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Bosch BULLS 650-185, Operating Instructions Manual

The Bosch BULLS 650-185 Operating Instructions Manual is a comprehensive guide to maximize the use of your Bosch BULLS 650-185 product. You can conveniently download this manual for free from our website, ensuring easy access to essential information on how to operate and maintain your product effectively.

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193

Troubleshooting, fault clearance and repair

9.1.7

Suntour suspension fork

9.1.7.1 Rebound too fast

The suspension fork rebounds too quickly, 
producing a "pogo stick" effect, where the wheel 
lifts from the ground in an uncontrolled way. This 
impairs traction and control (blue line).

Fork 

crown

 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 211:  Suspension fork rebounding too quickly

Solution

Figure 212:  Suntour rebound screw (1)

Turn 

rebound screw 

in a clockwise direction.

The rebound speed is decreased (slower
return).

1

Summary of Contents for BULLS 650-185

Page 1: ...3 650 185 650 189 657 198 I CONI C EVO TR 1 750 ICONIC EVO 1 750 ICONIC EVO 2 750 2perating nstructions or BULLS BOSCH KIOX300 Display IMPORTANT READ CAREFULLY BEFORE USE KEEP SAFE TO CONSULT AT A LATER DATE ...

Page 2: ...ect tightening torque 14 2 1 3 3 Incorrect component 14 2 1 4 Risk of amputation 14 2 1 5 Key breaking off 14 2 1 6 Malfunctions due to Bluetooth 15 2 1 7 Data privacy information 15 2 2 Toxic substances 16 2 2 1 Brake fluid 16 2 2 2 Defective battery 16 2 3 Requirements for the rider 16 2 4 Vulnerable groups 16 2 5 Personal protective equipment 16 2 6 Safety guards 16 2 7 Safety markings and safe...

Page 3: ...42 3 3 8 2 Rechargeable battery 42 3 3 8 3 Charger 43 3 3 8 4 Lighting 43 3 3 8 5 Integrated battery 43 3 3 9 On board computer 44 3 3 9 1 Display 44 3 4 Description of controls and screens 45 3 4 1 Handlebars 45 3 4 2 Control panel 46 3 4 2 1 System message 47 3 4 2 2 Creating a user account 48 3 4 2 3 Software updates 48 3 4 2 4 Activity tracking 48 3 4 2 5 Lock function 48 3 4 3 Display 49 3 4 ...

Page 4: ...LOC quick release 68 5 3 4 69 5 3 5 70 5 3 6 Fitting the pedals Preparing the LIMOTEC dropper post Checking the stem and handlebars 71 5 3 6 1 71 5 3 6 2 71 5 3 6 3 Checking the connections Checking stem is firmly in position Checking for headset play 71 5 4 71 6 Operation 6 1 72 6 2 74 6 3 eBike sale Risks and hazards Tips for a greater range Error message 75 6 3 1 On board computer 75 6 3 1 1 Le...

Page 5: ...djusting the rear shock rebound damper Adjusting the Suntour rear shock Compression adjuster on rear shock Adjusting the Suntour compression dial Lighting Adjusting the lights On board computer 108 6 5 18 1 Creating a user account 108 6 5 18 2 Connecting the on board computer with the smartphone 108 6 5 18 3 Update software 108 6 5 18 4 Activating activity tracking 108 6 5 18 5 Setting up the lock...

Page 6: ... 6 19 1 125 6 20 126 6 20 1 126 6 21 Brake Using the brake lever Derailleur Using the derailleur gears Parking 127 6 21 1 128 6 21 2 Tightening in the quickly adjustable stem Activating the lock function 129 7 Cleaning servicing and maintenance 7 1 Before each ride 134 7 1 1 134 7 1 2 134 7 1 3 134 7 1 4 134 7 1 5 134 7 1 6 134 7 1 7 134 7 1 8 134 7 1 9 134 7 1 10 135 7 1 11 135 7 1 12 135 7 1 13 ...

Page 7: ...nder Servicing the kickstand Stem Handlebars Hand grips 143 7 4 9 1 143 7 4 9 2 Rubber hand grips Leather handle Seat post Suspension seat post Carbon seat post 143 7 4 10 143 7 4 11 143 7 4 12 143 7 4 13 143 7 4 14 Rim Leather saddle Hub Spoke nipples Drivetrain 144 7 4 14 1 144 7 4 14 2 Rear derailleur cages and jockey wheels Shifter 144 7 4 15 Pedal 144 7 4 16 Caring for the chain 144 7 4 16 1 ...

Page 8: ...on 159 8 2 Maintenance 159 8 3 Component specific maintenance tasks 159 8 4 Carry out initial inspection 162 8 5 Maintenance instructions 163 8 5 1 Servicing the frame 170 8 5 1 1 Servicing the carbon frame 170 8 5 2 Checking the pannier rack 170 8 5 3 Servicing axle with quick release 170 8 5 4 Maintaining the stem 171 8 5 5 Servicing the gear hub 171 8 5 5 1 Adjusting the hub with cone bearing 1...

Page 9: ...nt light Checking tire clearance Replacing ebike components if lock function is installed 202 9 2 5 1 Replacing a smartphone 202 9 2 5 2 Replacing the on board computer 202 9 2 5 3 Activating the lock function after motor replacement 202 10 Recycling and disposal 10 1 Removal of waste guidelines 203 11 Documents 11 1 Assembly report 205 11 2 Maintenance log 207 11 3 Parts list 211 11 3 1 211 11 3 ...

Page 10: ...instructions and utilization or communication of their content is prohibited unless expressly approved Any infringement will render the offender 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 are the approved technical specifications at the ...

Page 11: ... 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 warnings in the operating instructions 1 4 2 Markups You will find ten text markups in the operating instructions May lead to serious or even fatal injuries if ignored Medium risk hazard May lead to minor or moderate injuries if ignored Low risk haza...

Page 12: ... on it see Figure 2 The frame number can be used to associate the ebike with the owner The frame number is the most important identifier for verifying ownership Type no Model ebike type Table 2 Type number model and ebike type 650 273 650 189 Iconic EVO 1 Wave 750 650 185 Iconic EVO 1 Diamond 750 657 198 Iconic EVO 2 750 City and trekking Iconic EVO TR 1 750 City and trekking City and trekking Cit...

Page 13: ...lighted in blue and marked with a spanner symbol These paragraphs aim to allow trained technical staff bicycle mechatronics engineers bicycle mechanics or similar to carry out initial assembly adjustment maintenance and repair safely Technical staff also need to read all sections for riders and operators to ensure they can provide a better customer service All documents in Section 11 need to be fi...

Page 14: ...e battery against heat Never store next to hot objects Never expose battery to continuous direct sunlight Avoid wide temperature fluctuations Chargers with excessive voltage damage batteries This may cause a fire or an explosion Only use approved batteries to charge Metal objects may interconnect the battery s electrical terminals The battery may self ignite and explode Never insert paper clips sc...

Page 15: ...e a crash with injuries Never fasten a quick release using a tool e g hammer or pliers Only use the clamping lever with the specified set clamping force 2 1 3 2 Incorrect tightening torque If a screw is fastened too tightly it may break If a screw is not fastened enough it may loosen This will cause a crash with injuries Always observe the indicated tightening torque on the screw or in the operati...

Page 16: ...n close proximity to medical devices filling stations chemical plants areas at risk of explosion and in blasting zones Never use ebike with Bluetooth in aircraft Avoid operating for longer periods in close proximity to the body 2 1 7 Data privacy information When the ebike is connected to the BOSCH diagnosis tool 3 data is transferred to BOSCH eBike Systems Robert Bosch GmbH on the use of the Bosc...

Page 17: ... sensory or mental capacities or lacking in experience and knowledge If minors use the ebike a legal guardian must should provide them with comprehensive instructions 2 5 Personal protective equipment Wear a suitable helmet The helmet must have a reflective strip or a light in a clearly visible colour Wear sturdy shoes Wear clothing which is as bright or retroreflective as possible Fluorescent mat...

Page 18: ...sources of ignition Avoid contact with skin and eyes After inhalation Take in fresh air Immediately consult a doctor in case of any discomfort After skin contact Wash affected skin with soap and water and rinse well Remove contaminated clothing Consult doctor in the event of pain or discomfort After contact with eyes Rinse eyes under flowing water for at least ten minutes with the lids open also r...

