Bike Friday Haul-a-Day User manual

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Using Your Bike Friday®
Haul-a-Day
Green Gear Cycling, Inc.
3364 W 11th Ave. Eugene, OR 97402
800-777-0258 USA & Canada
[phone] Int’l • [phone] Fax
www.bikefriday.com • [e-mail]
version 7/15/16

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Table of Contents
The story behind Haul-a-Day 4
The growth of Haul-a-Day 5
Anatomy of a Bike Friday Haul-a-Day 6
Anatomy of a Bike Friday Haul-a-Day: Closeup 7
Congratulations / If You Need Help 8
A Word on Safety / Your Tools 9
Unpacking your Haul-a-Day 10
Assembly: Connect Frame 11-12
Installing Seatmast 13
Using a Quick Release 14-15
Assembly: Install Front Wheel, V-Brake 16
Reconnect Linear Pull / V-Brake 17
Install Front Wheel, Disc Brake 18
Adding Brake Cable Slack 19
Stem Safety Check 19
Mount the Stem Riser 20
Double Check Steering 20
Install Pedals 21
Double Check Your Bike Friday 22
Adjusting your Haul-a-Day 23
Saddle Height 23
Handlebar Height 24-25
Quill Stem Handlebars 25
Main Frame: Gravity Technique 26-27
Adjusting Headset 28-31
Bike Friday Service Overhauls 32
Bike Friday Service 33
More Maintenance Tips and Information 34-36
Airport and Travel Tips 37
Warranty Information 38-39

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Versatile
Light for a Cargo Bike.
Fits on a Portland Bus Rack.
Hangs on Amtrak.
Works on a Car Rack.
Sky’s the limit, so add on!
Ready for real work.

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The story behind Haul-a-Day
A note from Bike Friday Co-Founder Alan Scholz:
Thank you for purchasing a Bike Friday Haul-a-Day, our
rst Cargo Bike. Your bike is an example of the wonderful
empowering relationships we have with our customers. It is the
combination of a number of concepts coming together to meet
the needs of today’s cycling families.
The idea of an adjustable frame bicycle came from our service
expert Tim Link, who mentioned to me that a number of
customers over the years expressed interest in the ability for
multiple users to share the same Bike Friday.
That idea simmered in my head for awhile. Then our local Safe
Routes to School Coordinator Shane MacRhodes stopped by to
have a conversation with Alan. The school program teaches kids
to ride safely, and uses eet bicycles. Fitting bikes to a class of
middle schoolers of various sizes and shapes created a challenge,
and those two ideas came together in our OSATA.
When Shane needed a bike for the class leader, we began to
design the Haul-a-Day to handle any challenges a teacher might
face.
The Haul-a-Day is designed to be whatever you need it to be, a
Swiss Army Knife of Cargo Bikes. It is light and agile, and allows
smaller riders to feel in control with a load.
I hope you enjoy your ride,
Alan Scholz
Alan Scholz, Bike
Friday Co-Founder,
not only designed
the Haul-a-Day, he
races it in Disaster
Relief Trials in the
Northwest.

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Listening to our early adopters
Since its inception as a simple Cargo Bike, the Haul-a-Day
has grown to address a laundry list of family needs.
Each Haul-a-Day owner appears to have his or her unique
set of challenges for a Cargo Bike, and the Haul-a-Day has
evolved to address those needs.
Building custom bikes to t an individual’s needs and body
has been the cornerstone of Bike Friday since 1992, and the
versatility of the Haul-a-Day reects that commitment to
deliver the perfect bike for you.
All Haul-a-Days have multi-person t capability and come
at Bike Friday’s affordable prices, starting less than $1,000
for a DIY Frame Kit with wheels.
The growth of Haul-a-Day
The Haul-a-Day can handle an nearly endless array of tasks that
includes providing a comfortable place for a nap.

