DAHON Folder 1987 - 6.3.1 Bottom Bracket Crankshaft Assembly; 6.3.2 Brake System

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