Page 19: ...mfort After contact with eyes Carefully rinse eyes with plenty of water for at least 15 minutes Protect unaffected eye Seek medical advice immediately After skin contact Remove any solid particles immediately Rinse the affected area with plenty of water for at least 15 minutes Then dab the affected skin gently Do not rub dry Remove contaminated clothing immediately Immediately consult a doctor if ...

Page 20: ...nsport In addition to being physically fit riders need time to adapt to using the ebike 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 rides on r...

Page 21: ...ing or acrobatics City and trekking bicycles Child s bicycles bicycles for young adults Mountain bikes Racing bicycle Cargo bike Folding bicycle City and trekking bicy cles 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 lighting a bell and othe...

Page 22: ...mitted total weight PTW The maximum permitted total weight is the weight of the fully assembled ebike plus body weight plus baggage Type no Model PTW lbs 300 330 330 330 Table 8 Type number model and PTW 650 273 650 189 Iconic EVO 1 Wave 750 650 185 Iconic EVO 1 Diamond 750 657 198 Iconic EVO 2 750 Iconic EVO TR 1 750 ...

Page 23: ...or children and young adults Mountain bike Racing bicycle Cargo bike Folding bicycle City and trekking 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 w...

Page 24: ...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 6 Never drive off road or perform jumps over 6 Never drive off road or perform jumps over 6 Never drive off road or perform jumps over 6 Never ride downhill or perform jumps over 24 Never ride downhill or perform jumps over 24 Never traverse ex...

Page 25: ...a motor that provides assistance only when the rider is pedaling and that ceases to provide assistance when the bicycle reaches the speed of 20 miles per hour 2 A class 2 electric bicycle or low speed throttle assisted electric bicycle is a bicycle equipped with a motor that may be used exclusively to propel the bicycle and that is not capable of providing assistance when the bicycle reaches the s...

Page 26: ...ght Headset Handlebars Stem Frame 10 11 12 13 14 15 16 17 18 Seat post Saddle Pannier rack Rear light Reflector Rear wheel fender Rear wheel brake Rear wheel Kickstand 19 Rear wheel hub 20 Chain 21 Chain guard 22 Frame number 23 Motor motor cover 24 Pedal 25 Battery and nameplate in the frame 26 Front wheel brake 1 3 6 8 2 4 5 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 ...

Page 27: ...readless fork steerers what are known as headsets 3 3 2 4 Stem The stem is the connecting component between the handlebars and the fork steerer tube The stem is used to adjust the handlebars to the rider The stem is used to adjust the handlebar height and the gap between the handlebars and saddle see Section 6 5 6 Quickly adjustable stems Quickly adjustable stems are an extension to the fork steer...

Page 28: ...n 3 4 1 Figure 5 Handlebar dimensions The main structural dimensions of handlebars are 1 Rise height 2 Width 3 Backsweep 3 3 2 6 Fork The stem and handlebars are attached to the top end of the fork steerer The axle is fastened to the fork ends The wheel is fastened to the axle Figure 6 Overview of fork 1 2 3 4 Fork steerer Side reflectors optional Fork dropout Fork leg 1 2 3 1 2 3 4 ...

Page 29: ...neled 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 from oscillating up and ...

Page 30: ...mps The suspension motion is predictable and controlled Figure 8 Optimum fork riding performance When optimally adjusted the fork counteracts deflection on hilly terrain and stays higher in its deflection range This makes it easier to maintain speed when riding over hilly sections of terrain Figure 9 Optimum fork riding performance on hilly terrain When optimally adjusted the fork travels quickly ...

Page 31: ...n green line when riding over bumps The suspension motion is predictable and controlled Figure 11 Optimum fork riding performance Suspension fork compression adjustment Only applies to ebikes with this equipment The compression adjuster allows the rider to make quick adjustments to the fork s suspension behaviour to adapt to the changes in terrain It is intended for adjustments made during the rid...

Page 32: ... 5 Q Loc 6 Axle 7 Fork end 8 Stanchion 9 Compression damper Air suspension fork structure Depending on the model the air suspension fork has either an air suspension assembly group orange and or a compression damper assembly blue and or a rebound damper assembly group red Figure 14 Internal structure of air suspension fork 1 Air valve 2 Air valve cap 3 Fork steerer 4 Sag setting wheel 5 Rebound ad...

Page 33: ...t 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 travels as soon as the wheel touches the ground after the bump The rear shock rebounds in a controlled way so that the rider remains sitting in a horizontal position when the next bump is absorbed The...

Page 34: ... the rear shock travels 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 17 Optimum rear shock ride performance over bumps ...

Page 35: ...suspension a compression damper and a rebound damper Figure 18 Example showing Suntour rear shock 1 2 3 4 5 6 7 8 Air chamber Rebound lever rebound setting Air valve Lockout lever Total damper length Negative deflection in the rear shock Damper unit O ring 3 1 7 2 4 8 5 6 ...

Page 36: ...ed 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 19 Optimum rear shock riding performance Rear shock compression adjuster Only applies to ebikes with this equipment The compression adjuster controls the compression lifting speed or the rate at which the rear shock travels in...

Page 37: ...driving braking and steering forces The tread can also help improve control on dirty road surfaces If a tire with a deep tread is used on asphalt this may make an unpleasant noise when the brakes are used In such a case the specialist dealer needs to replace the tire with a new one with a shallow tread Figure 22 Example Information on tires Tire pressure The permitted pressure range is indicated o...

Page 38: ...5 Schrader valve 3 3 4 4 Spoke A spoke is a rod that connects the hub to the rim The bent end of the spoke which is hooked into the hub is called the spoke head A thread between 10 mm and 15 mm is attached to the other end of the spoke 3 3 4 5 Spoke nipples Spoke nipples are screw elements with an internal thread which fits onto the spoke thread Fitted spokes are tensioned by tightening the spoke ...

Page 39: ...cy The brake is applied using the brake lever either with the brake lever and shift cable mechanical brake or with the brake lever and hydraulic brake cable hydraulic brake 3 3 5 1 Mechanical brake The brake lever is connected with the brake via a cable inside the cable housing Figure 26 Cable inside cable housing 3 3 5 2 Hydraulic brake The brake fluid is in a closed hose system If the brake leve...

Page 40: ... permanently to the wheel hub You increase brake pressure by pulling the brake lever The brake fluid is used to transfer pressure through the brake line to the cylinders in the brake caliper The braking force is boosted by a speed reduction and applied to the brake pads These apply the brake rotor mechanically If the brake lever is pushed the brake pads are pressed against the brake rotor and the ...

Page 41: ...e sufficient tension when tightening the bolt Standard saddle posts are fastened into the seat tube with either a quick release or a screwable clamp Figure 30 Example of a quick release 3 3 6 2 Suspension seat post Spring loaded seat posts can reduce shock after one time hard impacts thus improving ride comfort significantly However suspension seat posts are not able to compensate for bumps in the...

Page 42: ...irection of travel Chain or belt Rear gearing or belt pulley Front chainring or belt pulley Pedal The ebike is equipped with either a chain or belt drive 3 3 7 1 Chain drive layout Figure 32 Chain drive with derailleur gears 1 Rear derailleur 2 Chain A chain drive is compatible with Pedal brake Hub gear or Derailleur gears 3 3 7 2 Belt drive layout Figure 33 Belt drive 1 Front belt pulley 2 Rear b...

Page 43: ... 3 3 8 2 Rechargeable battery BOSCH batteries are lithium ion batteries which are developed and manufactured to the latest technical standards Each battery cell is protected by a steel cup and encased in a plastic battery housing Applicable safety regulations are met The battery has an interior electronic protection circuit which is specifically designed for the charger and the ebike The battery t...

Page 44: ...PC3400 Observe the operating instructions in the Section 11 4 Documents 3 3 8 4 Lighting When the riding light is activated the front light and rear light are switched on together at the same time 3 3 8 5 Integrated battery The following battery can be built into the ebike Figure 35 Overview of integrated battery Figure 36 Detail of PowerTube 750 1 Securing hook 2 Battery lock 3 Battery key 4 Reta...

