Radio Flyer FLYER 840BL User manual

FLYERTM 20” KIDS’ BIKE
OWNER’S MANUAL
MODELS 840BL, 840R, 840GY, 840T, 840PP

Welcome to the Flyer™ Fleet
Congratulations on your new Flyer™ bike!
The Flyer™ line delivers a high-performance experience for riders of all ages,
ranging from micromobility solutions for families to premium wheels for kids.
As an extension of the Radio Flyer® brand, Flyer™ products are created with
the same beautiful design and quality that has inspired our work for over a
century. We hope your new bike oers a fun, sustainable, and convenient
way to get out and explore your world.
We can’t wait to see where your new ride takes you.
Cheers,
The Radio Flyer Team
Time Flies. Enjoy the Ride.®
ABOUT THIS MANUAL
This owner’s manual contains details of your Flyer™ kids’ bike including instructions
for assembly, operating, and maintenance. To ensure safe use and prevent injury,
please carefully read all information in this manual before use. Take time to familiarize
yourself with your Flyer™ kids’ bike before use.
While this owner’s manual is meant to introduce you to your Flyer™ kids’ bike, it is
impossible to guide owners on every possible scenario when using a bicycle. There
are inherent risks using any bicycle and it is the owner’s sole responsibility to ensure
safe riding. Always take responsibility for you and your child’s own safety.
Please keep this manual for future reference. If you have any questions about your
bike, contact the Radio Flyer Customer Service Team. Our award-winning service
team is committed to providing you with world class support, right from Chicago.
Phone: [phone]
Email: customerservice@radioflyer.com
Customer Service Hours: 8am – 5pm CST, Monday through Friday
Flyer™ Service Website: flyer.radioflyer.com/customer-service

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5
TABLE OF CONTENTS
Important Safety Instructions
Getting Started
Assembly Instructions
Fastener Torque Values
Accessories
Adjusting Bike
Riding & Safe Operating Guidelines
Ride Safety Checklist
Braking and Shifting
Maintenance
Warranty
7
8
8
18
18
19
23
23
25
26
27

6
5
17
7
13
8 9 11 1210
4
6
3
2
1
14 15 16
18
19
20
21
1. Seat Post
2. Rear Reflector
3. Rear Brake
4. Cassette
5. Rims
6. Tires
7. Rear Derailleur
8. Chain
9. Kickstand
10. Chainwheel
11. Crank
12. Pedal
13. Saddle
14. Stem
15. Grips
16. Gear Shifter
17. Brake Levers
18. Front Brake
19. Fork
20. Front Fork Dropouts
21. Spokes
Component Guide

7
Important Safety Instructions
SAFETY WARNINGS
• Read all safety warnings and instructions before using the product.
Failure to follow warnings and instructions may result in serious injury
or death.
• A helmet should be worn at all times when riding the bike. Ensure that
the rider of the bike has a helmet that has been fit properly.
• Do not put fingers or hands near spokes or moving parts.
• Always ensure riders have the physical coordination and skill to
navigate the bicycle safely while managing road conditions, trac and
adhering to all laws for bicycle use.
• Regularly check brake wear and performance, tire pressure, steering
performance, and rim wear (see Maintenance Instructions).
• Avoid riding the bike in wet or icy conditions. If riding in wet or icy
conditions, the braking distance of the bike will be increased. Ride
more slowly and cautiously in these conditions.
• Avoid riding the bike at night and in the dark. If riding in the dark, use a
bike headlight (not included).
• This bike is not suitable for the fitting of a luggage carrier, child seat,
and/or bicycle trailer.
• Please check local laws to confirm legal requirements for using your
bike. This Flyer™ bike is meant for paved roads and sidewalks, not
o-road conditions.
• This Flyer™ 20” Kids’ Bike is intended for riders from 45”-52” tall.
SAVE THESE INSTRUCTIONS
WARNING! When using this product, basic precautions should
always be followed including the following:

