DAHON Folder 1987 User manual

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\Warning: Do not ride before fully adjusting all parts, especially
latches, brakes and gears.

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TABLE OF CONTENTS
INTRODUCTION
RBSPONSIBILITIES AND SECURITY
2.1 Owner's Responsibility
2.2 Protection Against Theft
2.3 Lighting and Ref lectors
HOW TO OPERATE DAHON FOLDER
3.1 Unfolding
3.2 Folding
3.3 Transporting \
PREPARING TO RIDE
4.1 Safety and Parts Inspection
4.2 While-riding Evaluation
4.3 Getting the "Feel" of the Bike
4.4 Tire Inflation
4.5 Rules of the Road
MAINTENANCE AND CLEANING
5.1 Maintenance
5.2 Cleaning and Care
ASSEMBLY, ADJUSTMENT AND TROUBLE SHOOTING
6.1 Tools
6.2 Nut and Bolt Guide
6.3 Servicing Gu ide
6.3.1 Bottom Bracket and Crankshaft Assembly
6.3.2 Brake System
6.3.3. Cranks and Pedals
6.3.4 Saddle and Seat Post System
6.3.5. Seat Post Clamos
6.3.6 Frame and Frame Latch
6.3.1 Handlebar and Stem
6.3.8 Handlebar Clamp, Brace, and Couplirrg Pin
6.3.9 Steering System
6.3.10 Sprockets and Chain
6i.3.1 1 Hubs
1 6.3.12 Wheels
6.3.13 Tires and Tubes
6.3.14 Mudguards
,6.3.15 Reflectors and LamP
r ii.3.16 Caster Wheel
6.3.11 Baggage-to-Rack Coupler
STEC'-FTCATTONS
IPAR.|S LIST
I.IMITED WARRANTY (BACK COVER)
1. INTRODUCTION
I Congratulations, you have iust acquired a high quality product made of the
finest materials and parts. DAHON Folder comes to you fully assembled and
is easily adjusted to perfectly fi.t the unique preferences of the rider. Since this
bike has been designed to be light-weight and provide good riding quality to a
wide range of people, it is mechanically more complex and thus requires more
careful use and maintenance than other bicycles. So that you may safely enjoy
this state-of-the-art producl, read and follow all of the instructions and helpful
hints contained in this manual. Pay special attention to items denoted; (caution),
(warning) and (note).
Caution: To prevent component failure or damage.
Warning: To prevent injury to the rider or others.
2. RESPONSIBILITIES AND SECURITY
2.1 Owner's Responsibility
1. Follow the instructions in this manual and any other literature supplied
with this bicycle. This information covers such important points as assembly,
fitting, equipment safety checks prior to and during riding, observation of legal
requirements, and rules for safe bicycle operation.
2. Th€ owner is responsibte for performing or having performed normal
maintenance service to keep this bicycle in safe operating condition.
Warning: Prior to riding, check equipment "safety and Parts Inspection" (Sec.
4.1\. Pay particular attention to the secure latching of clamps, braking
means, and gear shift adlustment.
2.2 Protection Agoinst Theft
l. Record the serial numer of your bicycle This is your
proof of ownership. lt is located on the left rear fork blade.
2. List special options or accessory equipment added at or al-ier'purchase:
J.
chase: Record name and location of store where purchased,'and date of pur-
4. Register your bicycle with your local law enforcemerrt a.gencY' and
obtain license if required. License No. -- Place registered:
5. Take the bicycle with you indoors whenever possible. * .
6. Purchase an adequate lock and chain. Record lock name, fyPb, and key

number:
7. Secure your bicycle to a fixed obiect when left outside and not within
your sight.
2.3 Lishting and Reflectors
Almost all jurisdictions require use of pedal, wheel, front, and rear reflectors.
An adequate electric headlamp is usually required for riding after dark.
An electric taillamp, even if not required, is recommended for your safety
and visibility. The use of light colored or reflective clothing is also strongly
advised. Clip-on, battery-operated lamps can be purchased from your local
dea I er.
3. HOW TO OPERATE DAHON FOLDER
order of certain steps to better suit your preference'
Attentionowners:Thefo||owing'instructionsexp|ainwhatwefeelisthe
fastestandmostefficientwaytotoldandunfoldDAHONFo|derwhi|e
,iunaing on the left side of the bike. Naturally, the steps can be done in many
differenl orders, and from either the left or right side. Feel free to change the
I Begin with bike folded in upright position.
2 Flip out on metal actuator to lower caster
3 Resting the bicycle on wheels and casler wheel,
adjusl scat posr by releasing clamps and pulling
upwards on saddle. Always adjust lower seat
pott flrsl to hiShest po5ition, being careful not
to exceed the "Safetv lllark."
4 Warning: Before riding, always double check
seat post clamps to insure they are cloted and
working properlyl
i
i)
5 Swing handlebar bface to upright polition

rd caster wheels for support, swing
alf of bicycle and straighten out.
ot s€curely fastened and held in
) afety spring hook, the mid-
ruld come undone while riding!
I
handlebar pin, slidein brace ring
guide, align and release pin.
7. Push mid-frame latch horizontally with thumb
until lockld securely in place by the efety
spring hook.
9 Raise handlbar to vertical position, while
twisting it slightly to the right.
11. Warning: Always push pin all the way down,
making sure it is inserted all the way inro
the brace ring.
12. Release handlebar quick release clamp and
adjust the height; clamp handlebar in proper
position. (Warning: Always be certain handle-
bar post and brace are properly and securely
fastened.)
14. l-ock crank in place by pushing inward on
crank latch.
1 3. Swing the right srank downwards.
'15 Warning: Make sure )ank is latched firmly
in place by pulling outwards bn it.
6