Page 45: ...p can be accessed via Bluetooth The control panel has an internal lithium ion battery The ebike battery powers the control panel If a sufficiently charged battery is inserted into the ebike and the drive system switched on the internal battery is charged 3 3 9 1 Display Figure 38 BOSCH Kiox300 display The display shows the main drive system functions and the ride data The display switches off auto...

Page 46: ...Figure 39 Detailed view of handlebars with BOSCH Kiox300 example 1 6 2 3 4 5 Hand grips Rear brake lever behind handlebars Bell Kiox300 display Front brake lever behind handlebars 7 LED Remote control panel 8 Air valve cap 9 Sag setting wheel 10 Shifter 1 4 7 9 5 3 2 8 6 10 ...

Page 47: ...on 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 12 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 maintenance ...

Page 48: ...ce on eliminating errors You will find more information and a table containing all system messages in Section 6 2 Level of assistance Colour Use OFF No When the drive system is switched on the motor assistance is switched off The ebike can be used like a normal bicycle by simply pedalling ECO Green Limited assistance with maximum efficiency for maximum range TOUR blue Constant assistance for long ...

Page 49: ...r location will only be logged if the on board computer is connected to the eBike Connect app Activities will be displayed after synchronization 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 removing t...

Page 50: ...re the drive system assists with pedalling eMTB mode is available for Performance Line CX drives In eMTB mode the assistance factor and the torque are dynamically adjusted depending on the pedalling force applied to the pedals 3 Riding light symbol The riding light symbol is shown when the riding light is on 4 Battery level indicator display screen If the on board computer is removed from its moun...

Page 51: ...level of assistance indicator 3 Riding light symbol 4 Battery level indicator display screen 5 Connections indicator 6 Symbol showing connection to smartphone 7 Settings 3 4 3 3 Settings All system and service relevant values can be read and changed in the settings The settings menu structure is customised and may change when components or services are added eMTB 80 VERBINDUNGEN 10 45 EINSTELLUNGE...

Page 52: ...or 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 53: ...W 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 44 SHIMANO SW E7000 gear shift 1 Up button gear shift 2 Down button gear shift 1 2 ...

Page 54: ...re brake levers on the left and right of the handlebars Figure 45 Front wheel 2 and rear 1 brake levers Shimano brake used as an example The left hand brake controls the front wheel brake The right hand brake controls the rear wheel brake 1 2 ...

Page 55: ...ghting Output voltage 4 75 5 4 V Output current max 1 5 A Operating temperature 23º 104ºF Storage temperature 50º 104ºF Protection class IP54 Table 20 Technical data for BOSCH Display Mount BDS3210 BDS3250 BDS3620 BDS3630 Internal lithium ion battery 3 7 V 75 mAh Charging temperature 32 113ºF Operating temperature 23º 104ºF Storage temperature 50º 122ºF Protection class IP54 Dimensions 74 53 35 We...

Page 56: ... V Nominal capacity 20 1 Ah Energy 750 Wh Weight 9 7lb Protection class IP54 Operating temperature 23º 104ºF Storage temperature 50º 104ºF Permitted charging temperature range 32º 104ºF Table 24 Technical data for BOSCH PowerTube 750 BBP3770 horizontal BBP3771 vertical ...

Page 57: ...chment screw cable fastener 2 5 Nm 5 Nm 4 mm hex bit 3 mm hex bit Axle Conventional axle nut 35 40 Nm SUNTOUR screw on axle 12AH2 Axle Securing screw 8 10 Nm 5 6 Nm 6 mm hex bit 5 mm hex bit SUNTOUR screw on axle 15AH2 Axle Securing screw 8 10 Nm 5 6 Nm 6 mm hex bit 5 mm hex bit Handlebars Clamping screw conventional 5 7 Nm Seat post by schulz G1 M8 seat clamping screw M5 fixing grub screws 20 24 ...

Page 58: ...leeve 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 Seat post clamping screw Saddle clamping screw 6 7 Nm 7 9 Nm SUNTOUR suspension seat post Seat clamping screw M5 fixing grub screws 15 18 Nm 3 Nm 2 5 mm hex bit Pedals Pedal conventional 33 35 Nm 15 mm combo wrench Table 25 Tightening torques and bits ...

Page 59: ...m 50 cm 55 cm 22 15 1075 45 cm 50 cm 55 cm 60 cm 22 15 1076 45 cm 50 cm 55 cm 22 15 1077 45 cm 50 cm 55 cm Table 26 Type number model and ebike type 22 15 1088 41 cm 44 cm 48 cm 54 cm 22 15 1089 44 cm 48 cm 54 cm 41 cm 22 15 4007 45 cm 50 cm 55 cm 60 cm 22 15 4008 45 cm 50 cm 55 cm 22 15 4009 45 cm 50 cm 55 cm Type no Frame Box dim cm Weight kg Shipping weight kg Table 26 Type number model and ebi...

Page 60: ...he battery in a dry clean position where it is protected from direct sunlight 4 3 3 Shipping a ebike When shipping the ebike we recommend that you have the specialist dealer place it in proper packaging 4 3 4 Transporting the battery Batteries are subject to hazardous goods regulations Undamaged batteries may be transported by private persons in road traffic Commercial transport requires complianc...

Page 61: ...s to be cleaned with a damp cloth and preserved with wax spray Never wax the friction surfaces of the brake Before longer periods without use it is recommended to have the specialist dealer carry out maintenance and basic cleaning and apply preservative agent 4 4 1 2 Carrying out a break in operation 1 Store the ebike battery and charger in a dry clean environment We recommend storing them in unin...

Page 62: ...se if components are set incorrectly They may cause serious injuries to the face Always wear safety glasses to protect eyes when assembling ebikes Crash and crushing hazard caused by unintentional activation There is a risk of injury if the drive system is activated unintentionally Remove the battery WARNING CAUTION 1 pre assembled ebike 1 front wheel 2 pedals 2 quick releases optional 1 charger 1...

Page 63: ... 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 ebike 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 Off button bat...

Page 64: ... a TORX T25 wrench to undo the screws in the battery mount Figure 47 Undoing screws on battery mount 2 Remove battery mount and turn over 3 Clamp the clip VLD I 1222 onto the battery mount on the rear Figure 48 Clip VLD I 12122 Figure 49 Clamping the clip 4 Turn battery mount over and place on the aluminium brace in the frame 5 Use a TORX T25 wrench to fasten the screws into the battery mount ...

Page 65: ...it 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 tires are mounted on the front and rear wheels in opposite directions On these tires there are two rotation direction arrows The FRONT rotation direction arrow indicates the recommended direction of rotation for the front whee...

Page 66: ...o the fork ends 2 Insert the axle into the hub on the drive side Figure 52 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 53 Tighten the axle in the direction of the arrow 4 Insert the securing screw on the non drive side Figure 54 Pushing the quick release lever into the axle 5 Tighten the ...

Page 67: ...loose quick release axle A faulty or incorrectly installed thru axle may become caught in the brake rotor and block the wheel This will cause a crash Never fit a defective thru axle Crash caused by faulty or incorrectly installed thru axle The brake rotor becomes very hot during operation Parts of the thru axle may become damaged as a result The thru axle becomes loose This will cause a crash with...

Page 68: ...er must be flush with the fork lowers Figure 60 Perfect position for the clamping lever 6 Use 4 mm hex wrench to adjust the clamping lever clamping force if required Figure 61 Adjusting the quick release clamping force 7 Check the quick release lever position and clamping force The wheel is now fitted ...

Page 69: ... incorrectly installed quick release may become caught in the brake rotor 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 rotor 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 fron...

Page 70: ...markings on pedals 1 Coat threads in both pedals with waterproof grease 2 Turn the pedal marked L counter clockwise by hand into the crank arm on the left as seen when facing the direction of travel Figure 67 L pedal in the left hand crank arm 3 Turn the pedal marked R counter clockwise by hand into the crank arm on the right as seen when facing the direction of travel Figure 68 R pedal in the rig...

Page 71: ...ate the optimum seat post height for the length of rider s leg Seat height SH inner leg length I 0 9 2 Lower the seat post further into the seat tube 3 The seat post cable must be tightened in the frame up to the remote control to the same length as the seat post was lowered 4 Trim cap the seat post cable on the handlebars if necessary ...

