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Bulls 22-15-1078, Translation Of Original Operating Instructions

The Bulls 22-15-1078 user manual offers a comprehensive Translation of Original Operating Instructions for hassle-free setup and operation. Available for free download at manualshive.com, this manual provides clear instructions, ensuring a smooth user experience. Maximize the potential of your Bulls 22-15-1078 by easily accessing the manual that guarantees optimal performance.

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MY22B01 - 12_1.0_26.08.2021

67

Assembly

5.3.4

Installing the wheel in the SUNTOUR fork

Only applies to Suntour forks with this equipment

5.3.4.1 Screw-on axle (12AH2 and 15AH2) 

Only applies to Suntour forks with this equipment 

Before installing the wheel, ensure that the O-ring 
is in the right position on the thread piece.

1

Insert the front wheel into the fork ends. 

2

Insert the axle into the hub on the drive side.

Figure 65:  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 66:  Tighten the axle in the direction of the arrow

4

Insert the securing screw on the non-drive 
side.

Figure 67:  Pushing the quick release lever into the axle

5

Tighten the securing screw with a 5 mm hex 
key using between 5 and 6 Nm. 

Figure 68:  Tightening the securing screw

The wheel is now fitted.

Summary of Contents for 22-15-1078

Page 1: ...08 2021 Cross Rider EVO 1 Cross Mover EVO 2 Cross Mover EVO 2 26 T U R B O S P O R T T O U R E C O O F F M P H K M H Reichweite AMM PMWH MIN MPH KM H RESET T U R B O S P O R T S T O U R E C O O F F M P H K M H Reichweite AMM PMWH M IN M PH K M H Translation of original operating instructions for BULLS Pedelecs with BOSCH Intuvia on board computer ...

Page 2: ...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 2 Toxic substances 15 2 2 1 Brake fluid 15 2 2 2 Suspension oil 15 2 2 3 Lubrication oil 15 2 2 4 Defective battery 15 2 3 Requirements for riders 15 2 4 Vulnerable groups 15 2 5 Personal protective equipment 15 2 6 Safety guards 15 2 7 Safety markings and safety instructions 16 ...

Page 3: ...k battery 38 3 3 8 5 Integrated battery 39 3 3 8 6 Charger 39 3 3 9 Lighting 39 3 3 10 On board computer 40 3 3 10 1 USB port 40 3 3 11 Control panel 40 3 4 Description of controls and screens 41 3 4 1 Handlebars 41 3 4 2 On board computer 42 3 4 2 1 Riding light indicator 42 3 4 2 2 Level of assistance indicator 42 3 4 2 3 Charge level indicator on board computer 43 3 4 2 4 Indicator for motor po...

Page 4: ...5 1 Unpacking 60 5 2 Required tools 60 5 3 Commissioning 61 5 3 1 Checking the battery 61 5 3 2 Preparing the battery 62 5 3 2 1 Retrofitting the PowerTube adapter 62 5 3 2 2 Fit battery cover onto Bosch PowerTube 625 battery horizontal 64 5 3 2 3 Fit battery cover onto Bosch PowerTube 500 battery horizontal 65 5 3 3 Preparing the wheel 66 5 3 4 Installing the wheel in the SUNTOUR fork 67 5 3 4 1 ...

Page 5: ...98 6 5 9 8 Grip distance on a SHIMANO ST EF41 brake lever 99 6 5 9 9 Pressure point on a MAGURA brake lever 100 6 5 9 10 Retracting the brake linings 101 6 5 10 Gear shift 102 6 5 10 1 SHIMANO shifter 102 6 5 11 Suspension 103 6 5 12 Fork sag 103 6 5 12 1 Adjusting the Suntour fork steel suspension 104 6 5 12 2 Adjusting the Suntour fork air suspension 105 6 5 13 Fork rebound damping 106 6 5 13 1 ...

Page 6: ...rive system 122 6 17 2 Switching off the electric drive system 122 6 18 Using the on board computer 123 6 18 1 Attaching the on board computer 123 6 18 1 1 Removing the on board computer 123 6 18 1 2 Attaching the on board computer 123 6 18 2 Securing the on board computer against removal 124 6 18 3 Charging the on board computer battery 124 6 18 3 1 Charging on the pedelec 124 6 18 3 2 Charging u...

Page 7: ...rd computer and control panel 140 7 3 2 Rechargeable battery 140 7 3 3 Motor 140 7 3 4 Frame fork pannier rack guards and kickstand 141 7 3 5 Stem 141 7 3 6 Handlebars 141 7 3 7 Handles 141 7 3 7 1 Leather handles 141 7 3 8 Seat post 141 7 3 9 Saddle 141 7 3 9 1 Leather saddle 142 7 3 10 Tyres 142 7 3 11 Spokes and spoke nipples 142 7 3 12 Hub 142 7 3 13 Switching elements 142 7 3 13 1 Shifter 142...

Page 8: ... Checking the rim brake 156 7 5 3 Checking the lighting 157 7 5 4 Checking the stem 158 7 5 5 Check the handlebars 158 7 5 6 Checking the saddle 158 7 5 7 Checking the seat post 158 7 5 8 Checking the chain 158 7 5 9 Checking the chain and belt tension 158 7 5 9 1 Checking the derailleur gears 159 7 5 9 2 Checking the hub gear 159 7 5 10 Checking the gear shift 159 7 5 10 1 Electric gear shift 159...