."'q1.4M4i{@
11 Caution: Failure to retract caster wheel
hitting it against a hard object can resulI
damage to this part!
or
ln
ct easter whcel by st€pping down cn
actuator.
AfteTDAHON Folder is fully unfolded, it is necessary to adiust the
height of the seat posts and nandlebar stem to fit the individual rider- This
bike can be adjusted to any rider with an inner leg length of 25 inches to 35
inches (approxim*ely 4Yz to 6/z feet tall), and can support a rider weighing
up to 250 pounds. Remember to always firsl raise thc lower scat post.
Warning: Both of the seat posts and the handlebar post have safety marks
indicating maxir,\,um height adjustments. Never extend these posts past this
level.
3 2 Folding I
'To fold DAHON Folder, you may use in reverse basically the same
method as unfording. There are, however, a few additional steps. Outlincd
hereafter is an ei'lry way to fold the Hon Convcrtiblc
l. Rotate left crank to vertical position, unlatch thc right crank and flip it up
into its folded position.
Fig. 1Fig.2
2. Release the handlebar clamp and lower the handlebar completely.
3. Pull up on handlebar pin and disengage the handlebar from the brace.
4. Raise the brace to a vertical position.
5. Flio down the handlebar and turn the wheel to the left until stopped by the
bicycle frame.
6. Step down on the caster wheel as shown (Fig. .l )
7. Depress the safety spring hook as you pull out and unlock the mid-frame
latch (Fig. 2). Partially fotd bicycle so it rests on all three wheels. (Note: lf
you do not depress the safety spring hook sufficiently, the mid-frame latch
cannot be unlocked.)
8. Rotate the front end of the bike inwards in a 180 degrees arc a;d fold the
bicycle in half. (Caution: Failure to turn the wheel all the wa;' to the left
bcfore doing step 8 can result in damage to the handlebar system )
DAHON Folder is now in its pushing mode. lf you wrsn to carry it
by hand, simply release the seat post clamp and push down the seat, lift the bike
to a standing position, and retract the caster wheel.
l

Fiq 1
Fig.4
3,3 Tmnspottatlng
There are two modes of transporting DAH ON Folder: Pushing and
Carrying.
.l ) DAH oN Folder can be pushed along beside you in a folded state oy
usrng the caster wheel and by extending the seat post to a convenient height
(Fig. 3). As the caster wheel is not designed for rough terrain, the bike should
either be lifted, or tilted backwards, to run on the 2 largc whccls when
crossing rough areas
2\ In some areas whereDAH ON Folder cannot be pushed, it c,rn be easily
carrieQby hand. By completety folding the bike and raising it to a standing
positiuFt, you can grasp the carrying bar with either hand and easily carry
the bike with you anywhere (Fig. a).
DAHON Folder in its folded state is very portable and can be placed
compactly lying, standing or leaning in all sorts of small convenient places. lt
is easily fitted under bus seats, subway seats, in car trunks, lockcrs, and any
space qeasuring at least 8" x 18" x 28".
Note: ln both the pushing and standing modes, greater stability can be ob
tained by keeping the wheels slightly wider apart.
4. PERPARING TO RIDE
4.1 Safety Points And Parts Inspection
To ensure your safety and protect your new product from unnecessary wear
or damage, carefully check all of the following points before ridingDAHoN
Folder. A conscious inspection of these items is essential before every ride.
Provided for your convenience is a "reference" to places in this manuat
where detailed adjustment and repair information is located. Make all needed
corrections at once!
1. Latches and clamps firmly
fastened, no slipping or cracks. (oK) (Ftx) (Ref. Sec.)
A. Mid-frame latch
B. Upper and lower seat
post clamps
C. Handlebar clamp
D. Handlebar brace latcn
E. Right crank latch
Tires, front and rear:
A. Inflation pressure
B. Valve straight
C. Adequate tread, no cuts
D. No uneven wear, bulges
E. Properly seated on rim
Wheels, front and rear:
A. No wobble side-to-side
B. No "hop" up-anddown
C. No dents or bulges
D. Freedom of rotation, no
tight spots
Spokes, front and rear:
A. Even tension
B. None missing or broken
Frame, fork and brace:
A. No bent components
B. No cracks
l-
3.
(6.3.6)
(6.3.s)
(6.3.8)
(6.3.10)
(6.3.3)
(a.a;6.3.13)
(6.3.13)
(6.3.18)
(6.3.13)
(6.3.13)
(6.3.12;6.3.11lr
(6.3.12)
(6.3.12)
(6.3.14;6.3.13;
(6.3.2)
(6.3.12)
(6.3.12)
(0.:.0;o.s.s;
,5.3.e)
i5.:.0;e.s.a;
6.3.e)
4
5
)
)
t0

6.
C. No gaps between
comDonents
D. Brace movement firm,
smooth - no wobbling
E. Brace coupling securely fastened
Brakes, front and rear:
A. Mounted properly, no loose
bolts or parts
B. Shoes grip firmly, no
slipping
C. Release action solid, equal
D. No excessive wear
E. No rubbing at any point
F. No broken or kinked cables
G. Cables attached properly
Steering and handlebar:
A. Smooth action of steering
head bearing
b. Firm, not loose or binding
steering head bearing
C. No play in handlebar post,
or handlebar
D. Adiusted to proper height
and latched
E. Properly positioned brake
and gear controls
F. Tightened brake and gear
cables and mounts
G. Smooth telescope action
H. No cracks or bent members
{
A
Saddle and post:
A. Properly adjusted
B. No slipping or wobbling
C. No cracks or excessivelv
worn nlarts
D. Not excessivelv extended
9.
't0.
(6.3.6;6.3.8;
6.3.e)
(6.3.8)
(3.1; 6.3.8)
(6.3.2)
(6.3.2)
(6.3.2)
(6.3.2)
(6.3.2)
(6.3.2)
(6.3.2)
(6.3.e)
(6.3.e)
(6.3.7;6.3.8)
(3.1; 6.3.8)
(e .z.z;6.3.1 1)
(6.3.2;6.3.1 1)
(6.3.7;6.3.8)
(6.3.9;6.3.7;
6.3.8)
(3.1;6.3.4;
6.3.s)
(613.s)
(ffi.a;6.3.s)
(3.1)
Pedals, left and right:
A. Firmly tightened into
crank
B. Bearings turn smoothly
Crank, chain wheel, and
bottom bracket bearings :
A. Crank firmly latched
B. No loose or wobbling parts,
ptns secure
C. No bends or cracks
D. Firm, but not binding,
bottom bracket bearings
E. No worn, broken or bent
teeth
Hubs:
A. Mounting nuts properly
tightened
B. Cog straight; no broken,
cracked, or bent teeth
C. Smooth spinning action
D. Locking nuts & sleeves
properly tightened
Chain:
A. Properly lubricated
B. Attached securely, not too
loose or tight (
C. No rubbing against frame or guard (
Mudguards:
A. No cracks
B. No rubbing
Carrier:
A. No cracks
B. Securely fastened
Ref lectors:
A. Clean
B. Tightly fastened at proper
angles
Caster wheel assembly :
ll.
1
12.
8.
13.
14.
15.
l1
16.
12
)
)
)
)
(6.3.3)
(6.3.3)
(3.1 ;6.3.3)
(6.3.3;6.3. 1 )
(6.3.3)
(6.3.1)
(6.3.10)
(6.3.11)
(6.3.1 1)
(6.3.11)
(6.3.11 ;6.3.12)
(s.2;6.3.10)
(6.3.10)
(6.3.10)
(6.3.14)
(6.3.14)
. (6.3.6)
(6.3.6)
,(6.3.1s)
,(6.3.1s)

