Follow the steps below to assemble your Flyer™ Folding Cargo eBike.
Questions? Contact Customer Service for fast & friendly help.
⚠️ Note: This guide is a general overview of the assembly process for your eBike. We recommend consulting a professional bicycle mechanic for assistance with your eBike’s assembly, maintenance, and repair.
This guide is not intended to comprehensively cover all aspects of your e-Bike’s assembly, maintenance, and repair.
Retain your Flyer™ product manual for future reference. Visit flyer.radioflyer.com or contact firstname.lastname@example.org for additional assistance assembling, using, repairing, or maintaining your e-Bike.
Note: Before unboxing your e-Bike, begin by taking photos of all four sides of the box, including all labels. Save these photos for your records.
Note: Due to the size and weight of the bike, it is recommended that two adults remove and lift the bike from the carton.
Note: It is helpful to have a partner help hold the bike during the early stages of the assembly. If a partner is not available, the bike can be leaned against a rigid wall until the kickstand is installed.
Tools Needed: Scissors or Diagonal Cutters, 5mm Allen wrench, 8mm Allen wrench, 13mm/15mm open-ended wrench
Compatible Models: Flyer™ Folding Cargo eBike, model #860
Preparing the Bike for Assembly
- Carefully open the shipping box.
- Remove the Charger Box and Components Box. Set these aside as they contain the tools and instructions to assemble the e-Bike as well as important maintenance and warranty information.
- Remove the additional cardboard packaging and set aside for recycling.
- With a partner carefully remove the e-Bike from the box and set on the floor or other flat, clean surface.
- Remove the bubble wrap and foam packaging, using scissors or diagonal cutters, where necessary to cut the zip ties.
- Remove the remaining cardboard packaging, setting aside for recycling, and extend the bike fully. Be sure to engage the frame latch by pushing against the frame until you hear the latch click into place.
Installing the Kickstand
- Remove the kickstand from the packaging and unscrew the mounting bolt by hand. Note: The kickstand has grease inside the joint that can stain clothing.
- Hold the kickstand centered in the kickstand bracket, just behind the battery, with the legs facing backward. Return the lock washer and flat washer to the bolt. Thread the bolt by hand into the top of the kickstand until it is too difficult to turn. Then tighten fully to 30 N-m using the 8mm Allen wrench.
- Once the kickstand is fully installed, engage the kickstand to keep the bike upright for the remaining assembly steps.
Positioning the Handlebar Stem
- The stem, the part which holds the handlebar, must be positioned and tightened. First, raise the stem so that it is above the frame.
- Using the alignment decals align the fork and stem to the frame.
- Next, the top cap bolt must be tightened to 6 N-m using the 5mm Allen wrench. This removes any additional space between the stem and fork allowing it to move smoothly without knocking.
- Next, the stem binder bolts must be tightened to 6 N-m using the 5mm Allen wrench. Warning: These bolts are responsible for maintaining stem attachment to the fork. If a torque wrench is unavailable, it is better to overtighten these bolts. Loosen stem binder bolts could result in a loss of bike steering.
- Once the stem is fully tightened, raise the stem and lock into place with the stem latch.
Installing the Handlebars
Using the 5mm Allen wrench, remove the two bolts on the stem clamp to remove the stem faceplate.
- Place the handlebar into the stem clamp. Check that the cables are on the left side of the bike, not in front of the fork and that they form smooth curves with no kinks. Be sure not to twist the cables during this step.
- Rotate the handlebars downward so that both bolt holes are visible in the stem clamp. Reinstall the stem faceplate and install both stem clamp bolts. Using the 5mm Allen wrench alternate tightening each bolt to maintain even spacing of the stem faceplate. Tighten fully to 6-8 N-m.
- Inspect the headlight plug and socket. Install the headlight plug into the socket making sure to match the orientation of the socket with the plug. Rotate the headlight upward so that the headlight beam faces forward.
Installing the Right Pedal
- Install the pedal washer on to the threaded shank of the pedal.
- Turn the pedal shank clockwise to thread it into the crank.
- Use the provided 15mm wrench to tighten the pedal to 35 Nm.Note: We recommend applying pedal grease prior to installation.
Checking and Inflating the Tires
Check that the tire bead is properly seated around the wheel rim.
Inflate the tires to 30psi. Be careful not to over inflate the tires.
Preparing to Ride
- ⚠️ Note: BEFORE RIDING, THE BRAKES MUST BE INSPECTED AND ADJUSTED ACCORDING TO THE BRAKE ADJUSTEMENT GUIDE
- Adjust the bike to fit the rider.
- Install the battery.
- Test bike fully before riding.
Download a PDF copy of your owner's manual below: