SatRDay™ - Bike Friday

SatRDay™ - Bike Friday
Using Your Bike Friday®:
SatRDay™
Queen Voice of Bike Friday, Gaylynn HanavanCoon, rides the SatRDay in the Cinderella
Century, 2006. Visit her www.bikefriday.com/bf/gaylynn
www.bikefriday.com/satrday
Green Gear Cycling, Inc.
3364 W 11th Ave. Eugene, OR 97402
800-777-0258 USA & Canada
+1-541-687-0487 Int’l • +1-541-687-0403 Fax
www.bikefriday.com • [email protected]
November 2006
Congratulations!
You have just purchased the finest travel bicycle available today.
Your bike has been carefully designed and constructed for your
personal travel needs. All of our bikes are manufactured in our
Eugene, Oregon factory by real cyclists who care about our
products and our customers.
Please take your time reviewing this manual and, if possible,
watch the movie clips at www.bikefriday.com/satrday before you
assemble your new Bike Friday travel bicycle. You will find your
new bicycle fun and reliable anywhere you go!
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
travel bicycle, 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 a.m. to 5 p.m. Monday through Friday, and 9 a.m. to 4
p.m. Saturdays, Pacific Standard Time. You can also email service
questions to [email protected]
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.
Extra Accessories
We also sell an extensive (and growing!) 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
info on spare tires & tubes, replacement parts, fenders, racks, bags,
or other items to complete your Travel System.
More Information
To check out our products, find other useful information, discover
Bike Friday events and Yak with other Bike Friday owners on the
bulletin board, go to our main web site at www.bikefriday.com. Or
just call us at 800-777-0258.
Welcome to the fold, from the Bike Friday Travel Team
Visit www.bikefriday.com/satrday for more tips
This edition last updated Nov 10, 2006 by Lynette Chiang
www.bikefriday.com
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Table of Contents
A Word on Safety
Anatomy of a SatRDay (Touring)
Getting Started
Assembly: Unpacking
Unfold Frame
Insert wheels
Unfold boom
Install Cranks
Install Chain/Stem
Install Bars
Install Seat
Front Wheel
Install Pedals
Packing the SatRDay: Materials
Seat Handlebars
Remove Stem/Crank
Remove Pedals/Crank
Remove left crank
Remove right crank
Front wheel
Important protection
Folding the boom
Folding the frame
Place bike in suitcase
Pack rear wheel
Crush protector
Fitting it all in
Quick Folding the SatRDay
Quick Fold/TravelBag
Getting a Good ‘Sit’
Eccentric
Accessories: TravelTrailer
Folding Rear Rack
Fenders
Using a Quick Release
About V-brakes (Tour model)
About 2006 Shimano Cranks
DualDrive™ Hub
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5
6
7
8
10
11
12
13
15
16
17
19
21
22
24
26
27
28
29
30
31
32
33
34
35
36
38
39
40
47
48
50
51
55
57
58
60
62
63
Table of Contents cont’d
Trouble Shooting
Bike Friday Service
Travel Tips
Warranty Information
Notes
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68
69
70
71
72
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A Word on Safety
Bicycles are a lot of fun, but they can also hurt if you don’t
ride carefully. So please always ride safe!
• Always wear a helmet.
• Follow the rules of the road, and be courteous. (We all need to
represent the best of cycling to the world.)
• Use front and rear lights after dark.
• Dress appropriately for the weather and the season.
• 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 SatRDay comes with a combination 5/6mm Swrench (pictured) stored in a rubber sleeve holding
the cables together. This wrench should get your new
bike on the road (along with your own pedal wrench).
Keep it in the cable sleeve so that you always have it
handy. All bikes ordered with a TravelCase™ suitcase
also come with a tool pouch. In the tool pouch you will find some
cotton gloves to keep your hands clean, a folding tool set, a combination headset and pedal/axle nut wrench (15mm), and a 4mm
ball-end driver. The ball-end driver is perfect for mounting bottle
cages, racks, and other accessories. If we needed to remove your
right crank arm in order to pack your bike, we also included a long
handled 8mm Allen wrench.
We also sell more
extensive tool kits for
home repair work. We
encourage you to learn
how to work on your
own bike. If you are not
familiar with bicycle
maintenance,
consider
taking a local class. It will
improve your confidence
and self-sufficiency as
you venture across the
globe.
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Rear Derailleur
Seat Support Quick Release
Rear brake
Cassette (Cogs)
Elastomer
suspension
Seat Adjustment
Seat Support
Chain Stays
Seat
Shifters
Chain Catch
Idler Pulley
Front Brake
Stem Collar
Head Set
Seat Rail
Monotube
Stem Riser
Handlebars
Rim
Head Tube
Stem hinge and
quick release
Brake Levers
Front hub
Fork
Eccentric
(touring
model only)
Boom
Chain
Rings
Bottom
Bracket
Crank Arm
Front Derailleur
Pedal
Anatomy of a SatRDay (Touring)
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Getting Started
Where to Begin
Opening your case for the first time may present an intimidating
sight, particularly if you ordered many extra travel accessories with
your Bike Friday travel bicycle. Don’t worry, we work hard to keep
our products simple, and with a little practice you will find that
using your new bicycle will become second nature to you.
We recommend finding a quiet area with access to the video,
these instructions, and some room to spread out. This manual
will address the fundamentals: packing and assembly tips and
techniques that are common to all of our travel bikes. However,
because this bike has been custom made for you, you may discover
that your bike was packed at the factory slightly different than
the one in this manual. Wherever possible, we mark any packing
materials unique to your bike.
Furthermore, you do not have to repack your bike in exactly the
same fashion. You may find a better way of stowing your accessories, and we encourage you to experiment. If you discover a
particularly good way of doing things, let us know. Some of our
best ideas have come from members of the Bike Friday family.
If you encounter difficulties assembling your SatRDay and the
instructions do not help, call us. Our goal is to get you quickly on
the road so that you can enjoy your Bike Friday SatRDay.
Illustrated Accessories
In order to illustrate the assembly and use of all of our travel accessories, the bike on the following pages has nearly everything we
could think of for a fully loaded tour. Your own bike may have only
a few or none of these accessories. If you ever choose to purchase
some of these accessories, this manual should help you pack the
extra items.
The SatRDay does not normally come with pedals, unless you
specifically ordered them from us. Tip: remember with all threaded
bolts and screws EXCEPT the left pedal, turn right (clockwise) to
make tight, left to make loose. The left pedal works in the opposite
manner. Be careful not to strip the threads.
The assembly and packing steps are generally the same across
all SatRDay configurations. Because of component differences,
wrench sizes and the number of bolts per clamp may vary from the
illustrations.
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Assembly: Unpacking
1. Open The TravelCase
Start by removing some of
the obviously loose items
from the case including
water bottles, accessible
colored felt bags, trailer
wheels, the plastic pouch
with extra materials, and so
on. Put any accessories such
as racks and trailers out of
the way for now. The lid is Fig. 1 The fully equipped travel bicycle
a good place to hold components and prevent parts being lost.
Assembly on grass is not recommended!
2. Crush Protector
The crush protector is a PVC
dowel with a couple of flat
caps on the ends. This piece
is a critical bit of packing
material: it spans the case so
that luggage dropped on top
of your bike is supported by
the dowel and not your bike.
The caps are lightly pressed Fig. 2 Remove crush protector
on—just pull the top cap off. Don’t worry if the dowel comes out
and the bottom cap is still in the case.
