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Bike Friday Family Tandem Traveler User Manual

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Using Your Bike Friday®:
• Family Tandem Traveler
Tandem Traveler XL
Ti Lite XL Traveler
Tandem TwosDay
• Project Q
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 • info@bikefriday.com
4/29/04
Brent Curry and Gary Pluim cycle from Calgary to the source of the Bow River on a
Two’sDay and canoe: Photo by David Garden.
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Bike Friday Family Tandem Traveler Specifications

General IconGeneral
Frame MaterialChromoly Steel
Wheel Size20 inches
FoldingYes
Gear SystemShimano
Weight Capacity400 lbs
Gearing27-speed
BrakesV-Brakes
Suitable ForTouring

Summary

Safety and Tools

General Safety Guidelines

Essential safety practices for riding and maintaining your Bike Friday bicycle.

Your Tools

Details about the tools provided with your Bike Friday bicycle for assembly and maintenance.

Using a Quick Release

Quick Release Operation

Explanation of how a quick release cam lever functions to secure components.

Adjusting and Securing Quick Release

Step-by-step guide on properly adjusting and securing quick release levers for safety.

Getting Started and Unpacking

Where to Begin Assembly

Initial steps and recommendations for preparing to assemble your Bike Friday bicycle.

Unpacking Travel Cases

Instructions for removing components from the travel case and preparing for assembly.

The Goodie Bag

Contents and purpose of the "Goodie Bag" containing miscellaneous bike parts and literature.

Assembly: Mid Top Tube

Tool Pouch Contents

Details on the tools and items included in the bicycle's tool pouch.

Mid Top Tube Installation

Guide for orienting and inserting the mid top tube into the frame sockets.

Assembly: Bottom Tube

Bottom Tube Orientation

Instructions for orienting the bottom tube before connecting it to the frame.

Connecting Frame Halves

Steps for joining the front and rear frame sections using the bottom tube.

Assembly: Connect Frame

Press Frame Together

Procedure for joining the frame halves and aligning the seat tubes.

Set Cable Stop Ring

Instructions for positioning and tightening the cable stop ring on the bottom tube.

Assembly: Drum Brake

Install Rear Wheel

Guide for installing the rear wheel into the frame dropouts.

Drum Brake and Brake Arm Pin

Steps for mounting the drum brake and engaging the brake arm pin.

Assembly: Timing Chain

Mount Brake Housing

Instructions for mounting the brake cable housing into the cable stop.

Connect Cable Splitter

Procedure for connecting the two halves of the brake cable splitter.

Install Timing Chain

Guide for installing the timing chain, noting its silver connector links.

Assembly: Drive Chain

Match Timing Marks

Aligning timing marks on chain rings before mounting the timing chain.

Mount and Attach Drive Chain

Steps for mounting the timing chain and attaching the drive chain.

Assembly: Captain Stem

Adjust Timing Chain

Adjusting the timing chain tension for proper operation before installing the stem.

Stem Installation and Safety

Procedures for installing, securing, and ensuring safety of the captain's stem.

Optional Adjustable Stem

Guide for adjusting and using the optional adjustable stem for personalized fit.

Assembly: Handlebar

Handlebar Installation

Steps for inserting and setting the captain's handlebars into the stem.

Tighten Handlebars

Instructions for securely tightening the handlebar clamp bolts.

Assembly: Connect Cables

Connect Cables

Guide for connecting the various cable splitters along the frame tubes.

Rear Brake Cable

Instructions for routing and connecting the rear brake cable.

Assembly: Front Wheel

Remove Fork Spreader

Procedure for removing the fork spreader before installing the front wheel.

Front Wheel Installation

Guide for properly installing the front wheel into the fork dropouts.

Assembly: Seat Masts

Seat Mast Installation

Guide for inserting and orienting the seat masts into the frame tubes.

Stoker Seat Post Installation

Procedure for inserting and setting the stoker seat post height.