A. Raised before riding
B. Pins and bolts fastened,
working properly
C. Elbow spring functioning
(3.1 ;6.3.16)
(6.3.16)
(6.3.16)
Warning: To avoid possible injury, all faulty points that can affect safety must
be corrected before riding.
4. 2 llhile-riding Evaluation
You can keep your equipment in tip-top shape if you continually do a
"While-riding Evaluation" of your equipment.
Examples:
Rattles, squeaks or rubbing? Where? \
Wheels firms or squishy? Wheels bumpy or wobbly?
Braking power OK? Brake action smooih, no grabby spots?
Reserve lever motion available when braking hard?
Brakes drag after release. Brakes squeal or shudder?
Tires firms or low in pressure? A flat coming on?
Gears shift full range. No slipping in any gear?
Saddle height and angle OK. Too high? Too low? Pitch?
Saddle tight, doesn't turn, change angle on bumps?
Saddle comfortable. Do you hurt. Where?
Shake, knock or bind in bottom, bracket?
Does bicycle coast easily?
Are handlebars seflfie when pulling hard?
Are brake and gear levers tightly attached? Comfortable?
Are pedals true and square? Are sprockets true, no wobble?
Lights bright, properly focused?
4.3 Getting The "Feel" of the Bike
DAHON Folder is a high performance bicycle designed for both com-
muting and recreational use on paved roads (Warning, fast riding on unpaved
areas could result in mechanical damage and bodily iniury). Although DAHON
Folder iseasily:ridden by people of various sizes and ages, it is necessaryto
first getthe"feel" of the bike to avoid unfortunate mishaps due to unfamiliarity.
Take the bike to a flat, uncrowded area and test the steering, pedalling, and
balance. lt is also suggested that you practice folding and unfolding the bicycle
so that you ean do it quickly and efficiently.
After sufficient practice. vou should be able to fold or unfoldDAHONEolder
in 10-20 secon*ds.
4,4 Tire Inflation
Prior to sitting upon or ridingDAHONFolder, the tire pressure must be
checked. The basic pressure reguired is molded onto the tire. However, a little
more pressure may be required for a heavier person, while a little less may be
needed for a person of smail stature. If your tire pressure is significantry berow
the basic range or you feer that the tires do not support your weight weil,
it is best to use a hand pump to pump in additionar air. Gas station pumps
supply too much air too quickry and may rupture your tire tube. rf a gas station
pump must be used, however, add air into the tire in small spurts until the de-
sired pressure is reached.
4.5 Rules of the Road
There are 12 basic rures of cycring. you shourd contact your rocar raw
enforcement officials for any additions to these rules.
warning: Failure to obey these rules of the road could result in iniurv to the
rider or to others.
1. Obey state and local traffic regulations, signs, and signals.
Check with your local police on bicycle licensing, inspection, and
)
)
riding on
sidewalks.
2. Keep to the right except for left turns.
Ride with traffic, not against it. Ride single file
close as practible to the curb, but at a distance in a straight line. Ride as
which still gives room for
maneuvering.
3. Watch for car doors opening.
Always be prepared to stop or turn quickry if necessary. watch for and
anticipate cars. when riding on or near the sidewalk, watch for cars and
other bikes that pull into or out of driveways. Do not assume that vou have
been seen,
4. Use hand signals for turns or stops.
Advise motorists what you pran to do by giving proper signals 100 feet
before turning or stopping.
5. Be extremely careful at intersections.
lf traffic is heavy, walk your bicycre with pedestrian traffic. Look both
ways when crossing streets and observe approaching cars.
6. Avoid: drain grates, soft road edges, gravel or sand, leaves (especially when
wet),wet and raised manhole covers, pot hores, ruts, uneven paving and any
other road surface hazaros.
Avoid these hazards to prevent loss of control or damage to your wheels.
Cross railroad tracks at right angles to prevent loss of control.
7. Use extreme caution at dusk and at night.
Be thoroughly familiar wirh the controls on your bicycle. Ride onlv wnen
13 14

necessary at night and avoid heavy traffic. Vision is quite limited at dusk
and at night, so be very careful to avoid any road hazards. Make sure your
bicycle is equipped with properly positioned and clean reflectors on pedrls
and side reflectors on wheel:. The purchase and installation of an adequate
headlight and taillight is strongly recommended and required by law in most
areas. Wear light-colored or reflective clothing. Ride slowly and ride only on
streets familiar to you. Check local laws regarding riding at night. Do not let
a coat or other clothing hang down and cover your rear reflector'
8. Use extra caution in wet weather.
Ride slowly on damp surfaces as tires will slip easily. Apply brakes sooner
than normal as a greater stopping distance is required, especially if your
brake shoes are wet.
warnihg: lf the front brake is applied too strongly, the bike might flip for-
waros.
9. Give pedestrians the right-of-way, make a sound loud enough to alert any
pedestrians that You want to Pass'
Do not ride too close to pedestrians. Don't park your bicycle where it will
get in someone's waY'
10. Don't
- CarrY Passengers
- Carry items or attach anything to your bicycle that might hinder your
vision or control'
- Hold onto or attach your bicycle to any car, truck, or other vehicle in
order for it to Pull You along'
- Carry.extra clothing where it can hang down and iam the wheel'
- Ride with both hands off the handlebars.
- Wear head phones.
1 1. Ride a safe bicycle and wear proper clothing'
Make sure your bicycle fits you and that all parts, especially the brakes, are
adiusted and working properly. Make sure loose fitting clothing (especially
your right pants leg) does not catch in moving bicycle parts'
12. Watch out for the other guy, ride defensively'
Watch the car or bicycle in front of you and be prepared to take defensive
action. Don't follow a car or another bicycle too closely'
Be especially aware of traffic approaching from behind in case you must
swerve to avoid something.
Warning: This bicycle has been designed for general transportation and recrea-
tional use. lt has not been designed to withstand abuse associated with
stuntinsandjumpingororganizedcompetitiveevents.Theuseris
warned that he assumes risk for iniuries, .losses and damage from
such uses.
5. MAINTENANCE AND CLEANING
5.1 Muintenance
In addition to the before-riding "Safety and Parts Inspection" and ,,While-
riding Evaluation" (sections 4.1 and 4.2 of this manual), a thorough inspection
of all inner and outer working parts should be performed by a professional bi-
cycle dealer after ,3 months, 6 months, 1 year and every 6 months thereafter.
lncluded is a form for the first three inspections of this type.
Upon completion of these three forms you are eligible for a USg20 factory
rebate off your next purchase of a Hon Convertible. Send the duly completed
forms and the receipts for the first three inspections and any repairs that were
necessary to the DAHON California, Inc. within l3 months of your first
purchase. When you purchase your next DAHON Folder, indicate on the
Warranty Card that you have completed and sent these foi-ms to the DAHON
California and. upon verification, a $20 check will be sent to you.
FrRST INSPECTTON FORM (3 MONTHS)
DEALERSHIP'S NAME:
COMPANY REGISTRATION NO:
DEALER'S SIGNATU RE:
TOTAL COST:
DATE:
FRAME AND LATCH
STEERING SYSTEM
HANDLEBAR SYSTEM
SADDLE, SEAT POST SYSTEM
DRIVE SYSTEM
WHEEL SYSTEM
BRAKE SYSTEM
CASTER WHEEL SYSTEM
LAMP AND REFLECTORS
t) 15

