Bike Friday Ever-E-Day 2021 User manual

Using Your Bike Friday®
Ever-E-Day

Green Gear Cycling, Inc.
3364 W 11th Ave. Eugene, OR 97402
800-777-0258 USA & Canada
[phone] Int’l • [phone] Fax
www.bikefriday.com • [email protected]
version 4/30/20
800-777-0258 •[phone] www.bikefriday.com

Table of Contents
Congratulations / If You Need Help
3
A Word on Safety / Your Tools
4
Unpacking your Ever-E-Day
5
Assembly: Install seatmast and seatpost
6-10
Assembling Riser, Stem, and Handlebars
7
Connect OSATA Frame
8
Installing wiring, housing, and cabling
9
Install and connect battery
10
Using a Quick Release
11-12
Assembly: Install Front Wheel, Disc Brake
12
Adding Brake Cable Slack
13
Double Check Steering
14
Install Pedals
15
Double Check Your Bike Friday
16
Adjusting your Ever-E-Day
17-18
Saddle Height
17
Handlebar Height
18
Bike Friday Service Overhauls
19
Bike Friday Service
20
More Maintenance Tips and Information
21-23
Airport and Travel Tips
24
Warranty Information
25
2www.bikefriday.com 800-777-0258 •[phone]

Welcome to the Community
Congratulations!
You have just purchased the most versatile Electric Cargo
Bike available today. Your bike has been carefully
designed and constructed for your personal needs. All of
our bikes are manufactured in our Eugene, Oregon factory
by real cyclists who care about our customers and our
products.
Please take your time reviewing this manual before you
assemble your new Bike Friday. You will find your new
bicycle to be simple and reliable anywhere you go!
If You Need Help . . .
If you need technical assistance with any Green Gear® Cycling
product, or are unclear on the proper operation of your Bike
Friday, please email us at [email protected] or give us a
call and a Service Technician will help you get back on the
road. Our toll-free number in the US and Canada is
800-777-0258; international is [phone]. Normal
business hours are 9 a.m. to 5 p.m. Monday through Friday
Pacific Time.. Because we understand the needs of world
travelers, we offer 24-hour technical support in emergencies.
If necessary, please call our regular number and our
answering service can forward you to a Service Technician on
call.
Extra Accessories
We also sell an extensive line of bicycle and travel
accessories. Whether you are riding the local back roads or
venturing into foreign lands we have the gear you need. Call
us for information on spare tires, tubes, replacement parts,
fenders, racks, bags, or other items to complete your Travel
System. You can purchase these products from our online
store: www.store.bikefriday.com
More Information
To check out our products, find other useful information,
discover Bike Friday events and Yak with other Bike Friday
owners on the bulletin board, go to our main website at:
www.bikefriday.com
Blue skies and happy trails from Green Gear Cycling
3www.bikefriday.com 800-777-0258 •[phone]

A Word on Safety
Bicycles are a lot of fun, but improper use can result in
harm. Please, always ride safely!
• Always have all passengers wear a helmet.
• Follow the rules of the road, and be courteous.
• Use front and rear lights after dark.
• Dress appropriately for the weather, the season, and
lighting conditions. Be seen!
• Always carry a spare tube, patch kit, pump and a tool
kit.
• Keep your bicycle in good shape.
• Check your tire pressure before every ride.
• Make sure all quick releases are secure.
• Have your bicycle routinely serviced for trouble-free
travels.
Bicycle Assembly and Maintenance
Correct assembly is essential to ensuring your comfort,
performance and safety while riding the Ever-E-Day. Even if
you have the experience and tools to complete these
essential assembly steps before your first ride, Bike Friday
recommends having a reputable bike mechanic check your
work.
If you feel you do not have the experience and tools to
complete assembly and fit, Bike Friday strongly
recommends having the bike assembled by a reputable bike
mechanic for best results.
Your Ever-E-Day uses industry standard components and
most bike shops should be able to service your bicycle.
They are welcome to call or email us with questions. We
also encourage you to learn how to work on your own bike.
If you are not familiar with bicycle maintenance, consider
taking a local class. It will improve your confidence and
self-sufficiency as you venture across the globe or explore
your own hometown.
4www.bikefriday.com 800-777-0258 •
[phone]

