Bosch 22-15-2061 Page 273 Translation Of Original Operating Instructions Download

Page: 273 / 299

MY22Z0a - 12_1.0_25.07.2022

272

Documents

Technical inspection, checking safety, test ride

Inspection

Tests

Maintenance

Accept-

ance

Rejection

Electric drive system

On-board

computer

6 months

Check for damage

Functional check

O.K.

No screen,

defective

screen display

Restart; test battery;

new software or new

on-board computer;

remove from service,

Control panel

6 months

Control panel Check

for damage

Functional check

O.K.

No response

Restart; contact

control panel

manufacturer, new

control panel

Tachometer

6 months

Speed

measurement

O.K.

Pedelec

travelling 10%

too fast/slow

Take pedelec out of

service until the

source of the error is

found

Cabling

6 months

Visual inspection

O.K.

Failure in sys-

tem, damage,

kinked cables

New cabling

Battery mount

6 months

Firmly in position,

lock, contacts

Functional check

O.K.

Loose; lock

doesn't close,

no contacts

New battery mount

Motor

6 months

Visual inspection and

mount

O.K.

Damage,

loose

Refasten motor,

contact motor

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 in brake

system and correct

Gear shift under

operating load

6 months

Functional check

O.K.

Problems when shifting

gear

Readjust gear shift

Suspension

components (fork,

shock absorber, seat

post)

6 months

Functional check

O.K.

Suspension too deep or no

longer exists

Locate defective component and

correct

Electric drive

6 months

Functional check

O.K.

Loose connection,

problems when riding,

accelerate

Locate faulty component in

electric drive and remedy

Lighting system

6 months

Functional check

O.K.

No continuous light, not

bright enough

Locate defective part in lighting

system and correct

Test ride

6 months

Functional check

No strange

noises

Strange noises

Locate source of noise and

correct

Date:

Fitter's name:

Final inspection by workshop manager:

Summary of Contents for 22-15-2061

Page 1: ... 22 15 2061 22 15 2066 SU E FS 12 ZE 12 ZE FS 12 Translation of original operating instructions for ZEMO pedelecs with BOSCH LED Remote on board computer IMPORTANT READ CAREFULLY BEFORE USE KEEP SAFE TO CONSULT AT A LATER DATE ...

Page 2: ...es 19 2 2 1 Toxic substances 19 2 2 2 Irritants and corrosive substances 19 2 3 Requirements for the rider 19 2 4 Vulnerable groups 19 2 5 Personal protective equipment 20 2 6 Safety guards 20 2 7 Safety markings and safety instructions 20 2 8 What to do in an emergency 21 2 8 1 Dangerous situation in road traffic 21 2 8 2 Leaked brake fluid 21 2 8 3 Battery vapour emission 21 2 8 4 Battery fire 2...

Page 3: ...4 Description of controls and screens 54 3 4 1 Handlebars 54 3 4 2 Control panel 55 3 4 2 1 System message 56 3 4 2 2 Creating a user account 57 3 4 2 3 Software updates 57 3 4 2 4 Activity tracking 57 3 4 2 5 Lock function 57 3 4 3 Battery level indicator battery 58 3 4 4 Gear shift 59 3 4 4 1 SHIMANO SW E7000 derailleur gears 59 3 4 5 SHIMANO gear shift 60 3 4 5 1 3 switch switch control panel 6...

Page 4: ...ount 84 5 3 2 Preparing the wheel 89 5 3 3 Installing the wheel in the SUNTOUR fork 90 5 3 3 1 Screw on axle 12AH2 and 15AH2 90 5 3 3 2 20 mm cross axle 91 5 3 3 3 Q LOC quick release 93 5 3 4 Fitting the pedals 94 5 3 5 Preparing the LIMOTEC seat post 95 5 3 6 Checking the stem and handlebars 96 5 3 6 1 Checking the connections 96 5 3 6 2 Checking stem is firmly in position 96 5 3 6 3 Checking th...

Page 5: ... 6 6 Adjusting the Ahead stem 118 6 5 6 7 Adjusting the angle adjustable stem 119 6 5 7 Handles 120 6 5 7 1 Replacing the handles 120 6 5 7 2 Adjusting ergonomic handles 120 6 5 7 3 Checking handlebar stability 120 6 5 8 Tyres 121 6 5 8 1 Adjust tyre pressure 121 6 5 9 Brake 122 6 5 9 1 Change handbrake position 122 6 5 9 2 Change handbrake inclination angle 122 6 5 9 3 Determining the grip distan...

Page 6: ...ck 158 6 6 7 Panniers and cargo boxes 158 6 7 Personal protective equipment and accessories for road safety 159 6 8 Before each ride 159 6 9 Straightening the quickly adjustable stem 160 6 10 Using the pannier rack 160 6 11 Raising the kickstand 161 6 12 Using the saddle 161 6 12 1 Using the leather saddle 161 6 13 Using the pedals 161 6 14 Using the bell 161 6 15 Using the handlebars 162 6 15 1 U...

Page 7: ...leaning the pedals 183 7 2 5 Cleaning the brake 183 7 2 6 Cleaning the suspension seat post 183 7 2 7 Cleaning the rear frame damper 183 7 3 Basic cleaning 184 7 3 1 Clean on board computer and control panel 184 7 3 2 Cleaning the battery 184 7 3 3 Cleaning the motor 184 7 3 4 Clean Frame fork pannier rack guards and kickstand 185 7 3 5 Cleaning the stem 185 7 3 6 Cleaning the handlebars 185 7 3 7...

Page 8: ... nipple well 196 7 5 1 6 Checking the rim hooks 196 7 5 1 7 Checking the spokes 196 7 5 2 Checking the brake system 197 7 5 2 1 Checking the handbrake 197 7 5 2 2 Checking the hydraulic brake system 197 7 5 2 3 Checking the Bowden cables 197 7 5 2 4 Checking the disc brake 198 7 5 2 5 Checking the back pedal brake 199 7 5 2 6 Checking the rim brake 200 7 5 3 Checking the chain 201 7 5 4 Checking t...

Page 9: ...k release 224 8 5 8 Inspecting the fork 225 8 5 8 1 Inspect the carbon suspension fork 225 8 5 8 2 Inspect the suspension fork 225 8 5 9 Inspecting the seat post 226 8 5 9 1 Inspect carbon seat post 226 8 5 9 2 Inspecting and greasing BY SCHULZ suspension seat post 227 8 5 9 3 Inspecting and greasing RS SUNTOUR suspension seat post 227 9 Troubleshooting fault clearance and repair 9 1 Preventing pa...

