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Bosch BULLS KIOX300, Translation Of Original Operating Instructions

The Bosch BULLS KIOX300 is a cutting-edge electric bike equipped with advanced features for an exhilarating ride. To fully understand its capabilities, it is crucial to have the "Translation Of Original Operating Instructions" manual. Download it for free from our website to ensure optimal usage of this exceptional product.

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22-15-1069…22-15-1077, 22-15-1087…22-15-1089, 22-15-4007…22-15-4009

MY22B0a - 62_1.0_16.09.2021

CROSS LITE EVO 1, CROSS LITE EVO 2, CROSS MOVER EVO 3, CROSS RIDER EVO 2, 

ICONIC EVO TR 1, ICONIC EVO TR 2

Translation of original operating instructions for 

BULLS Pedelecs with BOSCH KIOX300 Display and 

LCD Remote on-board computer

IMPORTANT

READ CAREFULLY BEFORE USE

KEEP SAFE TO CONSULT AT A LATER DATE

Summary of Contents for BULLS KIOX300

Page 1: ...SS LITE EVO 1 CROSS LITE EVO 2 CROSS MOVER EVO 3 CROSS RIDER EVO 2 ICONIC EVO TR 1 ICONIC EVO TR 2 Translation of original operating instructions for BULLS Pedelecs with BOSCH KIOX300 Display and LCD Remote on board computer IMPORTANT READ CAREFULLY BEFORE USE KEEP SAFE TO CONSULT AT A LATER DATE ...

Page 2: ... release setting 14 2 1 3 2 Incorrect 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 guar...

Page 3: ... system 42 3 3 8 1 Motor 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...

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

Page 5: ...ng the Suntour rear frame damper 103 6 5 16 Compression adjuster on rear frame damper 104 6 5 16 1 Adjusting the Suntour compression adjuster 105 6 5 17 Lighting 106 6 5 17 1 Adjusting the lights 106 6 5 18 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 1...

Page 6: ...24 6 19 Brake 125 6 19 1 Using the brake lever 125 6 20 Gear shift 126 6 20 1 Using the derailleur gears 126 6 21 Parking 127 6 21 1 Screwing in the quickly adjustable stem 128 6 21 2 Activating the lock function 129 7 Cleaning servicing and maintenance 7 1 Before each ride 134 7 1 1 Checking the guards 134 7 1 2 Checking the frame 134 7 1 3 Checking the fork 134 7 1 4 Checking the rear frame damp...

Page 7: ...ars 142 7 4 8 Handle 142 7 4 8 1 Rubber handles 142 7 4 8 2 Leather handle 142 7 4 9 Seat post 143 7 4 9 1 Suspension seat post 143 7 4 9 2 Carbon seat post 143 7 4 10 Rim 143 7 4 11 Leather saddle 143 7 4 12 Hub 143 7 4 13 Spoke nipples 143 7 4 14 Gear shift 144 7 4 14 1 Rear derailleur articulated shafts and jockey wheels 144 7 4 14 2 Shifter 144 7 4 15 Pedal 144 7 4 16 Caring for the chain 144 ...

Page 8: ...8 Maintenance 8 1 Initial inspection 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 Adj...

Page 9: ...1 9 2 5 Replacing pedelec 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 Cross Lite EVO 1 211 11 3 2 Cros...

Page 10: ...stribution or reproduction of these operating instructions and utilisation 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...

Page 11: ...an A translation is invalid without the original operating instructions 1 4 For your information Different markings are used in the operating instructions to make them easier to read 1 4 1 Warnings Warnings indicate hazardous situations and actions You will find three warnings in the operating instructions 1 4 2 Markups You will find ten text markups in the operating instructions May lead to serio...

Page 12: ... and trekking bicycle 22 15 1071 Cross Lite Evo 2 Wave City and trekking bicycle 22 15 1072 Cross Lite Evo 2 Wave City and trekking bicycle 22 15 1073 Cross Lite Evo 2 Wave City and trekking bicycle 22 15 1074 Cross Lite Evo 1 Gent City and trekking bicycle 22 15 1075 Cross Lite Evo 1 Trapez City and trekking bicycle 22 15 1076 Cross Lite Evo 1 Wave City and trekking bicycle 22 15 1075 Cross Rider...

Page 13: ...l staff are highlighted 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 ...

Page 14: ...e Protect the 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 pa...

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

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

Page 17: ...physical sensory or mental capacities or lacking in experience and knowledge If minors use the pedelec 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 Fluor...

Page 18: ... surfaces and 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 li...

Page 19: ...of pain or discomfort 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 cons...

Page 20: ... means of transport In addition to being physically fit riders need time to adapt to using the pedelec Appropriate training is required for its use It is especially impor tant to practice braking and riding around bends The strain on hands wrists arms shoul ders the neck and back is considerable Inexperienced riders tend to brake too hard and lose control as a result Racing bikes are designed for ...

Page 21: ...itions stunt riding 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...

Page 22: ...ez 150 22 15 1071 Cross Lite Evo 2 Wave 150 22 15 1072 Cross Lite Evo 2 Wave 150 22 15 1073 Cross Lite Evo 2 Wave 150 22 15 1074 Cross Lite Evo 1 Gent 150 22 15 1075 Cross Lite Evo 1 Trapez 150 22 15 1076 Cross Lite Evo 1 Wave 150 22 15 1075 Cross Rider Evo 2 Gent 135 22 15 1076 Cross Rider Evo 2 Trapez 135 22 15 1077 Cross Rider Evo 2 Wave 135 22 15 1087 Iconic Evo TR 1 135 22 15 1088 Iconic Evo ...

Page 23: ...for 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 ...

Page 24: ...Never drive off road or perform jumps Never drive off road or perform jumps Never drive off road or perform jumps Never drive off road or perform jumps over 15 cm Never drive off road or perform jumps over 15 cm Never drive off road or perform jumps over 15 cm Never drive off road or perform jumps over 15 cm Never ride downhill or perform jumps over 61 cm Never ride downhill or perform jumps over ...

Page 25: ...um permitted total weight is the weight of the fully assembled pedelec with the rider plus baggage 6 Year of manufacture The year of manufacture is the year in which the pedelec was manufactured 7 Pedelec type Each pedelec is assigned a pedelec type which determines its proper use function and area of use Section 3 2 8 Safety markings Safety markings warn of hazards Section 2 6 9 Disposal instruct...