3. The Goodie Bag
There might be a better name
for this pouch, but we’ve
always called it the Goodie
Bag. This bag holds a variety
of miscellaneous loose items
for your new bike. This may
include the technical literature that came with your Fig. 3 The goodie bag
components, spare spokes, some labels and decals, and always a
surprise! The component literature is not required reading, but we
supply it for those who are technically inclined.
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Assembly: Unpacking
4. Remove Tool Pouch
The tool pouch that comes
with the case is a light blue
colored felt bag with a cord
around it. Inside you should
find a folding tool set with
all of the Allen wrenches and
screwdrivers you will need
to assemble your bike, a pair
of cotton gloves to keep your Fig. 4 The tool pouch.
hands clean, and a 4mm ball-end driver. Note: You will also find a
combination 5/6mm S-wrench attached to your water bottle cage
for quick road-side adjustments.
5. Remove Rear Wheel
With the crush protector
removed, remove the rear
wheel. Locate the rear wheel
quick release, usually in
the tool pouch, and insert,
remembering
that
the
narrow ends of the two
springs face toward the hub.
Fig. 5 Remove front wheel and set up
See page 58 ‘Using a Quick Release’.
6. Remove handlebars
The handlebars will be in
the left side of the case. Pull
them out, and let them drape
by the attached cables over
the left side of the case.
Fig. 6 Remove front wheel and bars.
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Assembly: Unfold Frame
7. Remove Bike Frame
Lift the frame out of the
suitcase.
Note items stashed neatly
in lid.
Fig. 7 Remove bike frame.
8. Unfold rear end
As you unfold the rear end
of your bike, make sure
cables are not caught on the
hinges.
Fig. 8 Unfold rear end.
9. Unfold rear end
Swing rear end of the bike
until the two Suspension
Elastomers are seated against
the frame.
Remove protective packing
material.
Fig. 9 Unfold rear end.
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Assembly: Insert wheels
10. Remove rubber band
You will find it easier to
insert the rear wheel if you
first remove the rubber band
holding the chain to to the
Idler Pulley.
Fig. 10 Remove rubber band.
11. Insert rear wheel
If you have a DualDrive hub,
insert the shift pin and attach
the click box. See page 62
‘About the Dual Drive’ for
more information.
Insert rear wheel onto the
chainstays. Pull the rear
derailleur down and loop
the chain onto the cassette.
Fig. 11 Insert rear wheel.
12. Close rear brake
See page 60 ‘About V-Brakes’
for tips on closing V-brakes
(SatRDay tour model).
Fig. 12 Close rear brake.
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Assembly: Unfold boom
13. Unfold boom
Extend the boom fully and
remove protective packing
material. The front wheel
is installed in a later step,
allowing the front fork to act
as a stand while assembling
the SatRDay.
Fig. 13 Unfold boom.
TOURING MODEL ONLY:
You will have an eccentric adjustment ‘ring’ below the boom and in
front of the forls. This ring adjusts the rise of your boom to an angle
most comfortable to you. Once set, there is no need to re-adjust it
unless you desire a different rise. Please see page 50 ‘Getting a
Good Sit - Eccentric’
14. Check chain path
Make sure the chain is not
kinked and runs as follows:
From the crank, the UPPER
chain passes UNDER the
idler pulley ...
Fig. 14 Check chain path
15. Check chain path
... where it sits between the
teeth of the small, inner idler
pulley cog, and a braze-on
pin to keep it in place.
12
Fig. 15 Upper chain sits on inside teeth.
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Assembly: Install Cranks
16. Check chain path
cont’d
From the idler pulley, the
chain travels back to the rear
cassette, through the rear
derailleur and back to the
idler pulley where it sits on
the outer groove as shown.
Fig. 16 Upper chain sits on inside teeth.
17. Install right crank arm
Remove the crank from the
blue bag. The following
steps refer to the newer
2006 Shimano/FSA cranks.
See page 62 ‘About 2006
Shimano Cranks’ to see if
this relates to your model.
All other cranks require
simply tightening with a Fig. 17 Remove cap and ring.
8mm crank wrench supplied.
Unscrew the little black cap and remove the dustcap ring.
18. Install crank
Slide the crank spindle
through the hole on the
right side of the bike until it
bottoms out.
Slide the dustcap back onto
the spindle on the left side of
the bike.
Fig. 18 Insert crank, replace dustcover.
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Assembly: Install Cranks cont’d
19. Install the crank
Remove left crank from felt
bag. Install it on left side
ensuring that it is 180 degrees
opposed to the right crank.
Fig. 19 Install left crank
20. Install the crank
Replace black screw cap
and finger tighten slightly.
Locate the special circular
tightening tool, applicable
only to 2006 Shimano/FSA
cranks (see page 62 ‘About
2006 Shimano Cranks’) and
screw cap down. The tool is
designed to prevent over- Fig. 20 Replace cap and screw it down.
torquing of this cap.
21. Install crank
Using the
6mm Allen
wrench from your multitool, to initially tighten the
crank Allen most of the way.
Remember to do both sides
evenly!
For the 2006 Shimano/FSA
cranks only:
Fig. 21 Tighten crank allen bolts
Finish tightening ot the
prescribed torque with the supplied torque wrench (see page 62
‘About 2006 Shimano Cranks’). Do not over torque!
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Assembly: Install Chain/Stem
22. Install chain
Pull the chain (spring loaded
by the rear derailleur) over
the smallest chain ring.
Fig. 22 Install chain.
23. Release chain catch
Unhook the chain from the
chain catch and swing the
catch out of the way. It is
spring loaded and will stay
neatly against the frame. Recheck chain path through the
rear derailleur mechanism to
make sure it is in alignment
Fig. 23 Release chain catch.
all the way through.
24. Install stem
Start by removing the
headset protector tube and
safety plug from the head
tube as shown.
Fig. 24 Remove safety plug and protector tube.
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Assembly: Install Bars
25. Insert stem
Remove the stem from red
felt bag and pop it into the
head tube. Make sure cables
are routed behind the stem
before insertion.
Fig. 25 Insert stem.
26. Tighten stem
Turn the fork to the left until
the fork tab hits the stop.
Align the hinge to point
directly to the right. Now
turn the fork back to facing
forward (brakes are on the
back of the fork) and line up
the handlebars with the fork
Fig. 26 Tighten stem bolt.
using the upper clamp. With
the fork pointing forward, the hinge should be set to fold down to
about the 8:00 position when viewed from above. Tighten the stem
bolt with your multi tool. Tight!
27. Install handlebars
Remove the bars from felt
bags and slip into their
respective slots on the stem.
Fig. 27 Install handlebars.
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Assembly: Install Seat
28. Tighten handlebars
Make sure bars are pushed
in as far as the blue rings
will allow. Tighten BOTH
top clamp bolts as shown.
Fig. 28 Install handlebars.
29. Close stem quick
release
Close stem quick release
lever. Not that the lever can
be used to keep your sleeve
of cables neatly out of harm’s
way.
Fig. 29 Close stem quick release.
30. Install seat
Take the seat out of the large
blue felt bag and unfold so it
looks like this.
Fig. 30 Remove seat.
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Assembly: Install Seat
31. Install seat
Mount seat support bar on
rear bracket just behind your
nameplate. Don’t tighten just
yet.
Fig. 31 Mount seat support.
32. Install seat
Mount front of seat on seat
rail.
Fig. 32 Mount front of seat.
33. Install seat
Mount front of seat on seat
rail, sliding it all the way
back, and lock down the
quick release.
Fig. 33 Slide seat onto seat rail.
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Assembly: Front Wheel
34. Lock down seat
support quick release.
Double check that the seat
support quick release behind
is secure.