CORRECTION
\ME AND LATCH
ERING SYSTEM
!DLEBAR SYSTEM
)DLE. SEAT POST SYSTEM
IVE SYSTEM
EEL SYSTEM
\KE SYSTEM
;TER WHEEL SYSTEI\4
\4P AND REFLECTORS
SECOND TNSPECTION FORM (5 MONTHS)
DATE
TOTAL COST:
5.2 Cleoning and Care
Because of the great deal of contact between you and your bike, your cloth-
ing and hands are likely to get soiled if the bike is coated with oil and dirt, To
prevent this from happening, carefully clean the bike of dirt and oil deposits.
The use of solvents and other cleaners will help dislodge dirt and oil. Use a soft
rag and a toothbrush to thoroughly clean all parts of the bike. After you ride
through particularly dirty'and dusty areas or a rainstorm, the chain should be
given special attention. lf you own a chain breaker tool, the chain can be re-
moved entirely for cleaning. To keep your bicycle looki4g brand new and to
keep dirt from adhering, it is recommended that you use a high quality car wax
on Vour bicvcle.
To keep your bike running smoothly, it is necessary to lubricate all the
moving parts. Thoroughly clean the parts to be lubricated, and remove all for-
eign particles. Light oil of SAE 20 consistency can be used as a lubricant for
most parts. Frequency of lubrication depends on the arnount of use and weather
encou ntered.
Warning: Do not use gasoline for cleaning. Avoid fumes and clean out of doors
if possible.
Caution: Do not allow any solvent or oil to get on the wheels or caster wheel;if
you do, clean immediately.
6. ASSEMBLY, ADJUSTMENT AND TROUBIE SHOOTING
6.1 Tools
You DAHoN Folder is shipped completely assembled and with air in the tires.
Brakcs and gear shift should be already adiusted. Your dealer should check each
point in the safety list, but you will wish to have some tools for subsequent
adjustment and safety checks (a minimum shown below).
?l:';;-ff:l Aren wrences
\LERSHIP'S NAME:
v4PANY REGISTRATION NO:
\ LE R'S SIG N ATU RE:
THIRD INSPECTION FORM (I YEAR)
DATE
ffifl
m
ALERSHIP'S NAME:
I\4PANY REGISTRATION NO:
ALER'S SIGNATURE:
CO R RECTIO N
AME AND LATCH
SYSTEI\4
NDLEBAR SYSTEM
DDLE. SEAT POST SYSTEI\4
IVE SYSTEM
IEEL SYSTEM
AKE SYSTEM
STER WHEEL SYSTEM
MP AND REFLECTORS
1l
TOTAL COST:
18

Caution: When using an adjustable
wrench, make sure wrench,
wrench jaws are tight in
order to prevent damage
to bolts and nuts.
Right
6.2 Nut dnd Bolt Tightening Guide
Nuts and bolts must be adequately tightened for strength and security, but
not overtightened to the point of failure, or crdshing or expanding tubes. The
length of wrench, times the force applied at the end of the wrench, gives the
torque applied measured in inch-pounds.
Typical Examples:
8mm or 5116" thread:200-200
f N-f BS.9.5mm or 318":250-280
112" Pedal Thread: 260-280
9 11 6" Pedal Th read : 450-500
6mm Brake Bolt: 150-170
Figure for the required force (W) is to be
known In relatron !o the length of wrench
5mm Brake Cable and Shoe: 120
7mm Crank Cotter Nut:180-1 90 20
Front WheeJNr+t:20o-220 ro
Rear Wheel Nut: 250-280 i 4 5 6 t g 9 ro i
To prevent nuts and bolts from coming loose. "Locktite" bond has been used
wherever appropriate on your factory-built FoLDER After you have tigh-
tened any nuts and bolts, for utmost safety, it is stronS,lv recommended that
vou do the same.
6.3 Servicing Guide
The following sections include detailed informatiott needed for the disas-
sembly, maintenancc, adlustment, trouble shooting and reparr of the DAHON
Folder. Detailed sketches have been provided, while reference to the exploded
vrew of the entire bicycle is available ln section 8 of this manual'
Caution: Do not attempt to disassemble, adiust, or repair parts without first
having adequate tools and mechanical background'
6.3.1 Bottom Bracket Crankshaft Assembly
A. Disassembly
To disassemble, use lock ring
pliers to remove the right lock ring
(A-210). Then remove the bearing
race (1,-220) with a special bearing ffinS
vrl
A3i0 4330
moved from the right side.
0
I
A'210
60
50
40
30
To assemble, reverse the above order. Make sure that bearinls are properly
lubricated (use wheel bearing grease) and that the bearing race (A-220) has no
side wobble but can rotate with little resistance.
B. Adjustment, Trouble Shooting and Maintenace
A poorly adjusted bearing race (1,-ZZ0) can hinder the axle,s spinning ability
or cause it to wobble. Avoid excessive or uneven wear of axle assembly by first
loosening outer lock ring(e-210), properly adjusting inner bearing race (A-220),
and retightening lock ring while making sure not to change the setting of the
bearing race,
Lubrication of these bearings is also very important as dirt, grime or worn
bearing grease can cause damage to bearing races. Each time this assembly is dis-
mantled, all parts shou14 bc thoroughly clea-ned and dried and re-greaserl. This
process should be done at least once every 6 months, or sooner if there is any
grinding or tight movement after proper adjustment.
lf excessive looseness or tightness exist after parts are lubricated and adjust-
ed, one or more of the foremented parts is damaged and should be replaced at
once. Failure to replace a worn part will accelerate wear of other inner-working
bottom bracket parts.
6.3.2 Brake System
The brakes are one of the most important parts of your bicycle. To be sure
that the brakes work well when you really need them, perform all the adjust-
ment steps in this section exactly as instructed.
warning: lf brakes do not work well after making the following adiustments,
have brakes repaired or replaced at a bicycle service shop.
DAHON Folder uses the two typ€s of caliper brakes - in the front
brake is a side-pull caliper brake, on the rear is a cenrer.pull caliper brake (Fig. 1)
19 20

