Mechanical Brake Adjustments

Follow the steps below to adjust the brakes on your eBike.

     Questions? Contact Customer Service for fast & friendly help. 

     Tools Needed: 18mm wrench, Torque wrench with 18mm head, 5mm Allen wrench ,Short or low clearance 5mm Allen wrench, Torque wrench with 5mm 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.
   

Seating the Front Axle

1. 1. Open the quick release lever on the fork of the bike and press firmly on the stem in the center of the handlebars.
   2. Tighten the thumbnut of the quick release lever until the lever can hold its position parallel to the ground instead of falling open.
   3. While holding pressure on the bicycle stem, in the center of the handlebar, close quick release lever.
   4. Lift the bike and lower the front fork onto the wheel.
      Note: When installing the wheel, the axle should go inside the dropouts of the front fork. The brake rotor should insert itself into the brake caliper between the brake pads.
   5. Ensure that the wheel is centered in the fork dropouts. Press down on the fork to ensure the axle is fully seated.
   6. Hold the quick release lever so it is open and parallel with the ground. Tighten the opposite thumbnut completely.
      
   7. Rotate the quick release lever to secure the wheel to the fork. It should require significant force to close the quick release lever. The lever will leave an imprint in your hand if properly tightened.
      • Note: While closing the quick release lever, do not touch the brake rotor.
        
   8. Test bike to verify the noise persists. If axle adjustment did not solve the issue continue to “Checking the Brake Rotor.”

Seating the Rear Axle

1. 1. If servicing brakes on rear wheel of #885, first use a 5mm Allen wrench to unscrew the 3 bolts that hold the runner to the frame.
   2. Loosen the axle nuts
      • Slide the right rubber axle nut cover off of the nut and onto the motor wire.
      • Remove the left rubber axle nut cover
        
      • Use an 18mm wrench or adjustable wrench to loosen the large 18mm nut on each side until the nuts can be turned by hand.
        
   3. Seat the rear axle.
      • Press down on the rear rack to seat the axle in the rear dropouts
      • Maintain pressure
   4. Tighten the axle nuts
      • Tighten to 40Nm an 18mm wrench.
        
   5. Reinstall the rubber axle nut covers.
      
   6. Test bike to verify the noise persists. If axle adjustment did not solve the issue continue with following steps.

Checking the Brake Rotor

1. Put the bike on the kickstand so that the brake rotor and brake pads are clearly visible.
2. Spin the wheel to make sure it is not in contact with the brake pads or the brake rotor.

   • ⚠️Warning: Do not ever touch the brake rotor. This can reduce brake performance or cause injury.

     
3. While spinning the wheel, check the brake rotor condition. If the brake rotor is wobbling or damaged, it might need to be replaced. If so, see we recommend finding a local bike mechanic to assist with a brake rotor replacement. 
   
4. Squeeze the brake lever on the handlebars to stop the wheel.

Checking the Brake Caliper

1. Make cable slack in the brake cable by loosening the cable pinch bolt using a 5mm Allen wrench. Do not fully remove the cable pinch bolt.
   
2. Check to see if there is sufficient space between the brake pads and the brake rotor.
   
   • If there is insufficient space as shown in the below image, or the pads are not parallel to the rotor, the brake caliper will need to be adjusted using the following steps (“Adjusting the Brake Caliper”).
   • If the pads are parallel to the rotor and the inner pad is 0.3mm (half the thickness of a credit card) away from the rotor skip to (“Adjusting Cable Tension”).
     

Adjusting the Brake Caliper

1. Using a 5mm Allen wrench, loosen the brake caliper mounting bolts just enough so that you are able to slightly wiggle the brake caliper.
   
   
   
   
2. Use a 5mm Allen wrench for front wheel adjustment or a short/low clearance 5mm Allen wrench for rear wheel adjustment to tighten the silver dial (Inner pad adjustment dial) on the brake caliper by turning clockwise until there is no gap between the rotor and pads.
   