Page 72: ...dlebars 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 for headset play 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 ebike backwards and forwards Keep in mind that there may be ...

Page 73: ...traffic and speed before riding at speeds over 10 mph 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 crash with serious injuries ...

Page 74: ... 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 ebike functions such as braking This may cause a crash with injuries Remove coarse soiling before riding Notice Heat or direct sunlight can cause the tir...

Page 75: ...ing 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 minute are optimal Avoid high stress loads on the crank during a gear change Switch gear back in good time e g before inclines Tires Always select the right tires for the surface type As a general rule narrower treads are more efficient than wider...

Page 76: ...uits 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 riding If a mag...

Page 77: ...ebike Only a correctly adjusted ebike 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 ebike Crash caused by incorrectly adjusted torques If a bolt is fastened too tightly it may break If a bolt is not fastened enough it may loo...

Page 78: ...5 3 Stem 6 5 6 4 Hand grips 6 5 7 x 5 Tires 6 5 10 6 1 6 2 6 3 6 4 6 5 Brake Position of the brake lever Brake lever tilt angle Determine grip distance Adjust the grip distance Pressure point Retract the brake pads 6 5 9 1 6 5 9 2 6 5 9 3 6 5 9 4 6 5 9 8 6 5 9 4 7 Adjust suspension Adjust suspension fork sag 6 5 11 x Adjust the rear shock sag optional 6 5 12 x Adjust suspension fork rebound damper...

Page 79: ...rrect position red The pelvis is in the right position if the spine forms an S shape and a natural easy arch The hips are 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 sitting position must be selected beforehand depending on the ebike type physical fitness and desired trip distance or speed It i...

Page 80: ...The 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 promot...

Page 81: ...eight safely either Push the ebike near to a wall so that the rider can lean on the wall to support themselves or Ask another person to hold the ebike 1 Use the seat height formula to roughly set the saddle height Seat height SH inner leg length I 0 9 2 Climb onto the bicycle 3 Place your heel on the pedal and extend your leg so that the pedal is at the lowest crank rotation point Your knee should...

Page 82: ...ease the remote control operating lever when you have reached the desired height Figure 75 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 Crash caused by an excessively high seat post setting A seat post ...

Page 83: ...igure 76 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 5 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 optimized in this way if needed T...

Page 84: ...re advisable for sports bikes e g MTB They support direct steering behaviour but lead to peaks in pressure and greater muscular strain on the arm and shoulder muscles 6 5 5 3 Adjusting the handlebars The handlebars and their position determine the posture that the rider adopts on the ebike 1 After selecting the seating position see Section 6 6 2 1 determine the angle of the upper body and of the u...

Page 85: ...ck release clamping force If the handlebar clamping lever stops 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 1 2 Crash caused by incorrectly set clamping force Applying excessive clamping force damages the q...

Page 86: ...ll stem height 1 Undo screw 2 Pull quill stem out 3 Tighten screw 6 5 6 3 Adjusting the threadless stem Only applies to ebikes with this equipment In the case of an threadless stem the stem is placed directly on the fork steerer which protrudes over the frame Figure 83 Raising the Ahead stem by fitting spacer rings The handlebar height is adjusted once during production using spacer rings The part...

Page 87: ... available in different lengths for quill and threadless stems Figure 84 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 85 City bike blue and trekking bike position red by changing the angle a a b b c c ...

Page 88: ...reater contact surface means that the pressure is more evenly distributed Nerves and vessels are no longer squeezed in the carpal tunnel Figure 86 Correct 1 and incorrect 2 position of the handle 1 Undo the handle screw 2 Turn handle into the right position 3 Tighten the screw 6 5 7 1 Checking handlebar stability See Section 7 5 5 1 2 9 _ ...

Page 89: ... pressure often leads to premature wear in the tire Cracking in the side wall is a typical consequence of very low tire pressure Abrasion is also unnecessarily high On the other hand a tire can absorb road impacts more effectively at a low pressure As a general rule wide tires are operated at a lower tire pressure They provide the advantages of the lower tire pressure without the serious disadvant...

Page 90: ...end the index finger about 15 Figure 89 Brake handle position 3 Push brake lever outwards until the third finger phalanx sits in the brake lever recessed grip 6 5 9 2 Brake lever tilt 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 thus narrowing the ca...

Page 91: ...ure hand size using the grip distance gauge 2 Adjust the grip distance at the pressure point based on the hand size Figure 92 Brake lever position Saddle handlebar height difference mm Brake angle 10 20 25 0 10 25 30 0 10 30 35 10 35 45 Hand size Grip distance cm S 2 M 3 L 4 20 25 10 cm 25 30 0 10 cm 30 35 0 10 cm 35 45 10 cm E 3 2 1 ...

Page 92: ...ncreases over time The braking force is increased during break in time This is also the case when the brake pads or brake rotors are replaced 1 Accelerate ebike to 15 mph 2 Brake ebike until it comes to a halt 3 Repeat process 30 to 50 times The disc brake is bedded in and provides optimal braking power ...

Page 93: ...ively low tire pressure often leads to premature wear in the tire Cracking in the side wall is a typical consequence of very low tire pressure Abrasion is also unnecessarily high On the other hand a tire can absorb road impacts more effectively at a low pressure As a general rule wide tires are operated at a lower tire pressure They provide the advantages of the lower tire pressure without the ser...

Page 94: ...sted to the rider s requirements Such adjustment does not affect the pressure point or the position of the brake pads Turn setting screw counter 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 95 Setting screw position 1 1 ...

Page 95: ...brake lever Only applies to ebikes with brakes 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 brake lever position can be adjusted to the rider s requirements Contact your specialist dealer ...

Page 96: ...and is generally used on bicycles with shorter travel 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 as a starting point for subsequent optimized settings and as a safeguard against unintentional changes For ebikes with components onl...

Page 97: ...plastic cover Figure 96 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 counter clockwise to decrease the spring pre tensioning You will have made the ideal setting when the shock absorber travels 3 mm when subject to body weight 3 Replace the plastic cover on the crown after making the setting 1...

Page 98: ...or tree 8 Get off the ebike without allowing it to go further into suspension travel 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 travel 10 Increase or reduce air pressure until you have reached the desired sag 11 If the sag is correct turn the air valve cap clockwise 12 If you are unab...

Page 99: ...on ebikes with a longer travel 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 performance and is generally used on ebikes with a shorter travel The adjustment shown here represents a basic setting The rider should change the basic setting to suit the surface and their preferenc...

Page 100: ... Put on your normal cycling clothing including rider all gear 8 Sit on the ebike 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 ebike without causing the fork to drop further into its travel 11 Measure the distance between the air chamber seal and the O ring This measur...

Page 101: ...g stiffness travel the terrain and the 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 are increased The damper rebounds at a controlled speed if the fork is optimally adjusted The wheel stays in contact with the ground whe...

Page 102: ...kwise direction to the closed position until it stops 2 Turn the rebound screw slightly in a counter clockwise direction Adjust the rebound damping in such a way that the fork rebounds quickly but without bottoming out upwards 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 slight impact when...

Page 103: ...ed 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 100 Optimum rear shock 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 enough to sustain tract...

Page 104: ...lies to ebikes with this equipment Figure 101 Suntour rebound adjuster wheel 1 on the rear shock The sag in the rear shock is adjusted Turn rebound wheel towards minus The rebound movement is increased Turn rebound wheel towards plus The travel movement is reduced 1 ...

Page 105: ...s hard on bumpy terrain Figure 102 Optimum rear shock 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 pedaling efficiency over flat hilly level or slightly rugged terrain In threshold mode higher ebike speeds lead t...

Page 106: ...the ebike over a small obstacle Turn compression adjuster counter clockwise The damping and compression hardness is reduced The travel stroke speed is increased Turn compression adjuster clockwise The damping and compression hardness is increased The travel stroke speed is reduced 3 The ideal setting for the rebound damper has been achieved when the rebound movement of the rear wheel feels compara...

Page 107: ... If the front light 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 104 Light positioned too high 1 correctly 2 and too low 3 6 5 17 1 Adjusting the lights 1 Position the ebike so that its front is facing a wall 2 Mark the height of the front light 1 on the wall with chalk 3 Mark half the height of the front light 2...