Fig. 34 Tighten seat support quick
release.
35. Install front wheel
Remove the fork spreader
tube from the fork. Be careful
not to lose the two small
springs that accompany
your front wheel quick
release skewer.
Fig. 35 Remove fork spreader.
36. Install front wheel
Insert skewer in front wheel
making sure: a) the tire tread
turns in the correct direction
if applicable
(usually
indicated by an arrow on
the sidewall); b) the quick
release lever will be on the
left side of the bike; c) the
tapered ends of the springs Fig. 36 Install front wheel quick release.
face towards the hub and d) if you have a computer magnet installed
on the spokes, make sure it will end up facing the sensor mounted
on the fork.
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Assembly: Front Wheel
37. Install front wheel
cont’d
Make certain the wheel
is fully seated in the fork
dropouts, and securely close
the quick release as illustrated on page 58 ‘Using a
Quick Release’. If you have
a side-pull brake, close the
small lever on the brake Fig. 37 Install front wheel.
capiter at this point.
38 . Close brake
Close front wheel brake. If
it’s hard to close, use barrel
adjuster hear handlebar to
adjust length of brake cable
for more slack.
Fig. 38 Close front brake.
See page 60 ‘About V-Brakes’ for
more info.
Fig. 38a Adjust brake cable length.
39. Install seat cushion
Place seat cushion over the
velcro tabs.
Fig. 39 Install seat cushion.
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Assembly: Install Pedals
40. Thread In Pedals
Using your fingers, start
the pedal threads into the
proper crank arm (pedals
are marked L and R). Be
careful not to cross-thread
the pedals! Once started,
you may use a wrench to
finish threading them in,
and then tighten securely. Fig. 40 Tighten pedals (tighten in
Tip: Remember to tighten opposite direction for left pedal).
your pedals by turning both toward the front of the bike.
41. Double-Check This!
At this point your bike
should be ready to ride. See
page 48 ‘Getting a Good
Sit’. However, before you
ride away, check: Are the
handlebars tight? How
about the stem and pedals?
Are the quick releases all
secure? (see page 58 ‘Using
Fig. 41. Merle sitting pretty ...
a Quick Release’). Tighten
anything that seems loose,
especially the bolts on the stem. Although we always inflate the
tires at the factory, check your tire pressure for proper inflation.
Under-inflated tires not only wear faster and are more prone to
flats, but they also add drag. Be sure to have at least the 5/6mm Swrench on hand for quick road-side adjustments. If you have the
folding tool, take it with you. You will probably want to stop and
adjust saddle height and perhaps a few other items during your
first ride or two. Finally, install racks and other accessories.
TIP! Keep a light film of grease on any intersecting bike parts to help
to prevent corrosion, facilitate disassembly, and eliminate annoying
noises. Areas include seat posts, saddle rails, handlebars, stems, seat
masts and frame fork tips. Do this a couple of times per year. Wipe
off any excess grease. Lightly grease all bolt threads as you repair or
upgrade components. Lubricating bolts will allow you to adequately
tighten the fasteners and keep them from seizing in the future.
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Packing the SatRDay: Materials
Packing Materials
Because each bike is custom made and outfitted, there is some
variation in the selection of packing materials. Common pieces for
the SatRDay include:
• Boom cover (blue vinyl sleeve).
• Bottom braket shell cover (red and yellow felt bag).
• Crankarm cover (blue vinyl sleeve for left, felt bag for chainring
assembly).
• Chainstay cover (clear thick vinyl tube).
• Steerer tube support (short plastic tube).
• Handlebar covers (red and yellow felt bags).
• Fork spreader (white plastic tube).
• Crush protector (white plastic tube with two circular end caps).
Your own bike may have other pieces. These will be labeled
according to where they go. Generally, there is extra room in the
case to accommodate some accessories such as shoes, clothing, and
perhaps a helmet. As you travel with your bike and gain experience
in your own customized packing process, you may discover that
some of the original pieces are unnecessary. You may also feel that
you may need some extra protection with new accessories. Feel free
to experiment, and let us know if you have a great idea.
Now, let’s get packing ...
22
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Packing: Packing Materials
Illustration by Merle Rothweiler, BF Final Assembly Expert
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Packing: Seat
1. Ready case and
packing materials
Remove packing materials
and place in an orderly
manner where you can see
all components.
Fig. 1 Ready case & packing materials.
2. Remove Accessories
Before disassembling and
packing
your
SatRDay,
remove all extra accessories
including racks.
Now remove the seat pad
and set aside.
Fig. 2 Remove accessories and seat pad.
3. Remove seat
Loosen front seat quick
release (with rubber handle)
and slide seat forward off
seat rail.
Fig. 3 Slide seat off seat rail.
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Packing: Seat
4. Remove Seat cont’d
Flip seat bar over as shown
and undo seat quick release.
Remove seat completely,
insert quick release back in
mount and fasten it down.
See page 58 ‘Using a Quick
Release’.
Fig. 4 Remove seat quick release.
5. Collapse Seat
Collapse the seat.
Fig. 5 Collapse seat.
6. Stow seat
Locate large blue felt seat
bag and stow seat in it.
Fig. 6 Stow seat in blue felt bag.
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Packing: Handlebars
7. Install stay protectors
Locate the clear plastic seat
stay protector tubes and
place over the seat stays.
They are notched to fit over
the brake mounts (Tour
model).
Fig. 7 Protect seat stays.
8. Remove Handlebars
Loosen the handlebar bolts
clamp using the supplied
wrench or multi-tool.
Do not loosen or remove
the small painted rings on
the bar. They allow you
to return the bars to your
personal favorite riding
Fig. 8 Loosen handlebar bolts.
position.
9. Remove handlebars
Remove both handlebars.
Place in yellow and red
felt bags (Fig 9a) for bars,
Fig. 9 Remove handlebars.
securing with a rubber band. Place
bars to right side of the bike.
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Fig. 9a Place in felt bags.
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Packing: Remove Stem/Crank
10. Remove stem
Undo the lowest stem
bolt using the 6mm allen
wrench.
Fig. 10 Unbolt lower stem bolts.
11. Remove stem
Slide the stem out of the
socket and place it into the
red felt stem bag.
Fig. 11 Place stem in felt bag.
12. New style crank
If you have a new style
Shimano or FSA crank,
identified by this exterior
cartridge-bearing cup, you
will be taking the entire
crank off - both crank arms with the supplied tightening
tool. Otherwise, you may
leave the free crank arm
on the bike but remove the
crank and chainring unit.
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Packing: Remove Pedals/Crank
13. Remove pedals
Remove the pedals and
place in the light blue felt
pedal bag.
Fig. 13 Remove pedals.
14. Loosen bolts
Loosen crank bolts with
supplied 5mm allen wrench.
Fig. 14 Loosen crank bolts.
15. Loosen crank using
special tool
Insert special crank tool
(see page 62 ‘About 2006
Shimano Cranks’) and turn
counter clockwise to release
the cap from the crank arm.
Fig. 15 Loosen crank with crank
tightening tool.
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Packing: Remove left crank
16. Remove crank cap
Remove the crank cap and
set aside.
Fig. 16 Remove crank cap.
17. Remove left crank
Remove left crank arm. Place
in the yellow felt bag and
close with a rubber band.
Fig. 17 Remove crank arm.
Fig. 17a Place left crank in felt bag.
18. Remove crank ring
Remove the crank ring from
left crank arm and set aside.
Fig. 18 Remove crank ring.
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Packing: Remove right crank
19. Remove right crank
Remove the chain from
chainrings. Pull right crank
assembly from frame.