Page 9: ...ors 192 9 1 4 Battery error 193 9 1 5 On board computer error 194 9 1 6 Lighting does not work 194 9 1 7 Other drive system errors 195 9 1 8 Suntour suspension fork 196 9 1 8 1 Rebound too fast 196 9 1 8 2 Rebounding too slowly 197 9 1 8 3 Suspension too soft on inclines 198 9 1 8 4 Excessively hard damping on bumps 199 9 1 9 Other errors 200 9 2 Repair 201 9 2 1 Original parts and lubricants 201 ...

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: ...tructions identification number is located in bottom left hand corner of each page The identification number is composed of the document number the version number and the release date Type no Model Pedelec type 22 15 1078 Cross Rider EVO 1 Gent City and trekking bicycle 22 15 1079 Cross Rider EVO 1 Trapez City and trekking bicycle 22 15 4001 Cross Mover EVO 2 Gent City and trekking bicycle 22 15 4...

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: ...tures over 60 C can also cause liquid to leak from the battery and the battery will become damaged The battery may self ignite and explode 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 batt...

Page 15: ... break 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 sc...

Page 16: ...rns Never dismantle the battery Avoid contact with skin Do not inhale vapours 2 3 Requirements for riders The rider must have the required mental capacity and physical and motor skills to ride on public roads A minimum age of 14 years is recommended 2 4 Vulnerable groups Keep batteries and the charger away from children and people with reduced physical sensory or mental capacities or lacking in ex...

Page 17: ...rfaces 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 lids ...

Page 18: ...id particles immediately Rinse the affected area with plenty of water for at least 15 minutes Then dab the affected skin gently Do not rub dry Remove contaminated clothing immediately Immediately consult a doctor if there is any redness pain or discomfort 2 8 4 Battery fire The safety electronics may fail if the battery is damaged or faulty The residual voltage can cause a short circuit The batter...

Page 19: ...riod in addition to physical fitness Learning how to ride a mountain bike takes practice especially braking and riding around bends The strain on hands wrists arms shoul ders the neck and back is considerable Inexperienced riders tend to brake too hard and lose control as a result Racing bikes are designed for fast rides on roads and paths with a good undamaged road surface Racing bikes are sports...

Page 20: ...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 21: ...imum permitted total weight is the weight of the fully assembled pedelec plus body weight plus baggage Type no Model PTW kg 22 15 1078 Cross Rider EVO 1 Gent 135 22 15 1079 Cross Rider EVO 1 Trapez 135 22 15 4001 Cross Mover EVO 2 Gent 135 22 15 4002 Cross Mover EVO 2 Trapez 150 22 15 4003 Cross Mover EVO 2 Wave 150 22 15 4025 Cross Mover EVO 2 Wave 150 ...

Page 22: ...ts Mountain bikes Racing bicycle Cargo bike Folding bicycle Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked roads cycle paths and firm gravel paths and roads and longer sections with moderate slopes and jumps up to 15 cm Suitable ...

Page 23: ... 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 24: ...mitted 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 The production period is between June 2021 and June 2022 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 marki...

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

Page 26: ...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 27: ...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 28: ...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 29: ...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 30: ...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 31: ...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 32: ...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 16 Example Information on tyres Tyre pressure The permitted pressure range is i...

Page 33: ...alve Figure 19 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 34: ...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 20 Bowden cable structure 3 3 5 2 Hydraulic brake The brake fluid is in a closed hos...

Page 35: ... 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 36: ...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 24 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 37: ...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 26 Chain drive with derailleur gears 1 Front derailleur 2 Rear derailleur 3 Chain A chain drive is compatible with Back pedal brake Hub gear or Derailleur gears 3 3 7 2 Belt drive layout Figure 27 Belt drive ...

Page 38: ...of an emergency 3 3 8 2 Rechargeable battery BOSCH batteries are lithium ion batteries which are developed and manufactured to the latest technical standards Each individual cell is protected by a steel cup and encased in a plastic battery housing These batteries meet and exceed applicable industrial safety standards The battery has an interior electronic protection circuit which is specifically d...

Page 39: ...w of frame battery Figure 30 Details of frame battery 1 Battery housing 2 Battery lock 3 Battery key 4 On off button battery 5 Battery level indicator battery 6 Charging port cover 7 Charging port 3 3 8 4 Pannier rack battery Three different types of pannier rack batteries can be fitted Figure 31 Overview of pannier rack battery Figure 32 Details of pannier rack battery 1 Battery housing 2 Chargin...

Page 40: ...ery level indicator battery 6 Battery housing 3 3 8 6 Charger Each pedelec is supplied with a charger As a general rule any BOSCH charger may be used The 2 A compact charger The 4 A standard charger The 6 A fast charger Observe the operating instructions in the Section 11 4 Documents 3 3 9 Lighting When the riding light is activated the front light and the rear light are switched on together Power...

Page 41: ...nd the electric drive system is switched on If the rider removes the display from its mount the display is powered by a on board computer battery The on board computer battery cannot be replaced Figure 35 BOSCH Intuvia on board computer 3 3 10 1 USB port There is a USB port beneath the rubber cover on the right hand edge of the on board computer 3 3 11 Control panel The control panel controls the ...

Page 42: ...etailed view of handlebars with BOSCH Intuvia on board computer example 1 Rear wheel hand brake 2 Bell 3 Front light 4 On board computer 5 Front wheel hand brake 6 Handle 7 Seat post remote control 8 Control panel 9 Sag setting wheel 10 Fork lock lockout 11 Shift indicator 12 Shifter 1 2 4 5 6 7 8 9 10 12 11 3 ...

