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Step-1
Please check for any missing parts.
Model K9100 Compact
(Basic AirCaddy)
Model K8350
(Aircraft Kit)

(Optional)

(1) S7035-00
7mm Axle Washer
(1) B1000-00 Folded Triangular Corrugated Box
(1) T3230-00 Metal Wheel Truck
(2) C3750-00 Small
Corrugated Inserts
(2) C3755-00 Large
Corrugated Inserts

(1) B1350-00 2 Inch Wide Tape and Dispenser
(1) B1096-22 Heavy Duty Seat and Storage Bag
(1) B1250-00 Saddle Travel Bag
(1) B3197-00 Metal Fork Mount

(1) B3210 Metal Transit Plate
(6) B1220-00 Flat Nylon Ties
(6) B1220-00 Flat Nylon Ties

(1) B1382-00 5MM and 6MM Allen

Rear

Front
Step-2 Unfold the box so it looks like a butterfly from the top. The box should be upside-down, with the arrows and writing on the sides also upside-down.


Maximum height from floor to top of seat tube is 30.5in/78cm.

Maximum length of bike from fork tip to outside of the rear tire is 56in/143cm.
Top/Front

Maximum handlebar width is 25in/66cm.

Step-3 Continue to unfold the box until it looks like a triangle. The flat part facing you, as shown here, will now be called the front of the box. The narrow point will be called the rear of the box.
Rear

Front

Step-4  Unfold the four side flaps, top and bottom.  

  Step-5  Pull the two small front flaps from the inside.

Bottom
Step-6  The side flaps should be flipped over to begin forming the closed bottom of the box.  

  Step-7  Flip the front flaps over so that they are on top of the side flap (folded over in the previous step). Be sure to connect the matching numbers (ie. match "1" with "1").
Bottom

Step-8  Flip the last big flap over so that it completely closes the bottom of the box. This will match-up number "2" with "2". Tape the free edges of the box closed with six or seven strips to bridge the edges as shown. Place the strips approximately 8-inches apart. Then use a long, continuous strip to completely seal the edges of the box.


Wheel Truck
(only in K8350 Aircraft Kit)
Step-9 Place the wheel truck or ground transit plate at the front of the box so that the studs go through the holes into the box. This will connect number "3" with "3".

Ground Transit Plate

Step-10  Carefully flip the box over while holding the transit plate or wheel truck in place. Once this is done, pull the small flaps from the inside of the box to the outside.

Step-11 Fold the two large inserts as shown, steps A through I, and insert them into the box.
B
C
D
E
F
G
H
I

Step-12 Before going any further, mark your seatpost and handlebar position for later assembly. Now remove the front wheel and saddle/seatpost from your bicycle. Loosen the handelbar binder bolt just enough so that your handlebars can rotate in the stem. Shift your rear derailleur so that the chain is on the hub's largest sprocket. Make sure the seat post is lightly greased to prevent future problems.
 
    

     
Step-13A Place the fork mount on a flat surface outside the box. Depending on your wheel size, orient the fork mount as shown. Insert the fork into the fork mount and tighten the wing nut clockwise. Place the bike, with fork mount attached, into the box. Place the fork mount over the threaded studs protruding through the bottom of the box. Choose the pair of holes in the fork mount which allow the handlebar to be as close as possible to the front of the box, without touching. Place two wing nuts over the threadeed studs and tighten clockwise.
For Mountain Bicycles with Flat Bars (optional)

Step-13B1 Place the fork mount on a flat surface outside the box. Depending on wheel size, orient the fork mount as shown. Insert the fork into the fork mount and tighten the wing nut clockwise. Use as many washers as necessary to prevent interference. Remove the front 2 or 4 handlebar step bolts using allen wrench provided. Rotate the stem and fork so that the stem faces the back wheel as shown. Upon reinstallation always tighten the handlebar stem bolts to the recommended manufacturers torque settings found in the bicycle owners manual.
Front brake faces
the rear wheel.
Step-13B2  Place the bike with fork mount into the box. Place the fork mount over the threaded studs protruding through the bottom of the box. Choose the pair of holes in the fork mount which allow the head tube to be as close as possible to the front of the box without touching. Place two wing nuts over the threaded studs and tighten clockwise. Strap the handlebars to the sprocket side of the box at two points. If possible, lower the seat on the bicycle or place seat in the plastic bag provided on the sprocket side of the box. The crank arms should be perpendicular to the floor for the best fit.

Step-14 Fold the two small inserts and insert them into the box, as shown. Fine-position them foward the rear of the box to the point where the small inserts lightly press against the bicycle's seat stays and/or chain stays. Do not let the inserts touch the chain wheels.
B
C
D
E

Step-15 Place the front wheel inside the box, opposite the bicycle chain. Use one tie to secure the wheel to the side of the box (B). Use another tie to secure the wheel and the triangle of the large insert to the corner of the box (D).

Step-16 Place your saddle with seatpost into the small bag and secure it to the chain side of the box with one tie (A). Use one more tie to secure the triangle of the large insert to the front left corner of the box (C).



Step-17  Secure the rear wheel with one tie through the horizontal rear opening. Tie a square knot.

Step-18  To close the box, first close the inside flap "5" and then close the outside flap so the "5"'s match up. Next close the flap with the "aircaddy.com" logo on it, so that the "6"'s match up, this will complete the closure.

(Note: Numbers are prominent on the container)
 
  Step-19  Tape the free edges of the box closed with strips to bridge the edges as shown. Place five strips approximately 8-inches apart. Then use a long, continuous strip to completely seal the edges of the box. We suggest you print your home address on the label near No.6.

(Remember: If you fly commercially, do not tape the top of your box closed. After inspection the airport personal will tape the AirCaddy closed.)

Step-20  If you have the Aircraft Kit with the wheel truck, moving the box is as simple as picking up the pointed end and rolling it away. Grasp the box using the lower, vertical slot. Make sure to lift the pointed end high enough to engage the wheels and either push or pull the AirCaddy, whichever method gives you the most control.

Step-21  Multiple containers can be stacked on top one another in several ways as shown or nested next to another.

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