ed use. Be careful not to touch a disc brakeuntil it has had plenty of time to cool.

See the manufacturers instructions for opera-tion and care of your brakes. If you do not havemanufacturer instructions, call your dealer orthe brake manufacturer.

Brake Controls and Features

Its very important to learn and rememberwhich brake lever controls what brake. Yourbike will come already set and adjusted so thatthe right brake lever controls the rear brake.The left lever controls the front brake. Make

sure your hands can reach and squeeze thebrake levers.

NOTE: In the UK and Japan, the right levercontrols the front brake while the left levercontrols the rear brake. All brakes should beadjusted according to local regulations.

How Brakes Work

The action of a rim-actuated brake on a bi-cycle is a function of the friction between thebrake surfaces usually the brake pads andthe wheel rim. To make sure that you havemaximum friction available, keep your wheelrims and brake pads clean and free of dirt,lubricants, waxes or polishes. Another impor-

tant bicycle brake is a disc brake. To installdisc brakes, special disc brake mounts on theframe and fork and special hubs are necessary.These brakes are small and rely on brake padsthat squeeze both sides of a small disc rotorthat is mounted on each wheel. Disc brakesare quite resistant to weather and provide verystrong stopping power on steep hills or on wetterrain and are well suited for heavy riders.

Brakes are designed to control your speed, notjust to stop the bike. Maximum braking force foreach wheel occurs at the point just before thewheel locks up (stops rotating) and starts toskid. Once the tire skids, you actually lose mostof your stopping force and completely losedirectional control.

NOTE: Make sure that no oil or lubricationtouches your brake pads or the bicycles rimsbraking surfaces. Please replace worn brakeshoes only with factory authorized brakereplacements.

9


10/20

Shifting Gears

Your multi-speed bicycle will have a derailleurdrive train, an internal gear hub drive train or, insome special cases, a combination of the two.

How a Derailleur Drive Train Works

If your bicycle has a derailleur drive train, thegear-changing mechanism will have:

A rear cassette or freewheel sprocketcluster.

A rear derailleur.

Usually a front derailleur.

One or two shifters.

One, two or three front sprockets calledchain rings.

A drive chain.

Shifting Gears

There are several different types and styles ofshifting controls: levers, twist grips, triggers,combination shift/brake controls and push

buttons. Ask your dealer to explain the type ofshifting controls that are on your bike, and toshow you how they work.

A downshift is a shift to a lower or slowergear, one that is easier to pedal. An upshift isa shift to a higher or faster, harder to pedalgear. To select a gear that will make pedaling

easier on a hill, make a downshift in one of twoways: shift the chain down (the gear steps toa smaller gear at the front) or shift the chain up(the gear steps to a larger gear at the rear.)So, at the rear gear cluster, what is called adownshift actually moves the chain up to alarger gear. The way to keep things straight is

to remember that shifting the chain in towardsthe centerline of the bike is for accelerating andclimbing and is called a downshift. Moving thechain out or away from the centerline of thebike is for speed and is called an upshift.

Whether upshifting or downshifting, the bicyclederailleur system design requires that the drivechain be moving forward and be under at leastsome tension. A derailleur will shift only if youare pedaling forward.

Shifting the Rear Derailleur

The right shifter controls the rear derailleur.

The function of the rear derailleur is to movethe drive chain from one gear sprocket to an-other. The smaller sprockets on the rear wheelgear cluster produce higher gear ratios. Pedal-ing in the higher gears requires greater pedal-ing effort, but takes you a greater distance witheach revolution of the pedal cranks. The largersprockets produce lower gear ratios. Usingthem requires less pedaling effort, but takesyou a shorter distance with each pedal crankrevolution. There are two set screws or limitscrews on the rear derailleur body that limit the

travel of the rear derailleur. Tightening the rearderailleur high gear adjustment screw keepsthe chain from shifting off the small (high) gearthat is on the rear axle. Tightening the rearderailleur low gear adjustment screw keeps thechain from shifting off the large (low) gear intothe rear wheel. Moving the chain from a smaller

sprocket of the gear cluster to a larger sprocketresults in a downshift. Moving the chain fromthe smaller sprocket on the chain rings to alarger sprocket results in what is called anupshift. In order for the derailleur to move thechain from one sprocket to another, the ridermust be pedaling forward.