Page 43: ...dynamically depending on the pedalling force applied to the pedals If the pedelec has been configured with eMTB MODE eMTB MODEwill appear briefly when the SPORT level of assistance is selected T U R B O S P O R T T O U R E C O O F F MPH KM H Reichweite AMM PMWH MIN MPH KM H RESET TURB O SPOR T S TOUR ECO OFF MPH KM H Reichweite AMM PMW H MIN MPH KM H 1 2 3 4 5 6 7 8 5 1 2 3 4 6 7 TURBO SPORT TOUR ...

Page 44: ...gh power consumption 3 4 2 5 Gear recommendation indicator Pedalling frequencies higher than 50 revolutions per minute optimise drive unit efficiency However very slow pedalling uses up a great deal of energy The speed and range can be increased while applying the same force if you select the right gear The gear recommendation function reacts to excessively slow or excessively quick pedalling and ...

Page 45: ...unction is available on the function display Display Function CLOCK Current time MAX SPEED Maximum speed reached since the last RESET AVG SPEED Average speed reached since the last RESET TRIP TIME Journey time since last RESET RANGE Estimated range of the available battery charge ODOMETER Display of the total distance travelled cannot be changed TRIP DISTANCE Distance travelled since the last RESE...

Page 46: ...ange GEAR The gear shift currently selected is displayed on the on board computer display screen The new selected gear is shown briefly on the on board computer each time it is changed Table 20 Additional journey information eShift with ROHLOFF E 14 Speedhub 500 14 Display Function Changeable system settings CLOCK Changes the time WHEEL CIRCUM Wheel circumference in mm ENGLISH Changes the language...

Page 47: ...own when the on board computer is positioned in its mount Gear vx x x x this is the gear software version This menu option is only shown when the on board computer is positioned in its mount This menu option is only shown if you have an electronic control gear Table 23 Changing the system settings Display Change Gear adjustment You can use this menu option to make a fine adjustment to the SHIMANO ...

Page 48: ...re information and a table containing all system messages in Section 6 2 Display Change Start gear This is where you can set the start gear The automatic gear switch function is switched off in Position This menu option is only shown when the on board computer is positioned in its mount Gear vx x x x This is the gear software version This menu option is only shown when the on board computer is pos...

Page 49: ... 3 Control panel The on board computer is operated using four buttons on the control panel Figure 41 Overview of BOSCH control panel 1 Info button control panel 2 Push assist button 3 Plus button control panel 4 Minus button control panel 1 3 4 2 ...

Page 50: ...ehicles with this equipment The gear shift is on the right of the handlebars The gear shift has one or two shifters SHIMANO SL M315 gear shift Figure 42 Example of SHIMANO SL M315 1 Shifter A 2 Shifter B SHIMANO SL M3100 gear shift Figure 43 Example of SHIMANO SL M3100 1 Shifter A 2 Shifter B optional 1 2 1 2 ...

Page 51: ...brake There is a hand brake on the left and right of the handlebars Figure 44 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 52: ...sing the remote control on the handlebars 3 4 6 1 SR Suntour The following compression adjusters may be featured on the suspension fork Model RL RL R LO LO R HLO Lockout with remote control Lockout with remote control rebound adjustment Lockout on the fork Rebound adjustment lockout on the fork Hydraulic lockout Axon x x CR x x M3010 MOBIE25 x x NCX x x NEX x x x NVX x x XCE XCM x x x XCR x x x x ...

Page 53: ...cator battery The five green LEDs on the battery level indicator show the charge level when the battery is switched on Each LED represents 20 of battery capacity Symbols All five LEDs will light up when the battery is fully charged The charge level for the activated battery is also shown on the on board computer If the battery level falls below 5 all the LEDs on the operating status and battery le...

Page 54: ...Highest effective value of weighted acceleration for the entire body 0 5 m s Table 29 Emissions from the pedelec Voltage about 12 V Maximum output Front light 17 4 W Rear light 0 6 W Table 30 Bicycle lighting Internal lithium ion battery 3 7 V 230 mAh Operating temperature 5 40 C Storage temperature 10 40 C Charging temperature 0 40 C Protection class with USB cover closed IPx54 Weight about 0 15 ...

Page 55: ...and BBP283 vertical batteries Nominal voltage 36 V Nominal capacity 13 4 Ah Energy 500 Wh Weight 2 9 kg Protection class IP54 Operating temperature 5 40 C Storage temperature 10 40 C Permitted charging temperature range 0 40 C Table 35 Technical data for PowerTube 500 BBP280 horizontal and BBP281 vertical BOSCH batteries Nominal voltage 36 V Nominal capacity 16 7 Ah Energy 625 Wh Weight 3 5 kg Pro...

Page 56: ...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 57: ...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 37 Tightening torques and bits ...

Page 58: ...cle weight without battery Not yet available when the instructions were produced 4 2 Designated handles lifting points The box does not have any handles Type no Frame Box dim cm Weight kg Shipping weight kg 22 15 1078 45 50 55 60 22 15 1079 45 50 55 22 15 4001 45 50 55 60 22 15 4002 45 50 55 22 15 4003 45 50 55 22 15 4025 40 Table 38 Type number model and pedelec type ...

Page 59: ...e 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 tran...