Page 26: ...ront light 6 Steering headset 7 Handlebars 8 Stem 9 Frame 10 Seat post 11 Saddle 12 Pannier rack 13 Rear light 14 Reflector 15 Rear wheel mudguard 16 Rear wheel brake 17 Rear wheel 18 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...

Page 27: ...ng headsets for threadless 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...

Page 28: ...plays see Section 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 Fork steerer 2 Side reflectors optional 3 Fork end 4 Fork leg 1 2 3 1 2 3 4 ...

Page 29: ...h from being channelled directly into the body via the fork The impact is absorbed by the suspension system instead This causes the suspension fork to compress After compressing the suspension fork returns to its original position If the bike has a damper the damper will slow this movement down It thus prevents the suspension system from springing back in an uncontrolled manner and the fork from o...

Page 30: ...ine when riding over bumps 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 th...

Page 31: ...ollow terrain 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 pedelecs 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 ...

Page 32: ...wn 4 Dust seal 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 whee...

Page 33: ...ed The rear wheel does not bounce off rough surfaces or the ground it stays in contact with the ground instead blue line The saddle is raised slightly if the bump is compensated and gently sinks downwards when the suspension deflects as soon as the wheel touches the ground after the bump The rear frame damper rebounds in a controlled way so that the rider remains sitting in a horizontal position w...

Page 34: ...usted the rear frame damper deflects quickly and unhindered when the bike hits bumps and absorbs a bump Traction is retained blue line The saddle rises slightly when absorbing a bump green line Figure 17 Optimum rear frame damper ride performance over bumps ...

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

Page 36: ...ntrolled 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 frame damper riding performance Rear frame damper compression adjuster Only applies to pedelecs with this equipment The compression adjuster controls the compression lifting speed or the rate at which the...

Page 37: ...nsmit the driving braking and steering forces The tread can also help improve control on dirty road surfaces If a tyre 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 tyre with a new one with a shallow tread Figure 22 Example Information on tyres Tyre pressure The permitted pressure range is i...

Page 38: ...alve Figure 25 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 tighteni...

Page 39: ...rgency 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 wire inside the shift cable also known as a Bowden cable Figure 26 Bowden cable structure 3 3 5 2 Hydraulic brake The brake fluid is in a closed hos...

Page 40: ... is screwed 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 cables to the cylinders in the brake calliper The braking force is boosted by a speed reduction and applied to the brake linings These apply the brake disc mechanically If the brake lever is pushed the brake linings are pressed against the b...

Page 41: ...s to ensure sufficient tension when tightening the screw Patent 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 bum...

Page 42: ...ction of travel 2 Chain or belt 3 Rear chain wheel or belt pulley 4 Front chain wheel or belt pulley 5 Pedal The pedelec 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 Back pedal brake Hub gear or Derailleur gears 3 3 7 2 Belt drive layout Figure 33 Belt drive 1 Front be...

Page 43: ...cy 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 pedelec The batte...

Page 44: ...4 A Charger BPC3400 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 pedelec Figure 35 Overview of integrated battery Figure 36 Detail of PowerTube 750 1 Securing hook 2 Battery lock 3 Bat...

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

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

Page 47: ...bol Designation 1 Selected level of assistance indicator 2 ABS indicator optional 3 Battery level indicator control panel 4 Select button 5 On Off button control panel 6 Ambient light sensor Table 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...

Page 48: ... maximum capacity The two lower indicators will change colour if the capacity is low Table 14 Battery level indicator control panel The uppermost bar will flash if the battery is charging 3 4 2 1 System message The control panel indicates whether a critical or less critical error has arisen in the drive system The error messages generated by the drive system can be read in the eBike Flow app and b...

Page 49: ... Your location will only be logged if the on board computer is connected to the eBike Connect app Activities will be displayed after synchronisation in the app and on the portal 3 4 2 5 Lock function When the lock function is used the on board computer acts in a similar way to a key for the drive system Once the lock function is switched on the e bike drive unit assistance is deactivated by removi...

Page 50: ...tance the more 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 f...

Page 51: ...r 2 Selected 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...

Page 52: ...level indicator 1 The five green LEDs on the battery level indicator battery show the charge level when the battery is switched on Each LED represents about 20 battery capacity All five LEDs will light up when the battery is fully charged If the battery level falls below 5 all the LEDs on the operating status and battery level indicator will go out 1 ...

Page 53: ...5 1 SHIMANO SW E7000 derailleur gears Only applies to vehicles with this equipment The gear shift unit is on the left of the handlebars The gear shift unit features 2 buttons Figure 44 SHIMANO SW E7000 gear shift 1 Up button gear shift 2 Down button gear shift 1 2 ...

Page 54: ...brake There is a hand brake 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: ... Table 19 Bicycle lighting Output voltage 4 75 5 4 V Output current max 1 5 A Operating temperature 5 40 C Storage temperature 10 40 C Protection class IP54 Table 20 Technical data for BOSCH Display Mount BDS3210 BDS3250 BDS3620 BDS3630 Internal lithium ion battery 3 7 V 75 mAh Charging temperature 0 C 45 C Operating temperature 5 C 40 C Storage temperature 10 C 50 C Protection class IP54 Dimensio...

Page 56: ...minal voltage 36 V Nominal capacity 20 1 Ah Energy 750 Wh Weight 4 4 kg Protection class IP54 Operating temperature 5 40 C Storage temperature 10 40 C Permitted charging temperature range 0 40 C Table 24 Technical data for BOSCH PowerTube 750 BBP3770 horizontal BBP3771 vertical ...

Page 57: ...tpins Attachment screw Bowden 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 g...

Page 58: ...rew for outer sleeve 8 Nm 18 Nm 0 5 Nm 8 Nm 8 Nm 0 5 Nm 6 mm hex bit 3 mm hex bit 5 mm hex bit 5 mm hex bit 3 mm hex bit 3 mm hex bit LIMOTEC LimoDP 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 spanner Table 25 Tightening torques and bits ...

Page 59: ... weight kg 22 15 1069 45 cm 50 cm 55 cm 60 cm 22 15 1070 45 cm 50 cm 55 cm 22 15 1071 45 cm 22 15 1072 45 cm 50 cm 55 cm 60 cm 22 15 1073 45 cm 50 cm 55 cm 22 15 1074 45 cm 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 pedelec 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 40...

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

Page 61: ...The pedelec needs 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 pedelec battery and charger in a dry clean environment We recommend st...

