Servicing a Flat Tire on your Flyer™ eBike

Follow the steps below to service a flat tire on your eBike.

     Questions? Contact Customer Service for fast & friendly help. 

     Tools Needed: 18mm wrench or adjustable wrench, cable cutters, cable ties, something to cushion the front forks (examples: towel, book, foam etc.), two tire levers

     Compatible Models: Flyer™ M880 and Flyer™ L885

Getting the Bike Ready for Servicing

  1. Remove the battery.
    1__Remove-Battery_1.gif
  2. Turn the bike on, the screen should initially turn on, then quickly fade away.
    2__Remove-Excess-Power_1.gif
    **If only the front wheel needs to be serviced skip sections “Removing the Rear Wheel” and “Reinstalling the Rear Wheel.” If the rear wheel needs to be serviced please complete the rear wheel sections and the front wheel sections.**

Removing the Front Wheel

  1. Loosen the front axle quick release and remove the wheel from the bike
    • Reference Front Wheel Removal if necessary
      3__Remove-Front-Wheel.gif
  2. Place the cushioning material under the front dropouts and lower the front of the bike until the forks rest on the floor4__Tilt-Front-Down.gif

Removing the Rear Wheel

  1. If servicing the 880 skip to step 2. If servicing the 885 remove the side runners now to access the axle nuts.
  2. Disconnect the motor’s connection.
    • Trace the wire that goes into the motor back to the connector.
    • Locate the motor connector and the zip-ties that hold the motor cable in place.
      32__Locate-Motor-Connector-and-ZipTies.jpg
    • Carefully cut the zip-ties
      33__Cut-Zipties.gif
    • Pull the connector apart. Do not use any twisting motions; it may damage the internal connections.
      34__Disconnect-Motor-Connector.gif
  3. Remove Axle Hardware
    • Pull the motor wire through the bash guard
      35__Pull-Motor-Cord-Through-Brake-Cover.gif
    • Slide the right rubber axle nut cover to the end of the wire and over the connector
      36__Pull-Rubber-Cap-Off-Cable.gif
    • Use an 18mm wrench or adjustable wrench to remove the large 18mm nut and washer on the power supply side of the rear wheel (the one with the power wire)
    • Slide the nut, washer, and bash guard to the end of the power cable and over the connector
      37__Remove-Right-Rear-Wheel-Hardware.gif
    • Remove the left rubber axle nut cover.
    • Use an 18mm wrench or adjustable wrench to remove the opposite nut and the washer underneath.
      38__Remove-Rear-Left-Rubber-Cap-and-Hardware.gif
  4. Remove the rear wheel
    • Press downward on the rear wheel while holding the frame to loosen the rear wheel in the dropouts
    • Pull backward on the derailleur and guide the chain around the rear axle
    • Lift the frame upward and allow to rest on the front dropouts and kickstands
      39__Remove-Rear-Wheel.gif
  5. Perform desired maintenance, whether that be replacing the wheel, changing the tube, etc.

Removing the Inner Tube

  1. Make sure that the tire is flat before starting to work on it.

    ⚠️ Warning: It can be dangerous to work on a pressurized tire. Failure to depressurize the inner tube could result in serious injury.

    • Press down on the valve stem with something small like an Allen Key or inverted stem cap to let any residual pressure out of the tire. Apply pressure to the tread of the tire to deflate more quickly.
      7__Release-Air-From-Tire.gif
  2. Check the entire tire tread for any obvious punctures or foreign objects such as glass, metal wire or thorns and take note of the location.
    5__Check-Wheel.gif
  3. If any foreign objects are found, carefully remove them. There may be additional objects embedded in the tire.
    6__Pull-Out-Nail.gif
  4. Note the position of the tire relative to the valve stem and mark with a piece of masking tape. This will help to locate any foreign material in the tire.
    8__Mark-Tire-With-Tape.gif
  5. Unseat the tire bead from of the rim.
    • By hand, press inward on the tire at the point where it meets the rim. This will loosen the tire on the rim and make removal easier.
      9__Unseat-Tire-From-Rim.gif
    • On the opposite side of the tire from the valve stem (marked with tape in a previous step) slide two tire levers under the tire and use them to lift the tire off of the rim. Slide one of the levers around the rim to fully remove the tire bead from the rim.
      10__Loosen-Rubber-Tire-From-Rim.gif
    • With the tire loose on the rim, press the valve stem into the rim and remove the inner tube from the tire.
      11__Remove-Inner-Tube.gif

