DAHON - SERVICE INSTRUCTIONS 2010 Service Instructions Manual
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DAHON - SERVICE INSTRUCTIONS 2010 Service Instructions Manual

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SERVICE INSTRUCTIONS

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Summary of Contents for DAHON DAHON - SERVICE INSTRUCTIONS 2010

  • Page 1 SERVICE INSTRUCTIONS...

  • Page 2: Table Of Contents

    Axis Stem ................ 8 VRO Stem ..............12 Andros Stem ..............13 Handlepost Hinge ............15 Headset ................17 Frame Latch ..............18 LockJaw Hinge Adjustment ......... 22 Kore I-Beam Saddle ............27 Neos Derailleur ............. 28 © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 3: Dealer Pre-Delivery Checklist

    Name: Model: _________________________ ___________________________ Email: Year: _________________________ ___________________________ Address: _________________________ Serial #: ___________________________ _________________________ Dealer Information (stamp) Mechanic Information Name: _________________________ Signature: ___________________________ Email: _________________________ Name: ___________________________ Address: _________________________ Date of check: ___________________________ _________________________ © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 4 Front and rear calipers are correctly centered, movement is smooth and effective in Brake Calipers gripping the wheel rim. Pedal, cranks, chain rings, bottom bracket and derailleur(s) are securely fastened and Drivetrain correctly aligned. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 5 All seat bolts, saddle bolts, and seat quick releases are correctly tightened and adjusted. seatpost Saddle alignment is correct (forward and level) Saddle Slides freely and smoothly in the frame for folding. Seatpost (For bikes fitted with PostPumps or suspension seatposts) Functioning and operating correctly. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 6 The correct owner manual is supplied with the bicycle. Owner Manual Support bracket functions correctly. Magnetix is correctly aligned. Folding and Bike folds completely. unfolding Bike stands stably when folded. Bike unfolds completely. © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 7: Dahon F.i.t. Stem

    10 Nm. make these adjustments, take your bike to a qualified bicycle WARNING: Do not loosen WARNING: Do not raise technician for professional the top cap. the stem over the stem’s adjustment. top cap. © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 8: Axis Stem

    WARNING: If you are in any way unsure of how to make these adjustments, take your bike to a qualified bicycle technician for professional adjustment. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 9 4 with a 4 mm Allen key. Tighten to mm Allen key until the handlebar allow your fingers to easily reach a torque of 8 Nm. can be rotated. the brake levers. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 10 Step 6 – Retighten the angle adjustment bolt in the middle of the downwards. adjustment bolt so that the stem is securely attached to the bike when secure. folded. stem with a 5 mm Allen key © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 11 5 mm Allen key. other. that the handlebar is in the proper Tighten it to a torque of 10 Nm.. riding position. © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 12: Vro Stem

    NOTE: Make sure that the angle of the handlebar allows you easy access to the brake levers. WARNING: Make sure that the outside faces of the clamps are aligned to the stem mount T-bar. © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 13: Andros Stem

    “window of adjustment”. them head-on. NOTE: You have to push down on the lock lever slightly when you open the safety lock. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 14 You can adjust the height and City driving position Treking driving Road driving position of the Andros stem to position position achieve your preferred riding position. Move the Andros stem within the “window of adjustment”. Some suggested riding positions: © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 15: Handlepost Hinge

    Handlepost Hinge The Different Handlepost Hinges The latch of the handlepost hinge on Dahon folding bikes should be checked before each ride to make sure OPEN CLOSED that it closes tightly to secure the handlepost. A closed handlepost hinge with a properly adjusted and secured latch should have little to no side-to-side movement.
  • Page 16 6 mm force. wrench. An adjustable wrench or small pliers can be used if a WARNING: If the hinge is over tightened the tension 6 mm wrench is unavailable can cause damage to the hinge. © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 17: Headset

    Tighten the screw sure that the handlepost and with a torque of 11.3 Nm. handlebar are in correct alignment, and that they are perpendicular to the front wheel as shown in the picture above. © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 18: Frame Latch

    Do NOT cycle with a loose frame hinge. Dahon uses a variety of frame hinges on its bikes. Please check TIGHTEN: Turn the hinge latch LOOSEN: Turn the hinge latch bolt...
  • Page 19 Use an 8 mm wrench to adjust. half. The adjustment nut is on The lock nut needs to be loosened the outside. A 6 mm Allen key is with a 10 mm wrench. needed to adjust it. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 20 * Use an 8 mm wrench (you can also use an adjustable wrench or small pliers) to adjust the hinge. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 21 Turn the wrench as arrow. indicated by the arrow. NOTE: Hold the adjustment nut tight with an Allen key, while tightening the lock nut. © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 22: Lockjaw Hinge Adjustment

    Pivot Pivot mechanism. Bolt Bolt • Pivot Bolt – the actual hinge axle around which the two halves of the frame rotates. The pivot bolt can be adjusted to tighten or loosen the hinge. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 23 180º. OC bolt clockwise by 180º. If the adjustment bolt is properly adjusted, you should feel a slight “click” and the teeth of the LockJaw hinge will draw together. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 24 When the OC bolt closes with a “click” at the end, the tightness is just right. Once you have achieved the correct tightness, close the LockJaw First open the OC Bolt But DO NOT open the frame by turning the OC bolt 180º counter-clockwise. (turn 180º counter-clockwise) © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 25 When the OC bolt closes with a “click” at the end, the tightness is just right. 2.5 mm Allen key Once you have achieved the correct tightness, insert and tighten the safety screw. Loosen the safety screw by Then remove the safety screw turning it counter-clockwise © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 26 (e.g. a 1/8 turn) Step 3 - When you are finished each time otherwise you might close the lock screw with a torque over tighten or over loosen it. of 1 Nm. © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 27: Kore I-Beam Saddle

    Step 4 - Adjust the fore and aft Step 5 - Tighten the pre-greased position. bolts to 85 in/lbs or 9.5 NM. © 2009 DAHON, BPSA • 2009.09.DS.EN...

  • Page 28: Neos Derailleur

    Wire Adjustment Bolt professional adjustment. Due to its special design the Dahon Neos derailleur’s position differs from that of a conventional derailleur. Compared to a conventional derailleur it is aligned in the opposite direction, i.e. the adjustment screws and the wire adjustment bolt are facing forward.
  • Page 29 High Adjustment Turn the top adjustment screw to adjust so that the guide pulley is below the outer line of the smallest sprocket when looking from the rear. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 30 Low Adjustment Turn the low adjustment screw so that the guide pulley moves to a position directly in line with the largest sprocket. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 31 (turned clockwise) until noise occurs without the shifter being operated, and then loosened (turned counterclockwise) 360 degrees from that point. Operate shifter to change gears, and check that no noise occurs in any of the gear positions. © 2009 DAHON, BPSA • 2009.09.DS.EN...
  • Page 32 Dahon California INC. Dahon TW 833 Meridian Street 8F-8, #6, Lane 609, Chung Hsin RD., Sec 5 Duarte CA 91010 San Chung, Taipei Hsien ROC 241, Taiwan 1-800-442-3511 +886-2-2999-5623 www.dahon.com © 2009 DAHON, BPSA 2009.09.EN...

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