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

Page 63: ...e immediately after being assembled The assembly report see Section 11 2 describes all safety relevant inspections tests and maintenance tasks All assembly work must be completed to ensure the pedelec is ready to ride Complete an assembly report to document quality assurance see Section 11 1 5 3 1 Checking the battery The battery must be checked before it is charged for the first time Press the On...

Page 64: ...its rear 1 Use 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 batt...

Page 65: ...eds to transmit the drive forces the front wheel is responsible for transmitting braking and steering forces Drive and braking forces have different directions of action This is why some tyres are mounted on the front and rear wheels in opposite directions On these tyres there are two rotation direction arrows The FRONT rotation direction arrow indicates the recommended direction of rotation for t...

Page 66: ...ont wheel into 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...

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

Page 68: ...e lever must be flush with the shock absorber Figure 60 Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner 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: ...ulty or incorrectly installed quick release may become caught in the brake disc and block the wheel This will cause a crash Never fit a defective quick release Crash caused by faulty or incorrectly installed quick release The brake disc becomes very hot during operation Parts of the quick release may become damaged as a result The quick release comes loose This will cause a crash with injuries The...

Page 70: ...e 66 Example of markings on pedals 1 Coat threads in both pedals with waterproof grease 2 Turn the pedal marked L anti clockwise by hand into the crank arm on the left as seen when facing the direction of travel Figure 67 L pedal in the left hand crank arm 3 Turn the pedal marked R anti clockwise by hand into the crank arm on the right as seen when facing the direction of travel Figure 68 R pedal ...

Page 71: ... calculate 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 Bowden cable must be tightened in the frame up to the remote control to the same length as the seat post was lowered 4 Trim the seat post Bowden cable on the handlebars if necessary ...

Page 72: ... the handlebars cannot be fastened contact your specialist dealer Stem with clamping lever version II and stem with screw If the handlebars cannot be fastened contact your specialist dealer 5 3 6 3 Checking the headset backlash 1 Place the fingers of one hand on the upper headset cup Pull the front wheel brake with the other hand and try to push the pedelec backwards and forwards Keep in mind that...

Page 73: ...used to road traffic and speed before riding at speeds over 12 km h especially if you have not ridden a bike for some time Increase the levels of assistance gradually Practice braking hard on a regular basis Take and complete a riding safety course WARNING Injuries and death caused by distraction A lack of concentration while riding increases the risk of an accident This may cause a crash with ser...

Page 74: ... braking distance The braking sensation differs from the usual sensation This can cause loss of control or a crash which may result in injuries Ride slowly and brake in good time when it is raining CAUTION Crash caused by soiling Heavy soiling can impair pedelec functions such as braking This may cause a crash with injuries Remove coarse soiling before riding Notice Heat or direct sunlight can cau...

Page 75: ...ter the range is Gear shift 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 are optimal Avoid high stress loads on the crank during a gear change Switch gear back in good time e g before inclines Tyres Always select the right tyres for the surface type As a general rule narrower treads move along m...

Page 76: ...nd short circuits by Electronic Cell Protection ECP In the event of a hazard a protective circuit switches the battery off automatically If a fault is detected in the battery the LEDs flash on the battery level indicator Code Description Method of resolution 0x523005 0x514001 0x514002 0x514003 0x514006 The sensors do not detect the magnetic field properly Check that the magnet wasn t lost while ri...

Page 77: ...justing the pedelec Only a correctly adjusted pedelec will guarantee the desired ride comfort and health promoting activity All settings must be re configured if the body weight or maximum baggage weight changes 6 5 1 Preparing The following tools are required to adjust the pedelec Crash caused by incorrectly adjusted torques If a screw is fastened too tightly it may break If a screw is not fasten...

Page 78: ...rs 6 5 5 3 Stem 6 5 6 4 Handles 6 5 7 x 5 Tyres 6 5 10 6 1 6 2 6 3 6 4 6 5 Brake Position of the brake handles Brake handle tilt angle Determine grip distance Adjust the grip distance Pressure point Retract the brake linings 6 5 9 1 6 5 9 2 6 5 9 3 6 5 9 4 6 5 9 8 6 5 9 4 7 Adjust suspension Adjust suspension fork sag 6 5 11 x Adjust the rear frame damper sag optional 6 5 12 x Adjust suspension fo...

Page 79: ... green or incorrect position red The pelvis is in the right position if the spine forms an S shape and a natural easy arch The pelvis is positioned incorrectly if it tilts slightly backwards As a result the spine becomes curved and can no longer deflect to an optimal extent A suitable sitting position must be selected beforehand depending on the pedelec type physical fitness and desired trip dista...

Page 80: ...height 0 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 th...

Page 81: ...st the saddle height safely either Push the pedelec near to a wall so that the rider can lean on the wall to support themselves or Ask another person to hold the pedelec 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 poi...

Page 82: ...ower 3 Release 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 ...

Page 83: ... Figure 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 optimised in this way if needed...

Page 84: ...handlebars are 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 pedelec 1 After selecting the seating position see Section 6 6 2 1 determine the angle of the upper bod...

Page 85: ...usting the quick 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...

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

Page 87: ...ustable stems are available in different lengths for quill and Ahead 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: ...handle A greater 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: ... low tyre pressure often leads to premature wear in the tyre Cracking in the side wall is a typical consequence of very low tyre pressure Abrasion is also unnecessarily high On the other hand a tyre can absorb road impacts more effectively at a low pressure As a general rule wide tyres are operated at a lower tyre pressure They provide the option of exploiting the advantages of the lower tyre pres...

Page 90: ...ndlebar 2 Extend 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 handle 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 na...

Page 91: ...stance 1 Measure hand size using the grip distance gauge 2 Adjust the grip distance at the pressure point based on the hand size Figure 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: ...king force increases over time The braking force is increased during break in time This is also the case when the brake pads or brake discs are replaced 1 Accelerate pedelec to 25 km h 2 Brake pedelec until it comes to a halt 3 Repeat process 30 to 50 times The disc brake is retracted and provides optimal braking power ...

Page 93: ... low tyre pressure often leads to premature wear in the tyre Cracking in the side wall is a typical consequence of very low tyre pressure Abrasion is also unnecessarily high On the other hand a tyre can absorb road impacts more effectively at a low pressure As a general rule wide tyres are operated at a lower tyre pressure They provide the option of exploiting the advantages of the lower tyre pres...

