OWNERS MANUAL
Contents
1. HOW TO REMOVE FRONT AND REAR WHEELS IN THE EVENT OF PUNCTURES FRONT WHEEL REMOVAL REAR WHEEL REMOVAL C8 Model CHAIN TENSION C8 Model REAR WHEEL REMOVAL M9 Model REAR WHEEL REFITTING M9 Model CHAIN TENSION M9 Model ROUTINE MAINTENANCE CLEANING YOUR ORi SHIMANO PARTS DRIVE TRAIN BRAKE ADJUSTMENT TYRES WHEELS STEERING SEAT POST SOCKAL CLIP LUBRICATING YOUR ORi LUBRICATE THE FOLLOWING AREAS DO NOT LUBRICATE THE FOLLOWING AREAS 28 3 08 09 41 06 a W INTRODUCTION Congratulations and thank you for choosing ORi Your ORi has been designed and produced to make the most of the fantastic benefits that our advanced and unique design offers and to provide you with the best possible performance for many years to come To get the best from your new bike and for your own safety it is very important that you fully understand the operation of the ORi folding bike before riding This owner s manual assumes a working knowledge of bicycles and an understanding that the regu lar inspections and maintenance which are outlined are essential to ensure the safe performance and longevity of your bike If you are not experienced in owning and riding a bicycle always consult your ORi dealer about important issues This is especially important with any folding bike Please read understand and digest all the sections that apply to your bike before riding your bike for the first time The OR2. For riding advice and safety on the road we recommend that the rider reads understands and com plies with all the relevant sections of the Highway Code For rider training we recommend the rider contacts a nationally recognised organisation such as the CTC in the UK In addition to this manual we also recommend the rider thoroughly reads the documentation from the component manufacturers supplied with this bike that relates to riding and the safe operation of the bike For example Shimano Nexus Inter 4 Hub gear operation adjustment and service instrue tions The rider should always complete the pre ride check before every ride In addition to this for long term safe riding the rider also conducts periodic checks on other components in accordance with the Routine Maintenance section of this manual HOW TO REMOVE FRONT AND REAR WHEELS IN THE EVENT OF PUNCTURES FRONT WHEEL REMOVAL C8 and M9 models Tools Required 8mm socket tool Tightening Torque M5 Fasteners 5 0 Nm The design of the ORi folding bike means that the front wheel is retained inside the Front Mud guard In order to remove the front wheel from the bike the wheel has also to be removed from the front Mudguard Please refer to the photos for each step and the diagram on page 16 The front wheel is most easily removed when the bike is in the Parking Fold posi tion Please see Parking Fold section starting on page 18 for more information Figure 1 Undo t
3. Lower Stem position Check the Stem is not above the minimum insert mark Check for looseness by trying to move the handlebars from side to side forward and back Handlebar grips are secure and not rotating Handlebar ends are plugged Front Hinge Self locking Catch Check that the Catch is pressed fully closed and the Secondary Safety Clip is engaged into its recess Check for excessive looseness in the Hinge Catch mechanism by pulling up and down on the handlebar grips Rear Self locking Catch Check that the Catch is pressed fully closed Check for excessive looseness in the Catch mechanism by lifting the bike up and down by the saddle Front Wheel Quick Release Assembly Check that the Front wheel is FULLY located into the recesses in the fork dropouts Check that the Quick Release Lever is tight If necessary adjust the Adjusting Nut and Lock Nut to increase the tightness and security of the Front Wheel It is of vital importance that the Front Wheel is securely held in the Fork Dropouts Brake Levers and Shifter Check for looseness by trying to rotate the levers on the handlebars Headset With the front brake applied check for play in the headset bearing by rocking back and forth on the handlebars Wheels General No play in either front or rear hubs No broken or loose spokes Check Quick Release mechanisms are correctly closed and are tight Tyres Check inflated pressure is correct Very Important for efficient riding
4. assembly or use of the bike or your failure to carry out properly the pre ride checks g indemnify ATB Sales Limited and hold it harmless against all claims by other users of the bike whom through a failure on your part have not read the manual carefully and viewed the demonstrations and or whom you have permitted to incorrectly as semble or use the bike and or whom you have permitted to ride the bike without car rying out properly the pre ride checks h And you also agree that ATB Sales Limited will not be liable for any defect in the bike arising from fair wear or tear wilful damage negligence abnormal use a failure to fot low the guidance given misuse or alteration or repair other than a repair carried out by an authorised dealer PAGE 3 ORi Manual revised indd 3 28 3 08 09 41 06 Please Note 1 A copy of the manual with instructions for folding and unfolding the bike together with details of necessary pre ride checks and other guidance for maintenance is contained within the packaging 2 DVD demonstrating the correct ways to fold and unfold the bike is also contained in the packaging 3 demonstration of the correct way to fold and unfold the bike is also available for viewing on our website www oribikes com 4 Our authorised dealers will also demonstrate the folding and unfolding procedures to you a list of our authorised dealers is on our website The bike will be safe if it is a
