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Bosch 21-17-3234, Translation Of Original Operating Instructions

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Bosch 21-17-3234 Translation Of Original Operating Instructions Download Page 28

MY22Z01 - 12_1.0_25.07.2022

27

Description

3.3

Components

3.3.1

Overview 

Figure 3:  Pedelec viewed from right, Bull Cross Rider EVO 2 used as example

1

Front wheel

2

Front wheel hub

3

Fork

4

Front wheel mudguard

5

Front light

6

Steering headset

7

Handlebars

8

Stem

9

Frame

10

Seat post

11

Saddle

12

Pannier rack

13

Reflector

14

Rear light

15

Rear wheel mudguard

16

Rear wheel brake

17

Kickstand

18

Rear wheel

19

Gear shift and rear wheel 
hub

20

Chain

21

Frame number

22

Chain guard

23

Motor

23

Motor cover

24

Pedal

25

Rechargeable battery

22

Nameplate

 

26

Front wheel brake

1

2

3

14

4

5

6

7

8

9

10

11

16

12

13

18

15

19

20

21

22 23 24

17

25

26

Summary of Contents for 21-17-3234

Page 1: ...CO OFF M P H K M H Reichweite AMM PMWH M IN M PH K M H 21 17 3234 21 17 3237 22 15 2057 22 15 2062 SU E FS 12 ZE 10 ZE 5F ZE 5F Plus ZE 5R ZE 5R Plus Translation of original operating instructions for ZEMO pedelecs with BOSCH Intuvia on board computer IMPORTANT READ CAREFULLY BEFORE USE KEEP SAFE TO CONSULT AT A LATER DATE ...

Page 2: ...16 2 1 5 Key breaking off 16 2 2 Toxic substances 17 2 2 1 Carcinogenic substances 17 2 2 2 Toxic substances 17 2 2 3 Irritants and corrosive substances 17 2 3 Requirements for the pedelec rider 18 2 4 Vulnerable groups 18 2 5 Personal protective equipment 18 2 6 Safety guards 18 2 7 Safety markings and safety instructions 19 2 8 What to do in an emergency 19 2 8 1 Dangerous situation in road traf...

Page 3: ...45 3 3 12 Control panel 45 3 4 Description of controls and screens 46 3 4 1 Handlebars 46 3 4 2 On board computer 47 3 4 2 1 Riding light indicator 47 3 4 2 2 Level of assistance indicator 47 3 4 2 3 Charge level indicator on board computer 48 3 4 2 4 Indicator for motor power used 48 3 4 2 5 Gear recommendation indicator 48 3 4 2 6 Tachometer indicator 48 3 4 2 7 Function display 48 3 4 2 8 Journ...

Page 4: ... 500 battery horizontal 72 5 3 2 4 Securing the PowerTube BS2 battery mount 73 5 3 3 Preparing the wheel 78 5 3 4 Installing the wheel in the SUNTOUR fork 79 5 3 4 1 Screw on axle 12AH2 and 15AH2 79 5 3 4 2 20 mm cross axle 80 5 3 4 3 Q LOC quick release 82 5 3 5 Preparing the LIMOTEC seat post 83 5 3 6 Fitting the pedals 84 5 3 7 Checking the stem and handlebars 85 5 3 7 1 Checking the connection...

Page 5: ...ure point on a MAGURA brake lever 110 6 5 8 6 Replacing brakes 111 6 5 8 7 Retracting the brake linings 111 6 5 9 Gear shift 112 6 5 9 1 Replacing the gear shift 112 6 5 9 2 Adjusting the SHIMANO shifter 112 6 5 10 Suspension 113 6 5 11 Fork sag 113 6 5 11 1 Adjusting the SR SUNTOUR fork steel suspension 114 6 5 11 2 Adjusting the SR SUNTOUR fork air suspension 115 6 5 12 Fork rebound damping 116 ...

Page 6: ... 133 6 16 7 Waking the battery 133 6 17 Using pedelec with the electric drive system 134 6 17 1 Switching on the electric drive system 134 6 17 2 Switching off the electric drive system 134 6 18 Using the on board computer 135 6 18 1 Using the USB port 135 6 18 2 Switching on the on board computer 135 6 18 3 Switching off the on board computer 135 6 18 4 Using the push assist system 136 6 18 5 Usi...

Page 7: ...e battery 152 7 3 3 Cleaning the motor 152 7 3 4 Clean Frame fork pannier rack guards and kickstand 153 7 3 5 Cleaning the stem 153 7 3 6 Cleaning the handlebars 153 7 3 7 Clean handles 153 7 3 7 1 Cleaning leather handles 153 7 3 8 Clean seat post 153 7 3 9 Cleaning the saddle 154 7 3 9 1 Cleaning the leather saddle 154 7 3 10 Cleaning the tyres 154 7 3 11 Cleaning the spokes and spoke nipples 15...

Page 8: ...e disc brake 166 7 5 2 5 Checking the back pedal brake 167 7 5 2 6 Checking the rim brake 168 7 5 3 Checking the chain 169 7 5 4 Checking the chain tension 169 7 5 4 1 Check tension in derailleur gears 169 7 5 4 2 Check tension in hub gear 169 7 5 5 Checking the belt for wear 169 7 5 5 1 Rough check 169 7 5 5 2 Check 170 7 5 6 Checking the belt 171 7 5 7 Checking the belt for wear 171 7 5 8 Checki...

Page 9: ...spension seat post 195 9 Troubleshooting fault clearance and repair 9 1 Preventing pain 196 9 1 1 Sitting discomfort 197 9 1 2 Pain in hips 197 9 1 3 Backache 197 9 1 4 Pain in shoulders and nape of neck 198 9 1 5 Numb or aching hands 198 9 1 6 Pain in upper thigh 198 9 1 7 Knee pain 199 9 1 8 Pain in the foot 199 9 Troubleshooting fault clearance and repair 9 1 Troubleshooting and fault clearance...

Page 10: ...ge from impact on the carbon post seat post 219 9 2 4 Replacing the riding light 220 9 2 5 Adjusting the headlight 220 9 2 6 Checking suspension fork tyre clearance 220 10 Recycling and disposal 10 1 Guidelines on removal of waste 221 11 Documents 11 1 Assembly report 223 11 2 Inspection and maintenance log 225 11 3 Parts list 229 11 3 1 SU E FS 12 229 11 3 2 ZE 10 231 11 3 3 ZE 5F 233 11 3 4 ZE 5...

Page 11: ...n or reproduction of these operating instructions and utilisation or communication of their content is prohibited unless expressly approved Anyone who does not comply with these restrictions is liable for compensation All rights reserved in the event that a patent utility model or industrial design is registered Subject to internal changes The information contained in these operating instructions ...

Page 12: ...iginal operating instructions 1 4 For your information Different markings are used in the operating instructions to make them easier to read 1 4 1 Warnings Warnings indicate hazardous situations and actions You will find three categories of warnings in the operating instructions 1 4 2 Markups You will find ten text markups in the operating instructions Text for specialist dealers Notice on replaci...

Page 13: ...staff are highlighted in blue and marked with a spanner symbol These sections aim to allow trained technical staff bicycle mechatronics engineers bicycle mechanics or others to carry out initial assembly adjustment inspection and repair safely Technical staff also need to read all sections for pedelec riders and operators to ensure they can provide better customer service Always fill out all repor...

Page 14: ...cument number the version number and the release date Type no Model Pedelec type 21 17 3236 ZE 5R Diamant City and trekking bicycle 21 17 3237 ZE 5R Wave City and trekking bicycle 21 17 3234 ZE 5R Plus Diamant City and trekking bicycle 21 17 3235 ZE 5R Plus Wave City and trekking bicycle 22 15 2057 ZE 5F Diamant City and trekking bicycle 22 15 2058 ZE 5F Wave City and trekking bicycle 22 15 2057 Z...

Page 15: ...age damage batteries This may cause a fire or an explosion Only use approved batteries to charge Prevent short circuit due to interconnection Metal objects may interconnect the battery s electrical terminals The battery may self ignite and explode Never insert paper clips screws coins keys and other small parts into the battery Place the battery on clean surfaces only Prevent charging socket and c...

Page 16: ...charging Never leave battery unattended during charging Brakes and motors Cool down overheated brakes and motors The brakes and the motor may become very hot during operation There is a risk of burns or fire in case of contact Never touch the brakes or the motor immediately after a ride Never place the pedelec on a flammable surface such as grass or wood directly after use Store the battery in a s...

Page 17: ...k This will cause a crash with injuries Never fasten a quick release using a tool e g hammer or pliers Only use the clamping lever with the specified set clamping force 2 1 3 2 Incorrect tightening torque If a screw is fastened too tightly it may break If a screw is not fastened enough it may loosen This will cause a crash with injuries Always observe the indicated tightening torque on the screw o...

Page 18: ...tic make up of germ cells oil Never dismantle the rear frame damper or the suspension fork It is forbidden for pregnant women to carry out maintenance and cleaning tasks Avoid skin coming into contact with suspension oil Toxic substances also known as poison or toxins refer to substances which can cause damage to living beings if they enter the organism above a specific low dose The more the inges...

Page 19: ...ctions by a legal guardian 2 5 Personal protective equipment Wear a suitable helmet The helmet must have a reflective strip or a light in a clearly visible colour Wear sturdy shoes which are not too tightly laced Wear padded cycling gloves Wear clothing which is as bright or retroreflective as possible Fluorescent materials are also suitable High visibility jackets and straps on your upper body en...

Page 20: ...ake fluid as it poses a slip hazard Keep leaked brake fluid away from naked flames hot surfaces and sources of ignition Avoid contact with skin and eyes If inhaled 1 Take in fresh air 2 Immediately consult a doctor in case of any discomfort After skin contact 1 Wash affected skin with soap and water and rinse well 2 Remove contaminated clothing 3 Consult doctor in the event of pain or discomfort S...

Page 21: ...otect unaffected eye 2 Seek medical advice immediately After skin contact 1 Remove any solid particles immediately 2 Remove contaminated clothing immediately 3 Rinse the affected area with plenty of water for at least 15 minutes 4 Then dab the affected skin gently Do not rub dry 5 Immediately consult a doctor if there is any redness pain or discomfort 2 8 4 Battery fire The safety electronics may ...

Page 22: ...rs need time to adapt to using the pedelec Appropriate training is required for its use It is especially important to practice braking and riding around bends The strain on hands wrists arms shoulders the neck and back is consid erable Inexperi enced pedelec riders tend to brake too hard and lose control as a result Racing bikes are designed for fast rides on roads and paths with a good undamaged ...

Page 23: ...mpetitions stunt riding or acrobatics City and trekking bicycle Cycle for children and young adults Mountain bike Racing bicycle Cargo bike Folding bicycle City and trekking bicycles are not sports bicycles If used for sports the rider can expect reduced riding stability and dimin ished comfort Cycles for children and young adults are not toys Mountain bikes must be retrofitted with riding light a...

Page 24: ... pedelec plus body weight plus baggage Type no Model PTW kg 21 17 3236 ZE 5R Diamant 150 21 17 3237 ZE 5R Wave 150 21 17 3234 ZE 5R Plus Diamant 150 21 17 3235 ZE 5R Plus Wave 150 22 15 2057 ZE 5F Diamant 150 22 15 2058 ZE 5F Wave 150 22 15 2057 ZE 5F Plus Diamant 150 22 15 2058 ZE 5F Plus Wave 150 22 15 2059 ZE 10 Diamant 150 22 15 2060 ZE 10 Wave 150 22 15 2061 SU E FS 12 Diamant 150 22 15 2062 ...

Page 25: ...king bicycle Cycle for children and young adults Mountain bike Racing bicycle Cargo bike Folding bicycle Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked roads cycle paths and firm gravel paths and roads and longer sections with mo...

Page 26: ...Never drive off road or perform jumps Never drive off road or perform jumps Never drive off road or perform jumps Never drive off road or perform jumps over 15 cm Never drive off road or perform jumps over 15 cm Never drive off road or perform jumps over 15 cm Never drive off road or perform jumps over 15 cm Never ride down hill or perform jumps over 61 cm Never ride down hill or perform jumps ove...