Page 94: ...on can be adjusted to the rider s requirements Such adjustment does not affect the pressure point or the position of the brake linings Turn setting screw anti clockwise towards minus The brake lever moves closer to the handlebar grip Turn setting screw clockwise towards plus The brake lever moves away from the handlebar grip Figure 95 Setting screw position 1 1 ...

Page 95: ...ANO ST EF41 brake lever Only applies to pedelecs 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: ...de and is generally used on bicycles with a longer deflection The adjustment shown here represents a basic setting The rider should change the basic setting to suit the surface 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 optimised settings and as a safeguard against unintentional changes For pedelecs with comp...

Page 97: ...own Remove the 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 anti clockwise to decrease the spring pre tensioning You will have made the ideal setting when the shock absorber deflects 3 mm when subject to body weight 3 Replace the plastic cover on the crown after making ...

Page 98: ...ge 7 Sit on the pedelec in your usual riding position and support yourself against an object such as a wall or tree 8 Get off the pedelec without allowing it to deflect 9 Measure distance between the dust seal and the cable tie This measurement is the sag The recommended value is between 15 hard and 30 soft of the total fork deflection 10 Increase or reduce air pressure until you have reached the ...

Page 99: ...nd is used on pedelecs with a longer deflection Decreased sag 10 20 A decreased sag reduces sensitivity to bumps thus producing less suspension motion A lower sensitivity to bumps ensures a firmer more efficient ride performance and is generally used on pedelecs with a shorter deflection The adjustment shown here represents a basic setting The rider should change the basic setting to suit the surf...

Page 100: ...er body to gauge the sag correctly 7 Put on your normal cycling clothing including baggage 8 Sit on the pedelec in your usual riding position and support yourself against an object such as a wall or tree 9 Push the O ring or cable tie downwards against the air chamber seal 10 Get off the pedelec without the suspension fork deflecting 11 Measure the distance between the air chamber seal and the O r...

Page 101: ...o body weight spring stiffness deflection 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 cont...

Page 102: ...screw in a clockwise direction to the closed position until it stops 2 Turn the rebound screw slightly in an anti 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 sligh...

Page 103: ...nd controlled The rider is not thrown upwards or forwards green line The rebound adjuster setting depends on the air pressure setting A higher sag requires lower rebound damping Figure 100 Optimum rear frame damper riding performance The suspension rebound speed affects the wheel s contact with the ground which in turn has an influence on control and efficiency The damper should rebound fast enoug...

Page 104: ...ly applies to pedelecs with this equipment Figure 101 Suntour rebound adjuster wheel 1 on the rear frame damper The sag in the rear frame damper is adjusted Turn rebound wheel towards minus The rebound movement is increased Turn rebound wheel towards plus The deflection movement is reduced 1 ...

Page 105: ...ard on bumpy terrain Figure 102 Optimum rear frame damper ride performance over bumps Threshold The damping threshold prevents deflection until a medium impact or downward force occurs Threshold mode increases drive efficiency over level terrain The threshold setting can be used to improve pedalling efficiency over flat hilly level or slightly rugged terrain In threshold mode higher pedelec speeds...

Page 106: ...sition 2 Ride the pedelec over a small obstacle Turn compression adjuster anti clockwise The damping and compression hardness is reduced The deflection stroke speed is increased Turn compression adjuster clockwise The damping and compression hardness is increased The deflection stroke speed is reduced 3 The ideal setting for the rebound damper has been achieved when the rebound movement of the rea...

Page 107: ...sk Example 3 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 pedelec 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...

Page 108: ...high 1 correctly 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 dazzle 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 It the light beam is in front of the wall move f...

Page 109: ...vel indicator 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 a...

Page 110: ...ey to switch on the pedelec the battery and control panel can still be used on another unblocked pedelec 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 o...

Page 111: ...NGS menu Open 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 ...

Page 112: ...clock 1 Open System 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 ...

Page 113: ...ese operating 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: ...niers system component 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 atta...

Page 115: ...URLY CROOZER THULE Crash caused by brake failure The braking distance may be longer if the trailer is carrying excessive load The long braking distance can cause a crash or an accident and injuries Never exceed the specified trailer load Notice The operating and safety instructions for the trailer system must be observed The statutory regulations on the use of bicycle trailers must be observed Onl...

Page 116: ...reasons 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 s...

Page 117: ...ned so that it does not dazzle 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 pedelec must work at all times 8 The clear sounding bell must be fitted and must work 6 8 Before each ride Check pedelec before each ride see section 7 1 Be alert to any unusual noises vibrations or odours while riding Be alert...

Page 118: ...eer and brake This can lead to a loss of control This may cause a crash with injuries You should practice how to use a loaded pannier rack safely before using the pedelec in public spaces Crushing the fingers in the spring flap The spring flap on the pannier rack operates with a high clamping force There is a risk of crushing the fingers Never allow the spring flap to snap shut in an uncontrolled ...

Page 119: ... from material beneath and mould can form If the leather handles get wet dry handles completely 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 handle position to avoid overstraining and tiring the hands 6 14 1 Using leather handles ...

Page 120: ...tery key from the battery lock 6 16 1 1 Inserting the battery The key is inserted in the lock The lock is unlocked Figure 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 he...

Page 121: ...to the battery s charging port The charging process starts automatically The battery level indicator shows the charge level during charging When the drive system is switched on the on board computer displays the charging process The charging process is complete when the LEDs on the battery level indicator go out 4 Once charging is complete disconnect the battery from the charger 5 Disconnect the c...

Page 122: ...ctivated as soon as the pedals are moved with sufficient force except if the selected level of assistance is OFF The motor power is based on the level of assistance selected on the control panel 6 17 2 Switching off the electric drive system As soon as the rider stops pushing the pedals in normal mode or reaches a speed of 25 km h the drive system switches off the assistance system The assistance ...

Page 123: ...mputer the display or the display mount as a handle If the on board computer display or display mount are used to lift the pedelec components can become irreparably damaged Symbol Designation 1 Selected level of assistance indicator 2 ABS indicator optional 3 Battery level indicator control panel 4 Select button 5 On Off button control panel 6 Ambient light sensor Table 43 Overview of control pane...

Page 124: ...rightness button to set the brightness of the indicator LEDs 6 18 5 Using the push assist system The push assist helps move the pedelec The push assist system speed depends on the selected gear The lower the selected gear is the lower the speed in the push assist function is at full power The maximum speed is 6 km h We recommend using first gear for cycling uphill to protect the drive Figure 124 P...