Shifting the Front Derailleur

The front derailleur, which is controlled by theleft shifter, shifts the chain between the largerand smaller chain rings. Shifting the chain ontoa smaller chain ring makes pedaling easier (adownshift). Shifting to a larger chain r ing makespedaling harder (an upshift). There are 2 (two)adjustment screws on the front derailleur: oneis to limit the travel of the front derailleur sothat the chain can be shifted upwards towardsthe larger, higher or harder to pedal gears butwill not allow the chain to overshift. The otherscrew limits the travel of the front derailleurtowards the smaller or easier-to-pedal chain-wheel. By limiting travel, it prevents the chainfrom undershifting and keeps the chain fromfalling off the chainwheel onto the frame.

10


11/20

WARNING: Never shift a derailleuronto the largest or the smallest

sprocket if the derailleur is not shiftingsmoothly. The derailleur may be out ofadjustment and the chain could jam,causing you to lose control and fall.

Which Gear Should I Be In?

The combination of largest rear and smallestfront gears is for the steepest hills. The small-est rear and largest front combination is forthe greatest speed. It is not necessary to shiftgearsinsequence.Instead,ndthestartinggear which is right for your level of ability agear which is hard enough for quick accelera-tion but easy enough to let you start from a

stop without wobbling and experiment withupshifting and downshifting to get a feel for thedifferentgearcombinations.Atrst,practiceshifting where there are no obstacles, hazardsorothertrafc,untilyouvebuiltupyourcon-dence.Learntoanticipatetheneedtoshift,and shift to a lower gear before the hill gets toosteep.Ifyouhavedifcultieswithshifting,theproblem could be mechanical adjustment. Seeyour dealer for help.

How an Internal Gear HubDrive Train Works

If your bicycle has an internal gear hub drivetrain, the gear changing mechanism will consistof:

A 3, 5, 7, 8 or possibly 12-speed internalgear hub.

One, or sometimes two shifters.

One or two control cables.

One front sprocket called a chain ring.

A drive chain.

Shifting Internal Gear Hub Gears

Shifting with an internal gear hub drive trainis simply a matter of moving the shifter to theindicated position for the desired gear. Afteryou have moved the shifter to the gear positionof your choice, ease the pressure on the ped-als for an instant to allow the hub to completethe shift.

Which Gear Should I Be In?

The numerically lowest gear (1) is for thesteepest hills. The numerically largest gear (3,5, 7 or 12, depending on the number of speedsof your hub) is for the greatest speed.

11


12/20


13/20

Transporting Your Bike

All 16- and 20-inch wheeled folding bicyclescan be transported by the methods describedin sections a, b, c, and d below. Bikes with24- and 26-inch wheels, as well as road bikeswith 700c wheels, have limited carrying ability

andwillnottinpublicconveyanceoverheadcompartments. Of course, using the methodsdescribed in sections c and d below are noproblem. Our suggestion for commuting andmedium distance travel is that it is best to usea nylon bag carry bag. For long distance travel,the 24- and 26-inch wheeled bikes, and 700croad bicycles, should be packed in a sturdytravel case.

CarryingCarrying a 16- to 20-inch wheeled foldedbicycle is quite easy for extra short to me-dium distances. For Jetstream full suspen-sion bicycles, make sure you have the blacknylon strap that came with your bike to bindthe wheels together. Simply grab the bicycleand carry by the saddles edge. When cross-ing a threshold, boarding a bus, train orairplane or stowing the bike in an overheadcompartment, you will need to pick your bi-cycle up. When the occasion arises that youneed to travel or commute and want yourbicyclewithyou,feelcondentknowingyourbike is ready when you are.