1r
so far that it comes out of the part that it's threaded into, or out of the locknut;
turn the barrel in the direction which positions the brake shoe 1/16", from the
rrims. lf this minor adiustment does not suffice, a more complete cable adjust-
ment should be done by a qualified mechanic.
C. Changing and Adiusting Brake Shoes
lf brake shoes have no thread or if any part of the rubber block wears
down to 1/8" from the metal backing, it is necessary to replace them. To obtain
the performance built into your bicycle, be sure to only use top quality brake
shoes.
Remove the brake shoes by using a wrench to detach the nut and washer.
After positioning new brake shoes, replace the washer and nut to their original
location, being careful to observe the adiustment instructions illustrated below.
Make sure brake shoe
is lined up with
wheel rim
Right
D. Adlustment of Brake Levers
Brake and gear control levers must be fixed into a specific position for
proper folding of DAHON Folder. lf they are moved out of their proper
position they will interfere with folding and unfolding.To adjust a l9ver, simply
loosen the mounting nut and maneuver to the proper position. Always be certain
that mounting nuts are tight - if levers can be budged with moderate force, they
must be further tightened.
Fig2
The adjustment procedures is similar for these two types of caliper brakes,
with any deviations being clearly pointed out in the following paragraphs.
A. Ad justment of Brake BodY
For bcst braking action, it is vital that brakes are mounted so as to leave a
distance of approximately 1l16" between each brake shoe and the rim. (Fig 2).
Note: lf either wheel is not in alignment with the bicycle frame, rubbing will
occur between the rim and the brake shoes. To correct this, re-align the
wheel as instructed in section 6.3.12 of this manual.
lf the front brake shoes are not equally spaced, tap down lightly on one
side of the "return spring" with a screwdriver. lf this does not corrcct the prob-
lem, slightly loosen the mounting bolt and repeat the tapping procedure. For the
rear brake, adiustment should be made by slightly loosening the mounting bolt
and tapping the top of the brake arm until the brake shoes are evenly spaced.
Always be certain that both front and rear mounting bolts arc securely tightened
before riding the bikc. lf either one of the mounting bolts are stripped and can-
not be properly tightened, or lf it is damaged or bent, replace it immediately.
B. Minor Cable Adiustment
Now that the brakcs are pfoperly centered, if the space bctwccn the shoes
and thc rim is more or lcss Lhan 1116", it is necessary to adiust the brake cable.
A minor adjustment can be made by f irst looscning thc locknut until it is
against the adjusting barrel (Fig,. 2), being careful not to turn the adjusting barrel
Right
Make sure angle of
brake shoe matches
angle of wheel rim
Make sure brake shoe
will not rub tire
when brake is aPPlied
Right
ll
n
ril
Side-pu ll
Caliper Brake
Fig 1
'21 22

There is a metal anchor fasten-
ed to the end of the cable wire
which fits inside the brake lever.
You'll have to look up under brake
lever to see the anchor. Make sure
that each anchor is properly seated
in its recess, and has not iumPed
out. lf anchor is out of Position,
squeeze caliper arms in against
wheel rim in order to slacken the
cable wire and allow repositioning
of anchor.
if either one touches the handlebar
Firmly squeeze each brake lever and,
grip, recheck cable adiustment.
SatisfactorY Out of Adjustment
E. Other Maintenance and Lubrication
It is important to often check the brake cables for broken strands. lf the
cable wire is rusted or the cable sheath (cover ing) is bent and can't be straighten-
ed without damaging the cable, it is necessary to replace the brake cable at once'
The brake pivots and cable should be lubricated once every 4 months, or
more often if the brake does not operate smoothly and freely. To lubricate the
cable, put several drops of light-weight oil into each end of the cable sheaths or
take it to a service shop so that sheaths can be removed and cables thoroughly
inspected and lubricated'
Warning: Do not get any oil on caliper brake shoes as it will reduce braking ef-
fectiveness. Clean oil from the shoes or rim with a rag wet with soapy
water, and rinse.
Warning: lf brakes do not work well, have them repaired or replaced at a bicy-
cle service shop before riding your bike'
23
\
c-1?1 /\
24
6.3.3 Crank System and Pedals
Left Crank and Pedal
I
A. Disassembly s'221
nl'
U
The left crank is disassembled
by removing lhe nul (C-223),
washer (C222), and cotter pin
(C-221). The pcdal is removed by
rurning lhe pedal bolt (C-320)
cou nterclockwise.
B. Adiustment, Trouble Shooting and Maintenance
The crank can be slightly adjusted in or out (horizontally, to right or left),
by loosening the nut C-223 and tapping the crank to the desired position.
Note: Positioning the crank too far out may interfere with folding.
It is very important that the crank and pedal are always tirmly attached. lf
the crank becomes loose, first check to make sure that the nurC-223 is tighten-
ed. lf looseness continues, one or more of the following parts is excessively worn
and must be replaced;1) cotter pin 2) inner crank grooves 3) axle grooves. lf
pedal wobbles after being tightened, check; 1 ) lower crank threads. 2) pedal bolt
th rcad s.
lf the crank or pedals are cracked or bent, appropriate pieces must be re-
placed. Also, pedals should be lubricated by laying the bicycle on its side and
applying 2 or 3 drops of oil to the bearings once every month or when pedals do
not spin smoothly. lf rough spin continues, pedals should be replaced.
Right Crank
A. Disassembly
Remove the right crank by unscrewing the locknuts (C124); slide off
washcrs (C-123\, and bushings (C1221. Then tap the pin (C-121) out with a
plastic hcaded hammer. Remove the crank latch (f -210) by first sliding off the
chainwhccl, and then unscrewing the 4 mounting bolts (f -220) on the back side.
o f -22O
c222
- C223
\r-r.'o