Page 125: ...will also switch 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 b...

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

Page 127: ...rs 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 gear shift SL M315 as an example Lever A switches from a smaller pinion to a larger one The number of pinions switched depends on the selected position of lever A Place shifter A in position 1 System shifts one pinion higher Pl...

Page 128: ...roy the tyres Never park the pedelec in the sun On hot days regularly check the tyre pressure and adjust it as necessary Moisture penetrating at low temperatures may impair individual functions due to the open structural design Always keep the pedelec dry and free from frost If the pedelec is used at temperatures below 3 C the specialist dealer must perform maintenance beforehand and prepare it fo...

Page 129: ...ce when parking 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: ...during set up The lock function is activated The drive system now provides no assistance However the rider can continue to use the pedelec without assistance The drive unit will emit a lock sound an audible signal as long as the drive system is switched on The lock function status is displayed with a lock icon on the on board computer for around 3 seconds ...

Page 131: ... 2 1 Clean brake see Section 7 2 5 Clean suspension fork see Section 7 2 2 Care for suspension fork see Section 3 Clean suspension seat post see Section 7 2 6 Clean rear frame damper see Section 7 2 7 Clean the pedals see Section 7 2 4 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 condi...

Page 132: ... Section 7 3 7 1 Care for leather handles see Section 7 4 8 2 Clean the leather saddle see Section 7 3 9 1 Care for leather saddle see Section 7 4 11 Clean handlebars see Section 7 3 6 Cleaning the motor see Section 7 3 3 Clean hub see Section 7 3 12 Cleaning the frame see Section 7 3 4 Clean tyres see Section 7 3 10 Check back pedal brake see Section 7 5 2 5 Clean saddle see Section 7 3 9 Clean s...

Page 133: ... 1 Care for handlebars 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 S...

Page 134: ...d high pressures Damaged brakes can fail and cause an accident with injury Never clean the pedelec with a pressure washer or compressed air Take great care when using a hosepipe Never point the water jet directly at the seal section WARNING Crash and falling caused by unintentional activation There is a risk of injury if the drive system is activated unintentionally Remove the battery before clean...

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

Page 136: ...red check 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 pedelec 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 generate...

Page 137: ...or leaking 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 suspensi...

Page 138: ...tside with a soft damp cloth Tool Cleaning agent Gloves Toothbrush Water Lubricant Cloth Paintbrush Dish washing liquid Brake cleaner Sponge Watering can Degreaser Leather cleaner Brushes Bucket Table 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 ...

Page 139: ...ng can 7 3 7 Handles 1 Clean handles with sponge water and soapy water 2 Rinse off component with water from a watering can 3 Care for rubber handles after cleaning see Section 7 4 8 7 3 7 1 Leather handles 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 so...

Page 140: ...ge 3 Rinse off component with water from a watering can 4 Care for spoke nipples after cleaning see Section 7 4 13 7 3 12 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 gear shift shift cables and transmission with water a bru...

Page 141: ...ly slight pressure while slowly turning the rear wheel so the chain passes through the cloth 4 Wipe off oily dirty chains thoroughly with a cloth and degreaser 5 Care for 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 disc against lubricants a...

Page 142: ...with a cloth 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...

Page 143: ...ply silicone or Teflon oil to the stem shaft tube and the quick release lever pivot point with a cloth 4 If you have a Speedlifter Twist also apply oil to the unlocking bolt groove in the Speedlifter body 5 Apply a little acid free lubricant grease between the stem quick release lever and the sliding piece to reduce the quick release lever operating force 6 If you have a stem with a cone clamp app...

Page 144: ...are products keep leather smooth and resistant brighten its appearance and improve or replace stain protection 1 Try leather care product out on a less visible spot before use 2 Care for leather saddle from below with a leather care product Only care for the top of leather saddles with a leather care product if they are badly worn and dried out 3 Avoid wearing light coloured trousers after care du...

Page 145: ...of oil 3 Remove any surplus lubricant with a clean cloth 4 Spray metal foot rests with silicone spray 7 4 16 Caring for the chain Place newspaper or paper towels underneath to collect chain oil 1 Lift rear wheel 2 Turn the crank briskly in an anti clockwise direction 3 Use slight finger pressure to the chain oil bottle to apply a wafer thin thread of oil to the chain links The faster the crank is ...

Page 146: ...point in time 5 Leave chain oil to penetrate into the chain links for a few hours or overnight 7 4 17 Caring for the battery Grease plug terminals on the battery with terminal grease or contact spray from time to time 7 4 18 Caring for the brake 7 4 18 1 Caring for the brake Lubricate articulated joints and mechanical parts which are accessible from outside with a few drops of spray oil or precisi...

Page 147: ...ose pressure on a continuous basis since the air pressures in a pedelec tyre are significantly higher and the wall thicknesses significantly finer than in a car tyre Pressure loss of 1 bar per month can be regarded as normal During this process the pressure loss is significantly faster at high pressures and significantly slower at low pressures Checking tyre pressure The permitted pressure range i...

Page 148: ... easy bicycle pumps are unsuitable for filling tyres 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 tyre slowly and pay attention to the tyre pressure in the process The tyre 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 t...

Page 149: ...are visible Since resistance to punctures also depends on the thickness of the tread it may make sense to change the tyre at an earlier stage Figure 136 Tyre without tread which can still be used 1 and tyre 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 tyre must be replaced Figure 137 Examples of fatigue c...

Page 150: ...ole If there are 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 tyre bed Check to see if cracks are emerging from the nipple holes If there are cracks radiating from the nipple hole contact your specialist dealer 7 5 1 6 Checking the rim hooks Mechanical impacts can warp the rim hooks There is no longer a guaran...

Page 151: ... 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 linings If any brake fluid leaks from anywhere take pedelec out of service Contact specialist dealer 2 Push brake lever and hold several times If you are unable to clearly dete...

Page 152: ...he brake lining supporting plates If the transport safety wear gauge fits between the supporting plates the brake linings have not reached their wear limit Contact your specialist dealer if they are worn Checking the brake discs Put on gloves as the brake disc is very sharp 1 Take hold of brake disc and joggle it gently to check whether the brake disc is positioned against the wheel free of backla...