Rolling

Amucheasierandmoreefcientmethodto transport your 16 to 20-inch wheeledbicycles is to roll them on their wheels. Re-member that the Jetstream fork and framemust be bound together so the wheels will

roll. Raise the folded bikes seatpost andsaddle approximately 305 mm (12 inches)and tilt or angle the folded bike towards you.Then simply push the bicycle forward. Thisconveyance method is perfect for travelfrom parking lots to a bus, train or airplaneterminal and transition from rough tarmac ordrivewaystosmoothgraniteortileoors.

BagThisisacleanandefcientmethodofpack-ing and carrying any of the many Dahonbicycles. Simply place the folded, collapsedor packed-away bicycle on the opened bagthatislyingontheoor.Therearespaciousinternal pockets for any parts that must beremoved such as pedals and any tools thatyou might need later. A nice neat package isvisible when the sides of the bag are pulled

up tight and the handle/shoulder strap isfastened. The entire operation takes only afew seconds. It is perfect to carry your bikeon any sort of public conveyance or to carryin a car. However, the bag is not approvedfor airline check in.

Travel Case

A semi-hard travel case is a perfect longdistance transportation solution for manyfolding bicycles. They work well on any pub-lic transportation system. Many travel casesare safe enough to withstand the most

difcultluggagesafetychallenge,whichischecking luggage in at the airport. You canndtravelcaseslargeenoughformost16-,20-, and 24-inch wheeled bicycles. Howev-er, when carrying bikes with 26-inch wheels,the wheels must be removed.

13


14/20

WARNING: Technological advanceshave made bicycles and bicycle

components more complex, and the pace ofinnovation is increasing. It is impossible forthis manual to provide all the informationrequired to properly repair and/or maintainyour bicycle. In order to help minimize thechances of an accident and possible injury,it is critical that you have any repair ormaintenance that is not specicallydescribed in this manual performed by yourdealer. Equally important is that yourindividual maintenance requirements will bedetermined by everything from your riding

style to geographic location. Consult yourdealer for help in determining your mainte-nance requirements.

WARNING: Many bicycle service andrepair tasks require special knowl-

edge and tools. Do not begin any adjust-ments or service on your bicycle until youhave learned from your dealer how toproperly complete them. Improper adjust-ment or service may result in damage to thebicycle or in an accident that can cause

serious injury or death.

Service Intervals

Some service and maintenance can and shouldbe performed by the owner, and requires nospecial tools or knowledge beyond what is pre-sented in this manual.

The following are examples of the type ofservice you should perform yourself. All otherservice, maintenance and repair should be per-formed in a properly equipped facility by a qual-iedbicyclemechanic,usingthecorrecttoolsandproceduresspeciedbythemanufacturer.

Break-in Period

Your bike will last longer and work better ifyou break it in before riding it hard. Controlcables and wheel spokes may stretch or seatwhenanewbikeisrstusedandmayrequirereadjustment by your dealer. Your MechanicalSafety Check will help you identify some thingsthat need readjustment. But even if every-thingseemsnetoyou,itisbesttotakeyourbike back to the dealer for a checkup. Dealerstypically suggest you bring the bike in for a30-day checkup. Another way to judge when it

istimefortherstcheckupistobringthebikeinafterthreetovehoursofhardoff-roaduse,or about 10 to 15 hours of on-road or morecasual off-road use. But if you think somethingis wrong with the bike, take it to your dealerbefore riding it again.

After Every Long or Hard Ride

If the bike has been exposed to water or grit,or at least every 100 miles, clean it by wiping itcleanandlightlyoilthechainwithadryTeonlubrication or a synthetic based chain lube.Then, very importantly, wipe off excess oil.

Long lasting lubrication is a function of climate.(Hot or cold, wet or dry.) For general cyclelubrication, Dahon suggests using lightweightmineral based oil that is commonly availablein most bike shops or hardware stores. If youhave any questions, please talk to your dealeras an incorrect lubricant can damage thepainted surfaces.

