Family Tandem Traveler Tandem Traveler XL Ti Lite XL

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Family Tandem Traveler Tandem Traveler XL Ti Lite XL Powered By Docstoc
					                    Using Your Bike Friday®:
        • Family Tandem Traveler™
• Tandem Traveler XL™ • Ti Lite XL Traveler™
      Tandem Two’sDay™ • Project Q™

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.

                 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
                                                                        Table of Contents
Congratulations!                                                        A Word on Safety                                         4
You have just purchased the finest travel bicycle available today.      Anatomy of a Bike Friday Tandem                          5
Your bike has been carefully designed and constructed for your          Using a Quick Release                                    6
personal travel needs. All of our bikes are manufactured in our         Getting Started                                          8
                                                                        Assembly: Unpacking                                      9
Eugene, Oregon factory by real cyclists who care about our prod-
                                                                                     Mid Top Tube                               10
ucts and our customers.
                                                                                     Bottom Tube                                11
Please take your time reviewing this manual and, if possible, watch                  Connect Frame                              12
the video before you assemble your new Bike Friday travel bicycle.                   Drum Brake                                 13
You will find your new bicycle simple and reliable anywhere you                      Timing Chain                               14
go!                                                                                  Drive Chain                                15
                                                                                     Captain Stem                               16
If You Need Help . . .
                                                                                     Handlebar                                  18
If you need technical assistance with any Green Gear® Cycling                        Connect Cables                             19
product, or are unclear on the proper operation of your Bike Friday                  Front Wheel                                20
travel bicycle, please call us and a Service Technician will help you                Seat Masts                                 21
get back on the road. Our toll-free number in the US and Canada                      Pedals                                     22
is 800-777-0258, international is +1-541-687-0487. Normal business      Packing:     Pedals & Seat Posts                        24
hours are 8 a.m. to 5 p.m. Monday through Friday, and 9 a.m. to 4                    Seat Masts                                 25
p.m. Saturdays, Pacific Standard Time. You can also email service                    Front Wheel                                26
questions to                                                 Remove Stem                                27
Because we understand the needs of world travelers, we offer                         Loosen Mid Frame                           28
                                                                                     Rear Wheel                                 29
24-hour technical support in emergencies. If necessary, please call
                                                                                     Drum Brake                                 30
our regular number and our answering service can forward you to
                                                                                     Materials                                  31
a Service Technician on call.
                                                                                     Front End                                  32
Extra Accessories                                                                    Rear End                                   35
We also sell an extensive (and growing!) line of bicycle and travel                  Close TravelCase                           37
accessories. Whether you are riding the local back roads or ventur-     Q Transformation                                        38
ing into foreign lands we have the gear you need. Call us for info      Two’sDay Quick Fold                                     45
on spare tires and tubes, replacement parts, fenders, racks, bags, or   Accessories: TravelTrailer                              47
                                                                                     Rear Rack                                  52
other items to complete your Travel System.
                                                                                     Front Rack                                 54
More Information                                                                     Fenders                                    56
To check out our products, find other useful information, discover                   Fit Stem                                   57
Bike Friday events and Yak with other Bike Friday owners on the         V-Brake Operation                                       58
bulletin board, go to our main web site at Or       DualDrive™ Hub                                          60
just call us at 800-777-0258.                                           Trouble Shooting                                        65
Blue skies and happy trails from the gang at Green Gear Cycling.        Bike Friday Service                                     66
                                                                        Travel Tips                                             67
                                                                        Warranty Information                                    68

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A Word on Safety                                                      Anatomy of a Bike Friday Tandem
Bicycles are a lot of fun, but they can also hurt if you don’t
ride carefully. So please always ride safe!


                                                                                                                                                                                      Head Tube

• Always wear a helmet.

                                                                                                     Brake Levers

                                                                                                                           Shift Levers
• 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 a�er dark.
• Dress appropriately for the weather and the season.
• Always carry a spare tube, patch kit, pump and a tool kit.

                                                                       Captain Handlebar
• Keep your bicycle in good shape.
• Check your tire pressure before every ride.

                                                                                                                                                                                                                                                                     Down Tube
                                                                                                                                                                        Stem Collar (Clamp)
• Make sure all quick releases are secure!
• Have your bicycle routinely serviced for trouble-free travels.

                                                                                                                                                          Stem Riser
                                                                                                                         Captain Seat Mast
Your Tools

                                                                                                                                                   Top Tube
All Bike Friday bicycles are delivered with a combina-
tion 5/6mm S-wrench that is a�ached to your water
bo�le cage. This wrench should get your new bike on

                                                                                                                                                                                                                                                                                                                      Bottom Tube
the road (along with your own pedal wrench). Leave it
in your bo�le cage so that you always have it handy.

                                                                                                                                                                                                                                                     Timing Chain

                                                                                                                                                                                                                                                                                                                                            Bottom Brackets
                                                                                                                                                                                                                                                                                               Chain Ring Protector
All bikes ordered with a TravelCase™ suitcase also come with a

                                                                                                                                                                                                                                                                                 Chain Rings
                                                                                                                                                                                                                                        Seat Tubes
                                                                                                                                                                   Seat Mast Clamps
tool pouch. In the tool pouch you will find some co�on gloves to

                                                                                                                                                                                                                      Mid Top Tube
keep your hands clean, a folding tool set, a combination headset

                                                                                                                                                                      Seat Posts
and pedal/axle nut wrench (15mm), and a 4mm ball-end driver.

                                                                                                           Stoker Stem
The ball-end driver is perfect for mounting bo�le cages, racks, and

                                                                                                                                Stoker Handlebar
other accessories. If we needed to remove your right crank arm in
order to pack your bike, we also included a long handled 6mm or
8mm Allen wrench.

                                                                                                                                                                                                                                                                                                                              Chain Stays
We also sell more extensive

tool kits for home repair

                                                                                                                                                                                                                            Wish Bone
work. We encourage you to

                                                                                                                                                                                                                                                                                                                                                 Drive Chain
learn how to work on your

                                                                                                                                                                                                  Stoker Seat Mast
own bike. If you are not
familiar with bicycle main-
tenance, consider taking a

                                                                                                                                                                                                                       Seat Stays

                                                                                                                                                                                                                                                                                                                                    Rear Derailleur
local class. It will improve
your confidence and self-
sufficiency as you venture
across the globe.

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Using a Quick Release                                                     Using a Quick Release
Using Those Nifty Quick Releases                                          1. Adjust Knurled Nut
On a cold and snowy day in the 1927 Gran Premio della Vi�oria, a          With the wheel installed and
tired and numb Tullio Campagnolo struggled with the frozen wing           the axle properly seated in
nuts on his rear wheel while trying to change gears. In a moment          the frame (or the frame joint
of frustration and inspiration Campagnolo envisioned the modern           closed), position the QR lever
quick release, and the bicycle world was transformed.                     so that it is in line with the
The quick release is one of those simple but great inventions that        axle. Then turn the knurled
really makes life be�er. However, if used incorrectly you can             nut on the other side clock-
potentially endanger yourself. Although a reliable and safe prod-         wise until it is snug. When
uct, some people have been injured because they didn’t know how           the QR is properly adjusted, Fig. 1 Quick release operation.
to properly use this elegant device. Your Bike Friday travel bicycle      you should be able to freely swing the QR lever for the first half of
has several of them. If you are not familiar with their operation,        its arc, at which point the lever should offer resistance.
PLEASE study these directions carefully. If you are still unclear
on their operation, call us or contact your favorite local bike shop      2. Continue Closing QR
before you ride!                                                          Using the palm of your hand
Quick Release Operation                                                   press the QR lever through
A quick release is a simple cam with a lever that swings through an       the rest of its arc until the
arc that is square to the axle. As the lever moves the cam clamps the     lever is closed and parallel
wheel to the frame, or secures the frame joint. It is not a wing nut to   to the wheel. You should feel
be rotated about the axle.                                                very firm resistance when
                                                                          the QR is properly adjusted
The tension on the quick release is controlled by how tight the           (the lever may even leave a
knurled nut on the other end is set. Only wheel quick releases have       light imprint in the palm of Fig. 2 Setting quick release tightness.
the small cone-shaped springs. Note that the small ends of the            your hand).
springs face toward the center of the hub.
Quick Release Maintenance
We recommend adding a few drops of light oil to the lever where           3. Double-Check!
it enters the cap several times per year. This will keep your quick
                                                                          Ideally, the QR lever should
release working smoothly for years to come.
                                                                          be facing rearward or
                                       Open               (Loose)         upward. Levers which are
       Knurled Nut                                                        facing forward can catch on
  (adjust tightness here)                                      (starts    any number of things and be
                                                               getting    accidentally opened.
                                                                          Convention usually has the
                                                                          front wheel quick release
                                                                                                           Fig. 3 Closed QR pointing rearward.
                                                                          lever on the le� side of the
                                                              QR Lever    bike, although this is not critical.
                                       Closed            (Stiff)