5. 0 of your own inside leg measur ment should be a reasonable starting point from which to fine tune to your own preference Once the height has been set to the desired level close the Quick Release Lever Make sure that after adjusting the seat height you ensure the saddle is secure and aligned correctly to the centre line of the bike as a misaligned sad dle will be uncomfortable to ride on Note that the height of the saddle can be recorded using the scale permanently marked on the Seat Post IMPORTANT SAFETY NOTICES 1 If you are unsure of how to operate a Quick Release refer to the relevant sec tion on Quick Release operation in this manual 2 Never have less than the minimum amount of Seat Post inserted into the Mainframe The minimum insert mark is marked on the Seat Post and is ap proximately 100mm from the bottom of the Seat Post SADDLE FRONT AND BACK ADJUSTMENT Tools Required 6mm Allen Key Tightening Torque M7 socket head cap screw 18 Nm The saddle can be adjusted to move it closer or further away from the handlebars The saddle rail slots are to fit standard 7mm rails To adjust this position you need to loosen the M7 socket head cap screw with the 6mm Allen key there is no need to completely disassemble the clamp and slide the saddle forward or back to the desired position Check that the saddle is at the correct angle for riding comfortably and re tighten the M7 socket head cap screw to the specified to
6. 08 09 41 44 TYRES The tyres on the ORi folding bike have been specially manufactured to offer a tread that performs well in a variety of weather conditions together with the latest development in puncture resistant technology the Kevlar Inside strip help protect against punctures Replace worn tyres or tyres which have bad cuts from glass or other debris WHEELS It is normal for any spoke wheel to settle in after approximately one months of normal riding It is especially important with the 16 wheel to get the wheel spokes re tensioned after this first months use After this the spokes should not need any periodic adjustment except to make regular inspections for loose or broken spokes The braking surface of the wheel rims will wear with normal use Regularly inspect the braking sur face of both wheel rims and consult your ORi dealer for replacement wheel rims after approxi mately 1 year or 5000 miles of normal use whichever is sooner STEERING Inspect the head bearings and check for any play as recommended in the pre ride check We recom mend servicing the headset every 6 months usually before and after the winter months SEAT POST It is important that you maintain and inspect the Seat Post Check the Seat Post for sharp edges where the Seat Post enters the mainframe Also inspect for 2 dents and other deep scratches and gouges ideally before each ride Replace any Seat Post that has den
7. Check for correctly seated tyre walls Clean any dirt obscuring the reflective sidewall strip Check for deep cuts in the tread caused by glass or other debris which could lead to punctures Brakes Check both brake levers are operating the respective brakes correctly and the bike can be stopped by either or both brakes being applied Chain and Chainset Running freely and gears operate satisfactorily and sufficient lubrication of moving parts has been undertaken Pedals Check that the Pedals have been unfolded correctly and are not unscrewing from the chainset Saddle Check the Saddle height is set to the desired height but not above the minimum insert mark Check for looseness in the Saddle and Seat Post Quick Release Clamp by trying to twist the saddle from side to side PAGE 20 ORi Manual revised indd 20 28 3 08 09 41 31 Reflectors and Lights Clean reflector lenses Check lights operate correctly if fitted Brake and Gear Cables Ensure that cables are routed freely and are not caught such that they impair function of the folding locks brakes gears steering or transmission RIDING YOUR ORi The ORi folding bike has been designed and developed to ride as safely and securely as any other standard bicycle Smaller 16 wheels will mean that handling characteristics will feel slightly different from conventional 26 or 700c wheel bikes but not in any way to the detriment of handling or safety on the road
8. E TT Ori Y WWW ORIBIKES COM OWNERS MANUAL PAGE 3 PAGE 3 4 PAGE 4 PAGE 4 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 7 PAGE 8 PAGE 9 PAGE 9 PAGE 9 PAGE 10 PAGE 10 PAGE 11 PAGE 11 PAGE 11 PAGE 11 PAGE 12 13 PAGE 12 PAGE 12 PAGE 12 PAGE 12 PAGE 12 CS PAGE 13 PAGE 13 14 PAGE 15 17 PAGE 17 PAGE 18 PAGE 19 PAGE 20 PAGE 20 21 PAGE 21 PAGE 21 23 PAGE 21 23 PAGE 24 PAGE 24 PAGE 25 PAGE 25 PAGE 25 PAGE 25 PAGE 25 PAGE 26 PAGE 26 PAGE 26 PAGE 27 PAGE 27 PAGE 27 PAGE 27 PAGE 27 PAGE 28 PAGE 28 PAGE 29 PAGE 2 ORi Manual revised indd 2 CONTENTS INTRODUCTION DISCLAIMER GETTING TO KNOW YOUR ORi BEFORE RIDING YOUR ORi MAXIMUM WEIGHT LIMIT GLOSSARY OF PARTS Right hand side of the bike GLOSSARY OF PARTS Left hand side of the bike FRONT WHEEL QUICK RELEASE ASSEMBLY GLOSSARY OF TECHNICAL TERMS SAFETY AREAS OF ADJUSTMENT SADDLE HEIGHT SADDLE FRONT AND BACK ADJUSTMENT HANDLEBAR HEIGHT HANDLEBAR ROTATION BRAKE LEVER POSITION BRAKE LEVER REACH TYRE PRESSURES RECOMMENDED SPARES FOR YOUR ORi FOLDING AND UNFOLDING YOUR ORi SELF LOCKING CATCHES DROPOUT CATCH BRAKES SEAT POST FASTENERS FINGER TRAPS HOW TO UNFOLD YOUR ORi FROM STORAGE FOLD HOW TO STORAGE FOLD YOUR ORi TIPS FOR CARRYING YOUR ORi HOW TO PARKING FOLD YOUR ORi HOW TO UNFOLD YOUR ORi FROM PARKING FOLD ORi PRE RIDE CHECK CHECK LIST RIDING YOUR ORi