Fig. 19 Remove chain and pull right
crank assembly.
20. Replace crank ring
Place the silver ring back
onto crank spindle.
Fig. 12 Replace silver ring onto spindle.
21. Replace crank cap
Screw the small crank cap
back onto the right crank
arm spindle.
Fig. 21 Replace crank cap onto spindle.
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Packing: R crank/Front wheel
22. Bag crank
Place right crank in crank
bag. A rubber band will help
keep it in place (Fig 22a)
Fig. 22 Stow crank assembly in felt bag.
Fig. 22a Secure with rubber band.
23. Pack right crank
Place right crank in upper
right hand corner of the
suitcase. It must sit in this
location for a successful
packing.
Fig. 23 Pack right crank in suitcase.
24. Remove front wheel
Release front brake
remove the wheel.
and
Remove the quick release
taking care not to drop the
two springs.
See page 60 ‘About Vbrakes’
Fig. 24 Remove front wheel.
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31
Packing: Important protection
25. Install fork spreader
Assemble the quick release
inside fork spreader and reinstall in front fork.
Fig. 25 Assemble quick release in fork
spreader. Fig 25a (left) reinstall in fork.
26. Install headset
protector
Slide headset protector tube
into head tube as shown.
This protects the head tube
from damage.
Fig. 26 Install headset protector.
27. Lower chain catch
Before attempting to fold
the boom, release the chain
catch and make sure chains
are caught in hook.
NOTE: if you experience
difficulties with folding the
bike further along in this
procedure, try moving this
step after step 32, that is,
Fig. 27 Release chain catch.
lower the chain catch AFTER
the frame is folded.
32
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Packing: Folding the boom
28. Protect boom
Wrap vinyl packing material
around boom and fasten
with supplied velcro straps.
Protect bottom bracket shell
with the small red and
yellow cover and fasten with
built-in velcro straps.
Fig. 28 Protect boom.
29. Fold boom
Fold boom over as far as it
will go.
Fig. 29 Fold boom.
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Packing: Folding the frame
30. Open rear brake
Open rear brake. See page
60 ‘About V-brakes’.
Fig. 30 Open rear brake.
31. Fold Frame
As you begin to fold the
frame by pushing down
on the rear end of the bike,
make sure the brake cable
(ses arrow) is not caught on
anything.
Fig. 31 Make sure brake cable is free.
32. Fold Frame cont’d
Here’s the
folded.
frame
fully
Fig. 32 Welcome to the fold!
34
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Packing: Place bike in suitcase
33. Fold Frame cont’d
Use a rubber band to secure
all the chains together and
hook it around the idler
pulley bolt. If you have the
DualDrive hub, disconnect
the click-box and remove
the shift pin. See page 62
‘DualDrive’.
Fig. 33 Tie chains together.
34. Place Bike in Case
With the bike folded, lay
it derailleur side down
and oriented as shown.
Handlebars
can
hang
outside the case to start. The
forks should face out to the
side of the travel case. As in
this example, you may need
to remove the rear wheel to
get a good fit. In which case Fig. 34 Place bike in case.
...
35. Remove rear wheel
Undo the rear wheel quick
release, remove wheel and
set aside.
Bed the frame down in the
case, letting the spindle of
the crank assembly in the
felt bag protrude through
the frame for a snug fit (see
arrow).
Fig. 34 Remove wheel.
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Packing: Pack rear wheel
36. Protect rear wheel
Remove the quick release
skewer from rear wheel and
place in your tool pouch for
safe keeping.
Place the blue vinyl cassette
protector over the cassette
using the integrated rubber
bands to lash it to the other Fig. 36 Protect rear wheel.
side of the wheel.
37. Pack rear wheel
Lay the wheel as shown,
beween rear seat stays.
Fig. 37 Pack rear wheel.
38. Pack seat
Close the top of seat bag with
a rubber band. Slip the top
of the seat under the frame,
between the fork blades.
Fig. 38 Pack seat.
36
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Packing: Pack rear wheel
39. Pack seat
Make sure the seat fits as
far down in the suitcase as
possible.
Fig. 39 Pack seat.
40. Pack handlebars
Lift rear wheel and slip
handlebars underneath.
Fig. 40 Pack handlebars.
NOTE: TravelTrailer and TravelCase (see also page 51)
The Bike Friday Travel Trailer (chassis, wheels and axle) is
designed to fit in the suitcase with your SatRDay. If it does not,
or tips the weight over the airline regulation maxiumu, stow it in
a separate bag or as part of your other luggage.
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Packing: Crush protector
41. Place crush protector
Position the crush protector
in the case and leave the
bottom disk in the suitcase
for later use.
crush protector
Fig. 41 Place crush protector.
42. Pack stem
The stem goes at the
front of the case, near the
handlebars.
stem
Fig. 42 Pack stem.
43. Protect dropouts
Cover the ends of the rear
dropouts with felt, secure in
place with rubber bands.
dropouts
Fig. 43 Protect dropouts.
38
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Packing: Fitting it all in
44. Pack front wheel
Position the front wheel and
crush protector in the case to
make sure the lid closes.
Fig. 44 Pack front wheel.
45. Pack accessories
You can fit the Bike Friday
GD folding rack and lots of
small items in the cracks.
Folding rack
Fig. 45 Pack accessories.
46. Pack seat cushion
Fold the seat cushion in
half and pack it on the
right side of the case, again
making sure the lid closes.
It’s a good idea to weigh the
seat cushion
Fig. 46 Pack seat cushion.
case to make sure it is within domestic/
international airline weight limits.
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39
Quick Folding the SatRDay
1. Before you fold
• If your bike has a kickstand,
raise it at this point.
• Shift into the small cog in
the rear - best accomplished
when you are still riding
Fig. 1 Getting ready for the quick fold.
- change to small cog in rear.
2. Before you fold
If you have a front derailleur
with two or more chain rings
in front, shift the chain into
the small chain ring.
Fig. 2 Change to small cog on front.
3. Position chain catch
Pop the chain catch out from
where it is seated, next to
hinge. Elastic will keep it
attached to the frame. Swing
hook under chain as shown.
Fig. 3 Engage chain catch.
40
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Quick Fold
4. Loosen handlebars
You’ll need the supplied
allen wrench, which can
be optionally stored in the
sleeve holding the cables
together. You can also
use the appropriate sized
wrench in a standard bicycle
multitool.
Fig. 4 Locate allen wrench to unbolt
bars.
5. Loosen handlebars
cont’d
Loosen the bars by turning
wrench counter clockwise.
Do not loosen the bolts on
the painted rings. They help
‘remember’ your handlebar
position.
Fig. 5 Unbolt bars.
6. Fold handlebars
Bring handlebars up and
together.
Fig. 6 Bring handlebars together.
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Quick Fold
7. Open stem quick
release
Open stem quick release.
See page 58 ‘Using a Quick
Release’.
Fig. 7 Open stem quick release.
8. Rotate bars clockwise
Swivel the handlebars and
stem as one unit 180 degrees
clockwise (to the right).
Fig. 8 Rotate bars clockwise.
9. Release lower stem
quick release
Holding bars in place with
right hand, open stem quick
release with left hand and
lift it up to disengage.
Fig. 9a Release lower stem quick
release
Fig. 9b Detail
42
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Quick Fold
10. Fold bars
Let stem and bar unit fold
down on right side of the
bike.
Fig. 10 Fold bars.
11. Position front crank
Rotate pedals to approximately this position.
Fig. 11 Position front crank.