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Anatomy of an Haul-a-Day

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Anatomy: Closeups

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Extra Accessories
We also sell an extensive line of bicycle and travel
accessories. Whether you are riding the local back roads
or venturing into foreign lands we have the gear you need.
Call us for information on spare tires, tubes, replacement
parts, fenders, racks, bags, or other items to complete your
Travel System. You can purchase these products from our
online store: www.store.bikefriday.com
Congratulations!
You have just purchased the nest Cargo Bike available
today. Your bike has been carefully designed and
constructed for your personal needs. All of our bikes are
manufactured in our Eugene, Oregon factory by real
cyclists who care about our customers and our products.
Please take your time reviewing this manual before you
assemble your new Bike Friday. You will nd your new
bicycle to be simple and reliable anywhere you go!
More Information
To check out our products, nd other useful information,
discover Bike Friday events and Yak with other Bike Friday
owners on the bulletin board, go to our main website at:
www.bikefriday.com
Blue skies and happy trails from Green Gear Cycling
If You Need Help . . .
If you need technical assistance with any Green Gear®
Cycling product, or are unclear on the proper operation of
your Bike Friday, please call us and a Service Technician
will help you get back on the road. Our toll-free number in
the US and Canada is 800-777-0258; international is +1-541-
687-0487. Normal business hours are 8:30 a.m. to 5:30 p.m.
Monday through Friday, and 9 a.m. to 4 p.m. Saturdays,
Pacic Time. You can also email service questions to
[e-mail].
Because we understand the needs of world travelers, we
offer 24-hour technical support in emergencies. If necessary,
please call our regular number and our answering service
can forward you to a Service Technician on call.
Welcome to the Community

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A Word on Safety
Bicycles are a lot of fun, but improper use can result in
harm. Please, always ride safely!
• Always have all passengers wear a helmet.
• Follow the rules of the road, and be courteous.
• Use front and rear lights after dark.
• Dress appropriately for the weather, the season, and
lighting conditions. Be seen!
• Always carry a spare tube, patch kit, pump and a tool
kit.
• Keep your bicycle in good shape.
• Check your tire pressure before every ride.
• Make sure all quick releases are secure.
• Have your bicycle routinely serviced for trouble-free
travels.
Your Tools
Your Haul-a-Day was delivered with a combination
5/6mm S-wrench and 5/16mm wrench [right].
These wrenches should get your new bike on the
road (along with your own pedal wrench).
We also sell more extensive tool kits for home
repair work [See large photo below].
We encourage you to
learn how to work on
your own bike.
If you are not familiar
with bicycle mainte-
nance, consider taking
a local class.
It will improve your
condence and self-
sufciency as you ven-
ture across the globe
or explore your own
hometown.

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Unpacking your Haul-a-Day
Unpacking Your Haul-a-Day From a Box
Opening your box may present an intimidating sight,
particularly if you ordered many accessories.
Do not worry; we work hard to keep our products as
simple as possible. We recommend nding a quiet area
and some room to spread out.
This manual will address the fundamentals of unpacking,
assembly and adjusting techniques. However, because
your bicycle was built for you, you might discover that
your bike was packed at the factory slightly different than
the one in this manual.
Your Haul-a-Day should only require minimal assembly. It
will take approximately 30-60 minutes and require a basic
level of technical skill.
You will need a 5/6mm hex wrench, 5/16mm hex wrench,
a 15mm open/pedal wrench and a pair of scissors (or bet-
ter yet wire cutters, snips or diagonal cutters) to cut zip
ties.
Take care not to damage the frame while cutting zip ties.
[Note: Depending on the components you have purchased
with your Bike Friday, your specic model may require
Fig. 1 Haul-a-Day unboxed.

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Open the shipping box and remove the various bicycle
parts. Place the parts on the oor, as shown in the photo
[Fig. 1, page 10]. Remove the bubble wrap and zip ties to
be able to get the bicycle into this state the photo shows.
Attaching mid section to rear end
Locate the four 3/8x16 hex bolts that will be used to
secure the mid section to the rear end and set them
aside. Place the rear end upside down [Fig.2]. Move the
mid section upside down. Unwrap the chain and orientate
the chain like seen in Fig. 3.
Mechanic’s Tip: Put the chain on the crankset so the
chain rests on the arm, to the outside of the chaining.
If the chain was on the chainring, it will pull the front
end backward, creating tension and making the process
more difcult. By placing the chain on the side of the
crankarm, to the outside of the chainring, it will take up
some of the slack of the chain and hold it in place for the
purpose of afxing the rear end to the mid section.
Line up the bolt holes and hand thread in the M10 bolts to
secure the mid section to the rear end. on the right side
(rear) shifter.
Assembling your Haul-a-Day
Fig. 2 Rear end upside down. Fig. 3 Place chain on crankset.
Fig. 4 Hand thread 3/8x16 bolts.
Note: Washers may be
used on the lower drive
side bolt, underneath the
bolt head to ensure the
tip of the bolt does not
protrude into the chain
and then nish tightening
them with a 5/16mm hex
wrench. [Fig. 4]