B. Adjustment, Trouble Shooting and Maintenance
The two locknuts (C-124) should be periodically inspected and, when neces-
sary, adiusted so that the crank is held firmly, but not so tight that the crank re-
quires pounding or excessive pressure to be folded. lf the crank wobbles easily
when unlatched, the pin assembly may be worn and should be replaced if it is. lf
wobbling continues, take to a dealer for specialized servicing.
When the crank is latched, if it sirs loose in the crank latch (T-2110) or if the
latch requires excessive strength to close, adjust the crank',depth,,by turning
the two adjustment screws (c-1 1.1 ) with a philip screw driver counter clockwise
(for tightening) or clockwise (for loosening).
Caution: The latch should be closeable with ohly moderate force, pounding or
excessive force will damaee it.
6.3.4. Saddle and Seat Post System (Excluding Clamps)
A. Disassembly and Assembly
Remove saddle from upper seat post (P-200) by loosening saddle nuts
(P-1 20) and tapping upwards on saddle. Remove upper and middle sear posr
tubes by loosening quick-release clamp bolts P-320 and F-41 0 respectively.
@P322,
25 26
B. Ad justment, Trouble Shooting and Maintenance
Durable nylon sleeves (P-330 and F-300) have been placed between the
stiding seat posts and their respective seat post clamps' In order to keep the seat
posts aligned, these nylon sleeves have an extrusion which fits into the groove
built into the seat post. lf these sleeves become worn or cracked, they must be
replaced.
lf clamps are all properly adjusted (seesec.6.3.5) and nylon sleeves in good
condition, but the seat post fails to slide smoothly, one or more of the seat posts
have probably been bent or dented. lf the piece cannot be straightened without
damaging or weakenin$ it, replacement is necessary'
To adjust the saddle, simply loosen the saddle nut, adlust the saddle to your
comfort, and re-tighten the nut. For your safety, make sure that the saddle bolt
and nut are not bent, rusted, excessively worn and that threads are not stripped'
Also be certain that the braces which clamp the saddle in place (located between
the saddle nuts and saddle clamp) are properly positioned and are not bent'
rusted or otherwise damaged. Always be certain the bolt is properly tightened
with 200-220 foot pounds of torque.
6.3.5 Seat Post Quick Release Clamps
A. DisassemblY
Remove in order the adiusting
nut (P-332 or F-430), clamp bolt
1Pi20 or l!10) and the square
washer (e3Zl or F-420).
B. Adjustment, Trouble Shooting and Maintenance
lf properly adjusted, the seat posts should slide freely when the clamp is
released, but hold steady under the a person up to 250
pounds when the clamp is tightened. I the case, clamp and
adjust the tension by turning the "ad ' (P-332 o y means of
a wrench. Be careful not to tighten the nut to such a degree that sliding becomes
difficult. A small amount of bearing grease applied to the camming surfaces of
the clamp will extend its useful life.
After extended use, the inner working of the clamp bolt may wear down to
the point to where clamping action is limited. In such case, it is necessary to
replace the bolt, nut and washer. lt may also be possible that inspection shows
that replacement of the nylon sleeve is needed first'
Warning: Always be certain that the clamps are secured and properly adjusted
each time befo;e riding Your bike.

63.6 Frame and Frame Iatch
A. Disassemblv
To disassemble the frame, first remove the various components attached to
it, according to their various subsystems and disassembly instructions. Then,
unlatch the frame latch assembly and turn the entire frame upside down.
Remove the 2 F-870 C-clip retainers. Remove frame latch assembly by alternate-
ly tapping the 2 pins (F-860 and F-820) until the entire latch assembly is ex-
lracted downward.
To disassemble the frame latch, unscrew the rear pin and counter-threaded
nut (F-860 and F-850) in turn.
To separate the 2 halves of the frame, firlt remove the2lock nuts (F-620),
and then tap out the 2 pins (F-61 0).
B. Adjustment, Trouble Shooting and Maintenance
The only component to adjust on the frame is the frame latch. When
properly adjusted, the latch should not be able to pop open without first de-
pressing the safety spring (F-710). Moreover, the front and rear top lugs should
be flush, with no gaps, and there should be no wobbling between the front and
rear frames.
To adjust the frame latch, first release it, and then use pliers or a screwdriver
to turn the counter-threaded adiusting nut (F-850) clockwise to tighten, or
conterclockwise to loosen.When ad justment is complete, add a drop of "L ocktite ".
Double check to make sure that the safety spring holds the frame latch securely in
place. lf the latch is in place, but the spring fails to hold it securely, remove the
spring by detaching F-720,and adjust the spring by bending it in or out.
Warning: Never ride the bike without the safety spring working properly.
After adjustments have been made, if gaps or wobbling between the front
,-A
27 28
and rear frames still occur, replace or repair the following items'
A) Top/bottom lug pins (F-610, F-860 and F-820) -worn to a point where
1 a tight f it no longer exists; bent.
B) Lock nuts (F-620) or C-clips (F-870) missing or loose'
C) Counter-threaded adjusting nut (F-850)-bent, stripped or excessively worn.
Di Safery spring (F-710)--loose or missing bolt and nut (F-720, F-740); lacking
tension.
E) Frontlrear frames-out of alignment.
Warning: Never ride the Hon Convertible without first making certain that the
frame is sturdv and latch functioning properly.
6.3.7. Handlebar and Stem
A. DisassemblY
Remove the brake levers, gear
lever and grips. With an allen
wrench, loosen the handlebar ex-
pansion bolt (H-220) 7 full turns
counterclockwise. TaP the bolt
back down to its original Position,
and looscn by another 3 or 4
turns or until the handlebar can
be slid out of the handlebar stem
(u-210). Also, at this Point th€
handlebar stem can be removed
by pulling upwards.
B. Adiustment, Trouble Shooting and Maintenance
The handlebar should be curved horizontally backwards' To adiust, loosen
the expansion bolt (H-220), turn handlebar to proper position, and re-tighten
bolt.The brake levers and trigger gear control lever must be fitted in the proper
angle and position so that they do not hit the rear wheel when the Hon con
u.rtlbl. is folded. To adjust, loosen appropriate mounting bolts, turn each one to
form a 30 degree angle with the vertical, and re-tighten bolts. Before riding
"i*uy, be cerlin that these mounting bolts are securely tightened and that
cables are not kinked and are securely fastened.
lf the handlebar becomes bent out of its original shape, take it a profes-
s'ronal dealer to be re-straightened. lf excessive bending occurs, the structural
strength of the handlebar may be weakened and it should be replaced at once'
Moreover, if either the handlebaror handlebar stem should become cracked, im-
mediate replacement is vital.
I I l< H2ao
ill

