Dahon Recall tech bulletin

How To Identify An Affected Handlepost
The recall of 2008 Radius handlepost does not affect all models fitted with this handlepost. To determine if a model
is potentially affected please check with your local distributor or dealer. Once you have determined that a bicycle
is one of the potentially affected 2008 models, please use the following bulletin to see if the handlepost is affected.
There are three different potentially affected handleposts:
1. Radius Telescope Adjustable Handlepost
2. Radius Fixed Handlepost
3. Radius VRO Fixed Handlepost
Radius Handlepost Features:
1. Ring-shaped safety hook.
2. Internal clamp.
If your handlepost has these features, it is
POTENTIALLY AFFECTED by the recall.
These handleposts are NOT affected:
Radius Handlepost (Factory Replacement):
Radius V Handlepost Features:
• “R” Stamp inside handlepost hinge indicates the
handlepost has been replaced
1. V-shaped Autolock safety catch.
2. External clamp.
If your handlepost has this stamp, it is
NOT AFFECTED by the recall.
If your handlepost has these features, it is
NOT AFFECTED by the recall.
If the handlepost is one of the potentially affected handleposts:
1. Check the serial number on the
underside of the bottom bracket.
2. Once you have found the bike’s serial number,
please go to Dahon’s website to check if the serial
number is listed as one of the affected bicycles.
http://www.dahon.com/support/recall
3. Is the serial number in the list?
• NO: The bike is NOT AFFECTED by the recall. You can continue to
ride without worries.
• YES: Do the following:
If the serial number is listed as one of the affected bicycles, the
handlepost has to be replaced.
Do NOT ride the bike anymore, and bring it to your local dealer to
have the handlepost replaced.
Serial number location
If, for whatever reason, you cannot check the frame
number or you are not sure if your bike is affected,
bring it to your bike dealer. They will check for you at
no charge.
Handlepost Replacement Tech Bulletin
This Bulletin
Tools required:
This bulletin is written to aid in the removal and replacement of Radius handleposts affected by the
Radius handlepost recall. This shall be carried out by a qualified mechanic.
•
•
•
•
5mm allen key
6mm allen key
10mm allen key
Torque wrench
Replacement Instructions:
I. Remove Handlebar Assembly.
NOTE: Because the handlebar assembly is removed in one piece, it should not be
necessary to disconnect any of the brake or gear assembly to replace the handlepost.
A. For Handleposts With Quick Release (QR) Fixation Systems:
Step 1: Open the QR.
Step 2: Unscrew the QR screw.
Step 3: Remove the QR.
Step 4: Open the latch and remove
the handlebar
B. For Handleposts With VRO Handlebar:
Step 1: Loosen the bolts of the
VRO clamps with a 5mm Allen key.
Step 2: Move the VRO clamps laterally, so the handlebar assembly can
be removed from the handlepost.
Step 3: Remove handlebar
assembly.
NOTE: When removing handlebar assembly from handlepost, carefully leave all cables attached.
2. Disconnect Handlepost From Steerer Tube.
Step 1: Loosen stem nut. (Side
bolt) until handlepost turns
freely on the steerer (1-2 turns
counterclockwise) Open Radius
handlepost hinge to reveal inner
compression nut.
Step 2: Unscrew
(counterclockwise) the
compression nut completely.
Step 3: Remove the compression
nut and washer.
Step 4: Carefully lift off the
handlepost assembly away from
the steerer tube.
Handlepost Replacement Tech Bulletin
3. Install Replacement Handlepost to Steerer Tube.
NOTE: Make sure you have the correct replacement handlepost.
NOTE: Before tightening
stem nut and making
sure the headset is
correctly adjusted you
need to reinstall the
handlebar assembly.
Step 1: Slide new handlepost
assembly on to the steerer tube.
Step 2: Reinstall compression
nut (don’t forget the washer
underneath).
Step 3: Tighten until there is
no play in the head assembly.
Tighten the compression nut with a
torque of 6.8-11.3 Nm.
4. Install Handlebar Assembly
NOTE: Orient handlebar assembly so all cable routing is correct and the cables are not twisted.
A. For Handleposts With Quick Release (QR) Fixation Systems:
Step 1: Place handlebar and close
handlepost clamp.
Step 2: Reinstall the QR.
Step 3: Tighten the QR screw.
Step 4: Tighten the QR.
B. For Handleposts With VRO Handlebar:
6. Please check the handlepost hinge is
adjusted according to instructions in the
Dahon owner’s manual
NOTE: Although the brakes and gears were not adjusted,
we recommend you check that all brakes and gears are
functioning correctly after completing any replacement.
Step 1: Move the VRO clamps
laterally on to the handlepost.
Step 2: After establishing desired
position, tighten the bolts of the
VRO clamps with a 5mm Allen
key. Torque: 10 Nm.
5. Adjust Handlebar Alignment
Step 1: Align handlepost so
handlebar is perpendicular to the
front wheel.
Step 2: Tighten the clamp screw
Torque: 11.3 Nm.
7. Record All Audit Information As Required
8. Affix Identification Sticker
Please affix “Radius Handlepost” Sticker to the bottom
of the handlepost to show that the handlepost has been
replaced and the bicycle is no longer affected.