Page 153: ...There are sharp corners and edges on the back pedal brake Wear gloves 1 Hold and check counter support to ensure it is firmly attached to rear frame down tube Tighten screw into the counter support if it is loose 2 Carry out brake test Listen for noises while doing so If braking with the backpedal makes noises contact specialist dealer ...

Page 154: ...e twisted If the brake linings twist the brake lining bracket is defective and must be replaced Contact specialist dealer 5 Check that the brake linings move uniformly and symmetrically towards the rim when you pull and release the brake lever If the brake linings move unevenly contact your specialist dealer Checking the rim braking surface for wear The side wall is more prone to wear in rim brake...

Page 155: ...ialist dealer 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 pedelec out of service Contact specialist dealer 4 Place pedelec 5 m from the wall 5 Stand the pedelec up straight Hold the handlebars straight with both hands Do not use the kickstand Figure 139 Light positioned too high 1 correctly 2 and too low 3 6 Check the position of...

Page 156: ...twists tilts or can be pushed in one direction or other If the saddle twists tilts or can be pushed in one direction or other adjust the saddle see Section 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 ...

Page 157: ...on has been achieved if the chain can be pushed between a maximum of 10 and 15 mm in the middle between the pinion and the toothed wheel The crank must also turn without resistance 7 5 10 Checking the gear shift 1 Check whether all gear shift components are free of damage 2 Contact your specialist dealer if components are damaged 3 Place the pedelec on stand 4 Turn the pedal crank clockwise 5 Swit...

Page 158: ... 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 Bowden cable operated gear shift single cable Only applies to pedelecs with this equipment Adjust the play on the adjusting sleeves on the shifter housing to ensure a sm...

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

Page 160: ...aintenance book 8 3 Component specific maintenance tasks High quality components require extra maintenance Maintenance tasks require technical expertise special tools and special lubricants The pedelec may become damaged if the stipulated maintenance intervals and procedures are not carried out This is why only specialist dealers may carry out maintenance Correct maintenance on the fork not only g...

Page 161: ... suspension seat post Maintenance After the first 250 km every 1 500 km 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 mai...

Page 162: ...ervals for hub SHIMANO 11 speed hub Internal oil change and maintenance 1 000 km after start of use then every 2 years or 2 000 km All other SHIMANO gear hubs Lubricate internal components Once a year or every 2 000 km ROHLOFF Speedhub 500 14 Clean cable box and grease cable drum interior Every 500 km Oil change Every 5 000 km or at least once a year Pinion Maintenance 1 Check drive elements and r...

Page 163: ...ed and described 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...

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

Page 165: ...n oil change 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 frame damper as specified in parts list RockShox suspension fork optional 6 months Check for damage corrosion fracture Maintenance as specified by manufacturer Lubrication oil chan...

Page 166: ...ce a month Cleaning 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 ad...

Page 167: ...fter that Complete 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 p...

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

Page 169: ...On board computer 6 months Check for damage Check for damage O K No screen defective screen display Restart test battery new software or new on board 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 Pedelec ...

Page 170: ...ional 6 months 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 Gear shift under operating...

Page 171: ...cks and breaks 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...

Page 172: ...em may no longer be firmly fixed in its position as a result This will cause a crash with injuries Check the handlebars and the stem s quick release are firmly in position 8 5 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...

Page 173: ...aintwork remove the pedelec from service New 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 pressurised 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 th...

Page 174: ...ge from impact 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 pedelec 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 dam...

Page 175: ...lass to see if 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 pedelec out of service 2 New carbon seat post as specif...

Page 176: ...emove safety and 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 Lubr...

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 Bowde...

Page 178: ... Pull slide bushing 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...

Page 179: ...inserting and 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 cartri...

Page 180: ... interface against twisting with a 24 mm open end spanner 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 ...

Page 181: ...rrect Bowden cable 4 Carefully push cartridge into the seat tube Pull the Bowden 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 th...

Page 182: ...unting hole 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 p...

Page 183: ...189 Removing the seat post 3 Pull out the special end cap for the outer sleeve from the bracket 4 Detach the Bowden 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 Bowden cable Removing the outer sleeve and slide bushing 1 Use a 3 mm hex spanner to remove attachment screw on the outer sleeve...

Page 184: ...r sleeve with 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 ...

Page 185: ...your hand until 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 F...

Page 186: ...come damaged Figure 207 Attaching and pushing in the seat post 4 Hold the Bowden cable firmly on the handlebars while feeding it in Carefully pull the end of the Bowden 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 t...

Page 187: ...ation in germ cells Always 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 frame damper 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 workin...

Page 188: ...on forks rear frame dampers and suspension seat posts Maintenance includes a complete inspection of interiors exteriors All dampers 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 de service ...

Page 189: ...tery is switched on If not start the battery Contact your specialist dealer if the battery level indicator LEDs do not light up 2 If the LEDs on the Battery Level indicator light up but the drive system does not start remove the battery 3 Insert the battery 4 Start the drive system 5 If the drive system does not start up remove the battery 6 Clean all the contacts with a soft cloth 7 Insert the ba...

Page 190: ...for a long time 1 Switch off the drive system 2 Leave pedelec to cool down 3 Start the drive system The assisted journey distance is too short Is the battery fully charged 1 Check charge level 2 Recharge the battery if it is almost flat The battery does not perform as well in winter weather This does not indicate a problem The journey distance can be shorter depending on the road conditions the ge...

Page 191: ...rt charging when the charger is connected The battery may be at the end of its useful life Replace old battery with new one The battery and charger become hot Has the battery or charger temperature exceeded the operating temperature range 1 Interrupt charging process 2 Leave battery and charger to cool down 3 Start charging If the battery becomes too hot to touch there might be a problem with the ...

Page 192: ... fitted correctly 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 gear shift 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 ...

Page 193: ...s used pedal 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 gear shift setting may not have been made properly Contact your specialist dealer I...

Page 194: ...m the ground in an uncontrolled way This impairs traction and control blue line Fork head and handlebars are deflected upwards if the wheel bounces back from the ground Body weight may be thrown up and back in an uncontrolled way green line Figure 211 Suspension fork rebounding too quickly Solution Figure 212 Suntour rebound screw 1 Turn rebound screw in a clockwise direction The rebound speed is ...

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

Page 196: ...ight shifts forward and the pedelec 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 and the deflection stroke speed Efficiency on hilly and flat terrain is improved...