Page 10: ...6 2 Rebounding too slowly 260 9 1 16 3 Suspension too soft on inclines 261 9 1 16 4 Excessively hard damping on bumps 262 9 2 Repair 263 9 2 1 Original parts and lubricants 263 9 2 2 Repairing the frame 263 9 2 2 1 Removing paint damage on frame 263 9 2 2 2 Removing damage from impact on the carbon frame 263 9 2 3 Repairing the suspension fork 263 9 2 3 1 Removing paint damage on the fork 263 9 2 ...

Page 11: ...2 10 Contents 12 Glossary 12 1 Abbreviations 290 12 2 Simplified terms 290 13 Appendix I Translation of the original EC EU Declaration of Conformity 291 II Declaration of conformity for incomplete machine 292 14 Keyword index ...

Page 12: ...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 13: ...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 14: ...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 15: ...structions The operating instructions identification number is located in bottom left hand corner of each page The identification number is composed of the document number the version number and the release date Type no Model Pedelec type 22 15 2061 SU E FS Diamant City and trekking bicycle 22 15 2062 SU E FS Wave City and trekking bicycle 22 15 2063 ZE 12 Diamant City and trekking bicycle 22 15 2...

Page 16: ...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 17: ...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 18: ...r or pliers Only use the clamping lever with the specified set clamping force Using the correct 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 or in Section 3 5 Use approved brake only The wheels are designed exclusively for use with r...

Page 19: ...ec with Bluetooth when in close proximity to medical devices filling stations chemical plants areas at risk of explosion and in blasting zones Never use pedelec with Bluetooth in aircraft Avoid operating for longer periods in close proximity to the body 2 1 7 Data privacy information When the pedelec is connected to the BOSCH diagnosis tool 3 data is transferred to BOSCH eBike Systems Robert Bosch...

Page 20: ...nhaled Never dismantle the brake system Avoid contact with skin Do not inhale vapours Corrosive substances also known as corrosives destroy living tissue or attack surfaces Corrosive substances may be in solid liquid or gaseous form Irritants are hazardous substances which irritate the skin and mucous membranes once you come into contact with them This may cause inflammation of the affected areas ...

Page 21: ... heat Mudguards protect against dirt and water splashing up from the road Never remove the guards Check the guards on a regular basis Take pedelec out of service if a guard is damaged or missing Contact specialist dealer 2 7 Safety markings and safety instructions Pedelec and battery nameplates contain the following safety markings and safety instructions Symbol Explanation General warning Adhere ...

Page 22: ...the event of pain or discomfort After contact with eyes 1 Rinse eyes under flowing water for at least ten minutes with the lids open also rinse under lids 2 Immediately consult a doctor in case of any pain or discomfort If swallowed 1 Rinse out mouth with water Never induce vomiting Risk of aspiration 2 If a person is lying on their back and vomiting place them in the recovery position 3 Seek medi...

Page 23: ... electronics may fail if the battery is damaged or faulty The residual voltage can cause a short circuit The battery may self ignite and explode 1 Keep your distance if the battery becomes deformed or starts to emit smoke 2 If charging remove the plug connector from the socket 3 Contact the fire service immediately Use Class fire extinguishers to put out the fire Never extinguish damaged batteries...

Page 24: ...ns of transport In addition to being physically fit riders need time to adapt to using the pedelec Appropriate training is required for its use It is especially impor tant to practice braking and riding around bends The strain on hands wrists arms shoul ders the neck and back is considerable Inexperienced riders tend to brake too hard and lose control as a result Racing bikes are designed for fast...

Page 25: ...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 26: ... Copperhead EVO 2 750 27 5 Diamant 130 22 18 0019 Copperhead EVO 2 750 29 Diamant 130 22 18 0022 Copperhead EVO 2 750 27 5 Trapez 130 22 18 0025 Copperhead EVO 2 750 27 5 Wave 130 22 18 3010 Sonic EVO TR1 750 29 150 22 18 3011 Sonic EVO TR3 Carbon 750 29 150 Table 8 Type number model and PTW 22 18 3012 Sonic EVO TR I Carbon 750 29 150 22 18 3014 Sonic EVO AM 1 750 150 22 18 3015 Sonic EVO AM 2 Car...

Page 27: ...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 28: ...ever 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 over...

Page 29: ...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 30: ...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 31: ... 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 2 2 Tube type tyre A distinction is made between different kinds of tube type...

Page 32: ...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 33: ... 7 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 8 Effect of puncture protection be...

Page 34: ...resta valve also known as the Sclaverand valve or the French valve is the narrowest variant of all valves The Presta valve requires a smaller hole in the rim which is why it is especially suitable for the narrow rims on racing bikes It is about 4 to 5 g lighter than a Dunlop or Schrader valve Figure 10 Presta valve Schrader valve The Schrader valve can be pumped at filling stations Older simple bi...

Page 35: ...s Special hubs on the rear wheel perform additional functions There is a distinction between five types of hub Hubs without additional features Brake hub see back pedal brake Gear hub also known as a hub gear Generator hub for bicycles only Motor hubs for front and rear driven pedelecs only Hub without additional features The front wheel hubs on pedelecs with central or rear motors are normally hu...

Page 36: ...nd Steering headsets for threadless fork steerers what are known as headsets 3 3 3 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 steere...

Page 37: ...d displays see Section 3 4 1 Figure 15 Handlebar dimensions The main dimensions of handlebars are 1 Rise height 2 Width 3 Backsweep 3 3 3 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 16 Overview of fork 1 Fork steerer 2 Side reflectors optional 3 Fork end 4 Fork leg 1 2 3 1 2 3 4 ...

Page 38: ...c 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 fork...

Page 39: ...rain green line when riding over bumps The suspension motion is predictable and controlled Figure 18 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 19 Optimum fork ride performance on hilly terrain When optimally adjus...

Page 40: ...and body follow terrain green line when riding over bumps The suspension motion is predictable and controlled Figure 21 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 41: ...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 24 Internal structure of air suspension fork 1 Air valve 2 Air valve cap 3 Fork steerer 4 Sag setting wheel 5 Rebo...

Page 42: ...ed The rear wheel does not bounce off rough surfaces or the ground it stays in contact with the ground instead blue line The saddle is raised slightly if the bump is compensated and gently sinks downwards when the suspension deflects as soon as the wheel touches the ground after the bump The rear frame damper rebounds in a controlled way so that the rider remains sitting in a horizontal position w...

Page 43: ...djusted the rear frame damper deflects quickly and unhindered when the bike hits bumps and absorbs a bump Traction is retained blue line The saddle rises slightly when absorbing a bump green line Figure 27 Optimum rear frame damper ride performance over bumps ...