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Getting Started                                                           Assembly: Unpacking
Where to Begin                                                            1. Unpack Travel Cases
Opening your case for the first time may present an intimidating          Start by removing the loose
sight, particularly if you ordered many extra travel accessories with     items such as the small                Crush Protector
your Bike Friday travel bicycle. Don’t worry, we work hard to keep        colored felt bags and water
our products simple, and with a li�le practice you will find that         bo�les. You should also see a
using your new bike will become second nature to you.                     green blanket. This packing
We recommend finding a quiet area with access to the video,               blanket is a portable work
these instructions, and some room to spread out. This manual              space to spread out on as
will address the fundamentals: packing and assembly tips and              you assemble your tandem.
                                                                                                          Fig.1 The fully equipped tandem.
techniques that are common to all of our travel bikes. However,           Remove the crush protector.
because this bike has been custom made for you, you may discover          The crush protector is a PVC dowel with a couple of flat caps on the
that your bike was packed at the factory slightly different than          ends in the center of the case.
the one in this manual. Wherever possible, we mark any packing            Next remove the various frame pieces from the case and place them
materials unique to your bike.                                            on the packing blanket. It may look like a lot of tubes and cables,
Furthermore, you do not have to repack your bike in exactly the           but don’t worry, it will soon be a bicycle. All of the frame parts have
same fashion. You may find a be�er way of stowing your acces-             been carefully packed and labeled. We suggest leaving the packing
sories, and we encourage you to experiment. If you discover a             materials on until you are ready to use the part. This will help you
particularly good way doing things, let us know. Some of our best         keep the frame parts identified.
ideas have come from members of the Bike Friday family.
If you encounter difficulties assembling your bike, and the manual        2. The Goodie Bag
and video do not help, please call us. Our goal is to get you on the      There might be a be�er name
road so that you can enjoy your custom made Bike Friday bicycle.          for this pouch, but we’ve
Illustrated Accessories                                                   always called it the Goodie
In order to illustrate the assembly and use of all of our travel acces-   Bag. This bag holds a variety
sories, the bike on the following pages has nearly everything you         of miscellaneous loose items
might want for a fully loaded tour. Your own bike may have only           for your new bike. This may
a few or none of these accessories. If you ever choose to purchase        include the technical lit-
some of these accessories, this manual should help you pack the           erature that came with your
extra items.                                                              components, spare spokes, Fig. 2 The goodie bag.
                                                                          some labels and decals, and always a surprise! The component
Bike Fridays travel bicycles do not normally come with saddle or          literature is not required reading, but we supply it for those who
pedals, unless you specifically ordered them from us. However,            are technically inclined.
this manual shows them both to illustrate packing details.
Whether your own bike has drop handlebars or H-bars, V-brakes              pTip
or side-pull brakes, the assembly and packing steps are generally          Your tandem frame has many clamps with two adjoining binder
the same. Because of component differences, wrench sizes and the           bolts. Tighten these bolts in a 1-2-1 order. A�er tightening the
number of bolts per clamp may vary from the illustrations.                 first bolt, tighten the second; then tighten the first bolt again.
                                                                           These binder bolts work together for maximum clamping power
                                                                           and security.

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Assembly: Mid Top Tube                                                   Assembly: Bottom Tube
3. Tool Pouch                                                            6. Bottom Tube
The tool pouch that comes                                                Orientation
with the TravelCase is a                                                 Select the bo�om tube from
light blue colored felt bag                                              the felt sleeve. One end of
with a cord around it. Inside                                            the bo�om tube has a notch
you should find a folding                                                cut out of it and the other
tool set with all of the Allen                                           end has a square cut. The
wrenches and screwdrivers                                                end with the notch faces
you will need to assemble                                                rearward and goes into the
your bike, a pair of co�on Fig. 3 The tool pouch.                        rear lower socket.          Fig. 6 Bottom tube rearward end.
gloves to keep your hands clean, and a 4mm ball-end driver. Note:
You will also find a combination 5/6mm S-wrench a�ached to your
water bo�le cage for quick road-side adjustments.
4. Mid Top Tube                                                          7. Insert Bottom Tube
Orientation                                                              Push the bo�om tube into
Select the mid top tube from                                             the rear lower socket as far as
the grey felt sleeve. One                                                it will go, twisting it slightly
end has a notch cut out of                                               back and forth until it is all
it whereas the other end has                                             of the way in. The small
a square cut. The end with                                               peg on the bo�om tube is a
the notch faces forward and                                              pump peg which should be
is designed to engage the                                                squarely on top and pointing
captain’s seat tube inside the Fig. 4 Mid top tube notch.                forward. Securely tighten Fig. 7 Bottom tube installation.
forward socket. The notch is vertically oriented and keeps the top       the socket clamp bolts.
tube from twisting.

5. Insert Mid Top Tube                                                   8. Connect Frame
With the notch facing                                                    Slide the over-clamp for-
forward (the stoker’s water                                              ward on the top tube until
bo�les should be on top and                                              the square cut is exposed.
facing backwards) insert the                                             To connect the frame halves,
mid top tube into the upper                                              insert the bo�om tube front
forward socket, twisting it                                              end (with the square cut)
slightly back and forth until                                            into the forward lower
it is all of the way in. You                                             socket and push the frame
should feel the notch engage Fig. 5 Mid top tube inserted into socket.   halves together. Leave the Fig. 8 Connect frame halves.
the seat tube. Check that the water bo�le cages are on squarely on       forward lower socket loose for now.
top and securely tighten the forward upper socket clamp bolts.

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Assembly: Connect Frame                                                Assembly: Drum Brake
9. Press Frame Together                                                12. Install Rear Wheel
With the frame halves prop-                                            Install the rear wheel. Be cer-
erly joined, the rear of the                                           tain the rear brake is open. If
top tube and forward end                                               you are not certain how to
of the matching tube on the                                            operate a V-brake, see the
stoker’s seat tube should be                                           “V-Brake Operation” section
no more than 1⁄4 inch apart.                                           near the end of this manual.
                                                                       For details on working with
                                                                       a drum brake, refer to the
                               Fig. 9 Frame halves properly joined.    next few steps.                 Fig. 12 Install rear wheel.

10. Slide Over-Clamp Back                                              13. Drum Brake
With the frame halves                                                  If you have opted for a
engaged, slide the top tube                                            drum brake, the wheel
over-clamp back until it                                               mounts into the frame
equally covers the frame                                               nearly the same as a stan-
joint. Step behind the bike                                            dard wheel. You will need
and sight down the frame:                                              to guide the drive chain
the two seat tubes should                                              over the casse�e cogs, and
be parallel. At this point you                                         pull the derailleur cage back
can make minor adjustments Fig. 10 Over-clamp in position.             to allow the wheel to seat     Fig. 13 Drum brake view.
to the alignment by twisting the frame halves. Tighten the over-       into the drop outs. If you have a DualDrive hub, your wheel will
clamp securely.                                                        not have a quick release as shown in the illustration.

11. Set Cable Stop Ring                                                14. Engage Brake Arm Pin
Open the half-clamp cable                                              As you pull the hub axle up
stop ring and slip it over                                             into the frame drop outs,
the bo�om tube just behind                                             hook the pin at the end of
the forward lower bo�om                                                the brake arm into the cor-
tube socket. Reconnect the                                             responding drop out on the
bolts and then slide the                                               le� chain stay (in this case a
cable stop ring back until it                                          clamp-on mount). Securely
securely contacts the stop on                                          close the quick release, or
the frame. Turn the clamp so Fig. 11 Cable guide ring and springs.     tighten the axle nuts if you Fig. 14 Drum brake arm mounted.
that the cables are on the le� side of the bo�om tube and tighten      have a DualDrive hub. On the DualDrive hub make certain the
the ring clamp bolts. The springs help keep the cable housing in the   washer tabs are facing down and in. Refer to the section on the
cable stops when the bike is packed.                                   DualDrive hub near the end of this manual for more information.
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Assembly: Timing Chain                                                  Assembly: Drive Chain
15. Mount Brake Housing                                                 18. Match Timing Marks
If the cable housing is not in                                          Drape the chain over the rear
the cable stop, insert it now.                                          timing chain ring (you may
Pull the small spring over                                              need to slip the drive chain
the brake cable back from                                               off the drive chain ring,
the housing ferrule, and slip                                           depending on your model).
the brake cable into the cable                                          Line up a silver link with
stop (there is a slot in the                                            the small stamped mark on
cable stop for this). Release                                           the chain ring. (Some chain
the spring.                    Fig. 15 Drum brake cable housing stop.   rings have a small hole
                                                                        drilled instead.) Repeat with
                                                                        the front timing chain ring.
                                                                                                          Fig. 18 Front (left) and rear (right).
16. Connect Cable Splitter                                              19. Mount Timing Chain
Next connect the two ends                                               With the timing marks
of the brake cable split-                                               aligned, turn the crank arms
ter. Screw the two halves                                               until the timing chain is
together securely. Leave the                                            seated on both chain rings.
rim brake open for now.

                                Fig. 16 Drum brake cable splitter.                                        Fig. 19 Timing chain on.

17. Install Timing Chain                                                20. Attach Drive Chain
Remove the timing chain                                                 With the timing chain
from the felt pouch. The tim-                                           installed, pull the drive chain
ing chain has two separate                                              over the drive chain ring.
silver connector links. These
silver links are to help you
“time” the captain’s and
stoker’s crank arms.

                                Fig. 17 Timing chain silver link.                                         Fig. 20 Mounting timing chain.

