DAHON - 2010 Operating instructions

SERVICE INSTRUCTIONS

© 2009 DAHON, BPSA • 2009.09.DS.EN
Contents
Dealer Pre-Delivery Checklist......................................... 3
Dahon F.I.T. Stem ............................................................ 7
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
2

© 2009 DAHON, BPSA • 2009.09.DS.EN
Dealer Pre-delivery Checklist
This pre-delivery checklist needs to be lled out to activate the warranty.
This pre-delivery checklist is to be carried out by a qualied bicycle mechanic. If at any point the mechanic is unclear as to the requirements or
process needed to carry out any checklist item, he/she should seek assistance as required.
Customer Information
Name: _________________________
Email: _________________________
Address: _________________________
_________________________
Dealer Information (stamp)
Name: _________________________
Email: _________________________
Address: _________________________
_________________________
Bike Information
Model: ___________________________
Year: ___________________________
Serial #: ___________________________
Mechanic Information
Signature: ___________________________
Name: ___________________________
Date of check: ___________________________
3

© 2009 DAHON, BPSA • 2009.09.DS.EN
Dealer Pre-delivery Checklist
Part Item to Check Passed Remarks
Frame
The frame is free from damage or defect.
All frame joints are free from physical defect or damage.
The main hinge(s) opens and closes freely.
The main hinge(s) is free from all play when locked.
The main hinge safety latch functions correctly.
Any magnetix fold holding latches are securely tightened on both front and rear.
Brake Levers Moves and returns freely with the brake cable seated correctly within the lever.
Brake Cables
Calipers can move freely, are free from damage, and the cable locking nut is secure.
Any excess cable should be tied or cut to a sensible length and capped.
Brake Blocks Are correctly positioned to make contact with the rim. Retaining nuts are secure.
Brake Calipers Front and rear calipers are correctly centered, movement is smooth and effective in
gripping the wheel rim.
Drivetrain Pedal, cranks, chain rings, bottom bracket and derailleur(s) are securely fastened and
correctly aligned.
4

© 2009 DAHON, BPSA • 2009.09.DS.EN
Part Item to Check Passed Remarks
Chain The chain is correctly tensioned between the front and rear sprockets, free from physical
defects and rust.
Chain and gear
selector assembly
Moves freely and correctly through the gear selections, and are correctly aligned in all
gears.
Derailleur(s)/hub
actuator
Cable locking nut is secure.
Any excess cable should be tied or cut to a sensible length and capped.
Gear selection Mechanism is securely xed to the handlebars.
Chain guard Is free from physical defect or damage, is correctly positioned. Retaining nuts are secure.
Handlebar and
handlepost
Are free from physical defect or damage.
Handlepost, stem,
handlebar
All bolts are secure and correctly tightened.
Headset Is correctly tightened and adjusted.
Handlepost hinge
Opens and closes freely.
Is free from all play when locked.
Safety lock operates correctly.
Saddle and
seatpost
All seat bolts, saddle bolts, and seat quick releases are correctly tightened and adjusted.
Saddle Saddle alignment is correct (forward and level)
Seatpost
Slides freely and smoothly in the frame for folding.
(For bikes tted with PostPumps or suspension seatposts) Functioning and operating
correctly.
5

© 2009 DAHON, BPSA • 2009.09.DS.EN
Part Item to Check Passed Remarks
Tires
Are free from physical damage or defect, are correctly seated in the right direction.
Have the correct air pressure, dust caps are present on the valves.
Wheels
Wheel rims, bearings and spokes are free of physical damage or defect.
Wheel nuts and spoke nipples are tight.
Front and rear wheel are free from wobble or buckle, do not foul the brake blocks,
mudguards, or anything else.
Wheel quick release Are correctly installed and adjusted.
Wheel bearings Are correctly adjusted.
Reectors Are both present and securely fastened to the front and rear wheels, at the front of
the bike and at the rear of the bike.
Bell Is present and securely fastened to the handlebar
Accessories Mudguards, racks, kickstands, and supports are rmly attached to the bodywork,
all supports are in place and tight.
Lights Lights and wiring are rmly attached and functioning correctly. If a dynamo hub is
tted, check that rotation direction is correct.
Owner Manual The correct owner manual is supplied with the bicycle.
Folding and
unfolding
Support bracket functions correctly.
Magnetix is correctly aligned.
Bike folds completely.
Bike stands stably when folded.
Bike unfolds completely.
6