Page 27: ...m permitted total weight is the weight of the fully assembled pedelec with the body weight plus the baggage 6 Year of manufacture The year of manufacture is the year in which the pedelec was manufactured 7 Pedelec type Each pedelec is assigned a pedelec type which determines its proper use function and area of use Section 3 1 8 Safety markings Safety markings warn of hazards Section 2 7 9 Disposal...

Page 28: ...ght 6 Steering headset 7 Handlebars 8 Stem 9 Frame 10 Seat post 11 Saddle 12 Pannier rack 13 Reflector 14 Rear light 15 Rear wheel mudguard 16 Rear wheel brake 17 Kickstand 18 Rear wheel 19 Gear shift and rear wheel hub 20 Chain 21 Frame number 22 Chain guard 23 Motor 23 Motor cover 24 Pedal 25 Rechargeable battery 22 Nameplate 26 Front wheel brake 1 2 3 14 4 5 6 7 8 9 10 11 16 12 13 18 15 19 20 2...

Page 29: ...and Steering headsets for threadless fork steerers what are known as headsets 3 3 2 4 Stem The stem connects the handlebars to the fork steerer tube The stem is used to adjust the handlebars to body size The stem is used to adjust the handlebar height and the gap between the handlebars and saddle see Section 6 5 6 Quickly adjustable stems Quickly adjustable stems are an extension to the fork steer...

Page 30: ...nd displays see Section 3 4 1 Figure 6 Handlebar dimensions The main dimensions of handlebars are 1 Rise height 2 Width 3 Backsweep 3 3 2 6 Fork The stem and handlebars are attached to the top end of the fork steerer The axle is fastened to the fork ends The wheel is fastened to the axle Figure 7 Overview of fork 1 Fork steerer 2 Side reflectors optional 3 Fork end 4 Fork leg 1 2 3 1 2 3 4 ...

Page 31: ...ec s path from being channelled directly into the body via the fork The impact is absorbed by the suspension system instead This causes the suspension fork to compress After compressing the suspension fork returns to its original position If the bike has a damper the damper will slow this movement down It thus prevents the suspension system from springing back in an uncontrolled manner and the for...

Page 32: ...rrain green line when riding over bumps The suspension motion is predictable and controlled Figure 9 Optimum fork ride performance When optimally adjusted the fork counteracts deflection on hilly terrain and stays higher in its deflection range This allows the rider to maintain the same speed more easily on hilly terrain Figure 10 Optimum fork ride performance on hilly terrain When optimally adjus...

Page 33: ...and body follow terrain green line when riding over bumps The suspension motion is predictable and controlled Figure 12 Optimum fork ride performance Suspension fork compression damper The compression damper allows the rider to make quick adjustments to the fork s suspension behaviour to adapt to changes in terrain It is intended for adjustments made during the ride The compression damper controls...

Page 34: ...heel 3 Crown 4 Dust seal 5 Q Loc 6 Axle 7 Fork end 8 Stanchion 9 Compression damper Air suspension fork structure The air suspension fork comprises up to three assembly groups Air suspension assembly orange Compression damper assembly blue At times a rebound damper assembly red Figure 15 Internal structure of air suspension fork 1 Air valve 2 Air valve cap 3 Fork steerer 4 Sag setting wheel 5 Rebo...

Page 35: ...y able to support the pedelec if there is adequate tyre pressure The tyre pressure must be adjusted to the body weight and then checked on a regular basis Tyre design types There are five different tyre design types Tube type tyres Tubeless tyres also tubeless ready Tubular or single tube tyres Solid tyres Mixed types 3 3 4 2 Tube type tyre A distinction is made between different kinds of tube typ...

Page 36: ...cteristics on a smooth road The grip between the road and tyre is mainly provided by the rolling friction between the rubber and the road surface Slicks and road tyres Unlike cars a pedelec will not aquaplane The tread contact is small and the contact pressure high Thanks to the small contact surface on narrow and treadless tyres the tyre interlocks with the road surface finish Theoretically the t...

Page 37: ...19 Steel bead core 1 and Kevlar bead core 2 with a steel wire These tyres are called clinchers With aramid fibres Kevlar These tyres are called folding tyres Folding tyres are about 50 90 g lighter than clinchers It can also be folded into a smaller pack size Puncture protection belt There may be a puncture protection belt between the carcass and the tread Figure 20 Effect of puncture protection b...

Page 38: ... in an emergency The brake is applied using the brake lever either with the brake lever and shift cable mechanical brake or with the brake lever and hydraulic brake cable hydraulic brake 3 3 5 1 Mechanical brake The brake lever is connected to the brake via a wire inside the shift cable also known as a Bowden cable Figure 21 Bowden cable structure 3 3 5 2 Hydraulic brake The brake fluid is in a cl...

Page 39: ...isc is permanently screwed to the hub You increase brake pressure by pulling the brake lever The brake fluid is used to transfer pressure through the brake cables to the cylinders in the brake calliper The braking force is boosted by a speed reduction and applied to the brake linings These apply the brake disc mechanically If the brake lever is pushed the brake linings are pressed against the brak...

Page 40: ...djust the saddle horizontally with a clamping mechanism and adjust the saddle angle by swivelling the entire saddle clamping mechanism Retractable seat posts feature a remote control on the handlebars which can be used to lower the seat post at a traffic light for example and then raise it again 3 3 7 1 Patent seat post Figure 24 Example of ergotec patent seat post with either one or two seat clam...

Page 41: ... Suspension seat posts feature small heavy duty slide bearings guides and articulated joints If they are not lubricated on a regular basis the sensitive response behaviour diminishes considerably causing excessive wear The pre tensioning in non damped suspension seat posts must be adjusted in such a way that the suspension seat post does not deflect with just body weight This prevents the suspensi...

Page 42: ...on of travel 2 Chain or belt 3 Rear chainring or belt pulley 4 Front chainring or belt sprocket 5 Pedal The pedelec is equipped with either a chain or belt drive 3 3 8 1 Chain drive layout Figure 27 Chain drive with derailleur gears 1 Rear derailleur 2 Chain The chain drive is compatible with a Back pedal brake Hub gear or Derailleur gears 3 3 8 2 Belt drive layout Figure 28 Belt drive 1 Front bel...

Page 43: ...d safely in the event of an emergency 3 3 9 2 Rechargeable battery BOSCH batteries are lithium ion batteries which are developed and manufactured to the latest technical standards Each battery cell is protected by a steel cup and encased in a plastic battery housing Applicable safety regulations are met The battery has an interior electronic protection circuit which is specifically designed for th...

Page 44: ...e 30 Overview of frame battery Figure 31 Details of frame battery 1 Battery housing 2 Battery lock 3 Battery key 4 On off button battery 5 Battery level indicator battery 6 Charging port cover 7 Charging port 3 3 9 4 Pannier rack battery Three different types of pannier rack batteries can be fitted Figure 32 Overview of pannier rack battery Figure 33 Details of pannier rack battery 1 Battery housi...

Page 45: ...vel indicator battery 6 Battery housing 3 3 9 6 Charger Each pedelec is supplied with a charger As a general rule any BOSCH charger may be used The 2A compact charger The 4A standard charger The 6A fast charger Observe the operating instructions in the Section 11 4 Documents 3 3 10 Lighting When the riding light is activated the front light and rear light are switched on together at the same time ...

Page 46: ...he electric drive system is switched on If the rider removes the display from its mount the on board computer is powered by a on board computer battery The on board computer battery cannot be replaced Figure 36 BOSCH Intuvia on board computer 3 3 11 1 USB port There is a USB port beneath the rubber cover on the right hand edge of the on board computer 3 3 12 Control panel The control panel control...

Page 47: ...Detailed view of handlebars with BOSCH Intuvia on board computer example 1 Rear wheel hand brake 2 Bell 3 Front lamp 4 On board computer 5 Front wheel handbrake 6 Handle 7 Seat post remote control 8 Control panel 9 Sag setting wheel 10 Fork lock lockout 11 Shift indicator 12 Shifter 1 2 4 5 6 7 8 9 10 12 11 3 ...

Page 48: ...ted dynamically depending on the pedalling force applied to the pedals If the pedelec has been configured with eMTB MODE eMTB MODE will appear briefly when the SPORT level of assistance is selected T U R B O S P O R T T O U R E C O O F F MPH KM H Reichweite AMM PMWH MIN MPH KM H RESET TURB O SPOR T S TOUR ECO OFF MPH KM H Reichweite AMM PMW H MIN MPH KM H 1 2 3 4 5 6 7 8 5 1 2 3 4 6 7 TURBO SPORT ...

Page 49: ...up a great deal of energy The speed and range can be increased while applying the same force if you select the right gear The gear recommendation function reacts to excessively slow or excessively quick pedalling and recommends a change of gear The gear recommendation function has to be switched on in the system settings 3 4 2 6 Tachometer indicator The tachometer indicator shows the current speed...

Page 50: ...Distance travelled since the last RESET Table 16 Journey information Display Change AUTO ON AUTO OFF This menu option indicates whether the automatic mode is switched on or off Table 17 Additional journey information for SHIMANO DI2 automatic hub gears Display Change GEAR The gear shift currently selected is displayed on the on board computer display screen The new selected gear is shown briefly o...

Page 51: ...automatic gear switch function is switched off in Position This menu option is only shown when the on board computer is positioned in its mount Gear adjustment You can use this menu option to make a fine adjustment to the SHIMANO DI2 You ll find the specified setting range described in the gear manufacturer s operating instructions Make fine adjustments if the gear shift makes unusual noises This ...

Page 52: ...This menu option is only shown when the on board computer is positioned in its mount Gear vx x x x this is the gear software version This menu option is only shown when the on board computer is positioned in its mount This menu option is only shown if you have an electronic control gear Table 25 Changing the system settings Display Change Gear calibration This is where the continuously adjustable ...

Page 53: ... Control panel The on board computer is operated using four buttons on the control panel Figure 42 Overview of the BOSCH control panel 1 Info button control panel 2 Push Assist button 3 Plus button control panel 4 Minus button control panel 1 3 4 2 ...

Page 54: ...ehicles with this equipment The gear shift is on the right of the handlebars The gear shift has one or two shifters SHIMANO SL M315 gear shift Figure 43 Example of SHIMANO SL M315 1 Shifter A 2 Shifter B SHIMANO SL M3100 gear shift Figure 44 Example of SHIMANO SL M3100 1 Shifter A 2 Shifter B optional 1 2 1 2 ...

Page 55: ...rake There is a handbrake on the left and right of the handlebars Figure 45 Front wheel 2 and rear 1 brake levers Shimano brake used as an example The left handbrake 2 controls the front wheel brake The right handbrake 1 controls the rear wheel brake 1 2 ...

Page 56: ...ng the remote control on the handlebars 3 4 6 1 SR Suntour The following compression dampers may be featured on the suspension fork Suspension fork RL RL R LO LO R HLO Lockout with remote control Lockout with remote control rebound adjustment Lockout on the fork Rebound adjustment lockout on the fork Hydraulic lockout Axon x x CR x x M3010 MOBIE25 x x NCX x x NEX x x x NVX x x XCE XCM x x x XCR x ...

Page 57: ...icator battery The five green LEDs on the battery level indicator show the charge level when the battery is switched on Each LED represents 20 of battery capacity Symbols All five LEDs will light up when the battery is fully charged The charge level for the activated battery is also shown on the on board computer If the battery level falls below 5 all the LEDs on the operating status and battery l...

Page 58: ...on battery 3 7 V 230 mAh Operating temperature 5 40 C Storage temperature 10 40 C Charging temperature 0 40 C Protection class with USB cover closed IPx54 Weight about 0 15 kg Table 31 Technical data for BOSCH Intuvia on board computer BUI255 Charge voltage 5 V Charging current Max 500 mA Table 32 USB port technical data Maximum continuous power rating 250 W Max torque 85 Nm Nominal voltage 36 V D...

Page 59: ...ewheel body 35 50 Nm 10 mm hex bit SHIMANO FH MT200 FH TX505 FH TY505 Attachment screw freewheel body 147 200 Nm 12 mm hex bit SHIMANO FH M7010 FH M7010 B FH M6010 FH M6010 B FH M618 FH M618 B FH MT400 FH MT400 B FH MT500 FH MT500 B FH MT510 FH MT510 B Lock nut 15 20 Nm Hub spanner 17 mm SHIMANO HB M7000 HB M6000 HB M4050 Lock nut 10 15 Nm Hub spanner 13 mm and 17 mm SHIMANO HB M7010 HB M7010 B HB...

