Xtracycle RFA Utility User manual

RFA Utility Assembly Guide

Your e-bike will have pre-installed all bicycle components other than those listed below, and all Bosch
components including battery.
The following items will be included in the box and will not be installed on the e-bike: pedals, headset,
headset spacers, seatpost, stem, handlebars (with brake levers, shifters already mounted), Bosch
Purion display, front brake caliper, chain, handlebar stabilizer, fork, front wheel, front brake rotor, front
and rear e-bike specific lights, reflectors, and any additional ordered accessories.
This guide is designed to help you assemble an Xtracycle RFA in Utility mode as
efficiently as possible. Please follow the assembly instructions in order. While
thorough, this guide is not exhaustive–you should already be familiar with all
component installation and adjustment procedures.
Getting started

step 1
Unboxing the RFA
• Open box
• Cut zip ties holding the fork to the frame and remove
• Remove small parts box
• Lift RFA out of the box and mount in bike stand
• Remove front wheel
• Unclip handlebars and use a zip tie to hang them out
of the way
• Remove all protective packaging
• Open small parts box and set aside
• Remove seat post from fit kit
• Apply grease to seat post and install into seat tube
1a
1c 1d
1b
Unboxing the RFA

Installing the Fork
step 2
• Locate the headset in the small parts box
• Slide dust seal onto front fork crown race
• Grease the steer tube and insert up through the head tube
• The larger of the two headset bearing retainers goes on
the crown race, and the smaller goes on the top bearing cup
• Grease both bearing retainers
2a
2c
2b

step 3
• Stack top race, split race lock then FSA top cover
• Install handlebar faceplate with headlight mount
facing down
• Torque all stem bolts and handlebar controlls to 6Nm
• Build up the headset stack using the spacers
• Install stem and top cap with M6 bolt and tighten until
you’ve removed all end play in the headset
3c
3a 3b
• Install headlight with Allen key and 8mm open end wrench
3d
Assembling Headset and Installing Stem, Handlebar & Headlight

Installing Purion Display and Handlebar Stabilizer
step 4
• Locate the Handlebar Stabilizer spring in the small parts box
• Use pliers to assemble the stabilizer following the
included instructions
• Install protective cover over stabilizer spring
• Be sure to tighten the fork bolt to prevent slippage when
turning the wheel sharply.
4c 4d
• Mount Purion display to the left side of the handlebars,
right of the brake lever
• Be sure to position the display so it is visible from the
seated position
• Secure with a 3mm allen wrench
4a 4b

• Grease threads and install left and right pedals
5d
Installing the Front Wheel, Brakes, Cranks and Pedals
• Remove thru-axle from fork dropouts, discard cardboard tube
• Position the wheel in the fork and reseat the axle
• Install brake rotor onto front wheel and torque to 40nM
• Locate crank arms and crank bolts in small parts box
• Use 8mm Allen wrench to fasten crank arms with crank
arm bolts and tighten to 40Nm with a torque wrench
• Install front brake assembly (refer to the Shimano brake
owner’s manual for propper setup and installation)
• Use a zip tie to secure brake hose to fork cable boss
5a
5c
5b
step 5

step 6
• Remove rear wheel
• Remove three bolts holding the dynamic dropout insert
and locking plate and be mindful of the bolt positions
• Move the insert to the rear dropout mount position, drawing
any needed cable from further forward on the frame
• Replace the three bolts and locking plate, torquing to
20Nm, and repeat for the other side
6a 6b
Moving the Rear Wheel
• Replace the rear wheel
6c

step 7
• Locate the speed sensor post, washer and M5x20mm bolt
in the small parts box and mount to frame in the rear
position on the non-drive side with a 4mm Allen key
• Note: the rear mounting position is for Utility mode only
• Remove the cap to the speed sensor and position it on
the speed sensor post
7a 7b
Mounting the Speed Sensor
• Tighten the speed senor bolt with a T-30 star bit through
the wheel from opposite side
• Feed excess cabling into the drive housing and coil and zip
tie as needed
• Position sensor magnet on spoke opposite air valve and
align with the sensor
• Apply blue Loctite or comparable threadlocker and secure
with a Phillips head screwdriver
7c 7d

step 8
Installing the Rear Wheel Chain
• Locate the chain in the small parts box
• Feed chain through the derailleur
• Reconnect the chain with the quick link
8a 8b
• Engage the clutch
8c

Installing the Utility Rack and Tail Light
• Align the front of the rack with the forward rack mounting
position where the rear cross braces meet
• Loosly thread the front bolts on either side of the bike
• Feed the tail light cable along the inside of the non-drive
side of the rack and use small zip ties to secure it in place
• Lower the rear of the rack in line with the rear mounting
points and thread the bolts through the lower slotted holes
• Note: rear derailleur cable routed over rear dropout
• Torque all four bolts to 30Nm with a 5mm Allen key
9c
9a 9b
• Clip the end of the tail light cable into the tail light
• Align the two tail light mounting posts to the rear of the
rack and secure them with the two M4 lock nuts using a
8mm wrench
9d
step 9

Installing RFA WheelSkirts
10a 10b
step 10
• Locate the correct side WheelSkirt for the side of the rack
you are attaching
• Start by wrapping the upper hook-and-loop straps to the
skinny rail directly below the top rail of the rack
• Wrap the lower straps around the lower rack and bike frame
• Wrap the left, right and diagonal hook-and-loop straps to
the sides of the rack
• Repeat for the opposite side as needed
• Note: Either a WheelSkirt or CargoBay must be installed
on either side of the bike while in Utility mode