Page 44: ... 3 3 4 4 RockShox rear frame damper The rear frame damper features air suspension a compression damper and a rebound damper Figure 28 Monarch RL as an example 1 Threshold lever 2 Rebound damper adjuster 3 Air valve 4 O ring 5 Scale 1 2 3 4 5 ...

Page 45: ...able and controlled The rider is not thrown upwards or forwards green line The rebound adjuster setting depends on the air pressure setting A higher sag requires lower rebound damping Figure 29 Optimum rear frame damper riding performance Rear frame damper compression adjuster Only applies to pedelecs with this equipment The compression adjuster controls the compression lifting speed or amount by ...

Page 46: ...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 6 1 Patent seat post Figure 31 Example of ergotec patent seat post with either one or two seat clam...

Page 47: ... 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 48: ... heavy duty flat wire steel spring and the technical elastomers even hard impacts such as those occurring while riding through deep potholes do not cause the suspension to block The rear deflection is also damped by the hemispherical elastomers in the head and base sections Easily exchangeable suspension elements with different spring hardnesses and dampers are available to ensure optimum adjustme...

Page 49: ... 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 8 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 34 Bowden cable structure 3 3 8 2 Hydraulic brake The brake fluid is in a cl...

Page 50: ...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 51: ...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 9 1 Chain drive layout Figure 38 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 9 2 Belt drive layout Figure 39 Belt drive 1 Front bel...

Page 52: ...atteries 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 the charger and the pedelec The battery temperature is monitored at all times The battery is protected...

Page 53: ...he riding light is activated the front light and rear light are switched on together at the same time 3 3 10 5 Integrated battery The following battery can be built into the pedelec Figure 41 Overview of integrated battery Figure 42 Detail of PowerTube 750 1 Securing hook 2 Battery lock 3 Battery key 4 Retainer guard 5 On Off button battery 6 Battery level indicator battery 7 Socket for charger pl...

Page 54: ...ages on the display screen using seven buttons Figure 43 BOSCH LED Remote control panel The eBike Flow app can be accessed via Bluetooth The control panel has an internal lithium ion battery The pedelec battery powers the control panel If a sufficiently charged battery is inserted into the pedelec and the drive system switched on the internal battery is charged ...

Page 55: ...Handlebars Figure 44 Detailed view of handlebars with BOSCH Kiox300 example 1 6 Handle 2 Rear wheel hand brake behind handlebars 3 Bell 4 Kiox300 display 5 Front wheel hand brake behind handlebars 7 LED Remote control panel 8 Air valve cap 9 Sag setting wheel 10 Shifter 1 7 9 5 3 2 8 6 10 ...

Page 56: ...bol Designation 1 Selected level of assistance indicator 2 ABS indicator optional 3 Battery level indicator control panel 4 Select button 5 On Off button control panel 6 Ambient light sensor Table 13 Overview of control panel 7 Increase brightness button forward button 8 Decrease brightness button back button 9 Plus button light button 10 Minus button push assist button 11 Diagnosis connection for...

Page 57: ...ty The top bar indicates maximum capacity The two lower indicators will change colour if the capacity is low The uppermost bar will flash if the battery is charging 3 4 2 1 System message The control panel indicates whether a critical or less critical error has arisen in the drive system The error messages generated by the drive system can be read in the eBike Flow app and by the bicycle dealer Th...

Page 58: ...Your location will only be logged if the on board computer is connected to the eBike Connect app Activities will be displayed after synchronisation in the app and on the portal 3 4 2 5 Lock function When the lock function is used the on board computer acts in a similar way to a key for the drive system Once the lock function is switched on the e bike drive unit assistance is deactivated by removin...

Page 59: ...level indicator 1 The five green LEDs on the battery level indicator battery show the charge level when the battery is switched on Each LED represents about 20 battery capacity All five LEDs will light up when the battery is fully charged If the battery level falls below 5 all the LEDs on the operating status and battery level indicator will go out 1 ...

Page 60: ...4 1 SHIMANO SW E7000 derailleur gears Only applies to vehicles with this equipment The gear shift unit is on the left of the handlebars The gear shift unit features 2 buttons Figure 47 SHIMANOSW E7000 gear shift 1 Up button gear shift 2 Down button gear shift 1 2 ...

Page 61: ...el 1 Switch X 2 Switch A 3 Switch Y 3 4 5 2 2 switch switch control panel Figure 49 2 switch control panel 1 Switch X 2 Switch Y 3 4 5 3 MTB switch control panel Figure 50 MTB control panel 1 Switch Y 2 Switch X 3 4 5 4 Switch control panel functions on right If there is no switch A on the switch control panel the button on the on board computer will control these functions 3 4 5 5 Shifter SL M510...

Page 62: ...MY22Z0a 12_1 0_25 07 2022 61 Description 3 4 5 6 Shifter SL M8100 Figure 52 Shifter SL M8100 1 Shifter 2 Attachment screw for shifter 1 2 ...

Page 63: ...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 64: ...rake There is a handbrake on the left and right of the handlebars Figure 53 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 65: ...ltage about 12 V Maximum output Front light 17 4 W Rear light 0 6 W Table 18 Bicycle lighting Output voltage 4 75 5 4 V Output current max 1 5 A Operating temperature 5 40 C Storage temperature 10 40 C Protection class IP54 Table 19 Technical data for BOSCH Display Mount BDS3210 BDS3250 BDS3620 BDS3630 Internal lithium ion battery 3 7 V 75 mAh Charging temperature 0 C 45 C Operating temperature 5 ...

Page 66: ...minal voltage 36 V Nominal capacity 20 1 Ah Energy 750 Wh Weight 4 4 kg Protection class IP54 Operating temperature 5 40 C Storage temperature 10 40 C Permitted charging temperature range 0 40 C Table 22 Technical data for BOSCH PowerTube 750 BBP3770 horizontal BBP3771 vertical ...

Page 67: ...at an angle of almost 90 Position on roadster Table 23 BROOKS ENGLAND Specifications Suitable sit bone distance Medium position 12 16 cm Small medium 9 12 cm Table 24 ERGON Specifications Riding position Athletic Sharply inclined upper body back at an angle of 30 60 Position on trekking bike Moderate Slightly inclined upper body back at an angle of 60 70 Position on city bike Relaxed Upright almos...

Page 68: ...read Plus tyres combine one layer of GreenGuard beneath the tread and SnakeSkin on the side walls Tubeless Easy The Tubeless technology special monofile webbing SnakeSkin or MicroSkin prevent air loss and guarantee puncture protection in combination with sealant V GUARD The V Guard puncture protection belt comprises of lightweight cut resistant fibres Its webbing ensures highly effective puncture ...