Page 60: ...acket 3 4 Nm Screw wrench SHIMANO for racing bicycles Attachment screw for inner cable 6 7 Nm Hex key 4 mm Hex key 5 mm SHIMANO for racing bicycles Attachment screw for pulley 2 5 5 Nm Hex key 3 mm 3 5 8 4 Front derailleur SHIMANO for MTB trekking Attachment screw clip type E type and direct fitting 5 7 Nm Hex key 5 mm SHIMANO for MTB trekking Inner bearing adapter 35 50 Nm SHIMANO for MTB trekkin...

Page 61: ...at post axle Slipper clutch Valve cover Postpin axle Rear clamping screw saddle M5 attachment screw for outer sleeve 8 Nm 18 Nm 0 5 Nm 8 Nm 8 Nm 0 5 Nm 6 mm hex bit 3 mm hex bit 5 mm hex bit 5 mm hex bit 3 mm hex bit 3 mm hex bit LIMOTEC LimoDP Clamping screw for seat post Clamping screw for saddle 6 7 Nm 7 9 Nm SR SUNTOUR suspension seat post Seat clamp screw M5 fixing grub screws 15 18 Nm 3 Nm 2...

Page 62: ...8 16 Disc brake SHIMANO for centre lock type Attachment screw quick release 40 50 Nm TL LR15 TL FC36 TL LR11 Adjustable spanner SHIMANO for centre lock type Attachment screw nut version 40 50 Nm TL LR10 Screw wrench SHIMANO for 5 hole version Attachment screws 2 4 Nm Star bit no 25 SHIMANO for 6 hole version Attachment screws 2 4 Nm Star bit no 25 3 5 8 17 V Brake brake SHIMANO Attachment screw fo...

Page 63: ...NO FC M8000 single version Attachment screw for crank chainring 12 14 Nm Star bit no 30 SHIMANO FC M8000 dual version Largest chainring Smallest chainring 12 14 Nm 16 17 Nm Star bit no 30 Star bit no 30 SHIMANO FC M8000 triple version Largest chainring medium sized chainring Smallest chainring 10 12 Nm 16 17 Nm Star bit no 30 Star bit no 30 3 5 8 21 Crank bearing crank set Conventional cartridge c...

Page 64: ...ews for casing base locking mechanism 2 x attachment screws for cover 2 x attachment screws for cover 2 attachment screw for bracket on cable side 1 attachment screw for bracket on cable side 2 attachment screws for bracket on lock side 1 attachment screw for bracket on lock side 5 Nm 2 Nm 2 Nm 1 3 Nm 5 Nm 5 Nm 1 Nm Torx T25 M5 20 M3 5 12 M3 5 12 pointed Torx T15 Torx T25 M5 20 Torx T25 Torx T15 M...

Page 65: ... if there is no other data on the component 3 5 8 27 Headlight FUXON headlight Attachment screw 5 Nm SUPERNOVA M99 Pure Pure V521s Attachment screw 2 Nm M6 attachment screw self locking nut washer SUPERNOVA M99 Pure Pure V521s Stem screw 6 Nm ...

Page 66: ...ted handles lifting points The box does not have any handles Type no Frame Dimsions Box cm Weight kg Shipping weight kg 22 15 2061 43 cm 26 48 cm 26 53 cm 26 22 15 2062 43 cm 26 48 cm 26 53 cm 26 22 15 2059 43 cm 27 48 cm 27 53 cm 27 22 15 2060 43 cm 27 48 cm 27 53 cm 27 22 15 2057 43 cm 27 48 cm 27 53 cm 27 22 15 2058 43 cm 27 48 cm 27 53 cm 27 21 17 3236 43 cm 27 48 cm 27 53 cm 27 21 17 3237 43 ...

Page 67: ...tive covers Transport the battery in a dry clean position where it is protected from direct sunlight 4 3 3 Shipping a pedelec When shipping the pedelec we recommend that you have the specialist dealer place it in proper packaging 4 3 4 Transporting the battery Batteries are subject to hazardous goods regulations Undamaged batteries may be transported by private persons in road traffic Commercial t...

Page 68: ...d with a damp cloth and preserved with wax spray Never wax the friction surfaces of the brake Before longer periods without use it is recommended to have the specialist dealer carry out maintenance and basic cleaning and apply preservative agent 4 4 2 2 Carrying out a break in operation 1 Store the pedelec battery and charger in a dry clean environment We recommend storing them in uninhabited room...

Page 69: ...mble the pedelec Risk of eye injury Problems may arise if components are set incorrectly They may cause serious injuries to the face Always wear safety glasses to protect eyes when assembling pedelecs Crash and crushing hazard caused by unintentional activation There is a risk of injury if the electric drive system is activated unintentionally Remove the battery WARNING CAUTION 1 pre assembled ped...

Page 70: ...e immediately after being assembled The assembly report see Section 11 2 describes all safety relevant inspections tests and maintenance tasks All assembly work must be completed to ensure the pedelec is ready to ride Complete an assembly report to document quality assurance see Section 11 1 5 3 1 Checking the battery The battery must be checked before it is charged for the first time Press the On...

Page 71: ...to remove the two 4 mm hexagon screws from the PowerTube adapter You can use a hexagonal key to remove the screws if you don t have a small ratchet Figure 52 Removing the 4 mm hexagon screws 3 Use ratchet to remove the two 4 mm hexagon screws from the PowerTube adapter Figure 53 Removing hexagon screws 4 Remove the PowerTube adapter Figure 54 Pulling out the PowerTube adapter 5 Use adapter plates ...

Page 72: ...he battery mounting plate to the BOSCH PowerTube 625 battery with original BOSCH screws M4 8 T20 In doing so ensure that the removal tab faces the front of the battery Figure 58 Fitting the mounting plate 3 Press to push the battery cover onto the battery In doing so ensure that the battery On Off button fits through its designated slot in the cover The battery cover will lock into the fitting gro...

Page 73: ...pper surface of the PowerTube extension must face upwards away from the battery Figure 61 Fitting the PowerTube extension 3 Screw the battery mounting plate onto PowerTube extension with original BOSCH screws M4 8 T20 To do so use PowerTube extension screw plate as counter support When positioning the extension ensure that the removal tab faces the front of the battery Figure 62 Fastening the batt...

Page 74: ...in guard Figure 64 Position of mount screw Removing the pedals The mark is either on the top end the axle or the pedal body Figure 65 Example of mark on pedals 5 Use a 15 mm screw wrench to undo the left pedal thread in a clockwise direction and the right pedal thread in an anti clockwise direction 6 Turn the pedal marked R anti clockwise by hand out of the crank arm on the right as seen when faci...

Page 75: ...procket 13 Use BOSCH crank puller on a ratchet to remove the crank to the right 14 Detach crank 15 Unfasten belt sprocket with BOSCH removal tool on ratchet or torque wrench 16 Detach belt sprocket with washer Removing the motor 17 Unfasten the 3 attachment screws for lower motor cover with Torx TX 20 Figure 71 Attachment screws in lower motor cover 1 18 Remove lower motor cover 19 Unfasten the 2 ...

Page 76: ...ecified order 1 2 3 4 5 6 Figure 74 Position of motor screw 1 to 6 23 Remove the motor Undoing screws on battery mount 24 Use a TORX T25 wrench to undo the screws in the battery mount The counter nut will fall into the frame Figure 75 Undoing screws on battery mount 25 Remove battery mount and turn over 26 Clamp the clip VLD I 1232 onto the battery mount on the rear Figure 76 Clip VLD I 1232 Figur...

Page 77: ...hicles with a brake light function connect the rear light together with the brake light and if present the GPS cable in position 5 Power Port 33 Position the motor cover Fasten the 2 attachment screws with Torx TX 20 and torque of 2 0 5 Nm Figure 80 Position of attachment screws 1 34 Fasten the 3 attachment screws for lower motor cover with Torx TX 20 and torque of 2 0 5 Nm Figure 81 Attachment sc...

Page 78: ...21 38 Use a hex bit to fasten the retaining screws on the left and right Figure 82 Fastening the belt sprocket example Fitting the belt 39 Pull belt or chain over the belt sprocket or the chain wheel Figure 83 Fitting the belt 40 Push the rear wheel backwards to tension the belt or chain Figure 84 Pushing the rear wheel backwards 41 Check and adjust belt or chain tension see Section 7 5 9 or 7 5 4...

Page 79: ...eds to transmit the drive forces the front wheel is responsible for transmitting braking and steering forces Drive and braking forces have different directions of action This is why some tyres are mounted on the front and rear wheels in opposite directions On these tyres there are two rotation direction arrows The FRONT rotation direction arrow indicates the recommended direction of rotation for t...

Page 80: ...t the front wheel into the fork ends 2 Insert the axle into the hub on the drive side Figure 88 Inserting the axle in the direction of the arrow 3 Use a 6 mm hex key to tighten the axle using between 8 and 10 Nm The axle thread must be visible Figure 89 Tighten the axle in the direction of the arrow 4 Insert the securing screw on the non drive side Figure 90 Inserting the securing screw 5 Tighten ...

Page 81: ... Crash caused by loose cross axle A faulty or incorrectly installed cross axle may become caught in the brake disc and block the wheel This will cause a crash Never fit a defective cross axle Crash caused by faulty or incorrectly installed cross axle The brake disc becomes very hot during operation Parts of the cross axle may become damaged as a result The cross axle becomes loose This will cause ...

Page 82: ...e lever must be flush with the shock absorber Figure 96 Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required Figure 97 Adjusting the quick release clamping force 7 Check the quick release lever position and clamping force The wheel is now fitted ...

Page 83: ...aulty or incorrectly installed quick release may become caught in the brake disc and block the wheel This will cause a crash Never fit a defective quick release Crash caused by faulty or incorrectly installed quick release The brake disc becomes very hot during operation Parts of the quick release may become damaged as a result The quick release comes loose This will cause a crash with injuries Th...

Page 84: ...rmula to calculate the optimum seat post height for leg length Seat height SH inner leg length I 0 9 2 Lower the seat post further into the seat tube 3 The seat post Bowden cable must be tightened in the frame up to the remote control to the same length as the seat post was lowered 4 Trim the seat post Bowden cable on the handlebars if necessary ...

Page 85: ... 102 Example of markings on pedals 1 Coat threads in both pedals with waterproof grease 2 Turn the pedal marked L anti clockwise by hand into the crank arm on the left as seen when facing the direction of travel Figure 103 L pedal in the left hand crank arm 3 Turn the pedal marked R anti clockwise by hand into the crank arm on the right as seen when facing the direction of travel Figure 104 R peda...

Page 86: ...5 If the handlebars cannot be fastened contact your specialist dealer Stem with clamping lever version II and stem with screw If the handlebars cannot be fastened contact your specialist dealer 5 3 7 3 Checking the bearing clearance 1 Place the fingers of one hand on the upper headset cup Pull the front wheel brake with the other hand and try to push the pedelec backwards and forwards Keep in mind...

Page 87: ...lowly get used to road traffic and speed before riding at speeds over 12 km h especially if you have not ridden a bike for some time Increase the levels of assistance gradually Practice braking hard on a regular basis Take and complete a riding safety course WARNING Injuries and death caused by distraction A lack of concentration while riding increases the risk of an accident This may cause a cras...

Page 88: ...longer braking distance The braking sensation differs from the usual sensation This can cause loss of control or a crash which may result in injuries Ride slowly and brake in good time when it is raining CAUTION Crash caused by soiling Heavy soiling can impair pedelec functions such as braking This may cause a crash with injuries Remove coarse soiling before riding Notice Heat or direct sunlight c...

Page 89: ...ance are the greater the range is Gear switching habits Use a low gear and a low level of assistance on hills and when setting off Switch up a gear depending on the speed and terrain 50 80 crank rotations per minute are optimal Avoid high stress loads on the crank during a gear change Switch gear back in good time e g before inclines Tyres Always select the right tyres for the surface type As a ge...