9. N C8 The chain tension on the C8 is controlled by the double wheeled tensioner This device automati cally keeps the chain under tension during riding and at every point during the folding of the bike It should not be necessary for the customer to adjust the tension of the chain in any way Consult your ORi dealer if any problem with the tension of the chain should arise PAGE 24 ORi Manual revised indd 24 28 3 08 09 41 43 a ORi Manual revised indd 25 28 3 08 09 41 44 REAR WHEEL REMOVAL M9 No tools required To remove the rear wheel of the ORi M9 shift the chain into the smallest sprocket Next undo the Quick Release Lever on the rear brake calliper Figure 1 to allow the wheel to pass between the brake pads Next open the Quick Release Lever on the rear wheel Figure 2 and in the ner mal manner guide the wheel out of the dropouts whilst pulling the rear derailleur back Figure 3 to allow the rear wheel to come cleanly out of the frame The Wheel should now be free for service and repair REAR WHEEL REFITTING M9 No tools required Refitting the wheel is essentially the reverse of the removal Close the Quick Release Lever 31b according to the Closed 4 F position section on page 8 of this User Manual Also make sure you close the Quick Release Lever on the rear brake calliper Figure 4 and perform a check of the adjustment of the rear brake before riding See section below on brake adju
10. To adjust the position of the handlebars undo the two M6 socket head cap screws with the 5mm Allen key Figure 4 The handle bars can now be rotated forward and back relative to the seated position IMPORTANT SAFETY NOTE Never try and turn the handlebars with the clamp partially undone Turning the handlebars in this manner increases the risk of scoring the handlebars which signifi cantly reduces the fatigue life of the handlebar which could result in failure of the component and serious injury to the rider The handlebars have been designed with a 6 degree sweep to further enable different hand posi tions to be obtained Once you are happy with the position of the handlebar tighten the 2 M5 socket head cap screws to the specified tightening torque IMPORTANT SAFETY NOTE Please do NOT fit bar ends to the existing han dlebars The reason for this is as follows a To conform with the EN14764 safety standard the whole steering column assembly would have to be additionally fatigue tested for the specific case of bar ends being installed The previous Velotech DIN test did not include bar ends b The bar ends interfere with the bike fold making the folded width somewhat greater and potentially damaging the left side fork leg which is safety critical PAGE 10 ORi Manual revised indd 10 28 3 08 09 41 21 ORi Manual revised indd 11 28 3 08 09 41 21 BRAKE LEVER POSITION Figure 1a and effect
11. afe and dangerous bike to ride Make sure that your ORi dealer fully familiarise you with the folding clamping mechanisms on your ORi SELF LOCKING CATCHES The Self Locking catches on the ORi folding bike are a new innovation in the Folding Bike market They have been developed and tested to enable ease of use and provide the quickest folding and unfolding possible The Catches are spring loaded to constantly act to close the joint and have been engineered to allow for adjustment over time to combat normal and expected wear and tear It is important that both front and rear Self Locking catches are fully pressed closed and that the optional front secondary safety clip if fitted is engaged before you ride the bike BRAKES Using the braking system of the bike in an improper manner could lead to loss of control or cause an accident leading to severe injury We recommend that you take time to gain experience of how to apply the correct brake lever pressure to stop the bike safely together with reading and applying all relevant passages of the Highway Code to your riding Please note that braking performance is reduced in the wet A larger stopping distance is required in wet or icy conditions It is very impor tant to prevent all lubricants from coming into contact with the brake pads and wheel rims If lubricant does contact the brake pads you should replace the contaminated pads because the brakes may not work correctly causing an accide
12. ailed on Page 7 ORi Manual revised indd 5 e P bal gt _ s QD N O au G f oO OT BR 7 Number Component Description Mainframe Right Hand Pedal Right Hand Crank Arm Chain Set Chain Swinging Arm Sockal Clip Tensioner C8 Rear Derailleur M9 Wheel Nut C8 Quick Release Nut M9 PAGE 5 28 3 08 09 41 07 ST HERBE STANDING ON THE LEFT HAND SIDE OF THE BIKE Number Component Description PAGE 6 ORi Manual revised indd 6 28 3 08 09 41 07 Np 1 Ae i LA 7 gt z Fl DDD Es 2108 Number Component Description Front Mudguard Assembly Right Hand Fork Dropout 6 Quick Release Adjusting Nut 8 Quick Release Lever Cam ________ 0 Quick Release Sping GLOSSARY OF TECHNICAL TERMS There are also a few technical terms for parts and tools used in this manual that are not shown in the glossary of parts above They are The dropouts are the parts of the frame and front fork that the wheels slot into Also known as an Allen Bolt this is a bolt with a hexagonal cut out in its head An Allen Key is required to tighten loosen Used all over your ORi A twisting force in this case relating to the tightness of a nut and bolt screw or quick release A tool for setting and adjusting the tightness of nuts and bolts to a desired value ORi Manual revised indd 7 Adjustable clip used fo
13. f you intend to lift and carry the bike by the saddle nose TIPS FOR CARRYING YOUR ORi We recommend for ease of use Unfolded The easiest way to carry the ORi is to hold the bike with one hand placed under the Mainframe and the other holding the handlebars either at the handlebar grip or on the steering column Folded There are two preferred ways of carrying the ORi when folded 1 When lowering the saddle twist the nose of the saddle slightly away from your body and lift using the nose of the saddle This should let the bike hang naturally away from your body 2 Place your hand underneath the mainframe in line with the nose of the saddle For M9 derailleur bikes shift the chain into the middle of the sprockets before starting the folding procedure PAGE 17 OR Manual revised indd 17 28 3 08 09 41 30 HOW TO PARKING FOLD YOUR ORi STANDING ON THE RIGHT HAND SIDE OF THE BIKE Rotate the pedals so that the right hand Crank Arm points toward the centre of the rear wheel Figure 1 Lift the rear Self Locking Catch and release the back of the bike Swinging Arm from the Main Frame by continuing to lifting the Self Locking Catch upwards Figure 2 Still holding the Handlebars against the End Stop continue to lift the bike upwards and fold the Swinging Arm under the mainframe Figure 3 Place the bike back down on the ground The bike should be sitting on the Rear Rack Figure 4 The bike should be si