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Assembly: Captain Stem                                               Assembly: Captain Stem
21. Adjust Timing Chain                                              24. Mount Stem
Adjust the tightness of                                              Slide bo�om of stem into the fork steerer
the timing chain with the                                            tube, keeping the stem’s quick release
forward lower clamp loose.                                           assembly facing forward so that the hidden
If the chain is too tight,                                           stem pin will engage the slot in the fork.
squeeze the chain to add                                             Gently press the stem all the way down.
some slack. If the chain is too
loose, press down on the top
tube to add some tension.
When the chain tension is Fig. 21 Squeeze chain to add slack.
set, tighten the forward lower clamp securely. The timing chain
should move about 1⁄4 to 3⁄8 of an inch when pressed mid-span. All
mid frame clamp bolts should now be tight.                                                                          Fig. 24 Insert stem.
22. Install Captain Stem                                             25. Tighten Stem
Your stems are both packed in red                                    Tighten the quick release securely. It is
felt bags. Select the captain stem.                                  normally irrelevant whether the lever
Before mounting the stem, become                                     is on the le� or right side of the stem;
familiar with the stem safety tips in                                however, a few stem collars only accept
the following steps.                                                 the quick release from one direction.
                                                                     Also, some stem models will have a bolt
                                                                     instead of a quick release to save weight.

                                        Fig. 22 Captain stem.
                                                                                                                  Fig. 25 Stem clamp collar.
23. Stem Safety                                                      26. Adjustable Stem (Optional)            Set bar
                                                                                                             height here.
If you look carefully at the                                         If you have purchased one of our
base of your stem, you will                                          adjustable stems, set your desired
see a pin hidden under the                                           handlebar height using the clamp
clamping collar. This pin                                            directly above the stem collar. You
must engage the slot in the                                          may choose to precisely set the Release stem for
back of the fork’s steerer                                           height once, or vary it according to packing here.
tube (the threaded part                                              your riding needs; in either case be
sticking up).                                                        certain this bolt is tight before riding
                               Fig. 23 Stem pin & fork slot.         your bike. For fit stem instructions,
THE STEM PROPERLY YOU MAY COMPROMISE SAFETY!                         see the section on “Accessories.”
                                                                                                           Fig. 26 Adjustable stem.

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Assembly: Handlebar                                                    Assembly: Connect Cables
27. Captain Handlebars                                                 30. Connect Cables
To facilitate packing, all Bike                                        Connect the cable spli�ers
Friday travel bicycles have                                            along the bo�om tube. The
two-part handlebars with                                               top cable in the front cable
a reinforcing sleeve in the                                            guide goes with the top cable
le� handlebar. Make certain                                            in the rear cable guide. If the
the a�ached cables are not                                             cables are disturbed, trace
tangled or wrapped around                                              each cable from the handle
the frame or fork. Insert le�                                          bar control backwards, and
handlebar into stem clamp, Fig. 27 Handlebar sleeve.                   each cable from the appro- Fig. 30 Cable splitter.
then right bar.                                                        priate component forward to make a match.

28. Set Handlebars
With the handlebars in the
stem, press them firmly                                                31. Rear Brake Cable
together to ensure they are                                            If the rear brake cable along
fully seated. Custom stems                                             the top tube is not set into
for drop bars have a round                                             the cable guides, do so now.
window to allow you to cen-                                            Simply pull the spring back
ter the bar split in the stem.                                         and slip the cable into the
All other handlebar types                                              cable stops.
                                 Fig. 28 Set handlebars.
Fig. 28a Custom stem.
                         have a small bu�on screw on the stem
                         clamp to keep the bars centered. (Do not                                      Fig. 31 Front (top) & rear (bottom).
                         remove.) For the angle of the bars, experi-
                         ment with what feels appropriate.

29. Tighten Handlebars                                                 32. Brake Cable Splitter
Using the appropriate Allen                                            With the rear brake open,
wrench (5 or 6mm), tighten                                             screw the cable spli�er along
the handlebar clamp bolts                                              the mid top tube together.
securely. If your bar clamp                                            Then close the rim brake.
has two bolts, tighten both                                            If you are not familiar with
alternately.                                                           closing a V-brake, see the
                                                                       “V-Brake Operation” section
                                                                       near the end of this manual.
                                 Fig. 29 Tighten handlebar clamp.      (You can connect the spli�er Fig. 32 Rear brake cable splitter.
                                                                       with the brake closed, but it is slightly harder to pull the cables
                                                                       together under spring tension.)

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Assembly: Front Wheel                                                 Assembly: Seat Masts
33. Remove Fork Spreader                                              36. Seat Mast Installation
The PVC tube between your                                             All tandem models have a
fork legs is intended to help                                         seat mast that telescopes
prevent frame damage when                                             out of the lower seat tube.
traveling. It is held in place                                        If you bought a TravelCase
by the wheel’s quick release.                                         suitcase, the seat mast will
Open the quick release, un-                                           be in a blue felt bag. Place
thread the knurled nut, and                                           the captain and stoker seat
put the fork spreader in the                                          masts in their respective seat
tool pouch for future use.     Fig. 33 Remove fork spreader.          tubes. Orient the seat mast Fig. 36 Rear seat mast & seat tube.
                                                                      clamp slot so that it is facing backwards. There is a minimum inser-
                                                                      tion mark on each seat mast to avoid over-extension.
                                                                      37. Stoker Seat Post
34. Open Front Brake                                                  Remove the packing materi-
To install your front wheel,                                          als from your stoker seat
you will need to open the                                             post and then insert the seat
front brake to allow the tire                                         post into frame. Once you
to pass by the brake shoes. If                                        have your saddle height set,
your bike is equipped with                                            try adding a piece of electri-
a side-pull brake, simply                                             cal tape to the seat post or
move the small lever to the                                           use a permanent marker to
up position. If you have a                                            mark your saddle height for Fig. 37 Install seat post.
V-brake and are not familiar Fig. 34 Opening side-pull brake.         quick re-assembly. If you did not purchase a saddle with your bike,
with its operation, see the “V-Brake Operation” section.              now would be a good time to install your own saddle. Add a light
                                                                      dab of grease to the saddle rails and seat carriage clamp.
                                                                      38. Tighten Seat Post
35. Install Front Wheel                                               Whenever you install the seat
Now install the quick release                                         post, make certain the seat post
from the fork spreader on the                                         shim (the split aluminum sleeve
front wheel. Make certain                                             inside the seat mast) has its slot
that there is only one spring                                         aligned with the slot in the seat
per side and that the small                                           mast. (Some frames for larger
end of the spring is pointing                                         riders may not have a seat post
to the center of the hub on                                           shim). Also make certain the
each side. Loosely thread                                             seat mast collar has its slot
on the knurled nut for now. Fig. 35 Quick release spring and nut.     aligned with the slot in the seat
Install front wheel in fork, and tighten quick release securely. Be   mast. Tighten the seat post. (Be
certain to close the front brake again.                               careful not to overtighten, as the Fig. 38 Seat post shim.
                                                                      bolt can break).
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Assembly: Pedals
39. Captain Seat Post &                                              42. Double-Check Your Bike!
Stoker Handlebar                                                     At this point your bike should be ready to ride. However, before
Before installing the captain                                        you ride away, be sure to double-check your assembly. Are the
seat post, slide the stoker                                          handlebars tight? How about the stem and pedals? Are the quick
stem onto the seat post with                                         releases all secure?
the stem pointing up. Mount                                          Although we always inflate the tires at the factory, check your tire
the seat post into the captain                                       pressure for proper inflation. Under-inflated tires not only wear
seat mast and set the saddle                                         faster and are more prone to flats, but they also add drag.
height. Then align the stoker
stem with the frame. Mount Fig. 39 Stoker bar and stem.              Be sure to have at least the 5/6mm S-wrench in the mono-tube
the stoker handlebars with the reinforcing sleeve on the le� side.   bo�le cage 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.
40. Install The Pedals
Bike pedals have two differ-
ent thread directions. The                                            Be sure to keep a light film of grease on any intersecting bike
right pedal has a right-hand                                          parts. This will help to prevent corrosion, facilitate disassembly,
thread, and the le� pedal has                                         and eliminate annoying noises. Areas include seat posts, saddle
a le�-hand thread. Thread                                             rails, handlebars, stems, seat masts and frame fork tips. Doing
the right pedal in a clockwise                                        this a couple of times per year during routine maintenance
direction; thread the le�                                             should be enough. Wipe off any excess or visible grease.
pedal in a counter-clockwise                                          Also be sure to lightly grease all bolt threads on your bicycle as
direction. Pedals are usually Fig. 40 Check pedals for threading.     you repair or upgrade components. Lubricating your bolts will
stamped with a R or L on the pedal axle near the threads. A li�le     allow you to adequately tighten the fasteners and keep them
grease is always a good idea on pedal threads.                        from seizing in the future.

41. Thread In Pedals
Using your fingers, start
the pedal threads into the
proper crank arm. Be careful
not to cross-thread the ped-
als! Once the pedal threads
are started, you may use a
wrench to finish threading
them in, and then tighten
securely.                    Fig. 41 Tighten pedals (tighten in
                               opposite direction for left pedal).
Tip: Remember to tighten
your pedals by turning both toward the front of the bike.