Page 90: ...puter battery while in its mount or using USB port 431 Software version error 1 Re start the system 2 Contact your specialist dealer if the problem persists Table 40 List of on board computer error messages 440 Battery internal error 1 Re start the system 2 Contact your specialist dealer if the problem persists 450 Internal software error 1 Re start the system 2 Contact your specialist dealer if t...

Page 91: ...able 40 List of on board computer error messages 605 Temperature error The pedelec is outside the permitted temper ature range 1 Switch off the system to cool the motor and battery down or warm them to the permitted temperature range 2 Re start the system 3 Contact your specialist dealer if the problem persists 606 External fault 1 Check cabling 2 Re start the system 3 Contact your specialist deal...

Page 92: ...s 870 871 880 883 885 Communication error 1 Re start the system 2 Contact your specialist dealer if the problem persists 889 Internal ABS error Contact specialist dealer 890 ABS indicator lamp is defective or missing ABS may not be functioning Contact specialist dealer No screen display On board computer internal error Re start the drive system by switching it on and off Code Description Method of...

Page 93: ...justing the pedelec Only a correctly adjusted pedelec will guarantee the desired ride comfort and health promoting activity All settings must be re configured if the body weight or maximum baggage weight changes 6 5 1 Preparing The following tools are required to adjust the pedelec Crash caused by incorrectly adjusted torque If a screw is fastened too tightly it may break If a screw is not fastene...

Page 94: ... position Adjust saddle tilt 6 5 4 1 6 5 3 3 6 5 3 5 6 5 3 6 2 Handlebars 6 5 4 3 Stem 6 5 5 4 Handles 6 5 6 x 5 Tyres 6 5 7 6 1 6 2 6 3 6 4 6 5 Brake Position of the brake handles Brake handle tilt angle Determine grip distance Pressure point Retract the brake linings 6 5 8 1 6 5 8 2 6 5 8 3 6 5 8 5 6 5 8 7 7 Gear shift 6 5 9 9 Adjust suspension Adjust the suspension fork sag Adjust damper sag 6 ...

Page 95: ...k at an angle of 60 70 Upper arm upper body angle red line Extremely acute angle at around 20 The upper arms are almost parallel to the upper body Hands are simply placed loosely on the handlebars An angle of 75 80 is optimum Many people prefer a smaller angle of up to 60 as it requires to less effort to support the shoulders arms and hands Saddle handlebar height difference cm blue and green line...

Page 96: ...ure 106 Positioning the saddle in direction of travel 6 5 3 2 Positioning the saddle with eightpins suspension seat post Only applies to pedelecs with this equipment 1 Position saddle in direction of travel In doing so align the tip of the saddle with the top tube 2 Use a torque wrench to tighten the seat post axle with 8 Nm Figure 107 Tightening the seat post axle ...

Page 97: ...too high If your knees are painful after a few kilometres the saddle is too low Position the seat post according to needs if necessary Adjust the seat height with the quick release 5 Open the quick release on the seat post to change the seat height 1 To do so push the clamping lever away from the seat post 3 Figure 109 Opening the seat post quick release 6 Set the seat post to the required height ...

Page 98: ...red height Figure 111 Remote control operating lever 1 Raising the saddle 1 Remove any pressure from the saddle 2 Press the remote control operating lever The seat post will rise 3 Release the remote control operating lever when you have reached the desired height Notice If you are unable to achieve the required saddle height the seat post must be lowered further into the seat tube The seat post B...

Page 99: ...k Figure 112 Knee cap perpendicular line 3 Unfasten and adjust the designated screw connections and clamp them with the maximum tightening torque for the saddle clamping screws 6 5 3 6 Adjusting the saddle tilt The saddle tilt must be adjusted to the seat height the saddle and handlebar position and the saddle shape to ensure an optimum fit The seating position can be optimised in this way if need...

Page 100: ...timal position on the handlebars when the forearm and hand are in a straight line i e the wrist is not bent In this way the nerves are not pinched and do not cause pain Figure 115 Distribution of nerves with curved and straight handlebars The narrower the shoulders are the greater the bend of the handlebars should be maximum 28 Straight handlebars are advisable for sports bikes e g MTB They suppor...

Page 101: ...rain is with the back and abdominal muscles pre tensioned Passive muscles are not able to perform this important task 3 Set the required handlebar position by adjusting the stem height and angle see Section 6 6 6 4 After adjusting the handlebars check the saddle height and riding position again The position of the pelvis on the saddle may have changed when the handlebars were adjusted This can hav...

Page 102: ...ops before reaching its end position unscrew the knurled nut Tighten the knurled nut on the seat post if the seat post clamping lever s clamping force is not effective enough Contact your specialist dealer if the clamping force cannot be set Handlebar stem units are components that may be replaced after approval by the vehicle or parts manufacturer A stem must be replaced if cable and or line leng...

Page 103: ...e quill stem height 1 Undo screw 2 Pull quill stem out 3 Tighten screw 6 5 5 6 Adjusting the Ahead stem Only applies to pedelecs with this equipment In the case of an Ahead stem the stem is placed directly on the fork steerer which protrudes over the frame Figure 119 Raising the Ahead stem by fitting spacer rings The handlebar height is adjusted once during production using spacer rings The part o...

Page 104: ...stable stems are available in different lengths for quill and Ahead stems Figure 120 Different versions of angle adjustable stems Adjusting the stem angle c changes both the distance from the upper body to the handlebars b and the handlebar height a Figure 121 City bike blue and trekking bike position red by changing the angle a a b b c c ...

Page 105: ...and held in the correct position so that the hand can no longer bend If the pre mounted handles are uncomfortable or cause pain or numbness in the index middle finger or thumb ergonomic handles bar ends or multi position handlebars should be used 6 5 6 2 Adjusting ergonomic handles Only applies to pedelecs with this equipment Figure 122 Incorrect 1 and correct 2 position of the handle 6 5 6 3 Chec...

Page 106: ... pressure often leads to premature wear in the tyre Cracking in the side wall is a typical consequence of very low tyre pressure Abrasion is also unnecessarily high On the other hand a tyre can absorb road impacts more effectively at a low pressure As a general rule wide tyres are operated at a lower tyre pressure They provide the option of exploiting the advantages of the lower tyre pressure with...

Page 107: ...Different tyres need to be used when the area of use is changed more weight or greater puncture protection is added and greater acceleration or more dynamic cornering is used Tyres may be replaced if They are approved for use on e bikes They comply with ETRTO dimensions They have the same load capacity as a minimum They have a comparable level of puncture protection as a minimum ...

Page 108: ...of the handlebar 2 Extend the index finger about 15 Figure 125 Brake handle position 3 Push handbrake outwards until the third finger phalanx sits in the recessed grip 6 5 8 2 Change handbrake inclination angle The nerves that pass through the carpal tunnel are connected to the thumb and the index and middle fingers An excessively steep or excessively flat brake angle will cause the wrist to bend ...

Page 109: ...stance 1 Measure hand size using the grip distance gauge 2 Adjust the grip distance at the pressure point based on the hand size Figure 128 Handbrake positioning Saddle handlebar height difference mm Brake angle 10 20 25 0 10 25 30 0 10 30 35 10 35 45 20 25 10 cm 25 30 0 10 cm 30 35 0 10 cm 35 45 10 cm E Hand size Grip distance cm S 2 M 3 L 4 3 2 1 ...

Page 110: ...ckwise towards minus The brake lever moves closer to the handlebar grip Turn the setting screw twist knob 5 clockwise towards plus The brake lever moves away from the handlebar grip Figure 129 Adjusting the grip distance on a MAGURA disc brake lever Crash caused by incorrectly set grip distance If brake cylinders are set incorrectly or installed wrongly the braking power may be lost at any time Th...

Page 111: ... Turn the twist knob towards the minus The brake lever move further away from the handlebar grip Re adjust the grip distance as necessary The lever pressure point activates later Figure 130 Using the twist knob 1 to adjust the pressure point Brake failure due to incorrect setting If the pressure point is set with brakes where the brake linings and brake disc have reached their wear limit the brake...

Page 112: ...ring break in time This is also the case when the brake pads or brake discs are replaced 1 Accelerate pedelec to 25 km h 2 Brake pedelec until it comes to a halt 3 Repeat process 30 to 50 times The disc brake is retracted and provides optimal braking power Brake components may only be replaced with original components In the case of disc brake pads the optimum pad compound may be adapted to the su...

Page 113: ... the gear shift Not included in price 6 5 9 2 Adjusting the SHIMANO shifter Only applies to pedelecs with this equipment Figure 131 Position of attachment screw in SHIMANO shifter 1 All gear shift components rear derailleur shifter twist grip shift cables and sleeves may be replaced provided that All gear shift components are suitable for the number of gears All gear shift components are compatibl...

Page 114: ...deflection The adjustment shown here represents a basic setting Pedelec riders should change the basic setting to suit the surface and their preferences It is advisable to make a note of the basic settings These can then be used a starting point for subsequent settings and as a safeguard against unintentional changes All suspension components rigid and suspension forks and rear frame dampers are p...

Page 115: ...crown Remove the plastic cover Figure 132 Sag setting wheel 1 on the suspension fork crown Turn the sag setting wheel clockwise to increase the spring pre tensioning Turn the sag setting wheel anti clockwise to decrease the spring pre tensioning You will have made the ideal setting when the shock absorber deflects 3 mm when subject to body weight 3 Replace the plastic cover on the crown after maki...

Page 116: ...t on the pedelec in your usual riding position and support yourself against an object such as a wall or tree 8 Get off the pedelec without allowing it to deflect 9 Measure distance between the dust seal and the cable tie This measurement is the sag The recommended value is between 15 hard and 30 soft of the total fork deflection 10 Increase or reduce air pressure until you have reached the desired...

Page 117: ...dy weight spring stiffness deflection the terrain and the pedelec rider s preferences If the air pressure or spring stiffness increases the extension and rebound speeds also increase Rebound damping needs to be increased to achieve an optimal setting if the air pressure or spring stiffness is increased The damper rebounds at a controlled speed if the fork is optimally adjusted The wheel stays in c...

Page 118: ...d screw in a clockwise direction towards the closed position until it stops 2 Turn the rebound screw slightly in an anti clockwise direction Adjust the rebound damper in such a way that the fork rebounds quickly but without bottoming out upward Bottoming out refers to when the fork rebounds too quickly and stops moving abruptly once it has reached the full rebound distance You can hear and feel a ...

Page 119: ...s accident with fatalities Example 2 Positioning the headlight correctly can ensure that oncoming traffic is not dazzled and no one is put at risk Example 3 If the headlight is positioned too low the space ahead is not illuminated to an optimum extent and the rider s vision is reduced in the dark Figure 136 Light positioned too high 1 correctly 2 and too low 3 1 2 3 ...

Page 120: ...he handlebars straight with both hands Do not use the kickstand 7 Switch on riding light Figure 138 Light positioned too high 1 correctly 2 and too low 3 8 Check the position of the light beam I if the upper edge of the light beam is above the headlight height mark 1 the riding light will dazzle The headlight must be positioned lower If the mid point of the light beam is on or slightly below the m...

Page 121: ...centration while riding increases the risk of an accident This may cause a crash with serious injuries Never allow yourself to be distracted by the on board computer Stop pedelec if you want to make inputs on the on board computer other than change the level of assistance Only enter data when the bicycle is stationary Notice Do not use on board computer as a handle The on board computer may become...

Page 122: ... computer and the RESET button together SETTINGS is displayed on the on board computer The System settings is opened Press the info button on board computer repeatedly until the system setting which you wish to change is displayed Press the plus button or the minus button to change the displayed setting Press and hold the RESET button for 3 seconds to save the changed system settings and return to...

Page 123: ...0 40946 Rear wheel basket system component 051 20603 Bicycle box system component 080 40947 Table 49 Accessories Crash caused by incorrect child seat Pannier racks with a maximum load capacity under 27 kg and the down tube are unsuitable for mounting child seats and may break Such an incorrect position may cause a crash with serious injuries for the pedelec rider or child Never attach a child seat...

Page 124: ...ler BURLY CROOZER THULE Crash caused by brake failure The braking distance may be longer if the trailer is carrying excessive load The long braking distance can cause a crash or an accident and injuries Never exceed the specified trailer load Notice The operating and safety instructions for the trailer system must be observed Observe the statutory regulations on the use of bicycle trailers Only us...