B. Adiustment, Trouble Shooting and Maintenance
For adjustment, care and lubrication of the bearing head set (5-200), heed
the same points mentioned concerning the bottom bracket bearing set in Scc.
6.3.1 B. of this manual.
lf bearings are in good working condition and the brace (see Scc.6.3.10) is
properly adjusted, there should bb no movement in the steering column base
when the handlebar brace is fastened. lf play or gaps exist, check to make sure
that the base pin (5-330) is in its proper place, spring pin C-clips (5-322) are
securely fastened, and lock nut (5-340) is tightened. lf the problem continues,
check and replace bent or worn parts, such as the base pin, steering coupler,
steering column or front fiame. \
6.3.10 Sprockets and Chain (Chainwheel, Rear Cog, Chain Guards,andChain)
A. Disassemblv
Use chain breaker to remove the chain. To remove the chainwheel, first
disassemble the the right crank assembly (sccScc. 6.3.3). Slip the chainwheel off
of the axle. Unscrew and detach the outer chain guard (T-310) and then the
Ttt0
410
rso0
B. Adjustment, Trouble Shooting and Maintenance
By adlusting the position of the rear wheel axle, the chain should be ad-
justed to a point where it is not so loose that it sags or derails easily, but not so
tight rhat pulls exccssively on sprockets (about % inch slack at midpoint).
Check the chainwheel and rear cog to be sure that they are not bent. lfone
of the sprockets is bent, replace it or, if the deformation is not too severe, take it
to a bicycle dealer to be straightened. lf the chainwheel and cog are not in line,
make the necessary hub (seeScc.6.3.13) or right crank (seeScc.6.3.3) adjust-
ments. lf problem persists, there is a possibility that the rcar frame is out of
alignment and your bicyole should be taken to a dealer for needed servicing.
<:rn*,
31 32
Always be certain that chain guards are securely fastened to the chainwheel.
lf either the inner or outer chain guard becomea unevenly spaced with the chain-
wheel, bent, cracked, or otherwise damaged, replacement of the damaged or
vrlorn item is mandatory.
Caution: Chain guards are constructed of plactic and care should be taken so
that they are not damaged.
With the chain on, hold the rear wheel and put pressure on the pedals. Note
the position of the chain on the teeth. lf the teeth are worn excessively, or if the
chain is worn and stretched, you will note that the chain rides high on the teeth,
rather than lying in the bottom of the tooth spaces. The rear cog can be checked
at the same time. lf it is determined that the chain or sprockets are worn, or if
any teeth or the body of the cog or chainwheel is bent, it is necessary to replacc
darnaged or worn parts. lf the above condition is due to excessive wear, the
chain and sprockets should be replaced together.
The chain should be cleaned and lubricated at least once every 2 months
and more often if adverse weather or riding conditions are often encountered.
Oil should be placed between inner and outer plates of the chain. An efficicnt
method of lubricating the chain is to remove it, clean it thoroughly, and Iubri-
cate it with SAE 20 oil.
6.3.11 Hubs
Inner hub parts are a precise combination of delicate components. lf there is
any doubt concerning your hubs, take your bike to a professional dealer for
servicing. For a 3-speed version, the re-ar 3'specd goar tnrb, however, may require
some adjustments which can be performed by closely following the steps listed
below.
(1) First set trigger lever at posi-
tion No. 3 of gear speed indica-
tor .(Fig. 1 )
(2) Cfrcct that the cable nipple is
placed in the groove properly.
(Fie. 1)
(3) Tighten guide nut. (Fie.2)
(4) Insert coupling rod through
axle hole and turn it clockwise
until it stops. Then loosen it by
/z turn to assu re a smoother
speed change. Failure to do
this will result in the chain
';--/,)
Y ----

(7)
being slightly twisted. (Fig. 2)
(5) Screw indicator coupling con-
neclor into the coupling nut.
(Fie.2)
(6) lnsert cable into the cable
anchor bolt. (Fig. 2, 4)
Cable adiustment: While turn-
ing pedals, move trigger lever
to "normal" (No. 2) position.
Next, loosen indicator coupling
locknut and adlust coupling
nut until the end of the coupl-
ing rod is 1132 inch (0.8mm)
aside the extreme end of the
axle. This can be seen through
the "window" of the guide
nut. (Fig. 3)
Final adiustment:
(A) While turning pedals pull the trigger lever to position No. 1. lf it
is hard to set trigger lever at position No. 1, loosen the coupling nut
slightly until you can. Caution should be taken not to loosen the nut
too much.
(B) When the lever is positioned at position No. 1, if there is excessive
stack in the cabte, adiust tlre coupling nut until the eaAl€ is right.
(C) After checking that the shifter is working properly in all three speeds,
secure the coupling nut by tightening it down with rhe indicator
coupling locknut.
The hub should be lubricated with two or three drops of SAE 20 oil once a
montn.
lf the cable becomes frayed or broken, it should be replaced by a prcfes-
sional bicvcle dealer.
Always be certain that all parts are properly tightened, and that worn,
cracked or broken parts are replaced at once.
6.3.12 Wheels (Including Spokes and Rims)
A. Disassembly
To remove the front wheel, turn the bicycle upside down, remove the outer
nuts (W-1 25) and safety washers (W-120) on both sides of the axle, carefully
spread the fork blades out, and remove the wheel.
(8) Fs 3
33 34
To remove the rear wheel, put the gear shift lever (T 810) in middle (#2)
position. Check the cabfe adlustment as shown in Sec.6.3.13. Tighten the cable
locknut. Then, without disturbing the locknut position, completely unscrew the
t,.
aolusung sleeve.
Loosen the rear wheel nuts (W-222 andW-223). Note the position of the
flats on the rear axle in the slots. The rear wheel can now be slid downward and
outward from the frame.
Note: lt may be necessary to remove one caliper brake shoe (see Scc. 6.3.2)
-'6efore the tire will move out between the brake shoes.
o@t
w222
w\25 /
B. Adfustrnent, Trouble Shooting and Maintenance
When replacing the wheels, they should be carefully centered between the
forks and brakes. Be certain that wheel nuts are replaced while all spokes should
be adequately tightened. When the gear shift operating cable connector is re-
assemblcd, recheck its setting as described in Sec. 6.3.1 3.
Wheels should be regularly checked for "wobbling" from side to side, and
"hop"- being out of round or of unequal diameters.This misalignment can be
detected bcst by turning the bicycle upside down, rotating the wheel while
using our finger or a pencil placed next to the rim as a guide. Severe misalign-
ment will causc the tire to intermittently rub against the fork, or the rim against
the brake shoe.
Warning: Whccl misalignment will lead to grabbing or failure of braking power,
and should be corrected at once.
To correct this problem, first check the rim to make sure it is not dented or
twisted. lf it is, take the wheel to a dealer for specialized repair or replacement.
Uneven spoke tension, or missing, bent or broken spokes, will also cause the