Page 69: ...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 70: ...cket 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 10 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 71: ...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 72: ...10 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 10 17 V Brake brake SHIMANO Attachment screw ...

Page 73: ...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 10 21 Crank bearing crank set Conventional cartridge ...

Page 74: ...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 75: ...if there is no other data on the component 3 5 10 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 76: ... cm 22 15 1056 41 cm 44 cm 48 cm 54 cm 60 cm 22 15 1057 44 cm 48 cm 54 cm 60 cm 22 15 1059 41 cm 44 cm 48 cm 54 cm Table 26 Type number model and pedelec type 22 15 1062 41 cm 44 cm 48 cm 54 cm 60 cm 22 15 1064 41 cm 44 cm 48 cm 54 cm 22 15 4020 45 cm 50 cm 55 cm 60 cm 22 15 4021 45 cm 50 cm 55 cm 22 18 0013 41 cm 44 cm 48 cm 54 cm 22 18 0014 41 cm 44 cm 48 cm 54 cm 22 18 0015 41 cm 44 cm 48 cm 54...

Page 77: ... 48 cm 51 cm 22 18 3016 44 cm 48 cm 51 cm Type no Frame Dimsions Box cm Weight kg Shipping weight kg Table 26 Type number model and pedelec type 22 18 3017 44 cm 48 cm 51 cm 22 18 3018 44 cm 48 cm 51 cm 56 cm 22 18 3019 44 cm 48 cm 51 cm 22 18 5005 41 cm 44 cm 48 cm 54 cm 22 18 5006 44 cm 48 cm 54 cm 60 cm 22 18 5016 41 cm 44 cm 48 cm 54 cm 22 18 5018 41 cm 44 cm 48 cm 54 cm 22 18 5019 41 cm 44 cm...

Page 78: ...ons were produced 4 2 Designated handles lifting points The box does not have any handles 22 18 5026 41 cm 44 cm 48 cm 54 cm 22 18 5033 41 cm 44 cm 48 cm 54 cm 22 18 5034 41 cm 44 cm 48 cm 54 cm 22 18 5035 44 cm 48 cm 54 cm 60 cm Type no Frame Dimsions Box cm Weight kg Shipping weight kg Table 26 Type number model and pedelec type ...

Page 79: ...here 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 4 3 5 Shipping the battery The battery is considered a hazardous good a...

Page 80: ...basement 4 4 2 On board computer display and charger Store on board computer display and charger in a dry environment at room temperature 4 4 3 Rechargeable battery Storage at about 10 C to 20 C is beneficial to a long battery life Store batteries in rooms with smoke detectors A protection box with an electrical connection is an optimal solution Figure 56 Protection box Never store batteries near ...

Page 81: ...before maintenance or repair Treat unchecked batteries as faulty batteries When storing batteries treat them in the same way as a damaged or faulty battery until they are inspected 2 Inspect battery 3 Battery are stored as agreed with the insurance company Defective battery If batteries are faulty observe Section 2 1 Handling a damaged or faulty battery during storage and disposal Notice The batte...

Page 82: ...f 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 4 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 rooms with smoke alarms Dry locations with an ambient temperature between 10 C and 20 ...

Page 83: ...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 84: ...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 85: ...in guard Figure 57 Position of mount screw Removing the pedals The mark is either on the top end the axle or the pedal body Figure 58 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 86: ...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 64 Attachment screws in lower motor cover 1 18 Remove lower motor cover 19 Unfasten the 2 ...

Page 87: ...erTube BS3 battery mount must be secured by clamping a clip on its rear 24 Use a TORX T25 wrench to undo the screws in the battery mount Figure 68 Undoing screws on battery mount 25 Remove battery mount and turn over 26 Clamp the clip VLD I 1222 onto the battery mount on the rear Figure 69 Clip VLD I 12122 Figure 70 Clamping the clip 27 Turn battery mount over and place on the aluminium brace in t...

Page 88: ...f 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 73 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 74 Attachment screws in lower motor cover 1 Notice The motor can be damaged permanently if connected incorrec...

Page 89: ... 21 38 Use a hex bit to fasten the retaining screws on the left and right Figure 75 Fastening the belt sprocket example Fitting the belt 39 Pull belt or chain over the belt sprocket or the chain wheel Figure 76 Fitting the belt 40 Push the rear wheel backwards to tension the belt or chain Figure 77 Pushing the rear wheel backwards 41 Check and adjust belt or chain tension see Section 7 5 9 or 7 5 ...

Page 90: ...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 91: ...t the front wheel into the fork ends 2 Insert the axle into the hub on the drive side Figure 81 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 82 Tighten the axle in the direction of the arrow 4 Insert the securing screw on the non drive side Figure 83 Inserting the securing screw 5 Tighten ...

Page 92: ... 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 93: ...e lever must be flush with the shock absorber Figure 89 Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required Figure 90 Adjusting the quick release clamping force 7 Check the quick release lever position and clamping force The wheel is now fitted ...

Page 94: ...ulty 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 The...

Page 95: ...e 95 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 96 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 97 R pedal ...

Page 96: ...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 97: ...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 6 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 98: ...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 99: ...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 100: ...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 101: ...d short circuits by Electronic Cell Protection ECP In the event of a hazard a protective circuit switches the battery off automatically If a fault is detected in the battery the LEDs flash on the battery level indicator Code Description Method of resolution 0x523005 0x514001 0x514002 0x514003 0x514006 The sensors do not detect the magnetic field properly Check that the magnet wasn t lost while rid...

Page 102: ...djusting 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 fasten...

Page 103: ...6 4 Handles 6 5 7 x 5 Tyres 6 5 10 6 1 6 2 6 3 6 4 6 5 Brake Position of the brake handles Brake handle tilt angle Determine grip distance Adjust the grip distance Pressure point Retract the brake linings 6 5 9 1 6 5 9 2 6 5 9 3 6 5 9 4 6 5 8 5 6 5 9 5 7 Adjust suspension Adjust the suspension fork sag 6 5 11 x Adjust the rear frame damper sag optional 6 5 12 x Adjust suspension fork rebound dampe...

Page 104: ...he pelvis is on average a quarter lower than in the male pelvis The angle between the pubic bones is wider The pelvis is more mobile in women than it is in men Consequently the pelvis often tilts forward more on the saddle This causes high pressure in the genital area Figure 99 Pressure points on a saddle female anatomy Sitting discomfort due to wrong saddle Around 50 of all pedelec riders experie...

Page 105: ...neal area If the saddle is adjusted incorrectly too narrow or too hard the nose of the saddle presses directly onto the genitals Blood circulation deteriorates The genitals on the outside are seldom the cause of discomfort since they can move out of the way and are not compressed by bone structures You should always consult a doctorcif you have problems with the prostate After a prostate operation...