3. Using the same 5mm wrench turn the silver dial (Inner pad adjustment dial) on the brake caliper counterclockwise until it clicks 3 times.
   
4. Move the brake caliper so the inner pad is 0.3mm (half the thickness of a credit card) to the brake rotor. Make sure the inner pad is parallel to the brake rotor.
   • The caliper MUST be parallel to the rotor to ensure full stopping power of the brake.
     
5. Tighten the brake caliper mounting bolts using a 5mm Allen wrench until snug.
   • Take turns tightening each bolt a small amount rather than tightening one at a time. This will help maintain the alignment.
6. Ensure that the inner pad is still parallel to the brake rotor. Otherwise, repeat the above steps.
   • Note: You may need to repeat this process of loosening, adjusting, tightening, and checking alignment of the brake caliper a few times before the alignment is correct. Ensure alignment is correct before moving on to the next step.
7. Spin the wheel to ensure that the brake pads and brake rotor are not rubbing. Otherwise, repeat the above steps.
8. Torque the caliper bolts. When tightening, alternate between the two bolts. Torque the bolts to 10-12Nm using a torque wrench with 5mm Allen wrench.

Adjusting Cable Tension

1. Preset the brake lever barrel adjusters
   • Loosen the brake lever barrel adjuster locknut by turning counterclockwise until it contacts the head of the barrel adjuster.
   • Turn the barrel adjuster clockwise until it contacts the brake lever body.
     
   • Turn the barrel adjuster counterclockwise 3 turns and tighten the brake lever barrel adjuster by turning clockwise until it contacts the brake lever body.
     
2. Prepare the caliper barrel adjuster.
   • Locate the barrel adjuster at the brake caliper (near where wheel and mounted on the frame of the bike).
     
   • Loosen the lever barrel adjuster locknut by turning counterclockwise until it contacts the head of the barrel adjuster.
     
   • Turn the barrel adjuster clockwise until it contacts the brake caliper body.
   • Rotate barrel adjuster and locknut away from the body of the brake caliper by 3 turns then tighten the lockring.
     
3. Tension the brake cable.
   • Push up on the brake caliper arm while also pulling the brake cable down to properly create tension in the cable. Push and pull until the brake cable is taut.
   • Secure the cable by tightening the cable pinch bolt to 5Nm using a torque wrench with 5mm Allen head.
     
4. Check for a rubbing sound coming from the brake caliper or rotor.
   • If there is no sound turn the barrel adjuster counterclockwise just until there is a rubbing sound.
     
5. Once a rubbing sound is heard turn clockwise 1 turn past when it stops
   
6. Spin the wheel and squeeze the brake lever on the handlebars. The brake pads should begin to engage on the brake rotor when the brake lever is halfway squeezed, as shown below. If the brake does not engage at this point, follow the next steps to adjust cable tension. Otherwise, skip to the next section.
   

7. Adjust tension again by spinning the wheel and squeezing the brake lever.

   • If cable needs more tension, i.e. the brake pads do not engage on the brake rotor soon enough when you squeeze the brake lever, loosen the lockring, twist the barrel adjuster counterclockwise slightly, then tighten the lockring.
     
   • If the cable is too loose, i.e. the brake pads engage on the brake rotor too soon when you squeeze the brake lever, loosen the lockring, twist the barrel clockwise slightly, then tighten the lockring.
     
8. Test cable tension again and repeat the adjustment step (step 7) as needed.
9. Lastly, check again to make sure that the wheel spins freely and that there is clearance between the brake pads and brake rotor.
10. If servicing brakes on rear wheel of #885, Reinstall the Side Runner.
    • Use a 5mm Allen wrench to install the 3 bolts that hold the runner to the frame.
    • Note the smaller bolt is to be installed in the mounting hole near the rear of the bike.
      

 

Preparing to Ride

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