Tighten Seat Post

Instructions for securely tightening the seat post and seat mast collars.

Assembly: Pedals

Captain Seat Post & Stoker Handlebar

Steps for setting the captain seat post and aligning the stoker handlebar.

Pedal Installation

Guide for correctly threading and installing the pedals into the crank arms.

Final Bike Checks

Performing final checks on the bike after assembly, including tire pressure and fasteners.

Packing: Pedals & Seat Posts

Remove Accessories

Instructions for removing large accessories before packing the bicycle.

Remove Pedals

Procedure for loosening and removing the pedals from the crank arms.

Remove Stoker Seat Post

Steps for removing the stoker seat post from the frame.

Packing: Seat Masts

Remove Captain Seat Post, Stoker Stem & Bars

Instructions for removing the captain seat post, stoker stem, and handlebars.

Remove Seat Masts

Procedure for removing the seat masts from the tandem frame.

Open Brakes

Instructions for opening both the front and rear bicycle brakes for packing.

Packing: Front Wheel

Remove Front Wheel

Steps for removing the front wheel and preparing the quick release.

Install Fork Spreader

Procedure for inserting the fork spreader into the fork dropouts for protection.

Open Cable Splitters

Instructions for disconnecting all center section cable splitters.

Packing: Remove Stem

Remove Captain Handlebars

Steps for loosening and removing the captain's handlebars from the stem.

Remove Captain's Stem

Procedure for removing the captain's stem from the fork steerer tube.

Adjustable Stem Removal

Guide for removing an adjustable or fit stem for packing.

Packing: Loosen Mid Frame

Unhang Drive Chain

Procedure for unhooking the drive chain from the chain rings.

Loosen Frame Clamps

Instructions for loosening all frame clamps holding the center section together.

Remove Timing Chain

Steps for derailing and removing the timing chain from the bicycle.

Packing: Rear Wheel

Separate Frame

Instructions for separating the frame halves by sliding the over-clamp forward.

Remove Center Tubes

Procedure for removing the top tube and bottom tube from the frame.

Remove Rear Wheel

Guide for removing the rear wheel after the frame is separated.

Packing: Drum Brake

Unscrew Cable Splitter

Procedure for unscrewing the drum brake cable splitter.

Release Brake Housing

Instructions for releasing the brake cable housing from the cable stop.

Remove Wheel

Steps for removing the rear wheel, ensuring the brake arm clears the dropout.

Packing: Materials

Packing Materials Overview

Description of various labeled packing protection pieces for frame components.

Packing: Front End

Pack Front End

Instructions for placing the front end of the tandem into the travel case.

Add Stoker Bars

Guide for packing the stoker handlebars and stem, with options for separation.

Pack Captain Handlebars

Instructions for packing the captain's handlebars, noting cable care.

Packing: Front End (Continued)

Insert Seat Post

Procedure for placing the seat post and saddle under the handlebar bundle.

Add Front Wheel

Instructions for placing the front wheel in the left rear corner of the case.

Insert Center Tubes

Steps for placing the mid top tube and bottom tube over the front wheel.

Packing: Front End (Final)

Add Pedal Bags

Instructions for filling open areas with smaller felt bags like pedal bags.

Insert Seat Masts

Procedure for packing the captain stem and seat masts under the front wheel.

Insert Crush Protector

Steps for inserting the crush protector to support the case and protect the bike.

Packing: Rear End

Packing Blanket

Instructions for adding the packing blanket to the top of the case.

Pack Rear End

Guide for placing the rear end of the tandem into the second travel case.

Insert Rear Wheel

Instructions for placing the rear wheel in the front left corner of the case.

Packing: Rear End (Continued)

Other Seat Post

Procedure for placing the remaining seat post and saddle in the case.

Add Crush Protector

Steps for inserting the crush protector into the rear wheel.

Trailer Placement

Instructions for placing the trailer tongue and axle bag in the case.

Packing: Close TravelCase

Trailer Wheel Packing

Instructions for placing the trailer wheels into the travel case.