Page 197: ...onger touches the ground The headset and handlebars are deflected 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 deflection stroke speed is reduc...

Page 198: ...tion and control due to the uncontrolled speed at which the damper rebounds after deflecting blue line Saddle and handlebars are deflected upwards when the wheel bounces back from the ground The rider s body weight may be shifted upwards and forwards if the damper fully rebounds too quickly green line Figure 219 Rear frame damper rebounding too quickly Solution Figure 220 Suntour rebound adjuster ...

Page 199: ...ickly enough to make contact with the ground and return to the initial position again The available deflection and traction are reduced blue line The rear frame damper remains in a deflected state after contact with the first bump When the rear wheel hits the second bump the saddle follows the path of the rear wheel instead of remaining in a horizontal position The available deflection and potenti...

Page 200: ...up the rider s weight shifts forward and the bicycle loses some momentum Figure 223 Excessively soft suspension in the rear frame damper on hilly terrain Solution Figure 224 Suntour compression adjuster 1 on the rear frame damper Turn compression adjuster clockwise The damping and compression hardness is increased and the deflection stroke speed is reduced Efficiency on hilly and flat terrain is i...

Page 201: ...dle and rider are deflected 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 frame damper on bumps Solution Figure 226 Suntour compression adjuster 1 on the rear frame damper Turn compression adjuster anti clockwise The damping and compression hardness is reduced and the deflection stroke speed is in...

Page 202: ... new components 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 10 m in front of the pedelec 9 2 4 Checking tyre clearance The tyre needs to be checked each time a suspension fork tyre is changed to another size 1 Release pressure from the fork 2 Press ...

Page 203: ...function is shown 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 ha...

Page 204: ...damaged battery and the charger can be returned to any specialist dealer free of charge Further disposal options may be available depending on the region Store the individual parts of the decommissioned pedelec in a dry place free from frost where they are protected from direct sunlight 10 1 Removal of waste guidelines Waste type Disposal Non hazardous waste Recycling Waste paper cardboard Return ...

Page 205: ...il Cleaning cloths daubed in oil Lubrication oil Gear oil Lubricating grease Cleaning fluids Kerosene White spirit Hydraulic fluid Brake fluid Never mix different oil fluids Store in original container Small quantities usually 30 kg Take to municipal collection points for hazardous waste e g mobile toxic waste collection service Larger quantities 30 kg Collection by waste disposal companies Paints...

Page 206: ...sing New bell as specified in the parts list Suspension elements Fork suspension fork Check for damage O K Damage detected New fork as specified in the parts list Rear frame damper Check for damage O K Damage detected New fork as specified in the parts list Suspension seat post Check for damage O K Damage detected New fork as specified in the parts list Brake system Brake lever Check mount fasteni...

Page 207: ...ed measurement O K Pedelec travelling 10 too fast slow Take pedelec out of service until the source of the error is found Cabling Visual inspection O K Failure in system damage kinked cables New cabling Battery mount Firmly in position lock contacts Functional check O K Loose lock doesn t close no contacts New battery mount Motor Visual inspection and mount O K Damage loose Refasten motor contact ...

Page 208: ...se Retighten screws Saddle 6 months Check mount fastening O K Loose Retighten screws Seat post 6 months Check mount fastening O K Loose Retighten screws Guard 6 months Check mount fastening O K Loose Retighten screws Pannier rack 6 months Check mount fastening O K Loose Retighten screws Attachments 6 months Check mount fastening O K Loose Retighten screws Bell 6 months Functional check O K No ring...

Page 209: ...ts list replace if 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 Drive gear shift Chain cassette pinion chainring 6 months Check for damage O K Damage Refasten if neces sary or replace ...

Page 210: ...nufacturer new 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 br...

Page 211: ...MY22B0a 62_1 0_15 09 2021 210 Notes ...

Page 212: ...r SHIMANO Deore XT SL M8130 Shifter Derailleur Cassette cassette sprocket SHIMANO CS LG600 11 11 50T Chain SHIMANO CN LG500 Belt Front brake SHIMANO BR MT420 BR MT410 Hydraulic disc brake Brake lever front rear SHIMANO BL MT402 3A Disc front rear 180 mm centre lock Wheel set Rim front rear RYDE Taurus 2000 Hub front SHIMANO HB MT400 Cassette hub for disc brake Hub rear SHIMANO FH M3050 Freewheel S...

Page 213: ...perating instructions not available Information not available when document was produced Rechargeable battery BOSCH PowerTube 750 BBP3770 Horizontal 750 Wh On board computer BOSCH LED remote With KIOX300 display Charger BOSCH charger BPC3400 4 A ...

Page 214: ...s Shifter SHIMANO SLX SL M7100 Shifter Derailleur Cassette cassette sprocket SHIMANO SLX CS M7100 12 10 51T Chain SHIMANO CN M7100 Belt Front brake SHIMANO BR MT420 BR MT410 Hydraulic disc brake Brake lever front rear SHIMANO BL MT402 3A Disc front rear 180 mm centre lock Wheel set Rim front rear BULLS E Trekking Lite Hub front SHIMANO HB MT400 Cassette hub for disc brake Hub rear SHIMANO FH MT500...

Page 215: ...perating instructions not available Information not available when document was produced Rechargeable battery BOSCH PowerTube 750 BBP3770 Horizontal 750 Wh On board computer BOSCH LED remote With KIOX300 display Charger BOSCH charger BPC3400 4 A ...

Page 216: ...sette sprocket SHIMANO Deore CS M4100 10 11 42T Chain Belt Front brake SHIMANO BR MT200 Hydraulic disc brake Brake lever front rear Disc front rear 180 mm Wheel set Rim front rear RYDE Taurus 2000 Hub front SHIMANO HB MT400 Cassette hub for disc brake Hub rear SHIMANO Deore FH M6000 Freewheel Spokes Tyres SCHWALBE Big Ben Performance Line RaceGuard 55 622 28 x 2 15 Tube Front lamp FUXON FS 70 EB 7...

Page 217: ..._1 0_15 09 2021 216 About these operating instructions not available Information not available when document was produced On board computer BOSCH LED remote With KIOX300 display Charger BOSCH charger BPC3400 4 A ...