After Every Long or Hard Ride or After

Every 10 to 20 Hours of Riding

Squeeze the front brake and rock the bikeforward and back. If you feel a clunk with eachforward or backward movement of the bike,you probably have a loose headset. Have yourdealer check it.

Lift the front wheel off the ground and swingit from side to side. If you feel any binding orroughness in the steering, you may have a tightheadset. Have your dealer check it.

Grab one pedal and rock it toward and awayfrom the centerline of the bike; then do thesame with the other pedal. Anything feel loose?If so, have your dealer check it.

Service

14


15/20

Take a look at the brake pads. Starting to lookworn or not hitting the wheel rim squarely?Time to have the dealer adjust or replace them.

Carefully check the control cables and cablehousings. Any rust? Kinks? Fraying? If so, haveyour dealer replace them.

Squeeze each adjoining pair of spokes oneither side of each wheel between your thumbandindexnger.Dotheyallfeelaboutthesame? If any feel loose, have your dealercheck the wheel.

Check to make sure that all parts and acces-sories are still secure, and tighten any that arenot. When replacement parts are necessary,be sure to use factory authorized replacement

parts from your local authorized Dahon dealer.

Check the frame, particularly in the areaaround all tube joints; the handlebars; thestem; and the seatpost for any deep scratches,cracks or discoloration. These are signs ofstress-caused fatigue and indicate that a partis at the end of its useful life and needs to bereplaced.

WARNING: Like any mechanical

device, a bicycle and its componentsare subject to wear and stress. Differentmaterials and mechanisms wear or fatiguefrom stress at different rates and havedifferent life cycles. If a components lifecycle is exceeded, the component cansuddenly and catastrophically fail, causingserious injury or death to the rider. Scratch-

es, cracks, fraying and discoloration aresigns of stress-caused fatigue and indicatethat a part is at the end of its useful life andneeds to be replaced. While the materialsand workmanship of your bicycle or ofindividual components may be covered by awarranty for a specied period of time bythe manufacturer, this is no guarantee that

the product will last the term of thewarranty. Product life is often related to thekind of riding you do and to the treatment towhich you submit the bicycle. The bicycleswarranty is not meant to suggest that thebicycle cannot be broken or will last forever.It only means that the bicycle is coveredsubject to the terms of the warranty.

15


16/20

Dahon Five-Year LimitedWarranty

Dahon warrants its bicycle frames, handle-posts, and rigid forks to be free from defects inmaterialsandworkmanshipforaperiodofveyears. In addition, Dahon warrants all originalparts on the bicycle, excluding suspensionforks and rear shocks, for a period of one yearfrom the date of purchase. Suspension forksand rear shocks shall be covered by the war-ranty of their original manufacturers.

This warranty is limited to the repair or replace-ment of a defective frame, fork, or defectivepart and is the sole remedy of the warranty.This warranty applies only to the original ownerand is not transferable. This warranty onlycovers bicycles and components purchasedthrough an authorized Dahon dealer andare only valid within the country in which thebicycle was purchased. The warranty doesnot cover normal wear and tear, improper as-

sembly or follow-up maintenance, installationof parts or accessories not originally intendedor compatible with the bicycle as sold, damageor failure due to accident, misuse or neglect, ormodicationoftheframe,forkorcomponents.

Lifetime Warranty Upgrade

The warranty on the frame, handlepost andrigid fork may be upgraded to a lifetime war-rantyiftheoriginalownerllsouttheonlineregistration card. The warranty is activatedwhen the bicycle is tuned and adjusted by a

professionalmechanicbeforetheownersrstride. To activate your Dahon warranty and Life-time Frame Warranty, please visit our On-lineWarranty Registration page. Go to www.dahon.com/registration.htm. Registering your Dahonserves as proof of original ownership for futurewarranty issues.

*Exclusions from the Dahon Five-Year Lim-ited Warranty also apply to the lifetime framewarranty.

Exclusions

For all city, road or trekking bikes, damageresulting from commercial use, accident,misuse, abuse, neglect or from anythingother than normal and ordinary use of theproduct.