Page 60: ...he brake Before longer periods without use it is recommended to have the specialist dealer carry out an inspection 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 storing them in uninhabited rooms with smoke alarms Dry locations with an ambient temperature between 10 C and 20 C...

Page 61: ... 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 62: ...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 63: ...re 50 Undoing screws on battery mount 2 Use a ratchet to remove the two 4 mm hexagon screws in the PowerTube adapter If you don t have a ratchet you can use a hexagonal key to remove the screws Figure 51 Removing the 4 mm hexagon screws 3 Use a ratchet to remove the two 4 mm hexagon screws in the PowerTube adapter Figure 52 Removing hexagon screws 4 Pull out the PowerTube adapter Figure 53 Pulling...

Page 64: ...MY22B01 12_1 0_26 08 2021 63 Assembly 6 Use a TORX T25 wrench to fasten the screws into the battery mount Figure 55 Fastening the battery mount ...

Page 65: ...ry mounting plate to the BOSCH the PowerTube 625 battery with original BOSCH screws M4 8 T20 In doing so ensure that the removal tab faces the front of the battery Figure 57 Fitting the mounting plate 3 Press to push the battery cover onto the battery In doing so ensure that the battery On Off switch fits through its designated slot in the cover The battery cover will lock into the fitting grooves...

Page 66: ...the PowerTube extension must face upwards away from the battery Figure 60 Fitting the PowerTube extension 3 Screw the battery mounting plate onto the PowerTube extension with original BOSCH screws M4 8 T20 To do so use the PowerTube extension screw plate as a counter support When positioning the extension ensure that the removal tab faces the front of the battery Figure 61 Fastening the battery mo...

Page 67: ...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 68: ...ont wheel into the fork ends 2 Insert the axle into the hub on the drive side Figure 65 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 66 Tighten the axle in the direction of the arrow 4 Insert the securing screw on the non drive side Figure 67 Pushing the quick release lever into the axle 5...

Page 69: ...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 70: ...e lever must be flush with the shock absorber Figure 73 Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required Figure 74 Adjusting the quick release clamping force 7 Check the quick release lever position and clamping force The wheel is now fitted ...

Page 71: ...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 72: ... 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 73: ...e 79 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 80 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 81 R pedal ...

Page 74: ... the handlebars cannot be fastened contact your specialist dealer Stem with clamping lever version II and stem with screw If the handlebars cannot be fastened contact your specialist dealer 5 3 7 3 Checking the 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 75: ...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 76: ... 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 77: ...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 78: ...er battery flat Recharge on board computer battery while in its mount or using USB port 431 Software version error 1 Re start the system 2 Contact your specialist dealer if the problem persists Table 41 List of on board computer error messages 440 Battery internal error 1 Re start the system 2 Contact your specialist dealer if the problem persists 450 Internal software error 1 Re start the system ...

Page 79: ... persists Code Description Method of resolution Table 41 List of on board computer error messages 595 596 Communication error 1 Check cabling to the gears 2 Re start the system 3 Contact your specialist dealer if the problem persists 602 Internal error during charging 1 Disconnect charger from battery 2 Re start the system 3 Connect charger to the battery 4 Contact your specialist dealer if the pr...

Page 80: ...e problem persists 830 Error in the line to the rear wheel speed sensor Contact your specialist dealer 831 833 835 Implausible signals from the rear wheel speed sensor Sensor disc may be missing It is defective or incorrectly installed significantly different tyre diameter between the front wheel and rear wheel extreme riding such as riding on the rear wheel only 1 Re start the system 2 Take a tes...

Page 81: ...ery level indicator 1 Disconnect charger from battery 2 Leave battery to cool down 3 Contact your specialist dealer if the problem persists Code If a fault is detected in the battery two LEDs flash on the battery level indicator Contact your specialist dealer Code No LEDs will flash if the charger is defective and will not charge One or more LEDs will light up permanently depending on the battery ...

Page 82: ...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 83: ...ddle height Adjust saddle position Adjust saddle tilt 6 5 4 1 6 5 4 2 6 5 4 4 6 5 4 5 2 Handlebars 6 5 5 3 Stem 6 5 6 4 Handles 6 5 7 x 5 Tyres 6 5 8 6 1 6 2 6 3 6 4 6 5 Brake Position of the brake handles Brake handle tilt angle Determine grip distance Pressure point Retract the brake linings 6 5 9 1 6 5 9 2 6 5 9 3 6 5 9 9 6 5 9 10 7 Gear shift 6 5 10 8 Adjust suspension adjust suspension fork s...

Page 84: ... 60 70 Angle between upper arm upper body red line Extremely acute angle at around 20 The upper arms are almost parallel to the upper body The hands are simply placed loosely on the handlebars An angle of 75 80 is optimum Many people prefer a smaller angle of up to 60 as it requires to less effort to support the shoulders arms and hands Saddle handlebar height difference blue and green line 10 The...

Page 85: ...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 86: ...ower 3 Release the remote control operating lever when you have reached the desired height Figure 88 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 87: ... Figure 89 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 88: ...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 89: ...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 90: ... 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 96 Raising the Ahead stem by fitting spacer rings The handlebar height is adjusted once during production using spacer ring...

Page 91: ...ustable stems are available in different lengths for quill and Ahead stems Figure 97 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 98 City bike blue and trekking bike position red by changing the angle a a b b c c ...

Page 92: ...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 99 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 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 press...