14. for wear and be prepared to adjust the brakes as the pads start to wear to restore efficient braking performance Figure 1 Figure 2 Barrel adjuster on the Barrel adjuster on the brake callipers brake lever Adjustment of the brake pad position is achieved in two ways Screw out either the brake calliper Figure 1 or the brake lever Figure 2 barrel adjuster until the brake pads are as close to the wheel rim surfaces as possible without inhibiting the free rotation of the wheel Dual Pivot Callipers are not self centering and so it is important to check that both brake pads contact the rim simultaneously If one pad contacts the rim before the other you will need to cen tralise the calliper This is done by slackening the mounting bolt with the 5mm Allen key just enough to allow the calliper to be rotated into a central position Check that the brake pads are now contact ing the wheel simultaneously and whilst holding the pads against the wheel rim tighten the brake calliper mounting bolt to the specified torque setting Note 1 When adjusting the rear brake make sure the bike is completely unfolded Note 2 Some run out meaning it s slightly out of true of the wheel rim is to be expected but only in the region of 1 2mm maximum Maximum braking efficiency is gained by a true wheel and a wheel which is buckled or has excessive run out must be re trued by your ORi dealer PAGE 26 ORi Manual revised indd 26 28 3
15. he brake Quick Release Lever on the side of the front brake calliper to allow the removal of the wheel between the brake pads Figure 2 PAGE 21 ORi Manual revised indd 21 28 3 08 09 41 32 Whilst the Quick Release Lever is tight remove the M5 Lock Nut 7 from within the Adjusting Nut 6 using an 8mm across flats socket tool Figure 3 Next Undo the Front Wheel Quick Release Lever 5 from the CLOSED position to the OPEN position Figure 4 Unscrew the adjusting nut counter clockwise and remove from shaft Pull the shaft out of the front wheel Figure 5 Pulling the mudguard stays apart the front wheel can now be sprung out of the mudguard The wheel can now be accessed in the normal way for maintenance or repair Figure 6 ends of the axle into the ramps on the front of the Mudguard ends so as to push 4 the Mudguard stays apart making sure the direction of rotation of the tyre is ji A BY correctly orientated Spring the mudguard apart to allow the wheel hub to sit into h the bobbins Figure 7 To re install the front wheel insert the wheel into the mudguard by sliding the id 32 a Swing the front wheel into the Fork Dropouts 3 4 as shown in the unfolding procedure Figure 8 Next refit the Quick Release Lever and Shaft 4 5 Cam 8 coil spring 9 and Bobbin 10 as shown Make sure the Quick Release Lever 4 is on the right hand side of the bike so the bike can be correctl
16. he travel range when in the process of tightening the Quick Release Lever by swinging the Quick Release Lever around from the Open position to the Closed position We recommend a closing force on the Quick Release Lever applied tangentially to the Quick Release Lever of approximately 130N which if measured using a spring balance a load of 13kg IMPORTANT SAFETY NOTE Do not attempt to use the Quick Release Lever see glossary 17a as a wing nut style fastener Figure 3 IWARNING Failure to properly operate and install the Quick Release Components may cause the wheel and mudguard to become detached from the bicycle while you are riding result ing in a serious accident ALWAYS CHECK BEFORE RIDING IF YOU HAVE ANY QUESTIONS ASK YOUR DEALER IMPROPER USE CAN RESULT IN SERIOUS BODILY INJURY PAGE 8 ori Manual revised indd 8 28 3 08 09 41 20 AREAS OF ADJUSTMENT SADDLE HEIGHT Figure 1 Tools Required None Tightening Torque See Quick Release Tightening in the Safety Section Adjustment of the saddle height is made by releasing the Quick Release Lever at the mainframe and sliding the sad dle up and down to the required height The correct method for determining your own personal sad dle height can vary from person to person but as a rule of thumb measured from the pedal at the bottom of the crank stroke 6 o clock to the middle of the top of the saddle a distance equivalent to 9
17. he wheel to pass between the brake pads Next undo the 17mm nuts on both sides of the wheel Figure 2 amp 3 with the 17mm A F spanner and noting which colour anti rotation washer was fitted to which side remove the nuts and anti rotation washers Now guide the wheel out of the dropouts and pulling the chain tensioner Figure 4 backwards guide the wheel down and clear of the bike in the normal manner The Wheel should now be free for service and repair To replace the rear wheel first pull the tensioner backward as you guide the wheel up into the dropouts making sure that the chain is located on the sprock ets and the shifting cable receptacle is facing forward in the correct manner as described in the Shimano technical service document With the wheel now securely in the dropouts re fit the anti rotation washers Figure 5 respectively and the wheel nuts Re tighten the nuts using the 17mm A F spanner to the specified tightening torque With the wheels now securely fitted into the frame the shift cable can now be re fitted to the hub gear Refer to the Shimano technical service document for correct instructions The last step is to close the Quick Release Lever on the rear brake calliper Figure 6 and make a final check of the adjustment of the rear brake calliper If you are at all unsure about removing the Inter 4 rear wheel refer to the Shimano Technical Service Instruction sheet SI 4R35A CHAIN TENSIO