Page 108: ... 2 and too low 3 7 Check the position of the light beam I If the upper edge of the light beam is above the front light height mark 1 the light will blind The front light must be positioned lower II If the mid point of the light beam is on or slightly below the mark showing half the front light 2 the light is optimally positioned III If the light beam hits the ground before the wall move front ligh...

Page 109: ...or flashes blue The on board computer will switch the Bluetooth Low Energy connection on and change 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 18 3 Update software Software updates are managed by the Bosch eBike Flow smartphone app The on b...

Page 110: ...ch on the ebike the battery and control panel can still be used on another unlocked ebike 6 5 18 6 Inserting the display 1 Place display 1 on the locking hook 2 on the front edge of display mount 3 facing the direction of travel 2 Press display rear onto the display mount Figure 107 Inserting the display 6 5 18 7 Securing the on board computer optional It is possible to secure the on board compute...

Page 111: ...n start screen Press On Off button The START SCREEN is displayed Opening the screens Press the forward button or back button A new screen is displayed Open Status screen 1 Open the START SCREEN 2 Press the Back button The STATUS SCREEN is displayed Notice Never use on board computer the display or the display mount as a handle If the on board computer display or display mount are used to lift the ...

Page 112: ...ystem menu item 2 Open Time sub menu item 3 Follow the instructions on the on board computer The time has been set 6 5 18 13Adjusting the time format 1 Open System menu item 2 Open Time format sub menu item 3 Follow the instructions on the on board computer The Time Format is set 6 5 18 14Selecting units 1 Open System menu item 2 Open Units sub menu item 3 Follow the instructions on the on board c...

Page 113: ... instructions 6 5 18 16Reset settings 1 Open System menu item 2 Open Settings reset sub menu item 3 Follow the instructions on the on board computer All settings are reset to the factory settings All user data has been cleared ...

Page 114: ...nent 080 40946 Rear wheel basket system component 051 20603 Bicycle box system component 080 40947 Parking stand universal stand XX TWO14B Table 42 Accessories Crash caused by incorrect child seat The pannier rack and down tube are unsuitable for mounting child seats and may break Such an incorrect position may cause a crash with serious injuries for the rider or child Never attach a child seat to...

Page 115: ... 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 The statutory regulations on the use of bicycle trailers must be observed Only use type a...

Page 116: ... 6 6 5 Suspension fork coil spring If the desired suspension fork sag cannot be achieved after adjustment the coil spring assembly must be replaced with a softer or harder spring Fit a softer coil spring assembly group to increase the sag Fit a harder coil spring assembly group to decrease the sag 6 6 6 Pannier rack The specialist dealer will advise on choosing a suitable pannier rack The speciali...

Page 117: ...es not blind other road users If the white reflector is not integrated into the front light it must be clean at all times 7 The two separate brakes on the ebike must work at all times 8 The clear sounding bell must be fitted and must work 6 8 Before each ride Check ebike before each ride see section 7 1 Be alert to any unusual noises vibrations or odors while riding Be alert to any unusual operati...

Page 118: ...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 ebike 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 manner Be careful whe...

Page 119: ...ial beneath and mould can form If the leather hand grips get wet dry them completely before next usage 6 13 Using the pedals The ball of the foot is placed on the pedal when riding and pedalling Figure 117 Correct 1 and incorrect 2 foot position on the pedal 6 14 Using the multifunctional handlebars or bar ends Vary hand position to avoid overstraining and tiring the hands 6 14 1 Using leather han...

Page 120: ... the battery lock 6 16 1 1 Inserting the battery The key is inserted in the lock The lock is unlocked Figure 119 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 heard locking i...

Page 121: ... 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 charger from th...

Page 122: ...on 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 20mph the drive system switches off the assistance system The assistance system starts up...

Page 123: ...isplay or the display mount as a handle If the on board computer display or display mount are used to lift the ebike 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 43 Overview of control panel 1 2 3 4 5 6 ...

Page 124: ...s button to set the brightness of the indicator LEDs 6 18 5 Using the push assist system The push assist helps move the ebike 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 3 km h We recommend using first gear for cycling uphill to protect the drive Figure 124 Position of...

Page 125: ... off automatically if Push will also stop 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 deactivated 6 ...

Page 126: ...rake failure Oil or lubricant on the brake rotor in a disc brake or on the rim of a rim brake can cause the brake to fail completely This may cause a crash with serious injuries Never allow oil or lubricant to come into contact with the brake rotor or brake pads or on the rim of a rim brake If the brake pads have come into contact with oil or lubricant contact specialist dealer to have the compone...

Page 127: ...This makes it easier to switch gears and reduces wear on the drivetrain However keep the crank moving while switching gears Figure 127 Switching gears with lever A using shifter SL M315 as an example Lever A switches from a smaller gear to a larger one The number of gears switched depends on the selected position of lever A Place shifter A in position 1 System shifts one gear higher Place shifter ...

Page 128: ...tires Never park the ebike in the sun On hot days regularly check the tire pressure and adjust it as necessary Moisture penetrating at low temperatures may impair individual functions due to the open structural design Always keep the ebike dry and free from frost If the ebike is used at temperatures below 36 F the specialist dealer must perform maintenance beforehand and prepare it for winter use ...

Page 129: ...g 1 Open stem clamping lever Figure 129 Example of All Up with open stem clamping lever 2 Pull handlebars into highest possible position Figure 130 Example of All Up pulled into highest possible position 3 Turn handlebars 90 in a clockwise direction Figure 131 Example of All Up screwed in 4 Place handlebars at required height 5 Close stem clamping lever ...

Page 130: ... The lock function is activated The drive system now provides no assistance However the rider can continue to use the ebike 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 131: ...e 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 shock see Section 7 2 7 Clean the pedals see Section 7 2 4 Check list for 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 days In wet conditions every 2 6 days Trekk...

Page 132: ...are for leather hand grips 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 tires see Section 7 3 10 Check back pedal brake see Section 7 5 2 5 Clean saddle see Section 7 3 9 Clean seat post see Se...

Page 133: ...ars see Section 7 4 7 Check handlebars see Section 7 5 5 Check light see Section 7 5 3 Care for hub see Section 7 4 12 Check hub gear see Section 7 5 9 2 Check nipple holes see Section 7 5 1 4 Care for pedals see Section 7 4 15 Check pedal see Section 7 5 7 Care for frame see Section 7 4 1 Check belt tension see Section 7 5 9 Check saddle see Section 7 5 6 Care for shifter see Section 7 4 14 2 Car...

Page 134: ...sures Damaged brakes can fail and cause an accident with injury Never clean the ebike with a pressure washer or compressed air Take great care when using a hose 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 drive system is activated unintentionally Remove the battery before cleaning Notice Water ...

Page 135: ...act specialist dealer 7 1 5 Checking the pannier rack 1 Hold onto ebike by its frame Hold onto pannier rack with the other hand 2 Move the pannier rack backwards and forwards to check that all screw connections are firmly in place Tighten loose screws Attach loose baskets permanently with a basket bracket or cable ties 7 1 6 Checking the fenders 1 Hold onto ebike by its frame Hold onto fender rack...

Page 136: ...heck the position of the cover on the USB port on a regular basis and adjust if necessary 7 1 13 Checking the lighting 1 Switch light on 2 Check that the front and rear lights come on If the front and rear lights do not come on take ebike out of service Contact specialist dealer 7 1 14 Checking the brake 1 Pull both brake levers when stationary 2 Push the pedals If no resistance is generated in th...

Page 137: ...aking oil 2 Lubricate the dust seals and stanchions with a few drops of silicone spray 3 Care for 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 se...

Page 138: ...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 45 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 use a cleaning agent Risk of...

Page 139: ...nd grips 1 Clean hand grips with sponge water and soapy water 2 Rinse off component with water from a watering can 3 Care for rubber hand grips after cleaning see Section 7 4 8 7 3 7 1 Leather hand grips Leather is a natural product and has similar properties to human skin Regular cleaning and care help to prevent leather dehydrating fading or becoming brittle or stained 1 Remove dirt with a soft ...

Page 140: ...off component with water from a watering can 4 Care for spoke nipples after cleaning see Section 7 4 13 7 3 12 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 and a cloth 7 3 13 Switching elements 1 Clean shifter shifter cables and derailleurs with water a brush and dish w...