Page 94: ...dlebar 2 Extend the index finger about 15 Figure 102 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 95: ...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 105 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 96: ...ckwise towards minus The brake lever moves closer to the handlebar grip Turn the setting screw twist knob 5 clockwise towards plus The brake lever moves away from the handlebar grip Figure 106 Adjusting the grip distance on a MAGURA disc brake lever Crash caused by incorrectly set grip distance If brake cylinders are set incorrectly or installed wrongly the braking power may be lost at any time Th...

Page 97: ...bars The brake linings move closer to the rim The pressure point activates sooner Move the slider inwards to Position II or I The brake lever moves away from the handlebars The brake linings move away from the rim The pressure point activates later Figure 107 Setting the grip distance on a MAGURA HS 22 brake lever Crash caused by incorrectly set grip distance If brake cylinders are set or installe...

Page 98: ...t does not affect the pressure point or the position of the brake linings Use a T25 TORX wrench to turn the setting screw 1 to adjust the grip distance Turn the setting screw anti clockwise towards minus The brake lever moves closer to the handlebar grip Turn the setting screw clockwise towards plus The brake lever moves away from the handlebar grip Figure 108 Setting the grip distance on a MAGURA...

Page 99: ...n 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 109 Setting screw position 1 1 ...

Page 100: ...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 101: ... Turn the twist knob towards the minus The brake lever move further away from the handlebar grip Re adjust the grip distance as necessary The lever pressure point activates later Figure 110 Using the twist knob 1 to adjust the pressure point Brake failure due to incorrect setting If the pressure point is set with brakes where the brake linings and brake disc have reached their wear limit the brake...

Page 102: ...aking 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 103: ...ger 3 Tighten attachment screw 6 5 10 1 SHIMANO shifter Only applies to vehicles with this equipment Figure 111 Position of attachment screw in SHIMANO shifter 1 Model Tightening torque Screw DEORE SL M4100 3 Nm 4 mm hex bit DEORE SL M5100 3 Nm 4 mm hex bit DEORE SL M6100 3 Nm 4 mm hex bit DEORE XT SL M8100 3 Nm 4 mm hex bit DEORE XT SL M8130 3 Nm 4 mm hex bit SLX SL M7100 3 Nm 4 mm hex bit XTR SL...

Page 104: ... a firmer more efficient ride and is generally used on pedelecs with a shorter deflection The adjustment shown here represents a basic setting The rider should change the basic setting to suit the surface and their preferences It is advisable to make a note of the basic settings These can then be used a starting point for subsequent settings and as a safeguard against unintentional changes For ped...

Page 105: ...own Remove the plastic cover Figure 112 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 106: ...age 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 107: ...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 108: ...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 109: ...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 116 Light positioned too high 1 correctly 2 and too low 3 6 5 14 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 110: ...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 111: ...centration while riding increases the risk of an accident This may cause a crash with serious injuries Never allow yourself to be distracted by the on board computer Stop pedelec if you want to make inputs on the on board computer other than change the level of assistance Only enter data when the bicycle is stationary Notice Do not use on board computer as a handle The on board computer may become...

Page 112: ...d computer and the RESET button together SETTINGS is displayed on the on board computer The System settings is opened Press the info button on board computer repeatedly until the system setting which you wish to change is displayed Press the plus button or the minus button to change the displayed setting Press and hold the RESET button for 3 seconds to save the changed system settings and return t...

Page 113: ...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 51 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 114: ...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 115: ...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 116: ...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 117: ...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 118: ... 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 126 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 119: ... battery key from the battery lock 4 3 Tip the battery into the top section of the frame battery mount until it will go no further There is an audible clicking noise 4 Check the battery to make sure it is firmly in place 6 16 2 Pannier rack battery Only applies to pedelecs with this equipment 6 16 2 1 Removing the pannier rack battery Figure 128 Removing 2 and inserting 3 the pannier rack battery ...

Page 120: ... the frame 4 Remove the battery key from the battery lock 6 16 3 2 Inserting the integrated battery Figure 130 Inserting the integrated battery 1 Place the battery into the integrated battery lower mount with the contacts facing the front 1 2 Flip the battery upwards so that the battery is held by the retainer guard 2 3 Push the battery upwards 3 There is an audible clicking noise 4 Check battery ...

Page 121: ...with this equipment 6 16 5 1 Charging process when two batteries are used If two batteries are attached to a pedelec charge both batteries via the non sealed socket The two batteries are charged alternately during charging Charging switches automatically between the two batteries several times The charging time is twice as long The two batteries are discharged alternately during use 6 16 5 2 Charg...

Page 122: ... If you wish to use just one battery on a pedelec which is designed for two batteries cover the contacts in the free slot with the supplied cover cap 1 otherwise there is a risk of a short circuit caused by the open contacts 6 16 7 Waking the battery The battery switches to sleep mode to protect itself when not used for a longer period The LEDs on the battery level indicator do not light up Press ...

Page 123: ...istance is OFF The motor power is determined by the level of assistance set on the on board computer 6 17 2 Switching off the electric drive system As soon as you stop pushing the pedals in normal mode or reach a speed of 25 km h the drive system switches off the assistance system The assistance system starts up again when you push the pedals and your speed is less than 25 km h The system switches...

Page 124: ... pedelec if you want to make inputs on the on board computer other than change the level of assistance Only enter data when the bicycle is stationary Notice Do not use on board computer as a handle The on board computer may become irreparably damaged if you use it to lift the pedelec Remove the on board computer from its mount if the pedelec is not going to be used for several weeks Store the on b...