18. i has passed the arduous DIN testing standard This means ORi has been tested for its intended use of general road riding Do not ride your ORi on rough off road terrain Incorrect use can lead to serious injury DISCLAIMER By opening the packaging or by assembling the bike or by using the bike or by allowing it to be unpacked assembled or used you are agreeing to a accept and be bound by the terms set out below and b require anyone using the bike to be bound by such terms If you are unwilling to be bound by these terms you may return the bike unused for a full refund Terms You agree that you will a read the manual carefully and follow its instructions and guidance before assembling or using the bike e b view the demonstration of the correct folding unfolding procedures on the DVD pro vided or view this on our website or ask a dealer for a personal demonstration c carry out the pre ride checks described in the manual on each occasion before riding the bike d always make sure any other users of the bike carefully read the manual view the demonstration follow the instructions and guidance given and carry out the pre ride checks before they assemble use or ride the bike e assume all the risks resulting from or arising out of incorrect assembly or use of the bike or failure to carry out properly the pre ride checks f waive any claims you may have against ATB Sales Limited resulting from the incorrect
19. lf Locking Catch closes Figure 1 Press firmly to make sure the Front Self Locking Catch is securely closed Figure 2 Open the Seat Clamp Quick Release Lever and raise the Saddle to the desireq mark on the Seat Post for riding Close the Seat Clamp Quick Release Lever Figure 3 Lever with your right pull the wheel towards you releasing it from the spring clip Figure 4 i Holding the Lower Stem with your left hand and keeping the lock stop against its stop lift the lower stem upwards and carefully rotate the Front Wheel Mud guard into the Front Forks Do this slowly so that you see the Quick Release As f sembly move out and back in thereby locating and locking the wheel correctly into the dropouts Figure 5 WARNING If you do not see the Quick Release Assembly move back in to the locked position the front wheel may not be correctly located in the fork drop outs PAGE 13 ORi Manual revised indd 13 28 3 08 09 41 21 TS HOW TO UNFOLD YOUR ORi FROM STORAGE FOLD STANDING ON THE RIGHT HAND SIDE OF THE BIKE Make sure the Front Wheel and Quick Release Assembly are fully located into the Fork Dropouts before closing the Front Wheel Quick Release Lever Figure 6 Holding the Handlebars and the Saddle lift the bike upwards by the Saddle and allow the Swinging Arm to unfold until the Rear Self Locking Catch clicks shut Figure 7 Press the Rear Self Locking Catch to make sure it is secu
20. ndesired operation which may affect the safety of your ORi Folding Bike If you have any questions on the areas you should not lubricate please ask your dealer DO NOT LUBRICATE THE FOLLOWING AREAS Component Reason for no Lubrication Front Mudguard Dropout Faces Retain Clamping Friction of Quick Release Front Fork Inside Dropout Faces Retain Clamping Friction of Quick Release Rear Swinging Arm Pivot Bearings Sealed Bearings Seat Post Retain Clamping Friction Upper Handlebar Stem Retain Clamping Friction Front Hub Sealed Unit Shimano Inter 4 Hub Sealed Unit Service at Shimano Service Centre Rear Hub Sealed Unit WARNING It is very important to prevent all lubricants from coming into contact with the brake pads and wheel rims If lubricant does contact the brake pads you should replace the contaminated pads because the brakes may not work correctly causing an accident and serious injury could result PAGE 29 ORi Manual revised indd 29 28 3 08 09 41 47 Ori W NW ORIBIKES COM Untitled 2 25 9 08 09 31 58
21. nt and seri OUS njury could result As outlined in the pre ride check section check that both front and rear brakes are functioning sat isfactorily before riding the bike The ORi comes set up with the brakes working as follows As you sit on the Bike the Right Hand brake lever operates the front brake and the Left Hand brake lever operates the rear brake Please note that parts are not guaranteed against natural wear or deterioration resulting from normal use SEAT POST The folding nature of the ORi means that for a single folding and unfolding cycle the seat post will be pushed down and then pulled up Check your seat post regularly for wear and scratches Scratches running across the post not up and down can cause areas of stress concenitration which could lead to seat post failure Please refer to the maintenance section for more information FASTENERS Using a torque wrench periodically or whenever conducting routine maintenance check that the tightness of all important screws are to the recommended settings If you are unsure get your ORi dealer to inspect and check all important fasteners PAGE 12 ORi Manual revised indd 12 28 3 08 09 41 21 a r FINGER TRAPS Whilst folding or unfolding the bicycle avoid trapping fingers in between components that are clos ing together HOW TO UNFOLD YOUR ORi FROM STORAGE FOLD STANDING ON THE RIGHT HAND SIDE OF THE BIKE Fold up the Handlebars until the Se