Page 141: ...essure 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 chain after cleaning see Section 7 4 16 7 3 18 1 Chain with all round chain guard Clean water hole on the chain guard lower surface Care for chain after cleaning see Section 7 4 16 1 Notice Protect brake rotor against lubricants and grease f...

Page 142: ...2 Spray 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 46 Required tools and cleaning agents for servicing 2 y x 1 3 A A A Battery terminal grease Notice Hard wax polish and protection wax are part...

Page 143: ...il 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 clamp apply a new protective laye...

Page 144: ...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 colored trousers after care due to staining ...

Page 145: ... 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 counter 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 crank is turned the thinner the t...

Page 146: ...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 brakes 7 4 18 1 Caring for brakes Lubricate articulated joints and mechanical parts which are accessible from outside with a few drops of spray oil or precision mechanics oi...

Page 147: ...cantly higher and the wall thicknesses significantly finer than in a car tire Pressure loss of 15psi per month can be regarded as normal During this process the pressure loss is significantly faster at high pressures and significantly slower at low pressures Checking tire pressure The permitted pressure range is indicated on the side of the tire Figure 135 Tire pressure in bar 1 and psi 2 Verify t...

Page 148: ...umps are unsuitable for filling tires via a Schrader valve 1 Unscrew and remove the valve cap 1 Undo the rim nuts 2 Attach the bicycle pump 3 Pump up the tire slowly and pay attention to the tire pressure in the process The tire pressure has been adjusted as per the specifications 4 Remove the bicycle pump 5 Screw the valve cap tight 6 Screw the rim nut gently against the rim with the tips of your...

Page 149: ...Since resistance to punctures also depends on the thickness of the tread it may make sense to change the tire at an earlier stage Figure 136 Tire without tread which can still be used 1 and tire with puncture protection showing through 2 which needs to be replaced 2 Check the side walls for wear If there are any cracks or tears the tire must be replaced Figure 137 Examples of fatigue cracks 1 and ...

Page 150: ...e cracks on the edge of the nipple hole contact your specialist dealer 7 5 1 5 Checking the nipple well The nipple holes can weaken the tire 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 tire...

Page 151: ...6 5 9 8 Contact your specialist dealer if the pressure point cannot be reached 7 5 2 2 Checking the hydraulic system 1 Push the brake lever and check whether any brake fluid leaks out of the lines connections or on the brake pads If any brake fluid leaks from anywhere take ebike out of service Contact specialist dealer 2 Push brake lever and hold several times If you are unable to clearly detect t...

Page 152: ...ting plates If the transport safety wear gauge fits between the supporting plates the brake pads have not reached their wear limit Contact your specialist dealer if they are worn Checking the brake rotors Put on gloves as the brake rotor is very sharp 1 Take hold of brake rotor and joggle it gently to check whether the brake rotor is positioned against the wheel free of play 2 Check that the brake...

Page 153: ...arp corners and edges on the 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 pedal makes noises contact specialist dealer ...

Page 154: ...rake pads twist the brake pad bracket is defective and must be replaced Contact specialist dealer 5 Check that the brake pads move uniformly and symmetrically towards the rim when you pull and release the brake lever If the brake pads move unevenly 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 stre...

Page 155: ... 2 Switch light on 3 Check that the front and rear lights come on If the front or rear lights do not come on take ebike out of service Contact specialist dealer 4 Place ebike 15 feet from the wall 5 Stand the ebike up straight Hold the handlebars straight with both hands Do not use the kickstand Figure 139 Light positioned too high 1 correctly 2 and too low 3 6 Check the position of the light beam...

Page 156: ...shed in one direction or other If the saddle twists tilts or can be pushed in one direction or other adjust the saddle see Section xxx Contact your specialist dealer if the saddle cannot be fixed into position 7 5 7 Checking the seat post 1 Take seat post out of the frame 2 Check seat post for cracks and corrosion 3 Reinsert seat post 4 Check pedal 5 Hold pedal and try to move it sideways toward t...

Page 157: ...hieved if the chain can be pushed between a maximum of 10 and 15 mm in the middle between the rear gear and the chainring The crank must also turn without resistance 7 5 10 Checking the drivetrain 1 Check whether all drivetrain components are free of damage 2 Contact your specialist dealer if components are damaged 3 Place the ebike on stand 4 Turn the pedal crank clockwise 5 Switch through all sp...

Page 158: ...ox positioned on the left hand side 3 If the marking and numbers on the shift handle to no longer coincide after the gear shift is adjusted tighten one of the tension adjusters and screw out the other tension adjuster to the same extent 7 5 12 Cable actuated shifting single cable Only applies to ebikes with this equipment Reduce shifter housing play by using the barrel adjuster to ensure a smooth ...

Page 159: ...fter housing There is noticeable play of 2 to 5 mm 1 2 gear when you turn the twist grip Figure 145 Twist grip with barrel adjusters 1 and play in the housing 2 7 5 15 Checking kickstand stability 1 Place the ebike on a slight elevation of 5 cm 2 Extend kickstand 3 Jolt ebike to check stability If the ebike topples over tighten screws or change height of the kickstand 1 2 ...

Page 160: ...cial lubricants The ebike 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 only guarantees a long service life but also ensures optimal performance Each maintenance interval shows the maximum cycling hours for the required type of maintenance that the compo...

Page 161: ...t post Maintenance After the first 150miles every 900 miles after that 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 control lever and or maintenance of ...

Page 162: ... Internal oil change and maintenance 600 miles after start of use then every 2 years or 1 200 miles All other SHIMANO gear hubs Lubricate internal components Once a year or every 1 200 miles ROHLOFF Speedhub 500 14 Clean cable box and grease cable drum interior Every 300 miles Oil change Every 3 00 miles or at least once a year Pinion Maintenance 1 Check drive elements and replace if necessary Cle...

Page 163: ...bed 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 maintenance work Crash and falling caused by unintentional activation There is a risk of injury if the drive system is activated unintentionally Remove the battery before maintenance Crash caused by ma...

Page 164: ...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 shock as specified in parts list FOX Rear shock optional 6 months Check for damage corrosion fracture Send to FOX O K Damage detected New rear shock as specified in parts list Suntour Rear shock optional 6...

Page 165: ...hange as speci fied by manufac turer O K Damage detected New fork as specified 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 shock as specified in parts list RockShox suspension fork optional 6 months Check for damage corrosion fracture Maintenance as specified by manufacturer Lubrication oil change as speci fi...

Page 166: ...eaning Section 7 3 12 O K Dirt Cleaning Once a month Care for Section 7 4 12 O K Untreated Treat Hub with cone bearing optional Once a month Cleaning Section 7 3 12 O K Dirt Cleaning Once a month Care for 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 po...

Page 167: ...plete clean check fastening and paint protection film lubricate Section 8 6 8 2 O K Loose Tighten screws new paint protection film new seat post as specified in parts list if damaged 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 specif...

Page 168: ...en screws Brake fluid 6 months Check fluid level Depending on time of year O K Too little Top up brake fluid take ebike out of service if damaged new brake hoses Brake linings 6 months Brake pads brake rotors and rims Check for damage O K Damage detected New brake pads brake rotors and rims Back pedal brake braking armature 6 months Attachment Check mount fastening O K Loose Retighten screws Brake...

Page 169: ...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 computer decommissioning Electric drive control panel 6 months Check drive for damage Check drive for damage O K No response Restart contact control panel manu facturer new control panel Tachometer 6 months Calibration Speed meas urement O K ebike travel ling...

Page 170: ...s Attachment Check mount fastening O K Loose Retighten screws Components Fre quency 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 Derailleur under operating load 6 month...

Page 171: ...Replace damaged pannier racks If the paint protection film is missing or has worn away affix a new paint protection film 8 5 3 Servicing axle with quick release 1 Undo quick release 2 Fasten quick release 3 Check the position and clamping force of the quick release lever Crash caused by unfastened quick release A faulty or incorrectly installed quick release may become caught in the brake rotor an...

Page 172: ...er 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 5 Servicing the gear hub 8 5 5 1 Adjusting the hub with cone bearing In the case of hubs with a cone bearing the bearing shell fixed in the hub cone body rotates with its larger ball bearing surfaces around the inner bearing cone resting ...