Unpacking your Ever-E-Day
Unpacking Your Ever-E-Day From a Box
Opening your box may present an intimidating
sight, particularly if you ordered many accessories.
Do not worry; we work hard to keep our products as
simple as possible. We recommend finding a quiet
area and some room to spread out.
This manual will address the fundamentals of unpacking,
assembly and adjusting techniques. However, because
your bicycle was built for you, you might discover that
your bike was packed at the factory slightly different
than the one in this manual.
Your Ever-E-Day should only require minimal assembly. It
will take approximately 40-60 minutes and require a
basic level of technical skill.
You will need a safety knife for
cutting the box open, 4, 5 and
6mm Hex/Allen wrenches, a
15mm open/pedal wrench and
a pair of scissors (or better yet
wire cutters, snips or diagonal
cutters) to cut zip ties.
Fig. 1 Tools Required for Ever-E-Day assembly.
[Note: Depending on the components and accessories you
have purchased with your Bike Friday, your specific model
may require additional tools.]
Fig. 2 Open the shipping box and remove this manual,
packing material, and various bicycle parts at the top of
the box. Take care not to damage the frame while cutting
zip ties.
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Unpacking your Ever-E-Day
Remove the bubble wrap and zip ties
to expose your seatmast, seatpost, and
saddle. Minding the minimum insertion
marks, install these components using
the 5mm Allen as shown to the right in
Fig 3.
Note: The minimum insertion mark is
etched at 4” from the bottom on the
mast. This is the minimum amount of
the mast that must be inserted
(overlapped) in the frame.
Now the bike is ready to be lifted and clamped in a repair
stand if desired. The instructions for assembly will
proceed as if you do not have a repair stand available.
Fig. 4. Either cut the front panel of the box and fold it
down, or lift the bike out of the box so it is set up as
shown. Accessories and components will differ for your
specific Ever-E-Day ensemble.
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Assembling your Ever-E-Day
Assembling Riser, Stem, and Handlebars
Locate riser clamp [Fig.5] Push down the button on the steerer
tube, slide riser clamp over steerer tube until button pops into
place. [Fig. 6] Tighten riser clamp. [Fig. 7]
Check that this system is secure by holding the front wheel
between your legs and attempt to turn the handlebars. If
properly adjusted you should be unable to turn the handlebars
while the wheel is held in place.
Fig. 5 Riser Clamp Fig. 6 Push Button Fig. 7 Tighten Riser Clamp
Cut zip ties over the front wheel and handlebars [Fig.8]
Check that all cables and housing are not kinked or twisted
around before installing [Fig.9] . Also note minimum insertion
mark on aluminum riser. This mark must be covered by the top
of the riser clamp for safe riding. Use 5mm allen to tighten.
Fig. 8 Cut zip ties over the
front wheel and
handlebars
Fig. 9 Ensure housing is untwisted
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Assembling your Ever-E-Day
Fig. 10 Remove sizing bolt
Fig. 11 Insert front section
Fig. 12 OSATA frame aligned
properly
Fig. 13 Tighten pinch bolts and
sizing bolt.
Attaching front section to
mid section (One Size
Adjusts To All (OSATA))
Cut zip ties and remove packing
material on the front frame
section. Remove the sizing bolt
from the front frame section.
[Fig.10]
Insert the front frame section
(male) into the frame mid
section (female) opening.This
connection should be greased
and slide easily when aligned.
[Fig. 11] Align threaded hole at
end of front section to
preferred OSATA sizing hole.
50-60cm range. Reinsert sizing
bolt.[Fig. 13]
Before tightening the OSATA
pinch bolts, align the frame by
sighting along the riser and seat
mast. Riser and mast should be
parallel.[Fig.12]
Tighten the sizing bolt. Tighten
the main frame pinch bolts with
a 5mm hex wrench. [Fig. 13]
Alternate tightening OSATA
pinch bolts until 8-10 Nm
torque is reached. This is
important for handling and
safety!
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Assembling your Ever-E-Day
Installing wiring, housing, and cabling
Seat cable housing for rear brake
into rear cable stop and pull
front section of housing into front
cable stop. Repeat this process
for the rear derailleur.
[Fig. 14]
Fig. 14 Seat housing in stops
Integrated front and rear LED lights come
standard on the Ever-E-Day. Connect red to
red, black to black for the front light. If you
get the order incorrect don’t worry, the light
just won’t turn on. Flip the order and try
again. [Fig. 15] The rear light wiring
connects red to “+” and black to “-” [Fig. 16]
Fig. 15 Front Light
Fig. 16 Rear Light
Fig. 17 Wiring Detail Fig. 18 Speed Sensor
Wiring connections behind the bottom bracket shell are tested at the
factory. [Fig. 17] Small arrow/triangle on speed sensor should align
with magnet on rear wheel. [Fig. 18]
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Assembling your Ever-E-Day
Install, connect and charge battery
Locate Separately wrapped battery and battery bag. Bag can be
attached to saddle rails and seatpost. [Fig. 20] Bag and battery can also
be attached to seat stays between seatmast and rear rack. Battery,
battery cable, and charger use Anderson quick-connectors. Connect Red
to Red, Black to Black. [Fig. 20]
Batteries have built in protection against misuse, but it is still
important to prevent damage, including water penetration from
harming the Battery. We recommend fully closing the battery bag with
the wiring exiting the bag from the lowest point. [Fig. 21] To recharge
the battery use the barrel plug connector or Anderson connector
depending on the type of battery and charger you have.
Fig. 20 Battery in bag Fig. 21 Ready to connect or charge
Electrical wiring is secured with a combination of zipties, spiral wrap,
and velcro straps for ease of customization, maintenance, and
upgrading.
The battery charger works like a standard laptop battery charger.
Several hours may be required for charging, depending on battery size
and level of charge.
If you’re not using your electric bike for a while, it is best to remove it
from the bike and store it in a warm area at least 40 degrees
Fahrenheit or more It’s best to keep it around 40 to 90 percent charged
during this storage. Do not leave the battery on the charger during
storage, but charge it every month or so to keep the levels in check.
Batteries that are not cared for can deplete beyond the point of
recharge and become unusable or have a shortened lifespan.
10 www.bikefriday.com 800-777-0258 •[phone]