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Fig. 5 Stand bke on rear end.
Fig. 6 Insert front section..
Attaching front section to
mid section
Stand the bike up on its rear
end, front section pointing
upward. [Fig. 5]
Insert the front section (male)
into the mid section (female)
opening.
Depress the spring loaded
mainframe button to allow
the front section to settle into
one of the four holes in the
mid section. [Fig. 6]
Tighten the main frame pinch
bolts with a 5mm hex wrench.
[Fig. 7]
Assembling your Haul-a-Day
Fig. 7 Tighten pinch bolts.

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Assembling your Haul-a-Day
Fig. 8 Insert seatmast.
Installing the seatmast
The Haul-a-Day bicycle mod-
els have a sleeved seatmast
that telescopes out of the
lower seat tube.
Install the seatmast into the
seat tube.
Note: The minimum insertion
mark is etched at 4” from the
bottom on the mast. This is
the minimum amount of the
mast that must be inserted
(overlapped) in the frame.
[Fig. 8]

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Using a Quick Release
Using Those Nifty Quick Releases
On a cold and snowy day in the 1927 Gran Premio della
Vittoria, a tired and numb Tullio Campagnolo struggled
with the frozen wing nuts on his rear wheel while trying to
change gears. In a moment of frustration and inspiration
Campagnolo envisioned the modern quick release. The
bicycle world was transformed.
The quick release is one of those simple but great inventions
that really makes life better. However, if used incorrectly,
you can potentially endanger yourself. Although a reliable
and safe product, some people have been injured because
they didn’t know how to properly use this elegant device.
Your Bike Friday Haul-a-Day has several of them. If you are
not familiar with their operation, PLEASE study these direc-
tions carefully. If you are still unclear on their operation, call
us or contact your favorite local bike shop before you ride!
Quick Release Operation
A quick release is a simple cam with a lever that swings
through an arc that is square to the axle. As the lever moves,
the cam clamps the wheel to the frame, or secures the frame
joint. It is not a wing nut to be rotated around the axle.
The tension on the quick release is controlled by how tight
the knurled nut on the other end is set. Only wheel quick
releases have the small cone-shaped springs. Note that the
small ends of the springs face toward the center of the hub.
Quick Release Maintenance
We recommend adding a few drops of light oil to the lever
where it enters the cap several times per year. This will
keep your quick release working smoothly for years.
Open
Close
Knurled Nut
(adjust tightness here)
QR Lever
(Loose)
(Starts getting
tight here)
(Stiff)
Springs
Cam

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Using a Quick Release
Double-Check!
Ideally, the quick release
lever should be facing
the rear, or upward.
Levers that are facing
forward can catch on any
number of things and be
accidentally opened. Fig. 11 Closed QR points toward rear.
Adjust Knurled Nut
With the wheel installed
and the axle properly
seated in the frame (or
the frame joint closed),
position the quick release
lever so that it is in line
with the axle. Then turn
the knurled nut on the
other side clockwise until
it is snug. When the quick
release is properly adjusted, you should be able to freely
swing the quick release lever for the rst half of its arc, at
which point the lever should offer resistance.
Fig. 9 Quick release operation.
Continue Closing QR
Using the palm of your
hand press the quick
release lever through the
rest of its arc until the
lever is closed and parallel
to the wheel. You should
feel very rm resistance
when the quick release
is properly adjusted (the
lever may even leave a
light imprint in the palm of your hand).
Fig. 10 Setting quick release tightness.

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Assembling your Haul-a-Day
Install Front Wheel QR
Open the front brake release,
then position the front wheel
making certain that the wheel
axle is fully seated in the front
dropouts.
Now install the quick release
from the fork spreader on the
front wheel. Make certain that
there is one spring per side of
the hub axle and that the small
end of the spring is pointing
toward the center of the hub.
Loosely thread on the knurled
nut for now.
Fig. 12 Front Wheel QR.
Mechanic’s Tip: If you are ever unsure of the proper
direction of the front tire, looking down at the tire,
the tread should be oriented so that it is pointing for-
ward. Often the tread is in a arrow-ish pattern and this
makes it easy to point it in the forward direction. The
quick release levers, front and back are to be placed on
the non-drive side of the bicycle.
BRAKES
The Haul-a-Day comes with either linear pull /
V-brakes or disc brakes, please see the following
sections that are most appropriate for the brake type
you have.