Page 125: ...puter will then switch back off There are two options for charging the battery 6 18 3 1 Charging on the pedelec 1 Once a battery has been inserted into the pedelec place the on board computer in the on board computer mount Press the On Off button battery 2 Using the pedelec 6 18 3 2 Charging using the USB port 1 Open the protective flap on the USB port 2 Connect the USB port to a commercially avai...

Page 126: ...ced by the selection of gear We recommend using first gear for cycling uphill to protect the drive The level of assistance OFF must not be selected 1 Press the push assist button briefly 2 Press and hold the plus button within 3 seconds to switch on the push assist 3 Release the plus button to shut off the push assist The push assist system switches off automatically as soon as the wheels are bloc...

Page 127: ...the RESET button until the indicator is the factory setting value 6 18 11 Changing the system settings The System settings can be displayed and changed no matter whether the on board computer is inserted in the mount or not A few settings are only visible and changeable if the on board computer is inserted A few menu options may be missing depending on the equipment used Press the Info button on b...

Page 128: ...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 129: ...en absorbing a bump green line Threshold The damping threshold prevents deflection until a medium impact or downward force occurs Threshold mode increases drive efficiency over level terrain The threshold setting can be used to improve pedalling efficiency over flat or hilly terrain In threshold mode higher pedelec speeds lead to greater impact force when a pedelec hits a bump causing the fork to ...

Page 130: ...ion Place compression adjuster in the OPEN position The compression adjuster is open Place compression adjuster in the LOCK position The compression adjuster is locked Position compression adjuster between OPEN and LOCK This position allows you to fine tune the compression adjuster We recommend setting the compression adjuster to the OPEN position first 1 2 ...

Page 131: ...anging gears This makes it easier to switch gears and reduces wear on the drivetrain 6 21 1 Using the derailleur gears The speed and range can be increased while applying the same force if you select the right gear Use the derailleur gears Figure 136 Down shifter 1 and up shifter 2 on the left I and right II gear shift Select the appropriate gear with the shifter The gear shift switches the gear T...

Page 132: ...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 133: ...ce when parking 1 Open stem clamping lever Figure 137 Example of All Up with open stem clamping lever 2 Pull handlebars into highest possible position Figure 138 Example of All Up pulled into highest possible position 3 Turn handlebars 90 in a clockwise direction Figure 139 Example of All Up screwed in 4 Place handlebars at required height 5 Close stem clamping lever ...

Page 134: ... 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 135: ... 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 10 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 136: ... 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 11 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 137: ...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 138: ... 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 139: ...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 140: ...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 141: ...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 54 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 142: ...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 143: ...ge 3 Rinse off component with water from a watering can 4 Care for spoke nipples after cleaning see Section 7 4 12 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 144: ...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 145: ...sidue with a cloth 7 4 2 Fork 1 Dry frame 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 55 Required tools and cleaning agents for servicing 2 y x 1 3 A A A Notice Hard wax pol...

Page 146: ...em 1 Spray painted and polished metal surfaces with wax spray and leave to dry 2 Wipe away any wax residue with a cloth 3 Apply silicone or Teflon oil to the stem shaft tube and the quick release lever pivot point with a cloth 4 If you have a Speedlifter Twist also apply oil to the unlocking bolt using the groove in the Speedlifter body 5 Apply a little acid free lubricant grease between the stem ...

Page 147: ...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 due to staining...

Page 148: ...apply a wafer thin thread of oil to the chain links The faster the crank is turned the thinner the threads of oil will be Figure 141 Lubricating the chain 4 Remove excessive chain oil with a cloth If you apply too much oil it will make the chain all the dirtier at a later point in time 5 Leave chain oil to penetrate into the chain links for a few hours or overnight 7 4 16 1 Caring for the chain an...

Page 149: ... or precision mechanics oil 7 4 18 Lubricating the eightpins seat post tube Use a 2 5 ml syringe to carefully fill eightpins Fluid V3 very slowly into the lubricating nipple on the outer tube Figure 142 Lubricating the seat post tube Notice Never treat brake levers with degreaser or penetrating oil spray Notice Fill a maximum of 2 5 ml since otherwise the reservoir inside will overflow and the oil...

Page 150: ...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 151: ... 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 152: ...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 144 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 145 Examples of fatigue c...

Page 153: ...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 154: ...5 9 9 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 detec...

Page 155: ...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 156: ...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 157: ...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 158: ...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 147 Light positioned too high 1 correctly 2 and too low 3 6 Check the position of...

Page 159: ...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 160: ...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 161: ... 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 162: ...es on the shifter housing There is noticeable play of 2 to 5 mm 1 2 gear when you turn the twist grip Figure 153 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 163: ...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 164: ... 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 165: ...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 166: ...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 167: ... 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 168: ...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 169: ...ce a month Cleaning Section 7 3 12 O K Dirt Cleaning Once a month Care for Section 7 4 11 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 11 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 170: ...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 171: ...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 172: ...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 173: ...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 174: ...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 175: ...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 176: ...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 177: ...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 178: ...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 179: ...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 180: ...Remove outer sleeve from the seat post remote control Figure 159 Removing the cartridge 4 Use a 5 mm to undo Postpin axle and pull out Figure 160 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 161 Pulling the cartridge out 6 Hold the cartridge with one hand at the height of the mechanism and pull the Bowde...