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Packing: Pedals & Seat Posts                                             Packing: Seat Masts
1. Remove Accessories                                                    4. Remove Captain Seat
Before disassembling and packing your Bike Friday tandem,                Post, Stoker Stem & Bars
remove the larger accessories such as racks. Your computer and           Depending on your configu-
water bo�le cages can remain on the frame.                               ration, you may be able to
                                                                         leave the stoker bars intact
                                                                         and mounted in the stoker
                                                                         stem (unlike in the illustra-
                                                                         tion). While separating the
                                                                         stoker bars is minor step
                                                                         when packing your tandem, Fig. 4 Seat post & stoker stem.
                                                                         try leaving them connected for now. Remove the captain seat post
                                                                         and then remove the stoker stem. Set both parts aside for now.

2. Remove Pedals                                                         5. Remove Seat Masts
Loosen your pedals with                                                  Remove both seat masts
the supplied headset/pedal                                               from the tandem frame,
wrench (TravelCase suitcase                                              cover with their respective
only). The right pedal un-                                               grey felt sleeves and set
threads in a counter-clock-                                              aside.
wise direction and the le�
pedal un-threads in a clock-
wise direction. (Remember
that both pedals turn toward Fig. 2 Remove pedals (loosen in oppo-                                        Fig. 5 Remove seat masts.
the rear of the bike.)       site direction for left pedal).

Place both pedals in the light blue felt bag and set aside.

3. Remove Stoker Seat                                                    6. Open brakes
Post                                                                     Open both front and rear
Loosen the seat mast clamp-                                              brakes. If you have side-pull
ing collar and remove the                                                brakes, simply flip up the
stoker seat post. (The saddle                                            small lever on the side of the
can remain a�ached to the                                                brake. If you have V-brakes,
seat post). The seat post                                                refer to the section on V-
shim should remain in the                                                brake operation if needed.
seat mast. Cover the seat
post in the clear vinyl sleeve Fig. 3 Remove saddle and seat post.                                        Fig. 6 Open both brakes.
labeled “Seat Post.” Cover the saddle in a blue vinyl sleeve labeled
“Saddle;” the slot in the sleeve goes over the nose of the saddle. Set
the saddle aside.

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Packing: Front Wheel                                                      Packing: Remove Stem
7. Remove Front Wheel                                                     10. Remove Capt. Bars
A�er removing the front                                                   Loosen the handlebar clamp
wheel, close the brake again.                                             bolts on the stem, and pull
Remove the quick release                                                  the bars apart. Depending
from the axle by undoing                                                  on the model of stem, there
the knurled nut. Be careful                                               may be either one bolt or
not to lose the small cone-                                               two clamp bolts. Let the bars
shaped springs.                                                           hang to the side for now.
Put the quick release through                                             On bicycles equipped with
                              Fig. 7 Remove front wheel.                  flat or H-bars, there will be a Fig. 10 Remove captain’s handlebars.
the fork spreader (the short
PVC dowel), and thread on the knurled nut again. Both small cone-         small bu�on-head screw in the center of the clamp. Do not loosen
shaped springs should be on the quick release sha�.                       or remove this screw. It holds the black sleeve in the stem.

8. Install Fork Spreader                                                  11. Remove Captain’s Stem
Slip the fork spreader                                                    Open the stem quick release at the bot-
between the drop outs on                                                  tom of the stem (or loosen the clamp
the fork, and lightly tighten                                             bolt), and remove the stem.
the quick release.                                                        Put the stem into the red felt bag and set
The fork spreader will help                                               aside.
prevent damage to your
frame when traveling.
                                 Fig. 8 Fork spreader.

                                                                                                                       Fig. 11 Remove stem.
9. Open Cable Splitters                                                   12. Adjustable Stem
Disconnect all of the center                                              If you have an adjustable Leave tight for
section    cable     spli�ers,                                            stem or a fit stem, leave the stem height.
including the rear brake                                                  middle bolt tight to keep
cable spli�er. If you have a                                              your stem height set prop-                                 Loosen to
Project Q tandem, you can                                                 erly. Only loosen the lower                              remove stem.
leave the front section cable                                             clamp or quick release for
spli�ers connected.                                                       packing purposes.

                                 Fig. 9 Disconnect all cable splitters.

                                                                                                         Fig. 12 Adjustable stem removal.

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Packing: Loosen Mid Frame                                            Packing: Rear Wheel
13. Unhang Drive Chain                                               16. Separate Frame
Pivot the rear derailleur                                            With all of the frame center
forward to get some chain                                            section clamp bolts loose,
slack and then unhang the                                            slide the top tube over-clamp
drive chain from the chain                                           forward and then twist and
rings. If your tandem is set                                         pull the frame apart.
up with the timing chain on
the le� side there is no need                                        Fig. 16a Over-clamp.
to unhang the drive chain.
                                Fig. 13 Unhang drive chain.                                           Fig. 16 Pull frame apart.

14. Loosen Frame Clamps                                              17. Remove Center Tubes
Loosen all frame clamps                                              Remove both the top tube
that hold the center section                                         and the bo�om tube from
together, including the over-                                        the frame. Place the center
clamp for the rear end of the                                        tubes in their respective grey
mid top tube. If you have                                            felt sleeves.
a Project Q, the rear mono
stay does not need to be
                                Fig. 14 Loosen frame clamps.                                          Fig. 17 Extract center tubes.

15. Remove Timing Chain                                              18. Rear Wheel
Derail the timing chain by                                           With the rear brake open,
lightly pressing on the side                                         remove the rear wheel and
of the chain as you back                                             set aside. For details on
pedal the crank arm. If the                                          removing a rear wheel with
chain is too taut to derail, try                                     a DualDrive hub, see the sec-
loosening one of the bo�om                                           tion on DualDrive operation
tube clamps. Then remove                                             near the end of this manual.
the timing chain and place it                                        For details on a wheel with a
into the light blue felt bag.    Fig. 15 Remove timing chain.        drum brake, see the next few Fig. 18 Remove rear wheel.

  28        800-777-0258 • +1-541-687-0487     800-777-0258 • +1-541-687-0487      29
Packing: Drum Brake                                                       Packing: Materials
19. Unscrew Cable Splitter                                                22. Packing Materials
Unscrew the drum brake                                                    At this point you should add any remaining packing protection
cable spli�er.                                                            pieces to the frame. The various covers and sleeves will be labeled.
                                                                          Because each bike is custom made and outfi�ed, there is some
                                                                          variation in the selection of packing materials. Common pieces
                                                                          • Seat mast covers (grey felt sleeves).
                                                                          • Frame tube covers (blue vinyl sleeves).
                                 Fig. 19 Drum brake cable splitter.       • Crank arm covers (blue vinyl sleeve).
                                                                          • Crank arm bag (dark blue felt bag).
                                                                          • Chain stay covers (striped vinyl tube).
                                                                          • Steerer tube cover (short striped vinyl tube).
20. Release Brake Housing                                                 • Handlebar end covers (long and short striped vinyl tube).
Pull the small spring over
                                                                          Your own bike may have other pieces. These will be labeled accord-
the brake cable back from
                                                                          ing to where they go. Generally, there is extra room in the cases
the housing ferrule, and slip
                                                                          to accommodate accessories such as shoes, clothing, and even hel-
the brake cable out of the
                                                                          mets. As you travel with your tandem and gain experience in your
cable stop (there is a slot in
                                                                          own customized packing process, you may discover that some of
the cable stop for this).
                                                                          the original pieces are unnecessary. You may also feel that you
                                                                          may need some extra protection with new accessories. Feel free to
                                 Fig. 20 Drum brake cable housing stop.   experiment, and let us know if you have a great idea. Here are some
                                                                          examples of packing materials.

21. Remove Wheel
Now remove the rear wheel
by pushing down and for-
ward so that the pin on the
brake arm clears its clamp-                                               Fig. 22a Down tube cover.          Fig. 22b Seat post sleeve.
on drop out.

                                 Fig. 21 Drum brake hub out of frame.

                                                                          Fig. 22c Stoker stem red bag.      Fig. 22d Crank arm sleeve.
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Packing: Front End                                                       Packing: Front End
23. Pack Front End                                                       26. Insert Seat Post
In one of your empty cases,                                              Place either the captain
lay the front end of your                                                or stoker seat post (and
tandem into the case. The                                                saddle) under the bundle of
frame should sit towards                                                 handlebars, with the nose of
the rear of the case, with                                               the saddle pointing toward
the right side up. Two’sDay                                              the frame, and the seat post
frames can be le� unfolded.                                              pointing towards the front
The fork should be turned                                                bo�om bracket.
around to keep the frame Fig. 23 Front end in TravelCase.                                                Fig. 26 Saddle & seat post placement.
more compact. Let the captain handlebars hang out of the case for

24. Add Stoker Bars                                                      27. Add Front Wheel
Many stoker bars can be                                                  Lay the front wheel on top of
packed in the case without                                               the bike toward the le� rear
being separated, although                                                corner of the case.
you may need to loosen
the bar clamp in order to
rotate the stem slightly. If
you encounter difficulties in
packing the bike with the
intact stoker bars, separating Fig. 24 Stoker bars and stem in case.                                     Fig. 27 Front wheel placement.
them is a simple step. In either case, the stoker stem should be cov-
ered in a red felt bag. Refer to illustration for packing orientation.

