Folding Cargo Folding Cargo Getting Started ASSEMBLY INSTRUCTIONS The following steps provide a general overview of the assembly process for your eBike. It is recommended to consult a professional bicycle mechanic for assistance with your eBikes assembly, maintenance, and repair. Visit flyer.radioflyer.com or contact customerservice@ radioflyer.com for additional assistance assembling, using, repairing or maintaining your eBike. WARNING! Incorrect assembly, maintenance, or use of your Flyer eBike can cause component failure, loss of control, serious injury, or death. Please note, the assembly and first fit of your Flyer eBike require special tools and mechanical skills. It is highly recommended that the assembly and adjustment are completed by a reputable bicycle mechanic when possible. The following items are required for assembly:
5mm allen wrench (included) 8mm allen wrench (included) 15mm open-ended wrench (included) Step 1: Unpack your bike Note: Due to the size and weight of the bike, it is recommended that two adults remove and lift the bike from the carton. Remove the bike from the outer carton and set it on a flat, clean surface. Lean the bike up against a rigid wall and make sure it is stable. Remove all protective packaging material and carefully cut all zip-ties to avoid damaging the paint. Verify that you have all of the components listed below. Contact Radio Flyer Customer Service if any components are missing. Kickstand + Bolt & Washers Right Pedal + Washer Keys Charger Tool Kit Step 2: Install kickstand A. Release the rubber latch that holds the bike in the folded position. Re-attach this latch to the pin located on the rear frame. B. Unfold the bike frame until the front and rear frames are aligned. C. Push the frame folding latch closed until you hear a click. D. Make sure the bike is leaning against a stable surface. Unscrew the bolt and washers from the top surface of the kickstand. E. Align the kickstand in bracket underneath the bike frame. Make sure the legs are pointing towards the rear wheel. Reattach the lock washer on the bolt. Then, reattach the washer on the bolt. Tighten the bolt by hand until it is too difficult to turn. F. Tighten the kickstand bolt to 30 N-m using a torque wrench with 8mm hex bit. B D E A C F Warning: Failure to not secure the kickstand properly could cause it to fall off during riding. Step 3: Position handlebar stem Your Flyer eBikes handlebar stem is designed to be adjusted for optimal comfort. A. While holding the front wheel in place, rotate the stem to the rough location depicted below. B. Align the arrow decals on the frame, stem, and fork to ensure that the Stem is assembled straight. Check to make sure the cables are not twisted around the stem. C. While keeping the arrows aligned, tighten the top stem bolt to 6 N-m using the 6mm allen key. D. While keeping the arrows aligned, tighten the side stem bolts to 6 N-m using the 6mm allen key. E. Rotate the stem up until it is straight. F. Push the stem latch closed until you hear a click. Warning: Failure to properly tighten the stem may result in a loss of steering and could cause injury or death. A D B E C F Step 4: Install Handlebars A. Using the provided 4mm allen wrench, loosen the two stem clamp bolts. B. Place the center of the handlebar in between the stem clamps. Tighten both bolts by hand making sure the handlebar can still freely rotate. Check to see that the cables are not twisted around the stem. C. Rotate the plastic wire harness to the position depicted below. Make sure both cable bundles are fed through the hooks under the plastic housing. D. Rotate the handlebar until the preferred position is achieved checking to ensure the handlebar is centered left-to-right within the stem clamp. E. Evenly tighten the bolts to 6 to 8 Nm using a torque wrench. F. Ensure the gap between the stem and clamp is even. Note: Complete assembly of the bike per the steps above. The stem and handlebar angle can be adjusted as needed based on rider preference. Always re-tighten bolts to the specified torque values prior to riding. A D B E C F Step 5: Install headlight A. Fully install the connector to the rear of the headlight housing. Make sure the headlight wire is installed in the correct orientation by aligning the small rib on both connectors. B. Adjust the angle of the headlight beam to illuminate the road ahead, while ensuring the light will not blind or obscure the vision of oncoming traffic or pedestrians. A B Note: It is not recommended to ride at night. If riding at night cannot be avoided, ensure the headlight is always on and functioning correctly while you are riding. Step 6: Install right pedal A. Install washer onto the right pedal before installing. B. Install the right pedal to the crank arm by turning the axle clockwise by hand. C. Use the provided 15mm wrench to torque the pedal to 35 Nm. B A C Note: We recommend applying pedal grease to the threads prior to installation. If replacing the left pedal, make sure to install the pedal while screwing counterclockwise. Step 8: Check fastener torque values Step 9: Inflate tires to 40-50 psi Adjusting Seat Height The seat height should be set based on your personal preference. The initial seat position can be set by first placing the ball of your foot on the pedal with the crank arm in its lowest position. In this position, your leg should be almost fully extended with a slight bend in your knee. The proper seat position is important to avoid strain and potential injury during riding. Consult a trusted, reputable bike mechanic or contact Flyer customer service for any questions related to the seat position and fit of your bike. A. Open the quick release lever located under the saddle. Rotate the lever fully open to allow the seat post to slide easily. B. Move the seat up and down