Page 106: ...05 Measuring the distance The distance between the two centre points is the sit bone distance and corresponds to the minimum saddle width 7 Calculate saddle width see Section 6 5 4 4 6 5 3 4 Determining minimum saddle width with gel cushion 1 Smooth gel cushion 2 Place gel cushion on a flat hard unpadded seat 3 Sit in the middle of the gel cushion Figure 106 Sitting on the gel cushion Pull the sea...

Page 107: ...uipment In air cushion saddles the hardness of the saddle can be adjusted using the pump valve beneath the seat surface Table 35 VELO air cushion saddle settings 6 5 3 8 Straighten saddle Position saddle in direction of travel In doing so align the tip of the saddle with the top tube Figure 108 Positioning the saddle in direction of travel 6 5 3 9 Positioning the saddle with eightpins suspension s...

Page 108: ... 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 111 Opening the seat post quick release 6 Set the seat post to the required height...

Page 109: ...ired height Figure 113 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 ...

Page 110: ...or incorrect position red The pelvis is in the right position if the spine forms an S shape and a natural easy arch The pelvis is positioned incorrectly if it tilts slightly backwards As a result the spine becomes curved and can no longer deflect to an optimal extent A suitable riding position must be selected beforehand depending on the pedelec type physical fitness and desired trip distance or s...

Page 111: ...e saddle is positioned far higher than the handlebars Benefits The spine is intuitively moved into its natural S shape The strain on arms and hands is very slight no effort required to support The upright position provides a good over view in traffic Force can be applied to the pedals when pedalling without using much energy Shoulders neck and hands provide more of the support effort thus promotin...

Page 112: ...ure 115 Positioning the saddle in direction of travel 6 5 4 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 116 Tightening the seat post axle ...

Page 113: ...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 118 Opening the seat post quick release 6 Set the seat post to the required height ...

Page 114: ...ired height Figure 120 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 ...

Page 115: ...k Figure 121 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 4 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 116: ...ptimal 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 124 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 suppo...

Page 117: ...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 118: ...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 119: ...e quill stem height 1 Undo screw 2 Pull quill stem out 3 Tighten screw 6 5 6 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 128 Raising the Ahead stem by fitting spacer rings The handlebar height is adjusted once during production using spacer rings The part o...

Page 120: ...stable stems are available in different lengths for quill and Ahead stems Figure 129 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 130 City bike blue and trekking bike position red by changing the angle a a b b c c ...

Page 121: ...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 7 2 Adjusting ergonomic handles Only applies to pedelecs with this equipment Figure 131 Incorrect 1 and correct 2 position of the handle 6 5 7 3 Chec...

Page 122: ... A permanently excessively low tyre 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 advanta...

Page 123: ...of the handlebar 2 Extend the index finger about 15 Figure 134 Brake handle position 3 Push handbrake outwards until the third finger phalanx sits in the recessed grip 6 5 9 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 124: ...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 137 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 125: ...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 126: ...on can be adjusted to the rider s requirements Such adjustment does not affect the pressure point or the position of the brake linings Turn setting screw anti clockwise towards minus The brake lever moves closer to the handlebar grip Turn setting screw clockwise towards plus The brake lever moves away from the handlebar grip Figure 138 Setting screw position 1 1 ...

Page 127: ...NO ST EF41 handbrake Only applies to pedelecs with handbrakes BL M4100 BL M7100 BL M8100 BL MT200 BL MT201 BL MT400 BL MT401 BL MT402 BL T6000 GRX ST RX600 M7100 M8100 RS785 The handbrake position can be adjusted to the pedelec riders requirements Contact specialist dealer ...

Page 128: ...e 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 wit...

Page 129: ... 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 130: ... the gear shift Not included in price 6 5 11 2 Adjusting the SHIMANO shifter Only applies to pedelecs with this equipment Figure 141 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 compatib...

Page 131: ...formance and is generally used on pedelecs with a shorter deflection The adjustment shown here represents a basic setting The rider 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 optimised settings and as a safeguard against unintentional changes For pedelecs with ...

Page 132: ...crown Remove the plastic cover Figure 142 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 133: ...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 134: ... dust wiper and the O ring This distance is the sag Figure 145 Sag 1 7 Check the sag Figure 146 Mandatory sag range green and prohibited sag range red 8 If the desired sag is not achieved the spring preload must be adjusted inside and or the coil spring replaced Contact specialist dealer 1 Setting Sag Prohibited 30 High sensitivity 20 30 Low sensitivity 10 20 Prohibited 10 Table 42 Recommended sag...

Page 135: ... preload spacer is positioned as standard 1 Figure 147 Screwing and unscrewing the preload adjustment ring Remove the preload spacer to reduce the preload and increase the sag 2 Move the preload spacer to the 10 mm preload position to increase preload and reduce the sag 3 Figure 148 Screwing and unscrewing the preload adjustment ring 10 Check the sag 1 2 3 ...

Page 136: ...normal riding position 4 Ask your helper to push the O ring downwards until it reaches the top of the dust wiper seal Figure 150 Moving the O ring on the suspension fork 5 Get off the pedelec without allowing it to deflect 6 Note distance between dust wiper and the O ring This distance is the sag Figure 151 Sag 1 7 If the desired sag is not achieved the preload adjustment ring must be unscrewed bi...

Page 137: ...he O ring downwards until it reaches the top of the dust wiper seal Figure 153 Moving the O ring on the suspension fork 5 Get off the pedelec without allowing it to deflect 6 Note distance between dust wiper and the O ring This distance is the sag Figure 154 Sag 1 7 Check the sag 8 If the desired sag is not achieved the spring preload must be adjusted inside and or the coil spring replaced Contact...

Page 138: ...fied for the fork model in question Remove spacers to reduce preload and increase the sag Fit spacers to increase preload and decrease sag You will find instructions on adjusting the preload internally in the RockShox maintenance instructions 10 Check the sag The spring preload setting can be used to finely adjust the sag However the preload does not change spring stiffness and is not suitable to ...

Page 139: ...rmance and is used on bicycles with a longer deflection Decreased sag 10 20 A decreased sag reduces sensitivity to bumps thus producing less suspension motion A lower sensitivity to bumps ensures a firmer more efficient ride and is generally used on bicycles with a longer deflection The adjustment shown here represents a basic setting The rider should change the basic setting to suit the surface a...

Page 140: ...e damper body to gauge the sag correctly 7 Put on your normal cycling clothing including baggage 8 Sit on the pedelec in your usual riding position and support yourself against an object such as a wall or tree 9 Push the O ring or cable tie downwards against the air chamber seal 10 Get off the pedelec without the suspension fork deflecting 11 Measure the distance between the air chamber seal and t...