Page 181: ... Pull slide bushing tube out of the seat tube Figure 165 Removing the outer sleeve and slide bushing Caring for the outer sleeve 1 Detach spring washer or outer sealing ring Figure 166 Removed spring washer 2 Carefully remove the wiper from the groove Figure 167 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 182: ...inserting and fastening the wiper Cleaning the slide bushing 1 Clean the slide bushing tube with a damp cloth Figure 172 Cleaning the slide bushing tube Increasing the air pressure 1 Use 3 mm hex spanner to unscrew valve cap Figure 173 Unscrewing the valve cap 2 Screw valve adapter into mounting interface from below Figure 174 Screwing the valve adapter in 3 Use compression pump to pump the cartri...

Page 183: ... interface against twisting with a 24 mm open end spanner Figure 178 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 179 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 180 Fastening the cartridge valve lid Notice ...

Page 184: ...rrect Bowden cable 4 Carefully push cartridge into the seat tube Pull the Bowden cable out of the frame to help Figure 185 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 185: ...unting hole in the outer sleeve Turn outer sleeve into the right position Figure 190 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 191 Feeding the height adjustment clamp in 15 Push the seat post carefully downwards and feed into the wiper Figure 192 Pushing the seat p...

Page 186: ...197 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 198 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 187: ...r sleeve with a cloth Figure 204 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 205 Inserting the felt ring 13 ...

Page 188: ...your hand until it will go no further Figure 209 Pulling the seat post out 3 Clean the seat post longitudinal grooves with a damp cloth Figure 210 Cleaning the longitudinal groove 4 Apply grease into the longitudinal groove and on both cross pieces Figure 211 Applying grease 5 Push seat post together Figure 212 Pushing the seat post together 6 Push the height adjustment operating lever backwards F...

Page 189: ...come damaged Figure 215 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 216 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 190: ...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 191: ...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 192: ...t up remove the battery 3 Insert the battery 4 Start the drive system 5 If the drive system does not start up remove the battery 6 Clean all the contacts with a soft cloth 7 Insert the battery 8 Start the drive system 9 If the drive system does not start up remove the battery 10 Fully charge the battery 11 Insert the battery 12 Start the drive system 13 If the drive system does not start up remove...

Page 193: ...isted journey distance is too short The journey distance can be shorter depending on the road conditions the gear level and the entire light usage time 1 Check battery is charged 2 Recharge the battery if it is almost flat The battery does not perform as well in winter weather This does not indicate a problem The battery is a consumable Repeated charging and long periods of use cause the battery t...

Page 194: ...ist dealer The battery does not start charging when the charger is connected The battery may be at the end of its useful life Replace old battery with new one The battery and charger become hot The temperature of the battery or the charger may have exceeded the oper ating temperature range 1 Interrupt charging process 2 Wait a moment 3 Repeat charging process 4 If the battery is too hot to touch t...

Page 195: ... connector has not been disconnected Contact your specialist dealer if this is not the case A component may be connected which the system is unable to recognise Contact specialist dealer The gear level is not shown on the on board computer The gear level is only shown if the electronic gear shift is used Check that the power cable connector has not been disconnected Contact your specialist dealer ...

Page 196: ...ic gear shift is 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 specialist dealer It is normal to hear a noise coming from the rear wheel when cycling as normal The gear shift setting may not have been made properly Contact specialist dea...

Page 197: ...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 219 Suspension fork rebounding too quickly Solution Figure 220 Suntour rebound screw 1 Turn rebound screw in a clockwise direction The rebound speed is ...

Page 198: ...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 221 Suspension fork rebounding too slowly Solution Figure 222 Suntour rebound screw 1 Turn rebound screw in an anti clockwise directio...

Page 199: ...ight shifts forward and the pedelec loses some momentum Figure 223 Excessively soft suspension in the suspension fork on hilly terrain Solution Figure 224 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 200: ...onger touches the ground The headset and handlebars are deflected upwards significantly which can impair control Figure 225 Excessively hard damping in the suspension fork on bumps Solution Figure 226 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 201: ...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 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: ...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 paper collection bin paper container undamaged transport packaging to suppliers Scrap metal and aluminium Take to...

Page 204: ... 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 Varnishes Thinners Take to municipal collection points for hazardous waste e g mobile toxic waste collection serv...

Page 205: ...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 206: ...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 207: ...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 208: ...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 209: ...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 210: ...MY22B01 12_1 0_26 08 2021 209 Notes ...

Page 211: ...derailleur gears Shifter SHIMANO Deore SL M4100 Shifter Front derailleur Cassette cassette sprocket SHIMANO Deore CS M4100 10 11 42T Chain KMC E10S Belt Front brake SHIMANO BR MT200 Hydraulic disc brake Rear brake SHIMANO BR MT200 Hydraulic disc brake Brake lever front rear SHIMANO BR MT200 Brake lever Disc front 180 mm centre lock Disc rear 180 mm centre lock Wheel set Rim front rear STYX DDM 2 H...

Page 212: ...ailable Lock ABUS Stand stand mount Aluminium Motor BOSCH Performance Line CX BDU450 CX 250 Watt 85 Nm Rechargeable battery BOSCH PowerTube 400 BBP282 400 Wh Display BOSCH Intuvia with Intuvia control panel Charger BOSCH Compact Charger BCS230 2 A ...

Page 213: ...tte sprocket SHIMANO Deore CS M4100 10 11 42T Chain Belt Front brake SHIMANO BR MT200 Hydraulic disc brake Rear brake SHIMANO BR MT200 Hydraulic disc brake Brake lever front rear SHIMANO BR MT200 Brake lever Disc front 180 mm Disc 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 SCHWA...

