#880 Flyer™ M880 General Assembly Guide

Follow the steps below to assemble your Flyer™ M880 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.

Note: Some images will show the Flyer™ L885; however, the steps will be the same. 

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

     Compatible Models: Flyer™ M880

Getting the Bike Ready for Assembly

  1. Carefully open the outer and inner shipping boxes.
  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.
    1__Open-Box.gif
  3. With a partner carefully remove the e-Bike from the box and engage the kickstand before setting on the floor or workbench.
    2__Take-Bike-Out.gif
  4. Using flat side cutters, cut the zip ties holding the front wheel and the side boards to the frame of the bike. Set the these aside.
    3__Cut-Zip-Ties-1.gif
  5. Carefully remove the packaging from the bike except for the areas around the handlebar, where the handlebar is held to the frame and the front fork. Recycle packaging where possible.
    5__Remove-Foam-1.gif

Installing the Handlebars

  1. The stem, the part which holds the handlebar, must be rotated. This is oriented backward for shipping purposes. Using the 4mm Allen wrench, loosen the two stem bolts and rotate the stem around. Using the 4mm Allen wrench tighten the stem bolts to 5 N-m. Ensure the black braided cables leading to the handlebar stay on the left side of the bike (when oriented from the riding position).
    6__Rotate-Stem.gif
  2. Remove the handlebar stem clamp by using the 5mm Allen wrench to unscrew the 4 bolts on the handlebar stem clamp.
    7__Remove-Screws.gif
  3. Cut the zip ties holding the handlebar to the frame and remove the packaging from the handlebar and recycle contents where possible.
    8__Remove-Foam-From-Handlebar.gif
  4. Align and center the handlebar in the stem clamp according to the markings on the handlebar itself. The handlebar can be adjusted after bike assembly to best fit the rider. Reattach the handlebar stem clamp by using a torque wrench with 4mm Allen head to tighten the handlebar stem clamp bolts to 6Nm. Ensure the black braided cables leading to the handlebar stay on the left side of the bike (when oriented from the riding position); they should not loop behind the fork. 
    9__Install-Handlebar.gif
  5. Remove the remaining packaging on the bike frame and recycle contents where possible.
    10__Remove-Foam-2.gif

Installing the Fender

  1. Remove the fender from where it is packaged with the front wheel. Carefully remove the packaging and set fender aside.
    11__Unwrap-Fender.gif
  2. Locate the eyebolt near the top of the front fork and unscrew the eyebolt by hand.
  3. Position the fender in place on the fork.
    • Note: You will need to rotate the fender onto its side to slide it between the legs of the front fork.
  4. Line the bracket on the fender up to the top of the front fork. Fasten with the eyebolt. This can be done by hand.
    12__Install-Fender-1.gif
  5. Attach the fender arms to the fork. Remove the screws using a 4mm Allen wrench. Line up the fender arms to the brackets and reinstall the screws.
    13__Install-Fender-2.gif

Assembling and Mounting Front Wheel

  1. Using flat-side cutters, remove the foam protecting the front fork.
  2. Remove the front axle skewer and fork spacer from the frame.1__Remove_packaging_from_fork___skewer.gif
  3. Remove the plastic insert from the front wheel hub.
    2__Remove_pacakging_from_hub.gif
  4. Lift the bike and lower the front fork onto the wheel. Align the wheel to the forks on that the fork dropouts rest on the axle. Ensure the fork is fully seated on the axle by pushing down on the stem.
    ⚠️ Note:  Ensure the wheel is centered on the fork, and the brake rotor is centered in the caliper assembly.
    3__Install_front_wheel.gif
  5. Starting from the brake side of the fork, install the front axle by sliding it through the fork and front wheel hub. Install the axle nut onto the threaded section of the front axle. Tighten by hand.
    4__Install_skewer.gif
  6. While holding the axle nut, tighten the front axle to 6-8Nm using a 5mm allen wrench.
    5__Tighten_skewer.gif

Installing Front Fork Spring

  1. Locate the front fork spring in the provided Components Box.

  2. Remove the spring from its casing.

  3. Insert one end of the spring through the eyebolt on the fork.

  4. 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.
      18__Install-Spring.gif

  5. Install the spring cover onto the spring by pressing the open side of the cover onto the spring.
    19__Install-Spring-Cover.gif

Installing the Headlight

  1. To install the headlight, first locate the headlight mounting bolt on the front fork of the bike.
  2. Remove the bolt from the bike using a 4mm Allen wrench.
  3. Insert the headlight mounting bolt into the mount of the headlight and loosely screw it into the front fork of the bike.
  4. Position the headlight upright and tighten the mounting bolt using a 4mm Allen wrench until secure.
    20__Install-Headlight.gif
  5. To plug in the headlight first note the proper orientation of the headlight cable. There is a notch on the lower side of the cable and an associated tab on the lower side of the headlight assembly.
    •  Note: Improperly connecting the headlight cable can permanently damage the headlight or cable.
      21.A__Connect-Headlight.jpg
  6. Following the correct orientation of the cable shown in the image above. Plug in the headlight cable.21.B__Connect-Headlight.gif
  7. Position the reflector to point straight ahead. Position the headlight to point straight ahead, but the angle the headlight down slightly. This prevents the light from shining directly into oncoming traffic.

Installing Pedals

  1. Locate the pedals, which were provided in the Components Box.
  2. Determine which side each pedal is for. The right pedal has a smooth axle, while the left pedal has grooves along its axle.
    22__Determining-Pedals.jpg
  3. Apply a small amount of bicycle grease onto the threads of the cranks.
  4. Thread in each pedal by hand onto the corresponding crank. The right pedal screws on in a clockwise direction, while the left pedal screws on in a counterclockwise direction.
  5. Tighten the pedals onto the cranks with a 15mm wrench. Tighten to a torque of 35Nm.
    • Installing the Right Pedal by turning clockwise.
      24__Install-Right-Pedal.gif
    • Installing the Left Pedal by turning counterclockwise.
      23__Install-Left-Pedal.gif

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.
 

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. Adjust the bike to fit the rider.
  2. Install the battery.
    16__Install-Battery_1.gif
  3. Fully test the bike’s function prior to riding.

Download a PDF copy of your owner's manual

Was this article helpful?

49 out of 54 found this helpful

Have more questions? Submit a request

Comments

0 comments

Article is closed for comments.