Page 141: ...re corresponding to the total weight of the person riding including clothing and baggage 6 Deflect rear frame damper to compensate the air pressure 7 Put on normal cycling clothing including baggage 8 Ask someone to hold the pedelec Stand on the pedals 9 Deflect rear frame damper fully gently two or three times 10 Ask your helper to push the O ring against the wiper seal Figure 158 Moving the O ri...

Page 142: ...e The optimum sag percentage is 25 The sag level may be adjusted by 5 depending on the rider s preferences 20 to 30 12 The air pressure must be adjusted if the sag level is not reached Increase the air pressure to reduce the sag Decrease the air pressure to increase the sag ...

Page 143: ...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 144: ...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 145: ...pedelecs with this equipment Figure 161 Adjusting the RockShox rebound The fork sag is adjusted Turn the rebound screw clockwise towards the tortoise symbol The rebound speed is decreased slower return Turn the rebound screw anti clockwise towards the hare symbol The rebound speed is increased fast return ...

Page 146: ...nd controlled The rider is not thrown upwards or forwards green line The rebound adjuster setting depends on the air pressure setting A higher sag requires lower rebound damping Figure 162 Optimum rear frame damper riding performance The suspension rebound speed affects the wheel s contact with the ground which in turn has an influence on control and efficiency The damper should rebound fast enoug...

Page 147: ... with this equipment Figure 163 Position and shape of the rebound adjuster red depends on the model The sag in the rear frame damper is adjusted Turn rebound adjuster in the clockwise direction The rebound damping is increased Turn rebound adjuster in the anti clockwise direction The rebound damping is reduced 2 5 ...

Page 148: ...ard on bumpy terrain Figure 164 Optimum rear frame damper ride performance over bumps 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 hilly level or slightly rugged terrain In threshold mode higher pedelec speeds...

Page 149: ...sition 2 Ride the pedelec over a small obstacle Turn compression adjuster anti clockwise The damping and compression hardness is reduced The deflection stroke speed is increased Turn compression adjuster clockwise The damping and compression hardness is increased The deflection stroke speed is reduced 3 The ideal setting for the rebound damper has been achieved when the rebound movement of the rea...

Page 150: ...iddle position 2 Ride the pedelec over a small obstacle Turn compression adjuster clockwise The damping and compression hardness is increased The deflection stroke speed is reduced Turn compression adjuster anti clockwise The damping and compression hardness is reduced The deflection stroke speed is increased 3 The ideal setting for the rebound damper has been achieved when the rebound movement of...

Page 151: ...ver in the threshold position 2 The threshold function is switched on Place threshold lever in the open position 1 The threshold function is switched off The damper can deflect quickly and unhindered Figure 168 Changing compression adjuster to a harder setting To increase sensitivity to small bumps turn compression adjuster anti clockwise to decrease damping and hardness and increase the deflectio...

Page 152: ...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 169 Light positioned too high 1 correctly 2 and too low 3 1 2 3 ...

Page 153: ...he handlebars straight with both hands Do not use the kickstand 7 Switch on riding light Figure 171 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 154: ... to pairing mode 5 Release the On Off button 6 Accept the connection prompt in the app 7 Follow the instructions on the display The user data will be synchronised once the pairing process is complete 6 5 19 3 Update software Software updates are managed by the Bosch eBike Flow smartphone app The on board computer is now connected to the smartphone The drive system is switched on The pedelec is sta...

Page 155: ...indicate a search for the key If the key is found the battery level indicator flashes white The last configured level of assistance is displayed If the key cannot be found on the smartphone the pedelec drive system switches off The indicators on the control panel go off As the smartphone is only used as a contactless key to switch on the pedelec the battery and control panel can still be used on a...

Page 156: ...0 40946 Rear wheel basket system component 051 20603 Bicycle box system component 080 40947 Table 48 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 157: ...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 158: ...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 159: ... 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 160: ...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 161: ...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 162: ...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 163: ...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 164: ...tery key from the battery lock 6 16 1 1 Inserting the battery The key is inserted in the lock The lock is unlocked Figure 182 Inserting the integrated battery 1 Place the battery into the 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 Keep the lock open with the key 4 Push the battery upwards 3 The battery can be he...

Page 165: ...to the battery s charging port The charging process starts automatically The battery level indicator shows the charge level during charging When the drive system is switched on the on board computer displays the charging process The charging process is complete when the LEDs on the battery level indicator go out 4 Once charging is complete disconnect the battery from the charger 5 Disconnect the c...

Page 166: ...ctivated as soon as the pedals are moved with sufficient force except if the selected level of assistance is OFF The motor power is based on the level of assistance selected on the control panel 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 ...

Page 167: ...mputer the display or the display mount as a handle If the on board computer display or display mount are used to lift the pedelec components can become irreparably damaged Symbol Designation 1 Selected level of assistance indicator 2 ABS indicator optional 3 Battery level indicator control panel 4 Select button 5 On Off button control panel 6 Ambient light sensor Table 49 Overview of control pane...

Page 168: ...ghtness button to set the brightness of the indicator LEDs 6 18 5 Using the push assist system The push assist helps move the pedelec The push assist system speed depends on the selected gear The lower the selected gear is the lower the speed in the push assist function is at full power The maximum speed is 6 km h We recommend using first gear for cycling uphill to protect the drive Figure 187 Pos...

Page 169: ...ush assist will also switch off automatically if the rear wheel blocks speed bumps cannot be ridden over a part of the body is blocking the bicycle crank an obstacle turns the crank further the rider pedals the plus button or On Off button is pressed The push assist mode of operation is subject to country specific regulations and may therefore differ from the above description or may be deactivate...

Page 170: ...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 lubricant contact specialist dealer to have the components cleaned or replaced If the brakes are applied continuously for a long time e g while ...

Page 171: ...rs This makes it easier to switch gears and reduces wear on the drivetrain However keep the crank moving while switching gears Figure 190 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 Pl...

Page 172: ...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 173: ...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 174: ... the deflection stroke speed is reduced Efficiency on hilly and flat terrain is improved Figure 194 Changing compression adjuster to a harder setting Turn compression adjuster anti clockwise The damping and compression hardness is reduced and the deflection stroke speed is increased Sensitivity to small bumps is increased Figure 195 Changing compression adjuster to a softer setting ...

Page 175: ... can cause the tyre pressure to increase above the permitted maximum pressure 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 to be used at t...