25. Pack Captain Bars                                                    28. Insert Center Tubes
Now pack the captain                                                     Place both the mid top tube
handlebars. The illustration                                             and the bo�om tube (in their
shows drop bars, placed                                                  respective sleeves) on top of
mirror image to the drop                                                 the front wheel and through
stoker bars with the drops                                               the handlebars toward the
overlapping. Other types of                                              rear of the case.
handlebars will be packed
similarly, sort of parallel to
the fork and nested together. Fig. 25 Captain bar placement.                                             Fig. 28 Bottom & top tube placement.
Be careful not to kink the cables.

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Packing: Front End                                                         Packing: Rear End
29. Add Pedal Bags                                                         32. Packing Blanket
Start to fill in some open                                                 Add the packing blanket to
areas with the smaller felt                                                the top of the case. Leave
bags. The pedal bags, tim-                                                 this case open until the other
ing chain bag, and tool kit                                                case has been packed with
can fit along the rear of the                                              the rear end; there may be
case. Try to keep these small                                              miscellaneous loose items
heavy items packed snugly.                                                 such as shoes and helmets to
Otherwise they can bounce                                                  distribute between the cases.
around the case.              Fig. 29 Miscellaneous bags.                                                   Fig. 32 Packing blanket in case.

30. Insert Seat Masts                                                      33. Pack Rear End
Pack the captain stem (in the                                              Lay the rear end in the right
red felt bag) and the two seat                                             rear corner of the other case
masts (in their felt sleeves)                                              with the right side facing up,
along the front of the case                                                and right crank arm pointing
under the front wheel.                                                     up.

                                 Fig. 30 Stem and seat masts.                                               Fig. 33 Rear end placement.

31. Insert Crush Protector                                                 34. Insert Rear Wheel
Slip one of the crush protec-                                              Place the rear wheel in the
tor disks into the bo�om                                                   front le� corner of the case
center of the case. Thread                                                 with the casse�e side facing
the crush protector dowel                                                  up. The rim and tire will rest
through the front wheel                                                    between the chain stays.
and into the socket of the
lower flange. The top flange
should be nearly the highest
part of your bike. This piece Fig. 31 Crush protector placement.                                            Fig. 34 Rear wheel placement.
is a critical bit of packing material: it spans the case so that luggage
dropped on top of your case is supported by the dowel and not
your bike.
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Packing: Rear End                                                       Packing: Close TravelCase
35. Other Seat Post                                                     38. Trailer Wheel
Add the remaining seat                                                  Lay one of the trailer wheels
post and saddle to the case.                                            in the le� front corner on top
The large end of the saddle                                             of the rear bicycle wheel.
should be in the front right
corner, with the saddle nose
pointing at the rear bo�om
bracket. The seat post will
lay across the rear wheel.
                                Fig. 35 Saddle & seat post placement.                                    Fig. 38 Trailer wheel placement.

36. Add Crush Protector                                                 39. Second Trailer Wheel
Slip one of the crush protec-                                           Lay the second trailer wheel
tor flanges into the bo�om                                              toward the rear of the case
of the case, and then thread                                            on top of the rear end. The
the dowel through the rear                                              short end of the stacker will
wheel.                                                                  hook over the right side of
                                                                        the bike, and the long end
                                                                        will lay across the top of the
                                Fig. 36 Crush protector placement.                                       Fig. 39 Stacker placement.

37. Trailer Placement                                                   40. Miscellaneous Items
Lay the trailer tongue in the                                           At this point the bike is
long blue felt bag toward                                               nearly packed. Any remain-
the rear of the case, on top                                            ing loose items such as
of the bike. The S-shaped                                               the water bo�les, clothing,
end of the tongue will point                                            shoes, helmet etc. should be
towards the center right side                                           set into any openings. Fend-
of the case. Lay the trailer                                            ers can be nested together.
axle bag on top of the frame                                            There should also be ample
next to the tongue bag.       Fig. 37 TravelTrailer bags.               space for the front and rear Fig. 40 Close TravelCase.
                                                                        racks in one of the two cases. Close the case lid, tucking any loose
                                                                        cables and felt bags into the case. You should be able to feel that the
                                                                        crush protector is the highest point of the case.
  36        800-777-0258 • +1-541-687-0487        800-777-0258 • +1-541-687-0487         37
Q Transformation                                                             Q Transformation
If you purchased a Project Q tandem, this section will guide you             4. Center Derailleur
through the transformation of your bike from a tandem into a                 Cables
single.                                                                      A�er disconnecting the
1. Center Cable Splitters                                                    front cable spli�ers, slip the
First, unscrew all of the cen-                                               forward ends of the housing
ter cable spli�ers along the                                                 along the down tube out of
mid top and bo�om tubes.                                                     their respective cable stops.
                                                                             The cables should remain
                                                                             connected to the cable stop
                                                                             ring on the bo�om tube Fig. 4 Lower cables on bottom tube.
                                                                             (the springs on the cables help keep them a�ached), but the cables
                                                                             should be free of the front end of the frame.
                                 Fig. 1 Disconnect center cable splitters.
                                                                             5. Remove Stoker Stem
2. Front Cable Splitters                                                     Pull out the captain seat post
Disconnect all of the front                                                  and remove the stoker stem
cable spli�ers along the                                                     and handlebars. Put the
captain down tube.                                                           stoker bars aside. Reinstall
                                                                             the seat post and set to the
                                                                             proper height.

                                                                                                              Fig. 5 Remove stoker stem.
                                 Fig. 2 Disconnect front cable splitters.

3. Center Brake Cable                                                        6. Detach Rear Brake
Remove the center section                                                    Cable
of brake cable and housing                                                   Detach the rear brake cable
along the top tube by pull-                                                  housing from the cable stop
ing the springs back over the                                                on the top tube by the stoker
brake cable, and slipping the                                                seat mast. This cable should
cable out of the cable stop.                                                 now be directly connected to
Keep this loose piece of cable                                               only the rear brake.
and housing in a safe place
for future use.                Fig. 3 Center brake cable & housing.                                           Fig. 6 Detach rear brake housing.

  38        800-777-0258 • +1-541-687-0487             800-777-0258 • +1-541-687-0487          39
Q Transformation                                                        Q Transformation
7. Detach Lower Cables                                                  10. Unhang Drive Chain
Detach the lower cluster of                                             Gently pull the rear derail-
cables from the cable stops                                             leur forward and slip the
on the lower socket of the                                              drive chain off the chain
stoker seat tube, like you                                              ring. This will be easier to
did in the previous step. The                                           do when the chain is in the
cables should now be only                                               small cog on the casse�e.
connected to the rear end.

                                Fig. 7 Detach lower control cables.                                    Fig. 10 Drive chain.

8. Loosen Mono Stay                                                     11. Remove Timing Chain
Loosen the mono stay clamp                                              Derail the timing chain by
bolts on the rear end.                                                  pressing on the side of the
                                                                        chain as you turn the crank
                                                                        arms. When the chain falls
                                                                        off, remove the chain and
                                                                        put it aside for future use.

                                Fig. 8 Mono stay clamp bolts.                                          Fig. 11 Derail timing chain.

9. Loosen Clamp Bolts                                                   12. Separate Frame
Next loosen all frame clamp                                             Slip the top tube over-clamp
bolts on the center section,                                            forward, then twist and
including the top tube over-                                            pull the frame halves apart.
clamp.                                                                  Remove the top and bo�om
                                                                        tubes and set them aside.

                                Fig. 9 Loosen all center clamp bolts.                                  Fig. 12 Separate frame.

  40       800-777-0258 • +1-541-687-0487         800-777-0258 • +1-541-687-0487     41
Q Transformation                                                      Q Transformation
13. Loosen Wish Bone                                                  16. Tighten Rear End
The wish bone connects the                                            Re-a�ach the wish bone
upper part of the rear end to                                         half-shell and the bolts, then
the stoker seat tube. Loosen                                          tighten this clamp securely.
these two bolts completely                                            Then tighten the mono stay
and remove the half-shell                                             clamp bolts securely.

                                Fig. 13 Wish bone half-shell clamp.                                    Fig. 16 Close up of wish bone clamp.

14. Separate Rear End                                                 17. Insert Top Tube Plug
With the wish bone clamp                                              With your Project Q tandem
open and the mono stay                                                you should have found a
clamp loose, separate the                                             painted capped tube with
rear end from the stoker                                              a cross bar welded to it.
seat tube by twisting and                                             This piece is a plug to cover
pulling.                                                              the top tube socket for the

                                Fig. 14 Separate rear end.                                             Fig. 17 Top tube socket plug.

15. Attach Rear End                                                   18. Re-Hang Drive Chain
Slip the mono stay on the                                             Gently pull the rear derail-
rear end into the socket on                                           leur forward and drape the
the front end at the bo�om                                            drive chain over the large
bracket. Push the frame                                               front chain ring.
together until the wish bone
clamp is engaged to the seat

                                Fig. 15 Attach rear end to frame.                                      Fig. 18 Drive chain installation.

