#852 Flyer™ Cruiser Step-Thru 2.0 General Assembly Guide

Follow the steps below to assemble your #852 Flyer™ Cruiser Step-Thru 2.0 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 [e-mail] 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: #852 Flyer™ Cruiser Step-Thru 2.0

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.
   
   
   
   
   
2. Unclip the carton clips located along the bottom edge of both sides of the carton.
   
   
   
   
   
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.
   
   
   
   
   
4. Locate the hardware box on the rear rack of the bike. Inside you will find the owner’s manual.
   
   
   
   
   
5. It is recommended that two adults remove the bike from the tray and place it on a clean flat surface to continue unpacking.
   
   
   
   
   
6. Cut the zip ties securing front wheel and kickstand to the bike. Remove all the packaging from the bike except for the two corrugated supports, located at the front wheel and rear wheel, which should remain on the bike until instructed to remove them.
   

Installing the Kickstand

1. Locate the keys zip tied to handlebar and snip them free.
   
   
   
   
   
2. Turn the key clockwise to release the battery latch. Remove the battery by sliding it vertically until is disengages from the dock rail. Slide the battery outward between the rear frame as shown below.
   
   
   
   
   
3. Remove the kickstand from its packaging.
   
   
   
   
   
4. Locate the tool bag in the Components Box.
   
   
   
   
   
5. Remove the kickstand bolt and washers using the provided 8mm allen wrench. Set aside.
   
   
   
   
   
6. Align the kickstand with the mounting plate located near the rear fender. Ensure the kickstand is oriented in the correct direction and is installed above the chain.
7. Install the kickstand bolt and washers through the mounting plate and into the top of the kickstand bracket. Tighten by hand.
8. Fully tighten the bolt to 30Nm using the 8mm allen wrench.
   
   
   
   
   
9. Deploy the kickstand and rest the bike on the kickstand and rear wheel for the remaining assembly steps.
   
   
   

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.
   
   
   
   
   
2. Remove the Velcro keeping the chain ring in place.
   
   

Installing the Handlebar

Note: the stem clamp bolts will be fully tightened after positioning the handlebar in Step 5.

1. Remove the stem from its packaging.
   
   
   
   
2. Remove the protective cap from the top of the head tube and discard.
   
   
   
3. Using the 5mm allen wrench, loosen and remove the two stem clamp bolts. Remove the stem clamp plate.
   
   
   
   
4. Align the center of the handlebar in the clamp, using the marking as guides. Reinstall the stem clamp plate and use the 5mm allen wrench to tighten the bolts.
   
   
   

Installing the Handlebar Stem

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 markins are clearly visible.
3. Insert the handlebar stem at a minimum of 45mm into the fork steerer tube. Ensure that the minimum insertion markings are fully inside the fork steerer tube before proceeding.
   
   
   
4. Align the handlebar with front fork.
5. Tighten the stem bolt to 20Nm using the provided 6mm allen key.
   
   
   
   
6. Install the rubber caps over the stem bolt and stem clamp screws.
   
   
   

Adjusting and Tightening the Handlebar

1. If necessary, loose the clamp bolts and rotate the handlebar until the preferred position is achieved, checking to ensure the handlebar is centered left-to-right within the stem clamp.
   
   
   
2. Evenly tighten the bolts to 6-8Nm using a torque wrench. Ensure the gap between the stem and clamp is even at the front and rear of the clamp.
   

Installing the Front Wheel

1. Remove the brake pad spacer from the front caliper before attempting to install the front wheel. Note, while the spacer is removed, do not squeeze the front brake lever as it may damage the brake pads.
   
   
   
   
   
2. Remove the front fork spacer using the 19mm open-ended wrench.
   
   
   
   
3. Remove the packaging from the front wheel.
   
   
   
   
   
4. Remove the nuts and washer from the front axle and set aside.
   
   
   
   
5. Align the front wheel with 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 ont he fork. Ensure that the brake rotor is on the left side of the wheel is centered in the brake caliper.
   
   
   
   
   
6. Reinstall the washers and thread the nuts onto the axle by hand. Ensure the hook of the anti-rotation washers are fully inserted into the slots on the fork before tightening the nuts.
7. Fully tighten the nuts using the 15mm open ended wrench, Confirm the nuts are torqued to 25Nm.
   
   
   

Installing the 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.
   
   
   
   
   
2. Using the provided 3mm allen wrench, remove the screw and washers from the front of the fork. Set aside.
3. Align the headlight bracket with the fork and reinstall the screw with washers using the 3mm allen wrench.
   
   
   
   
   
4. Plug the connector from the headlight into the connector on the main wire harness. Ensure that the arrows of the connectors are aligned and push firmly to make the connection.
   
   
   
   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 Fender

1. Carefully remove the front fender from its packaging.
   
   
2. Remove the screw and washers at the rear of the fork using the 3mm allen wrench. Set aside.
   
3. Position the fender inside the fork, lining 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 stay with the threaded holes in the fork. Re-install the screws and washers using the 3mm allen wrench.
   
   

Installing the Pedals

1. Locate the pedals, in the Components Box.
   
   
   
   
   
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.
   
   
   
   
   
3. Install a washer over the axle of the left pedal. Install the left pedal to the crank arm by thread the axle in counterclockwise by hand. Use the 15mm wrench to torque the pedal to 35Nm.
   
   
   
   
   
4. Install a washer over the axle of the right pedal. Install the right pedal to the crank arm by thread the axle in clockwise by hand. Use the 15mm wrench to torque the pedal to 35Nm.
   
   

Adjusting the Bike Fit

Handlebar Position

1. To adjust the handlebar position, start by removing the rubber caps from the stem clamp bolts.
2. Use the 5mm allen wrench to loosen the two stem clamp bolts.
3. Rotate the handlebar to the desired position and retighten the clamp bolts.
   
   
   
   

Handlebar Height

1. To adjust the handlebar height, start by removing the stem bolt cover.
2. Use the 5mm allen wrench to loosen the stem bolt.
3. Raise or lower the handlebar to the desired height.
4. Retighten the stem bolt.
   
   

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.
   
   

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 straight section of the saddle rails. Retighten the saddle bolt.
   
   

Getting Ready to Ride

1. Reinstall the battery.
   
   

Download a PDF copy of your owner's manual

• 852-eBike-Manual.pdf6 MB