22. ppropriate clearance of the brake blocks from the rim Refer to page 24 for adjustment instructions TYRE PRESSURES Make sure that the tyres are inflated to the correct and recommended inflation pressure See Side wall of Tyre With small 16 wheels under inflated tyres lead to drastically reduced efficiency for the rider wasted energy greater rate of wear and increase risk of sustaining punctures from impact with potholes Keep Tyre pressures near to the upper range of the recommended settings RECOMMENDED SPARES FOR YOUR ORi When riding the ORi we recommend the rider carry the following spares as a minimum require ment 1 spare inner tubes Size 16 349 x 1 3 8 Pump A Set usually 3 levers of tyre Levers A selection of Allen Keys most important sizes are 2 5 4 5 and 6mm A 17mm A F spanner to remove C8 rear wheel nuts A small flat bladed screwdriver to assist in disconnecting the C8 rear gear cable from the hub An 8mm socket tool IWARNING These instructions are intended as a simple set up guide for the rider We strongly recommend the areas not covered by these instructions are only adjusted and serviced by your ORi dealer PAGE 11 FOLDING AND UNFOLDING YOUR ORi The folding structures of the ORi incorporate clamping mechanisms and it is essential you fully understand their operation and function Failure to operate these clamping mechanisms in the cor rect manner could result in an uns
23. r securing the front wheel assembly to the side of the bike when folded PAGE 7 28 3 08 09 41 08 SAFETY Quick Release The first Quick Release mechanism was designed and patented in 1930 by the Italian designer Tullio Campagnolo and since then has become an industry standard fastening technique for the bicycle The ORi Folding Bike uses Quick Release mechanisms in two places during the folding and unfold ing of your bike It is extremely important for your own safety that you understand and can operate the Quick Release mechanism correctly and safely Please refer to the folding and unfolding sequence section of this manual The Quick Release mechanism is essentially a simple over centre cam device with two positions Open and Closed Open Position Figure 1 In the open position the Quick Release mechanism freely rotates and nothing is clamped The OPEN mark is displayed on the Quick Release Lever Closed Position Figure 2 To close the Quick Release mechanism the Quick Release Lever must be rotated so the Quick Release Lever operates the cam and clamps the Quick Release mechanism it is restraining The CLOSED mark is displayed on the Quick Release Lever Tightening Quick Release mechanisms No Torque settings are specified for Quick Release mechanisms However you should adjust the Quick Release mechanism with the Quick Release Nut so as to feel resistance just before half way through t
24. rely closed Figure 8 8 Rotate the Handlebars clockwise to the riding position Figure 9 To unfold the pedal rotate the pedal body outwards until the mechanism snaps closed Figure 10 IMPORTANT SAFETY NOTICE Make sure the Front Wheel Quick Release Lever and the Front and Rear Self Locking Catches are pressed fully closed before riding IMPORTANT SAFETY NOTICE Make sure the rider completes the quick pre ride safety check before every trip PAGE 14 OR Manual revised indd 14 28 3 08 09 41 24 HOW TO STORAGE FOLD YOUR ORi STANDING ON THE RIGHT HAND SIDE OF THE BIKE For M9 derailleur bikes shift the chain into the middle of the sprockets B d y Pg mr TA before starting the folding procedure L4 Ji T Ma rv A x PDA T i N Rotate the pedals so that the right hand Crank Arm points toward the centre of the rear wheel Figure 1 Rotate the handlebars anti clockwise as far as they will go and hold against the end stop Figure 2 Continue to hold against the end stop and Figure 3 Lift the rear Self Locking Catch and release the back of the bike Swinging 4 Arm from the Main Frame by continuing to lifting the Self Locking Catch upwards Figure 4 PAGE 15 ORi Manual revised indd 15 28 3 08 09 41 24 Continue to lift the bike upwards and fold the Swinging Arm under the mainframe Figure 5 Place the bike back down on ground The bike sho
25. res sure hoses or jet washes These can lead to forced ingression of dirt and other contaminants into moving parts as well as into the frame itself We recommend cleaning the bike using a bristly brush with warm soapy water and remove all mud and dirt especially in areas near moving parts such as inside the mudguards Then wash the soapy water away with a sponge and wipe the bike clean with an old towel PAGE 25 r SHIMANO PARTS For up to date Shimano technical information please refer to the relevant model service guide on line or contact your local ORi dealer or Shimano Service centre DRIVE TRAIN chain sprocket s chain ring derailleur tensioner We recommend that you take time to first clean then lubricate the drive train on a regular basis to reduce the potential for accelerated wear brought about by ingression of salt mud and water etc Refer to the Lubrication table for the necessary maintenance information BRAKE ADJUSTMENT Tools Required 5mm Allen Key Tightening Torque Brake Calliper Mounting Bolt 8 10Nm Brake Pad Bolts 5 7Nm Cable Bolt 6 8Nm Both front and rear brakes on all Mezzo folding bikes are the dual pivot calliper types The set up and initial adjustment should be completed at the Factory and checked again by your ORi dealer before you purchase your bike Over time and after extensive use especially in periods of prolonged wet weather you will need to check your brake pads
26. rication Note We Recommend 3 in 1 with PTFE aerosol lubricant For Grease any good quality lithium based grease Refer to component manufacturer s service instructions Freq of Areas to Type of Lubrication Lubricate Lubrication Once a month evir Pivot Gabig Waterproof Grease Nipple Barrel Catch Pivots Hinge 3 in 1 with PTFE Pivots Once a month Catch Bar Waterproof Grease Catch Pivots Catch Bar 3 in 1 with PTFE Rear Self locking Catch Once a month Catch Bar Waterproof Grease Once a month Catch Pivot 3 in 1 with PTFE Once a month Both sides of Pivot 3 in 1 with PTFE Every six months Strip and re assemble Waterproof Grease e Once a month Calliper Pivots 3 in 1 with PTFE Every ride Chain Links 3 in 1 with PTFE Component Brake Levers Gear Shifters Front Self locking Catch Fork Dropout Catch Front Mudguard Pivot Headset Front Rear Brakes Chain Rear Derailleur Every ride Mechanism and Wheels 3 in 1 with PTFE Inter 4 Tensioner Mechanism and Wheels 3 in 1 with PTFE Front Wheel Quick Cam amp Cam Pivot Seat FOR Quick Spee men Cam Surface amp Cam 3 in 1 with PTFE Release Pivot M9 Rear Wheel Quick Cam amp Cam Pivot PAGE 28 ORi Manual revised indd 28 28 3 08 09 41 45 LUBRICATING YOUR ORi The areas detailed below are designed to operate without lubrication If these areas are lubricated the performance of the part in question will be adversely affected and could cause u