Miscellaneous Items

Guide for packing remaining items like water bottles, shoes, and helmets.

Q Transformation

Center Cable Splitters

Procedure for unscrewing center cable splitters to begin the transformation.

Front Cable Splitters

Instructions for disconnecting front cable splitters along the captain down tube.

Center Brake Cable

Steps for removing the center brake cable and housing from the top tube.

Q Transformation (Continued)

Center Derailleur Cables

Guide for slipping derailleur cable housings out of their stops.

Remove Stoker Stem

Procedure for removing the stoker stem and handlebars.

Detach Rear Brake Cable

Instructions for detaching the rear brake cable housing from the top tube stop.

Q Transformation (Further Steps)

Detach Lower Cables

Procedure for detaching lower control cables from the stoker seat tube.

Loosen Mono Stay

Instructions for loosening the mono stay clamp bolts on the rear end.

Loosen Clamp Bolts

Steps for loosening all frame clamp bolts on the center section.

Q Transformation (Frame Separation)

Unhang Drive Chain

Procedure for unhanging the drive chain from the chain ring.

Remove Timing Chain

Steps for derailing and removing the timing chain.

Separate Frame

Instructions for separating the frame halves by twisting and pulling.

Q Transformation (Rear End Reassembly)

Loosen Wish Bone

Instructions for loosening wish bone bolts and removing the half-shell clamp.

Separate Rear End

Procedure for separating the rear end from the stoker seat tube.

Attach Rear End

Steps for reattaching the rear end to the front end at the bottom bracket.

Q Transformation (Finalizing)

Tighten Rear End

Instructions for reattaching and securely tightening the wish bone and mono stay.

Insert Top Tube Plug

Procedure for inserting the plug into the top tube socket for the single bike.

Re-Hang Drive Chain

Steps for re-hanging the drive chain over the large front chain ring.

Q Transformation (Connecting Cables)

Connect Cables

Instructions for connecting rear end control cables to the down tube guides.

Connect Rear Brake

Steps for attaching the rear brake cable housing and splitter.

Two'sDay Quick Fold

Getting Ready for Quick Fold

Preparing the bike by shifting gears and raising the kickstand.

Rear Brake Cable Disconnection

Procedure for undoing the rear brake cable splitter.

Fold Rear End

Steps for folding the rear end under the frame after disconnecting the brake cable.

Two'sDay Quick Fold (Continued)

Release Captain's Stem

Instructions for releasing and removing the captain's stem from the fork.

Fold Front End

Steps for folding the front end under the frame and packing the stem/handlebars.

Accessories: Travel Trailer

Travel Trailer Parts

Overview of the components included in the Travel Trailer kit.

Connect Axles

Instructions for assembling the trailer axles and T-bar.

Stacker Frame Setup

Guide for setting up the stacker unit for traveling with two cases.

Accessories: Travel Trailer (Assembly)

Attach Trailer Axle

Steps for attaching the trailer axle assembly to the travel case.

Add Thumb Nuts

Instructions for placing and loosely threading thumb nuts onto the axle studs.

Attach Trailer Tongue

Guide for attaching the trailer tongue to the T-bar and travel case.

Accessories: Travel Trailer (Wheel and Hitch)

Add Last Thumb Nut

Procedure for securely finger-tightening all thumb nuts inside the case.

Wheel Axles

Notes on the order of parts for installing trailer wheels.

Install Trailer Wheel

Steps for sliding the trailer wheel onto the axle end.

Accessories: Travel Trailer (Final Setup)

Add Axle End Washers

Instructions for adding the rubber O-ring and flat washer to the axle end.

Insert Clevis Pin

Procedure for inserting the clevis pin to secure the trailer wheel.

Mount Other TravelCase

Steps for mounting the second travel case onto the stacker unit.

Accessories: Travel Trailer (Hitch Connection)

Stacker Strap

Instructions for using the nylon strap to secure the upper case.