Page 214: ...8 2021 213 Documents not available Motor BOSCH Performance Line CX BDU450 CX 250 Watt 85 Nm Rechargeable battery BOSCH PowerTube 625 BBP290 Horizontal 625 Wh Display BOSCH Intuvia with Intuvia control panel Charger BOSCH ...

Page 215: ...MY22B01 12_1 0_26 08 2021 214 Documents 11 4 Charger operating instructions 0123435678 9 78 7 3951 8 ABC D ABC D ABC ...

Page 216: ... 2 15A Output 36V 6A Made in Vietnam Fast Charger BCS250 eBike Battery Charger 36 4 230 0 275 007 907 Li Ion Use ONLY with BOSCH Li Ion batteries Input 230V 50Hz 1 5A Output 36V 4A Made in PRC Robert Bosch GmbH 72757 Reutlingen Germany Standard Charger BCS220 Robert Bosch GmbH 72757 Reutlingen Germany Standard Charger Fast Charger EBE D F A G A C ...

Page 217: ...MY22B01 12_1 0_26 08 2021 216 Documents D Compact Charger A G A C EBE D F ...

Page 218: ...MY22B01 12_1 0_26 08 2021 217 Documents D EBE D F A G A C ...

Page 219: ...MY22B01 12_1 0_26 08 2021 218 Documents D A G A C EBE D F ...

Page 220: ...MY22B01 12_1 0_26 08 2021 219 Documents D EBE D F A G A C ...

Page 221: ... C 0 C H G M G N G C 0 G N N G G G C 0 0 G G G M G G G G C C 0 0 C 0 0 C 0 C G N G C 0 0 0 0 0 G G G G G G C C C C C 0 0 0 0 C G M G N C C 0 0 C 0 K G G G N G G L G G G G V S Pk G A CBU G L 0 7 G N G G M G N G N N G A G A G Q N G L A G A N G 0 0 G N G G N G L G G G N G G NN G N G G a N A BG H H BG N BG C N G BG L N G A NN C A G A C EBE D F ...

Page 222: ...J J G N G G G G B G L N G C 0 C G G NN N G G A OG M G L N G 0 C 0 C M M G G G G N G G G G C 0 G C G G NN B G N G G M M G G L P N G N G G G G G G 0 0 0 0 C C C 0 N G M G N G G G OG M G L N G N N A M G G G GM G G N G G G G Q f I i M G G G N G G G PKH N G G OG G M N G L N G N G G M G G G G G G L G G G G 5 H G G G G L N G A G G G L 5 H G G G L G G G G G L OG G G G L M G G G G OG G L M G L N G G N G G ...

Page 223: ... NN 5 H N G G G G M N G G G G N G L M G N G G N G N G M N N G G G G N M G G N G N G G G N D 0 0 0 0 A N C B G G A C H G N G G G G G G H G G G G G G G G G G 5 C C B G G C B G BG A B N G M G N BG G M G G G G G A N B G G K K N G G N M G L G 1 0 0 N G a G G M L G G T N G G M GL BG M G N H N G G G G J C 0 H G K H F F KS O K K Ka L M G G L N L N 0 9 0 A G A C EBE D F ...

Page 224: ...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 225: ...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 226: ...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 227: ...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 228: ... Directive 2014 30 EU The safety objectives in the Low Voltage Directive 2014 35 EU have been met in compliance with Appendix I No 1 5 1 of the Machinery Directive 2006 42 EC The following harmonised standards have been applied ISO 20607 2018 Safety machinery Instruction handbook General drafting principles EN 15194 2017 Cycles Electrically power assisted cycles EPAC Bicycles The following other t...

Page 229: ...MY22B01 12_1 0_26 08 2021 228 Appendix II Declaration of conformity for incomplete machine ...

Page 230: ...MY22B01 12_1 0_26 08 2021 229 Appendix ...

Page 231: ...MY22B01 12_1 0_26 08 2021 230 Appendix ...

Page 232: ...rrying out 59 preparing 59 Button On Off battery 38 39 C Carbon seat post caring for 146 Cassette cleaning 142 Chain guard 15 cleaning 143 Chain tension checking 158 Chain wheel 36 Chain wheels cleaning 142 Chain 24 36 caring for 147 cleaning 143 maintaining 150 159 Charger 39 disposing of 202 Charging port cover 38 Charging port 38 Chassis 25 Child seat 112 Clamping force Adjusting the quick rele...

Page 233: ... P Pannier rack battery removing 118 119 120 Pannier rack 24 caring for 145 changing 117 cleaning 141 using 116 Patent seat post 35 Pedal 36 caring for 147 cleaning 139 Pedelec shipping 58 transporting 58 Plus button 48 Protective cap 42 Push assist button 48 Push assist using 125 Q Q Loc 30 R Rear derailleur 36 caring for 147 Rear light 37 Rear wheel brake 34 Rebound adjuster 30 Rebound damping 2...

Page 234: ...e size 31 Tyres 31 checking 151 cleaning 142 converting 114 Airless 114 Tubeless 114 U USB port 40 42 using 125 V Valve 31 Dunlop valve 32 Presta valve 32 Schrader valve 32 Vehicle Technical data 53 W Weight Shipping weight 57 Weight 57 Wheel 31 installing 67 70 Winter break see Break in oper ation ...

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