8
Getting Started
ASSEMBLY INSTRUCTIONS
The following steps provide a general overview of the assembly process for your
bike. It is recommended to consult a professional bicycle mechanic for assistance
with the bike’s assembly, maintenance, and repair.
Visit flyer.radioflyer.com or contact customerservice@radioflyer.com for
additional assistance assembling, using, repairing or maintaining your bike.
WARNING! Incorrect assembly, maintenance, or use of your Flyer™ kids’ bike can cause
component failure, loss of control, serious injury, or death. Please note, the assembly
and first fit of your Flyer™ kids’ bike 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)
• 6mm allen wrench (included)
• 15mm open-ended wrench (included)
• Scissors or flat-sided cutters
Step 1: Unpack your bike
Remove the bike from the outer carton and set it on a flat, clean surface. Place
the bike upright, resting on the front fork dropouts and rear wheel. 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.
• Frame, Fork, and Rear Wheel
• Handlebars
• Front Wheel
• Saddle and Seat Post
• Pedals
• Reflectors
• Tool Kit
• Philips screwdriver
• Tire pump
• Pedal grease (recommended)
• Torque wrench (recommended)

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Note: Complete assembly of the bike per the steps below. The handlebar angle can be
adjusted as needed based on rider preference. Always re-tighten bolts to the specified
torque values prior to riding.
Step 2: Install the handlebar
A. Using the provided 6mm allen wrench, loosen the two bolts and remove the
stem faceplate. Ensure to rotate the fork so that the stem is facing forwards as
in the image below.
B. Align and center the handlebar in the stem. Check that the handlebar
orientation matches the image below and that the cables are not twisted.
C. Reinstall the stem faceplate and two bolts using the 5mm allen wrench. Evenly
tighten the bolts to 10 to 12 Nm using a torque wrench.
A
Continued on next page

10
B
C

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Step 3: Install the front wheel
The bike is shipped with a spacer installed in the fork dropouts to prevent damage during
shipment. Prior to installing the front wheel, this spacer must be removed. Once removed,
the spacer may be discarded.
A. Squeeze the brake arms together, move the rotating metal linkage downwards, and
unhook the metal tube from the linkage to detach the two sides.
B. Remove the nuts and washers from both sides of the front wheel.
C. Align the wheel to the fork so that the fork dropouts rest on the axle. Ensure the fork
is fully seated on the axle, the wheel is centered on the fork, and the brake arms are
facing forwards.
D. Place the washers over the threaded ends of the front wheel hub, inserting the bent
tab into the hole on the fork dropouts. Tighten the nuts on each side of the front hub
to 28 to 32 Nm.
E. Press the brake arms together and attach the two sides using the rotating metal
linkage. Tune the brakes to ensure ideal performance (see Maintenance Instructions).
A
Continued on next page

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E
C
D
B

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Step 4: Install the saddle
A. Deploy the kickstand to allow the bike to stand freely.
B. Open the quick-release lever and insert the seat post into the seat tube.
C. Position the seat post at an appropriate height for the rider. See page 19.
D. Tighten the adjustment nut on the quick-release clamp, then close the
quick-release lever.
Note: Closing the quick release lever should require enough pressure that it leaves an imprint
in your hand. If it’s too easy or too dicult to close, adjust the lever tension by turning the
adjustment nut opposite the quick release lever.
WARNING! The seat post must be inserted to the minimum insertion mark. Do not
raise the seat post beyond the minimum insertion marking on the seat post tube. If the
seat post is not inserted properly, the seat may be loose which can lead to serious injury
or death. After assembly, reflectors should be visible and not obscured by the rear wheel.
AB
CD

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Step 5: Install pedals
A. Identify the right and left pedals before assembling. The dierent pedals are
specified with stickers on their surface, as well as an engraving on the end of
the threaded portion of the pedal. The right pedal corresponds to where the
rider’s right foot is during use.
B. Install the right pedal to the right side crank arm by turning the axle
clockwise by hand.
C. Install the left pedal to the left side crank arm by turning the axle counter-
clockwise by hand.
D. Use the provided 15mm wrench to tighten the right pedal onto the crank arm.
Torque the right pedal to 35 to 40 Nm using a torque wrench.
E. Use the provided 15mm wrench to tighten the left pedal onto the crank arm.
Torque the left pedal to 35 to 40 Nm using a torque wrench.
Note: We recommend applying pedal grease to the threads prior to installation

