#850 and #851 Flyer™ Cruiser eBike and Flyer™ Cruiser Step-Thru General Assembly Guide

Follow the steps below to assemble your Flyer™ Cruiser or Flyer™ Cruiser Step-Thru 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 customerservice@radioflyer.com 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: 3mm allen wrench (included), 4mm allen wrench (included), 5mm allen wrench (included), 6mm allen wrench (included), 8mallen wrench (included), 15mm open-ended wrench (included), 18mm open-ended wrench (included), Scissors or flat-side cutters, Tire pump, Pedal grease (recommended), Torque wrench (recommended)

     Compatible Models: Flyer™ Cruiser eBike model #850, Flyer™ Cruiser Step-Thru eBike model #851 

Note: This guide will demonstrate assembly of the Flyer™ Cruiser Step-Thru model; however, assembly will be the same on the Flyer™ Cruiser eBike model.

Preparing the Bike for Assembly

  1. Carefully open the shipping box.
  2. 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.
  3. Remove the front and rear packaging foam and set aside.
  4. With a partner, remove the bike from the outer shipping box and set on a flat clean surface. Be sure to place the bike upright resting of the rear wheel and front fork.
  5. Remove all protective packaging material. Do not remove the yellow tags and labels. Using flat side cutters, cut the zip ties holding the front wheel and the fender and kickstand to the frame of the bike.850-Assembly-2.gif
  6. Verify that you have all the components listed below. Contact Radio Flyer Customer Service if any components are missing.
    • Front Wheel

    • Front Fender

    • Pedals

    • Headlight

    • Headset Cover

    • Handlebar Stem Rubber Plugs

    • FLYER™ Front Logo Plate

    • Charger

    • Tool Kit

    • Keys

Installing the Kickstand

  1. Turn the key clockwise to release the battery latch then remove key. Remove the battery by sliding it vertically until it disengages from the dock rail. Slide the battery outward between the rear frame as shown.
  2.  Remove the kickstand from the packaging and verify that the kickstand bolt and washers are installed.
  3. Remove the kickstand bolt and washers using the provided 8mm allen wrench if necessary. Set these aside.
  4. Align the kickstand with the mounting plate located near the rear fender. Ensure the kickstand is oriented with the legs facing rearward and is installed above the chain.
  5. Install the kickstand bolt and washers through the mounting plate and into the top of the kickstand bracket. Start the bolt by hand, then tighten fully to 30Nm using the provided 8mm allen wrench.
  6. Deploy the kickstand and rest the bike on the kickstand and front fork for remaining assembly steps.

Installing handlebar stem

Your Flyer™ eBike’s handlebar stem is designed to be adjusted for optimal comfort.

  1.   Remove the protective cover from the handlebar stem and discard.

  2. Slide the headset cover onto the handlebar stem ensuring that the minimum insertion markings are clearly visible.
  3. Lift the handlebar stem above the bike frame. Inspect the cable routing and verify that the cables are on the left side of the bike and that the cables are not kinked or twisted.

  4. Insert the handlebar stem a minimum of 45mm into the fork steerer tube. Ensure that the minimum insertion markings are fully inside the fork steerer tube before proceeding.

  5. Align the handlebar with the front fork. Check that the handlebar orientation matches the image below. Ensure that the brake assembly is on the left side of the fork and that the cables are not twisted.
  6. Tighten the stem bolt to 20 Nm using the provided 6mm allen key.
  7. Slide the protective cover down to cover the headset and install the rubber caps over the stem bolt and stem clamp screws.

    Note: Complete assembly of the bike per the steps below. The stem and handlebar angle can be adjusted as needed based on rider preference. Always re-tighten bolts to the specified torque values prior to riding.

Installing the front wheel

  1. Remove the steel fork spacer by disassembling with the 18mm wrench and retain with packaging.

  2. Remove the wheel protectors taking care not to touch the silver brake disk.
  3. Remove the nuts and washers from the front axle and set aside.
    • If the axle nuts cannot be removed by hand use an adjustable wrench to hold the nut on the opposite side of the wheel. 
  4. Align the wheel to the fork so that the fork dropouts rest on the axle. Ensure the fork is fully seated on the axle and the wheel is centered on the fork. Ensure that the brake rotor is on the left side of the wheel and is centered in the brake caliper assembly.
  5. Reinstall the flat washer first, then follow with the hook washer and axle nut. Thread the nuts onto the axles by hand. Ensure that the tab of the hook washer is fully inserted into the hold of the fork before tightening the axle nuts.
  6.  Fully tighten the nuts using the provided 15mm open-ended wrench. Confirm the nuts are tightened to 25 Nm using a torque wrench.

    ⚠️ Warning! An improperly secured front wheel or handlebar stem can cause serious injury or death. Always check that the front wheel and handlebar stem are secured to the bike before each ride.

Installing Front Fender

  1. Remove the fork from the packaging and set aside.

  2. Remove the screw and washers at the top of the fork and near the hub using the provided 3mm allen wrench. Set these aside.
  3. Position the fender inside the fork. Linking up the bracket to the threaded hole in the rear of the fork. Reinstall the screw and washers using the 3mm allen wrench.
  4. Align the fender frame with the threaded holes in the fork. Re-install the screws and washers using the provided 3mm allen wrench.

    🛑 STOP: If you purchased a front storage basket of front rack accessory, please skip to installing the pedals to complete assembly of the bike. The front logo plate and headlight will be completed during the assembly of the accessories. 

Installing the Front Logo Plate

  1. Remove the screws and washers using the 3mm allen wrench and set these aside.

  2. Align the wire harness, rear brake cable, and shifter cable between the logo plate mounting posts on the headtube, Route the front brake cable to the side of the logo plate mounting posts as shown in image B.

  3. Align the logo plate with the threaded holes and reinstall the washers, lock washers, and screws using the provided 3mm allen wrench.
  4. Check that the cables and wires can move freely by turning the handlebars fully to either side. If any resistance occurs, the wires and cables should be repositioned by sliding them up or down along the headtube.850-Assembly-19.gif

Installing Headlight

  1. Using the provided 3mm allen wrench, remove the screw and washers form the front of the fork. Set these aside.

  2. Check the orientation of the headlight connector. The connector and headlight have a small tab to align the connector correctly.

  3. Fully install the connector to the rear of the headlight housing ensuring the terminals are properly aligned.

  4. Align the headlight bracket with the fork and reinstall the screw with washers using the 3mm allen wrench.

Installing Pedals

  1. Identify the right and left pedals before assembling. The pedals should be marked with a “L” and “R” and these correspond to the left and right sides of the bike relative to the rider.

  2. Install the washers onto each pedal before installing.

  3. Install the right pedal onto the crank arm by turning the axle clockwise by hand.

  4. Install the left pedal onto the crank arm by turning the axle counterclockwise by hand.

  5. Use the provided 15mm wrench to torque both pedals to 35Nm.

Reinstall the Battery

  1. Insert the battery between the frame rails and line it up above the battery dock. Press the battery downward until you hear an audible click.

Checking and Inflating Tires

  1. Check that the tire bead is properly seated around the wheel rim.

  2. Inflate the tires to 35-55 psi. Be careful not to over inflate the tires.

Preparing to Ride

  2. Reinstall the battery.
  3. Fully test the bike’s function prior to riding.

Download a PDF copy of your owner's manual

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