© 2009 DAHON, BPSA • 2009.09.DS.EN
The F.I.T. system makes it easy
for a rider to adjust the height of
the handlebars. An integrated
groove in the stem keeps the
handlebars in the correct position
perpendicular to the frame of the
bike. Distance marks on the stem
itself let the rider know to exactly
what height he has adjusted his
handlebars.
WARNING: If you are in
any way unsure of how to
make these adjustments, take
your bike to a qualied bicycle
technician for professional
adjustment.
5mm5mm
Step 1 - Loosen the bolt with a 5
mm Allen key.
WARNING: Do not loosen
the top cap.
Step 2 - Adjust the stem to the
desired height.
WARNING: Do not raise
the stem over the stem’s
top cap.
5mm5mm
Step 3 - Tighten the bolt with a
5 mm Allen key. Tighten it with a
torque of 10 Nm.
Dahon F.I.T. Stem
7

© 2009 DAHON, BPSA • 2009.09.DS.EN
Step 1 - Loosen the height
adjustment bolt at the back of the
stem with a 5 mm Allen key.
WARNING: Do not loosen the
top cap.
The newly developed Axis stem
makes it easy for a rider to
adjust the height and angle of
the handlebars. An integrated
groove in the stem keeps the
handlebars in the correct position
perpendicular to the frame of the
bike while an adjustment joint
in the middle of the stem allows
for angle adjustments. Distance
marks on the stem itself let
the rider know to exactly what
height the handlebars have been
adjusted.
Additionally, a second groove
in the stem makes it possible to
take off the stem and handlebar,
reposition it 90 degrees and put
it back onto the handlepost. In
this way, the stem and handlebar
can be securely attached to the
bike when it is folded and stored
instead of dangling loosely from
the bike.
WARNING: If you are in
any way unsure of how to
make these adjustments, take
your bike to a qualied bicycle
technician for professional
adjustment.
Handlebar Height
Adjustment
Tools Needed:
• 5 mm Allen Key
Step 2 - Adjust the stem to the
desired height.
WARNING: Do not raise the
stem over the stem’s top cap.
Step 3 - Retighten the height
adjustment bolt with a 5 mm Allen
key. Tighten it to a torque of 10 Nm.
Axis Stem
8

© 2009 DAHON, BPSA • 2009.09.DS.EN
Step 1 - Loosen the angle
adjustment bolt in the middle of the
stem with a 5 mm Allen key.
4mm
Step 4 - Loosen (but do not
remove) the plate bolts with a 4
mm Allen key until the handlebar
can be rotated.
Adjust Handlebar Angle
Tools Needed:
• 4 mm Allen Key
• 5 mm Allen Key
Step 2 - Adjust the stem to the
desired angle.
Step 5 – Adjust the handlebar to
desired position. The angle should
allow your ngers to easily reach
the brake levers.
Step 3 - Retighten the angle
adjustment bolt to a torque of 10
Nm.
4mm
Step 6 – Tighten the plate bolts
with a 4 mm Allen key. Tighten to
a torque of 8 Nm.
9

© 2009 DAHON, BPSA • 2009.09.DS.EN
Step 1 - Loosen the height
adjustment bolt at the back of the
stem with a 5 mm Allen key.
Step 4 - Loosen the angle
adjustment bolt in the middle of the
stem with a 5 mm Allen key.
Position Stem for Folding
Tools Needed:
• 5 mm Allen Key
Step 2 – Lift the stem off the
handlepost, turn it counter-
clockwise by 90°, and put it back
onto the handlepost.
Step 5 – Adjust the handlebar
downwards.
Handlebar and front wheel should
now be parallel to each other.
Step 6 – Retighten the angle
adjustment bolt so that the stem is
secure.
Step 3 - Retighten the height
adjustment bolt at the back of the
stem with a 5 mm Allen key so that
the stem is secure.
Stem and handlebar remain
securely attached to the bike when
folded.
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