12. Lift boom
Lift the boom
towards the seat.
upwards
Fig. 12 Lift boom towards seat.
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Quick Fold
13. Lift boom cont’d
The chain will slide across
stem hinge, which is
protected by a clear plastic
guard.
Fig. 13 Lift boom cont’d.
14. Open seat quick
release
Open the seat quick release
Fig. 14 Open seat quick release.
15. Release seat
Release front of seat from
frame.
Fig. 15 Release seat from frame.
44
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Quick Fold
16. Flip seat
Flip the front of the seat up
and over seat support bar.
Fig. 16 Flip seat over.
17. Flip seat
Let the seat rest on ground
behind rear wheel.
Fig. 17 Rest seat on ground behind rear
wheel.
18. Remove safety strap
This strap is used to secure
the bike in the unfolded
position.
Fig. 18 Close strap.
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45
Quick Fold
19. Fold frame
Grasp main tube with right
hand and using your right
foot, swing rear wheel
towards front wheel. The
front wheel should be turned
180 degrees.
Fig. 19 Fold rear wheel.
20. Fold frame
Bring the rear wheel towards
the front wheel. It may be
necessary to turn the front
wheel slightly so that it clears
the rear derailleur.
Fig. 20 Bring rear wheel in.
21. Fold boom and seat
Swing boom over to meet
the main tube. If it does
not, repeat from step 19 and
don’t swing the rear wheel
quite so fast or far this time.
Finally, fold the seat over.
NOTE:
bikes with an extra
long boom may cause the
Fig. 21 Fold boom and seat.
chainring to come in contact
with the seat support frame. In this case, loosen the seat support
bar quick release lever all the way and completely remove seat.
46
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Quick Fold/TravelBag
22. Welcome to the fold!
Sierra Lapchynski and Dave
Seybert demonstrate a fold well
done.
Fig. 23 The SatRDay folded.
23. Travel Bag
Merle shows a SatRday
folded and placed in the
soft TravelBag. Generally
the wheels should lie at the
bottom of the bag, Close the
sides, fasten the clips and ...
Fig. 24 Place in TravelBag.
24. Travel Bag cont’d
... take it away! There is also
a shoulder strap attached for
added convenience.
26. Unfolding Your
SatRDay
Fig. 24 Into the soft bag for transport.
Unfolding your bike into riding condition is just the reverse of
these steps. Before you ride your bike again, double-check to make
certain that all of the quick releases and handelbar bolts are secure,
the chain is on the idler pulley and chainrings, and the cables aren’t
kinked or pinched, and are seated properly in the shifters and
brakes.
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47
Getting a Good ‘Sit’
on Your SatRDay
Bike Friday Sales
Expert and Recumbent
specialist Dave Seybert
offers pertinent pointers
on getting a good ‘sit’ on
the new SatRDay
The first aspect to focus on
is the fore/aft position of
the seat on the track that it
slides on.
This is done by loosening
the quick release under the seat with the black rubber handle, and
sliding the seat base forward or backward. Just like an upright bike,
you want to have the seat positioned so that your leg is almost
fully extended, but your knees are not locked, when your foot is at
furthest point away from you in the pedalling cycle. Don’t extend
your toes out to reach the pedals either, just let your foot and ankle
move in a comfortable range of motion.
The next step is to set the angle of the seat back.
This is done by loosening the two small screws where the rectangular support behind the seat changes from black to silver. You
can slide the silver upper portion in and out of the black portion to
change the angle.
Don’t pull the
silver section out
past the knurling
marks
at
the
minimum insertion
point. The flat
center section of
the seat should be
around 45 degree
to the horizontal.
The exact position
is a matter of Sue McWilliams takes her new bent for its maiden
preference,
but spin ... July, 2006
should allow you
48
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Getting a Good ‘Sit’ (cont’d)
Larry Varney writes for www.bentrideronline.com. photo by Jim Harris.
to see over the handlebars, and not strain your neck.
Finally, you want to set the fore/aft position and height of the
handlebars. To do this, you will need to loosen the two large hex
bolts at the top of the stem, and the smaller bolts on the colored
rings just in front of the stem clamp. The objective is to position
the bars so that your arms are relaxed and slightly bent, with
your upper arms just grazing your ribcage. You can move the bars
forward and back, and “butterfly” them up and down until you find
the right position. It shouldn’t take any effort to hold your arms up
or extended with the steering centered, otherwise the handling will
feel wobbly when your arms get tired.
Until you find the right position, just tighten the big hex bolts;
they hold the bars in place. The smaller bolts on the colored rings
are there to “remember” the position when you are folding and
unfolding the bars.
Once you get the bars where you want them, slide the rings back
against the stem clamp. Next, twist one ring until the bottom of
the hex bolt is touching the other bar. Tighten it, and then twist the
other ring until the bottom of its hex bolt is touching the first hex
clamp. When you have both tightened, they will stop the bars in the
right position when you unfold the bars.
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49
Getting a Good ‘Sit’ : Eccentric
The Eccentric:
A Special Fit
Feature of the
SatRDay Touring
model
On the SatRDay
Tour model, the
height
of
the
bottom bracket is
adjustable. When
you took delivery
of your SatRday, Close up of the ‘eccentric’ - used for adjusting the
the bottom bracket height of the bottom brac ket and pedals.
was set to the
highest position. You can adjust the height of the bottom bracket
and pedals to your preference by turning the eccentric inside the
cradle that the folding boom rests on. You will need a 5mm allen
wrench (your multi tool has one) and pair of needlenose pliers or a
Park Tool pin spanner (the right one has a green vinyl handle).
Loosen the outer ring on the eccentric with the Allen wrench and
hold it in place, with the boom cradle at 12 o’clock. Put the tips of
the needle nose pliers (or the pins on the spanner) in the indentations on the eccentric and rotate it forward.
Tighten the bolt on the outer ring to secure the cradle in the new
position. The cradle should be flush with the bottom and one side
of the boom to reduce boom flex.
Before you ride, spin the cranks and turn the front wheel from side
to side to make sure that the pedals or your foot won’t interfere
with the tire (or fender) on the down stroke of the pedal. That
would limit your ability to steer in certain situations.
It may be necessary to revisit the earlier steps of the fitting process
to fine tune your riding position to his new adjustment.
For more tips, see www.bikefriday.com/satrday
50
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Accessories: TravelTrailer
The Bike Friday TraveCase
(suitcase) has undergone
several changes over the
years, and many are still in
use. Pictured is the original
Samsonite suitcase. The
TravelTrailer
(chassis)
has
largely
remained
unchanged.
1. Trailer Parts
Fig. 1 Travel Trailer parts.
If you purchased a Travel­Trailer with your bike, you should have
two trailer wheels and two yellow felt bags with the tongue and
axle. The bottom of your TravelCase should have three holes drilled
in it if you ordered the trailer with your bike. If you ordered the
TravelTrailer system separately, you will need to find the three
dimple marks in the bottom of your case and drill them through
2. Connect Axles
In the smaller yellow felt
bag there should be two
axles and a T-bar. Slip the
open ends of the axles over
the “T” of the T-bar. Each
axle will have a threaded
stud with a thumb nut and
two flat washers. Remove
the thumb nuts and one of Fig. 2 Assemble trailer axle.
the washers from each stud
(leaving one washer over each stud post).
3. Attach Trailer Axle
With the case open and
standing on its left side,
attach the axle assembly by
slipping the two threaded
studs through the two holes
in the right side of the case.
The end of the T-bar should
be pointing at the third hole
Fig. 3 Attach trailer axle.
