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MK2 Fat Boy Power Porter Assembly Guide: Quick, Simple, Ready for the Bank

The MK2 Fat Boy Power Porter is the simplest Power Porter in our entire range — designed for those who want reliable performance without complexity. This lightweight but powerful barrow is easy to assemble and even easier to use. Follow this straightforward guide to get your barrow up and running in no time.

Before you begin, unpack everything from the box and lay it out for easy access.

Step 1: Fitting the Front Wheel to the Frame

Your front wheel unit comes fully assembled from the factory. All that’s required is fitting it to the barrow frame.

Turn the barrow frame upside down, with the fork lugs pointing upwards.
Ensure the thumbscrews on the front forks are undone.
Carefully slide the wheel unit down into the forks. You may need to gently wiggle it into position to seat it fully.
Check orientation: the two 10mm bolts and washers should face forward.
Tighten the two short T-screws on the sides of the fork assembly.
Locate the two long T-screws (found in your parts box) and install them in the rear of the fork assembly.

Important: Tighten all screws firmly to prevent loosening during use — but do not overtighten, as this could deform the metal forks.
Lastly, check the bolts at the front crossbar to ensure everything is secure.

Step 2: Frame Assembly and Rear Legs

With the barrow still upside down:

Take the rear legs from the box and pull out the locking pin on one side.
Slide the leg onto the frame, aligning it with the locking pin hole near the M6 pivot hole.
Let the pin click into place — this will hold the leg in the correct position for final fixing.

To secure the legs:

Place a small washer near the head of the M6 bolt and feed it through the frame and leg bracket.
Add a second washer to the end and secure with a nyloc nut.
Use a screwdriver and 10mm spanner to tighten. Only tighten until the thread bites into the nylon — overtightening will prevent the legs from pivoting properly.

Next, fit the feet into the legs and secure using the thumbscrews.

Flip the barrow onto its wheels and rear legs. Now we move to the handlebars.

Step 3: Handlebar Installation

Take the two handlebar arms and loosely fit the crossbar between them.
Leave the thumbscrews on the crossbar undone at this stage — this makes it easier to attach the handles to the frame.
Slide each handlebar fully into the rear frame.
Once fully inserted, tighten the thumbscrews to secure the handles to the frame.
Then, return to the crossbar thumbscrews and tighten those as well.

Your handlebars are now fully fitted and ready for use.

Step 4: Connecting the Electronics

Time to power up your Power Porter:

Ensure the hand controller is turned off by rotating the speed dial fully anti-clockwise.
Locate the connector near the front wheel unit.
Align the white arrows on each half of the connector before pushing them together. Do not force the connector if the arrows are not lined up — misalignment may damage internal pins and is not covered under warranty.
When aligned, push the connectors together and allow the winged collar to twist and click into place.

Repeat the process for the handlebar-to-frame connector.

Now connect the battery:

Place the battery onto the battery tray.
Locate the black and orange connector.
Align black to black, orange to orange — the connector sides are shaped to guide correct fitting.
Push them together firmly until secure.

Ready to Go

That’s it — your MK2 Fat Boy Power Porter is now fully assembled and ready for its first trip to the bank. Make sure your battery is fully charged before heading out.

For a full operational guide, including how to use the hand controller and maximise your Power Porter’s performance, check out our detailed [Operation Guide here].

Need assistance?
Our support team is always here to help. Whether it’s setup queries or technical advice, just get in touch.