DAHON bike Service Manual
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DAHON bike Service Manual

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See also: Owner's Manual
Service
Instructions

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  • Page 1 Service Instructions...

  • Page 2: Table Of Contents

    Contents 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: Dealer Pre-Delivery Checklist

    WARNING: All Dahon bikes use only original Dahon component specifications. The company will not be liable for any damages caused by non-original Dahon parts. Customer Information...
  • Page 4 Dealer Pre-delivery Checklist Item Description Remarks The frame is not damaged or defective. All frame joints do not have physical defect or damage. Main hinge(s) opens and closes freely. Frame Main hinge(s) is not obstructed when locked. Main hinge safety latch functions properly. Magnetix holding latches are securely tightened in front and rear of bicycle.
  • Page 5 Item Description Remarks Blocks are correctly positioned to make contact with Brake Blocks the rim. Retaining nuts are secure. Front and rear calipers are correctly centered; they Brake Calipers are smooth and effective in gripping the wheel rim. Saddle and All seat bolts, saddle bolts, and seat quick releases are seatpost correctly tightened and adjusted.
  • Page 6 Owner Manual Correct owner manual is with the bicycle. Support brackets function properly. Magnetix correctly aligned. Folding and Bike folds properly. unfolding The bike stands firmly when folded. Bike unfolds completely.

  • Page 7: Vro Stem

    VRO Stem With a VRO clamp, the handlebar can be easily adjusted to fit the rider’s height or desired riding position by simply moving it up and down, forward and backward. The following instructions explain how to adjust the VRO clamp. Step 2 -Using a 5mm Allen key, loosen the bolts of theVRO clamps.

  • Page 8: Flat Pak Stem

    Flat Pak Stem 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 forward for more competitiveness. The Flat Pak stem also rotates 90°...
  • Page 9 Flat Pak Stem Continued To achieve your preferred riding position, you can adjust the height and position of the Flat Pak stem. Here are some suggested riding positions: High City position Step 3 - Lift front lock lever and rotate handlebars to desired position.

  • Page 10: Handlepost Hinge

    Several versions of handlepost can be found on different Dahon models. With a slight difference, RADIUS the adjustment of the hinge latch is virtually the same. Check the handlepost hinge to find out which version is used, then proceed to follow the appropriate instructions for adjusting the latch.
  • Page 11 Adjusting the Handlepost Hinges NOTE: To avoid over tightening or loosening the hinge, make adjustments in small(1/16) increments. NOTE: LOOSEN: TIGHTEN: If the hinge is very tight, please clear off Follow the arrows on Follow the arrows on dirt and add lubricating oil. which way to turn the which way to turn the latch bolt.

  • Page 12: Headset

    Headset Periodically check your headset. If the handlepost should ever feel too loose, or you have noticed there is an abundant amount of movement in the fork, the headset may need to be adjusted. A properly adjusted headset eliminates the possibility of movement, while still allowing the handlebars to be turned.
  • Page 13 NOTE: When you fold your bike please note that the red mark point on handle post should just be visible. In this situation the stem Step 3 has the best folding effect.

  • Page 14: Frame Latch

    Do NOT cycle with a loose frame hinge. Dahon uses several different frame hinges on its bikes. Check your bike to see which instructions are applicable to you. The ViseGrip™ Hinge (also applies to the Vybe frame hinges)
  • Page 15 There are a several versions of the V-Clamp. Learn how to adjust the V-Clamp with the instructions provided below. Check your bike to determine which V-Clamp version is being used and apply the appropriate instructions to the correct V-clamp version.
  • Page 16 Adjust the hinge bolt to allow the hinge to open and close with the same amount of force (39~88 Nm). NOTE: While adjusting a V-Clamp hinge, turn in increments of 1/16 for the best result in securing the hinge. Failure to effectively adjust the hinge could result in the hinge being too tight or too loose.
  • Page 17 Adjust the hinge bolt to allow the hinge to open and close with the same amount of force (39~88 Nm). NOTE: While adjusting a V-Clamp hinge, turn in increments of 1/16 for the best result in securing the hinge. Failure to effectively adjust the hinge could result in the hinge being too tight or loose. WARNING: If the hinge is too tight, it could cause tension and damage to the frame.

  • Page 18: Lockjaw Hinge Adjustment

    LockJaw Hinge Adjustment Overview Bikes equipped with the LockJaw hinge look like your average bike. In order to see the LockJaw, pinpoint where the bike folds. Read the following There are two versions of the LockJaw directions carefully to ensure safety when available.
  • Page 19 Open/Close the LockJaw Hinge Use a 6 mm Allen key. Please refer to the folding instructions that were included with your bicycle on how to properly fold a LockJaw equipped bicycle. Turning the OC bolt counter-clockwise To lock the LockJaw hinge, simply close the 180°...
  • Page 20 Adjust the Tightness of the LockJaw (The Adjustment Bolt) Adjust the Adjustment Bolt The LockJaw is exceptionally secure,but will while the frame is closed. require periodic inspection and adjustment to ensure that it is properly working. Adjust the LockJaw according to the following instructions. Version A Do not over-loosen the adjustment bolt TIGHTEN...
  • Page 21 Adjust the Adjustment Bolt Version B while the frame is closed. Tools Needed: • 6mm Allen key • 2.5mm Allen key NOTE: Only turn the adjustment bolt in small increments (e.g. an 1/8 turn) each time, otherwise it could result in too much constriction and/or movement.
  • Page 22 The pivot bolt and its lock counter-clockwise. See picture above. screw are on the bike’s non-chain side. NOTE: Only turn the adjustment bolt in small increments (e.g. an 1/8 turn) each time, otherwise it could result in too much constriction and/or movement.

  • Page 23: Kore I-Beam

    Kore I-Beam The Kore I-beam is a ground-breaking new saddle system. As well as dramatically cutting down weight, the system allows the rider to achieve maximum saddle adjustability. The saddle can be moved forward and backward on the rail, while the tilt can be adjusted up or down. Tools Needed: •...
  • Page 24 Seatpost Your seatpost is secured by a quick release that allows for easy height adjustment to the proper and most comfortable height. Step 1 Open quick release Step 2 Move saddle to proper position WARNING: Do not adjust the seatpost height beyond the Min Insertion or Max Insertion lines.

  • Page 25: Dahon Neos Derailleur

    Dahon Neos Derailleur The low-profile Dahon Neos derailleur was specially designed for small-wheeled bicycles. The Neos allows much more ground clearance than a conventional derailleur. Using cache technology, it permits the derailleur body to lie flat underneath the chain stays. This way the derailleur body only...
  • Page 26 High Adjustment When looking from the 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.
  • Page 27 Index Shifting Adjustment While turning the crank arm, 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. Best Setting For the best possible outcome, tighten the cable adjustment bolt (clockwise) until you hear a noise that occurs without harming the shifter being operated.
  • Page 28 Service Instructions Headquarters Dahon Technologies, Ltd. Dahon Europe Dahon North America INC. Dahon Bldg, Furong 6th No.1 P.O. Box 17, 833 Meridian Street Rd., Shajing Goliamokonarsko Shosse Str. Duarte CA 91010 Shenzhen, 518125, P.R.C Tsaratsovo Village, 4027, Bulgaria +1 800 442 3511...

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