Using a Quick Release
Using Those Nifty Quick Releases
The quick release is one of those simple but great inventions that really
makes life better. However, if used incorrectly, it can be potentially
dangerous. Although a reliable and safe product when used properly,
people have been injured or killed due to improper use.
If you are not familiar with their operation,PLEASE study these
directions carefully. If you are still unclear on their operation, call
us or contact your local bike shop before you ride!
Quick Release Operation
A quick release has a simple cam with a lever that swings through an
arc that is square to the axle. As the lever moves, the cam clamps the
wheel to the frame, or secures the frame joint. It is not a wing nut to
be rotated around the axle.
The tension on the quick release is controlled by how tight the knurled
nut on the other end is set. Only wheel quick releases have the small
cone-shaped springs. Note that the small ends of the springs face
toward the center of the hub.
Quick Release Maintenance
We recommend adding a few drops of light oil to the lever where it
enters the cap several times per year. This will keep your quick release
working smoothly for years.
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Assembling your Ever-E-Day
Install the Front Wheel
Make certain the wheel is fully
seated in the fork drop-outs,
with the disc brake rotor
properly aligned, you can now
securely close the quick release
lever. [Fig 20.] The quick release
levers (front and rear) are to be
placed on the non-drive side of
the bicycle. When the quick
release is properly adjusted, you
should be able to freely swing
the quick release lever for the
first half of its arc, at which
point the lever should offer
resistance but still allow for the
lever to be fully closed.
Fig. 20 Secured quick release.
Disc Brakes
When inserting the front wheel into the fork, ensure the disc
rotor (on wheel) fits nicely into the slot on the caliper (installed
on the fork leg). You will want to avoid the rotor getting hung
up or caught on some part of the caliper as you are installing
the wheel into the fork to prevent rotor damage. Also avoid
touching the disc brake rotor as oil can make your brakes squeal
and degrade brake performance.
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Assembling your Ever-E-Day
Fine Tuning the Brakes
For quick minor adjustments to
the brake tension in the brake
cable, you can turn the barrel
adjuster on the brake lever. Turn
this adjuster clockwise to loosen
the cable or counter clockwise to
add tension to the cable. Ensure
that you don’t thread the barrel
adjuster out too far and always
tighten the lock nut to the lever
after making an adjustment.
More major adjustments can be performed at the brake caliper. Some
brake calipers feature both individual pad and cable adjustment while
others only off cable adjustment and control over the fixed pad. Since
these adjustments can, please consult with the manufacturer's
instructions or contact us and we can provide you with the necessary
information.
ALWAYS DOUBLE CHECK YOUR BRAKES BEFORE RIDING!
Improperly adjusted brakes can be a recipe for disaster.
If you are not confident in your brakes, please have them inspected by
a local bike shop.
Assembly: Pedals
Pedal Thread Directions
Bike pedals have two different thread directions. The right pedal has a
right-hand (clockwise) thread, and the left pedal has a left-hand
(counter-clockwise) thread. Pedals are often stamped with an R or L on
the pedal axle near the threads. Always grease your pedal threads on
new pedals before their first installation. We recommend starting
thread engagement with your hands instead of a wrench. If something
doesn’t feel right STOP. It is very easy to trip the thread of an
aluminum crank arm if pedals are installed incorrectly.
Mechanic’s Tip: You can put a wrench on the pedal’s wrench flats,
and use a back pedaling motion to screw the pedals on. This is a
quick and easy way to remember which way to thread your pedals
on and is applicable to either side of the bike.
13 www.bikefriday.com 800-777-0258 •[phone]