Page 125: ...e case in the holder and turn 90 to the right To release turn the SP Connect mobile case 90 to the left and remove 6 6 4 Tubeless and airless tyres Riding a pedelec without tubes reduces the risk of tyre punctures or even avoids them completely The specialist dealer will advise you on which tyre system is suitable for the pedelec A specialist dealer must carry out conversion to tubeless or airless...

Page 126: ... the pedelec and that all components are installed and firmly fastened They will also ensure that shift cables brake cables hydraulic lines and electrical cables are adjusted as necessary the person riding has optimum freedom of movement and the pedelec s maximum permitted total weight is not exceeded The specialist dealer will provide instruction on how to handle the pedelec and the pannier rack ...

Page 127: ...be positioned so that it does not dazzle other road users The white front light and the white reflector must be clean at all times 7 The two separate brakes on the pedelec must work at all times 8 The clear sounding bell must be fitted and must work 6 8 Before each ride Check pedelec before each ride see Section 7 1 Be alert to any unusual noises vibrations or odours while riding Be alert to any u...

Page 128: ...teer and brake This can lead to a loss of control This may cause a crash with injuries You should practice how to use a loaded pannier rack safely before using the pedelec in public spaces Crushing the fingers in the spring flap The spring flap on the pannier rack operates with a high clamping force There is a risk of crushing the fingers Never allow the spring flap to snap shut in an uncontrolled...

Page 129: ...riosteum around the sitting bones is irritated as it is unaccustomed to the chafing To reduce chafing wear cycling shorts with shock absorbing seat padding use a chamois cream or ointment The sensation of pain is reduced after five to six rides although it may increase again after two to three weeks of riding 6 12 1 Using the leather saddle Sunlight and UV light tarnish the colour and cause the le...

Page 130: ...and relax tension In the bottom position place your upper body slightly lower Keep your fingers close to the brake handle ready for use 6 15 2 Using bar ends Only applies to pedelecs with this equipment Bar ends can be added to normal handlebars Adjustable bar ends feature a ball joint which you can use to choose the optimum position as required Adjust bar ends correctly To do so your hand elbow a...

Page 131: ... battery key from the battery lock 4 3 Tip the battery into the top section of the frame battery mount until it will go no further There is an audible clicking noise 4 Check the battery to make sure it is firmly in place 6 16 2 Pannier rack battery Only applies to pedelecs with this equipment 6 16 2 1 Removing the pannier rack battery Figure 150 Removing 2 and inserting 3 the pannier rack battery ...

Page 132: ... the frame 4 Remove the battery key from the battery lock 6 16 3 2 Inserting the integrated battery Figure 152 Inserting the integrated battery 1 Place the battery into the integrated battery lower mount with the contacts facing the front 1 2 Flip the battery upwards so that the battery is held by the retainer guard 2 3 Push the battery upwards 3 There is an audible clicking noise 4 Check battery ...

Page 133: ...h this equipment 6 16 5 1 Charging process when two batteries are used If two batteries are attached to a pedelec charge both batteries via the non sealed socket The two batteries are charged alternately during charging Charging switches automatically between the two batteries several times The charging time is twice as long The two batteries are discharged alternately during use 6 16 5 2 Charging...

Page 134: ... If you wish to use just one battery on a pedelec which is designed for two batteries cover the contacts in the free slot with the supplied cover cap 1 otherwise there is a risk of a short circuit caused by the open contacts 6 16 7 Waking the battery The battery switches to sleep mode to protect itself when not used for a longer period The LEDs on the battery level indicator do not light up Press ...

Page 135: ...nce is OFF The motor power is determined by the level of assistance set on the on board computer 6 17 2 Switching off the electric drive system As soon as the rider stops pushing the pedals in normal mode or reaches a speed of 25 km h the drive system switches off the assistance system The assistance system starts up again when you push the pedals and your speed is less than 25 km h The system swi...

Page 136: ...sk of an accident This may cause a crash with serious injuries Never allow yourself to be distracted by the on board computer Stop pedelec if you want to make inputs on the on board computer other than change the level of assistance Only enter data when the bicycle is stationary Notice Do not use on board computer as a handle The on board computer may become irreparably damaged if you use it to li...

Page 137: ...nd partially reset If the on board computer is removed from its mount all function values are saved and can still be displayed 6 18 7 1 Switching the displayed journey information Press the on board computer info button or the operating element info button repeatedly until the required journey information is displayed 6 18 7 2 Resetting the journey information If you wish to reset the journey info...

Page 138: ...esired speed has been reached Crash caused by brake failure Oil or lubricant on the brake disc in a disc brake or on the rim of a rim brake can cause the brake to fail completely This may cause a crash with serious injuries Never allow oil or lubricant to come into contact with the brake disc or brake linings or on the rim of a rim brake If the brake linings have come into contact with oil or lubr...

Page 139: ...y when absorbing a bump green line Threshold The damping threshold prevents deflection until a medium impact or downward force occurs Threshold mode increases drive efficiency over level terrain The threshold setting can be used to improve pedalling efficiency over flat or hilly terrain In threshold mode higher pedelec speeds lead to greater impact force when a pedelec hits a bump causing the fork...

Page 140: ...sition Place compression adjuster in the OPEN position The compression adjuster is open Place compression adjuster in the LOCK position The compression adjuster is locked Position compression adjuster between OPEN and LOCK This position allows you to fine tune the compression adjuster We recommend setting the compression adjuster to the OPEN position first 1 2 ...

Page 141: ...uces Wear on the drive train However keep the crank moving while switching gears Figure 157 Switching gears with lever A using gear shift SL M315 as an example Lever A switches from a smaller pinion to a larger one The number of pinions switched depends on the selected position of lever A Place shifter A in position 1 System shifts one pinion higher Place shifter A in position 2 System shifts two ...

Page 142: ... Switching down several gears to a low gear may cause the twist grip outer sleeve to suddenly come off This will not have an adverse effect on the twist grip s correct functioning since the outer guide returns to its original position after the gear change is complete Apply little pressure on the pedals while changing gears Never change more than one gear at a time Notice The interior hub is not c...

Page 143: ...d then switches through all gears during the first ride The new gear is shown briefly on the on board computer each time it is changed Since the motor detects the gear shift and consequently reduces motor assistance briefly it is possible to switch gears under load or on hills If the pedelec is brought to a halt from a speed greater than 10 km h the system can automatically switch back to a pre se...

Page 144: ... This can destroy the tyres Never park the pedelec in the sun On hot days regularly check the tyre pressure and adjust it as necessary Moisture penetrating at low temperatures may impair individual functions due to the open structural design Always keep the pedelec dry and free from frost If the pedelec is used at temperatures below 3 C the specialist dealer must perform maintenance beforehand and...

Page 145: ...le stem to save space when parking 1 Open stem clamping lever Figure 160 Example of All Up with open stem clamping lever 2 Pull handlebars into highest possible position Figure 161 Example of All Up pulled into highest possible position 3 Turn handlebars 90 in a clockwise direction Figure 162 Example of All Up screwed in 4 Place handlebars at required height 5 Close stem clamping lever ...

Page 146: ...eflectors See Section 7 2 1 Clean brake See Section 7 2 5 Clean suspension fork See Section 7 2 2 Care for suspension fork See Section 3 Clean suspension seat post See Section 7 2 6 Clean rear frame damper See Section 7 2 7 Clean the pedals See Section 7 2 4 Checklist weekly tasks Clean chain See Section 7 3 18 City folding cargo and children s bikes and bicycles for young adults When dry every 10...

Page 147: ...ion 7 3 7 1 Care for leather handles See Section 7 4 8 2 Clean the leather saddle See Section 7 3 9 1 Care for leather saddle See Section 7 4 11 Clean handlebars See Section 7 3 6 Cleaning the motor See Section 7 3 3 Clean hub See Section 7 3 12 Cleaning the frame See Section 7 3 4 Clean tyres See Section 7 3 10 Check back pedal brake See Section 7 5 2 5 Clean saddle See Section 7 3 9 Clean seat p...

Page 148: ...e for handlebars See Section 7 4 7 Check handlebars See Section 7 5 12 Check light See Section 7 5 10 Care for hub See Section 7 4 12 Check hub See Section 7 5 14 2 Check nipple holes See Section 7 5 1 4 Care for pedals See Section 7 4 15 Check pedal See Section 7 5 14 Care for frame See Section 7 4 1 Check belt tension See Section 7 5 9 Check saddle See Section 7 5 13 Care for shifter See Section...

Page 149: ...stand high pressures Damaged brakes can fail and cause an accident with injury Never clean the pedelec with a pressure washer or compressed air Take great care when using a hosepipe Never point the water jet directly at the seal section WARNING Crash and falling caused by unintentional activation There is a risk of injury if the electric drive system is activated unintentionally Remove the battery...

Page 150: ... damage to the paintwork Also look at hidden parts on the underside If there are any cracks warping tarnished components leaked oil or damage to the paintwork remove the pedelec from service Contact specialist dealer 7 1 5 Checking the pannier rack 1 Hold onto pedelec by its frame Hold onto pannier rack with the other hand 2 Move the pannier rack backwards and forwards to check that all screw conn...

Page 151: ...ing the handles Check the handles are firmly in place Screw loose handles firmly into place 7 1 12 Checking the USB cover If featured check the position of the cover on the USB port on a regular basis and adjust if necessary 7 1 13 Checking the riding light 1 Switch light on 2 Check that the headlight and rear light come on If the headlight and rear lights do not come on take pedelec out of servic...

Page 152: ...ubricate the dust seals and stanchions with a few drops of silicone spray 3 Service the suspension fork after cleaning 7 2 3 Caring for the suspension fork Treat dust seals with fork oil 7 2 4 Cleaning the pedals Clean pedals with a brush and soapy water 7 2 5 Cleaning the brake Clean dirt on the rim and brake components with a slightly dampened cloth 7 2 6 Cleaning the suspension seat post Clean ...

Page 153: ...motor on the outside with a soft damp cloth Tool Cleaning agent Gloves Toothbrush Water Lubricant Cloth Paintbrush Dish washing liquid Brake cleaner Sponge Watering can Degreaser Leather cleaner Brushes Bucket Table 51 Required tools and cleaning agents for basic cleaning Notice If water enters the on board computer it will be permanently damaged Never immerse the on board computer in water Never ...

Page 154: ... grips with a cloth and soapy water 2 Rinse off component with water from a watering can 7 3 7 Clean handles 1 Clean handles with sponge water and soapy water 2 Rinse off component with water from a watering can 3 Care for rubber handles after cleaning see Section 7 4 8 7 3 7 1 Cleaning leather handles Leather is a natural product and has similar properties to human skin Regular cleaning and care ...

Page 155: ...spokes from the inside to the outside with a sponge brush and soapy water 2 Clean rim with a sponge 3 Rinse off component with water from a watering can 4 Care for spoke nipples after cleaning see Section 7 4 13 7 3 12 Clean hub 1 Put on protective gloves 2 Remove dirt from hub with a sponge and soapy water 3 Rinse off component with water from a watering can 4 Wipe off oily dirt with a degreaser ...

Page 156: ...hain 3 Hold and apply slight pressure while slowly turning the rear wheel so the chain passes through the cloth 4 Wipe off oily dirty chains thoroughly with a cloth and degreaser 5 Care for the chain after cleaning see Section 7 4 16 7 3 18 1 Clean chain including all round chain guard Clean water hole on the chain guard lower surface Care for the chain after cleaning see Section 7 4 16 1 Notice P...

Page 157: ...k with a cloth 2 Spray frame care oil on frame and leave to dry 3 Wipe away any wax residue with a cloth Tool Cleaning agent Cloth Toothbrush Frame wax spray Silicone or Teflon oil Acid free lubricating grease Fork oil Teflon spray Spray oil Chain oil Leather care product Table 52 Required tools and cleaning agents for servicing 2 4 5 1 3 A A A Battery terminal grease Notice Hard wax polish and pr...