  42       800-777-0258 • +1-541-687-0487       800-777-0258 • +1-541-687-0487          43
Q Transformation                                                         Two’sDay Quick Fold
19. Connect Cables                                                       1. Getting Ready
Slip the rear end control                                                Shi� the drive chain into
cables into the proper cable                                             the small cog in back and
guides on the down tube. Be                                              the small chain ring in front
certain to match the vertical                                            (the la�er only if you have a
order of the corresponding                                               standard drive train). This is
cable from the handle bar.                                               best accomplished when you
For instance, if the top cable                                           are still riding just before
from the handlebar is for the                                            coming to a stop. If your
rear derailleur, then the rear Fig. 19 Connect control cables.           bike has a kickstand, raise it Fig. 1 Getting ready for the quick fold.
derailleur cable should be in the top position in the rear cable stop.   at this point.
Then connect the down tube cable spli�ers.

20. Connect Rear Brake                                                   2. Rear Brake Cable
A�ach the rear brake cable                                               Next, undo the rear brake
housing to the top tube rear                                             cable spli�er along the top
cable stop by pushing the                                                tube. It may easier if you
spring aside. Connect the                                                open the rear brake. Then
cable spli�er, then close the                                            slip the rear-most section of
rear brake.                                                              brake cable housing out of
Your tandem is now a single!                                             the rear cable guide.
Before you ride, double
                             Fig. 20 Connect rear brake.                                                  Fig. 2 Disconnect brake cable splitter.
check all connections, cable
spli�ers and clamps.

21. Making your single a tandem again.                                   3. Fold Rear End
Transforming your Project Q single back into a tandem again is just      With the rear brake cable
the reverse of these steps. If you encounter difficulties in reassem-    disconnected       from the
bling your tandem, refer to the first section on tandem assembly.        frame, open the rear end
                                                                         quick release and fold the
                                                                         rear end under the frame as
                                                                         far as it will go.

                                                                                                          Fig. 3 Fold under rear end.

  44       800-777-0258 • +1-541-687-0487          800-777-0258 • +1-541-687-0487         45
Two’sDay Quick Fold                                                      Accessories: TravelTrailer
4. Release Captain’s Stem                                                1. Trailer Parts
Open the stem quick release (or loosen                                   If you purchased a Travel-
the lower-most bolt) and remove the                                      Trailer kit with your tandem,
stem from the fork.                                                      you should have two trailer
                                                                         wheels and two blue felt
                                                                         bags with the tongue and
                                                                         axle. The bo�om of your
                                                                         TravelCase suitcase should
                                                                         have three holes drilled in
                                                                         it if you ordered the trailer Fig. 1 Travel Trailer parts.
                                                                         with your bike. If you ordered the trailer separately, you will need
                                                                         to find the three dimple marks in the bo�om of your case and drill
                                            Fig. 4 Remove Stem.
                                                                         them through with a 1⁄4” drill.
5. Fold Front End                                                        2. Connect Axles
Now open the front end                                                   In the smaller blue felt bag
quick release and fold the                                               there should be two axles
front end under so that it                                               and a T-bar. Slip the open
rests next to the folded rear                                            ends of the axles over the
end. Lay the captain stem                                                “T” of the T-bar. Each axle
and handlebar over the                                                   will have a threaded stud
bike. To further compact the                                             with a thumb nut and two
tandem, you can loosen the                                               flat washers. Remove the
seat mast clamps and push Fig. 5 The folded Two’sDay.                    thumb nuts and one of the Fig. 2 Assemble trailer axle.
the seat masts down into the seat tubes. If you have a TravelBag,        washers from each stud (leaving one washer over each stud post).
place the bike in it now and zip it shut.

6. Unfolding Your Tandem Two’sDay                                        3. Stacker Frame
Unfolding your tandem into riding condition is just the reverse of       If you are traveling with
these steps. Unfold the front end first, then the rear end. Before you   two cases, you will need to
ride your bike again, double-check to make certain that all of the       install the stacker unit. The
quick releases are secure, that the rear brake cable is connected and    two sleeves in the stacker
the rear brake is closed, and that the alignment pin in the stem is      slip over the axles with the
properly engaged to the fork.                                            T-bar in the middle opening.
                                                                         The axles and trailer tongue
                                                                         then mount to the first case
                                                                         as shown in the next few Fig. 3 Stacker frame set up.
                                                                         steps. It does not ma�er which case is on the bo�om.

  46       800-777-0258 • +1-541-687-0487          800-777-0258 • +1-541-687-0487      47
Accessories: TravelTrailer                                             Accessories: TravelTrailer
4. Attach Trailer Axle                                                 7. Add Last Thumb Nut
With the case open and                                                 Place one flat washer over
standing on its le� side,                                              the threaded stud inside the
a�ach the axle assembly by                                             case and add the last thumb
slipping the two threaded                                              nut. Now securely finger
studs through the two holes                                            tighten all three thumb
in the right side of the case.                                         nuts inside the case. Each
The end of the T-bar should                                            a�achment point should be
be pointing at the third hole                                          a sandwich consisting of
in the case.                   Fig. 4 Attach trailer axle.             trailer frame, flat washer, Fig. 7 Tongue thumb nut.
                                                                       nylon TravelCase, flat washer and then thumb nut.

5. Add Thumb Nuts                                                      8. Wheel Axles
Place one of the flat washers                                          From one axle end remove
over each threaded stud, and                                           the clevis pin, the flat washer
then loosely thread on the                                             and the rubber O-ring. Note
thumb nuts—do not tighten                                              the order of these parts when
them yet.                                                              installing the trailer wheel.

                                 Fig. 5 Attach washers & thumb nuts.                                     Fig. 8 Axle washers.

6. Attach Trailer Tongue                                               9. Install Trailer Wheel
Take the long trailer tongue                                           Each trailer wheel has two
and remove the thumb nut                                               bearings; one is flush with
and one washer from the                                                the outside of the wheel, and
threaded stud. Slip the hol-                                           the other is recessed. Slide
low end of the tongue over                                             the trailer wheel over the
the end the of the T-bar so                                            axle end with the recessed
that the threaded stud in the                                          side down and the flush side
tongue fits into the remain-                                           up (away from the trailer).
ing hole in the case.         Fig. 6 Trailer tongue over T-bar.                                          Fig. 9 Mount trailer wheel.

  48         800-777-0258 • +1-541-687-0487      800-777-0258 • +1-541-687-0487    49
Accessories: TravelTrailer                                                   Accessories: TravelTrailer
10. Add Axle End Washers                                                     13. Stacker Strap
First install the rubber O-                                                  The supplied nylon strap
ring so that it sits next to the                                             holds the upper case in
wheel bearing. Then install                                                  place. Slip the small loop
the flat washer over the O-                                                  over the trailer tongue and
ring.                                                                        run the strap through the
                                                                             case pull handle.

                                   Fig. 10 First O-ring, then flat washer.                                   Fig. 13 Stacker setup.

11. Insert Clevis Pin                                                        14. Connect Trailer Hitch
Insert the clevis pin through                                                To a�ach the trailer hitch to
the hole in the axle end to                                                  your frame, simply pull the
secure the wheel. The flat                                                   knurled collar on the coupler
washer should be lightly                                                     back while you push the
pressing against the clevis                                                  coupler over the nipple on
pin from the inside, with                                                    the frame.
the O-ring acting as a sort
of spring to keep the wheel
from ra�ling on the axle.     Fig. 11 Insert clevis pin.                                                     Fig. 14 Using your trailer hitch.

12. Mount Other                                                              15. Ready To Go!
TravelCase                                                                   When you release the
Lean the stacker unit back                                                   knurled collar, the coupler
and remove the two thumb                                                     should be secure and ready
nuts and washers. Place the                                                  to go. If the knurled collar
other case on the stacker so                                                 becomes stiff and does not
that the two threaded studs                                                  spring closed, add some light
go into the axle holes in the                                                lubricant such as TriFlow™
case. On the inside of the                                                   or WD-40® to the coupler.
case replace the washers and Fig. 12 Lower TravelCase access.                                                Fig. 15 Trailer hitch connected.
thumb nuts and tighten securely. The photo also shows how you
would access the lower case when touring. The upper case simply
pivots back.
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Accessories: Rear Rack                                                Accessories: Rear Rack
1. GD Folding Rear Rack                                               4. Mount Legs To Frame
This handmade folding cro-                                            Thread the bolts into the
moly rear rack will securely                                          eyelets on the drop outs on
carry your travel gear any-                                           each side of the bike. The
where in the world. Plus, it                                          rack legs should have their
folds quickly and compactly                                           ends on the outside of the
for easy packing in your                                              drop outs. Leave the bolts
case. The GD rack is packed                                           loose for now.
in a yellow felt bag, and has
two extra 5mm bolts for Fig. 1 GD Folding Rear Rack.                                                     Fig. 4 Mount rack legs to drop outs.
mounting it to your bike. (The other two required bolts are already
in your frame.)

2. Unfold Rack                                                        5. Attach Stays To Frame
The two sets of main legs                                             Remove the two bolts on the
unfold down, while the                                                sides of the wish bone. (The
two black aluminum stays                                              wishbone is the part of the
unfold over the top.                                                  frame that engages the frame
                                                                      quick release.) Rea�ach the
                                                                      two bolts through one of the
                                                                      two holes in the rack stays.
                                                                      Experiment with which rack
                              Fig. 2 Unfold GD rack.                  stay hole provides the most Fig. 5 Attach rack stays to wish bone.
                                                                      level rack position.

3. Insert 5mm Bolts                                                   6. Tighten Bolts
Let the holes in the main                                             Tighten all four mounting
legs overlap at the bo�om                                             bolts securely. If you would
and then insert a supplied                                            like to a�ach a rear reflector
5mm bolt through each pair                                            or a rear tail light, there is a
of legs.                                                              threaded mount on the rear
                                                                      of the rack.