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Accessories: TravelTrailer
4. Add Thumb Nuts
Place one of the flat washers
over each threaded stud, and
then loosely thread on the
thumb nuts—do not tighten
them yet.
Fig. 4 Attach washers & thumb nuts.
5. Attach Trailer Tongue
Take the long trailer tongue
and remove the thumb
nut and one washer from
the threaded stud. Slip the
hollow end of the tongue
over the end the of the T-bar
so that the threaded stud
in the tongue fits into the
Fig. 5 Trailer tongue over T-bar.
remaining hole in the case.
6. Add Last Thumb Nut
Place one flat washer over the
threaded stud inside the case
and add the last thumb nut.
Now securely finger tighten
all three thumb nuts inside
the case. Each attachment
point should be a sandwich
consisting of trailer frame,
flat washer, nylon case, flat Fig. 6 Tongue thumb nut.
washer and then thumb nut.
52
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Accessories: TravelTrailer
7. Wheel Axles
From one axle end remove
the clevis pin, the flat washer
and the rubber O-ring. Note
the order of these parts when
installing the trailer wheel.
Fig. 7 Axle washers.
8. Install Trailer Wheel
Each trailer wheel has two
bearings; one is flush with
the outside of the wheel, and
the other is recessed. Slide
the trailer wheel over the
axle end with the recessed
side down and the flush side
up (away from the trailer).
Fig. 8 Mount trailer wheel.
9. Add Axle End Washers
First install the rubber Oring so that it sits next to the
wheel bearing. Then install
the flat washer over the Oring.
Fig. 9 First add O-ring, then flat washer.
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Accessories: TravelTrailer
10. Insert Clevis Pin
Insert the clevis pin through
the hole in the axle end to
secure the wheel. The flat
washer should be lightly
pressing against the clevis
pin from the inside, with
the O-ring acting as a sort
of spring to keep the wheel
Fig. 10 Insert clevis pin.
from rattling on the axle.
11. Connect Trailer Hitch
To attach the trailer hitch to
your frame, simply pull the
knurled collar on the coupler
back while you push the
coupler over the nipple on
the frame.
Fig. 11 Using your trailer hitch.
12. Ready To Go!
When you release the
knurled collar, the coupler
should be secure and ready
to go. If the knurled collar
becomes stiff and does not
spring closed, add some light
lubricant such as TriFlow™
or WD-40® to the coupler.
54
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Fig. 12 Trailer hitch connected.
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Accessories: Folding Rear Rack
1. GD Folding Rear Rack
This ingenious handmade
folding cro-moly rear rack,
named after its inventor
Gavin Donahue formerly
of Bike Friday, will securely
carry your travel gear
anywhere in the world.
Plus, it folds quickly and
Fig. 1 GD Folding Rear Rack.
compactly for easy packing
in your TravelCase suitcase. The GD rack is packed in a yellow felt
bag, and has two extra 5mm bolts for mounting it to your bike. (The
other two required bolts are already in your frame.)
The SatRDay variant is mounted a little differently from the other
Bike Friday models. See following section.
2. Unfold Rack
The two sets of main legs
unfold down, while the
two black aluminum stays
unfold over the top.
Fig. 2 Unfold GD rack.
3. Insert 5mm Bolts
Let the holes in the main
legs overlap at the bottom
and then insert a supplied
5mm bolt through each pair
of legs.
Fig. 3 Place bolts through leg holes.
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Accessories: Folding Rear Rack
The following instructions
are specific to the
SatRDay model only.
4. Mount Legs To Frame
Thread the bolts into the
eyelets on the drop outs on
each side of the bike. The
rack legs should have their Fig. 4 Mount rack legs to drop outs.
ends on the outside of the
drop outs. Leave the bolts loose for now.
5. Attach Struts
The pair of narrow front strut
attaches to the rear bolts (Fig
5a). The pair of rear struts
Fig. 5a (left), 5b (above) Attach struts
crosses over the front struts and
attaches to the forward bolts (Fig
5b)
6. Attach struts cont’d
Attach pair of wide front
struts to the bolts on the
frame as shown. Tighten all
mounting bolts securely. If
you would like to attach a
rear reflector or a rear tail
light, there is a threaded
mount on the rear of the
Fig. 6 Tighten all bolts securely.
rack.
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Accessories: Fenders
1. Front Fender
Your front fender has an
alignment pin (a small bolt)
through the aluminum tab
beneath the mounting hole.
The fender is attached to the
fork by the upper hole, while
the alignment pin keeps
the fender from rotating.
Example shown is a SatRDay Fig. 1 Front fender.
Tour - note the eccentric adjustment ring for the boom.
2. Rear Fender
Your rear fender has one hole
in the aluminum tab, and
the fender extends farther
forward of the tab than the
front fender. The fender is
attached to the rear end by
the bolt in the wish bone.
Fig. 2 Rear fender.
Stay nice and
dry on the road!
says long time
SatRDay owner
and Bike Friday
Customer Service
Rep Hugh
Larkin.
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57
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 - and 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 travel bike
has several of them. If you are not familiar with their operation,
PLEASE study these directions 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 about 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 to come.
Open
(Loose)
Knurled Nut
(adjust tightness here)
(Starts
getting
tight
here)
QR Lever
Closed
58
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(Stiff)
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Using a Quick Release
1. Adjust Knurled Nut
With the wheel installed
and the axle properly seated
in the frame (or the frame
joint closed), position the
QR 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 QR is properly Fig. 1 Quick release operation.
adjusted, you should be able to freely swing the QR lever for the
first half of its arc, at which point the lever should offer resistance.
2. Continue Closing QR
Using the palm of your hand
press the QR lever through
the rest of its arc until the
lever is closed and parallel
to the wheel. You should feel
very firm resistance when
the QR is properly adjusted
(the lever may even leave a
light imprint in the palm of Fig. 2 Setting quick release tightness.
your hand).
3. Double-Check!
Ideally, the QR lever should
be facing rearward, or
upward. Levers which are
facing forward can catch on
any number of things and be
accidentally opened.
Convention usually has the
front wheel quick release
Fig. 3 Closed QR pointing rearward.
lever on the left side of the
bike, although this is not critical.
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59
About V-brakes (Tour model)
Reconnect V-Brake
If you have a V-brake, before
closing it, check to make
certain that the housing
is properly seated into its
ferrules (metal end tubes)
at both ends. With the brake
open, the housing can slip
to the side and keep the
brake from closing properly. 1. Check housing for seating.
Common places to check are the brake lever barrel adjuster (top),
and where the housing enters the noodle (bottom).
Close V-Brake
To close the V-brake, press
both arms together (A), and
insert the noodle (B) into the
noodle holder (C).
B
A
The end of the noodle has a
bullet shaped tip that should
be inside the holder, but just
sticking through the cable
2. Close V-brake.
keyhole.
C
Double-Check Brake!
Regardless of which model
of brake you have, make
certain your brake is properly
set up. Test squeeze the
brake levers; you may have
to adjust the barrel adjuster
to remove any excess cable
slack. A final check can be
done after the rest of the bike 3. Proper noodle tip position.
is assembled.
Continued next page.
60
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A
About V-brakes, cont’d
Opening Front Brake
If you have a side-pull brake,
simply flip up the small lever
on the side of the brake (not
shown).
B
If you have V-brakes, press
the arms together (A), and
A
A
then pull the elbow-shaped
C
noodle out and up (B) while
Fig. 4 Open brake arms (V-brake).
pushing the noodle holder
down (C). There is a slot in the end of the noodle holder for the
brake cable to slip out.
Removing Front Wheel
After removing the front
wheel, close the brake again.