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Assembling your Haul-a-Day
Reconnect Linear Pull
Brakes / V-Brakes
To close the V-brake to the
riding position, while fac-
ing the brake, with your
left hand (index nger and
thumb), grab the noodle
carrier and with your right
hand grab the noodle and
slip the noodle tip into the
slot on the noodle carrier.
If you cannot get enough
“slack” to put the noodle
tip into the noodle holder,
then the brake cable may
need to be loosened a
bit. See the next step for
instructions to add some
slack to the cable. Repeat
this procedure on the rear
brake.
Mechanic’s Tip: Sometimes
the cable housing can come
unseated either where it
enters the noodle or where
the housing enters the
brake lever barrel adjuster.
If the housing is unseated,
it will not be possible
insert the noodle tip into
the noodle holder. In fact,
it will make the process
quite frustrating; make
sure the housing is properly
seated at both ends.
Fig. 13 V-brake open.
Fig. 14 Grab the noodle carrier.
Fig. 15 Slip noodle into slot.
Fig. 16 V-brake closed.
NOODLE
NOODLE
CARRIER

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Install the Front Wheel
Make certain the wheel is
fully seated in the fork drop-
outs and securely close the
quick release lever, as illus-
trated in the quick release
section [page 15]. The quick
release levers (front and
rear) are to be placed on the
non-drive side of the bicycle.
Fig. 17 Insert quick release in wheel.
Connect the Front Brake
There are several possible congurations of front brakes. The
Haul-a-Day is available with disc, V-brake, or linear pull (front
only). Please read directions specic to the brake type that
appear on the following pages.
Disc Brakes
When inserting the front wheel into the fork, ensure the disc
rotor (on wheel) ts nicely into the slot on the caliper (installed
on fork). You will want to avoid the rotor getting hung up or
caught on some part of the caliper as you are installing the
wheel into the fork to prevent rotor damage.
Fig. 18 Disc brake rotor and slot. Fig. 19 Disc rotor slips into slot.
Assembling your Haul-a-Day

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Adding Cable Slack
to Brakes
To increase slack in the
brake cable, you can turn
the barrel adjuster on the
brake lever. The barrel
adjuster is the knurled
bolt that the cable hous-
ing goes through as it
enters the brake lever.
Turn this adjuster clock-
wise (inward toward the
brake lever) to loosen the cable. Conversely, if you want
to bring the brake pads closer to the rim to compensate for
cable stretch from use, unscrew the barrel adjuster away
from the brake lever. Note: Some models may have a lock
nut on the adjuster, which will need to be loosened rst.
ALWAYS DOUBLE CHECK YOUR BRAKES BEFORE RIDING.
Fig. 20 Brake barrel adjuster.
Barrel
Adjuster
Assembling your Haul-a-Day
Fig. 21 Stem pin.
Stem Safety Check
If you look carefully at the base of
your stem from the underside, you will
see a pin hidden under the clamping
collar. This pin must engage the slot
in the back of the fork’s steerer tube
(the unpainted tube sticking up from
the frame’s headtube.) Additionally,
the stem should be fully seated onto
the fork steerer tube.
Mounting Your Stem Riser

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Mount the Stem Riser
*WARNING! Do not loosen the
locking Headset spacer bolt.
Slide the bottom of the stem
riser onto the fork steerer
tube, keeping the stem riser’s
lower clamp forward so the
hidden stem pin will engage
the slot in the fork. Gently
press the stem all the way
down. You should feel it
“bottoming out” on the end of
the slot. Once the lower stem
riser is in place, tighten lower
stem riser bolt. NOTE: Do not
adjust the locking headset
spacer.
Assembling your Haul-a-Day
Fig. 22 Lower stem riser.
Upper Stem
Riser Bolt
Lower Stem
Riser Bolt
Locking
Headset
Spacer*
Double Check Your Steering System Integrity:
Now is a good time to double check your steering system.
Try standing in front of your bike with your front wheel
between your legs. Twist the bars to make sure everything
is secure, that the bars do not turn independent of the
fork /front wheel.
Fig. 23 Mounting stem
riser, part 1.
Fig. 24 Mounting stem
riser, part 2.