                              Fig. 3 Place bolts through leg holes.                                      Fig. 6 Tighten all bolts securely.

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Accessories: Front Rack                                                                 Accessories: Front Rack
1. Front Rack                                           Cross Bar                       4. Mount Lower Eyelets
The front rack consists of                                                              Insert one of the short 5mm
two mirror image sides, a                                                               bolts through the recessed

                                  Right Side

                                                                            Left Side
long cross bar, and assorted                    Long                                    eyelet at the bo�om of the
bolts and spacers. The cross                  Spacers                                   rack. Place one of the short
                                              & Bolts
bar uses two 6mm bolts. The                                                             spacers over the bolt on the
lower mount uses two short                                                              inside of the rack. Repeat                 ar
                                                Short                                                                           Re                   Short
5mm bolts and spacers; the                    Spacers                                   with the other side. Place
                                               & Bolts                                                                                              Spacer
upper mount uses two long                                                               the assembly over the front
5mm bolts and spacers. Look Fig. 1 Front rack parts.                                    wheel, and then loosely Fig. 4 Right side view of rack.
at the mounting eyelets on the rack. The recessed side of the eyelets                   thread the bolts into the eyelets on the fork drop outs. The part of
face out and are for the bolt heads. The flush side faces in.                           the rack hanging below the drop out is on the rear side of the drop
2. Mount Cross Bar                                                                      5. Mount Upper Eyelets
Select either side of the rack,                                                         Using the remaining long 5mm bolts,
the cross bar and one 6mm                                                               slip the bolts through the upper eyelets,
bolt. Insert the bolt through                                                           and then slide the long spacers over the
the recessed side of the eye-                                                           bolts on the inside. Thread the bolts
let near the ball-stop on top                                                           into the braze-ons on the fork legs.
of the rack. Screw the bolt
loosely into the cross bar.

                                  Fig. 2 Mount cross bar.

                                                                                                                                    Fig. 5 Upper mount.
3. Mount Other Rack Side                                                                6. Tighten All Bolts
Insert the remaining 6mm                                                                Now tighten all six bolts
bolt through the other rack                                                             carefully. Your front V-
side and loosely thread                                                                 brake noodle might touch
into the cross bar. The rack                                                            the right rack side. This is
should now resemble Figure                                                              generally not an issue. If the
3.                                                                                      interference is significant, it
                                                                                        is acceptable to lightly bend
                                                                                        the noodle a bit tighter to
                                  Fig. 3 Attach other side of rack.                     help clear the rack.            Fig. 6 Completed front rack.

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Accessories: Fenders                                                Accessories: Fit Stem
1. Front Fender                 Mounting                            Fit Stem (Optional)
Your front fender has an                                            If your bike was designed to receive a Custom Ultra-light Stem,
alignment pin (a small bolt)                                        then most likely the bike you just received has a Fit Stem installed.
through the aluminum tab                                            The Fit Stem process is designed to ensure the highest level of
beneath the mounting hole.                                          accuracy and satisfaction in producing a truly custom fit for your
The fender is a�ached to the                                        new bike.
fork by the upper hole, while                                       The Fit Stem is a temporary, but fully usable stem which can be
the alignment pin keeps the                                 Pin     adjusted to any height and projection. Ride with the Fit Stem as
fender from rotating.                                               you would normally ride and tour. Either take a wrench with you,
                                Fig. 1 Front fender.
                                                                    or use your 5/6mm S-wrench in the bo�le cage, and stop to adjust
                                                                    your fit as necessary. We encourage you to put 125 miles or more on
                                                                    the stem, until you are satisfied with the overall fit of your bike.
                                                                    When you have finished the fi�ing process, remove the stem and
2. Rear Fender                                                      send it back to us in the supplied FedEx box along with the infor-
Your rear fender has one                                            mation card. The only essential details are your name, address and
hole in the aluminum tab,                                           bike color. Once you have the stem boxed up and the card filled out,
and the fender extends far-                                         call FedEx at 800-463-3339 to arrange a pick up. It normally takes
ther forward of the tab than                                        about two weeks to complete your new Custom Ultra-light Stem.
the front fender. The fender                                        If you need a quicker turnaround for a trip or event, let us know
is a�ached to the rear end by                                       on the card or call us to arrange for expedited service. We have
the bolt in the wish bone.                                          completed stems in as short as two Horizontal Adjustment
                                                                    working days. (There is a fee for         (Leave Tight)
                                Fig. 2 Rear fender.                 this service.)
                                                                    Fit Stem Adjustment
                                                                    Set the stem projection by loosen-
                                                                    ing the two bolts at the top of the
                                                                    stem and moving the bars horizon-
                                                                    tally. Set the stem height by loosen-  Vertical
                                                                    ing the single bolt at the top of the Adjustment
                                                                    lower stem sleeve and moving the (Leave Tight)
                                                                    bars vertically.
                                                                    Returning Fit Stem
                                                                    When you are ready to send the
                                                                                                     Stem Clamp
                                                                    stem back to us (or to pack the (Remove
                                                                    bike), leave the two adjusting      Here)
                                                                    clamps tight. Only remove the
                                                                    handlebars and loosen the lowest
                                                                    stem collar.
                                                                                                          Fig. 1 Removing fit stem.
  56       800-777-0258 • +1-541-687-0487     800-777-0258 • +1-541-687-0487         57
V-Brake Operation                                                         V-Brake Operation
1. Operating V-Brakes                                                     4. Brake Barrel Adjuster
To open your V-brake, start                                               To add some more brake
by pressing the brake arms                                                cable slack, you can turn the
together.                                                                 barrel adjuster on the brake
                                                                          lever. The barrel adjuster
                                                                          is the knurled bolt that the                   To Add
                                                                          cable housing goes through                   Cable Slack
                                                                          as it enters the brake lever.
                                                                          Turn this adjuster clockwise
                                Fig.1 Press V-brake arms together.        to loosen the cable. Note:    Fig. 4 V-brake barrel adjuster.
                                                                          Some models may have a lock nut on the adjuster, which will need
                                                                          to be loosened first.

2. Release V-Brake                                                        5. Reconnect V-Brake
While continuing to press                                                 Before closing the brake
the arms together (A), pull                                               check to make certain that
the elbow-shaped noodle                                                   the housing is properly
out and up (B) and then push                     B                        seated into the ferrules at
the noodle holder down (C).                                               both ends. With the brake
There is a slot in the end of                                             open, the housing can slip to
                                  A                                   A
the noodle holder for the                                                 the side and keep the brake
brake cable to slip out.                                                  from closing properly. Com-
                                Fig. 2 Pull out noodle from holder.       mon places to check are the Fig. 5 Check housing for seating.
                                                                          brake lever barrel adjuster (top), and where the housing enters the
                                                                          noodle (bo�om).

3. Open V-Brake                                                           6. Close V-Brake                              B
At this point you should be                                               Close the V-brake in the
able to open the brake arms.                                              reverse order of opening it.
If you cannot release the                                                 Press both arms together
noodle from the noodle                                                    (A), and insert the noodle (B)
                                                                          into the noodle holder (C).         A              C                 A
holder, then the brake cable
may need to be loosened                                                   The end of the noodle has
a bit. See the next step for                                              a bullet shaped tip that
instructions to add some                                                  should be inside the holder,
                             Fig. 3 Open brake arms.                                                     Fig. 6 Close V-brake.
slack to the cable.                                                       but just sticking through the
                                                                          cable keyhole. Test squeeze the brake lever, it the brake is too loose
                                                                          remove some cable slack at the barrel adjuster.

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DualDrive™ Hub                                                               DualDrive Hub
Using Your Optional DualDrive Hub                                            1. The Click Box
For many bike travelers, the DualDrive hub offers the perfect com-           The DualDrive shi� cable
bination of wide gear ratios, simplicity, and durability.                    connects to a grey and/or
As with a standard drive train, there is no single best shi�ing order        black box a�ached to your
on a DualDrive equipped bicycle. Experiment and find what works              rear hub axle above the
well for you. A cyclist with a standard drive train must be conscious        rear derailleur. To install
to avoid cross-chaining, which occurs when you shi� into a small             and remove the rear wheel
gear in front and a small one in back, or a vice versa. Cross-chaining       you will need to detach and
can cause excessive wear on your components. Since cross-chaining            reconnect this click box to the
is not an issue with the DualDrive hub, any gear combination is              axle in a few simple steps.     Fig. 1 The click box.

acceptable.                                                                  Start by shi�ing the DualDrive hub into the lowest gear (uphill
Other benefits include being able to shi� the hub when standing              icon, or repeatedly press the small lever on STI shi�ers).
still at a stop light or the bo�om of a hill. Simply shi� the internal
hub to a lower gear (without even pedaling) and off you go.                  2. Attachment Button
The DualDrive single-sided shi�er has an icon depicting uphill,              The small black bu�on on
flat, and downhill terrain to identify low, middle, and high gears.          the click box is used to a�ach
If your Bike Friday travel bicycle is equipped with different shi�           the box to the axle. In the
levers, the le� hand lever controls the internal hub. Pulling the            up position the box is con-
cable in shi�s the hub to a higher gear for descending hills. For            nected.
those who are curious about the gear ratios, adjust your gear inches         To remove the click box,
for low gear by 73%, mid-range 100% (1:1), and high gear 136%.               press this bu�on down until
                                                                             it is flush with the top of the
Maintenance                                                                                                  Fig. 2 Click box button up (connected).
Your DualDrive hub requires li�le maintenance. The shielded
bearings are very durable, and the internal mechanism is highly
reliable. Periodically applying a li�le oil to the shi�ing rod is all
that is required. If you ride casually, then once a year is sufficient. If   3. Remove Click Box
you ride a lot more or in poor weather, then every six months will           With the black bu�on down,
suffice.                                                                     the click box should just slide
To lubricate the rod, remove the click box and the shi�ing rod (see          off of the axle end. The click
the following directions). Lay the bike on its le� side, or remove the       box will remain connected to
wheel and then lay the wheel on its le� side. Dip or coat the shi�ing        the shi� cable.
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-a�ach the
                                                                                                               Fig. 3 Click box button down (detach).
shi�ing rod (do not over tighten) and the click box.