Page 158: ...h 3 Apply silicone or Teflon oil to the stem shaft tube and the quick release lever pivot point with a cloth 4 If you have a Speedlifter Twist also apply oil to the unlocking bolt groove in the Speedlifter body 5 Apply a little acid free lubricant grease between the stem quick release lever and the sliding piece to reduce the quick release lever operating force 6 If you have a stem with a cone cla...

Page 159: ...her care products keep leather smooth and resistant brighten its appearance and improve or replace stain protection 1 Try leather care product out on a less visible spot before use 2 Care for leather saddle from below with a leather care product Only care for the top of leather saddles with a leather care product if they are badly worn and dried out 3 Avoid wearing light coloured trousers after ca...

Page 160: ...rops of oil 3 Remove any surplus lubricant with a clean cloth 4 Spray metal foot rests with silicone spray 7 4 16 Caring for the chain Place newspaper or paper towels underneath to collect chain oil 1 Lift rear wheel 2 Turn the crank briskly in an anti clockwise direction 3 Use slight finger pressure to the chain oil bottle to apply a wafer thin thread of oil to the chain links The faster the cran...

Page 161: ...nt in time 5 Leave chain oil to penetrate into the chain links for a few hours or overnight 7 4 17 Caring for the battery Grease plug terminals on the battery with terminal grease or contact spray from time to time 7 4 18 Caring for the brake 7 4 18 1 Caring for handbrake Lubricate articulated joints and mechanical parts which are accessible from outside with a few drops of spray oil or precision ...

Page 162: ...service life Air loss Even the most airtigfht tube will lose pressure on a continuous basis since the air pressures in a pedelec tyre are significantly higher and the wall thicknesses significantly finer than in a car tyre Pressure loss of 1 bar per month can be regarded as normal During this process the pressure loss is significantly faster at high pressures and significantly slower at low pressu...

Page 163: ...ure gauge Older and simple bicycle air pumps are unsuitable for filling tyres via a Schrader valve 1 Unscrew and remove the valve cap 2 Undo the rim nuts 3 Connect the bicycle air pump 4 Pump up the tyre slowly and pay attention to the tyre pressure in the process The tyre pressure has been adjusted as per the specifications 5 Remove the bicycle air pump 6 Screw the valve cap tight 7 Screw the rim...

Page 164: ...ass cords are visible Since resistance to punctures also depends on the thickness of the tread it may make sense to change the tyre at an earlier stage Figure 167 Tyre without tread which can be replaced 1 and tyre with puncture protection showing through 2 which must be replaced 2 Check the side walls for wear If there are any cracks or tears the tyre must be replaced Figure 168 Examples of fatig...

Page 165: ...the nipple hole contact your specialist dealer 7 5 1 5 Checking the nipple well The nipple holes can weaken the tyre bed Check to see if cracks are emerging from the nipple holes If there are cracks radiating from the nipple hole contact your specialist dealer 7 5 1 6 Checking the rim hooks Mechanical impacts can warp the rim hooks There is no longer a guarantee that a tyre can be fitted safely if...

Page 166: ...tact your specialist dealer if the pressure point cannot be reached 7 5 2 2 Checking the hydraulic brake system 1 Pull on the handbrake and check whether any brake fluid leaks out of the lines connections or on the brake linings If any brake fluid leaks from anywhere take pedelec out of service Contact specialist dealer 2 Pull brake handbrake and hold several times If you are unable to clearly det...

Page 167: ...etween the brake lining supporting plates If the transport safety wear gauge fits between the supporting plates the brake linings have not reached their wear limit Contact your specialist dealer if they are Wear Checking the brake discs Put on gloves as the brake disc is very sharp 1 Take hold of brake disc and wiggle it gently to check whether the brake disc is positioned against the wheel free o...

Page 168: ...pment There are sharp corners and edges on the back pedal brake Wear gloves 1 Hold and check counter support to ensure it is firmly attached to rear frame down tube Tighten screw into the counter support if it is loose 2 Carry out brake test Listen for noises while doing so If braking with the backpedal makes noises contact specialist dealer ...

Page 169: ...he brake linings move irregularly contact your specialist dealer Checking the rim braking surface for wear The side wall is more prone to wear in rim brakes The Wear depends on the stress loads during rides Dirt between the brake lining and rim and strong braking forces can have an impact on the service life The rim must be replaced if the wall is less than 0 9 mm thick If deep grooves are visible...

Page 170: ...eck the chain tension at three to four points If the deviation is greater than 20 mm tighten chain If the deviation is less than 10 mm Loosen chain If a hub gear is fitted the rear wheel must be pushed backwards and forwards to tighten the chain Contact specialist dealer In the case of pedelecs with a hub gear or back pedal brake the chain is tensioned by an eccentric bearing or movable fork end i...

Page 171: ...175 Example of a ROHLOFF gauge Figure 176 Example of a KMC digital gauge 1 Insert gauge between two chain links on the right hand side Figure 177 Gauge is inserted 2 Lower gauge down to the left hand side Figure 178 Lower gauge to the left If the gauge does not fit between the links the chain is not worn yet Figure 179 Gauge does not fit If the gauge does not fit between the links the chain is wor...

Page 172: ...d teeth have worn thinner Replace belt sprocket Contact specialist dealer Figure 183 Worn tooth profile Figure 184 Photo showing example of worn tooth profile 7 5 9 Check belt tension If the belt tension is too low this can cause the system to miss out a tooth or slip i e the teeth on the belt slip over the teeth on the rear wheel belt sprocket Excessive tension can cause damage to the bearings sl...

Page 173: ... of charge from the App Store or Google Play on your mobile phone Measure in a quiet environment Ensure that the phone microphone is switched on 1 Open app 2 Click on the voltage symbol 3 Click on MEASURE 4 Point phone microphone towards the belt 5 Pluck the belt so that the belt vibrates like a guitar string 6 It is recommended to take several measurements for comparison Turn the crank a quarter ...

Page 174: ...h Table 44 Tension specification If the value is higher than the specification reduce belt tension If the value is within the specified range the belt tension has been correctly adjusted If the value is lower than the specification increase belt tension 7 5 9 3 ECO tension tester Not included in price 1 Attach the measuring stick on the belt Figure 189 Attached measuring stick 2 Place the ruler on...

Page 175: ...t specialist dealer 2 Switch light on 3 Check that the headlight and rear light come on If the headlight or rear lights do not come on take pedelec out of service Contact specialist dealer 4 Place pedelec 5 m from the wall 5 Stand the pedelec up straight Hold the handlebars straight with both hands Do not use the kickstand Figure 192 Light positioned too high 1 correctly 2 and too low 3 6 Check th...

Page 176: ... the saddle 1 Hold saddle firmly 2 Check whether the saddle twists tilts or can be pushed in one direction or other If the saddle twists tilts or can be pushed in one direction or other adjust the saddle see Section 6 5 4 Contact your specialist dealer if the saddle cannot be fixed into position 7 5 14 Checking the seat post 1 Take seat post out of the frame 2 Check seat post for cracks and corros...

Page 177: ...as been achieved if the chain can be pushed between a maximum of 10 and 15 mm in the middle between the pinion and the toothed wheel The crank must also turn without resistance 7 5 15 Check gear shift 1 Check that all gear shift components are free of damage 2 Contact your specialist dealer if components are damaged 3 Place the pedelec on stand 4 Turn the pedal crank clockwise 5 Switch through all...

Page 178: ...adjuster to increase the shift cable tension Tighten the tension adjuster to decrease the shift cable tension Figure 194 The tension adjuster on ROHLOFF hub versions with internal switch control is located on the tension counter support Figure 195 The tension adjuster on ROHLOFF hub versions with external switch control is located on the cable box positioned on the left hand side 3 If the marking ...

Page 179: ...djusting sleeves on the shifter housing There is noticeable play of 2 to 5 mm 1 2 gear when you turn the twist grip Figure 197 Twist grip with adjusting sleeves 1 and play in the gear shift 2 7 5 19 Checking kickstand stability 1 Place the pedelec on a slight elevation of 5 cm 2 Extend kickstand 3 Jolt pedelec to check stability If pedelec topples over tighten screws or change height of the kickst...

Page 180: ...pection tasks in the maintenance book 8 3 Component specific maintenance High quality components require extra maintenance Tasks require technical expertise special tools and special lubricants The pedelec may become damaged if the stipulated maintenance intervals and procedures are not carried out This is why only specialist dealers may carry out maintenance Correct maintenance on the fork not on...

Page 181: ...seat post by schulz suspension seat post Maintenance After the first 250 km every 1 500 km after that SR SUNTOUR suspension seat post Maintenance Every 100 hours or once a year eightpins suspension seat post Clean wiper 20 hours Clean slide bushing 40 hours Replace slide bushing wiper and felt strip 100 hours Seal service for gas pressure spring 200 hours RockShox dropper post Venting of remote co...

Page 182: ...tion and maintenance intervals for hub SHIMANO 11 speed hub Internal oil change and maintenance 1 000 km after start of use then every 2 years or 2 000 km All other SHIMANO gear hubs Lubricate internal components Once a year or every 2 000 km ROHLOFF Speedhub 500 14 Clean cable box and grease cable drum interior Every 500 km Oil change Every 5 000 km or at least once a year Pinion Maintenance 1 Ch...

Page 183: ...scribed in the brake operating instructions Injury to the eyes Problems may arise if the settings are not made properly and you may sustain serious injuries as a result Always wear safety glasses during Inspection and maintenance work Crash and falling caused by unintentional activation There is a risk of injury if the electric drive system is activated unintentionally Remove the battery before in...

Page 184: ...amper optional 6 months Check for damage corrosion fracture See ROCK SHOX compo nent maintenance instructions Maintenance as specified by manufacturer Air chamber assembly group damper and spring O K Damage detected New rear frame damper as specified in parts list FOX Rear frame damper optional 6 months Check for damage corrosion fracture Send to FOX O K Damage detected New rear frame damper as sp...

Page 185: ...ubrication oil change as specified by manufacturer O K Damage detected New fork as speci fied in the parts list FOX suspen sion fork optional 6 months Check for damage corrosion fracture Send to FOX O K Damage detected New rear frame damper as specified in parts list RockShox suspension fork optional 6 months Check for damage corrosion fracture Maintenance as specified by manufacturer Lubrication ...

Page 186: ...reat Hub with cone bearing optional Once a month Cleaning Section 7 3 12 O K Dirt Cleaning Once a month Care Section 7 4 12 O K Untreated Treat 6 months Check mount fastening O K Loose rust Retighten screws new handlebars as specified in parts list if necessary Once a year Adjust O K Not adjusted New position Hub gear optional Once a month Cleaning Section 7 3 12 O K Dirt Cleaning Once a month Car...

Page 187: ...screws new paint protection film new seat post as specified in parts list if damaged SR SUNTOUR suspension seat post Every 100 hours or Once a year Complete clean check fastening and paint protection film lubricate Section 8 6 8 3 O K Loose Tighten screws new paint protection film new seat post as specified in parts list if damaged eightpins NGS2 Suspension seat post 20 Hours Refill oil Section 7 ...

Page 188: ... Retighten screws Brake fluid 6 months Check fluid level Depending on time of year O K Too little Top up brake fluid take Pedelec out of service if dam aged new brake hoses Brake linings 6 months Brake linings brake discs and rims Check for damage O K Damage detected New brake linings brake discs and rims Back pedal brake braking armature 6 months Attachment Check mount fastening O K Loose Retight...

Page 189: ... drive system On board computer 6 months Check for damage Check for damage O K No screen defective screen display Restart test battery new software or new on board com puter decommis sioning Control panel 6 months Check control panel for damage Check for damage O K No response Restart contact control panel manu facturer new con trol panel Tachometer 6 months Calibration Speed meas urement O K Pede...

Page 190: ...tional 6 months Attachment Check mount fastening O K Loose Retighten screws Components Frequency Description Criteria Measures if rejected Components Description Criteria Measures if rejected Assembly inspection Tests Acceptance Rejection Brake system 6 months Functional check O K No full braking braking distance too long Locate defective part in brake system and correct Gear shift under operating...

Page 191: ...rised If the air system is serviced in a rear frame damper it can explode and cause serious injury Wear safety goggles protective gloves and safety clothing when assembling or carrying out maintenance on the bicycle Release the air for the air chambers Detach all air insert fitments Never service or dismantle a rear frame damper if it has not completely rebounded Intoxication from suspension oil S...