Double Check Your Friday
Double Check Your Bike Friday!
At this point your bike should be ready to ride. However,
before you ride away, be sure to double-check your assembly.
• Are the handlebars tight?
• How about the stem and pedals?
• Are the quick releases all secure?
• Is the saddle secure and at a reasonable angle?
• Are the handlebar and control levers in a proper place
and clamped tight?
• Do the electronics power on?
Although we always inflate the tires at the factory, check
your tire pressure for proper inflation. Under-inflated tires
not only wear faster and are more prone to flats, but they
also add rolling resistance.
Be sure to have at least the 5/6mm wrenches with you for
quick roadside adjustments. You will probably want to stop
and adjust saddle height and the angle, as well as perhaps
adjust a few other items during your first ride or two.
Mechanic’s Tip: Grease is your friend. Be sure to keep a
light film of grease on any intersecting bike parts. This
will help to prevent corrosion, facilitate disassembly, and
eliminate annoying noises. Areas include: Ever-E-Day frame
coupling joint, seatposts, saddle rails, handlebars, stems,
pedal threads and seatmast. Doing this a couple of times
per year during routine maintenance should be enough.
Wipe off any excess or visible grease. Also be sure to
lightly grease all bolt threads on your bicycle as you repair
or upgrade com-ponents. Lubricating your bolts will allow
you to adequately tighten the fasteners and keep them
from seizing in the future.
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Adjusting your Ever-E-Day
How to Adjust Your Ever-E-Day to Fit Each Individual Rider
The Ever-E-Day is adjustable to a wide range of riders.
Adjustments can be made to the main frame (frame size) as well
as the seatmast / saddle height and stem / handlebar height.
Frame Size: The Ever-E-Day frame can be adjusted between a
50 cm and 60 cm in 2 cm increments.
If you are comfortable with your current bike, you can use that
measurement as a guideline for your frame adjustment.
If you experience pain in your neck, shoulders, back or knees
from your current bike, you might want to go to a bike shop that
offers fitting. They can find the correct size to set your
Ever-E-Day to for a perfect fit.
Saddle Height: Proper saddle height is important in
prevent-ing injuries as well as increasing riding efficiency and
com-fort. A rough rule of thumb method for determining
proper saddle height is when the pedal is in the 6 o’clock
position, your leg should have a slight bend in it with the ball
of your foot centered on the pedal, your knee almost fully
extended (but not quite). A quick way of achieving this is to
raise your saddle in small increments until you notice your leg
is fully extended in the 6 o’clock position and then lower the
saddle slightly. Rocking your hips to be able to reach the
pedals during the pedal stroke is to be avoided.
Special Feature: If you require the saddle to be lower than
the current lowest setting, you can purchase a shim and
seatpost from Bike Friday so the seat post is usable directly
inserted into the mainframe without the use of the seatmast.
Fig. 27 Lower Seatmast
no seatpost.
Fig. 26 Lower Seatmast, shim.
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Adjusting: Handlebar
Handlebar Height: This is a subjective preference. Handle-
bar height can be classified into three general categories:
1) bars below saddle; 2) bars level with saddle; 3) bars
higher than saddle.
For reference you can use an existing comfortable bike or
you can try out the three settings and see which one works
best for you.
Do note that humans tend to acclimate to whatever position
we are given to the point that we may subsequently be set up
with a properly sized bike and it will feel improper.
You may find it quite constructive to try a few positions,
just be sure to try them out for more than a few minutes
because that initial period may feel awkward, but possibly
because you have acclimated to incorrect sizing.
The beauty of the Ever-E-Day is the ability to try and use a
wide range of positions on the bike.
16 www.bikefriday.com 800-777-0258 •[phone]