Page 173: ...ew fork as specified in the parts list 3 Clean inside and exterior 4 Grease fork 5 Install fork Injury due to explosion The air chamber is pressurized If the air system in a faulty suspension fork is maintained 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 cham...

Page 174: ...act There may be damage to the laminate beneath the paintwork in the case of impact damage The fork may break even under light stress Take ebike out of service New fork as specified in the parts list The fork must be free from any defects 4 Clean inside and exterior 5 Grease fork 6 Install fork 8 5 7 2 Servicing the suspension fork 1 Remove fork 2 Check fork for cracks warping and damage to the pa...

Page 175: ... fibres are permanently damaged Damage to paintwork 1 Gently sand paintwork damage with 600 grit sandpaper 2 Smooth edges 3 Apply one or two coats of repair paint Damage from impact There may be damage to the laminate beneath the paintwork in the case of impact damage The carbon seat post may break even under light stress 1 Take ebike out of service 2 New carbon seat post as specified in the parts...

Page 176: ...d protective 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 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 no 9170 001 7 Lubricate pressure ...

Page 177: ... Remove outer sleeve from the seat post remote control Figure 151 Removing the cartridge 4 Use a 5 mm to undo Postpin axle and pull out Figure 152 Undoing the Postpin axle 5 Pull cartridge from the piston rod while pushing the outer sleeve into the frame at the same time to help Figure 153 Pulling the cartridge out 6 Hold the cartridge with one hand at the height of the mechanism and pull the cabl...

Page 178: ...ushing tube out of the seat tube Figure 157 Removing the outer sleeve and slide bushing Caring for the outer sleeve 1 Detach spring washer or outer sealing ring Figure 158 Removed spring washer 2 Carefully remove the wiper from the groove Figure 159 Removing the wiper 3 Use a small sharp object to look for and remove the end of the felt ring 4 Carefully take out the felt ring 5 Remove felt ring 6 ...

Page 179: ... fastening the wiper Cleaning the slide bushing 1 Clean the slide bushing tube with a damp cloth Figure 164 Cleaning the slide bushing tube Increasing the air pressure 1 Use 3 mm hex spanner to unscrew valve cap Figure 165 Unscrewing the valve cap 2 Screw valve adapter into mounting interface from below Figure 166 Screwing the valve adapter in 3 Use compression pump to pump the cartridge up to 24 ...

Page 180: ...inst twisting with a 24 mm combination wrench Figure 170 Securing against twisting 3 Set the torque to 18 Nm with a torque wrench and a 6 mm hex bit with a shaft length of at least 25 mm Rotate clockwise Figure 171 Setting in a clockwise direction 4 Use a 3 mm hex spanner to screw the valve lid on and tighten with a maximum of 0 5 Nm Figure 172 Fastening the cartridge valve lid Notice The cartridg...

Page 181: ...t and incorrect cable 4 Carefully push cartridge into the seat tube Pull the cable out of the frame to help Figure 177 Fastening the cartridge valve lid 5 Look at the frame interface through the hole in the Postpin Push the cartridge down until the Postpin mounting interface on the seat post reaches the Postpin interface on the frame 6 If necessary turn the seat post slightly and push it to the co...

Page 182: ...in the outer sleeve Turn outer sleeve into the right position Figure 182 Fastening the outer sleeve 14 Feed height adjustment clamp into the seat tube The two height adjustment clamp guides are in the longitudinal grooves inside the seat post Figure 183 Feeding the height adjustment clamp in 15 Push the seat post carefully downwards and feed into the wiper Figure 184 Pushing the seat post downward...

Page 183: ...he seat post 3 Pull out the special end cap for the outer sleeve from the bracket 4 Detach the cable head from the hydraulic activation lever bracket 5 If necessary operate the lever by hand to make more space for detaching it Figure 190 Removing the cable Removing the outer sleeve and slide bushing 1 Use a 3 mm hex spanner to remove attachment screw on the outer sleeve 2 Detach outer sleeve by pu...

Page 184: ... a cloth Figure 196 Cleaning the outer sleeve 10 Carefully re insert dry felt ring with one end in the designated groove 11 Unfurl felt ring within the outer sleeve so that it lies on the groove 12 Carefully press felt ring into the groove by hand Ensure that both ends are fully pressed in and meet and that they do not overlap and are not twisted Figure 197 Inserting the felt ring 13 Insert cleane...

Page 185: ...il it will go no further Figure 201 Pulling the seat post out 3 Clean the seat post longitudinal grooves with a damp cloth Figure 202 Cleaning the longitudinal groove 4 Apply grease into the longitudinal groove and on both cross pieces Figure 203 Applying grease 5 Push seat post together Figure 204 Pushing the seat post together 6 Push the height adjustment operating lever backwards Figure 205 Clo...

Page 186: ...ed Figure 207 Attaching and pushing in the seat post 4 Hold the cable firmly on the handlebars while feeding it in Carefully pull the end of the cable from the frame so that the seat post slides downwards unhindered Figure 208 Attaching the end cap 5 Look at the frame interface through the hole in the Postpin Push the seat post down until the Postpin mounting interface on the seat post reaches the...

Page 187: ...lways wear safety goggles and nitrile gloves when carrying suspension oil Never perform maintenance when you are pregnant Use an oil catchment tray under the section where the rear shock is being serviced 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 Lubri...

Page 188: ...rks rear shocks and suspension seat posts Maintenance includes a complete inspection of interiors exteriors All shocks are reconditioned The airtight seals are replaced in air suspension forks The air spring is reconditioned The oil is changed The dust wipers are replaced More information at www foxracingshox com ...

Page 189: ...hed 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 battery 8 Start...

Page 190: ...e 1 Switch off the drive system 2 Leave ebike 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 conditions the gear level and the...

Page 191: ...hen 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 with the battery 4 Con...

Page 192: ...orrectly contact your specialist dealer A component may be connected which the system is unable to recognise Contact specialist dealer The gear level is not shown on the display screen The gear level is only shown if the electronic shifter is used 1 Check that the power cable connector has not been disconnected 2 If this is not the case contact your specialist dealer The settings menu cannot be op...

Page 193: ...l assistance becomes weaker 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 your specialist dealer It is normal to hear a noise coming from the rear wheel when cycling as normal The shifter setting may not have been made properly Contact your specialist dealer If the ebike is...

Page 194: ...in an uncontrolled way This impairs traction and control blue line Fork crown 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 211 Suspension fork rebounding too quickly Solution Figure 212 Suntour rebound screw 1 Turn rebound screw in a clockwise direction The rebound speed is decreased sl...

Page 195: ...he hardness of impacts Available travel traction and control decrease blue line The fork remains in a compressed state causing the headset and handlebars to move to a lower position Body weight is shifted forward after the impact green line Figure 213 Suspension fork rebounding too slowly Solution Figure 214 Suntour rebound screw 1 Turn rebound screw in an counter clockwise direction The rebound s...

Page 196: ... forward and the ebike loses some momentum Figure 215 Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 216 Changing compression adjuster to a harder setting Turn compression adjuster in a clockwise direction towards LOCK The damping and compression hardness are increased decreasing stroke speed Efficiency on hilly and flat terrain is improved 1 2 ...

Page 197: ...r touches the ground The headset and handlebars move upwards significantly which can impair control Figure 217 Excessively hard damping in the suspension fork on bumps Solution Figure 218 Changing compression adjuster to a softer setting Turn compression adjuster in a clockwise direction towards OPEN The damping and compression hardness reduces and the stroke speed is increased Sensitivity to smal...

Page 198: ...and control due to the uncontrolled speed at which the shock rebounds after compresion blue line Saddle and handlebars move upwards when the wheel bounces back from the ground The rider s body weight may be shifted upwards and forwards if the shock fully rebounds too quickly green line Figure 219 Rear shock rebounding too quickly Solution Figure 220 Suntour rebound adjuster wheel 1 on the rear sho...

Page 199: ...h to make contact with the ground and return to the initial position again The available travel and traction are reduced blue line The rear shock remains in a compressed 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 travel and potential absorption of bumps ar...