27. rque setting using the 6mm Allen Key Recheck the tightness of the M7 socket head cap screw with a torque wrench after approximately 80kms of riding IMPORTANT SAFETY NOTE Please make sure that the seat post clamp sits on the parallel section of the seat rails Figure 2 PAGE 9 ORi Manual revised indd 9 28 3 08 09 41 20 HANDLEBAR HEIGHT Tools Required 5mm Allen Key Tightening Torque M6 Fastener 7 0 8 5Nm The height of the handlebars can easily be adjusted Undo the M6 Socket head 1 cap screw with the 5mm Allen key Fig ure 1 amp 2 until the handlebar stem can easily be raised or lowered to the desired height Make sure that the handlebars En are straight and correctly aligned to the L front wheel before tightening the clamp to the specified torque setting Figure 3 IMPORTANT SAFETY NOTE Never have less than the minimum amount of handlebar stem inserted into the Upper Hinge The minimum insert mark is marked on the handlebar stem and is approximately 65mm from the bottom of the handlebar stem HANDLEBAR ROTATION and effects on folding efficiency Tools Required 5mm Allen Key Tightening Torque M6 Fastener 12 14Nm The handlebars can be rotated to provide more adjustment for the rider It is worth noting however that in the extreme ranges of adjustment the folding size will increase as the handlebars will not fold inward as closely and thus will pre trude further from the bike
28. s on folding efficiency Tools Required 5mm Allen Key Tightening Torque M6 Fastener 6 8Nm The brake lever position can be rotated on the handlebars To adjust the post tion of a brake lever undo the M6 socket head cap screw with the 5mm Allen key until the brake lever can be freely moved It is worth noting that in extreme ranges of adjustment the folding size will increase as the brake levers will not fold inward as closely and cause them to protrude further from the bike IMPORTANT SAFETY NOTE Do not partially undo the socket head cap screw and then try and force the brake lever to turn Scoring the handlebars can reduce the fatigue life of the handlebar BRAKE LEVER REACH Figure 2a Tools Required 3mm Allen Key No Torque setting adjustment only Adjustments can be made to the distance the lever is positioned from the han dlebar this is known as the reach of the lever Using the 2mm Allen key simply screw in the M3 grub screw situated on the clamp body of the Brake lever Tura ing clock mwise will reduce the distance from the lever to the handlebar and I turning anti clockwise will increase the distance from the lever to the handlebar Notes From new the lever will be positioned at maximum adjustment i e farthest away from the handle bars Changes made to the brake lever reach may require the cable to be adjusted via the barrel adjusters at either the brake lever or the brake calliper to restore an a
29. ssembled and used in accordance with the instructions and guid ance However incorrect assembly incorrect unfolding or incorrect use may result in serious injury or death Your statutory rights are not affected by these Terms and they do not exclude or limit ATB Sales Limited s liability for personal injury or death caused by its negligence GETTING TO KNOW YOUR ORi BEFORE RIDING YOUR ORi The ORi is folded and unfolded in a series of individual steps It is important that these steps are made in the correct sequence to ensure the most efficient and safe folding and un folding Please e take some time to refer to the ORi Folding Bike Folding Sequences on pages 13 19 If you received your ORi in its shipping box it is important to undertake a comprehensive check of your bike to satisfy yourself that the bike is in a safe condition to ride Please refer carefully to all the sections below Remove all extraneous packaging and protective material from the bike You will need to unfold the bike and perhaps make some adjustments to accommodate your requirements please refer to areas of adjustment starting on Page 9 MAXIMUM WEIGHT LIMIT The maximum combined weight of rider and luggage should not exceed 110kg PAGE 4 ORi Manual revised indd 4 28 3 08 09 41 06 GLOSSARY OF PARTS K STANDING ON THE RIGHT HAND SIDE OF THE BIKE 39 38 37 Component Description Number Comprised of Number 7 amp 8 as det
30. stment CHAIN TENSION M9 The chain tension on the M9 ORi is controlled by the standard rear derailleur Figure 5 It should not be necessary for the customer to adjust the tension of the chain in any way Consult your ORi dealer if any problem with the tension of the chain should arise ROUTINE MAINTENANCE There is no given rule for service intervals but usually the bike should be checked every 2000 4000 km under normal conditions This service interval may vary in case of rain dust hard use or other variables that may require the bicycle to be serviced more frequently Repairs should be carried out immediately a problem becomes apparent This increases safety and reduces repair costs by avoid ing secondary damage Handlebars should be replaced periodically or following a crash that inflicts any visible damage to the bars controls or grips The recommended interval between bar replace ments is 3 years or 40 000 km whichever is sooner Only replace the bars with a standard ORi bar or you will adversely affect folding performance CLEANING YOUR ORi In order to make routine maintenance easier and quicker we recommend cleaning your ORi regu larly As well as making the use of the bike more enjoyable the process of cleaning a bike is in itself a good way of giving the bike a good overall check Many elements of the Pre Ride Check can be covered whilst in the process of cleaning the bike When cleaning the bike NEVER use high p