Page 192: ...rrectly fastened screws may come loose due to impact The stem may no longer be firmly fixed in its position as a result This will cause a crash with injuries Check the handlebars and the stem s quick release are firmly in position 8 5 6 Inspect and grease steering headset 1 Remove fork 2 Clean steering headset If it is very dirty flush the bearing with cleaning agents such as WD 40 or Karamba 3 Ch...

Page 193: ...y become caught in the brake disc and block the wheel This will cause a crash Install the front wheel quick release lever on the opposite side to the brake disc Crash caused by faulty or incorrectly installed quick release The brake disc becomes very hot during operation Parts of the quick release may become damaged as a result The quick release comes loose This will cause a crash with injuries Th...

Page 194: ...mage to the paintwork If there are any cracks warping or damage to the paintwork remove the pedelec from service New fork as specified in the parts list 3 Dismantle suspension fork 4 Lubricate dust seals and slide bushings 5 Check torques 6 Clean inside and exterior 7 Grease fork 8 Install fork 9 Adjust suspension fork see Section 6 3 14 Injury due to explosion The air chamber is pressurised When ...

Page 195: ...twork and impacts if the carbon seat post paintwork is damaged Ask customer what caused the damage Examine damage with a magnifying glass to see if fibres are permanently damaged or delamination has taken place Intoxication from lubrication oil The lubrication oil for Eightpins seat posts is toxic if touched or inhaled Always wear safety goggles and nitrile gloves when working with lubrication oil...

Page 196: ...e cover 3 Examine seat post rack for scratches cracks and breaks Replaced damaged seat post as specified in the parts list If the paint protection film protecting a child seat is missing or has worn away affix a new paint protection film 4 Undo pre tensioning adjuster and take out steel spring 5 Clean seat post on inside and outside 6 Grease seat post on inside with SR SUNTOUR grease no 9170 001 7...

Page 197: ...he cause of pain Any such problems should thus always be discussed openly with a doctor In most cases however pain after pedelec rides is due to a lack of training and components set incorrectly or components that are not adjusted to the rider s physique The most common complaints are 1 Sitting discomfort 2 Pain in hips 3 Backache 4 Pain in shoulders and nape of neck 5 Numb or aching hands 6 Pain ...

Page 198: ...inning a posture where you lean too far forward can lead to pain in the back arms and wrists The abdominal muscles are the counterpart to the back muscles and stabilise the pelvis and the back Back pain is thus often caused by weak abdominal muscles z Solution Adopt an optimal riding position see Section 6 5 3 Adjust the saddle height and tilt see Section 6 5 4 Wear cycling shorts and use chamois ...

Page 199: ...ere is almost no weight applied whereas body weight is at its highest in the sports position The force is applied to a small area on the handle meaning the pressure load on the hands is very high Hands are highly sensitive and can bear a maximum of 20 of body weight during prolonged exposure to load 9 1 6 Pain in upper thigh Pain in the upper thigh is usually due to muscular problems A muscular im...

Page 200: ...ain on the top of the kneecap often indicates a muscular imbalance Pain under the kneecap is usually related to excessive pressure in the knee joint and consequential irritation to the patellar tendon 9 1 8 Pain in the foot Your feet are one of three points of contact when you ride a pedelec Feet transmit force from the upper thigh to the pedal thus driving the pedelec In the process your feet are...

Page 201: ...remove the battery 3 Insert the battery 4 Start the drive system 5 If the drive system won t start remove the battery 6 Clean all the contacts with a soft cloth 7 Insert the battery 8 Start the drive system 9 If the drive system won t start remove the battery 10 Charge battery fully 11 Insert the battery 12 Start the drive system 13 If the drive system does not start up remove the on board compute...

Page 202: ... again The assisted journey distance is too short The journey distance can be shorter depending on the road conditions the gear level and the total usage time 1 Check battery is charged 2 Recharge the battery if it is almost flat The battery does not perform as well in winter weather This does not indicate a problem The battery is a consumable Repeated charging and long periods of use cause the ba...

Page 203: ...t dealer The battery does not start charging when the charger is connected The battery may be at the end of its useful life Replace old battery with new one The battery and charger become hot The temperature of the battery or the charger may have exceeded the operating temperature range 1 Interrupt charging process 2 Wait a moment 3 Repeat charging process 4 If the battery is too hot to touch ther...

Page 204: ...ialist dealer A component may be connected which the system is unable to recognise Contact specialist dealer The gear level is not shown on the on board computer The gear level is only shown if the electronic gear shift is used Check that the power cable connector has not been disconnected If this is not the case contact your specialist dealer The settings menu cannot be opened while you are pedal...

Page 205: ...m the ground in an uncontrolled way This impairs traction and control blue line Fork head and handlebars are deflected upwards if the wheel bounces back from the ground Body weight may be thrown up and back in an uncontrolled way green line Figure 202 Suspension fork rebounding too quickly Solution Figure 203 SR SUNTOUR rebound screw 1 Turn rebound screw in a clockwise direction The rebound speed ...

Page 206: ...d increases the hardness of impacts Available deflection traction and control decrease blue line The fork remains in a deflected state causing the headset and handlebars to move to a lower position Body weight is shifted forward after the impact green line Figure 204 Suspension fork rebounding too slowly Solution Figure 205 SR SUNTOUR rebound screw 1 Turn rebound screw in an anti clockwise directi...

Page 207: ...ight shifts forward and the pedelec loses some momentum Figure 206 Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 207 Changing compression adjuster to a harder setting Turn compression adjuster in a clockwise direction towards LOCK The damping and compression hardness are increased and the deflection stroke speed Efficiency on hilly and flat terrain is improved...

Page 208: ...onger touches the ground The headset and handlebars are deflected upwards significantly which can impair control Figure 208 Excessively hard damping in the suspension fork on bumps Solution Figure 209 Changing compression adjuster to a softer setting Turn compression adjuster in a clockwise direction towards OPEN The damping and compression hardness reduces and the deflection stroke speed is reduc...

Page 209: ... fitted the wrong way round after assembly Contact specialist dealer Check installation correct Hub is stiff when turned Ball bearings are worn Contact specialist dealer Replace ball bearings Ball bearings have been driven in too firmly after assembly Contact specialist dealer Check installation correct Installation sequence for ball bearings not observed Contact specialist dealer Check installati...

Page 210: ...gear speed cannot be changed The cable was not set correctly Contact specialist dealer Reset gear shift unit check whether the gear speed can be changed when the wheel is detached from the frame Strange noises are produced When switching gears Contact specialist dealer When pedalling The gear speed shown on the indicator differs from the speed in the hub The cable was not set correctly Contact spe...

Page 211: ...kes are applied Contact specialist dealer Rotation feels stiff during free rotation Contact specialist dealer Chain jumps between the gearwheels when gear is changed Gearwheels and or chain worn Contact specialist dealer New chain gearwheels or hub Symptom Cause Remedy Table 61 Error solution for limit stop ...

Page 212: ...nings and brake disc Spongy soft or poor pressure point in disc brakes Brake calliper fitted incorrectly brake disc loose brake disc or brake lining worn or brake system leaking Contact specialist dealer Noises when rim brake is applied Dirt 1 Clean brake disc and brake thoroughly 2 If the problem is not solved contact your specialist dealer Worn or wrong brake linings Contact specialist dealer Ne...

Page 213: ...ring the first 50 km or so after replacing the brake linings check the rims and brake linings regularly and clean to remove any residues Dirt 1 Clean rim and brake thoroughly 2 If the problem is not solved contact your specialist dealer Worn or wrong brake linings Contact specialist dealer New brake linings and rims Wheels hub or axle fitted incorrectly Contact specialist dealer Check brake system...

Page 214: ...nternal hub unit The rider needs to push the pedals too far back before the brakes engage 1 Contact specialist dealer Replace brake shoe unit 2 If the problem should persist replace the internal hub unit The wheels block if the pedelec is pushed backwards Contact specialist dealer Replace internal hub unit Unusual noises when braking 1 Contact specialist dealer Lubricate brake hub 2 Replace brake ...

Page 215: ...rolled way This impairs traction and control blue line Fork head and handlebars are deflected upwards if the wheel bounces back from the ground Body weight may be thrown up and backwards in an uncontrolled way green line Figure 210 Suspension fork rebounding too quickly Solution Figure 211 Turning the rebound screw damper towards tortoise symbol Turn the rebound screw clockwise towards the tortois...

Page 216: ...hardness of impacts Available deflection traction and control decrease blue line The fork remains in a deflected state causing the headset and handlebars to move to a lower position Body weight is shifted forward after the impact green line Figure 212 Suspension fork rebounding too slowly Solution Figure 213 Turning the rebound screw damper towards hare symbol Turn the rebound screw anti clockwise...

Page 217: ... up body weight shifts forward and the pedelec loses some momentum Figure 214 Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 215 Changing compression adjuster to a harder setting Turn compression adjuster clockwise The damping and compression hardness is increased and the deflection stroke speed is reduced Efficiency on hilly and flat terrain is improved ...

Page 218: ...wheel no longer touches the ground The headset and handlebars are deflected upwards significantly which can impair control Figure 216 Excessively hard damping in the suspension fork on bumps Solution Figure 217 Adjust the compression adjuster so that it is softer Turn compression adjuster anti clockwise The damping and compression hardness is reduced and the deflection stroke speed is increased Se...

Page 219: ...dal assistance becomes less effective when the gear is changed This is because the computer sets the pedal assistance to the optimum level This is not a malfunction A noise can be heard after switching Contact specialist dealer It is normal to hear a noise coming from the rear wheel when cycling as normal The gear shift setting may not have been made properly Contact specialist dealer If the pedel...

Page 220: ...e of impact The frame may break even under light stress 1 Take pedelec out of service 2 Send frame to a fibre composite repair company or purchase new frame as specified in the parts list 9 2 3 Repairing the suspension fork 9 2 3 1 Removing paint damage on the fork 1 Gently sand paintwork damage with 600 grit sandpaper 2 Smooth edges 3 Apply one or two coats of repair paint 9 2 3 2 Removing damage...

Page 221: ...earance needs to be checked each time a suspension fork tyre is replaced 1 Release pressure from the fork 2 Press fork together fully 3 Measure the gap between the top of the tyre and the crown s lower surface The gap must not be less than 10 mm If the tyre is too large the tyre will touch the crown s lower surface when the fork is fully pressed together 4 Release pressure on fork and pump it up a...

Page 222: ...amaged battery and the charger can be returned to any specialist dealer free of charge Further disposal options may be available depending on the region Store the individual parts of the decommissioned pedelec in a dry place free from frost where they are protected from direct sunlight 10 1 Guidelines on removal of waste Waste type Disposal Non hazardous waste Recycling Waste paper cardboard Retur...

Page 223: ... oil Cleaning cloths daubed in oil Lubrication oil Gear oil Lubricating grease Cleaning fluids Kerosene White spirit Hydraulic fluid Brake fluid Never mix different oil fluids Store in original container Small amounts mainly 30 kg Take to municipal collection points for hazardous waste e g mobile toxic waste collection service Larger quantities 30 kg Collection by waste disposal companies Paints V...

Page 224: ...et missing New bell as specified in the parts list Suspension elements Fork suspension fork Check for damage O K Damage detected New fork as specified in the parts list Rear frame damper Check for damage O K Damage detected New fork as specified in the parts list Suspension seat post Check for damage O K Damage detected New fork as specified in the parts list Brake system Handbrake Check mount fas...

Page 225: ...measurement O K Pedelec travelling 10 too fast slow Take pedelec out of service until the source of the error is found Cabling Visual inspection O K Failure in system damage kinked cables New cabling Battery mount Firmly in position lock contacts Functional check O K Loose lock doesn t close no contacts New battery mount Motor Visual inspection and mount O K Damage loose Refasten motor contact mot...

Page 226: ...nd adjustment O K Loose Retighten screws Saddle 6 months Check mount fastening O K Loose Retighten screws Seat post 6 months Check mount fastening O K Loose Retighten screws Guard 6 months Check mount fastening O K Loose Retighten screws Pannier rack 6 months Check mount fastening O K Loose Retighten screws Attachments 6 months Check mount fastening O K Loose Retighten screws Bell 6 months Functio...