Page 200: ...ight shifts forward and the bicycle loses some momentum Figure 223 Excessively soft suspension in the rear shock on hilly terrain Solution Figure 224 Suntour compression adjuster 1 on the rear shock 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 1 ...

Page 201: ...e and rider are pushed upwards and forwards the rear wheel loses contact with the ground and control is reduced green line Figure 225 Excessively hard damping in the rear shock on bumps Solution Figure 226 Suntour compression adjuster 1 on the rear shock Turn compression adjuster counter clockwise The damping and compression hardness is reduced and the stroke speed is increased Sensitivity to smal...

Page 202: ...9 2 2 Replacing the lighting Only use components of the respective power class for replacement 9 2 3 Setting the front light The front light must be set so that its light beam shines on the road 30 feet in front of the ebike 9 2 4 Checking tire clearance The tire needs to be checked each time a suspension fork tire is changed to another size 1 Release pressure from the fork 2 Press fork together f...

Page 203: ...own as set up in the BOSCH eBike Connect app 9 2 5 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 5 3 Activating the lock function after motor replacement The lock function is displayed as deactivated in the eBike Connect app when the motor has been replace...

Page 204: ...ce with applicable statutory regulations Separate collection and recycling saves reserves of raw materials and ensures that all the regulations for protection of health and the environment are adhered to when recycling the product and or the battery 10 1 Removal of waste guidelines Waste type Disposal Non hazardous waste Recycling Waste paper cardboard Return paper collection bin paper container u...

Page 205: ... 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 quantities usually 30lbs Take to municipal collection points for hazardous waste e g mobile hazardous waste collection service Larger quantities lbs Collection by waste disposal companies Paints Varnishes Thinn...

Page 206: ... 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 shock 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 Brake lever Check mount fastening O K Loos...

Page 207: ...ment O K ebike travelling 10 too fast slow Take ebike 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 motor manufact...

Page 208: ...ghten 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 Functional check O K No ring too qu...

Page 209: ... necessary Front lamp 6 months Side light daytime riding light Functional check O K No constant light New front 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 Drivetrain Shifting Chain cassette pinion chainring 6 months Check for damage O K Damage Refasten if neces sary or replace as specified in...

Page 210: ...motor take out of service Software 6 months Check version In latest version 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 ...

Page 211: ...210 Notes ...

Page 212: ...120 mm Derailleur Shimano Deore RD M5120 SGS Gear 10 speed Crankset FSA 165 mm Cassette Shimano CS M4100 11 46T Brakes Tektro TR203 45 HD M530 203 180 mm Handlebar BULLS Alloy 31 8mm 740mm 25mm raise 9º back swept Stem SUVi internal cable routing Seatpost Limotec A1 Z dropper post 30 9mm Seat Iconic SUV Hubs Formula CL 811 ECT 148S Rims Ryde Disc 30 Tires Supero All Ground 62 584 27 5 x 2 40 Pedal...

Page 213: ...212 About these operating instructions ...

Page 214: ...5120SGS Gear 10 speed Crankset FSA 165 mm Cassette Shimano CS M4100 11 42T Brakes Tektro HD M390 hydraulic disc 180 180mm Handlebar BULLS Alloy 31 8mm 740mm 25mm raise 9º back swept Stem aluminum adjustable Seatpost Limotec A3 Z dropper 30 9 mm Seat Iconic SUV Hubs Formula HCL 81 CL 2241QR Rims Ryde Disc 30 Tires Supero All Ground 62 584 27 5 x 2 40 Pedals Wellgo C 098DU black body Front light Fux...

Page 215: ...214 About these operating instructions ...

Page 216: ...120SGS Gear 10 speed Crankset FSA 165 mm Cassette Shimano CS M4100 11 42T Brakes Tektro HD M390 hydraulic disc 180 180 mm Handlebar STYX MTB Alloy 31 8mm 740mm 25mm raise 9º back swept Stem aluminum adjustable Seatpost Limotec A3 Z dropper 30 9 mm Seat Iconic SUV Hubs Formula HCL 81 CL 2241QR Rims Ryde Disc 30 Tires Supero All Ground 62 584 27 5 x 2 40 Pedals Wellgo C 098DU black body Front light ...

Page 217: ...216 About these operating instructions ...

Page 218: ... RD M5100 SGS Gear 11 speed Crankset FSA 165 mm Cassette Shimano CS M5100 11 11 51T Brakes Shimano HD M390 180 180 mm Handlebar STYX MTB Alloy 31 8mm 740mm 25mm raise 9º back swept Stem Aluminium adjustable Seatpost Limotec A3 Z dropper 30 9 mm Seat Iconic SUV Hubs Shimano HB MT200 FH MT200 B Rims Ryde Disc 30 Tires Supero All Ground 62 584 27 5 x 2 40 Pedals Wellgo C 098DU black body Front light ...

Page 219: ...218 About these operating instructions ...

Page 220: ...219 About these operating instructions ...

Page 221: ...220 About these operating instructions ...

Page 222: ...221 About these operating instructions ...

Page 223: ...222 About these operating instructions ...

Page 224: ...223 Documents 11 4 Charger operating instructions ABCDE ...

Page 225: ...224 Documents F 4A Charger DCG F H A I A J ...

Page 226: ...225 Documents F A I A J DCG F H ...

Page 227: ...226 Documents F DCG F H A I A J ...

Page 228: ... 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 229: ...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 P I ...

Page 230: ...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 regional and national law R N N Nb O P I I Q O Q 9 A I A J DCG F H ...

Page 231: ...ctional capability Disc brake Source EN 15194 2017 brake in which brake pads are used to grip the lateral faces of a thin rotor 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 components provid...

Page 232: ...osition and with the seat post set to the minimum insertion depth mark Maximum tire pressure Source EN 15194 2017 maximum tire pressure recommended by the tire or rim manufacturer for a safe and efficient performance If the rim and tire both indicate a maximum tire pressure the maximum inflation pressure is the lower of the two pressures indicated Minimum insertion depth Source EN 15194 2017 mark ...

Page 233: ...l number Source BULLS each ebike has an eight digit type number which is used to specify the design model year the type and the version Shut off speed Source EN 15194 2017 speed reached by the ebike at the moment the current has dropped to zero or to the no load current value Slippage Source DIN 75204 1 1992 05 the difference in relation to vehicle speed between the vehicle speed and the speed of ...

Page 234: ...ar in which the ebike was manufactured The production period is always from May to July the following year 12 1 Abbreviations ABS anti locking system ECP electronic cell protection 12 2 Simplified terms The following terms are used for better legibility Term Meaning Operating instruc tions Original operating instruc tions Damper Rear shock Specialist dealer Bicycle specialist dealer Motor Drive mo...

Page 235: ...nery Directive 2006 42 EC RoHS Directive 2011 65 EU Electromagnetic Compatibility Directive 2014 30 EU The safety objectives in No 1 5 1 of the Machinery Directive 2006 42 EC The following harmonised standards have been applied ISO 4210 2 Cycles Safety requirements for bicycles EN 15194 2017 Cycles Electrically power assisted cycles EPAC Bicycles The following other technical standards have been a...

Page 236: ...onformity with RED Directive Robert Bosch GmbH Bosch eBike Systems hereby declares that the LED Remote radio system type complies with Directive 2014 53 EU The complete EU declaration of conformity is available online at https www ebike connect com conformity ...

Page 237: ...uard 16 Chain tension checking 155 Chainring 41 Chain wheels cleaning 139 Chain 25 41 cleaning 140 maintaining 147 156 servicing 144 Charger 43 disposing of 203 Frameset 26 Child seat 113 Clamping force Adjusting the quick release 66 Checking quick release 66 Clock setting 111 Compression adjustment 30 Compression damper 31 Control panel cleaning 137 Crown 31 D Dimensions 58 Direction of travel 41...

Page 238: ...light 42 Rear wheel brake 39 Rebound adjuster 31 Rebound damping 30 Reflector Position 25 Retainer guard 43 Riding light switching off 123 switching on 123 Rim brake locking lever 38 Rim 36 servicing 143 S Saddle 118 changing the saddle tilt 80 changing the seat length 82 cleaning 138 determining the saddle height 80 82 using 118 Sag Position of setting wheel 45 Setting wheel 31 Seat post 40 clean...

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