by sliding the seat post in or out of the seat tube. Set the saddle to the desired height based on rider preference. Ensure that the seat post does not extend beyond the minimum seat post insertion markings on the seat post. C. Close the quick release lever fully against the seat post tube. This should take some force to ensure the seat post will stay firmly in place while riding. A B C Adjusting Stem Height The stem height should be set based on your personal preference. The proper stem position is important to avoid back strain. WARNING! The stem post must be inserted to the minimum insertion mark. Do not raise the stem post beyond the minimum insertion marking on the seat post tube. If the stem post is not inserted properly, the stem may be loose which can lead to serious injury or death. A. Open the quick release lever located under the handlebar. Rotate the lever fully open to allow the seat post to slide easily. B. Move the handlebars up and down by sliding the stem post in or out of the stem tube. Set the handlebars to the desired height based on rider preference. Ensure that the stem post does not extend beyond the minimum seat post insertion markings on the seat post. B A C Proper Bike Usage**
Folding the Bike Note: Ensure the bike is on flat ground and the kickstand is deployed before folding. Remove any accessories attached to the bike that could inhibit the folding. A. Slide the round switch on the frame folding latch. B. While holding the round switch, swing the frame folding latch open. C. Rotate the front frame 180 degrees, and make sure the front wheel rotates 180 degrees with the front frame. D. Slide the round switch on the stem folding latch. E. While holding the round switch, swing the stem folding latch open. F. Rotate the stem 180 degrees. G. Unhook the rubber latch located under the rear rack. Secure the bike closed by wrapping the rubber latch around the stem and hook it on to the metal peg. B A C F G D E Deploying and Retracting the Kickstand Warning: Make sure the kickstand is deployed before loading and unloading kids or cargo from the bike. Incorrect kickstand use could cause injury or death. A. Push the kickstand feet to the ground with your foot. B. While holding the kickstand against the ground, roll the bike backwards to engage the kickstand. C. To disengage the kickstand, roll the bike forward. If there is not enough friction between the ground and kickstand, place your foot in front of the kickstand leg before rocking the bike forward. B A C Folding and Unfolding the Pedals Warning: Always use the bike when the pedals are unfolded. Riding the bike with folded pedals could cause injury or death. A. To unfold the pedals, squeeze the plunger to disengage the lock. B. While squeezing the plunger, rotate the pedal down until you hear a click. C. To fold the pedals, squeeze the plunger to disengage the lock. D. While squeezing the plunger, rotate the pedal up until the pedal is perpendicular to the ground. A C B D Install Bluetooth tag (optional) The bike includes a holder that can house one Bluetooth location tag as a security feature. The tag must be purchased separately and activated prior to installation. For a list of compatible tags visit flyer.radioflyer.com or contact customerservice@radioflyer.com You can access the Bluetooth tag holder by removing the battery and locating the tag pocket on the dock. Push down on the tag device until you hear a click. Some Bluetooth tags require an adhesive tape to fit securely in the pocket. Charging the Battery The Flight SpeedTM battery can be charged while installed in the bike or when removed from the bike frame. Before charging, ensure the battery is off by powering off the display as described in the Handlebar Display section above. A. If removing the battery to charge, lay it down on a stable flat surface. B. Remove the rubber cover to reveal the battery charging port C. Plug the charger into the battery charging port. Push the charger plug firmly into the charging port. D. Plug the charger into a power outlet. Only connect your charger to an outlet with a rated voltage of 110-220VAC. The LED in the charger housing will turn red to indicate the charger is connected properly. E. Once the charger LED turns green (indicating the battery is fully charged), unplug the charger from the power outlet. F. Unplug the charger plug from the charging port and replace the rubber cover A D B E C F Removing the Battery Note: The battery should only be removed when the bike is stationary and powered off. Failure to do so could result in damage to the battery or electrical system of the bike. A. Insert the provided key into the battery lock. If you own multiple Flyer bikes, please ensure the 3-
digit codes on the key and lock are matching. B. Turn the key clockwise to release the battery latch. C. Remove the battery by sliding it vertically first, then diagonally towards the gap in front of the rear rack. A B C Installing the Battery A. Slide the battery down through the gap in front of the rear rack. Ensure that the ledges on the back of the battery pack align with the hooks on the dock. B. Push the battery down until you hear a click. Check to make sure the bottom of the battery sits flush against the battery dock. WARNING: Always lock the battery in place before riding. Failure to lock the battery could cause damage to the bike. A B Checking Battery Charge Level In addition to the main display, the battery charge level can also be checked directly on the battery. Before checking the fuel gauge, remove the battery following the steps outlined in the Removing the Battery section. A. Locate the battery fuel gauge at the top of the battery B. Push the button on the battery fuel gauge. Fuel gauge LEDs will light up corresponding to the level of charge in the battery pack. A B