Pre-Assembly
Unpacking
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To remove the bike safely from its packaging, cut the straps along the dotted line on the bottom of the box, then lift the box over the unit and unpack.
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Locate the hardware package. The hardware is separated into four steps. Remove the tools first. Remove the hardware for each step as needed to avoid confusion. The numbers in the instructions that are in parenthesis (#) are the item number from the assembly drawing for reference.
Tools and Parts Included
| Tools Included |
| 14/15mm Wrench |
| 12/14mm Wrench |
| Phillips Screwdriver |
| Parts Included | |
| Quantity | Part Name |
| 1 | Main Frame |
| 1 | Console Mast |
| 1 | Rear Stabilizer |
| 1 | Seat Back Frame |
| 1 | Front Handlebar |
| 1 | Console Mast Cover |
| 1 | Console |
| 1 | Seat Cushion |
| 2 | Cup Holders |
| 2 | Pedals |
| 1 | Hardware Kit |
Assembly
CR800 Step-by-Step Assembly Instructions
1. Rear Stabilizer and Handlebar Cables
| Hardware Needed for This Step | |||
| PART | TYPE | DESCRIPTION | QUANTITY |
| #65 | Bolt | 3/8" x 2-1/4" | 4 |
| #71 | Bolt | 3/8" x 2" | 4 |
| #77 | Flat Washer | 3/8" x 19 | 6 |
| #84 | Flat Washer | 3/8" x 1" | 4 |
| #89 | Nylon Nut | 3/8" | 6 |
| #175 | Bolt | 3/8 x 2-3/4" | 2 |
a. Install the REAR STABILIZER (7) onto the MAIN FRAME with four BOLTS (#65) and four WASHERS (#84).
b. Install the HANDLEBAR ASSEMBLY (6) onto the SEAT CARRIAGE (4) with four BOLTS (#71) installed through the top holes and secured with four FLAT WASHERS (#77) and NYLON NUTS (#89). Install two BOLTS (#175) through the side holes and secure with two FLAT WASHERS (#77) and NYLON NUTS (#89).
c. Plug the LEFT HAND PULSE WIRE (27) into the corresponding LEFT SOCKET (42) located in the left plastic side case under the seat carriage, and the RIGHT HAND PULSE WIRE (21) into the RIGHT SOCKET (26).
2. Seat Back
| Hardware Needed for This Step | |||
| PART | TYPE | DESCRIPTION | QUANTITY |
| #77 | Flat Washer | 3/8" x 19mm | 6 |
| #136 | Screw | M5 x 15 | 4 |
| #176 | Bolt | 3/8" x 3/4" | 6 |
a. Install the SEAT BACK FRAME (5) onto the SEAT CARRIAGE (4) with six BOLTS (#176) and FLAT WASHERS (#77).
b. Install the SEAT BACK COVER (128) onto the seat back with four PHILLIPS HEAD SCREWS (#136).
3. Front Handlebar and Console Cables
| Hardware Needed for This Step | |||
| PART | TYPE | DESCRIPTION | QUANTITY |
| #68 | Hex Head Bolt | 5/16" x UNC18 x 5/8" | 8 |
| #76 | Flat Washer | 8 x 19 x 1.5T | 6 |
| #82 | Split Washer | 5/16" x 1.5T | 2 |
| #83 | Curved Washer | 5/16" x 19 x 1.5T | 2 |
a. Gather all hardware needed for this step.
b. Install the CONSOLE MAST COVER (31) onto the CONSOLE MAST (2), making sure it is facing the correct direction as in the picture below. Run the two wire harnesses through the bottom of the console mast tube and out the top opening.
c. Slide the CONSOLE MAST into the RECEIVING TUBE (1) being careful to not pinch the wires. Fasten the console mast with six BOLTS (#68) and four FLAT WASHERS (#76) on the side bolts and two CURVED WASHERS (#83) on the front bolts. Snap the CONSOLE MAST COVER in place.
d. Install the FRONT HANDLEBARS (3) onto the CONSOLE MAST with two BOLTS (#68), SPLIT WASHERS (#82) and FLAT WASHERS (#76).
4. Console
| Hardware Needed for This Step | |||
| PART | TYPE | DESCRIPTION | QUANTITY |
| #186 | Screw | M6 x 18mm | 4 |
| #99 | Screw | M5 x 12mm | 10 |
| #105 | Screw | 4mm x 16mm | 4 |
a. Install the front and rear STABILIZER COVERS (32, 37) and secure to the frame with four SCREWS (#99).
b. Install the left and right CUP HOLDERS (39, 38) to the rear handlebars with four SELF-TAPPING SCREWS (#105).
c. Install the bottom SEAT CUSHION (61) to the SEAT CARRIAGE (4) with four SCREWS (#98).
d. Install the PEDALS (116-L, 117-R) into the CRANK ARMS (51-L, 51-R). Remember that the left pedal has a reverse thread and will be screwed in with the opposite rotation. Make sure to tighten the pedals as much as you possibly can.
e. Connect the seven WIRE HARNESSES (44, 195, 190, 191, 192, 193, 197) to the corresponding connectors on the back of the console. Install the CONSOLE onto the CONSOLE MAST and secure with four SCREWS (#99) being careful to not pinch the wires.