Page 176: ...ve space when parking 1 Open stem clamping lever Figure 196 Example of All Up with open stem clamping lever 2 Pull handlebars into highest possible position Figure 197 Example of All Up pulled into highest possible position 3 Turn handlebars 90 in a clockwise direction Figure 198 Example of All Up screwed in 4 Place handlebars at required height 5 Close stem clamping lever ...

Page 177: ...mputer used during set up The lock function is activated The drive system now provides no assistance However the rider can continue to use the pedelec without assistance The drive unit will emit a lock sound an audible signal as long as the drive system is switched on The lock function status is displayed with a lock icon on the on board computer for around 3 seconds ...

Page 178: ...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 179: ...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 180: ...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 181: ...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 182: ... 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 183: ...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 184: ...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 185: ...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 186: ... 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 187: ...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 188: ...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 189: ...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 190: ...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 191: ...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 192: ...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 193: ...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 194: ...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 195: ...re 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 196: ...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 203 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 204 Examples of fatig...

Page 197: ...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 198: ...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 199: ...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 200: ...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 201: ...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 202: ...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 203: ...211 Example of a ROHLOFF gauge Figure 212 Example of a KMC digital gauge 1 Insert gauge between two chain links on the right hand side Figure 213 Gauge is inserted 2 Lower gauge down to the left hand side Figure 214 Lower gauge to the left If the gauge does not fit between the links the chain is not worn yet Figure 215 Gauge does not fit If the gauge does not fit between the links the chain is wor...

Page 204: ...d teeth have worn thinner Replace belt sprocket Contact specialist dealer Figure 219 Worn tooth profile Figure 220 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 205: ... 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 206: ...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 225 Attached measuring stick 2 Place the ruler on...

Page 207: ...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 228 Light positioned too high 1 correctly 2 and too low 3 6 Check th...

Page 208: ... 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 209: ...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 210: ...adjuster to increase the shift cable tension Tighten the tension adjuster to decrease the shift cable tension Figure 230 The tension adjuster on ROHLOFF hub versions with internal switch control is located on the tension counter support Figure 231 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 211: ...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 233 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 212: ...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 213: ...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 214: ...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 215: ...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 216: ...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 217: ...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 218: ...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 219: ...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 220: ... 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 221: ... 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 222: ...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 223: ...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 224: ...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 225: ...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 226: ...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 227: ...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 228: ...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 229: ...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 230: ...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 231: ...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 232: ...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 233: ...ry is switched on If not start the battery Contact your specialist dealer if the battery level indicator LEDs do not light up 2 If the LEDs on the Battery Level indicator light up but the drive system does not start remove the battery 3 Insert the battery 4 Start the drive system 5 If the drive system does not start up remove the battery 6 Clean all the contacts with a soft cloth 7 Insert the batt...

Page 234: ...vy load for a long time 1 Switch off the drive system 2 Leave pedelec to cool down 3 Start the drive system The assisted journey distance is too short Is the battery fully charged 1 Check charge level 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 journey distance can be shorter depending on the road condition...

Page 235: ... 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 Has the battery or charger temperature exceeded the operating temperature range 1 Interrupt charging process 2 Leave battery and charger to cool down 3 Start charging If the battery becomes too hot to touch there might be a problem w...

Page 236: ... battery charged If the battery is fitted to the pedelec and is being charged it cannot be switched on Interrupt charging Is the connector fitted to the power cable correctly 1 Check whether the connector is fitted to the power cable correctly 2 If the connector is not fitted correctly contact your specialist dealer A component may be connected which the system is unable to recognise Contact speci...

Page 237: ...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 238: ... 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 239: ...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 240: ...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 241: ... 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 242: ...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 243: ...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 65 Error solution for limit stop ...

Page 244: ...ings 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 New...

Page 245: ...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 246: ...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 247: ...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 248: ...om 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 238 Suspension fork rebounding too quickly Solution Figure 239 SR SUNTOUR rebound screw 1 Turn rebound screw in a clockwise direction The rebound speed...

Page 249: ...nd 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 240 Suspension fork rebounding too slowly Solution Figure 241 SR SUNTOUR rebound screw 1 Turn rebound screw in an anti clockwise direct...

Page 250: ...ight shifts forward and the pedelec loses some momentum Figure 242 Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 243 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 251: ...longer touches the ground The headset and handlebars are deflected upwards significantly which can impair control Figure 244 Excessively hard damping in the suspension fork on bumps Solution Figure 245 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 redu...

Page 252: ...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 246 Suspension fork rebounding too quickly Solution Figure 247 Turning the rebound screw damper towards tortoise symbol Turn the rebound screw clockwise towards the tortois...

Page 253: ...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 248 Suspension fork rebounding too slowly Solution Figure 249 Turning the rebound screw damper towards hare symbol Turn the rebound screw anti clockwise...

Page 254: ... up body weight shifts forward and the pedelec loses some momentum Figure 250 Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 251 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 255: ...wheel no longer touches the ground The headset and handlebars are deflected upwards significantly which can impair control Figure 252 Excessively hard damping in the suspension fork on bumps Solution Figure 253 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 256: ...tion and control due to the uncontrolled speed at which the damper rebounds after deflecting blue line Saddle and handlebars are deflected upwards when the wheel bounces back from the ground The rider s body weight may be shifted upwards and forwards if the damper fully rebounds too quickly green line Figure 254 Rear frame damper rebounding too quickly Solution Figure 255 SR SUNTOUR rebound adjust...

Page 257: ...ckly enough to make contact with the ground and return to the initial position again The available deflection and traction are reduced blue line The rear frame damper remains in a deflected state after contact with the first bump When the rear wheel hits the second bump the saddle follows the path of the rear wheel instead of remaining in a horizontal position The available deflection and potentia...

Page 258: ...ed up body weight shifts downwards and the pedelec loses some momentum Figure 258 Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 259 SR SUNTOUR compression adjuster 1 on the rear frame damper 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 ...

Page 259: ...nd pedelec rider are deflected upwards and forwards the rear wheel loses contact with the ground and control is reduced green line Figure 260 Excessively hard damping in the rear frame damper on bumps Solution Figure 261 SR SUNTOUR compression adjuster 1 on the rear frame damper Turn compression adjuster anti clockwise The damping and compression hardness is reduced and the deflection stroke speed...

Page 260: ...ed speed at which the damper rebounds after deflecting blue line Saddle and handlebars are deflected upwards when the wheel bounces back from the ground The rider s body weight may be shifted upwards and forwards if the damper fully rebounds too quickly green line Figure 262 Rear frame damper rebounding too quickly Solution Figure 263 Position and shape of the rebound adjuster red depends on the m...