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DualDrive Hub                                                           DualDrive Hub
4. Shifting Rod                                                         6. Reattaching Click Box
Underneath the click box is                                             To rea�ach your click box
a small screw head called         Tighten                               to the axle, first ensure the
the shi�ing rod. The click                                              black bu�on is all the way
box pulls or pushes this rod                                            down, flush with the top as
in and out to shi� gears.                                               in Figure 3. If you cannot
Normally you do not need                                                get the bu�on down, it is
to remove this rod to remove                                            because the shi� cable pulled
the wheel.                                                              the small black shi�ing fork
However, be careful not to
                               Fig. 4 Shifting Rod.                     (circled in Figures 6 and 6a) Fig. 6 Shifting fork down, button down.
bend the rod head. If you need to remove the rear wheel to pack         out of its proper position.
your bike, either remove the rod and keep it in a safe location or      This can happen when the
put the protector sleeve (required for only a few bike models) over     click box hangs by the shi�
the axle and pin head.                                                  cable. First, make certain the
If you wish to add some oil to the hub, remove the shi�ing rod and      shi� cable housing is prop-
dip or coat the rod with good quality oil. See the paragraph on hub     erly seated at the shi� lever,
maintenance for more information.                                       any cable stops, and in the
                                                                        click box barrel adjuster.
When screwing the shi�ing rod back into the hub, be careful not to
over-tighten. Just lightly tighten the shi�ing rod with a flat screw-   Next, to get the bu�on
                                                                                                      Fig. 6a Shifting fork up, button stuck.
driver, until snug.                                                     down, push the fork tip
                                                                        down toward the hole in the box with your finger while applying
5. Removing Rear Wheel                                                  pressure to the black bu�on. You may need to keep your finger on
With the click box removed,                                             this bu�on to keep it from popping up from cable movement.
loosen the two axle nuts                                                7. Mount Click Box
with a 15mm wrench, a
                                                                        With the bu�on down,
crescent wrench, or your
                                                                        place the click box over the
pedal/headset wrench in
                                                                        axle end as far as it will go,
the tool pouch. The wheel          Loosen                  Tighten      and then press the black
should slide out.
                                                                        bu�on up. Your click box
The axle washers have a tab                                             is now properly connected.
                                Fig. 5 Axle washer, bottom view.
on one side. When reinstall-                                            With very gentle tugging
ing the rear wheel, place the washers on the outside of the drop        you should only feel slight Fig. 7 Place over axle end.
outs (the part of the frame which holds the wheels), with the tab       spring-like resistance.
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 a�er installing the wheel!

                                                                                                         Fig. 7a Button up (connected again).

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DualDrive Hub                                                        Trouble Shooting
8. Adjusting DualDrive                                               V-Brake Centering And Spring Adjustment
The DualDrive hub adjust-                                            V-brake arms are held off of the rim by a spring in each arm. To
ment is very simple. First                                           center the brake (allowing both arms to retract an equal amount),
shi� the DualDrive into the                                          you need to adjust the respective spring tensions. At the base of
middle gear (flat terrain,                                           each V-brake arm near the pivot is a small screw pointing to the
or middle STI position).                                             side. Turning this screw will change the centering of the brake.
On top of the click box is a                                         On the side which needs to retract farther, tighten this screw in
small clear window show-                                             half-turn increments. You may also consider loosening the side
ing a couple of ladder-like                                          which retracts too far.
bars over a brightly colored Fig. 8 Adjusting window.
indicator needle.                                                    Thread Sizes
                                                                     The stainless steel bolts that a�ach your rack to your bicycle use one
Turn the tapered barrel adjuster, where the housing enters the
                                                                     of the most common thread sizes available today. If you lose one of
click box (Fig. 8a), until the needle is centered between the bars
                                                                     these small bolts you will most likely find replacement hardware
in the clear window. It’s that
simple. When you move the
shi� lever you can see the                       Needle In           The thread size for the rack, water bo�le cage, derailleur and brake
needle move to the different                                         cable clamp bolts is a metric 5mm x 0.8mm. A US standard thread
positions.                                                           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.
All new bikes will need
                                                                     Every bike shop and virtually any hardware store world-wide will
some initial adjustment
                                                   Needle Out        stock these bolts in a variety of lengths.
as parts wear in, housing
compresses and the cables                                            If you are unable to find replacements while on tour give us a call
stretch. If your bike does not Fig. 8a Barrel adjuster.              or send us an email and we can ship to you what you need to get
shi� properly, take it to your                                       back on the road.
local bike shop for adjustment. Before long, however, your bike      What is it?
should be functioning trouble free.
                                                                     This li�le mysterious tool is supplied with
                                                                     Shimano crank arms. To remove the new
                                                                     generation of Shimano crank arms with the
                                                                     over-size bo�om bracket spindles you need to
                                                                     use this temporary plug with your crank arm
                                                                     removal tool.

  64       800-777-0258 • +1-541-687-0487       800-777-0258 • +1-541-687-0487       65
Bike Friday Service                                                      Travel Tips
New Bike Maintenance                                                     Airport Security
Like all bikes, your Bike Friday travel bike will go through a break-    Traveling with your Bike Friday travel bike on the airlines today
in period. A�er the first few weeks of riding you may find that your     will, for the most part, be as convenient as it was just a few years
drive train doesn’t shi� as crisply as it did when new, or perhaps       ago in the good old days. However, because of the need for exten-
the brakes are slightly loose. This happens as new cables stretch,       sive inspections required by the TSA, there are a few points to be
housing compresses and parts wear in.                                    aware of.
A�er the initial break-in period, but before a significant tour, it is   • Do not lock your TravelCase when traveling by air. All luggage
important to have your Bike Friday bicycle professionally serviced       must be inspected by TSA agents when checking in your luggage.
at your local favorite bike shop. A new bike tune up takes very          TSA agents can, and have, broken open locked TravelCases. Even
li�le time and the small cost for the work is minor considering the      a�er the initial inspection do not lock your case, we have had
improved performance and reliability it provides. Then at least          reports of subsequent inspections where the TravelCase lock was
once a year and before any major tour, take your bike back to your       broken open.
local shop for another tune-up to be sure that it runs smoothly.         • You may ask to be present during the inspection, however you
A�er a few years of use and a few thousand miles of riding, you          may not touch your bike or TravelCase once you have handed it
may notice that the decals on your bike are starting to look worn        over to the TSA. By asking to be present, you may be able to give
and the paint has some scratches. Perhaps your bike doesn’t ride as      some repacking tips to a very busy agent.
smoothly as it used to, and the local bike shop can’t get it to func-    • When traveling by air, you might consider not over packing
tion as well as you would like. We offer factory service programs        your TravelCase. With some practice it is quite possible to get a
including tune-ups, overhauls, and other repair work by our expert       tremendous amount of gear into your TravelCase; however this
mechanics. A month or two before your next big ride, you may             only obscures the inspectors view and they will deconstruct your
wish to send the bike back for a complete overhaul.                      carefully packed case.
Visit our web site for repair packages, costs, and details at            • Consider using extra straps, bungee cords, or toe straps to bundle For those who plan             the packed bike. This way an inspector can remove the bike as
ahead, we can generally offer the quickest repair turn-around dur-       once piece, look it over, and replace it into the case quickly and
ing the winter months.                                                   accurately.
                                                                         • Observe airline luggage weight limitations. For domestic flights
                                                                         (including domestic legs of international flights), the checked lug-
                                                                         gage limit is 50 pounds. For international flights, the checked lug-
                                                                         gage limit is 70 pounds. Luggage which exceeds these limitations
                                                                         may be charged an excess baggage fee.

                                                                          B��� F�����®, the B��� F�����® logo, G���� G���® C������, F����� T��-
                                                                          ��� T�������™, T����� T������� XL™, T� L��� XL T�������™, T�����
                                                                          T��’�D��™, Project Q™, T����� S�����™, T�����T������™, T�����C���™,
                                                                          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 wri�en consent. Other trademarks are the property
                                                                          of their respective owners.

  66       800-777-0258 • +1-541-687-0487          800-777-0258 • +1-541-687-0487               67
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 responsi-
bility. 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 origi-
nal 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. Cus-
tomers 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
  68        800-777-0258 • +1-541-687-0487

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