Page 227: ... parts list replace if necessary Headlight 6 months Side light daytime riding light Functional check O K No constant light New headlight light as specified in parts list replace if necessary Reflectors 6 months All complete state fastening O K Damaged or not all complete New reflectors Drive gear shift Chain cassette pinion chainring 6 months Check for damage O K Damage Refasten if neces sary or r...

Page 228: ...r manufacturer new motor take out of service Software 6 months Check version In lat est ver sion Not latest version Import update Components Frequency Description Criteria Measures if rejected Components Description Criteria Measures if rejected Assembly inspection Tests Accept ance Rejection Brake system 6 months Functional check O K No full braking braking distance too long Locate defective part...

Page 229: ...MY22Z01 12_1 0_25 07 2022 228 Documents Notes ...

Page 230: ...36 Sand paper Rear derailleur SHIMANO XT Derailleur gears 12 speed Shifter SHIMANO XT Shifter Front derailleur Cassette cassette sprocket SHIMANO CS M6100 12 10 51T Chain KMC X10E Toothed belt Brake front rear MAGURA MT4e MT5e Hydraulic disc brake Brake lever front rear MAGURA MT4e MT5e Brake lever with rear light function Disc front rear Magura Storm HC 180 mm Rim front rear RODI Tryp 30 27 5 Hub...

Page 231: ...e Lock ABUS Bordo 6015 Kickstand PLETSCHER Comp40 Flex Motor BOSCH Performance Line CX BDU3740 250 Watt 85 Nm Rechargeable battery BOSCH PowerTube 750 BBP3770 Horizontal 750 Wh On board computer BOSCH LED Remote BHU3600 Charger BOSCH charger BPC3400 4 A ...

Page 232: ...ip Rear derailleur SHIMANO 10 speed hub Deore Derailleur gears 10 speed Shifter SHIMANO Deore Shifter Front derailleur Cassette cassette sprocket SHIMANO CS HG500 11 42T Chain KMC X10E Toothed belt Brake front rear MAGURA MT4e Hydraulic disc brake Brake lever front rear MAGURA MT4e Brake lever with rear light function Disc front rear Magura Storm HC 180 mm Front rim 180 mm Hub front Hub rear SHIMA...

Page 233: ...MY22Z01 12_1 0_25 07 2022 232 Documents not available Rechargeable battery BOSCH Performance Line CX 85 Nm Display BOSCH PowerTube 625 625 Wh vertical Charger BOSCH Intuvia with Intuvia control panel ...

Page 234: ...ne pedals anti slip Rear derailleur Shifter SHIMANO Nexus 5 Twist grip Front derailleur Cassette cassette sprocket Chain Toothed belt GATES Brake front rear MAGURA MT4e Hydraulic disc brake Brake lever front rear MAGURA MT4e Brake lever with rear light function Disc front rear Magura Storm HC 180 mm Front rim Hub front SHIMANO with E THRU quick release axle Hub rear SHIMANO Nexus 5 Gear hub 5 spee...

Page 235: ...MY22Z01 12_1 0_25 07 2022 234 Documents not available Rechargeable battery BOSCH PowerTube 625 625 Wh vertical Display BOSCH Intuvia with Intuvia control panel Charger BOSCH standard charger 4 A ...

Page 236: ...Grip Zone pedals anti slip Rear derailleur Shifter SHIMANO Nexus 5 Twist grip Front derailleur Cassette cassette sprocket Chain Toothed belt GATES Brake front rear MAGURA MT4e Hydraulic disc brake Brake lever front rear MAGURA MT4e Brake lever with rear light function Disc front rear Magura Storm HC 180 mm Front rim 180 mm Hub front Hub rear SHIMANO with E THRU quick release axle Spokes SHIMANO Ne...

Page 237: ...MY22Z01 12_1 0_25 07 2022 236 Documents not available Rechargeable battery BOSCH Performance Line CX 85 Nm Display BOSCH PowerTube 625 625 Wh vertical Charger BOSCH Intuvia with Intuvia control panel ...

Page 238: ... pedals anti slip Rear derailleur Shifter SHIMANO Nexus 5 Twist grip Front derailleur Cassette cassette sprocket Chain Toothed belt GATES Brake front rear TEKTRO HD E395 Hydraulic disc brake Brake lever front rear TEKTRO HD E395 Brake lever with rear light function Disc front rear TEKTRO 180 mm Front rim 180 mm Hub front Hub rear SHIMANO with E THRU quick release axle Spokes SHIMANO Nexus 5 Gear h...

Page 239: ...MY22Z01 12_1 0_25 07 2022 238 Documents not available Rechargeable battery BOSCH Performance Line CX 85 Nm Display BOSCH PowerTube 625 625 Wh vertical Charger BOSCH Intuvia with Intuvia control panel ...

Page 240: ...ne pedals anti slip Rear derailleur Shifter SHIMANO Nexus 5 Twist grip Front derailleur Cassette cassette sprocket Chain Toothed belt GATES Brake front rear TEKTRO HD E395 Hydraulic disc brake Brake lever front rear TEKTRO HD E395 Brake lever with rear light function Disc front rear TEKTRO 180 mm Front rim 180 mm Hub front Hub rear SHIMANO with E THRU quick release axle Spokes SHIMANO Nexus 5 Gear...

Page 241: ...MY22Z01 12_1 0_25 07 2022 240 Documents not available Rechargeable battery BOSCH Performance Line CX 85 Nm Display BOSCH PowerTube 625 625 Wh vertical Charger BOSCH Intuvia with Intuvia control panel ...

Page 242: ...MY22Z01 12_1 0_25 07 2022 241 Documents 11 4 Charger operating instructions 0123435678 9 78 7 3951 8 ABC D ABC D ABC ...

Page 243: ... 2 15A Output 36V 6A Made in Vietnam Fast Charger BCS250 eBike Battery Charger 36 4 230 0 275 007 907 Li Ion Use ONLY with BOSCH Li Ion batteries Input 230V 50Hz 1 5A Output 36V 4A Made in PRC Robert Bosch GmbH 72757 Reutlingen Germany Standard Charger BCS220 Robert Bosch GmbH 72757 Reutlingen Germany Standard Charger Fast Charger EBE D F A G A C ...

Page 244: ...MY22Z01 12_1 0_25 07 2022 243 Documents D Compact Charger A G A C EBE D F ...

Page 245: ...MY22Z01 12_1 0_25 07 2022 244 Documents D EBE D F A G A C ...

Page 246: ...MY22Z01 12_1 0_25 07 2022 245 Documents D A G A C EBE D F ...

Page 247: ...MY22Z01 12_1 0_25 07 2022 246 Documents D EBE D F A G A C ...

Page 248: ... C 0 C H G M G N G C 0 G N N G G G C 0 0 G G G M G G G G C C 0 0 C 0 0 C 0 C G N G C 0 0 0 0 0 G G G G G G C C C C C 0 0 0 0 C G M G N C C 0 0 C 0 K G G G N G G L G G G G V S Pk G A CBU G L 0 7 G N G G M G N G N N G A G A G Q N G L A G A N G 0 0 G N G G N G L G G G N G G NN G N G G a N A BG H H BG N BG C N G BG L N G A NN C A G A C EBE D F ...

Page 249: ...J J G N G G G G B G L N G C 0 C G G NN N G G A OG M G L N G 0 C 0 C M M G G G G N G G G G C 0 G C G G NN B G N G G M M G G L P N G N G G G G G G 0 0 0 0 C C C 0 N G M G N G G G OG M G L N G N N A M G G G GM G G N G G G G Q f I i M G G G N G G G PKH N G G OG G M N G L N G N G G M G G G G G G L G G G G 5 H G G G G L N G A G G G L 5 H G G G L G G G G G L OG G G G L M G G G G OG G L M G L N G G N G G ...

Page 250: ... NN 5 H N G G G G M N G G G G N G L M G N G G N G N G M N N G G G G N M G G N G N G G G N D 0 0 0 0 A N C B G G A C H G N G G G G G G H G G G G G G G G G G 5 C C B G G C B G BG A B N G M G N BG G M G G G G G A N B G G K K N G G N M G L G 1 0 0 N G a G G M L G G T N G G M GL BG M G N H N G G G G J C 0 H G K H F F KS O K K Ka L M G G L N L N 0 9 0 A G A C EBE D F ...

Page 251: ...ject s functional capability Disc brake Source EN 15194 2017 brake in which brake pads are used to grip the lateral faces of a thin disc attached to or incorporated into the wheel hub Drive belt Source EN 15194 2017 seamless ring belt which is used as a means of transmitting drive force Electrical control system Source EN 15194 2017 electronic and or electrical component or an assembly of componen...

Page 252: ...to the point where the top of the seat surface is intersected by the seat post axis measured with the saddle in a horizontal position and with the seat post set to the minimum insertion depth mark Maximum tyre pressure Source EN 15194 2017 maximum tyre pressure recommended by the tyre or rim manufacturer for a safe and efficient performance If the rim and tyre both indicate a maximum tyre pressure...

Page 253: ...le battery is an energy storage device that can store supplied electrical energy as chemical energy charging and release it as electrical energy when required discharging Seat post Source EN 15194 2017 component that clamps the saddle with a bolt or assembly and connects it to the frame Shut off speed Source EN 15194 2017 speed reached by the pedelec at the moment the current has dropped to zero o...

Page 254: ... Year of manufacture Source ZEG the year of manufacture is the year in which the pedelec was manufactured The production period is always from May to July the following year 12 1 Abbreviations 12 2 Simplified terms The following terms are used for better legibility Abbreviation Meaning derivation ABS Anti blocking system EPAC Electric power assisted cycle PTW permitted total weight Table 67 Table ...

Page 255: ...with the following applicable EU pro visions Machinery Directive 2006 42 EC RoHS Directive 2011 65 EU Electromagnetic Compatibility Directive 2014 30 EU The safety objectives in the Low Voltage Directive 2014 35 EU have been met in compliance with Appendix I No 1 5 1 of the Machinery Directive 2006 42 EC The following harmonised standards have been applied ISO 20607 2018 Safety machinery Instructi...

Page 256: ...MY22Z01 12_1 0_25 07 2022 255 Appendix II Declaration of conformity for incomplete machine ...

Page 257: ...MY22Z01 12_1 0_25 07 2022 256 Appendix ...

Page 258: ...MY22Z01 12_1 0_25 07 2022 257 Appendix ...

Page 259: ...ean 155 service 160 Brake linings 38 check 166 replace 111 219 retract 111 position 38 torque 61 Brake 37 check 150 check brake disc 166 check brake linings 166 check pressure point 165 check 165 clean 151 secure during transport 66 cable clip 37 cover cap 37 hydraulic 37 insert pin 37 knob 37 mechanical 37 union nut 37 Brake use 137 Brakes replace 111 Braking distance 250 Break in operation 67 ca...

Page 260: ...hub inspect 191 Gear recommendation 47 48 Gear shift twist grip 47 Gear shift adjust Bowden cable oper ated twist grip dual cable 178 check 176 check electric gear shift 176 switch gears 143 use 140 Guards check 149 H Handbrake 250 position 46 torque 60 Handlebars 29 46 care for 157 check 175 check 85 clean 153 use 129 use bar ends 129 use multi position handle bars 129 position 27 torque 60 Handl...

Page 261: ... specialist dealer 179 major inspection 179 sell 85 service 156 ship 66 transport 66 unpacking 68 use 127 Placing on the market 252 Plus button 52 Pressure point 252 Profile position 34 Protective cap 47 Puncture protection belt 36 position 34 Push assist button 52 Push assist use 136 Q Q Loc 33 position 33 Quick release 252 inspect 192 Quick releases check 149 R Racing bicycle 252 Rear derailleur...

Page 262: ...on seat post 40 care for 158 clean 151 Switching element clean 154 System message 51 89 System setting 50 changeable 49 50 51 121 T Tachometer 47 Torques 58 Total deflection 252 Total journey duration 50 Trailer 123 Transportation 65 Transporting see Transporta tion Tread 35 position 34 Tube replace 219 Tyre design types 34 Tyre pressure 34 change 161 check 161 Tyre size 34 Tyre position 34 Tyres ...

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