wheel to be out of the true. Replace damaged and missing spokes, and with a
spoke wrench or smalladjustable wrench, turn the nipples of loose spokes clock-
wise to achieve even tension. Then, if the wheel is off center to the left, tighten
the spokes on the right, and loosen the spokes on the left. "Hop"isremoved by
tightening spokes on both sides of the high area. Final spoke adjustments should
be done in small increments.
After this adjustment has been completed, if the wheel remains out of align-
ment, your bicycle should be taken to a professional dealer for servicing.
6.3.13 Tires and Tubes
A. Disassembly
Remove the wheel as instructed in Sec. 6.3.14. Deflate the tire by pushingin
on the pin inside of the tire valve, squeeze the tire to force out as much air as
possible. Pinch the tire together all around the rim to break it loose from the
rim. Roll the tire off the rim, starting from the opposite side of the tire valve.
Note: lf tire removal or installation is too difficult to do with your hands, have
it done by a bicycle service shop, as special tools may be required.
Caution: Do not use screwdrivers or other pointed tools which may damage
tire, tube or rim.
Before installing the tire, make certain that the rubber rim strip is not
damaged and.covers all spoke ends. File down any spoke ends prolecting out
from the spoke nipple. Check the inside of the tire for damage and any object
that mighr punctrrre the inner tube.
Then, inflate the tube lightly to help keep it in the tire and gradually push
one side of the tire onto the rim, again starting from the side opposite the infla-
tion valve. Pull the valve firmly through the valve hole in the rim, and install the
other side of the tire starting at the inflation value. lf the valve does not project
straight out of the rim hole after the tire is installed, slide the tire around the rim
until it is properly positioned. Inflate the tire slightly and then release air to
straighten out the inner tube. Then inflate tire as instructed in Sec. 4.4 of this
manual.
6.3.14 Mudguards
A. Disassembly-front
Take off the nuts (W-125) and washers (W-1 20) on both sides of the axle,
thus freeing the mudguard stay (M-140). Unscrew the brake and mudguard
mounting bolt extruding through the fork crown (S-110), and remove the front
brake and mudguard.
J) 36
B. Disassembly rear
Remove the rear wheel as describcd in Sec. 6.3.14. Then remove thc two
mounting bolts, thus releasing it from the rear frame.
C. Maintenance:
The mudguards are constructcd of plastic, and special care should be take so
as not to break or damage them. They have a fixed form - under no cir-
cumstance should this form bc altered with plicrs or other instruments!
Allv,rys bc surc that nrounting bolts irrc sccure ly f astencd, lf the mudguard
becomes cracked, chipped or broken, or if it rubs against the tire, replace it so as
not to cause a hazard to the tire.
6.3.r5
A: Disassembly
Front, rear, pedal and wheel reflectors are easily removed by unscrewing
their rcspective mounting bolts.
B. Adjuslmcnt and Maintcnancc
Bc ccr Lain that mounting bolts are always properly tightened. Often clean
your rcllcctors. lf a reflector becomes cracked or otherwise damaged, replace it
before riding your bicycle at night.
Although a head lamp may not be included withDAHON Folder , if you
ride your bicycle at night, it is strongly recommended-if not required-that an
adequate lamp bc installed. So that the bicycle can be fully unfolded, this head-
lamp must be easily removable. When attached, be certan that it provides ample
lighting and is properly adiusted.
Caution: Nevcr adjust reflectors with levers or pointed tools which may crack,
scratch and otherwise damage the reflector or other parts of the
bicycle'
l^\ {}l
\

6.3.16 Caster Wheel (Third Wheel)
A. Disassembly-
Unscrew the two elbow assembly mounting bolts (U-320 and U-340),
and remove the elbow assembly. Take out the pin (U-120) by first removing
the spring clip retainer (U-1 30) and tapping it out. To remove the caster wheel
(U-210), loosen the 4 screws (U-220) which mount it to the caster wheel
bracket (U-1 10).
B. Trouble Shooting and Maintenance
The caster wheel is made of 3 separate components. Cracked, bent, broken
or excessively worn components demand replacement. lf bolt or screws do not
tighten properly, or if the pin is bent or spring pin damaged, replace the neces-
sary fasteners. Always use new mounting screws (U-220) when replacing the
caster wheel (U-210). Replace all mounting screws (U-220) together; be careful
not to overtighten them, thus stripping out the holes in the bracket (U-1 1 0) and
causing replacement of this piece.
The elbow assembly will not function properly if it is bent. Try to straight-
en it out by hand. lf thls does not work, replace the assembly.
Caution: Failure to raise the caster wheel before riding, or forceful impact
against the caster wheel assembly whether in its up or down position,
may cause severe damage to the caster wheel assembly.
37 38
3-speed, gear hub 36 holds 1 3T
7. SPECIFICATIONS
I Bicycle Unfolded size
Folded size
Weight
52/2" Lx19" Wx40"H max.
2J" Lx9 %"xWx1l"H
28 pounds
Frame Front Frame Built of 1-1 /8" plain gauge hardened
stainless steel tubing and stainless steel in-
vestment castings.
Rear Frame
Front Fork Fork blade made of 1-1 fB,'plain gauge
hardened stainless steel tubing.
Fork crowns are of investment castinq.
Saddle & Seat
Post
S Steel Tubing
Upper Seat
Post
Sadd le Padded vinyl top racing saddle
1 -1 /8" plain gauge hardened stainless steel
Middle Seat
Post 1-13132" plain gauge hardened stainless
steel tubing
Handlebar tfandtebar 778ligtrf alloy
Handlebar
Stem Top Light alloy
Handlebar
Stem 1-1 18" plain gauge hardened stainless
steel tubing
Handlebar
Post 1-318" plain gauge hardened stainless
steel tubing
Wheel Rim 16x1.75
Tires & Tubes 16 x 1 .7 5, tire pressure 45 psi
Spokes 15g
Front Hub Light alloy, small flanged, 36 holes
Gear Hub (Rear) Suntour
(3-speed) hub cog

Rear Hub
Single Speed Semi-flanges steel, 36 holes
Front Brake Side-pull design caliper, forged light alloy
brake
Rear Brake Center-pull design caliper, forged light
alloy brake
and
kCrank lnvestment casted cotter crank,6lz" long
Chain Wheel /2" x3132" x 527
/2" x3l32" x 47 links
Light alloy made, rat-trap with amber re-
flectors
39
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