Remove the quick release
from the axle by undoing the
knurled nut. Be careful not to
lose the small cone-shaped
springs. Because of the
special ‘lawyer lips’ which
are designed to prevent the Fig. 5 Remove front wheel.
wheel from falling out when riding, you may have to jiggle the
wheel a bit to allow it to drop out.
Put the quick release through the fork spreader (the short PVC
dowel), and thread on the knurled nut again. Both small coneshaped springs should be on the quick release shaft.
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About 2006 Shimano Cranks
How to use the torque
wrench (supplied)
If you ordered your SatRDay
with 2006 Shimano 105,
Ultegra or Dura-Ace cranks,
you will notice two 6mm
bolts on either side of the
crank spindle. These must Fig. 1 Torque wrench supplied
be tightened with a special
torque wrench supplied
with your bike (Fig 1). The
wrench prevents overtightening and thus voiding the
warranty. Shimano’s Sora,
Tiagara, and all other nonShimano name cranks do
not have these bolts, and
are tightened in the usual Fig. 2 First tighten with 6mm wrench
manner with a standard
8mm wrench or the little removeable Allen
Fig. 3
head that comes with your multi-tool - the
106 inchwrench or multi tool will come with your
pounds
bike.
To use the torque wrench: First, tighten
the crank bolts with your 6mm wrench.
Next, calibrate the wrench to 106-132
inch-pounds (12-15 Newton Meters) as
follows: screw the barrel up to the 95 mark
on the vertical scale, then turn the barrel so
that the mark representing 11 is lined up
with the center line on that scale (95+11 =
106 - see Fig 3. Insert the head in the bolt
and start turning clockwise. When the
maximum calibrated torque is reached,
the tool will ‘spin out’ and not allow you
to tighten the bolt any further.
Fig. 4 Tightening tool
These newer cranks also come with a
special tightening tool for the crank spindle itself (Fig 4). This tool
is also used to prevent overtightening.
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DualDrive™ Hub
Using Your Optional DualDrive Hub
For many bike travelers, the DualDrive hub offers the perfect
combination of wide gear ratios, simplicity, and durability.
As with a standard drive train, there is no single best shifting order
on a DualDrive equipped bicycle. Experiment and find what works
well for you. A cyclist with a standard drive train must be conscious
to avoid cross-chaining, which occurs when you shift into a small
gear in front and a small one in back, or a vice versa. Cross-chaining
can cause excessive wear on your components. Since cross-chaining
is not an issue with the DualDrive hub, any gear combination is
acceptable.
Other benefits include being able to shift the hub when standing
still at a stop light or the bottom of a hill. Simply shift the internal
hub to a lower gear (without even pedaling) and off you go.
The DualDrive single-sided shifter has an icon depicting uphill,
flat, and downhill terrain to identify low, middle, and high gears.
If your Bike Friday travel bicycle is equipped with different shift
levers, the left hand lever controls the internal hub. Pulling the
cable in shifts the hub to a higher gear for descending hills. For
those who are curious about the gear ratios, adjust your gear inches
for low gear by 73%, mid-range 100% (1:1), and high gear 136%.
Maintenance
Your DualDrive hub requires little maintenance. The shielded
bearings are very durable, and the internal mechanism is highly
reliable. Periodically applying a little oil to the shifting rod is all
that is required. If you ride casually, then once a year is sufficient.
If you ride a lot more or in poor weather, then every six months
will suffice. We recommend a service inspection/overhaul every
2 years or 3000 miles, which ever comes first, to ensure optimum
hub performance.
To lubricate the rod, remove the click box and the shifting rod (see
the following directions). Lay the bike on its left side, or remove the
wheel and then lay the wheel on its left side. Dip or coat the shifting
rod in a good quality synthetic oil such as Phil Wood Tenacious Oil.
Do not over lubricate!
Let the bike or wheel lay on its side overnight. Then re-attach the
shifting rod (do not over tighten) and the click box.
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DualDrive Hub
1. The Click Box
The DualDrive shift cable
connects to a grey and/or
black box attached to your
rear hub axle above the
rear derailleur. To install
and remove the rear wheel
you will need to detach and
reconnect this click box to the
Fig. 1 The click box.
axle in a few simple steps.
Start by shifting the DualDrive hub into the lowest gear (uphill
icon, or repeatedly press the small lever on STI shifters).
2. Attachment Button
The small black button
on the click box is used to
attach the box to the axle.
In the up position the box is
connected.
To remove the click box,
press this button down until
it is flush with the top of the
Fig. 2 Click box button up (connected).
box.
3. Remove Click Box
With the black button down,
the click box should just slide
off of the axle end. The click
box will remain connected to
the shift cable.
Fig. 3 Click box button down (detach).
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DualDrive Hub
4. Shifting Rod
Underneath the click box is
a small screw head called
the shifting rod. The click
box pulls or pushes this rod
in and out to shift gears.
Normally you do not need
to remove this rod to remove
the wheel.
Tighten
Loosen
Fig. 4 Shifting Rod.
However, be careful not to
bend the rod head. If you need to remove the rear wheel to pack
your bike or fix a flat, either remove the rod and keep it in a safe
location or put the protector sleeve (required for only a few bike
models) over the axle and pin head.
If you wish to add some oil to the hub, remove the shifting rod and
dip or coat the rod with good quality oil. See the paragraph on hub
maintenance for more information.
When screwing the shifting rod back into the hub, be careful not to
over-tighten. Just lightly tighten the shifting rod with a flat screwdriver, until snug.
5. Removing Rear Wheel
With the click box removed,
loosen the two axle nuts
with a 15mm wrench, a
crescent wrench, or your
pedal/headset wrench in
the tool pouch. The wheel
should slide out.
Loosen
Tighten
The axle washers have
Fig. 5 Axle washer, bottom view.
a tab on one side. When
reinstalling the rear wheel, place the washers on the outside of
the drop outs (the part of the frame which holds the wheels), with
the tab pointed down and facing toward the wheel. With the axle
properly seated in the drop outs, tighten the axle nuts securely.
Do not forget to reconnect the brake after installing the wheel!
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DualDrive Hub
6. Reattaching Click Box
To reattach your click box
to the axle, first ensure the
black button is all the way
down, flush with the top as
in Figure 3. If you cannot
get the button down, it is
because the shift cable pulled
the small black shifting fork
(circled in Figure 6 and 6a) Fig. 6 Shifting fork down, button down.
out of its proper position.
This can happen when the
click box hangs by the shift
cable. First, make certain
the shift cable housing is
properly seated at the shift
lever, any cable stops, and in
the click box barrel adjuster.
Next, to get the button
Fig. 6a Shifting fork up, button stuck.
down, push the fork tip
down toward the hole in the box with your finger while applying
pressure to the black button. You may need to keep your finger on
this button to keep it from popping up from cable movement.
7. Mount Click Box
With the button down,
place the click box over
the axle as far as it will go,
and then press the black
button up. Your click box
is now properly connected.
With very gentle tugging,
you should only feel slight Fig. 7 Place over axle end.
spring-like resistance.
Fig. 7a Button up (connected again).
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DualDrive Hub
8. Adjusting DualDrive
The
DualDrive
hub
adjustment is very simple.
First shift the DualDrive into
the middle gear (flat terrain,
or middle STI position). On
top of the click box is a small
clear window showing a
couple of ladder-like bars
over a brightly colored Fig. 8 Adjusting window.
indicator needle.
Turn the tapered barrel adjuster, where the housing enters the click
box (Figure 8a), until the needle is centered between the bars in
the clear window. It’s that
simple. When you move the
Needle In
shift lever you can see the
needle move to the different
positions.