Connect Trailer Hitch

Procedure for attaching the trailer hitch to the bicycle frame.

Ready To Go

Final check and lubrication recommendation for the trailer hitch connection.

Accessories: Rear Rack

GD Folding Rear Rack

Overview of the GD Folding Rear Rack features and benefits.

Unfold Rack

Instructions for unfolding the GD Folding Rear Rack.

Insert 5mm Bolts

Steps for inserting 5mm bolts through the main legs of the rack.

Accessories: Rear Rack (Mounting)

Mount Legs To Frame

Instructions for threading bolts into frame dropouts to mount rack legs.

Attach Stays To Frame

Guide for attaching rack stays to the frame's wish bone.

Tighten Bolts

Instructions for securely tightening all four mounting bolts for the rear rack.

Accessories: Front Rack

Front Rack Components

Overview of the parts included with the front rack, including bolts and spacers.

Mount Cross Bar

Steps for mounting the cross bar to the rack side.

Mount Other Rack Side

Instructions for attaching the second side of the front rack.

Accessories: Front Rack (Mounting)

Mount Lower Eyelets

Instructions for mounting the lower eyelets to the fork dropouts.

Mount Upper Eyelets

Steps for mounting the upper eyelets to the fork legs.

Tighten All Bolts

Instructions for securely tightening all six bolts for the front rack.

Accessories: Fenders

Front Fender Installation

Guide for installing the front fender, noting the alignment pin.

Rear Fender Installation

Instructions for installing the rear fender onto the rear end of the frame.

Accessories: Fit Stem

Fit Stem Process

Overview of the Fit Stem process for custom fitting a bicycle stem.

Fit Stem Adjustment

Guide for adjusting stem projection and height for optimal fit.

Returning Fit Stem

Instructions for preparing and returning the Fit Stem for final customization.

V-Brake Operation

Operating V-Brakes

Steps for opening the V-brake arms by pressing them together.

Release V-Brake

Procedure for releasing the brake cable noodle from the holder.

Open V-Brake

Instructions on how to fully open the V-brake arms.

V-Brake Operation (Continued)

Brake Barrel Adjuster

Guide on using the barrel adjuster to add brake cable slack.

Reconnect V-Brake

Steps for reconnecting the brake cable and ensuring housing seating.

Close V-Brake

Procedure for closing the V-brake arms and reinserting the noodle.

DualDrive Hub

Using Your Optional DualDrive Hub

Benefits and usage of the DualDrive hub for bike travelers.

The Click Box

Description of the click box and its connection to the rear hub axle.

Attachment Button

Explanation of the attachment button used to connect the click box to the axle.

DualDrive Hub (Maintenance)

Remove Click Box

Steps for removing the click box from the axle end.

DualDrive Hub (Shifting Rod)

Shifting Rod

Description of the shifting rod and its function in gear shifting.

Removing Rear Wheel

Guide for removing the rear wheel, noting axle washer orientation.

DualDrive Hub (Reattaching)

Reattaching Click Box

Steps for reattaching the click box to the axle, including alignment.

Mount Click Box

Procedure for pressing the button up to secure the click box onto the axle.

DualDrive Hub (Adjustment)

Adjusting DualDrive

Guide for adjusting the DualDrive hub using the clear window indicator.

Trouble Shooting

V-Brake Centering And Spring Adjustment

Instructions for centering V-brakes by adjusting spring tensions.

Thread Sizes

Information on common thread sizes for rack and frame bolts.

Crank Arm Removal Tool

Explanation of a mysterious tool supplied with Shimano crank arms.

Bike Friday Service

New Bike Maintenance

Recommendations for break-in period maintenance and professional servicing.

Travel Tips

Airport Security

Guidelines for traveling with your Bike Friday travel bike through airport security.

Warranty Information

Bike Friday Guarantee

Details of the 30-day money-back guarantee and return policy.

Limited Warranty

Information on the frame set warranty and coverage limitations.

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