Brake Lever Replacement on your Flyer™ eBike

Follow the steps below to replace the brake lever on your eBike.

     Questions? Contact Customer Service for fast & friendly help. 

     Tools Needed: 5mm Allen wrench, Torque wrench with 5mm Allen head
     If replacing the right brake lever, you will also need: 3mm Allen wrench, Torque wrench with 3mm Allen head

     Compatible Models: Flyer™ M880 and Flyer™ L885

Getting the Bike Ready for Servicing

1. Remove the battery.
   
2. Turn the bike on, the screen should initially turn on, then quickly fade away.
   

Accessing the Brake Lever

1. To access the brake lever for replacement, remove the appropriate handlebar grip by pulling and twisting.
   
   Note: If the handlebar grips are too difficult to remove try one of the following
   • Apply a few drops of rubbing alcohol under the grip as a lubricant
     
   • Use compressed air to force the handlebar grip off the handlebar
     
     
     
2. Partially remove the cable wrap to access the throttle connector and the brake lever electrical connectors.
   
3. If the right brake lever requires replacement complete the following steps to remove the throttle. If you are not replacing the right brake lever skip to “Removing Old Brake Lever”
   • Disconnect the throttle
   • Using a 3mm Allen wrench, loosen the throttle clamp bolt and remove the throttle and spacer.
     

Removing the Old Brake Lever

1. The brake cables must be loosened to allow removal of the brake lever. This will make braking impossible until the cables are tightened and adjusted.
   ⚠ DO NOT RIDE THE BIKE AFTER LOOSENING THE BRAKE CABLES
2. Locate the brake caliper that corresponds to the brake lever you are replacing.
   • Note: The right lever connects to the rear caliper, and the left lever connects to the front caliper.
3. Using a 5mm Allen wrench, loosen the appropriate cable pinch bolt. Do not fully remove the cable pinch bolt.
   • Loosening the right (rear) cable:
     
   • Loosening the left (front) cable:
     
4. To remove the cable from the lever, turn the barrel adjuster and locknut to align the slots and allow clearance for the cable.
5. Pull the cable through the brake lever housing and press the brake lever to expose the cable head.
6. Remove the cable head from the brake lever.
   • Remove the right cable:
     
   • Remove the left cable:
     
7. Locate the brake connector by following along the brake cable.
8. Disconnect the brake connector by pulling it apart on both ends without any twisting motion.
   • Disconnect the right brake connector
     
   • Disconnect the left brake connector
     
9. Using a 5mm Allen wrench, remove the brake lever clamp bolt to remove the brake lever from the bike.
   • Remove the right brake lever
     
   • Remove the left brake lever
     

Installing the Brake Lever

1. Slide the new brake lever onto the handlebar.
2. Tighten the brake clamp bolt using the 5mm Allen wrench. Then use a torque wrench with 5mm Allen head to tighten the bolt to 6Nm.
   ⚠ Brakes are a key safety feature on the bike, be sure to torque the brake lever clamp bolt properly.
   • Install right brake lever:
     
   • Install left brake lever:
     
3. Connect the brake cable by lining up the pins and holes on both sides of the connector, as well as the arrows embossed on both sides of the connector. Press the two ends together firmly; do not use any twisting motion.
   • Connect right brake lever:
     
   • Connect left brake lever:
     
4. Line up the slits in the barrel adjuster, lock nut, and brake lever body.
5. Squeeze the brake lever and slide the cable head into the end of the brake lever.
6. Release the brake lever and pull the brake cable into the brake lever body.
7. Tighten the barrel adjuster and lock nut into place by twisting the lock nut away from the barrel adjuster until the nut is pressed against the brake lever body.
   • Install right (rear) brake cable
     
   • Install left (front) brake cable
     
8. At the brake caliper loosen the locknut by turning counterclockwise and turn the barrel adjuster clockwise to fully seat the barrel adjuster.
9. Turn the barrel adjuster counterclockwise by 2 full turns counterclockwise and lock the barrel adjuster locknut by turning the locknut clockwise until it contacts the brake caliper.
10. At the brake caliper pull on the brake cable and tighten the cable pinch bolt with a 5mm Allen wrench. Then, using a torque wrench with 5mm Allen head, tighten the cable pinch bolt to 6Nm.
    • Tighten the right (rear) brake cable
      
    • Tighten the left (front) brake cable
      

Adjusting the Brake Lever

1. Test the new brake lever by squeezing the brake lever a few times. When the lever is squeezed about halfway, the brake pads should close against the brake rotor. If the brake pads close when the lever is halfway skip to “Installing Handlebar Grips”
2. Locate the appropriate barrel adjuster attached to the brake caliper.
3. Loosen the locknut by turning it counterclockwise until it contacts the head of the barrel adjuster
4. If the brake pads are contacting before the lever is depressed halfway turn the barrel adjuster ½ turn clockwise and check again. Continue this adjustment and check until the brake pads contact when the lever is depressed about halfway.
5. If the brake pads are contacting after the lever is depressed halfway turn the barrel adjuster ½ turn counterclockwise and check again. Continue this adjustment and check until the brake pads contact when the lever is depressed about halfway.
6. Once proper adjustment is reached. Hold the barrel adjuster stationary and turn the locknut clockwise until it is snug against the brake caliper body.
7. If these adjustment steps are unable to adjust the brake fully follow the Brake Adjustment Guide located here.

Reinstalling the Handlebar Grip

1. If replacing the left brake lever, i.e. handlebar side without throttle, then skip to Step #7. If replacing right brake lever, i.e. handlebar side with throttle, continue to next steps.
2. Slide the throttle onto the handlebar.
3. Then slide the spacer onto the handlebar. Ensure that the spacer is properly seated between the throttle and handlebar.
4. Use a 3mm Allen wrench head to tighten the clamp bolt on the throttle to a torque of 3Nm.
5. Plug in the throttle connector by matching the correct colors and aligning the arrows on the connector heads. Press the connector ends firmly together; do not use any twisting motion to connect.
   • Installing the throttle:
     
6. Reinstall the handlebar grips by pressing them on firmly.
   • Note: If the handlebar grips are too difficult to install apply a few drops of rubbing alcohol under the grip as a lubricant
     
7. Reinstall any coiled cable wrap that was removed at the beginning of the shifter replacement process.
   

Preparing to Ride

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