Page 218: ...L SX PA A1 Derailleur Cassette cassette sprocket SRAM SX Eagle CS PG 1210 A1 11 50T Chain SRAM SX Eagle CN EAGLE SX A1 Belt Front brake SHIMANO BR MT200 Hydraulic disc brake Brake lever front rear SHIMANO BR MT201 DUAL CONTROL lever Disc front rear 180 mm centre lock Wheel set Rim front rear BULLS DDM 2 Hub front SHIMANO HB MT400 Cassette hub for disc brake Hub rear SHIMANO FH M3050 Freewheel Spok...

Page 219: ..._1 0_15 09 2021 218 About these operating instructions not available Information not available when document was produced On board computer BOSCH LED remote With KIOX300 display Charger BOSCH charger BPC3400 4 A ...

Page 220: ... speed derailleur gears Shift motor SHIMANO Deore RD M5120 SGS Shadow Plus Shifter Cassette cassette sprocket Chain SHIMANO Deore CS M4100 10 11 42T Belt KMC E10S Front brake Rear brake SHIMANO BR MT420 Hydraulic disc brake Brake lever front rear SHIMANO BR MT410 Disc front SHIMANO BL MT410 Disc rear 203 mm centre lock 180 mm centre lock Wheel set Rim front rear RYDE Disc 30 Hub front SHIMANO HB M...

Page 221: ...ailable Information not available when document was produced Motor BOSCH Performance Line CX BDU3740 250 Watt 85 Nm Rechargeable battery BOSCH PowerTube 750 BBP3770 Horizontal 750 Wh On board computer BOSCH LED remote With KIOX300 display Charger BOSCH charger BPC3400 4 A ...

Page 222: ...SHIMANO Deore XT SL M610 I Shifter Shift motor Cassette cassette sprocket SHIMANO SLX CS M7100 12 10 51T Chain SHIMANO CN M7100 Belt Front brake SHIMANO BR MT420 Hydraulic disc brake Rear brake SHIMANO BR MT410 Hydraulic disc brake Brake lever front rear SHIMANO BL MT4100 Disc front rear 203 mm centre lock 180 mm centre lock Wheel set Rim front rear RYDE Disc 30 Hub front SHIMANO HB MT400 Cassette...

Page 223: ...ailable Information not available when document was produced Motor BOSCH Performance Line CX BDU3740 250 Watt 85 Nm Rechargeable battery BOSCH PowerTube 750 BBP3770 Horizontal 750 Wh On board computer BOSCH LED remote With KIOX300 display Charger BOSCH charger BPC3400 4 A ...

Page 224: ...MY22B0a 62_1 0_15 09 2021 223 Documents 11 4 Charger operating instructions ABCDE ...

Page 225: ...MY22B0a 62_1 0_15 09 2021 224 Documents F 4A Charger DCG F H A I A J ...

Page 226: ...MY22B0a 62_1 0_15 09 2021 225 Documents F A I A J DCG F H ...

Page 227: ...MY22B0a 62_1 0_15 09 2021 226 Documents F DCG F H A I A J ...

Page 228: ...T K Q I 0 C C C 7 K I P I Q I 7 C I Q Q I I I C I I I P I I I I C C C C C I Q I C I I I I I I C C C C C C I P I Q C C C N I I I Q I I O I I I I Y V Si I A JCX I O I Z 6 I Q I I P I Q I Q Q I A I A I T Q I O A I A Q I I Q I I Q I O I I I Q I I QQ I Q I I b Q A A I K K CI Q CI J Q I CI I A QQ B A I A J DCG F H ...

Page 229: ...I I I I C J I I QQ C I Q I I P P I I O S Q I Q I I I I I I C C C Q I P I Q I I I RI P I O Q I I I I I O I I I I 4 F I I I I O Q I A I I I O 4 F I I I O I I I I I O RI I I I O P I I I I RI I O P I O Q I I Q I I I O I I I O O I SNK I I Q I I I N I SNK O T h Q I I I Q I SNK I T h I I A Q I P I SNK O I O I QQ I I I Q I Q I QQ I A K I I Q I I Q I I RI I Q I I P I O I QQ 4 F Q I I I I P Q I I I I Q I O ...

Page 230: ... C C I I A 7 C K I Q I I I I I I K I I I I I I I I I I 4 7 7 C C C I I C C I CI A C Q I B P I Q CI I P I I I I I A Q C I I J J Q I I Q P I O I 0 Q I b I A P I W Q I I P IO 7 CI P I Q K Q I I I I I C F I N K H NV R N N Nb O P I I O Q O Q 9 A I A J DCG F H ...

Page 231: ...ct s functional capability Disc brake Source EN 15194 2017 brake in which brake pads are used to grip the lateral faces of a thin disc attached to or incorporated into the wheel hub Drive belt Source EN 15194 2017 seamless ring belt which is used as a means of transmitting drive force Electrical control system Source EN 15194 2017 electronic and or electri cal component or an assembly of component...

Page 232: ...ontal position and with the seat post set to the minimum insertion depth mark Maximum tyre pressure Source EN 15194 2017 maximum tyre pressure recommended by the tyre or rim manufacturer for a safe and efficient performance If the rim and tyre both indicate a maximum tyre pressure the maximum inflation pressure is the lower of the two pressures indicated Minimum insertion depth Source EN 15194 201...

Page 233: ...rame Serial number Source ZEG each pedelec 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 pedelec 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 t...

Page 234: ...the year in which the pedelec was manufactured The pro duction period is always from May to July the fol lowing year 12 1 Abbreviations ABS anti blocking 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 frame damper Specialist dealer Bicycle specialist dea...

Page 235: ...ycle 22 15 4008 Cross Mover Evo 3 City and trekking bicycle 22 15 4009 Cross Mover Evo 3 City and trekking bicycle Year of manufacture 2021 and year of manufacture 2022 complies with the following applicable EU provisions Machinery Directive 2006 42 EC RoHS Directive 2011 65 EU Electromagnetic Compatibility Directive 2014 30 EU The safety objectives in the Low Voltage Directive 2014 35 EU have bee...

Page 236: ...laration of conformity 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: ...rd cleaning 140 Chain guard 16 Chain tension checking 155 Chain wheel 41 Chain wheels cleaning 139 Chain 25 41 cleaning 140 maintaining 147 156 servicing 144 Charger 43 disposing of 203 Chassis 26 Child seat 113 Clamping force Adjusting the quick releas es 66 Checking the quick releas es 66 Clock setting 111 Compression adjustment 30 Compression damper 31 Control panel cleaning 137 Crown 31 D Dime...

Page 238: ... 35 102 Rear 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 ...

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