For all mountain bikes, damage result-

ing from uses beyond cross-country andmarathon riding or from anything other thannormal and ordinary use of the product.

Making a Warranty Claim

You must at your own expense, deliver, mailor ship the damaged part, a photo of the de-fective part, and a description of the defect,together with both the original bill of sale andthis limited warranty statement as proof of war-

ranty coverage, to your place of purchase. Awarranty registration card must be completedand received by Dahon before a warranty claimcan be processed. The retailer from whomyou bought your bicycle will contact Dahon todetermine if the necessary repairs are coveredby the warranty.

NOTE: This warranty does not affect the statu-tory rights of the consumer. Where applicable,local laws will take precedent over this contract.

Warranty

16


17/20

Handlebar, Headset, Saddle, and Seat Post

Component inlbs Newton Meters (Nm) kgfcm

Dahon large hex key headset screw (10mm) 52~87 6.8~11.3 60~100

Dahon handlepost clamp screw (6mm) 87 11.3 100

Stem steer tube binder bolts; threadless headset 115~145 13~16.4 132~167

Dahonthreadlessinniteadjustablestemh/barclamp 44~53 5~6 51~61

Dahonthreadlessinniteadjustablestemrearstemclamp 62~71 7~8 71~82

Stem handlebar clamp 1 or 2 binder bolts 175~260 19.8~29.4 201~299

Stem handlebar clamp 4 binder bolts 120~145 13.6~16.4 138~167

MTB bar ends, alloy 144 16.3 164

MTB bar ends, magnesium 70 7.9 81

Seat rail binder 35~60 4~6.8 40~69

Kore I-beam rail clamp 85 9.6 98

Torque Values

17


18/20

Brake-Rim and Disc and Brake Lever


Brake lever - MTB type 53~60 6~6.8 61~69

Brake lever - drop bar type (including STI & ERO types) 55~80 6.2~9 63~92

Disc rotor to hub (M5 bolts) 18~35 2~4 21~40

Disc rotor to hub (M965 rotor lockring) 350 39.5 402.5~

Disc rotor to hub (Avid) 55 6.2 63

Caliper mount 55~70 6.2~7.9 63~81

Crankset, Bottom Bracket and Pedal Area


Pedal into crank 307 34.7 353

Crank bolt - including spline and square type spindles 300~395 33.9~44.6 345~454

Crank bolt - one key release 44~60 5~6.8 51~69

Crank bolt - one key release (Truvativ) 107~125 12.1~14.1 123~144

Bottom bracket adjustable type 610~700 68.9~79.1 702~805

Bottom bracket cartridge type 435~610 49.1~68.9 500~702

18


19/20

Front and Rear Hubs; QR and Nutted Axles


Freehub body 305~434 34.5~49 35~499

Cassette sprocket lockring; disc brake lockring 260~434 29.4~49 299~499

Front axle nuts 180 20.3 207

Rear axle nuts to frame (non-quick release type wheels) 260~390 29.4~44.1 299~449

Frame and Fork


BAB lower frame coupling 35 4 40

BAB upper seat binder bolt 35~55 4~6.2 40~63

BB mid seat mast binder bolt 35~55 4~6.2 40~63

Kickstand mounting bolt 60 6.8 69

H2O cage mounting screw 25~35 2.8~4 29~40

Frame front or rear rack braze-on bolt torque 25~35 2.8~4 29~40

Fender to frame mounting bolt torque 50~60 5.6~6.8 58~69

Formulas for converting to other torque designations:inlb=ftlbx12inlb=Nmx8.851inlb=kgfcm/1.15

19


20/20

2009 DAHON, BPSA

2009.09.EN

Dahon California INC.833 Meridian Street

Duarte CA 910101-800-442-3511

www.dahon.com

Dahon TW8F-8, #6, Lane 609, Chung Hsin RD., Sec 5

San Chung, Taipei Hsien ROC 241, Taiwan+886-2-2999-5623

2010 Dahon Owner Manual en 21

Documents

Transcript of 2010 Dahon Owner Manual en 21