DAHON Freedom unifolds Service Manual
Service
Instructions
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
02
Dealer Pre-delivery Checklist
Please fill out the pre-delivery checklist to activate the warranty.
This following pre-delivery checklist information should be filled out by
a qualified bicycle mechanic. If the mechanic is unclear of the requirements
and process needed to carry out any checklist item, he/she should seek the
appropriate assistance.
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
Name:
Email:
Address:
Dealer Information (stamp)
Name:
Email:
Address:
Bike Information
Model:
Year:
Serial #:
Mechanic Information
Signature:
Name:
Date of check:
03
Dealer Pre-delivery Checklist
Item Description RemarksOK
The frame is not damaged or defective.
All frame joints do not have physical defect or damage.
Frame
Drivetrain
Chain
Chain and gear
selector assembly
Main hinge(s) opens and closes freely.
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.
Pedal, cranks, chainrings, bottom bracket and derailleur(s)
are securely fastened and correctly aligned.
The chain is correctly wired between the front and rear
sprockets; chain is free from physical defects and rust.
Moves freely and accurately through all gear selections.
Correctly aligned with all gears.
Cable locking nut is secure.
Derailleur(s) /
hub actuator
Gear selection
Excess cable should be tied, cut (reasonable length) and
capped.
Mechanism(s) is securely fixed to the handlebars.
Chain guard
Brake Levers
Brake Cables
Free of physical defect or damage. Correctly positioned.
Retaining nuts are secure.
Moves and returns without restraint with the brake cable
positioned correctly within the lever.
Calipers can move and are free from damage.
Cable locking nut is secure.
Excess cable should be tied or cut to a sensible
length and capped.
04
Item Description RemarksOK
Brake Blocks
Brake Calipers
Saddle and
seatpost
Saddle
Seatpost
Handlebar and
handlepost
Handlepost,
stem,handlebar
Headset
Blocks are correctly positioned to make contact with
the rim. Retaining nuts are secure.
Front and rear calipers are correctly centered; they
are smooth and effective in gripping the wheel rim.
All seat bolts, saddle bolts, and seat quick releases are
correctly tightened and adjusted.
Saddle alignment is correct (forward and level).
Ability to fold your frame efficiently.
(For bikes fitted with suspension seatposts) Functioning
and operating properly.
Free of physical defect or damage.
All bolts are fastened and correctly tightened.
Correctly tightened and adjusted.
Opens and closes.
Handlepost
hinge
Wheels
Free of all obstruction when locked.
Safety lock operates properly.
Wheel rims, bearings and spokes do not have any
physical damage or defect.
Wheel nuts and spoke nipples are tight.
Front and rear wheels are securely fastened; do not
foul the brake blocks, mudguards, or anything else.
05
Dealer Pre-delivery Checklist
Item Description RemarksOK
Wheel quick
release
Wheel bearings
Tires
Bell
Reflectors
Accessories
Lights
Owner Manual
Correctly installed and adjusted.
Correctly installed and adjusted.
Free of physical damage or defect; properly positioned and
facing the correct direction.
Have the correct air pressure; dust cap can be located
on the valves.
Check that the bell is present and securely fastened to
the handlebar.
Check that both reflectors are present and securely
fastened to your front and rear wheels.
Mudguards, racks, kickstands, and supports are firmly attached
to your bicycle. All supports are in place and tightly fastened.
Lights and wiring are firmly attached and functioning properly.
if a dynamo hub is fitted, check that the rotation direction is correct.
Correct owner manual is with the bicycle.
Support brackets function properly.
Folding and
unfolding
Magnetix correctly aligned.
Bike folds properly.
The bike stands firmly when folded.
Bike unfolds completely.
06
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.
WARNING:
Check to see if the clamps are
facing the outside; properly
aligned to the stem mount T-bar.
WARNING:
If you are unsure of how to make
proper adjustments to your bicycle,
seek a qualified bicycle technician
for professional adjustments.
Step 3 - Adjust the height and position of the
handlebar to attain your preferred riding position.
Move the VRO clamp within the window of
adjustment - front, backwards, up and down.
Step 4 - When you have established your desired
position, proceed to tighten the bolts of the VRO
clamps using a torque of 10 Nm.
Step 1 - Taking 5mm Allen Key out of tool box.
Step 5 - Putting Allen key into tool box.
NOTE:
Check to see that the angle of the handlebar
allows immediate access to the brake levers.
07
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° to save room in tight spaces.
Flat Pak Stem Adjustment
Front Lock Lever
Lock Lever
Overview
Step 2 - To adjust the height and position of
the Flat Pak stem, close lock lever tightly by
pushing forward. Lock lever tension can be
adjusted with the screw below the stem. Rotate
within the window of adjustment for preferred
riding position
Step 1 - When facing the stem from riding
position, open the lock lever on top of the
Flat Pak stem by pulling it towards you.
08
Flat Pak Stem Continued
Step 3 - Lift front lock lever and rotate handlebars
to desired position. While establishing your
perferred riding position, check to see that the
handlebar is readjusted in the right position.
The correct angle of the handlebars should
allow the fingers to reach the brake levers.
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 4 - After the handlebar has been
placed in the desired position, close front
lock lever tightly.
NOTE: Check that the angle of the
handlebar will allow immediate
access to the brake levers.
NOTE: To avoid rust, regularly apply
grease to the joints.
Level
Trekking position
Low
Road position
Flat For folding
WARNING:
Before you start riding your bicycle, check
to see that all screws and lock levers are
tightly secured.
09
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