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BC
DE
A
RIGHT LEFT
LEFTRIGHT
LEFTRIGHT

16
A
BC
Step 6: Install the reflectors
A. If necessary, use a Phillips head screwdriver to remove the screw from the
mounting portion of each reflector.
B. Mount the white reflector to the front of the handlebar. Insert and tighten
down the mounting screw to secure the reflector. Ensure the reflector is facing
directly forwards. (See next page)
C. Mount the red reflector to the back of the seat post, about 3” (75mm) below
the saddle. Tighten down the mounting screw to secure the reflector. The face
of the rear reflector is positioned at an angle to the mounting bracket. When
installing, ensure the face of the reflector is installed so as to be facing directly
backwards, not tilted downwards. (See next page)

17

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Step 7: Check fastener torque values
Step 8: Inflate tires to 45 psi
WARNING! It is important to maintain proper air pressure in
the tires while riding. Do not over inflate or under inflate the tires.
Overinflated tires may burst. Inflate the tires using an air source
with a pressure gauge to avoid overinflation. Underinflated tires
may impair the control of the bike and cause a safety hazard.
ACCESSORIES
Radio Flyer carries a full line of accessories to enhance the usability of your Flyer™
kids’ bike. Please refer to the instruction sheets provided with each accessory to
ensure proper assembly. Visit flyer.radioflyer.com or contact
customerservice@radioflyer.com for additional assistance assembling, using,
or repairing your accessories.
WARNING! Incorrect installation of accessories can cause
damage to the bike frame, loss of control, serious injury, or death.
Area of Bike Hardware Torque (Nm)
Handlebar Stem Clamp Bolts 18 to 20
Brake Lever Clamp Bolts 7 to 9
Stem Faceplate Bolts 10 to 12
Seat Post Quick Release Level (closed) 13 to 15
Seat Mounting Bolts 8 to 12
Kickstand Kickstand Bolt 18 to 22
Front/Rear
Brakes
Brake Cable Pinch Bolt 7 to 9
Brake Pad Threaded Stud 10 to 12
V Brake to Frame 10 to 12
Front/Rear
Dropout
Rear Axle Nuts 28 to 32
Front Axle Nuts 28 to 32
Bottom
Bracket
Crank Arm Bolt 38 to 42
Pedal into Crank Arm 35 to 40
Chain Ring Bolts 4 to 6

19
WARNING! The seat post must be inserted to the minimum insertion mark. Do not
raise the seat post beyond the minimum insertion marking on the seat post tube. If the
seat post is not inserted properly, the seat may be loose which can lead to serious injury
or death. After assembly, reflectors should be visible and not obscured by the rear wheel.
ADJUSTING SEAT HEIGHT
The seat height should be set based on the rider’s personal preference. The initial seat
position can be set by first placing the ball of the rider’s foot on the pedal with the crank
arm in its lowest position. In this position, the rider’s 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
Radio Flyer customer service for questions related to the seat position and fit of the 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.
AB
C

20
ADJUSTING HANDLEBAR ROTATIONAL POSITION
Following the initial assembly of the handlebar, the handlebar rotational position
should be adjusted for the rider. Ensuring that the handgrips and brake levers are in
the correct position will avoid any strain or discomfort while riding.
A. Using the provided 6mm allen wrench, loosen the two stem faceplate bolts.
B. Rotate the handlebar until the preferred position is achieved checking to ensure
the handlebar is centered left-to-right within the stem faceplate.
C. Retighten the two stem faceplate bolts using the 6mm allen wrench. Evenly
tighten the bolts to 10 to 12 Nm using a torque wrench.
AB
C
WARNING! The stem on your FlyerTMkids’ bike comes factory assembled to the front
fork, and does not need to be removed to adjust the handlebars. If the stem is loosened
or removed from the fork, care must be taken during re-assembly to avoid damaging
the stem-to-fork connection. Overtightening the stem clamp bolts can damage the
stem-to-fork assembly, which can lead to risk of injury. To avoid overtightening, use a
torque wrench to tighten the stem clamp bolts to 18 to 20 Nm.