Bike Friday Service
Bike Friday Service Overhauls
All of this, and the health of other components, can be checked
by our mechanics during your optional yearly overhaul.
A Bike Friday Overhaul includes:
• Check all components for wear and recommendations
on replacements
• Strip frame and clean components (optional solvent tank
option)
• Clean and optional alignment of the frame
• Replace stickers
• New cables and housing
• New bar tape, where applicable
• Test ride and packing
Don’t hesitate to call Bike Friday’s Customer Service
Depart-ment for help: 1-800-777-0258 (U.S.) or 1-541-687-0487
(world), or email [email protected]
17 www.bikefriday.com 800-777-0258 •[phone]

Bike Friday Service
New Bike Maintenance
Like all bikes, your Bike Friday travel bike will go through a break-in
period. After the first few weeks of riding you might find that your
drive train doesn’t shift as crisply as it did when new, or perhaps the
brakes are slightly loose. This happens as new cables stretch, housing
compresses and parts wear in.
After the initial break-in period, but before a significant tour, it is
important to have your Bike Friday bicycle professionally serviced at
your local favorite bike shop. A new bike tune-up takes very little time
and the small cost for the work is minor considering the improved
performance and reliability it provides. Then, at least once a year and
before any major tour, take your bike back to your local shop for
another tune-up to be sure that it runs smoothly.
After a few years of use and a few thousand miles of riding, you might
notice that the decals on your bike are starting to look worn and the
paint has some scratches. Perhaps your bike doesn’t ride as smoothly as
it used to, and the local bike shop can’t get it to function as well as
you would like. We offer factory service programs including tune-ups,
overhauls, and other repair work by our expert mechanics. A month or
two before your next big ride, you may wish to send the bike back for a
complete overhaul.
Visit our website for repair packages, costs, and details at
www.bikefriday.com/Service/. For those who plan ahead, we can
gen-erally offer the quickest repair turn-around during the winter
months.
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Bike Friday Maintenance
New Bicycle Tips and Maintenance Recommendations
Unlike other new bicycles purchased from a shop, your Bike
Friday Ever-E-Day has been disassembled partly and placed in a
suitcase or box. Then it was shipped across town, the country
or the world.
As with any new bicycle, your Bike Friday will need several
minor adjustments as it “settles in.” Knowing how to use barrel
adjusters on brakes and derailleurs and adjust spring tension on
brakes will help you through this settling in period. These skills
are also handy for when you travel with your bike.
Your local bike shop can help, or, check out the excellent
adjustment and repair guides at Park Tool Company’s
website: http://www.parktool.com/repair.
The Initial Break-in Period
It is reasonable to expect that a new bicycle will have an initial
break-in period where adjustments will need to be made after
a hundred-ish miles. The following items may occur or need
at-tention during this break in period:
• Brake and derailleur cables may stretch. You can perceive
this as you squeeze the brake lever and you have to
squeeze farther than previously OR you have to squeeze so
far before the pads contact the rims that there is not
sufficient braking force.
• Some bearing surfaces, notably some headsets, might
settle in after some use. If they are properly adjusted after
this initial break in period, they tend to then hold that
adjust-ment for a much longer period of time.
• For square taper bottom brackets (and the
corresponding crankset), it is a good idea to use an 8mm
hex / Allen wrench to ensure the crank bolt is tight.
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