31. ts and other deep scratches and gouges immediately and destroy the damaged Seat Post for safety reasons Sharp edges dents and deep scratches induce stress concentration areas which could result in Seat Post failure SOCKAL CLIP The Sockal Clip is designed to be adjustable On the top and the bottom of the Sockal Clip you will find a grub screw Using a 3mm Allen key screw both grub screws in Clockwise half a turn each to increase the force required to push and pull the Mudguard stay into and out of the Sockal Con versely screw both grub screws out Anti Clockwise half a turn each to reduce the force required to push and pull the Mudguard stay into and out of the Sockal See Step 10 To Fold Your ORi The rubber insert in the Sockal is replaceable when it wears out Contact your ORi dealer for further information WARNING As with all mechanical components the bicycle is subjected to wear and high stresses Different materials and components may react in different ways If the design life of a component has been exceeded it may suddenly fail possibly causing injuries to the rider Any form of crack scratches or change of colouring in highly stressed areas indi cate that the end of the components life has been reached and it should be replaced PAGE 27 ORi Manual revised indd 27 28 3 08 09 41 45 LUBRICATING YOUR ORi The following regime of lubrication should be undertaken Always wipe away any excess lub
32. tting on the Rear Rack Figure 5 IMPORTANT SAFETY NOTICE Make sure the Front and Rear Self Locking Catches are pressed fully closed before riding PAGE 18 ORi Manual revised indd 18 28 3 08 09 41 31 r a HOW TO UNFOLD YOUR ORi FROM PARKING FOLD STANDING ON THE RIGHT HAND SIDE OF THE BIKE The bike should be sitting on the Rear Rack Figure 1 Holding the Handlebars and the Saddle lift the bike upwards by the Saddle Figure 2 Continue to lift the bike upwards and allow the Swinging Arm to unfold until the Rear Self Locking Catch clicks shut Figure 3 Press the Rear Self Locking Catch to make sure it is securely closed Figure 4 The bike is now ready to complete the quick pre ride safety check Figure 5 IMPORTANT SAFETY NOTICE Make sure the rider com pletes the quick pre ride safety check before every trip PAGE 19 ORi Manual revised indd 19 28 3 08 09 41 31 ORi PRE RIDE CHECK All ORi bikes undergo a Pre Delivery Inspection check by your Dealer before you collect your bike however it is important before every ride to run through a pre ride check to ensure the bike is completely safe to ride If you are unsure about any area in the list below and do not feel confident to make necessary adjustments do NOT ride the bike and contact your ORi Dealer CHECK LIST Frame Fork Swinging Arm Check the condition and integrity Handlebar Upper Stem
33. uld be sitting on the Rear Rack Figure 6 Supporting the bike undo the Front Wheel Quick Release Lever Figure 7 Operate the Quick Release Assembly like a syringe to dis engage it from the recesses in the Dropouts This will release the Front Wheel and Mud guard from the Front Forks Let it swing down until it touches the ground Figure 8 Holding the Handlebars against the End Stop lean the bike away from you and swing the Front Wheel towards the middle of the bike holding on to the Front Wheel Quick Release Lever Figure 9 On the M9 model if the spokes hit the Rear Derraileur rotate the wheel slightly to avoid contact When the mudguard strut lines up with the Sockal clip push it in to lock it in place It will click in and hold Figure 10 PAGE 16 ORi Manual revised indd 16 28 3 08 09 41 30 Open the Seat Clamp Quick Release Lever and slide the Seat Post down in to the frame as far as it will go Do not lift the bike in the folded position unless the Seat Post is fully lowered and clamped Figure 11 Pushing the Secondary Safety Catch to the side open the Front Self Lock ing Catch Figure 12 Fold down the Handlebars to the side of the bike Figure 13 Stow the pedals by pushing inward towards the bike on the outside edge of the pedal body then folding downwards Figure 14 IMPORTANT SAFETY NOTICE Make sure you close the Seat Post Quick Release Lever after the Saddle has been lowered i
34. y folded Figure 9 PAGE 22 ORi Manual revised indd 22 28 3 08 09 41 40 r a Next screw the Quick Release Adjusting Nut 6 clock wise onto the Quick Re lease Shaft 5 until the Quick Release Lever 4 can be closed with enough force to clamp the wheel securely To adjust this correctly please refer to the Tightening Quick Release mechanisms section on page 8 of this User Manual Figure 10 Once the Quick Release has been correctly adjusted close the Quick Release Lever 4 to the CLOSED position Figure 11 Screw on the M5 Lock Nut 7 clock wise to lock the Adjusting Nut onto the Quick Release shaft Tighten to 5 Nm torque Figure 12 Finally Close the cable release lever on the front brake caliper and make a final check that the front brake operates correctly Figure 13 PAGE 23 ORi Manual revised indd 23 28 3 08 09 41 43 r a REAR WHEEL REMOVAL C8 Tools required 17mm AF spanner Small Flat Bladed Screw Driver Shimano technical service document SI 6E60A Tightening Torque 30 0 45 0 Nm The rear wheel of the ORi C8 is the Nexus Inter 4 hub gear Before the wheel can be removed you must disconnect the shifting cable from the hub Refer to the Shimano technical service document SI 6E60A for the correct procedure necessary With the shifting cable safely removed from the rear hub first undo the Quick Release Lever on the rear brake calliper Figure 1 to allow t
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