#886 Flyer™ Via™ Pro General Assembly Guide

Follow the steps below to assemble your #886 Flyer™ Via™ Pro eBike.

     Questions? Contact Customer Service for fast & friendly help. 

⚠️ Note: This guide is a general overview of the assembly process for your e-Bike. We highly recommend consulting a professional bicycle mechanic for assistance with your e-Bike’s assembly, maintenance, and repair. Your e-Bike will require tuning and adjustments out of the box. This can be completed by a bicycle mechanic or through following the adjustment guides below. 

This guide is not intended to comprehensively cover all aspects of your e-Bike’s assembly, maintenance, and repair.

Maintain your Flyer™ product manual for future reference. Visit https://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.

     Tools Needed: Flat-side cutters, 4mm Allen wrench, 5mm Allen wrench

     Compatible Models: #886 Flyer™ Via™ Pro

Getting the Bike Ready for Assembly

  1. Using scissors or flat-sided cutters, cut the outer carton straps located on the exterior of the packaging.

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  2. Unclip the carton clips located along the bottom edge of both sides of the carton.

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  3. Once the clips and straps are removed, the top carton can be lifted up and away, leaving the bike and lower tray intact on the floor.

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  4. Locate the hardware box on the rear rack of the bike. Inside you will find the owner’s manual.

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  5. It is recommended that two adults remove the bike from the tray and place it on a clean flat surface to continue unpacking.

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  6. Cut the zip ties securing front wheel and kickstand to the bike. Remove all the packaging from the bike except for the three corrugated supports located at the rear wheel, kickstand plate, and front wheel should remain on the bike until instructed to remove them.

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Installing the Kickstand

It's recommended that two adults are present during the completion of this assembly step to ensure the stability of the bike.

  1. Remove the packaging located beneath the kickstand mounting plate between the pedals and rear wheel. 

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  2. Remove the kickstand from its packaging.

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  3. Locate the tool kit in the hardware box. Inside the tool kit, you will find an 8mm allen wrench for installing the kickstand.

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  4. Using the provided 8mm allen wrench, remove the kickstand bolt and washers. Set them aside.

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  5. Align the kickstand with the mounting plate located between the pedals and rear fender. Ensure that the kickstand is oriented in the correct direction with the feet angled rearward, positioned below the chain. 
  6. Install the kickstand bolt and washers through the mounting plate and into the top of the kickstand bracket. Tighten the bolt by hand.
  7. Fully tighten the kickstand bolt using the 8mm allen wrench (Required Torque: 30Nm). Deploy the kickstand.

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Removing the Remaining Packaging

  1. Prop the bike on its kickstand. Remove the remaining packaging from the bike, including the corrugate supports at the front and rear wheels.

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Installing the Handlebars

Note: Complete the assembly of the handlebar per the steps below. The height of the stem and angle of the handlebars can be adjusted, as needed, based on ride preference. Always retighten bolts to their specified torque values prior to riding.

  1. Using the 4mm allen wrench, loosen the four bolts and remove the handlebar clamp.

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  2. Reinstall the handlebar clamp and tighten the four bolts with the 4mm allen wrench (Required Torque: 6-8Nm).

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  3. Be sure to align the center of the handlebar in the clamp, using the markings as guides, before tightening the clamp bolts.
    886-Assembly-Guide-Gif-13.3.gif

  4. The gap between the clamp and stem should be even on the front and back after tightening.

    886-Assembly-Guide-Gif-13.gif

 

Installing the Fender & Headlight

🛑 STOP: Note, if you plan to install a front accessory, like the Front Storage Basket, you should follow the instructions included with the front accessory as the mounting location of the headlight will vary,

  1. Locate the headlight in the components box.

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  2. Using the 4mm allen wnrech, remove the screws on either side of the fork. Set aside.

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  3. Align the fender stays with the threaded holes on either side of the fork. Reinstall the bolts and washers using the 4mm allen wrench. Be sure to match the hardware stack-up shown below.

    1- Plastic spacer
    2- Fender stay
    3- Washer
    4 - Bolt

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  4. Using the 5mm allen wrench, remove the screw and washer from the back of the fork. Align the fender followed bythe headlight bracket with the fork. Reinstall the bolt using the 5mm allen wrench.

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  5. Align the terminals on the headlight connector with the plug hanging from the bike.

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    Note: The headlight angle should be adjusted to illuminate the road ahead while ensuring the beam will not blind or obscure the vision of oncoming traffic or pedestrians.

    It is not recommended to ride at night. If riding at night cannot be avoided, ensure that the headlight is always on and functioning correctly while you are riding.


Installing the Front Wheel

Note: Touching the brake rotor or pads with bare skin can result in natural oils transferring to components which can results in reduced braking performance or noisy operation. 

  1. Remove the brake pad spacer from the front caliper before attempting to install the front wheel. While the spacer is removed, do not squeeze the front brake lever as it may damage the brake pads.
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  2. Using a 6mm allen wrench to remove the front through-axle. Note: bike is shipped with an aluminum spacer installed in the fork dropouts to prevent damage during shipment. Remove the spacer and discard.
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  3. Align the wheel to the fork so that the fork dropouts align on the axle. Ensure the wheel is centered on the fork, and the brake rotor is centered in the caliper assembly.

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  4. Starting from the brake side on the fork, install the front through-axle by sliding through the fork and front wheel hub. Tighten by hand.