Page 261: ...turn to the initial position again The available deflection and traction are reduced blue line The rear frame damper remains in a deflected state after contact with the first bump When the rear wheel hits the second bump the saddle follows the path of the rear wheel instead of remaining in a horizontal position The available deflection and potential absorption of bumps are reduced which causes ins...

Page 262: ...ckly used up to the pedelec rider s weight shifts forward and the pedelec loses some momentum Figure 266 Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 267 Position and shape of the compression adjuster blue depends on the model Turn compression adjuster clockwise The damping and compression hardness is increased and the deflection stroke speed is reduced 1 2...

Page 263: ...ec rider are deflected upwards and forwards the rear wheel loses contact with the ground and control is reduced green line Figure 268 Excessively hard damping in the rear frame damper on bumps Solution Figure 269 Position and shape of the compression adjuster blue depends on the model Turn compression adjuster anti clockwise The damping and compression hardness is reduced and the deflection stroke...

Page 264: ...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 265: ...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 266: ...tion is shown as set up in the BOSCH eBike Connect app 9 2 7 2 Replacing the on board computer Connect on board computer with the smartphone while the on board computer is in use The lock function is shown as set up in the BOSCH eBike Connect app 9 2 7 3 Activating the lock function after motor replacement The lock function is displayed as deactivated in the eBike Connect app when the motor has be...

Page 267: ...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 268: ... 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 269: ...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 270: ...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 271: ...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 272: ... 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 273: ...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 274: ...MY22Z0a 12_1 0_25 07 2022 273 Documents Notes ...

Page 275: ...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 276: ...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 277: ...lleur 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 Hydraulic disc brake Brake lever front rear MAGURA MT4e Brake lever with rear light function Disc front rear Magura Storm HC 180 mm Rim front rear RODI BlackRock 28 Hub front SHIMANO with E THRU quick release axle Hub rear S...

Page 278: ... 277 Documents not available 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 279: ...s 12 speed Shifter SHIMANO XT Shifter Front derailleur Cassette cassette sprocket SHIMANO CS M6100 12 10 51T Chain KMC X10E Tooth 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 BlackRock 27 5 Hub front SHIMANO with E THRU quick release axle Hub rear S...

Page 280: ... 279 Documents not available 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 281: ...MY22Z0a 12_1 0_25 07 2022 280 Documents 11 4 Charger operating instructions ABCDE ...

Page 282: ...MY22Z0a 12_1 0_25 07 2022 281 Documents F 4A Charger DCG F H A I A J ...

Page 283: ...MY22Z0a 12_1 0_25 07 2022 282 Documents F A I A J DCG F H ...

Page 284: ...MY22Z0a 12_1 0_25 07 2022 283 Documents F DCG F H A I A J ...

Page 285: ...T K Q I 0 C C C 7 K I P I Q I 7 C I Q Q I I I C I I I P I I I I C C C C C I Q I C I I I I I I C C C C C C I P I Q C C C N I I I Q I I O I I I I Y V Si I A JCX I O I Z 6 I Q I I P I Q I Q Q I A I A I T Q I O A I A Q I I Q I I Q I O I I I Q I I QQ I Q I I b Q A A I K K CI Q CI J Q I CI I A QQ B A I A J DCG F H ...

Page 286: ...I I I I C J I I QQ C I Q I I P P I I O S Q I Q I I I I I I C C C Q I P I Q I I I RI P I O Q I I I I I O I I I I 4 F I I I I O Q I A I I I O 4 F I I I O I I I I I O RI I I I O P I I I I RI I O P I O Q I I Q I I I O I I I O O I SNK I I Q I I I N I SNK O T h Q I I I Q I SNK I T h I I A Q I P I SNK O I O I QQ I I I Q I Q I QQ I A K I I Q I I Q I I RI I Q I I P I O I QQ 4 F Q I I I I P Q I I I I Q I O ...

Page 287: ... C C I I A 7 C K I Q I I I I I I K I I I I I I I I I I 4 7 7 C C C I I C C I CI A C Q I B P I Q CI I P I I I I I A Q C I I J J Q I I Q P I O I 0 Q I b I A P I W Q I I P IO 7 CI P I Q K Q I I I I I C F I N K H NV R N N Nb O P I I O Q O Q 9 A I A J DCG F H ...

Page 288: ...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 289: ...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 290: ...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 291: ... 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 71 Table ...

Page 292: ...4 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 Instruction handbook General drafting principles EN 15194 2017 Cycles Electrically power assisted cycles EPAC Bicycles The following other technical stand...

Page 293: ...MY22Z0a 12_1 0_25 07 2022 292 Appendix II Declaration of conformity for incomplete machine ...

Page 294: ...MY22Z0a 12_1 0_25 07 2022 293 Appendix ...

Page 295: ...MY22Z0a 12_1 0_25 07 2022 294 Appendix ...

Page 296: ...t 197 check 197 clean 183 secure during transport 78 cable clip 48 cover cap 48 hydraulic 48 insert pin 48 knob 48 mechanical 48 union nut 48 Brakes replace 124 Braking distance 287 Break in operation 80 carry out 81 prepare 81 Button minus 55 166 On Off battery 52 plus 55 push assist 55 166 C Cantilever brake torque 72 Carbon seat post care for 190 Carbon suspension fork inspect 225 Carcass 31 po...

Page 297: ...k 96 clean 185 use 162 use bar ends 162 use multi position handle bars 162 position 29 torque 70 Handles care for 189 check 182 clean 185 use leather handles 162 Headlight adjust 152 check 206 clean 183 torque 74 Headset see steering headset Hub axle position 34 Hub body position 34 Hub gear check 208 Hub 34 adjust ROHLOFF 209 care for 190 clean 186 position 30 torque 68 without additional feature...

Page 298: ... inspect 222 maintain 222 structure 41 43 44 145 Rear light 51 clean 183 Rear wheel brake 49 Rebound adjuster 40 position 40 Rebound adjustment 62 Rebound damping 39 Rebound 289 Rechargeable battery 51 289 Rechargeable battery see bat tery Reflector position 36 Reflectors clean 183 Retainer guard 52 Riding light switch on 167 Riding light adjust 152 check 182 206 switch off 167 Rim brake locking l...

Page 299: ...3 Tyre design types 30 Tyre pressure 30 change 193 check 193 Tyre size 30 Tyre position 30 Tyres 30 check 195 clean 186 convert 157 airless 157 tubeless 157 Tyres Tube type tyres 30 U USB cover check 182 USB port use 166 use 166 V V Brake brake torque 71 Valve 30 Dunlop valve 33 position 30 Presta valve 33 Schrader valve 33 V brake adjust 200 Vehicle technical data 64 W Wear 289 Weight shipping we...

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