Inspect Tire and Inner Tube for Damage

  1. Identifying the damage in the Tire and Inner Tube will prevent damage to the new inner tube. There may be sharp objects trapped in the tire and the following steps will help to locate these for removal.
  2. Partially inflate the new inner tube until the tube holds its shape.
    12__Pump-Inner-Tube.gif
  3. Use a basin of water to submerge the Inner Tube. Look for bubbles rising from the Inner Tube to indicate the location of holes.
    13__Check-Inner-Tube-With-Water.gif
  4. If bubbles are coming from the valve stem area only, then the leak is not caused by a sharp object in the tire. This kind of leak is caused by too low of pressure when riding. Be sure to inflate tires to the value specified on the tire sidewall and in the user instructions. Skip to “Installing the New Inner Tube”
    15__Look-For-Bubbles-2.gif
  5. If the bubbles are coming from a pinhole in the side of the Inner Tube, then the hole is likely caused by a sharp object in the tire. Note the location of the hole relative to the valve stem.
    14__Look-For-Bubbles-1.gif
  6. Press the remaining tire bead over the rim to remove it fully from the Rim.
    16__Remove-Rubber-Tire-From-Rim.gif
  7. Use the marking tape to align the Inner Tube with the Rim.
    17__Lineup-Inner-Tube-With-Rubber-Tire.gif
  8. Use the hole identified in the water bath to locate the remaining foreign objects in the tire and remove them.
    18__Remove-Nail-From-Rubber-Tire.gif
  9. Perform one last check of the inside of the tire to identify any remaining foreign objects.
    19__Check-Rubber-Tire.gif

Installing the New Inner Tube

  1. Align the valve stem hole on the rim with the pressure rating on the tire sidewall.
    20a__Locate-Fill-Hole.jpg
  2. Ensure that the direction of rotation printed on the tire matches with the rotation of the rim. Place the rim inside of the rubber tire.
    20b__Lineup-Frame-With-Rubber-Tire.gif
  3. Working around the rim, press the tire bead on to the rim.
    21__Install-Frame-In-Rubber-Tire.gif
  4. Verify that the replacement tube matches the original tube size.
    22a_Check-Inner-Tube-Dimensions.jpg
  5. Partially inflate the new inner tube until it will hold its shape.

    ⚠️ Warning: DO NOT attempt to inflate the tube to the specified pressure now. Serious injury can occur.
    22b__Inflate-Inner-tube.gif

  6. Install the Inner Tube into the Tire
    • Align the valve stem with the valve stem hole on the rim.
    • Press the tube into the space between the tire and the rim.
    • Pass the valve stem through the valve stem hole on the rim.
      23__Install-Inner-Tube.gif
  7. Starting at the valve stem work around the wheel to press the bead onto the rim as much as is possible by hand.
    24__Install-Rubber-Tire-1.gif
  8. Using tire levers, carefully lift the remaining section of the tire bead over the rim.
    • Take care not to pinch the tube between the tire lever and the rim.
      25__Install-Rubber-Tire-2.gif
  9. Partially inflate the tire to 1/4 the recommended pressure. Inspect for any sign of a pinched inner tube or unseated tire bead.
    • Holding the axle, spin the wheel and inspect the bead to be sure that the tire is fully seated on the rim
    • If the bead is not fully in the rim, use a small Allen Wrench or the valve stem cap to let the air out and manually press the bead in place.
    • If the bead is too deeply in the rim, use a small Allen Wrench or the valve stem cap to let the air out and manually press the tire to adjust.
      26__Inflate-Tire.gif27__Check-Seam.gif
  10. Once the bead is properly set and the tire is centered on the rim. Inflate the tire to pressure rating specified on the tire sidewall and replace the valve stem cap.
    28__Inflate-Tire-2.gif
    29__Install-Tire-Cap.gif

Reinstalling the Rear Wheel

  1. Seating the chain
    • Set the wheel near the rear of the bike between the dropouts
    • Pull back on the derailleur and allow the chain to wrap over the smallest sprocket.
      41__Replace-Rear-Wheel.gif42__Reference.jpg
    • Lower the frame onto the rear axle making sure to rotate the anti-rotation washers with the tabs down
      43__Locate-Washer.jpg
    • A 10 mm wrench or adjustable wrench can be used to rotate the axle into position
      44__Rotate-Stem-With-Wrench.gif
  2. Reattach hardware
    • On the left slide install the washer then axle nut
      46__Replace-hardware-On-Left-Side.gif
    • On the right slide install the bash guard then washer and axle nut
      45__Replace-Hardware-On-Right-Side.gif
    • Press down on the frame to ensure that the axle is fully in the rear dropout. Then, using a 18mm wrench tighten both axle nuts to 40Nm 
      47__Tighten-Rear-Right-Nut.gif
      48__Tighten-Hardware-On-Left-Side-and-Install-Rubber-Cap.gif
  3. Reconnect
    • Slide the right side cover over the motor cable
      49__Replace-Rubber-Cap-On-Right-Side.gif
    • Reconnect the motor’s connection by lining up the pins and holes and embossed arrows on both connector heads. Firmly pressing both ends of the connector together. Do not use any twisting motions.
      50__Reconnect-Motor-Connector.gif
    • Reinstall zip-ties to hold cable in place.
      51__Install-Zipties.gif

Reattaching the Front Wheel

  1. Reinstall the Front wheel
    • Reference “Front Wheel Removal and Installation” if needed.
    • 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.
    • Ensure that the wheel is centered in the fork dropouts. Press down on the fork to ensure the axle is fully seated.
    • Hold the quick release lever so it is open and parallel with the ground. Tighten the opposite thumbnut completely.
      Front-Wheel-Edit-1.gif
    • 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.
        Front-Wheel-Edit-2.gif

Preparing to Ride

  1. Reinstall the battery.
    16__Install-Battery_1.gif
  2. Fully test the bike’s function prior to riding.

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