  5. Tighten the front through-axle using the 6mm allen wrench (Required Torque: 6-8Nm)

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Installing the Steering Spring

  1. Locate the steering spring and cover in the tool kit.

  2. Pull the spring to hook the other end of the spring around the eyebolt on the frame.

    • Note: To gain additional grip on the spring, use the 4mm Allen wrench to hook the open end of the spring.
    • Note: You should be an audible snap noise when the spring seats itself properly into hole.Insert one end of the spring through the eyebolt on the fork.

     

  3. Install the spring cover onto the spring by pressing the open side of the cover onto the spring.



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Installing the Pedals

  1. Locate the pedals, in the Components Box.

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  2. STOP! Properly identify the right and left pedals before assembling to avoid damage to the pedals or crank. The right will have a smooth axle while the left pedal will have notched in axle. 

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  3. Thread in the left pedal by hand onto the corresponding crank. The left pedal screws on in a counterclockwise direction. Tighten the pedal onto the crank with a 15mm wrench (Required Torque: 35Nm).

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  4. Thread in the right pedal by hand onto the corresponding crank. The right pedal screws on in a clockwise direction. Tighten the pedal onto the crank with a 15mm wrench (Required Torque: 35Nm).

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Installing the Running Boards

  1. Use the 5mm allen wrench to remove the two bolts from the bottom of both running boards.

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  2. Align the frame-ends of the right running board with the receivers in the frame. Insert the running board into the frame.

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  3. Ensure the align tabs on the bottom edge of the triangle-shaped fender cover engage with the two cut-outs on the footboards. It may be necessary to lift the triangle cover up slightly by hand to align the tabs.

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  4. Reinstall the bolts and washers using the 5mm alle wrench. Fully tighten the screws (Required Torque: 10Nm).

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  5. Repeat this section for the left running board.

Assembling the Kid & Cargo Carrier

  1. Align the left and right hoops with the front A-frame support. Note, the front support has the smaller baseplate. Be sure the Flyer logo on the endcaps is facing up.
  2. Install the four 25mm barrel bolts through the holes that run through the top hoops and the A-frame support. Install a 10mm screw into the bottom of each barrel bolt, by hand. Repeat this process to secure the top hoop to the rear A-frame support.

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  3. Slide a lock washer and a flat washer onto each of the four M5x22 bolt.

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  4. Set the Kid & Cargo Carrier onto the bike’s rear rack. Ensure the A-frame with the larger plate is at the back of the bike. Align the holes in the A-frame supports with the holes in the rear rack.
  5. Thread the four M5x22 bolts into place by hand. Note, the two bolts at the rear will be installed from underside, while the two at the front will be installed from the top. 

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  6. Fully tighten the bolts to 3Nm using the 4mm allen wrench.

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  7. Use one 3mm allen wrench to hold the barrel bolts in place, while the second wrench to tighten the screws to 3Nm.

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  8. Place the short seat pad in the rear position on the rear rack and the long seat pad in the front position. Note, the notched ends should face outward. Make sure all the straps hang down outside of the rear rack. The raised features on the bottom side of the seat should align with the horizontal bars.
  9. Loop the long Velcro strap in between the opposing D-ring under the rack. Secure the seat pad in place by pulling firmly on the Velcro strap and adhering it to itself. If properly tightened, the seat pad should not shift when jostled.


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  10. Repeat on for the front seat pad.


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  11. Wrap the padded backrest around the rear A-frame so that the Flyer logo is facing rearwards. Secure the snaps along the bottom edge.

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Checking and Inflating Tires

  1. Check that the tire bead is properly seated around the wheel rim.
  2. Inflate the tires to 30psi. Be careful not to over inflate the tires.

Adjusting the Bike Fit

Handlebar Position

  1. To adjust the handlebar position. Use the 4mm allen wrench to loosen the four stem bolts.

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  2. Rotate the handlebar to the desired position, checking to ensure the handlebar is centered left-to-right in the stem clamp. Retighten the four stem bolts (Required Torque: 6-8Nm). The spacing should be equal on the front and rear of the clamp.

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Brake Lever Position

  1.  To adjust the position of the brake levers, use the 5mm allen wrench to loosen the two clamps bolts on the brake lever.
  2. Rotate the brake lever to the desired position and retighten the bolts.

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Saddle Position

  1. To adjust the position of the saddle, use the 6mm allen wrench to loosen the saddle clamp bolt. Slide the seat forward or rearward about the seat post to the desired position. Be sure the saddle position is within the marked range on the righthand saddle rail. Retighten the saddle bolt.

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Preparing to Ride

BEFORE RIDING, THE BRAKES MUST BE INSPECTED AND ADJUSTED ACCORDING TO THE BRAKE ADJUSTEMENT GUIDE

BEFORE RIDING, THE HEADSET MUST BE INSPECTED AND ADJUSTED ACCORDING TO THE HEADSET ADJUSTEMENT GUIDE

  1. Install the battery.
  2. Fully test the bike’s function prior to riding.
  3. Note: To adjust the tension on the suspension fork, you will need a 6mm Allen wrench. For a looser suspension, turn the wrench counterclockwise. You can back it out until you hit a wall. To tighten, turn the wrench clockwise. Once you start hearing a click, you have tightened the suspension all the way.

Download a PDF copy of your owner's manual

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