All new bikes will need
some initial adjustment
Needle Out
as parts wear in, housing
compresses and the cables
stretch. If your bike does not Fig. 8a Barrel adjuster.
shift properly, take it to your
local bike shop for adjustment. Before long, however, your bike
should be functioning trouble free.
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Trouble Shooting
V-Brake Centering And Spring Adjustment (Touring models)
V-brake arms are held off of the rim by a spring in each arm. To
center the brake (allowing both arms to retract an equal amount),
you need to adjust the respective spring tensions. At the base of
each V-brake arm near the pivot is a small screw pointing to the
side. Turning this screw will change the centering of the brake.
On the side which needs to retract farther, tighten this screw in
half-turn increments. You may also consider loosening the side
which retracts too far.
Thread Sizes
The stainless steel bolts that attach your rack to your bicycle use one
of the most common thread sizes available today. If you loose one
of these small bolts you will most likely find replacement hardware
locally.
The thread size for the rack, water bottle cage, derailleur and brake
cable clamp bolts is a metric 5mm x 0.8mm. A US standard thread
of 10-32 can also be used. The thread size for many of the frame
parts and the front rack cross bar is a slightly larger 6mm x 1.0mm.
Every bike shop and virtually any hardware store world-wide will
stock these bolts in a variety of lengths.
If you are unable to find replacements while on tour give us a call
or send us an email and we can ship to you what you need to get
back on the road.
What is it?
This little mysterious tool is supplied with
Shimano crank arms. To remove the new
generation of Shimano crank arms with the
over-size bottom bracket spindles you need to
use this temporary plug with your crank arm
removal tool.
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Bike Friday Service
New Bike Maintenance
Like all bikes, your Bike Friday travel bike will go through a breakin period. After the first few weeks of riding you may find that your
drive train doesn’t shift as crisply as it did when new, or perhaps
the brakes are slightly loose. This happens as new cables stretch,
housing compresses and parts wear in.
After the initial break-in period, but before a significant tour, it is
important to have your Bike Friday bicycle professionally serviced
at your local favorite bike shop. A new bike tune up takes very
little time and the small cost for the work is minor considering the
improved performance and reliability it provides. Then at least
once a year and before any major tour, take your bike back to your
local shop for another tune-up to be sure that it runs smoothly.
After a few years of use and a few thousand miles of riding, you
may notice that the decals on your bike are starting to look worn
and the paint has some scratches. Perhaps your bike doesn’t
ride as smoothly as it used to, and the local bike shop can’t get
it to function as well as you would like. We offer factory service
programs including tune-ups, overhauls, and other repair work by
our expert mechanics. A month or two before your next big ride,
you may wish to send the bike back for a complete overhaul.
Visit our web site for repair packages, costs, and details at
www.bikefriday.com/ServiceCenterInfo.cfm. For those who plan
ahead, we can generally offer the quickest repair turn-around
during the winter months.
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Travel Tips
Airport Security
Traveling with your Bike Friday on the airlines today will, for the
most part, be as convenient as it was just a few years ago in the
good old days. However, because of the need for extensive inspections required by the TSA, there are a few points to be aware of.
• Do not lock your TravelCase when traveling by air. All luggage
must be inspected by TSA agents when checking in your luggage.
TSA agents can, and have, broken open locked TravelCases. Even
after the initial inspection do not lock your case, we have had
reports of subsequent inspections where the TravelCase lock was
broken open.
• You may ask to be present during the inspection, however you
may not touch your bike or TravelCase once you have handed it
over to the TSA. By asking to be present, you may be able to give
some repacking tips to a very busy agent.
• When traveling by air, you might consider not over packing
your TravelCase. With some practice it is quite possible to get a
tremendous amount of gear into your TravelCase; however this
only obscures the inspectors view and they will deconstruct your
carefully packed case.
• Consider using extra straps, bungee cords, or toe straps to bundle
the packed bike. This way an inspector can remove the bike as
once piece, look it over, and replace it into the case quickly and
accurately. A laminated photo of your bike folded and unfolded
may also dissuade inspectors from unpacking the bike.
• Luggage weight limitations: for domestic flights (including
domestic legs of international flights), the checked luggage must
tweigh less than 50 pounds to avoid excess baggage charges. For
international flights, the checked luggage limit is between 50 and
70 pounds depending on the airline - find out before you fly.
Bike Friday®, the Bike Friday® logo, Green Gear Cycling®, Pocket Rocket™,
Pocket Rocket Pro™, Pocket Pilot™, Air Friday™, Triday™, Pocket
Crusoe™, Pocket Tourist™, New World Tourist™, Air Glide™, Pocket
Llama™, Pocket Gnu™, Air Llama™, Family Tandem Traveler™, Tandem
Traveler™, Ti Lite XL Traveler™, Tandem Two’sDay™, Twin Air™, Q
Tandem™, Sat R Day™, Double Day™, Travel System™, TravelTrailer™,
TravelCase™, as well as certain other marks are trademarks exclusively owned
by Green Gear Cycling, Inc. in the U.S. and/or other countries. No such marks,
names or logos may be used without prior written consent.
70
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Warranty Information
Bike Friday Guarantee
We at Green Gear Cycling Inc. (Bike Friday) want you, the customer, to be
happy with your new bicycle. If for any reason you are dissatisfied you
may return the bicycle to us within 30 days for a full refund, less return
shipping charges. This applies to purchases of new bicycles. We also
accept returns on parts within 30 days as long as the part is unused and
undamaged. In all cases, the return shipping charges are your responsibility. To take advantage of this guarantee, you must notify us within 30
calendar days of receiving the bike of your intent to return the bike and
the bike must be received by us within 35 calendar days of you taking
delivery of the bike.
Limited Warranty:
As part of the consideration for buyer’s purchase, buyer understands and agrees
to the following: Green Gear Cycling warrants your bicycle frame set, including
fork purchased from Green Gear Cycling or an authorized Green Gear dealer
against defects in workmanship and materials for as long as the original owner
has possession of the bicycle. This does not cover paint or powder coat finishes.
Green Gear Cycling honors the original manufacturer’s warranty on parts and
components against defects in manufacturing. Tubes and tires are sold as-is.
This warranty is expressly limited to the repair or replacement of the defective
frame, fork, or defective part at the discretion of Green Gear Cycling. This is the
sole remedy of the warranty. This warranty applies only to the original owner and
is not transferable.
Claims must be made through Green Gear Cycling or an authorized dealer. Proof
of purchase is required. This warranty covers bicycles and components purchased
outside of the United States only if purchased through an authorized Green Gear
Cycling dealer.
This warranty does not cover normal wear and tear, improper assembly or maintenance, folding or unfolding, or installation of parts or accessories not originally
intended or compatible with the bicycle as sold. Under no circumstance(s) shall
Green Gear Cycling be responsible for incidental or consequential damages.
This warranty gives you specific rights, and those rights may vary from place
to place. This warranty does not affect the statutory rights of the consumer.
The 30-day money back guarantee and our warranty apply to bicycles and
parts purchased directly from Green Gear Cycling, Inc. Customers who have
purchased bicycles and parts from dealers must abide by the dealer’s policies.
Except as provided herein, this product is provided “as is” without any additional
WARRANTY of any kind, including the WARRANTY OF MERCHANTABILITY
and the WARRANTY of FITNESS FOR A PARTICULAR PURPOSE, whether
EXPRESSED or IMPLIED.
Welcome to the fold, and have a great trip!
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Notes
72
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